Xerox WorkCentre 3025BI Service Manual
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Xerox
WorkCentre
3025BI/NI
®
®
Service Manual
702P02831
June 2014
Initial Issue

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Table of Contents
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Summary of Contents for Xerox WorkCentre 3025BI

  • Page 1 Xerox WorkCentre 3025BI/NI ® ® Service Manual 702P02831 June 2014 Initial Issue...
  • Page 3 Xerox service documentation is intended for use by certified, product-trained service per- sonnel only. Xerox does not warrant or represent that it will notify or provide to such customer any future change to this documentation. Customer performed service of equipment, or mod- ules, components, or parts of such equipment may affect whether Xerox is responsible to fix machine defects under the warranty offered by Xerox with respect to such equipment.
  • Page 4 Draft June 2014 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 5: Table Of Contents

    How to Use this Manual ....................Service Safety Summary....................Reference Symbology..................... Voltage Specifications..................... Health and Safety Incident Reporting ................viii Regulatory Specifications....................Translation of Warnings ....................Tag Usage........................WorkCentre 3025 Overview .................... Introduction June 2014 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 6 Introduction June 2014 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 7: About This Manual

    The Xerox® WorkCentre® 3025 Printer Service Manual is part of the multinational documenta- Section 7 Wiring Data tion for the Xerox® WorkCentre® 3025 Multifunction Printer. It is structured in standard Xerox This section contains Block Schematic Diagrams (BSDs), Plug/Jack locations, Voltage service documentation format.
  • Page 8: How To Use This Manual

    NOTE: A note is used where it is essential to highlight a procedure, practice, condition or state- ment. Introduction June 2014 How to Use this Manual Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 9: Service Safety Summary

    Do not use aerosol cleaners. The use of supplies that are not approved may cause poor performance and could create a hazardous condition. • Do not burn any consumables or routine maintenance items. For information on Xerox supplies recycling programs, go to www.xerox.com. June 2014 Service Safety Summary Xerox®...
  • Page 10: Reference Symbology

    Arrow • This symbol points to the location to install, gain access to, or to release a compo- nent. The following reference symbols are used throughout the Xerox® WorkCentre® 3025 Printer Service Documentation. Flag • This symbol indicates a reference point into a circuit diagram from a RAP.
  • Page 11: Voltage Specifications

    TP33. If a second test point is not given, it is assumed that the black meter lead may be attached to the copier frame. June 2014 Reference Symbology, Voltage Specifications Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 12 Fund all field retrofits. II. Scope Field Service Operations shall: Preserve the Xerox product involved and the scene of the incident inclusive of any Xerox Corporation and subsidiaries worldwide. associated equipment located in the vicinity of the incident. III. Objective Return any affected equipment/part(s) to the location designated by Xerox EH&S...
  • Page 13: Regulatory Specifications

    Xerox has tested this product to electromagnetic emission and immunity standards. These A signed copy of the Declaration of Conformity for this product can be obtained from Xerox. standards are designed to mitigate interference caused or received by this product in a typical office environment.
  • Page 14: Translation Of Warnings

    GP 16. Das Modul ist sehr schwer. de las normas sobre incendios. AVISO: Utilice los procedimientos de seguridad cuando elimine el módulo. Consulte el GP 16. El módulo es pesado. Introduction June 2014 Translation of Warnings Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 15: Tag Usage

    Tag Usage WARNING Use only Xerox materials and components. This product is safety certified using Xerox Tags materials and components. The use of non Xerox materials and components may invali- If different parts or actions exist because of a modification, the Tag number will identify the date the safety certificate.
  • Page 16: Workcentre 3025 Overview

    E-mail Not Applicable Not Applicable USB Device Standard Standard USB Host Not Applicable Not Applicable Network Printing Not Applicable Standard Wi-Fi Standard Standard Wi-Fi Direct™ Standard Standard Introduction June 2014 WorkCentre 3025 Overview Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 17 Safety Precautions ......................SCP 01 Introduction to Service Call Procedures ............SCP 02 Initial Actions...................... SCP 03 Corrective Actions....................SCP 04 Final Actions ...................... System/Subsystem Maintenance HFSI’s ..........................Service Call Procedures June 2014 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 18 Service Call Procedures June 2014 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 19: Service Call Overview

    Diagnostic Mode The Xerox® WorkCentre® 3025 has built-in diagnostics to test components, display status and some NVM access. The diagnostic tests are accessed through the Control Panel. Refer to the User Guide for detailed instructions on using the Control Panel buttons and menus. Refer to Section 6 for information regarding diagnostic testing.
  • Page 20: Scp 01 Introduction To Service Call Procedures

    SCP 02 Initial Actions Purpose Purpose Service Call Procedures (SCP) are the guide to performing a service call on the Xerox® Work- The purpose of the Initial Actions is to help organize the service call. Customer input, machine Centre® 3025 Multifunction Printer.
  • Page 21: Scp 03 Corrective Actions

