Xerox® WorkCentre® 3025BI/NI

Service Manual

702P02831
June 2014
Initial Issue
Xerox® WorkCentre® 3025 Multifunction Printer Service Manual WARNING
This equipment generates, uses and can radiate radio frequency energy, and if not
Service Documentation
installed and used in accordance with the instructions documentation, may cause inter-
ference to radio communications. It has been tested and found to comply with the limits
Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
for a Class A computing device pursuant to subpart J of part 15 of FCC rules, which are
designed to provide reasonable protection against such interference when operated in
702P02831
a commercial environment. Operation of this equipment in a residential area is likely to
cause interference in which case the user, at his own expense, will be required to cor-
June 2014
rect the interference.
DANGER: Cet équipement génère, utilise et peut émettre des fréquences radio, et, s'il
Prepared by:
n'est pas installé et utilisé selon les recommandations du manuel d'instructions, peut
Content Development and Language Services - North America causer des interférences aux communications radio. Il a été testé et jugé conforme aux
limites des systèmes de catégorie A, conformément à la partie 15 de l'alinéa J des règle-
800 Phillips Road - Building 218-01A ments FCC, établis pour protéger contre de telles interférences pendant le fonctionne-
ment en milieu commercial. Dans une zone résidentielle, il peut causer des
interférences; dans ce cas, l'utilisateur devra corriger le problème à ses propres frais.
Webster, New York 14580-9791

ISO9001 and ISO27001 Certified

©2014 Xerox Corporation. All rights reserved. Xerox®, Xerox and Design®, and Xerox® are
trademarks of Xerox Corporation in the US and/or other countries.

Printed in the United States of America.

***Xerox Private Data***

All service documentation is supplied to Xerox external customers for informational purposes
only. 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. You
should consult the applicable warranty for its terms regarding customer or third-party provided
service.

While Xerox has tried to make the documentation accurate, Xerox will have no liability arising
out of any inaccuracies or omissions.

June 2014
Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 1
June 2014 Draft
2 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
 Introduction
About This Manual .......................................................................................................... iii
How to Use this Manual .................................................................................................. iv
Service Safety Summary................................................................................................. v
Reference Symbology..................................................................................................... vi
Voltage Specifications..................................................................................................... vii
Health and Safety Incident Reporting ............................................................................. viii
Regulatory Specifications................................................................................................ ix
Translation of Warnings .................................................................................................. x
Tag Usage....................................................................................................................... xi
WorkCentre 3025 Overview ............................................................................................ xii

June 2014 Introduction

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual i
Introduction June 2014
ii Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
About This Manual Section 6 General Procedures and Information
This section contains general information, change tag information, and general proce-
Introduction dures.
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. This manual is the primary document used for diagnosing,
Specifications, and I/O Module locations and information.
repairing, maintaining, and troubleshooting these systems. The Service Manual is the control-
ling publication for a service call. Information about using this document is found in the Intro-
duction section. To ensure understanding of this product, complete the Xerox Service Training
Program for this particular device. Component Names
Names of parts that appear in the procedures may not be exactly the same as the names that
Organization appear on the part or listed in the Parts List. For example: a part called the Registration
The WorkCentre® 3025 Service Manual is organized and defined within the following sections: Assembly may appear on the Parts List as Assembly, REGI.

Section 1 Service Call Procedures

This section contains procedures that determine what actions are to be taken during a
service call on the machine and in what sequence they are to be completed. This is the
entry level for all service calls.
Section 2 Status Indicator RAPs
This section contains the diagnostic aids for troubleshooting the Fault Code and non-Fault
Code related faults (with the exception of image quality problems).
Section 3 Image Quality Repair Analysis Procedures
This section contains the diagnostic aids for troubleshooting any image quality problems,
as well as image quality specifications and image defect samples.
Section 4 Repairs and Adjustments
This section contains the Adjustment and Repair procedures.

Repairs include procedures for removal and replacement of parts which have the following
special conditions:
• When there is a personnel or machine safety issue.
• When removal or replacement cannot be determined from the exploded view of the Parts
List.
• When there is a cleaning or a lubricating activity associated with the procedure.
• When the part requires an adjustment after replacement.
• When a special tool is required for removal or replacement.
Use the repair procedures for the correct order of removal and replacement, for warnings, cau-
tions, and notes.

Adjustments include procedures for adjusting the parts that must be within specification for the
correct operation of the system.

Use the Adjustment Procedures for the correct sequence of operation for specifications, warn-
ings, cautions and notes.

Section 5 Parts List

This section consists of a series of illustrations and an associated parts listing. Any part
that is spared or any part that must be removed to access a spared part is illustrated.
Common hardware is shown as a letter callout.

June 2014
Xerox® WorkCentre® 3025 Multifunction Printer Service Manual iii About This Manual
How to Use this Manual
Always start with the Service Call Procedures, Section 1. Perform Initial Actions and verify the
problem, then follow the directions given.

How to Differentiate Between Machine Variants

The machine configuration will be identified in this manual by the configuration identifiers
3025BI and 3025NI.

The WorkCentre® 3025 is Blue Angel certified with software configuration for up to 21 ppm
capability. Refer to the User Guide, Parts List and Procedures for information specific to printer
configuration.

When a procedure, parts list description or other reference is unique amongst different configu-
rations of the machine, the appropriate configuration designator is indicated. Any artwork is
also specific.

NOTE: This manual services all configurations of the machine. Ignore references to options
not installed on the machine.

Warnings, Cautions and Notes

WARNING
A warning is used whenever an operating or maintenance procedure, practice, condi-
tion or statement, if not strictly observed, could result in personal injury.
A translated version of all warnings is in Translation of Warnings.

CAUTION
A caution is used whenever an operation or maintenance procedure, practice, condition or
statement, if not strictly observed, could result in damage to the equipment.

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 iv Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
Service Safety Summary Warning Labels
General Guidelines Read and obey all posted warning labels. Throughout the printer, warning labels are displayed
on potentially dangerous components. As you service the printer, check to make certain that all
For qualified service personnel only: Refer also to the preceding Electrical Safety.
warning labels remain in place.
Avoid servicing alone: Do not perform internal service or adjustment of this product unless
another person capable of rendering first aid or resuscitation is present. Safety Interlocks
Make sure all covers are in place and all interlock switches are functioning correctly after you
Use care when servicing with power applied: Dangerous voltages may exist at several points in have completed a printer service call. If you bypass an interlock switch during a service call,
this product. To avoid personal injury, do not touch exposed connections and components use extreme caution when working on or around the printer.
while power is on. Disconnect power before removing the power supply shield or replacing
components. Electrostatic Discharge (ESD) Field Service Kit
The purpose of the ESD Protection Program is to preserve the inherent reliability and quality of
Do not wear jewelry: Remove jewelry prior to servicing. Rings, necklaces and other metallic electronic components that are handled by the Field Service Personnel. This program has
objects could come into contact with dangerous voltages and currents. been implemented as a direct result of advances in microcircuitry technology, as well as a new
acknowledgment of the magnitude of the ESD problem in the electronics industry today.
Electrical Safety
• Use the Power Cord supplied with the printer. This program will reduce Field Service costs that are charged to PWB failures. Ninety percent
• Plug the Power Cord directly into a properly grounded electrical outlet. of all PWB failures that are ESD related do not occur immediately. Using the ESD Field Service
• Do not use a ground adapter plug to connect the printer to an electrical outlet that does Kit will eliminate these delayed failures and intermittent problems caused by ESD. This will
improve product reliability and reduce callbacks.
not have a ground connection terminal.
• Do not use an extension cord or power strip.
The ESD Field Service Kit should be used whenever Printed Wiring Boards or ESD sensitive
• Do not place the system in an area where people might step on the power cord. components are being handled. This includes activities like replacing or re-seating of circuit
• Do not place objects on the power cord. boards or connectors. The kit should also be used in order to prevent additional damage when
• Do not block the ventilation openings. These openings are provided to prevent overheat- circuit boards are returned for repair.
ing of the printer.
The instructions for using the ESD Field Service Kit can be found in [GP 8] in the General Pro-
• Do not drop paper clips or staples into the printer.
cedures Section of the Service Manual.
Operational Safety
The printer and supplies were designed and tested to meet strict safety requirements. These Product Safety Certification
include safety agency examination, approval, and compliance with established environmental This product is certified by various NRTLs/NCBs to the safety standards listed below:
standards. UL60950-1/CSA22.2, No. 60950-1 (USA/Canada)

Pay attention to these safety guidelines to ensure the continued, safe operation of the printer. IEC60950-1 (CB Scheme)
• Use the supplies specifically designed for your system. The use of unsuitable materials
may cause poor performance and a possible safety hazard.
• Follow all warnings and instructions marked on, or supplied with, the system, options and
supplies.

