Xerox WorkCentre 5021 WorkCentre 5019 Service Manual & Parts List

Service Manual & Parts List Xerox WorkCentre 5021 WorkCentre 5019;
This manual is in the PDF format and have detailed Diagrams, pictures and full procedures to diagnose and repair your Xerox WorkCentre copier.
You can print, zoom or read any diagram, picture or page from this Service Manual & Parts List. Every chapter on this manual is fully detailed and contain all theĀ  simulation codes, trouble codes, maintenance procedures, reset procedures, diagnose procedures of Xerox WorkCentre 5021 WorkCentre 5019 photocopier. You can find easily everything what do you need.
To see what contain, please read table of contents:

1. SERVICE CALL PROCEDURES
1.1 Before Starting the Servicing
1.2 Service Call Procedure
1.3 Detailed Contents of the Service Call
1.4 TRIM Check List
1.5 Periodic Replacement Parts/Consumables List

2. STATUS INDICATOR RAPs
2.1 Introduction
2.1.1 How to Troubleshoot
2.1.2 How to Switch the Error Code Display
2.1.3 Glossary
2.2 Product FIP
2.2.1 Level 1 FIP
2.2.1.1 Level 1 FIP
2.2.2 Level 2 FIP
CHAIN 3
003-500/795 N-Up NG Out Of Range/ AMS NG Out Of Range
003-754 IPS Overrun
003-942 Not-Supported Doc Size
003-951 1Job Max Page Over
003-963 APS NG Out Of Range
003-972 EPC Memory Full
003-973 Auto Rotation NG Out Of Range
CHAIN 4
004-345 HVPS Communication Error
CHAIN 5
005-122 DADF Simplex/Side 1 Pre Regi Sensor On Jam
005-123 DADF Simplex/Side 1 Regi Sensor On Jam
005-125/145 DADF Regi Sensor Off Jam/ DADF Regi Sensor Off Jam on Inverting
005-131/132 DADF Invert Sensor On Jam on Inverting/ DADF Invert Sensor On Jam.2-13
005-134/139 DADF Invert Sensor Off Jam on Inverting/ DADF Invert Sensor Off Jam.2-14
005-135 DADF Side 2 Pre Regi Sensor On Jam
005-136 DADF Side 2 Regi Sensor On Jam
005-147 DADF Pre Regi Sensor Off Jam on Inverting
005-196 Size Mismatch Jam on No Mix-Size
005-197 Prohibit Combine Size Jam
005-198/199 Too Short Size Jam/ Too Long Size Jam
005-210 DADF Download Fail
005-275/280 DADF RAM Fail/ DADF EEPROM Fail
005-305 DADF Feeder Cover Interlock Open
005-500 DADF Download Flash Write Error
005-907/908/913 DADF Pre Regi Sensor/DADF Regi Sensor/DADF Invert Sensor Static Jam2-16
005-940 DADF No Original Fail
005-948 SS-Size Mismatch Jam on No Mix-size
CHAIN 10
010-311 Fusing Unit Center Thermistor Defect
010-312 Fusing Unit Rear Thermistor Defect
010-320 Over Heat Temperature Fail
010-327 Fusing Unit On Time Fail
010-379 Fusing Unit Hot Not Ready Return Time Fail
010-392 NOHAD Fan Defect
010-602 Over Temp Cooling Mode
CHAIN 16
016-500 Controller Download Flash Write Error
016-501 Controller Boot Flash Write Error
016-502 UI Panel Download Flash Write Error
016-570 No Response from USB-Host for Scan Job
016-571 No Response from USB-Host for Print Job
016-742/744 Download File Error/ Download File Check Sum Error
016-749/799 HBPL or XPJL Syntax Error/ Print Instruction Fail
016-759 Copy Counter Full
016-776 Marker Code Detection Fail
CHAIN 23
023-600 Held Down key Error (UI Panel)
CHAIN 24
024-910/911/915 Tray 1/Tray 2/MSI Paper Length Mismatch
024-950/951/954 Tray 1/Tray 2/MSI No Paper
024-958/959/960 MSI/Tray 1/Tray 2 Paper Size Mismatch
024-965 APS NG Unselected
CHAIN 41
041-210/211 STM NVM Out-Of-Order/ STM NVM R/W Error
CHAIN 42
042-325/614 Main Motor Rotation Error/ Main Motor Rotation Warning
CHAIN 45
045-310 Image Ready Error
045-313 IOT Logic Fail
CHAIN 61
061-321 ROS Motor Fail
061-325 No SOS Fail
CHAIN 62