    Troubleshoot fault codes with the lowest chain number first. If the problem is IQ related, refer to Section 3, Image Quality. When the primary problem is resolved, proceed to Final Actions. Service Call Procedures June 2014 SCP 03, SCP 04 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 22 Customer and Service HFSI’s As with other CSE actions, these actions should be performed according to customer run requirements. Some actions may be deferred to a Xerox Initiated activity, taking into consider- ation any risks with deferring those actions. Table 1 Customer/Service HFSI’s...
  • Page 23 20-400 / 410 Line Fault ....................2-15 20-500 Memory Full Fault ....................2-15 20-600 No Answer Fault ....................2-16 20-700 Number Not Assigned Fault................2-16 20-900 Retry Redial Fault ....................2-17 Status Indicator RAPs June 2014 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 24 Status Indicator RAPs June 2014 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 25 Check that there is no contamination present. • Check for broken or defective wires or cables. • Replace the Main PWB (REP 1.7), 1.1. Replace the LVPS/HVPS PWB (REP 1.5), 5.1. Status Indicator RAPs June 2014 01-100 , 03-410 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 26 Check the paper path drives and clear any jammed sheets from the paper path. If problem per- sists, replace the Main PWB (REP 1.7), 1.1. Status Indicator RAPs June 2014 05-100 / 900 , 05-500 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 27 Nichteinhaltung dieser Regel kann zu ernsthaften körperlichen Verletzungen führen. AVISO: Use gafas de protección para realizar el procedimiento siguiente. No proteger los ojos puede ocasionar daños personales graves. Status Indicator RAPs June 2014 06-100 / 200 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 28 Ensure that paper is loaded in the tray. Clear any jammed sheets. Refer to Section 7: Trouble- • Disconnect and securely reconnect the harness. shooting, in the Xerox® WorkCentre® 3025 User Guide for detailed instructions on clearing Check the harness for a short circuit or open circuit (BSD 6.1). The harness is OK. paper jams.
  • Page 29 If problem continues, Remove the Fuser Assembly REP 1.18 and replace if necessary 5.2. Exit Diagnostic Mode and perform SCP Final Actions Exit Diagnostics Mode and perform SCP Final Actions. Status Indicator RAPs June 2014 08-100 , 08-500 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 30 If the Print Cartridge has reached end of life, switch Off the power and replace the Print If the Print Cartridge is at end of life, switch Off the power and replace the Print Cartridge. Cartridge Status Indicator RAPs June 2014 09-100 , 09-350 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 31 Check the CRUM contact area for contamination and clean if necessary. Reinstall the Print Cartridge. If the problem continues, install a new Print Cartridge. Status Indicator RAPs June 2014 09-450 , 09-550 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 32 Do not handle the fuser components until they have cooled. Some fuser components operate at hot temperatures and can produce serious personal injury if touched. Replace the Print Cartridge if it is not a genuine Xerox® cartridge. DANGER: Ne pas manipuler les éléments du four avant de les laisser refroidir. Certains If problem continues, go to RAP 09-500, Toner Cartridge Undetected Fault to check for éléments du four fonctionnent à...
  • Page 33 If problem is intermittent, check the circuit of the Fuser Assembly for one of the following • All connectors are securely connected and no contamination is present. • Short circuit or damaged wire. Repair as necessary. Status Indicator RAPs June 2014 10-100 , 10-200/ 300 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 2-11...
  • Page 34 Procedure Switch Off the power then switch On the power. (The Contact Image Sensor should move dur- Use Xerox Easy Print Manger to obtain a new IP address. ing start up.) From the menu, select: [Machine Settings, Network Settings, Assign IP address].
  • Page 35 Replace the Fax PWB (REP 1.9), PL 1.2 • Check that no contamination is present. • Replace the Main PWB (REP1.17), PL 1.1 PL 1.2 Status Indicator RAPs June 2014 17-310 , 20-100 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 2-13...
  • Page 36 Clear any jammed sheets. Refer to the WorkCentre® 3025 User Guide for detailed jam clear- ance instructions. Check the scanner. Refer to RAP 14-100 for troubleshooting the scanner. Resubmit fax using a group location. Resubmit the job. Status Indicator RAPs June 2014 20-120 , 20-200 2-14 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 37 Delete necessary documents, resend job when memory becomes available, or split the trans- Resubmit fax job. If problem persists, resubmit after an hour. mission into multiple operations. Status Indicator RAPs June 2014 20-400 / 410 , 20-500 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 2-15...
  • Page 38 Ensure that remote machine is powered on and reattempt submission. Dial the number manually or assign the number to the speed dial location. Refer to Section 8: Address Book, Using Address Book from the Control Panel in the Xerox® Phaser® 3025 User Guide on assigning speed dial numbers.
  • Page 39 20-900 Retry Redial Fault The machine is waiting for the programmed interval to automatically redial. BSD-Reference: Procedure Press <START> to immediately redial or <STOP> to cancel the redial operation. Status Indicator RAPs June 2014 20-900 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 2-17...
  • Page 40 Status Indicator RAPs June 2014 20-900 2-18 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 41 IQ7 Uneven Density RAP....................IQ8 Background RAP ...................... IQ9 Residual Image (Ghosting) RAP ................IQ10 Side 2 Staining ....................... IQ11 Blank Page RAP..................... 3-10 IQ12 Partial Image Deletions RAP.................. 3-11 Image Quality June 2014 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 42 Image Quality June 2014 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 43: Image Quality Overview