NOTE: The Total Satisfaction Guarantee is available in the United States and Canada. Cover-
age may vary outside these areas; please contact your local representative for details.

Maintenance Safety
• Do not attempt any maintenance procedure that is not specifically described in the docu-
mentation supplied with the printer.
• 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
Xerox® WorkCentre® 3025 Multifunction Printer Service Manual v Service Safety Summary
Reference Symbology 7. 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.
1. Flag
• This symbol indicates a reference point into a circuit diagram from a RAP.

Safety Symbols and Terminology

The following are examples of the terminology and symbols that are used in this documenta-
tion for an Electrostatic Device Caution, Laser Warning, and general Warnings, Cautions, or
2. Note Notes.
• This symbol is used to refer to notes that are found on the same page of a circuit dia-
gram. A note is used whenever it is necessary to highlight an operating or mainte- WARNING
nance procedure, a practice, condition, or statement. Improper operation may result in injury to a person.
• Hints or other information that may assist the user.

3. Parts List
• This symbol, example (PL2.1), refers to the Parts List exploded view page where the CAUTION
part can be found. Improper operation may result in machine damage.
4. Adjustment
• This symbol refers to an adjustment procedure in the Repair/Adjustments section.

Laser
5. Test Point, Test Hole, Test Stake
Indicates that Laser safety precautions must be used.
• This symbol is used to indicate that a test point, test hole, or test stake is available
for accessing the signal line. The prefix indicates whether the access is a test point
(TP), test hole (TH), or test stake (TS).

6. Commoning Point Hot Surface

• This symbol is used to refer to a location in the machine wiring where more than two Indicates that a surface can be hot. Use caution when reaching in the machine to avoid touch-
wires a connected together at a single point. ing the hot surface.

Introduction June 2014

Reference Symbology vi Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
 Voltage Specifications
AC and DC Voltages
Measurements of DC voltage must be made with reference to the specified DC Common,
unless some other point is referenced in a diagnostic procedure. All measurements of AC volt-
age should be made with respect to the adjacent return or ACN wire (Table 1).
Electrical Current
Danger label indicates where electrical currents travel when the machine is closed and operat- Table 1 Voltage Measurement and Specifications
ing. Use caution when reaching in the machine.
VOLTAGE SPECIFICATION
110 to120 VAC 60Hz 100 to 132 VAC
Neutral to Ground VAC 0 VAC (+/- 5VAC)
+5 VDC +5.05 VDC TO +5.25 VDC
+12 VDC +11.4 VDC TO +12.6 VDC
-12 VDC -11.4 VDC TO -12.6 VDC
ESD +24 VDC +22.8VDC TO +25.2 VDC
Certain components in this product are susceptible to damage from Electrostatic Discharge. +36 VDC +34.2 VDC TO +37.8 VDC
Observe all ESD procedures to avoid component damage.
Logic Voltage Levels
Measurements of logic levels must be made with reference to the specified DC Common,
unless some other point is referenced in a diagnostic procedure (Table 2).

Table 2 Logic Levels

VOLTAGE H/L SPECIFICATIONS
+5 VDC H= +3.00 TO +5.25 VDC, L=
0.0 TO 0.8 VDC
+24 VDC H= +23.37 TO +27.06 VDC,
L= 0.0 TO 0.8 VDC

DC Voltage Measurements in RAPs

The RAPs have been designed so that when it is required to use the DMM to measure a DC
voltage, the first test point listed is the location for the red (+) meter lead and the second test
point is the location for the black meter lead. For example, the following statement may be
found in a RAP:

There is +5 VDC from TP7 to TP68.

In this example, the red meter lead would be placed on TP7 and the black meter lead on TP68.

Another example of a statement found in a RAP might be:

There is -15 VDC from TP21 to TP33.

In this example, the red meter lead would be placed on TP21 and the black meter lead would
be placed on 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
Xerox® WorkCentre® 3025 Multifunction Printer Service Manual vii Reference Symbology, Voltage Specifications
Health and Safety Incident Reporting Responsibilities for resolution:
1. Business Groups/Product Design Teams responsible for the product involved in the inci-
I. Summary dent shall:
This section defines requirements for notification of health and safety incidents involving Xerox
a. Manage field bulletins, customer correspondence, product recalls, safety retrofits.
products (equipment and materials) at customer locations.
b. Fund all field retrofits.
II. Scope 2. Field Service Operations shall:
a. 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 b. Return any affected equipment/part(s) to the location designated by Xerox EH&S
and/or the Business Division.
To enable prompt resolution of health and safety incidents involving Xerox products and to
c. Implement all safety retrofits.
ensure Xerox regulatory compliance.
3. Xerox EH&S shall:
IV. Definitions a. Manage and report all incident investigation activities.
Incident: b. Review and approve proposed product corrective actions and retrofits, if necessary.
c. Manage all communications and correspondence with government agencies.
An event or condition occurring in a customer account that has resulted in injury, illness or d. Define actions to correct confirmed incidents.
property damage. Examples of incidents include machine fires, smoke generation, physical
injury to an operator or service representative. Alleged events and product conditions are
included in this definition.

V. Requirements
Initial Report:
1. Xerox organizations shall establish a process for individuals to report product incidents to
Xerox Environment Health & Safety within 24 hours of becoming aware of the event.
2. The information to be provided at the time of reporting is contained in Appendix A (Health
and Safety Incident Report involving a Xerox product).
3. The initial notification may be made by any of the following methods:
• For incidents in North America and Developing Markets West (Brazil, Mexico, Latin
American North and Latin American South):
– Phone* Xerox EH&S at: 1-800-828-6571.
– Electronic mail Xerox EH&S at: [email protected].
– Fax Xerox EH&S at: 1-585-216-8817 [intelnet 8*219-8817].
• For incidents in Europe and Developing Markets East (Middle East, Africa, India,
China and Hong Kong):
– Phone* Xerox EH&S at: +44 (0) 1707 353434 [intelnet 8*668 3434]
– Electronic mail Xerox EH&S at: EH&[email protected]
– Fax Xerox EH&S at: +44 (0) 1707 353914 [intelnet 8*668 3914]
*Initial notification made by phone must be followed within 24 hours by a completed inci-
dent report and sent to the indicated electronic mail address or fax number.

NOTE: If sending a fax, please also send the original via internal mail.

Introduction June 2014

Health and Safety Incident Reporting viii Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
Regulatory Specifications To ensure compliance with European Union regulations, use shielded interface cables.

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.

United States (FCC Regulations)

The Xerox® WorkCentre® 3025 has been tested and found to comply with the limits for a
Class A digital device pursuant to Part 15 of the FCC Rules. These limits are designed to pro-
vide reasonable protection against harmful interference in a commercial installation. This
equipment generates, uses, and can radiate radio frequency energy. If it is not installed and
used in accordance with these instructions, it may cause harmful interference to radio commu-
nications. Operation of Class A equipment in a residential area is likely to cause harmful inter-
ference in which case the user will be required to correct the interference at his/her own
expense. There is no guarantee that interference will not occur in a particular installation.

If this equipment does cause harmful interference to radio or television reception, which can be
determined by turning the equipment Off and On, the user is encouraged to try to correct the
interference by one or more of the following measures:

• Reorient or relocate the receiver.

• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to which the receiver
is connected.
• Consult the dealer or an experienced radio/television technician for help.
Any changes or modifications not expressly approved by Xerox could void the user's authority
to operate the equipment. To ensure compliance with Part 15 of the FCC rules, use shielded
interface cables.

Canada (Regulations)
This Class A digital apparatus complies with Canadian ICES-003.

Cet appareil numérique de la classe A est conforme à la norme NMB-003 du Canada.

European Union

CE Mark

The CE mark applied to this product symbolizes Xerox’s

declaration of conformity with the following applicable Direc-
tives of the European Union as of the dates indicated:
Figure 1 CE Symbol

December 12, 2006: Low Voltage Directive 2006/95/EC

December 15, 2004: Electromagnetic Compatibility Directive 2004/108/EC

This product, if used properly in accordance with the user's instructions, is neither dangerous
for the consumer nor for the environment.