062-277 DADF Communication Fail
062-311 IIT Software Logic Fail
062-360 Carriage Position Fail
062-371/380 Lamp Illumination Fail/ AGC Fail
062-386 AOC Fail
062-389 Carriage Over Run Fail (Scan End Side)
062-396 CCD Cable Connection Fail
CHAIN 71
071-105 Regi Sensor On Jam (Tray 1)
CHAIN 72
072-102 Feed Out Sensor 2 On Jam
072-105 Regi Sensor On Jam (Tray 2)
072-210 Tray 2 Lift Up Fail
072-212 Tray 2 Size Sensor Broken
072-215 MCU-STM Communication Fail
CHAIN 75
075-135 Regi Sensor On Jam (MSI)
CHAIN 77
077-101 Regi Sensor Off Jam
077-103 Fusing Unit Exit Sensor Off Jam (Long)
077-104 Fusing Unit Exit Sensor Off Jam (Short)
077-106 Fusing Unit Exit Sensor On Jam
077-129 Regi Sensor On Jam (Duplex Wait)
077-212 Tray Module Reset Fail
077-300/301/305 Front Cover/Left Hand Cover/STM Cover Open
077-900/901/904 Regi Sensor/Fusing Unit Exit Sensor/Feed Out Sensor 2 Static Jam2-42
CHAIN 91
091-313 CRUM ASIC Communication Fail
091-401/402 Drum Cartridge Quality Life Over/ Drum Cartridge Life Over
091-406/424 Drum Cartridge Normal Life Over/ Drum Cartridge Abnormal Life Over
091-430 Drum Cartridge Life End
091-440 Drum Cartridge Pre Near End
091-441 Drum Cartridge Near End
091-914 Drum CRUM Communication Fail
091-915/916 Drum CRUM ID Error/ Drum CRUM Market Identity Mismatch
CHAIN 92
092-660/668 ATC Amplitude Fail/ ATC Average Fail
092-661 Temperature Sensor Fail
092-910 ATC Sensor Fail
CHAIN 93
093-312 Toner Dispense Motor Rotation Fail
093-400 Toner Near Empty
093-406 Toner Pre Near Empty
093-912 Toner Empty
093-956 Drum New CRU Installation Fail
093-959 Drum New CRU Installation Fail Exceeds Thresholding Times
CHAIN 95
095-910 No Drum Cartridge
CHAIN 116
116-321 Controller Logic Fail
116-323 Controller NVM Data Defect
116-334 NVM Data Mismatch
116-377 IIT Interrupt Time out
116-747 Invalid Page Margin
CHAIN 117
117-326 Controller Backup NVM Data Defect
CHAIN 123
123-314 UI Panel Communication Fail
2.2.3 Other Failure FIP
2.2.3.1 AC Power FIP
2.2.3.2 +5VDC Power FIP
2.2.3.3 +24VDC Power FIP
2.2.4 Generic FIP
2.2.4.1 Reflective Sensor Failure FIP
2.2.4.2 Permeable Sensor Failure FIP
2.2.4.3 Switch (Normal/Open) Failure FIP
2.2.4.4 Solenoid/Clutch Not Energized Failure FIP
2.2.4.5 Solenoid/Clutch Left Energized Failure FIP
2.2.4.6 Motor Does Not Rotate Failure FIP
2.2.4.7 Motor Left Running Failure FIP
2.2.4.8 NIP/RELEASE SOLENOID Not Energized Failure FIP
2.3 NET System Fault Check
2.3.1 No output is available, no data is printed
2.3.2 Printing can be performed but abnormally

3. IMAGE QUALITY
3.1 Introduction
3.1.1 Composition of Chapter 3 Image Quality Troubleshooting
3.1.2 Test Pattern
3.1.3 Image Quality Troubleshooting
3.2 Image Quality RAPs
IQ1 IOT Image Quality Entry RAP
IQ2 IIT Image Quality Entry RAP
IQ3 Low Image Density RAP
IQ4 Wrinkled Image RAP
IQ5 Residual Image (Ghosting) RAP
IQ6 Background RAP
IQ7 Deletion RAP
IQ8 Skew/Misregistration RAP
IQ9 Process Direction Bands,Streaks,and Smears RAP
IQ10 Unfused Copy/Toner Offset RAP
IQ11 Repeating Bands,Streaks,Spots,and Smears RAP
IQ12 Mottle RAP
IQ13 Spots RAP
IQ14 Black Prints RAP
IQ15 Blank Image RAP
3.3 Image Defect Sample
3.3.1 IOT Image Defect Sample
3.3.2 IIT Image Defect Sample
IDS1 Auger Mark
IDS2 Strobing (27mm or 13.5mm Pitch Density)
IDS3 White Streaks (Process Direction)
IDS4 Black Bands
IDS5 Toner Contamination
IDS6 Toner Splattering
IDS7 White Spots (Irregular)
IDS8 Regular Blank Areas In Process Direction (Spots, Streaks, Bands etc.)