    Areas of the printed image are light or missing entirely IQ12 • Vertical white lines tions on limited areas of the paper. • Vertical black line or band Image Quality June 2014 Image Quality Overview Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 44: Iq1 Vertical Black Line And Band Rap

    Switch On the power and make a test print. The defect is gone. Replace the Fuser Module; (REP 1.19), 5.2. Switch on the power. Perform Final Actions. Figure 1 Black lines and bands Figure 1 White lines and bands Image Quality June 2014 IQ1, IQ2 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 45: Iq3 Horizontal Black Bands Rap

    Print Cartridge. If problem persists, replace the Fuser Module; (REP 1.19), 5.2. Figure 1 Horizontal black bands Figure 1 Black spots Image Quality June 2014 IQ3, IQ4 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 46: Iq5 Low Image Density Rap

    The Charge Roller is likely defective, replace the Toner Cartridge. Refer to the WorkCentre® 3025 User Guide, Section 6 Maintenance, General Care, for detailed instructions on how to replace the Toner Cartridges. Figure 1 Light Image Image Quality June 2014 IQ5, IQ6 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 47: Iq7 Uneven Density Rap

    Check the Transfer Roller for wear or damage. The Transfer Roller is OK. Replace the Transfer Roller; (REP 1.17), 5.1. If problem persists, replace the LVPS / HVPS PWB; (REP 1.6), 5.1. Image Quality June 2014 IQ6, IQ7 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 48: Iq8 Background Rap

    Switch on the power and make a test print. The test print looks OK. Replace the LVPS / HVPS PWB; (REP 1.6), 5.1. Go to Call Closeout. Figure 1 Uneven Density Figure 1 Background Image Quality June 2014 IQ7, IQ8 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 49: Iq9 Residual Image (Ghosting) Rap

    Print Cartridge. • Fuser Module; (REP 1.19), 5.2. • LVPS / HVPS PWB; (REP 1.6), 5.1. Figure 1 Side 2 Staining Figure 1 Ghost Image Image Quality June 2014 IQ9, IQ10 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 50: Iq11 Blank Page Rap

    Main PWB to High Voltage Power Supply Wire Harness. • Main PWB; (REP 1.7), PL 1.1 1.2. • LVPS / HVPS PWB; (REP 1.6), 5.1. Replace the LSU; (REP 1.12), 5.6. Image Quality June 2014 IQ11 3-10 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 51: Iq12 Partial Image Deletions Rap

    • Wear or damage. • The left and right tension springs for damage. • Be sure all parts are installed correctly. Figure 1 Image Deletions Image Quality June 2014 IQ12 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 3-11...
  • Page 52 Image Quality June 2014 IQ12 3-12 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 53 REP 1.21 LSU Cable ...................... 4-36 REP 1.22 Automatic Document Feeder (ADF) ............... 4-37 REP 1.23 Platen Cover ....................4-38 REP 1.24 ADF Feed Separation Pad................4-39 REP 1.25 ADF Feed Rolls Assembly................4-40 Repairs June 2014 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 54 Repairs June 2014 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 55: Rep 1.1 Left And Right Side Covers

    Remove the Side Covers being careful not to damage the Fastening Hooks (Figure Pull the bottom of the cover away from the printer to remove it. Figure 2 Fastening Hooks Repairs June 2014 REP 1.1 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 56: Rep 1.2 Front Cover

    Release the Side fasteners, then the Top fasteners. Left Hinge Figure 1 Paper Tray Cover Removal (Front View) Figure 3 Fastening Hooks Replacement Install the components in the reverse of removal. Repairs June 2014 REP 1.2 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 57: Rep 1.3 Rear Cover

    Screws Figure 2 Rear Cover Screws and Connector Locations (Rear View 3025 BI) Wire Guides Figure 1 Rear Cover Wires to Release Remove the Scanner Module (REP 1.10). Repairs June 2014 REP 1.3 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 58: Rep 1.4 Middle Cover

    Make sure that the Plastic Screws go into plastic components and Machine Screws go into the metal frame. Install the components in the reverse of removal. Figure 1 Exit Cover Pivots (Top View) Repairs June 2014 REP 1.3, REP 1.4 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 59 Release the wires from the Main PWB, from the wire guides on the underside of the Mid- dle Cover (Figure Remove the Middle Cover front screws (2) (Figure Repairs June 2014 REP 1.4 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 60: Rep 1.5 Control Panel Pwb

    Make sure that the Plastic Screws go into plastic components and Machine Screws go into the metal frame. Figure 1 Releasing the Control Panel (Bottom View) Install the components in the reverse of removal. Repairs June 2014 REP 1.4, REP 1.5 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 61 Figure 2 Control Panel Removal 3025 BI (Front View) Screws Figure 5 Control Panel PWB Removal 3025 NI Figure 3 Control Panel Removal 3025 NI (Front View) Replacement Install the components in the reverse of removal. Repairs June 2014 REP 1.5 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 62: Rep 1.6 Lvps / Hvps