June 2014
Xerox® WorkCentre® 3025 Multifunction Printer Service Manual ix Regulatory Specifications
Translation of Warnings WARNING
WARNING Follow the service procedure exactly as written. Use of controls or adjustments other
than those specified in this manual, may result in an exposure to invisible laser radia-
Switch off the electricity to the machine. Disconnect the power cord from the customer
tion. During servicing, the invisible laser radiation can cause eye damage if looked at
supply while performing tasks that do not need electricity. Electricity can cause death or
directly.
injury. Moving parts can cause injury.
DANGER : Les procédures de dépannage doivent être suivies à la lettre. Si les réglages
DANGER : Mettez la machine hors tension. Déconnectez le cordon d'alimentation de
ou vérifications ne sont pas effectués suivant les instructions de ce manuel, il peut y
l'alimentation du client lorsque vous réalisez des tâches qui ne nécessitent pas d'élec-
avoir un risque d'exposition dangereuse au faisceau laser. Celui-ci peut provoquer des
tricité. L'électricité peut être à l'origine de blessures, voire d'un accident mortel. Les
lésions oculaires s'il est observé directement.
pièces amovibles peuvent être à l'origine de blessures.
AVVERTENZA: Eseguire le procedure di servizio esattamente come descritto. L'utilizzo
AVVERTENZA: Spegnere la macchina. Scollegare il cavo di alimentazione dall'alimenta-
di dispositivi di controllo o di registrazione diversi da quelli riportati in questo manuale
tore quando si eseguono attività che non richiedono elettricità. L'elettricità può causare
potrebbe comportare un'esposizione a radiazioni laser invisibili. Tali radiazioni possono
morte o lesioni personali. Le parti in movimento possono causare lesioni personali.
danneggiare gli occhi se si guarda direttamente il fascio laser durante gli interventi di
VORSICHT: Schalten Sie die Stromversorgung der Maschine ab. Ziehen Sie das Stromk- servizio.
abel ab, wenn Sie Aufgaben ausführen, für die keine Stromversorgung benötigt wird.
VORSICHT: Die Wartungsarbeiten genau den Anweisungen entsprechend durchführen.
Stromschläge können Todesfällen oder Verletzungen verursachen. Bewegliche Teile
Der Umgang mit Steuer- oder Bedienelementen, deren Verwendung nicht ausdrücklich
können zu Verletzungen führen.
in diesem Handbuch angewiesen wurde, kann dazu führen, dass unsichtbare Laser-
AVISO: Apague la electricidad de la máquina. Desconecte el cable de alimentación eléc- strahlung frei gesetzt wird. Direkter Blickkontakt mit dem Laserstrahl kann bleibende
trica de la toma de pared mientras esté realizando tareas que no necesiten corriente. La Augenschäden verursachen.
electricidad puede causar daños o la muerte. Las partes móviles pueden causar daños.
AVISO: Siga los procedimientos de mantenimiento tal como están descritos. El uso de
controles o ajustes no especificados en este manual puede tener como resultado la
exposición a radiación láser invisible. Durante las operaciones de mantenimiento, la
WARNING radiación de láser invisible puede causar daños en los ojos si se mira directamente a
Do not work in a confined space. 1 m (39 inches) space is needed for safe working. ella.
DANGER : Ne pas travailler dans un espace restreint. 1 mètre d'espace est nécessaire
pour un dépannage en toute sécurité.
AVVERTENZA: Non lavorare in uno spazio limitato; è necessario uno spazio di almeno WARNING
un metro attorno alla macchina per la sicurezza dell'operatore. USA and Canada. Do not install this machine in a hallway or exit route that does not
VORSICHT: Nur mit ausreichendem Bewegungsspielraum (1 m) arbeiten. have 1.12 m (44 inches) of space additional to the normal space requirements in front of
AVISO: No trabaje en un espacio reducido. Se necesita 1 metro de espacio para trabajar the machine. To conform with fire regulations this additional 1.12 m (44 inches) of space
is needed in front of the machine in hallway and exit routes.
con seguridad.
DANGER : États-Unis et Canada. Si cette machine est installée dans un couloir ou une
WARNING voie de sortie, 1,12 m (44 pouces) d'espace supplémentaire à l'espace normal doit être
Use safe handling procedures when removing the module. Refer to GP 16. The module disponible devant la machine conformément aux normes de sécurité d'incendie.
is heavy.
AVVERTENZA: N/A
DANGER: Conformez-vous aux procédures de manipulation de sécurité pour le retrait
VORSICHT: N/A
du module. Reportez-vous à GP 16. Le module est lourd.
AVISO: Estados Unidos y Canadá. No instale esta máquina en un corredor o ruta de sal-
AVVERTENZA: Utilizzare procedure di gestione sicure durante la rimozione del modulo.
ida que no tenga 1.12 m (44 pulgadas) de ancho delante de la máquina, sin incluir el
Vedere GP 16. Il modulo è pesante.
espacio que ocupe la máquina. Este espacio adicional de 1.12 m (44 pulgadas) delante
VORSICHT: Verwenden Sie sichere Vorgehensweisen zum Entfernen des Moduls. Siehe de la máquina en corredores y rutas de salida es necesario para cumplir los requisitos
auch 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 x Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
 WARNING Tag Usage
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.
appropriate part or action.
DANGER : N'utilisez que des matières premières et des composants Xerox. La sécurité
du produit est assurée dans le cadre de son utilisation avec des matières premières et • Example 1). Tag xx: PWB
des composants Xerox. L'utilisation de matières premières et de composants autres
• Example 2) PWB (Tag xx)
que ceux de Xerox risque d'invalider le certificat de sécurité.
AVVERTENZA: Utilizzare solo materiali e componenti Xerox per avvalersi della certifi- Tag Symbols
cazione di protezione. L'utilizzo di materiali e componenti non Xerox può rendere nulla This symbol is used to show a particular part or area of a figure that has been modified by the
la certificazione di protezione. Tag number within the circle.
VORSICHT: Verwenden Sie nur Materialien und Komponenten von Xerox. Dieses
Produkt besitzt die Sicherheitszertifizierung bei Verwendung von Xerox-Materialien und
-Komponenten. Die Verwendung von Materialien und Komponenten anderer Hersteller
setzt möglicherweise das Sicherheitszertifikat außer Kraft.
AVISO: Utilice solo los materiales y componentes Xerox. Este producto dispone de un
certificado de seguridad si se utilizan los materiales y componentes Xerox. Este certifi-
cado de seguridad no será válido si se utilizan materiales y componentes que no sean
de Xerox. This symbol is used to show a particular part or area of a figure that has not been modified by
the Tag number within the circle.
WARNING
Do not touch the fuser while it is hot.
DANGER : Ne pas toucher au four pendant qu'il est encore chaud.
AVVERTENZA: Non toccare il fonditore quando è caldo.
VORSICHT: Fixierbereich erst berühren, wenn dieser abgekühlt ist.
AVISO: No toque el fusor mientras está caliente.
This symbol is used to show a Tag change has modified an area of the terminal.

This symbol is used to show a Tag change has not modified an area of the terminal.

June 2014
Xerox® WorkCentre® 3025 Multifunction Printer Service Manual xi Translation of Warnings, Tag Usage
WorkCentre 3025 Overview
Refer to the WorkCentre® 3025 User Guide for detailed descriptions and illustrations of Con-
trol Panel functions, machine features and options.