IDS9 Regular Toner Contamination In Process Direction (Spots, Streaks, Bands etc.)3-20
IDS10 Regular Toner Contamination In Process Direction (Side 2)
IDS11 Moire Due to Interference With Copy Documents
IDS12 Light Background Due to Background Suppression in Copies of Documents With Frames
IDS13 Background Smear When Using Platen Copy With Non-Standard Documents.3-23
IDS14 Fluctuation In Background Suppression Values for Copies of Documents With Medium Density
IDS15 Defects Related To Scan Print
3.4 Fusing Unit Paper Wrinkle Alignment Adjustment
3.5 Cycle Table

4. REPAIRS AND ADJUSTMENTS
4.1 Introduction
4.1 Introduction
1. IIT/UI
REP 1.2.1 IIT Top Cover
REP 1.3.1 IIT Carriage
REP 1.3.2 IIT Carriage Belt
REP 1.4.1 Carriage Motor
REP 1.5.1 LED Lamp PWB
REP 1.6.1 LCD Display
2. ROS
REP 2.1.1 ROS Assembly
3. Drive
REP 3.1.1 Main Drive Motor
REP 3.1.2 Main Drive Housing
4. NOHAD
REP 4.1.1 NOHAD Fan
6. Transfer
REP 6.1.1 BTR Roll
7. Fusing Unit
REP 7.1.1 Fusing Unit
8. Xero./Deve.
REP 8.1.1 Drum Cartridge
REP 8.2.1 Cartridge Guide
REP 8.2.2 Dispense Drive
9. Feeder,Tray (Tray 1)
REP 9.1.1 Tray 1 Feed Clutch
REP 9.1.2 Tray 1
REP 9.2.1 Tray 1 Feed Roll and Tray 1 Retard Pad
10. One Tray Module (Tray 2)
REP 10.1.1 Tray 2 Feeder
REP 10.3.1 Tray 2 Feed/Retard/Nudger Roll
REP 10.6.1 STM PWB
REP 10.6.2 STM Takeaway Motor
13. MSI
REP 13.1.1 MSI
REP 13.3.1 MSI Nudger/Feed Roll
REP 13.3.2 MSI Retard Pad
14. L/H Cover
REP 14.1.1 L/H Cover
15. Registration
REP 15.1.1 Registration Chute
REP 15.1.2 Registration Roll
17. Exit
REP 17.1.1 Exit Cover
REP 17.1.2 Exit Roll
18. Electrical
REP 18.1.1 ESS/MCU PWB
REP 18.1.2 HVPS
REP 18.1.3 LVPS
19. Cover
REP 19.1.1 Front Cover
REP 19.1.2 Top Cover
REP 19.2.1 Rear Cover
56. DADF
REP 56.1.1 DADF
REP 56.1.2 DADF Platen Cushion
REP 56.2.1 DADF Front Cover
REP 56.2.2 DADF Rear Cover
REP 56.2.3 DADF PWB
REP 56.2.4 Upper Feeder
REP 56.2.5 DADF Feeder Assembly
REP 56.3.1 Left Counter Balance
REP 56.3.2 Right Counter Balance
REP 56.5.1 DADF Feed/Nudger Roll
REP 56.6.1 Harness Guide and Wire Harness
REP 56.6.2 DADF Feed Motor
REP 56.7.1 DADF Drive Belt
REP 56.9.1 Document Tray
REP 56.9.2 Retard Chute
REP 56.9.3 Invert Chute
REP 56.10.1 DADF Takeaway Roll
REP 56.10.2 Sensor Bracket
REP 56.13.1 DADF Retard Pad
1. IIT/UI
ADJ 1.3.1 IIT Lead Edge Registration
ADJ 1.3.2 IIT Side Registration
8. Xero./Deve.
ADJ 8.1.1 ATC Sensor Read & Tone Up/Down
18. Electrical