    For a 3025 NI, remove the FAX PWB (REP 1.9) and the Speaker (2 screws). Remove the Main PWB (REP 1.7). Figure 1 Fax PWB and Metal Shield Screws Repairs June 2014 REP 1.6 4-10 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 63 Make sure that the Plastic Screws go into plastic components and Machine Screws go into the metal frame. Install the components in the reverse of removal. Repairs June 2014 REP 1.6 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-11...
  • Page 64: Rep 1.7 Main Pwb

    Switch Off the Printer and unplug the Power Cord. Figure 1 Main PWB Connectors Remove the following covers: The Front Cover (REP 1.2). The Right Side Cover (REP 1.1). The Rear Cover (REP 1.3). Repairs June 2014 REP 1.7 4-12 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 65 Double-click the executable file and follow the steps listed in the USB Serial applica- tion window to write the machine serial number to the new Main PWB. Figure Repairs June 2014 REP 1.7 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-13...
  • Page 66: Rep 1.8 Left Frame And Drive Motor

    Disconnect the Drive Motor connector (Figure Figure 2 Main Drive Unit Removal (Left View) Connector Figure 1 Drive Motor Connector (Front View) Remove the Fuser Module (REP 1.17). Repairs June 2014 REP 1.8 4-14 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 67 Install, but do not tighten, the screws (7) (Figure Tighten the Frame screws from the center of the Frame: To the Front of the printer, then to the Rear of the Printer. Repairs June 2014 REP 1.8 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-15...
  • Page 68: Rep 1.9 Fax Pwb

    Make sure that the Plastic Screws go into plastic components and Machine Screws go into the metal frame. Install the components in the reverse of removal. Repairs June 2014 REP 1.9, REP 1.10 4-16 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 69 The Figure shows the 3025 BI, the connectors are in the same location for the 3025 NI. Hinge Pivot Slot Figure 2 Scanner Support Hinge Removal (Top View) Connectors Figure 3 Main PWB Scanner/ Control Panel Connectors Repairs June 2014 REP 1.10 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-17...
  • Page 70 Lift the Scanner Module and release it from the hinges (2). Hinge Latch Hinges Figure 4 Scanner Support Hinge (Right Side View) Figure 5 Scanner Removal Replacement Install the components in the reverse of removal. Repairs June 2014 REP 1.10 4-18 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 71: Rep 1.11 Scanner Drive Motor

    Open the Scanner and release the Control Panel from the Scanner (Figure Remove the screws (4). Release the latches (2). Latches Figure 2 Control Panel Removal (Front View) Screws Figure 1 Control Panel Bottom Screws (Bottom View) Repairs June 2014 REP 1.11 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-19...
  • Page 72 Remove the Platen bottom screws (2). Release the latches (8) around the Platen and remove it. Screws Figure 3 Platen Top Screws Screws Figure 4 Platen Removal Repairs June 2014 REP 1.11 4-20 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 73: Rep 1.12 Lsu

    Make sure that the Plastic Screws go into plastic components and Machine Screws go into the metal frame. Install the components in the reverse of removal. Repairs June 2014 REP 1.11, REP 1.12 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-21...
  • Page 74 LSU in the same location. Remove the inside LSU cover screws (2). Screw Screw Figure 2 LSU Cover Top Screws (Top View) Connector Figure 1 LSU Connectors and Screws (Front View) Repairs June 2014 REP 1.12 4-22 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 75: Rep 1.13 Feed Rolls And Retard Pad

    Make sure that the Plastic Screws go into plastic components and Machine Screws go into the metal frame. Connector Install the components in the reverse of removal. Figure 1 Motor Connector and LSU Cover Screws (Front View) Repairs June 2014 REP 1.12, REP 1.13 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-23...
  • Page 76 Remove the Feed Rolls Assembly screws (2) through the bottom of the Printer (Figure Screwdriver Access Holes Front View Screw Figure 2 LSU Cover Top Screws (Top View) Figure 3 Feed Rolls Assembly Screws Removal Repairs June 2014 REP 1.13 4-24 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 77 Move the Retard Pad into the printer to remove it. Latches Figure 4 Feed Rolls Assembly Removal (Top View) Spring Figure 5 Retard Pad Removal (Rear View) Repairs June 2014 REP 1.13 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-25...
  • Page 78: Rep 1.14 Paper Drive Roll And Drive Gear

    Remove the Main Drive Unit (4 screws) (Figure Locating Pins Figure 6 Feed Rolls Assembly Locating Pins (Top View) Screws Figure 1 Main Drive Unit (Left View) Repairs June 2014 REP 1.13, REP 1.14 4-26 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 79 Note the location of the Spring in the frame cutout for reinstallation. Unlatch and remove the actuator. Spring Gear Figure 2 Paper Drive Roll Gear (Left View) Latch Feed Sensor Actuator Figure 3 Feed Sensor Actuator (Rear View) Repairs June 2014 REP 1.14 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-27...
  • Page 80: Rep 1.15 Paper Feed Sensors Pwb And Actuators