Product Configurations

Table 1
Component WorkCentre 3025BI WorkCentre 3025NI
Automatic Document Feeder - 40 sheets Not Applicable Standard
Paper Tray1 - 150 Sheets Standard Standard
Output Tray - 100 Sheets Standard Standard
Direct Printing Standard Standard
AirPrint Standard Standard
Google Cloud Print Standard Standard
Copy Standard Standard
Scan Standard Standard
Fax Not Applicable Standard
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 xii Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
 1 Service Call Procedures
Call Flow
Service Call Overview ..................................................................................................... 1-3
Safety Precautions .......................................................................................................... 1-3
SCP 01 Introduction to Service Call Procedures ............................................................ 1-4
SCP 02 Initial Actions...................................................................................................... 1-4
SCP 03 Corrective Actions.............................................................................................. 1-5
SCP 04 Final Actions ...................................................................................................... 1-5

System/Subsystem Maintenance
HFSI’s ............................................................................................................................. 1-6

June 2014 Service Call Procedures

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 1-1
Service Call Procedures June 2014
1-2 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
Service Call Overview Safety Precautions
This section provides an overview of actions a service technician should take when servicing a Ensure that all Cautions and Warnings detailed in the service procedures are followed when
machine. Refer to the checklist below as a guide for steps to take when troubleshooting prob- servicing the machine.
lems with the printer. Follow all precautions listed in the Safety Precautions section.
Failure to follow the following instructions could cause an electrical shock or fire hazard.
1. Identify the problem • Only use the Power Cord supplied with this product.
• Verify that the problem exists. Do not allow the Power Cord to become twisted, bent, or damaged.
• Record any error codes. • Do not allow liquids to spill on or into the machine.
• Print both customer and test prints. • Do not allow paper clips, pins or other objects to fall into the machine.
• Make note of any image quality problems in the test prints. • When replacing the LVPS PWB wait 5 minutes after unplugging the Power Cord before
• Observe if any unusual odors or noises coming from the printer. removing the PWB. This allows the PWB to discharge, preventing electrical shock.
• Ensure that the AC input power is within specifications. Laser Safety
• From the Diagnostics Mode, print an Error Information Report. • The Laser system is designed so there is never human access to the Laser radiation dur-
2. Inspect and clean the printer ing normal operation, user maintenance, or service maintenance.
• Disconnect and inspect the power cord. • Do not bypass or disable any laser safety devices or attempt to service the Laser.
• Inspect the interior of the printer. Remove any debris or contamination.
• Inspect the printer for damaged wires, loose connections toner leakage or any other
worn or damaged parts.
3. Find the cause of the problem.
• Use troubleshooting procedures to find the root cause of the problem
• Use diagnostics to check the printer and components
• Use the BSDs and wiring diagrams to locate test points.
• Take voltage readings as instructed in the troubleshooting procedure.
4. Correct the problem
• Use the Parts List to locate part numbers.
• Use the Repair Procedures to replace parts.
5. Final Actions
• Test the printer to verify that the problem has been corrected and that there are no
additional problems.

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.

June 2014 Service Call Procedures

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 1-3 Service Call Overview, Safety Precautions
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.
observations and print samples are all used to gather information about the condition of the
system. Gather a list of symptoms, error codes, or other information concerning the problem
The Operator has been trained in the use of the Xerox® WorkCentre® 3025 User Guide, Trou-
that the customer may provide. This information may help identify and correct intermittent or
bleshooting in Section 12, to help analyze the fault. The Troubleshooting section directs the
unusual problems.
Operator in the following:
During each service call, perform all Primary Maintenance Activities, then decide if Secondary
• Faults indicated by a Status Code or UI message
Maintenance Activities are needed.
• Web Registration Module problem solving
• Image quality defect initial actions • Primary Maintenance Activities are actions performed which relate to the customer’s com-
• Image quality defect diagnosis plaint.
• Image quality fault code problem solving • Secondary Maintenance Activities are any activities identified during the service call
which are not related to the primary activity, but may lead to a future service call or other-
If the Operator is unable to resolve the problem, they initiate a service call by contacting The
Xerox Support Center at: www.xerox.com/support. wise negatively affect the customer’s satisfaction.
Before deciding to perform any secondary maintenance, first determine if the customer is
SCP 02 Initial Actions in a time-sensitive print run. If so, perform only those actions required to ensure comple-
tion of the run, and defer all other actions-- including HFSI’s that are not required to com-
The purpose of Initial Actions is to gather information and organize the service call. The cus-
plete the print run. The objective of any service call during a time-sensitive print run is to
tomer is questioned, and the complaint is verified.
return the system to production as soon as possible.

All anticipated service actions are classified as primary or secondary. Primary service actions Before performing any secondary maintenance actions, first inform the customer of what
secondary actions are indicated and the system down time required. You may want to
are those actions that directly relate to the reason for the call.
return on another, mutually agreeable time to perform the secondary maintenance activ-
ity/actions.
SCP 03 Corrective Actions
Likewise, for any secondary maintenance actions deferred during a time-sensitive print
Corrective Actions are the diagnostic and repair activities required to correct the problem that
run, inform the customer of what remaining secondary actions are indicated and the down
initiated the service call (primary actions), as well as any other problems or secondary actions
time required. Coordinate with the customer’s print schedule to determine a mutually-
identified in Initial Actions.
agreeable time frame to complete these activities.

When performing maintenance actions, either scheduled or unscheduled, always consider the Procedure
customer’s print schedule and whether they are in a highly time-sensitive print run, or in a less 1. Discuss the problem with the customer.
time-sensitive print run. The customer’s current mode of operation will determine the service 2. If the problem is IQ related, run prints to verify that the problem is present.
actions on Unscheduled Maintenance (UM) calls. The objective of all service actions is to inte-
3. Determine if there are any bulletins, or Eureka tips relating to the Customer's primary
grate the Xerox service process with the customer’s printing process in a manner that maxi- problem. Bulletins are on Eureka and are searchable with SearchLite.
mizes customer equipment up-time and productivity during periods of time-sensitive print runs. 4. When all information has been gathered, and all anticipated service actions have been
classified as primary or secondary, proceed to Corrective Actions.

Service Call Procedures June 2014

SCP 01, SCP 02 1-4 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
SCP 03 Corrective Actions SCP 04 Final Actions
Purpose Purpose
Final Actions verify total operation of the machine, ensures that the HSFI’s are completed.
The Corrective Actions procedure will direct you to the appropriate section of the service man-
ual to diagnose and repair the primary problem, and provides the information required to iden-
tify any due HFSI items. Procedure
1. Print a Sample Job and verify with the operator the total operation of the machine. If any
Procedure problems are identified, return to SCP 03 Corrective Actions.
1. Using the Supplies Information report, review the HFSI’s in to identify any due HFSI’s. 2. Complete the service call:
Clean/replace only components that are due and that may be contributing to the problem. • Check the customer consumables.
System Fault Analysis • Service tools are properly stored and secured.
1. If the problem is a machine fault, determine if the type of fault code. • Verify the access to the circuit breakers is clear.
a. If the problem is a Printer fault code: • Check that covers are in place and closed.
• Enter Diagnostic Mode and print an Error Information Report. Menu sequence • Verify that all mandatory retrofits have been installed. If required, set a time with the
for entering Diagnostics will vary depending on machine model. Refer to Sec- customer to install any mandatory retrofits.
tion 6 Diagnostics for detailed information.
• Check for associated fault codes that have the same or nearly the same times-
tamp as the primary fault code.
• Troubleshoot fault codes with the lowest chain number first.
2. If the problem is IQ related, refer to Section 3, Image Quality.
3. When the primary problem is resolved, proceed to Final Actions.

June 2014 Service Call Procedures

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 1-5 SCP 03, SCP 04
HFSI’s If necessary, and if the customer agrees, clean/replace any secondary HFSI’s that are due or
may cause a return service call.
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

HSFI Item Action Customer Service Reference Interval Notes
Toner Cartridge Replace X N/A 1,500 standard yield (approxi- Initial cartridge yield is approximately 700 prints.
mate impressions)
Drum Cartridge (OPC) Replace X N/A 10,000
Fuser Replace X REP 1.18 30,000
Transfer Roller Replace X REP 1.17 30,000
Pickup (Feed) Roller Replace X REP 1.14 30,000
ADF Feed Roller Replace X REP 1.13 20,000
ADF Rubber Pad Replace X X REP 1.24 20,000