ADJ 18.1.1 IOT Lead Edge/Side Edge Registration
ADJ 18.1.2 Edge Erase Value Adjustment
ADJ 18.2.1 Things to take note when replacing Important Information Stored Components (ISC)
ADJ 18.2.2 Firmware Version Upgrade
56. DADF
ADJ 56.1.1 DADF Lead-Skew Adjustment
ADJ 56.1.2 DADF Side Registration
ADJ 56.1.3 DADF Lead Edge Registration

5. PARTS LIST
5.1 Introduction
5.1.1 How to Use the Parts List
5.1.2 Precautions
5.1.3 Plate Composition
5.1.4 Terminology and Symbols
5.1.5 Using Parts Navigation
5.2 Parts List
1. IIT/UI
PL 1.1 Platen Cover
PL 1.2 Top Cover (with Platen Glass),Front Cover
PL 1.3 IIT Base Frame Component
PL 1.4 Carriage Motor
PL 1.5 IIT Carriage
PL 1.6 Control Panel
2. ROS
PL 2.1 ROS
3. Drive
PL 3.1 Main Drive Motor
PL 3.2 Main Drive Housing
4. NOHAD
PL 4.1 NOHAD
6. Transfer
PL 6.1 Transfer
7. Fusing Unit
PL 7.1 Fusing Unit
8. Xero./Deve.
PL 8.1 Drum Cartridge,Toner Cartridge
PL 8.2 Toner System
PL 8.3 Dispense Drive
9. Feeder;Tray (Tray 1)
PL 9.1 Tray 1,Tray Drive
PL 9.2 Tray 1 Component
10. One Tray Module (Tray 2)
PL 10.1 Tray 2 ,Feeder
PL 10.2 Tray 2 Component
PL 10.3 Tray 2 Feeder
PL 10.4 Left Cover
PL 10.5 Takeaway Roll
PL 10.6 Electrical
PL 10.7 Cover
12. Stand
PL 12.1 Stand
13. MSI
PL 13.1 MSI
PL 13.2 MSI Component
PL 13.3 MSI Lower Feeder
14. L/H Cover
PL 14.1 Simplex/Duplex L/H Cover
PL 14.2 Simplex L/H Cover
PL 14.3 Duplex L/H Cover-Chute,Latch
PL 14.4 Duplex L/H Cover-Roll,Gear
15. Registration
PL 15.1 Registration
17. Exit
PL 17.1 Simplex/Duplex Exit
18. Electrical
PL 18.1 Electrical
PL 18.2 Wire Harness
19. Cover
PL 19.1 Cover-Front,Top,Right
PL 19.2 Cover-Rear,Left Rear
56. DADF
PL 56.1 DADF Accessory
PL 56.2 DADF Component
PL 56.3 DADF Base Frame
PL 56.4 Upper Feeder
PL 56.5 Feed Roll Nudger Roll Assembly
PL 56.6 DADF Feed Motor,Harness Guide
PL 56.7 DADF Feeder Rear Frame
PL 56.8 DADF Feeder Front Frame
PL 56.9 DADF Tray,Chute
PL 56.10 DADF Roll,Sensor Bracket
PL 56.11 Document Tray
PL 56.12 Invert Chute
PL 56.13 Retard Chute
PL 56.14 Sensor Bracket
98. Screws
98.1 Screws
99. Adjustment/Consumables Area Code List
99.1 Paper
99.2 Environment
99.3 Consumables
99.4 Electrical Adjustment
99.5 Mechanical Adjustment
99.6 Originals
99.7 Accessories Related
99.8 DMP/Network Functions Related
5.3 Parts Navi
Navi 1.1 Processor + Option
Navi 2.1 IOT
Navi 2.2 One Tray Module
Navi 2.3 DADF

6. GENERAL PROCEDURES
6.1 Specifications
6.1.1 Product Name/Product Code/Serial No