    NOTE: When replacing the Main Drive Unit, the drive gears may need to be rotated to align them with the other drives. Install the components in the reverse of removal. Repairs June 2014 REP 1.14, REP 1.15 4-28 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 81: Rep 1.16 Paper Tray

    Release the Paper Tray from the Right Frame. into the metal frame. NOTE: Make sure that the Actuator Spring is location in frame cutout (Figure Repairs June 2014 REP 1.15, REP 1.16 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-29...
  • Page 82: Rep 1.17 Transfer Roll

    NOTE: Make sure the Locating Pins and Tabs on the Paper Tray align with the cutouts in the frame. Figure 1 Transfer Roll Bushing Latches (Rear View) Repairs June 2014 REP 1.16, REP 1.17 4-30 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 83 Transfer Roll Figure 2 Transfer Roll Removal (Top View) Guide Slot Figure 3 Transfer Roll Bushing Alignment (Top View) Install the components in the reverse of removal. Repairs June 2014 REP 1.17 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-31...
  • Page 84: Rep 1.18 Feed Clutch

    Make sure that the Plastic Screws go into plastic components and Machine Screws go into the metal frame. Install the components in the reverse of removal. Connector Figure 1 Feed Clutch Connector Remove the Left Frame (REP 1.8). Repairs June 2014 REP 1.18 4-32 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 85: Rep 1.19 Fuser Module

    Switch Off the Printer and unplug the Power Cord. Remove the Middle Cover (REP 1.4). Remove the Main PWB (REP 1.7). Repairs June 2014 REP 1.19 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-33...
  • Page 86 Remove the Plastic Shield (2 screws) (Figure Disconnect the Fuser Connector (Figure Route the Fuser wires through the frame. Screws Connector Figure 2 Plastic Shield Removal Figure 3 Fuser Connector Repairs June 2014 REP 1.19 4-34 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 87 (Figure Install the components in the reverse of removal. Repairs June 2014 REP 1.19 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-35...
  • Page 88: Rep 1.20 Wnpc (Wifi) Pwb

    Figure 1 LSU Connectors Remove the SMPS / HVPS PWB (REP 1.6). WNPC PWB Figure 1 WNPC (WiFi) PWB Replacement Install the components in the reverse of removal. Repairs June 2014 REP 1.20, REP 1.21 4-36 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 89: Rep 1.22 Automatic Document Feeder (Adf)

    Make sure that the Plastic Screws go into plastic components and Machine Screws go into the metal frame. Install the components in the reverse of removal. Repairs June 2014 REP 1.21, REP 1.22 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-37...
  • Page 90: Rep 1.23 Platen Cover

    Figure 2 ADF Connector Replacement Install the components in the reverse of removal. Figure 1 Platen Cover Removal Replacement Install the components in the reverse of removal. Repairs June 2014 REP 1.22, REP 1.23 4-38 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 91: Rep 1.24 Adf Feed Separation Pad

    Remove the ADF Cover, release the Rear Pivots and remove the cover (Figure Rear Pivot Latches Figure 1 ADF Cover Pivots (Top View) Figure 2 Separation Pad Latches (Top View) Repairs June 2014 REP 1.24 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-39...
  • Page 92: Rep 1.25 Adf Feed Rolls Assembly

    Remove the ADF Cover, release the Rear Pivots and remove the cover (Figure Rear Pivot Spring Figure 1 ADF Cover Pivots (Top View) Figure 3 Separation Pad Spring (Top View) Repairs June 2014 REP 1.24, REP 1.25 4-40 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 93 NOTE: Install the E-rings in the following order: The E-ring by the gear. The E-ring (center) by the Spring. The E-ring at the end of the shaft. Repairs June 2014 REP 1.25 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-41...
  • Page 94 Repairs June 2014 REP 1.25 4-42 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 95 PL 5.5 Right Main Frame ....................5-15 Middle And Bottom Frame PL 5.6 Paper Tray and LSU Frame................. 5-16 Idle Feed PL 5.7 Paper Feed Assembly ..................5-17 Part Number Index ......................5-18 Parts List June 2014 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 96 Parts List June 2014 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 97: 1.1 Main

    Paper Support (Black) 002N03180 Right Cover – 002N03181 Right Cover (Black) 140N63718 PWB-MAIN-3025 BI (USB / Wifi) 140N63727 WNPC (WiFi) PWB – Controller Shield – Document Pad Parts Lists June 2014 PL 1.1 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 98: 1.2 Main

    FAX Board Cover 140N63726 Fax PWB 140N63717 PWB-MAIN-3025 NI (NW / Wifi) 140N63727 WNPC (WiFi) PWB – Speaker – Controller Shield 005N01172 Surge Protector (South Africa Only) Parts Lists June 2014 PL 1.2 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 99: 1.3 Adf (Automatic Document Feeder)

    PL 1.3 ADF (Automatic Document Feeder) Item Part Description 022N02801 ADF Feed Roll Assembly 127N07864 ADF Drive Motor 022N02800 ADF Separation Pad Parts Lists June 2014 PL 1.3 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 100: Middle Cover