Service Call Procedures June 2014

1-6 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
 2 Status Indicator RAPs
01-100 Top Cover Open Fault ........................................................................................ 2-3
03-410 Paper Mismatch at Tray 1 ................................................................................... 2-3
05-100 / 900 Paper Jam in Automatic Document Feeder (ADF) Fault ........................... 2-4
05-500 Document Feeder Cover Open Fault .................................................................. 2-4
06-100 / 200 LSU Motor Fault ......................................................................................... 2-5
07-110 Paper Jam or Tray Empty Fault .......................................................................... 2-6
08-100 Paper Feed Fault - Tray 1................................................................................... 2-7
08-500 Paper Jam in Fuser Area Fault ........................................................................... 2-7
09-100 Print Cartridge Near End of Life Fault ................................................................. 2-8
09-350 Print Cartridge End of Life Fault.......................................................................... 2-8
09-450 Print Cartridge At End of Life Fault ..................................................................... 2-9
09-550 Print Cartridge Undetected Fault ........................................................................ 2-9
09-800 Incompatible Print Cartridge Fault ...................................................................... 2-10
10-100 Fuser Temperature (Open) Fault ........................................................................ 2-10
10-200/ 300 Fuser Under/ Over Temperature Fault........................................................ 2-11
14-100 Document Scanner Assembly Locked Fault ....................................................... 2-12
17-100 IP Conflict Error Fault.......................................................................................... 2-12
17-310 Communication Error (Main PWB to Wireless PWB) Fault................................. 2-13
20-100 Fax Communication Error Fault .......................................................................... 2-13
20-120 Scanning Error Fault ........................................................................................... 2-14
20-200 Group Not Available Fault ................................................................................... 2-14
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

June 2014 Status Indicator RAPs

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 2-1
Status Indicator RAPs June 2014
2-2 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
01-100 Top Cover Open Fault 03-410 Paper Mismatch at Tray 1
The Front cover is open or the cover open switch is defective. The size setting for the Paper Tray does not match the paper size loaded in the tray.

BSD-Reference: 1.1 AC/Low Voltage and High Voltage Power / Interlocks BSD-Reference: 7.1 Paper Feed and Registration

Initial Actions Initial Actions

Ensure that the Front cover is completely closed. • Check the media size settings for the tray from the Control Panel.
• Adjust the Paper Tray Guides to match the size of the paper that is loaded into the tray.
Procedure • Place the correct size paper into the tray for the tray size setting.
WARNING
Do not perform repair activities with the power on or electrical power supplied to the Procedure
machine. The machine could activate and cause serious personal injury when the power 1. Switch Off the power then switch On the power.
is on or electrical power is supplied. 2. If problem continues, replace the Main PWB (REP 1.7) , PL 1.1.
DANGER: Ne pas effectuer de dépannage avec le contact principal activé ou avec l'ali-
mentation électrique appliquée à la machine: celle-ci pourrait démarrer et causer de
graves blessures.
AVVERTENZA: Non effettuare alcuna riparazione con la macchina accesa o con l'ali-
mentazione elettrica inserita. La macchina potrebbe avviarsi all'improvviso e causare
gravi ferite.
VORSICHT: Es dürfen keine Reparaturarbeiten durchgeführt werden, solange das Gerät
eingeschalten oder mit der Stromquelle verbunden ist. Das Gerät kann u.U in den Aktiv-
Zustand übergehen und somit erhebliche körperliche Schäden verursachen.
AVISO: No realice reparaciones con la máquina encendida o conectada a la corriente. La
máquina podría activarse y ocasionar daños personales graves.
Check the Top Cover Open Switch Actuator for binding or damage. The Actuator moves
freely.
Y N
Replace the LVPS/HVPS PWB (REP 1.5), PL 5.1.

Check the connection between the Main PWB and the HVPS. The connection is secure.
Y N
• Check that there is no contamination present.
• Check for broken or defective wires or cables.
• Replace the Main PWB (REP 1.7), PL 1.1.

Replace the LVPS/HVPS PWB (REP 1.5), PL 5.1.

June 2014 Status Indicator RAPs

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 2-3 01-100 , 03-410
05-100 / 900 Paper Jam in Automatic Document Feeder 05-500 Document Feeder Cover Open Fault
(ADF) Fault The Document Feeder or Document Feeder Top Cover is not securely latched.
The machine has detected a paper jam in the Automatiac Document Feeder (3025NI).
BSD-Reference: 5.1A Automatic Document Feeder
BSD-Reference: 5.1B Automatic Document Feeder
Initial Actions
Initial Actions • Close the Document Feeder unit.
• Remove jammed sheets from the document feeder and paper path. Refer to The Work- • Close the Document Feeder top cover.
Centre® 3025 User Guide, Section 11 for jam clearance instructions.
• If necessary, power the machine Off then On to clear the fault message. Procedure
• Open the top cover of the Document Feeder and check the Feed Roll for contamination or Check the circuit between the ADF Cover Sensor and the Main PWB. The circuit is good.
wear. Y N
• Check for broken or defective wires and that no contamination is present.
Procedure • Secure the connection.
Inspect the Paper Feed Sensor for damage or contamination. Remove any debris from the • Replace parts as required.
sensor.
Enter Diagnostic (EDC) Mode. Select: [DC330 Component Control, 102 Sensor, Feed Replace the Main PWB (REP 1.7), PL 1.1.
Sens] to test the Paper Feed Sensor. The sensor is OK.
Y N
• Check for any open or short circuit and clear any contamination that is present.
• Replace the paper Feed Sensor PWB (REP 1.15), PL 5.3.

Check circuit between the ADF Drive Motor and the Main PWB. The circuit is good.
Y N
• Check for an open or short circuit and clear any contamination that is present.
• Replace the ADF Drive Motor PL 3.1.

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), PL 1.1.

Status Indicator RAPs June 2014

05-100 / 900 , 05-500 2-4 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
06-100 / 200 LSU Motor Fault
The machine has detected that the Laser Module Drive Motor is not working correctly.

BSD-Reference: 6.1 (Laser (ROS)

Procedure
WARNING
Do not perform repair activities with the power on or electrical power supplied to the
machine. The machine could activate and cause serious personal injury when the power
is on or electrical power is supplied.
DANGER: Ne pas effectuer de dépannage avec le contact principal activé ou avec l'ali-
mentation électrique appliquée à la machine: celle-ci pourrait démarrer et causer de
graves blessures.
AVVERTENZA: Non effettuare alcuna riparazione con la macchina accesa o con l'ali-
mentazione elettrica inserita. La macchina potrebbe avviarsi all'improvviso e causare
gravi ferite.
VORSICHT: Es dürfen keine Reparaturarbeiten durchgeführt werden, solange das Gerät
eingeschalten oder mit der Stromquelle verbunden ist. Das Gerät kann u.U in den Aktiv-
Zustand übergehen und somit erhebliche körperliche Schäden verursachen.
AVISO: No realice reparaciones con la máquina encendida o conectada a la corriente. La
máquina podría activarse y ocasionar daños personales graves.
WARNING
Use eye protection when performing the following procedure. Failure to wear eye pro-
tection could result in serious personal injury.
DANGER: Porter des lunettes de sécurité pendant la procédure suivante. À défaut, de
graves blessures peuvent se produire.
AVVERTENZA: Indossare occhiali di protezione durante la seguente procedura. In caso
contrario, si possono provocare gravi ferite.
VORSICHT: Folgende Verfahren dürfen nicht ohne Schutzbrille angewandt werden. Die
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.

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Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 2-5 06-100 / 200
Enter Diagnostic (EDC) Mode. Select: [DC330 Component Control, 110 LSU, LSU Mot1 07-110 Paper Jam or Tray Empty Fault
Run] to test the LSU motor. The motor runs.
The Tray Empty Sensor failed to detect paper in the tray.
Y N
Check the Main Wire Harness and connectors between the Laser Module and the Main
BSD-Reference: 7.1 Paper Feed and Registration
PWB. The connections are secure.
Y N
• Check that the connectors are secure and no contamination is present. Initial Actions
• Disconnect and securely reconnect the harness. Ensure that paper is loaded in the tray. Clear any jammed sheets. Refer to Section 7: Trouble-
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.
Y N
• Check that the connectors are secure and no contamination is present. Procedure
• Replace the harness (REP 1.21), PL 5.6. Check the actuators for the Feed and Width Sensors. The actuators move freely and are
undamaged.
Replace the Laser Module. (REP 1.12), PL 5.6. Y N
Replace the Feed or Width Sensor actuator, (REP 1.15), PL 5.3.
Go to [SCP 04] Final Actions.
Enter Diagnostic(EDC) Mode. Select: [DC330 Component Control, 102 Sensor, Feed Sen-
sor. Actuate and deactuate the Feed Sensor. The sensor signal changes.
Y N
1. Check that there is no contamination present.
2. Check the circuit between the Paper Feed PWB and the Main PWB for an open or
short circuit.
3. Replace parts as required.

If the problem is intermittent, check the circuit of the Feed Sensor PWB.