6.1.2 Standard Specification of IIT, IOT, and PANEL
6.1.3 Standard Specification of Controller
6.1.4 Standard Specification of Host I/F
6.1.5 Operating Modes
6.1.6 Machine Sizes and Basis Weights
6.1.7 Installation Space
6.1.8 Leveling
6.1.9 Operating Air Pressure
6.1.10 Electrical Characteristics
6.1.11 Environmental Friendliness
6.1.12 Installation Environment
6.1.13 Warm-up Time
6.1.14 FCOT :First Copy Output Time (Warm start)
6.1.15 Print Speed
6.1.16 Tray (Paper Feed)
6.1.17 Classifications and Functions
6.1.18 Auto 2 Sided Printing
6.1.19 Output Function
6.1.20 Resolution/Gradation
6.1.21 Paper Selection
6.1.22 Image Loss
6.1.23 Print Area
6.1.24 Alignment Specification
6.1.25 Print Feature
6.1.26 Local Scan Feature
6.1.27 Document Feeder (DADF)
6.1.28 Count-up for Print/Copy jobs
6.1.29 Count-up modes
6.2 Tools/Service Consumables/Consumables
6.2.1 Tools and Service Consumables
6.2.2 Consumables
6.3.1 Input Component Check List
6.3.1.1 DADF Input Component Check List
6.3.1.2 IIT Input Component Check List
6.3.1.3 IOT Input Component Check List
6.3.2 Output Component Check List
6.3.2.1 DADF Output Component Check List
6.3.2.2 IIT Output Component Check List
6.3.2.3 IOT Output Component Check List
6.3.3 Analog Monitor Code List
6.3.3 Analog Monitor Code List
6.3.4 HFSI Counters
6.3.4.1 DADF HFSI List
6.3.4.2 IIT HFSI List
6.3.4.3 IOT HFSI List
6.3.5 NVM DADF
6.3.5 NVM DADF
6.3.6 NVM IIT
6.3.6 NVM IIT
6.3.7 NVM DIAG
6.3.7 NVM DIAG
6.3.8 NVM DRIVE & NOHAD
6.3.8 NVM DRIVE & NOHAD
6.3.9 NVM PH
6.3.9 NVM PH
6.3.10 NVM Fusing
6.3.10 NVM Fusing
6.3.11 NVM Xfer
6.3.11 NVM Xfer
6.3.12 NVM XERO
6.3.12 NVM XERO
6.3.13 NVM ROS
6.3.13 NVM ROS
6.3.14 NVM PROCON
6.3.14 NVM PROCON
6.3.15 NVM CRUM
6.3.15 NVM CRUM
6.3.16 NVM SYSTEM
6.3.16 NVM SYSTEM
6.3.17 NVM IPS
6.3.17 NVM IPS
6.3.18 NVM JOB ATTRIBUTE
6.3.18 NVM JOB ATTRIBUTE
6.3.19 NVM ACCOUNT MODE
6.3.19 NVM ACCOUNT MODE
6.3.20 NVM Jam Counter Clear & Initialize HFSI
6.3.20 NVM Jam Counter Clear & Initialize HFSI
6.4 Service Mode
6.4.1 How to Enter the CE DIAG Mode/How to Exit from the CE DIAG Mode
6.4.1.1 UI CE Diag Mode Structure
6.4.1.2 How to Enter the CE Diag Mode
6.4.1.3 How to Exit from the CE Diag Mode
6.4.2 How to Use the CE DIAG Mode
6.4.2.1 Shutdown History
6.4.2.1.1 Initialize Fault History
6.4.2.1.2 DATA All Delete
6.4.2.2 NVM Read/Write
6.4.2.3 Analog Monitor
6.4.2.4 Read Temperature
6.4.2.5 NVM Initialize
6.4.2.6 Component Check (IOT/IIT/DADF)