    Top Cover Closed Switch Actuator – Spring – Latch – Spring – Middle Cover 002N03185 Middle Cover Assembly – 002N03186 Middle Cover Assembly (Black) – Output Tray – Output Support Parts Lists June 2014 PL 2.1 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 101: 3.1 Control Panel Assembly

    Key Holder Cover – LCD Cover – LED Status Indicator – Power Key – Stop Key – Power Saver Key – Start Key 140N63732 Control Panel Assembly Parts Lists June 2014 PL 3.1 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 102: 3.2 Control Panel Assembly

    Control Panel Cover – Function Key – FAX Key – Tel Key – LCD Cover 140N63722 Control Panel PWB – Key Holder Cover 140N63731 Control Panel Assembly Parts Lists June 2014 PL 3.2 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 103: 4.1 Scanner

    Upper Scanner Frame – Lower Scanner Frame – Sensor – Flat Cable – Platen Scanner – Scanner Drive Motor – Drive Belt – Contact Image Sensor (CIS) Parts Lists June 2014 PL 4.1 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 104: 4.2 Scanner

    Upper Scanner Frame – Lower Scanner Frame – Scanner PWB – Flat Cable – Sensor – Platen Scanner – Platen Drive – Drive Belt – Contact Image Sensor Parts Lists June 2014 PL 4.2 5-10 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 105: 5.1 Frame

    Fuser (PL 5.2) – LSU Cover – Right Frame – HVPS Insulator – HVPS Contacts 105N02303 LVPS/HVPS 220V – 105N02302 LVPS/HVPS 110V – Input Guide – HVPS/SMPS Cover Parts Lists June 2014 PL 5.1 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 5-11...
  • Page 106: 5.2 Fuser

    – Exit Shaft – Rubber Rolls – Exit Roll – Exit Holder – Exit Roll – Spring 126N00432 FUSER Module 110V – 126N00433 FUSER Module 220V Parts Lists June 2014 PL 5.2 5-12 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 107: 5.3 Frame Path

    Paper Path Guide – Feed Roll Shaft 121N01246 Feed Clutch 007N01801 Feed Gear – Left Bushing – Spring – Right Bushing 001N00547 Retard Pad – Path Frame Parts Lists June 2014 PL 5.3 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 5-13...
  • Page 108: Left Main Frame

    Fuser Drive Gear – RDCN Fuser Gear – RDCN A Gear – Drive Motor – Left Main Frame – Drive Mounting Plate 001N00548 Drive Gear Assembly Parts Lists June 2014 PL 5.4 5-14 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 109: Right Main Frame

    Right Frame – CRUM Contacts – Spring – Ground Clip – Washer – Screw – CRUM Cover – Print Cartridge Guide – Main Right Frame Assembly Parts Lists June 2014 PL 5.5 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 5-15...
  • Page 110: 5.6 Paper Tray And Lsu Frame

    Left Guide – Rubber Friction Pad – Bottom Plate – Pinion Gear – Sponge Damper 062N00293 – Motor Cover – LSU Frame 117N01971 LSU Flat Cable Parts Lists June 2014 PL 5.6 5-16 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 111: 5.7 Paper Feed Assembly

    Pickup Roller – Washer – Bushing – Sleeve – Spring – Pickup Gear – Feed Gear – Shaft Drive Roller – Right Latch – Sponge Damper Parts Lists June 2014 PL 5.7 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 5-17...
  • Page 112: Part Number Index