Status Indicator RAPs June 2014

06-100 / 200 , 07-110 2-6 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
08-100 Paper Feed Fault - Tray 1 08-500 Paper Jam in Fuser Area Fault
The lead edge was not detected by the Paper Feed Sensor. The machine has detected a jam in the Fuser area.

BSD-Reference: 1.1 AC Low Voltage and High Voltage Power/Interlocks BSD-Reference: 10.1 Fuser

BSD-Reference: 7.1 Paper Feed and Registration Initial Actions

Open the Top Cover and remove any jammed sheets from Fuser area. Refer Section 11 in the
Initial Actions WorkCentre® 3025 User Guide for detailed Jam Clearance instructions.
NOTE: When clearing any jams, see if the Lead Edge of the Jammed Sheet reached the
Retard Roller. BSD-Reference:

Clear any jammed sheets. (Refer to Section 11 in the WorkCentre® 3025 User Guide for Procedure
detailed instructions on jam clearance.)
WARNING
Procedure 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.
Check the Feed Sensor Actuator. The Actuator moves freely.
DANGER: Ne pas manipuler les éléments du four avant de les laisser refroidir. Certains
Y N
éléments du four fonctionnent à des températures très élevées et peuvent causer de
Replace the Feed Sensor Actuator (REP 1.15) [PL 5.3].
graves blessures s'ils sont touchés.
Check the position of the jammed sheet. The lead edge reached the Retard Roller. AVVERTENZA: Non maneggiare i componenti del fusore finché non sono raffreddati.
Y N Alcuni di questi componenti funzionano ad alte temperature e possono provocare gravi
Enter Diagnostics (EDC) Mode. Select: [DC330 Component Control, 101-Clutch, Tray ferite se vengono toccati.
1 Pick up] to engage the drive to pick up paper from tray 1 The clutch engages. VORSICHT: Die Fixieranlage sollte erst gehandhabt werden, wenn diese genügend
Y N abgekühlt ist. Einige Teile der Fixieranlage erzeugen übermäßige Hitze und führen bei
• Check the Feed Clutch connections on the Main PWB for contamination. Clean der Berührung zu schweren Verbrennungen.
as necessary. AVISO: No manipule los componentes del fusor antes de que se enfríen. Algunos de los
• Check the circuits from the Feed Clutch to the LVPS/HVPS for an open or short componentes del fusor funcionan a altas temperaturas y pueden ocasionar daños per-
circuit. sonales graves si se los toca.
• If the circuits are good replace the Feed Clutch (REP 1.18), PL 5.3. 1. Enter Diagnostics Mode and select [Data Setup, Wrap Jam Clear] then press <OK>.
The fault clears.
In Diagnostics Mode. Select: [102-Sensor, Feed Sensor] to block and clear the Paper Y N
Feed Sensor. The signal changes. • Switch Off the Power and disconnect the Power Cord.
Y N • Remove the Left, Right REP 1.1, and Rear Covers REP 1.3.
• Check that the connection is secure and no contaminatin or damage is present
• Ensure the connectors are firmly secured to the PWBs.
• Check that there is no damage or contamination on any connectors from the
• Switch On the power while pressing the <Cancel> button to reboot the machine.
Feed Sensor to the LVPS/HVPS PWB. Repair as necessary.
The fault clears.
• Replace the Paper Feed Sensor PWB (REP 1.15 , PL 5.3.
Y N
• Switch Off the power.
Perform SCP Final Actions.
• If problem is intermittent, check the Fuser Sensor. Replace if necessary PL 5.2.
If the problem is intermittent, recheck the cables and look for a cable that is binding. • If problem continues, Remove the Fuser Assembly REP 1.18 and replace if
necessary PL 5.2.

Exit Diagnostic Mode and perform SCP Final Actions

Exit Diagnostics Mode and perform SCP Final Actions.

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Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 2-7 08-100 , 08-500
09-100 Print Cartridge Near End of Life Fault 09-350 Print Cartridge End of Life Fault
The Print Cartridge life is less than 10%. The Print Cartridge has reached end of life.

BSD-Reference: None BSD-Reference: None

Procedure Procedure
1. Check the remaining life of the Print Carftridge by using one of the methods listed below: 1. Check the remaining life of the Print Carftridge by using one of the methods listed below:
• Print a Supplies Information Report. [GP 2] • Print a Supplies Information Report. [GP 2]
• Open Easy Print Manager, check Toner life under printer information • Open Easy Print Manager, check Toner life under printer information
• Open the CWIS application. Select: [Status, Supplies, Print Cartridge]. • Open the CWIS application. Select: [Status, Supplies, Print Cartridge].
2. Check the remaining life of the Print Cartridge. 2. Check the remaining life of the Print Cartridge.
3. If the Print Cartridge has reached end of life, switch Off the power and replace the Print 3. 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 2-8 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
09-450 Print Cartridge At End of Life Fault 09-550 Print Cartridge Undetected Fault
The Print Cartridge is empty. The Print cartridge has not been installed or machine software is unable to detect the Print
Cartridge.
BSD-Reference: None
BSD-Reference: None
Procedure
Switch Off the power and replace the Print Cartridge. Initial Actions
Ensure that the Print Cartridge has been installed and the cover is fully closed and latched.

Procedure
1. Switch Off the power.
2. Remove the Print cartridge. Rotate the cartridge five to six rotations to distribute the toner
evenly.
3. Check the CRUM contact area for contamination and clean if necessary.
4. Reinstall the Print Cartridge.
5. If the problem continues, install a new Print Cartridge.

June 2014 Status Indicator RAPs

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 2-9 09-450 , 09-550
09-800 Incompatible Print Cartridge Fault 10-100 Fuser Temperature (Open) Fault
The Print Cartridge is not compatible with the printer. The temperature of the Fuser is outside of the normal operating range of 383°F ± 5°F (195°C ±
5°C.)
BSD-Reference: None
BSD-Reference: 1.1 AC/Low Voltage and High Voltage Power Supplies/Interlocks
Procedure
BSD-Reference: 10.1 Fuser
1. Perform one of the following to obtain a Supplies Info report.
• From Diagnostics Mode, use the Control Panel buttons to scroll to: [Report, Sup-
plies Info] to print a Supplies Information report. (Press the <OK> button to confirm
Initial Actions
menu selections) Switch Off the power then switch On the power. If the error code returns, continue with this pro-
cedure.l
• From Easy Print Manager Advanced Mode menu, select [Machine Settings, Print
Information, Supplies Information] and print the Supplies Info Report.
• From CWIS, select [Status, Print Information] and check the Supplies Information Procedure
box and print the report. WARNING
2. Check the Print Cartridge Supplier information. Do not handle the fuser components until they have cooled. Some fuser components
3. Replace the Print Cartridge if it is not a genuine Xerox® cartridge. operate at hot temperatures and can produce serious personal injury if touched.
4. If problem continues, go to RAP 09-500, Toner Cartridge Undetected Fault to check for DANGER: Ne pas manipuler les éléments du four avant de les laisser refroidir. Certains
CRUM faults. éléments du four fonctionnent à des températures très élevées et peuvent causer de
graves blessures s'ils sont touchés.
AVVERTENZA: Non maneggiare i componenti del fusore finché non sono raffreddati.
Alcuni di questi componenti funzionano ad alte temperature e possono provocare gravi
ferite se vengono toccati.
VORSICHT: Die Fixieranlage sollte erst gehandhabt werden, wenn diese genügend
abgekühlt ist. Einige Teile der Fixieranlage erzeugen übermäßige Hitze und führen bei
der Berührung zu schweren Verbrennungen.
AVISO: No manipule los componentes del fusor antes de que se enfríen. Algunos de los
componentes del fusor funcionan a altas temperaturas y pueden ocasionar daños per-
sonales graves si se los toca.

Power Off the machine and check that the Fuser connection is fully seated. The Fuser con-
nections are OK.
Y N
Firmly reconnect the Fuser assembly. Switch the power ON.

Check for +3.3 VDC to the Thermistor at P/J 16 on the Main PWB. The voltage is present.
Y N
• Check the wire harness for open circuit, short circuits or contaminati\on.
• Firmly reconnect the Fuser assembly.
• Replace the Main PWB (REP 1.7), PL 1.1, PL 1.2.