6.4.2.7 Maintenance Report
6.4.2.8 HFSI Counter Reset
6.4.2.9 HFSI Read/Clear
6.4.2.10 Jam Counter Reset
6.4.2.11 DRUM Counter Reset
6.4.2.12 ATC Sensor Read
6.4.2.13 Tone Up/Down
6.4.2.14 Test Pattern Print
6.4.2.15 Checking and Repairing the Billing Counter (621-400)
6.4.3 Error Display during Diag
6.6 KO PROGRAM# LIST
6.6 KO PROGRAM# LIST

7. WIRING DATA
7.1 Plug/Jack Location List
7.1.1 Plug/Jack Location List
7.1.2 Plug/Jack Location
7.2 Wire Network
7.2.1 IOT/IIT
7.2.1.1 ACH
7.2.1.2 ACN
7.2.1.3 +2.5VDC/+3.3VDC
7.2.1.4 +5VDC-1
7.2.1.5 +5VDC-2
7.2.1.6 5V RTN-1
7.2.1.7 5V RTN-2
7.2.1.8 +24VDC-1
7.2.1.9 +24VDC-2
7.2.1.10 24V RTN
7.2.1.11 IIT +3.3VDC/+5VDC/+24VDC
7.2.1.12 IIT 3.3V/5V/24V RTN
7.2.2 DADF
7.2.56.1 DADF +5VDC
7.2.56.2 DADF 5V RTN
7.2.56.3 DADF +24VDC
7.2.56.4 DADF 24V RTN
7.3 BSD
7.3.1 Preface
1. How to Use BSDs
2. Explanation of Symbols
3. Signal Name
4. DC Voltage
5. Other Descriptions
Chain 1 Standby Power
CH1.1 Main Power On and M/C Power Control
CH1.2 DC Power Generation (+5VDC)
CH1.3 DC Power Generation (+24VDC)
CH1.4 IIT/DADF DC Power Distribution
CH1.5 Power Interlock Switching (1 of 2)
CH1.6 Power Interlock Switching (2 of 2)
Chain 2 Mode Selection
CH2.1 Control Panel
Chain 3 Machine Run Control
CH3.1 PWB Communication (ESS/MCU-IIT and ESS/MCU-DADF)
CH3.2 PWB Communication (ESS/MCU-STM and ESS/MCU-NET)
CH3.3 Electric Billing
Chain 4 Start Print Power
CH4.1 Main Drive Control
Chain 5 Document Transportation
CH5.1 DADF Interlock and Document Setting
CH5.2 Document Size Sensing (1 of 2)
CH5.3 Document Size Sensing (2 of 2)
CH5.4 Document Feeding
CH5.5 Document Scan, Invert and Exit Transportation
CH5.6 Document Path
CH5.7 Document Transmission
Chain 6 Imaging
CH6.1 Document Illumination
CH6.2 Carriage Control
CH6.3 Image Input
CH6.4 Laser Control
Chain 7 Paper Supplying
CH7.1 Tray 2 Sensing (1TM)
CH7.2 Tray 1 Paper Stacking
CH7.3 Tray 2 Paper Stacking (1TM)
CH7.4 MSI Paper Stacking
Chain 8 Paper Transportation
CH8.1 Tray 1 and MSI Paper Transportation
CH8.2 Tray Module Paper Transportation (1TM)
CH8.3 Registration
CH8.4 Paper Path
Chain 9 Marking
CH9.1 Xero Life Control
CH9.2 Charging, Exposure and Development
CH9.3 Toner Dispense and Toner Life Control
CH9.4 Image Transfer and Stripping
Chain 10 Fusing & Paper Transportation
CH10.1 Fusing Heat Control (1 of 2)
CH10.2 Fusing Heat Control (2 of 2)
CH10.3 Fusing
CH10.4 Exit and Duplex Paper Transportation

Number of pages: 466.