    PL 1.2 062N00293 PL 5.6 090N00183 PL 1.2 090N00184 PL 1.1 090N00185 PL 1.1 105N02302 PL 5.1 105N02303 PL 5.1 117N01971 PL 5.6 120N00546 PL 5.3 Parts Lists June 2014 Part Number Index 5-18 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 113 Entering Diagnostic Mode (Tech Mode)................6-21 Data Setup ........................6-24 Machine Test........................6-25 Report ..........................6-26 EDC (Diagnostic) Mode ....................6-26 6d Glossary Glossary of Terms......................6-29 General Procedures and Information June 2014 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 114 General Procedures and Information June 2014 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 115 • Sensor Locations - Figure 5 • Laser Scanner Unit (LSU) - Figure 6 Refer to Xerox® WorkCentre® 3025BI/3025NI User Guide for detailed feature and configura- tion information. • Drives - Figure 7 •...
  • Page 116 The following diagrams display the path that the paper follows during the printing process. Figure 3 System Layout Figure 1 Paper Path Figure 2 Automatic Document Feeder (ADF) 3025NI Model General Procedures and Information June 2014 Product Overview Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 117 Figure 5 shows the areas of the printer where the sensors are located on the 3025NI model. cess. Figure 4 Print Process Figure 5 Sensor Locations General Procedures and Information June 2014 Product Overview Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 118 (OPC) with a laser to create a latent image. with various gears for the Drum Cartridge (OPC), Fuser, Pick-up, Registration, Feed and Exit Rollers. Figure 6 Laser Scanner Unit Figure 7 Drives General Procedures and Information June 2014 Product Overview Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 119 From Platen in Power Save Mode 42 seconds From ADF in Standby Mode 15 seconds From ADF in Power Save Mode 42 seconds Resolution 1200 x 1200 dpi General Procedures and Information June 2014 Product Overview, Product Specifications Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 120 256 Color 300dpi: 65 ipm on Document Glass, 70 ipm from ADF • True Color 300dpi: 70 ipm on Document Glass, 70 ipm from ADF General Procedures and Information June 2014 Product Specifications Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 121 Windows® 2000/ XP (32/64bit) Windows® Vista(32/64bit) Windows® 2003 Server (32/64bit) Windows® 2008 Server (32/64bit) Windows® 7 (32/64bit) Windows® 2008 Server R2 (64bit) Windows® 8 (32/64bit) General Procedures and Information June 2014 Product Specifications Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 122 12.04, 12.10, 13.04 (32/64 bit) SuSE Linux Enterprise Desktop 10, 11 (32/64 bit) Debian 5.0, 6.0, 7.0, 7.1 (32/64 bit) Mac OS X 10.5 through 10.8 General Procedures and Information June 2014 Product Specifications 6-10 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 123 Face down: 100 sheets @ 80 gsm Output Full Sensing Duplex Supporting Printable Area Non-Printable Area 3 mm (0.12 in.) from edge (top, bottom, left, right) General Procedures and Information June 2014 Product Specifications Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 6-11...
  • Page 124 3025BI: 14.66.lbs. (6.65 Kg) Print cartridge) • 3025NI: 17.64 lbs. (8.0 Kg) Operating Environment Temperature 50°- 90°F (10°C to 32°C) Humidity 20% - 80% RH General Procedures and Information June 2014 Product Specifications 6-12 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 125 Login to CWIS: username (admin) password (1111) NOTE: It may be necessary to obtain the username and password from the customer if they have been changed. General Procedures and Information June 2014 GP 1, GP 2 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 6-13...
  • Page 126 Printing machine reports Use the up/down arrows to select <Usage Counter>, then press <OK>, then <OK> again to print a Usage Counter report. General Procedures and Information June 2014 GP 2, GP 3 6-14 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 127 Open Easy Printer Manager. Select: [Machine Settings, System Altitude Adjustment]. Select the correct altitude value for the placement of the machine. Table 1. Press <OK>. General Procedures and Information June 2014 GP 4, GP 5 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 6-15...
  • Page 128 Login in to CWIS. Username: (Admin) Password: (1111) NOTE: It may be necessary to obtain the username and password from the customer if they have been changed. General Procedures and Information June 2014 GP 6 6-16 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 129 Click [Apply] to save the changes. 10. Select the [Support] tab. 11. In the [Firmware Upgrade] link, select the [Upgrade Wizard] button. In the Firmware File area, select [Browse]. General Procedures and Information June 2014 GP 7 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 6-17...
  • Page 130 Panel. Press the Copy Mode button to continue. Test the display buttons by pressing them sequentially, as indicated on the Control Panel display. General Procedures and Information June 2014 GP 8, GP 9 6-18 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 131 Continue pressing the <Stop> button until all control panel indicator lights are turned off and the machine is returned to Copy mode. General Procedures and Information June 2014 GP 9, GP 10 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 6-19...