A
Status Indicator RAPs June 2014
09-800 , 10-100 2-10 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
A
Check the voltage to the Over Heat Thermostat. The voltage is present.. 10-200/ 300 Fuser Under/ Over Temperature Fault
Y N
10-200: The temperature of the Fuser is below of the normal operating range of 383°F ± 5°F
• Check for AC line voltage to the LVPS/HVPS PWB,
(195°C ± 5°C.)
• Check that the connectors are tight and no contamination is present.
• Check the wire harness from the LVPS/HVPS PWB for a open or short circuit. 10-300: The temperature of the Fuser is above the normal operating range of 383°F ± 5°F
• Replace the LVPS/HVPS PWB (REP 1.6), PL 5.1. (195°C ± 5°C.)

Check the circuits and connectors for the Fuser Module. BSD-Reference: 10.1 Fuser
Check the Heat Lamp for an open circuit.
Replace the Fuser Assembly (REP 1.19), PL 5.2. Initial Actions
Switch Off the power. Remove and reinstall the Fuser Assembly. Switch On the power.

Procedure
WARNING
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.
DANGER: Ne pas manipuler les éléments du four avant de les laisser refroidir. Certains
éléments du four fonctionnent à des températures très élevées et peuvent causer de
graves blessures s'ils sont touchés.
AVVERTENZA: Non maneggiare i componenti del fusore finché non sono raffreddati.
Alcuni di questi componenti funzionano ad alte temperature e possono provocare gravi
ferite se vengono toccati.
VORSICHT: Die Fixieranlage sollte erst gehandhabt werden, wenn diese genügend
abgekühlt ist. Einige Teile der Fixieranlage erzeugen übermäßige Hitze und führen bei
der Berührung zu schweren Verbrennungen.
AVISO: No manipule los componentes del fusor antes de que se enfríen. Algunos de los
componentes del fusor funcionan a altas temperaturas y pueden ocasionar daños per-
sonales graves si se los toca.

Enter Diagnostic (EDC) Mode. Select: [DC330 Component Control, 109 Fuser Heat, Temp
A] to obtain a temperature reading from the Fuser. The Fuser temperature is within normal
operating range.
Y N
Replace the Fuser Assembly (REP 1.19), PL 5.2.

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.

June 2014 Status Indicator RAPs

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 2-11 10-100 , 10-200/ 300
14-100 Document Scanner Assembly Locked Fault 17-100 IP Conflict Error Fault
The Document Scanner Assembly does not move. The IP address conflicts with that of another system causing a machine communication error.

BSD-Reference: BSD 14.1 Scanning BSD-Reference: None

Initial Actions 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].
Procedure
Check the Scanner Cable to make sure it is securely connected. The scanner cable is con-
nected.
Y N
• Check that the connectors are secure and no contamination is present
• disconnect and securely reconnect the Scanner Cable.

Enter Diagnostic (EDC) Mode. Select [DC330, Component Control, 100 Scanner Drive
Motor] to test the Scanner Drive Motor. The Motor runs.
Y N
Check the connectors between the Scan Motor and the Control PWB. The connections
are secure.
Y N
• Check that no contamination is present.
• Disconnect and securely reconnect the connector

Replace the Scanner Drive Motor (REP 1.11), PL 4.1 and PL 4.2.

If the problem continues, replace the Main PWB (REP 1.8), PL 1.1.

Status Indicator RAPs June 2014

14-100 , 17-100 2-12 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
17-310 Communication Error (Main PWB to Wireless PWB) 20-100 Fax Communication Error Fault
Fault A communication error occurred during a fax transmission.
The machine software has detected a communication error between the Main PWB and the
BSD-Reference: BSD 3.1B Communications
Wireless PWB.

BSD-Reference: 3.1A Communications Initial Actions

1. Call the target fax number to confirm a fax response.
Initial Actions 2. Check condition of the fax line and connection.
• Switch Off the power then switch On the power. 3. Verify that the fax line is an analog phone line.
• Check machine network and data configuration settings. 4. Switch Off the power then switch On the power.
5. Verify that the country setting is correct.
Procedure 6. Resend the fax job.
1. Ensure that the connectors are fully seated between the Main PWB and the Wireless 7. Check fax communications to a different machine.
PWB and no contamination is present.
2. If the problem persists, replace parts in the following order: Procedure
• Flat Cable PL 4.1 Enter Diagnostic Mode. From the Control panel, select: [Report, Error Info, Print] to print the
• Wireless PWB (REP 1.20), PL 1.1 and PL 1.2 Error Information Report. The target fax is causing the error.
• Main PWB (REP 1.8), PL 1.1 and PL 1.2 Y N
In Diagnostics, select: [Report, Fax Options] to verify Fax Send settings are at default.

Check that the Target Fax configuration is OK. The Target Fax is OK.
Y N
Reconfigure Target Fax.

Check the voltage between the Fax PWB and the Main PWB. The voltage is present.
Y N
• Check that no contamination is present.
• Check the connection between the Fax PWB and the Main PWB for an open or short
circuit.
• 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 and PL 1.2

June 2014 Status Indicator RAPs

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 2-13 17-310 , 20-100
20-120 Scanning Error Fault 20-200 Group Not Available Fault
A error such as a paper jam or scanner fault has occurred during a manual-dial fax operation. User has selected a group location where only a single location number can be used. (I.e.:
Adding locations for a multi-dial operation.)
BSD-Reference: BSD 14.1 Scanning
BSD-Reference: None
Procedure
Clear any jammed sheets. Refer to the WorkCentre® 3025 User Guide for detailed jam clear- Procedure
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
20-400 / 410 Line Fault 20-500 Memory Full Fault
Unable to connect with the remote machine. The fax line is busy or an error has occurred with The memory is full.
fax transmission due to a phone line problem.
BSD-Reference: None
BSD-Reference: None
Procedure
Procedure 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.

June 2014 Status Indicator RAPs

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 2-15 20-400 / 410 , 20-500
20-600 No Answer Fault 20-700 Number Not Assigned Fault
The printer unable to connect to remote machine after maximum redial attempts. The speed dial location used has no number assigned to it.

BSD-Reference: BSD-Reference:

Procedure Procedure
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.

Status Indicator RAPs June 2014

20-600 , 20-700 2-16 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
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.

June 2014 Status Indicator RAPs

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 2-17 20-900
Status Indicator RAPs June 2014
20-900 2-18 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
 3 Image Quality
Image Quality Overview .................................................................................................. 3-3
IQ1 Vertical Black Line and Band RAP ........................................................................... 3-4
IQ2 Vertical White Line and Band RAP........................................................................... 3-4
IQ3 Horizontal Black Bands RAP.................................................................................... 3-5
IQ4 Spots RAP ................................................................................................................ 3-5
IQ5 Low Image Density RAP .......................................................................................... 3-6
IQ6 Black or Dark Image RAP ........................................................................................ 3-6
IQ7 Uneven Density RAP................................................................................................ 3-7
IQ8 Background RAP ...................................................................................................... 3-8
IQ9 Residual Image (Ghosting) RAP .............................................................................. 3-9
IQ10 Side 2 Staining ....................................................................................................... 3-9
IQ11 Blank Page RAP..................................................................................................... 3-10
IQ12 Partial Image Deletions RAP.................................................................................. 3-11