  • Page 132 General Procedures and Information June 2014 GP 9, GP 10 6-20 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 133 In Diagnostic Mode, use the navigation buttons to scroll to the following sub-menus. Press<OK> after selecting menu items. • Data Setup • Machine Test • Report • Exit Diagnostics General Procedures and Information June 2014 Diagnostic Information, Entering Diagnostic Mode Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 6-21...
  • Page 134 *Caller ID Off/On *Busy Tone Off/On Wrap Jam Clear No/Yes F/W Upgrade Off/On **Set Serial No. Enter machine serial number (Numeric characters only) General Procedures and Information June 2014 Entering Diagnostic Mode 6-22 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 135 K THV - Bias Status: Off/On 109 Fuser Temp A Status: 110 LSU LSU Mot1 Run Status: Off/On LD Power4 Status: Off/On LSU HSync4 Status: General Procedures and Information June 2014 Entering Diagnostic Mode Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 6-23...
  • Page 136 Pickup Roll – Retard Roller – Forward Roller – Feed Roller – ADF Rubber Pad NOTE: A passcode is required to reset these counters. General Procedures and Information June 2014 Entering Diagnostic Mode 6-24 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 137 Image Sensor. • Scan Aging An internal Engineering tool that tests the reliability of the Scanner Motor. (Not a field diagnostic function.) General Procedures and Information June 2014 Data Setup, Machine Test Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 6-25...
  • Page 138 109 Fuser Fuser Temp A Detects what the tem- Input Numeric 3 perature A is on fuser. digits General Procedures and Information June 2014 Report, EDC (Diagnostic) Mode 6-26 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 139 LSU Motor1 On/Off Output On [Off] LSU LD Power4 LSU LD4 Power On/Off Output On [Off] (black) LSU HSync4 LSU Horizontal Sync Input [Low] General Procedures and Information June 2014 EDC (Diagnostic) Mode Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 6-27...
  • Page 140 General Procedures and Information June 2014 EDC (Diagnostic) Mode 6-28 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 141 Glossary of Terms Table 1 Glossary Term/Acronym Definition NOTE: For a comprehensive list of Xerox acronyms, refer to the Xerox Acronym database at: Gateway A node (a router) on a TCP/IP network that serves as an access point https://open.xerox.com/Services/acronym to another network.
  • Page 142 Internet. The first part of the address indicates what protocol to use, the second part specifies the IP address or the domain name where the resource is located. General Procedures and Information June 2014 Glossary of Terms 6-30 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 143 Content Development and Language Services - North America Xerox Corporation 800 Phillips Road; Building 0218-01A Webster, New York 14580 USA ©2014 Xerox Corporation. All rights reserved. Xerox® and the sphere of connectivity design are trademarks of Xerox Corporation in the US and/or other countries..
  • Page 144 THIS PAGE INTENTIONALLY BLANK June 2014 ® ® Xerox WorkCentre 3025 Multifunction Printer Service Manual BSDs...
  • Page 145 DC COM DC COM DC COM +5VDC +5 VDC +5 VDC +5 VDC DC COM +3.3 VDC +24 VDC POWER GENERATION DC COM +3.3 VDC +3.3 VDC +3.3 VDC +3.3 VDC June 2014 BSD’s Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 146 LED Y ANODE DC COM DC COM DC COM +5 VDC +5 VDC +5 VDC DC COM SIGNAL +3.3 VDC SIGNAL SIGNAL WIDTH SENSOR FEED SENSOR June 2014 ® ® Xerox WorkCentre 3025 Multifunction Printer Service Manual BSDs 7- 2...
  • Page 147 ECO KEY WPS LED WPS KEY POWER LED POWER KEY DC COM DC COM DC COM +5 VDC +5 VDC +5 VDC CANCEL KEY READY LED ERROR LED TONER LED June 2014 BSD’s Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 148 4.1 MAIN DRIVE MAIN PWB PL 1.1 - 1.2 +24 VDC DRIVE MOTOR PL 5.4 MOTOR DRIVER PHASE A PHASE B PHASE C PHASE D June 2014 ® ® Xerox WorkCentre 3025 Multifunction Printer Service Manual BSDs...
  • Page 149 +3.3 VDC DC COM +3.3 VDC DC COM DC COM +3.3 VDC +3.3 VDC DC COM DC COM DC COM DC COM DC COM +3.3 VDC +3.3 VDC +3.3 VDC June 2014 BSD’s Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 150 PL 1.1 - 1.2 ADF PWB +24 VDC ADF MOTOR PL 3.1 MOTOR DRIVER PHASE A PHASE A PHASE B PHASE B PHASE C PHASE C PHASE D PHASE D June 2014 ® ® Xerox WorkCentre 3025 Multifunction Printer Service Manual BSDs...
  • Page 151 MOTOR READY MOTOR CLOCK POWER MOTOR SIGNAL SIGNAL DC COM DC COM DC COM SIGNAL SIGNAL DC COM DC COM DC COM SYNC SIGNAL +3.3 VDC +3.3 VDC +3.3 VDC June 2014 BSD’s Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 152 +3.3 VDC WIDTH SENSOR PAPER AT REG SENSOR (L) +3.3 VDC +3.3 VDC +3.3 VDC FEED CLUTCH PL 5.3 +24 VDC FEED CLUTCH ON (L) +24 VDC DC COM June 2014 ® ® Xerox WorkCentre 3025 Multifunction Printer Service Manual BSDs...
  • Page 153 DEVELOPER ENABLED DEVELOPER AC DEVELOPER DC TRANSFER ENABLED SUPPLY PR DRUM ROLL CHARGE ENABLED TRANSFER CHARGE ON ROLL CRUM +3 VDC +3.3 VDC CRUM SIGNAL CRUM SIGNAL DC COM DC COM June 2014 BSD’s Xerox® WorkCentre® 3025 Multifunction Printer Service Manual...
  • Page 154 PL 5.1 FUSER THERMISTOR RT10-001 Fuser Temperature Enable Fuser Signal Relay Fuser Relay +3.3 VDC FUSER MODULE PL5.2 +3.3 VDC OVERTEMPERATURE THERMOSTAT Heat Lamp On ACH HEAT LAMP June 2014 ® ® Xerox WorkCentre 3025 Multifunction Printer Service Manual BSDs 7-10...
  • Page 155 PHASE B SCAN HOME SENSOR SIGNAL PHASE C SCANNER HOME +5 VDC SENSOR SCANNER HOME PHASE D (H) +5 VDC DC COM DC COM +5 VDC +5VDC June 2014 ® ® Xerox WorkCentre 3025 Multifunction Printer Service Manual BSDs 7-11...
  • Page 156 ©2014 Xerox Corporation. All rights reserved. Xerox® and the sphere of connectivity design are trademarks of Xerox Corporation in the US and/or other countries..

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