June 2014 Image Quality

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 3-1
Image Quality June 2014
3-2 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
Image Quality Overview • Stains on the page back
Fuser:
Image quality defects can be attributed to printer components, consumables, media, internal
software, external software applications, and environmental conditions. To successfully trou- • Ghosting
bleshoot print-quality problems, eliminate as many variables as possible. • Stains on the page back or front
• Poor image adhesion
If the print-quality defect is still present after printing on approved media from an unopened Print Cartridge:
ream of paper, investigate software applications and environmental conditions. Check the tem-
• Uneven density
perature and humidity under which the printer is operating. Compare this to the Environmental
Specifications listed in Section 6. • Background contamination
• Spots, smudges, or smears
When analyzing a imaging defect, determine if the defect is repeating or random. Check the • Ghosting
Supplies Information Report for end of life conditions. Inspect the visible surfaces of all rollers • Vertical white lines
for obvious defects. If a cursory inspection does not reveal any obvious defects, continue trou-
• Vertical black line or band
bleshooting the defect.
• Stains on the page front
WARNING • Blank prints
Do not perform repair activities with the power on or electrical power supplied to the • Black prints
machine. Some machine components contain dangerous electrical voltages that can • Horizontal Black lines or bands
result in electrical shock and possible serious injury. After determining the defect type and possible source, match the defect with those listed in
DANGER: Ne pas effectuer de dépannnage avec le contact principal activé ou avec l'ali- Table 1. Go to the RAP listed to correct the defect.
mentation électrique appliquée à la machine. Certains éléments de la machine compor-
tent des tensions électriques dangereuses qui peuvent causer un choc électrique et de Image Defect Definitions
graves blessures. Table 1 lists image defect definitions and the RAP used to correct the problem.
AVVERTENZA: Non effettuare alcuna riparazione con l'alimentazione elettrica inserita.
Alcuni componenti contengono corrente ad alta tensione che può provocare forti Table 1 Image Defect Definitions
scosse e gravi ferite.
Defect Definition Go To
VORSICHT: Es dürfen erst Reparaturarbeiten durchgeführt werden, wenn das Gerät aus-
geschaltet ist oder der Netzstecker nicht mehr mit der Stromquelle verbunden ist. Ein- Vertical Black Line Vertical black lines or bands occur in the printed image. IQ1
ige Komponenten des Gerätes sind stromführend und können daher zu ernsthaften and Band
Verletzungen oder Stromschlägen führen. Vertical White Line Vertical white lines or bands occur in the printed image. IQ2
AVISO: No realice reparaciones con la máquina encendida o conectada a la corriente. and Band
Algunos componentes de la máquina contienen voltajes eléctricos peligrosos que Horizontal Black Periodic dark or blurry horizontal bands in the printed IQ3
pueden producir una descarga eléctrica y causar daños graves. Band image.
Defects Associated with Specific Components Spots Random or periodic dark areas in the low density IQ4
areas of a print, or voids in the dark areas of a print.
To aid with diagnosis, the list below outlines image defects associated with specific compo-
nents. Low Image Density Printed image is light with no ghosting. IQ5
Black or Dark Image Printed image is totally dark or black IQ6
Laser Scanner Unit: Uneven Density Print density is uneven between the left and right por- IQ7
• Black Print tion of the printed image.
• Vertical white lines Background Uniform toner contamination in most or all non-image IQ8
• Curved lines areas.
Transfer Roller: Residual Image The image from a previous print appears on the current IQ9
(Ghosting) print.
• Uneven Density
Side 2 Staining Side two of a simplex or duplex print is stained. IQ10
• Background contamination
Blank Page The entire image area is blank. IQ11
• Ghosting
• Vertical white lines Partial Image Dele- Areas of the printed image are light or missing entirely IQ12
tions on limited areas of the paper.
• Vertical black line or band

June 2014 Image Quality

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 3-3 Image Quality Overview
IQ1 Vertical Black Line and Band RAP IQ2 Vertical White Line and Band RAP
Thin black vertical lines or black vertical bands occur in the printed image (Figure 1). Thin white vertical lines or white vertical bands occur in the printed image (Figure 1).

Procedure Initial Actions

Switch Off the power. • Check the life of the Print Cartridge, refer to GP 2 Machine Status and Reports.
Check the Transfer Roller, PL 5.1 for wear or damage. The Transfer Roller is OK. Replace the Print Cartridge if it is at end of life, refer to the Workcentre® 3025 User
Y N Guide, Section 6 Maintenance, General Care, for detailed instructions on how to replace
Replace the Transfer Roll; (REP 1.16), PL 5.1. the Print Cartridge.
• Clean the surface of the LSU window with a clean cotton swab and recommended
Switch On the power and make a test print.
cleaner.
If problem persists, replace the Print Cartridge, refer to the WorkCentre® 3025 User Guide for
detailed instructions on how to replace the Print Cartridge.
Procedure
Switch off the printer.
Check the space between the LSU and the Drum Cartridge, remove any debris or blockage.
Switch On the power and make a test print. The defect is gone.
Y N
Replace the Fuser Module; (REP 1.19), PL 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 3-4 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
IQ3 Horizontal Black Bands RAP IQ4 Spots RAP
Periodic dark of blurry horizontal stripes in the printed image (Figure 1). Random or periodic dark areas in the low density areas of a print, or voids in the dark areas of
a print (Figure 1).
Procedure
• Switch Off the power. Initial Actions
• Check the contacts on the Print Cartridge and the LVPS / HVPLS PWB for contamination Ensure that the Print Cartridge is firmly seated.
or damage.
• Switch On the power and make a test print. Procedure
The defect is still present. Switch off the power.
Y N Check the Transfer Roller for wear, damage and remaining life. The Transfer Roller is OK.
Go to Call Closeout. Y N
Replace the Transfer Roller, (REP 1.17), PL 5.1.
Replace the Print Cartridge, refer to WorkCentre® 3025 User Guide for detailed instructions on
how to replace the Print Cartridge. Check the circuit for the Print Cartridge, refer to BSD 9.1.
Switch on the power and make a test print. The test print looks OK.
Y N
Replace the Print Cartridge, refer to WorkCentre® 3025 User Guide for detailed instruc-
tions on how to replace the Print Cartridge.

If problem persists, replace the Fuser Module; (REP 1.19), PL 5.2.

Figure 1 Horizontal black bands

Figure 1 Black spots

June 2014 Image Quality

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 3-5 IQ3, IQ4
IQ5 Low Image Density RAP IQ6 Black or Dark Image RAP
The printed image is light, with no ghosting (Figure 1). The printed image is totally dark or black (Figure 1).

Initial Actions Procedure

• Check the life of the Print Cartridge, refer to GP 2 Machine Status and Reports. WARNING
Replace the Print Cartridge if it is at end of life, refer to the Workcentre® 3025 User Do not perform repair activities with the power on or electrical power supplied to the
Guide, Section 6 Maintenance, General Care, for detailed instructions on how to replace machine. Some machine components contain dangerous electrical voltages that can
the Print Cartridge. result in electrical shock and possible serious injury.
• Remove Print Cartridge. Rotate the cartridge 5-6 full rotations to redistribute the toner. DANGER: Ne pas effectuer de dépannnage avec le contact principal activé ou avec l'ali-
Reinstall the cartridge and make a test print. mentation électrique appliquée à la machine. Certains éléments de la machine compor-
If the problems continue, follow the procedure. tent des tensions électriques dangereuses qui peuvent causer un choc électrique et de
graves blessures.
Procedure AVVERTENZA: Non effettuare alcuna riparazione con l'alimentazione elettrica inserita.
• Switch off the power. Alcuni componenti contengono corrente ad alta tensione che può provocare forti
scosse e gravi ferite.
• Clean the contacts on the Print Cartridge and the on the LVPS / HVPS PWB.
VORSICHT: Es dürfen erst Reparaturarbeiten durchgeführt werden, wenn das Gerät aus-
• Switch on the power and make a test print.
geschaltet ist oder der Netzstecker nicht mehr mit der Stromquelle verbunden ist. Ein-
The problem continues. ige Komponenten des Gerätes sind stromführend und können daher zu ernsthaften
Y N Verletzungen oder Stromschlägen führen.
Go to Call Closeout.
AVISO: No realice reparaciones con la máquina encendida o conectada a la corriente.
Algunos componentes de la máquina contienen voltajes eléctricos peligrosos que
Replace the LVPS / HVPS PWB; (REP 1.6), PL 5.1.
pueden producir una descarga eléctrica y causar daños graves.
• Switch off the power.
• Clean the contacts on the Print Cartridge and the LVPS / HVPS PWB.
• Switch on the power and make a test print.
The problem continues.
Y N
Go to Call Closeout.

• If the image is Black, replace the LVPS / HVPS PWB; (REP 1.6), PL 5.1.
• 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 3-6 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
 IQ7 Uneven Density RAP
Print density is uneven between the left and right portion of the printed image (Figure 1).

Initial Actions
• Ensure that the printer is level.
• Remove the Print Cartridge. Rotate the Print Cartridge 5-6 full rotations to redistribute the
toner.
• Check the life of all components, refer to GP 2 Machine Status and Reports.
Replace the any component if it is at end of life, refer to the Workcentre® 3025 User
Guide, Section 6 Maintenance, General Care, for detailed instructions on how to replace
components.

Procedure
WARNING
Do not perform repair activities with the power on or electrical power supplied to the
machine. Some machine components contain dangerous electrical voltages that can
result in electrical shock and possible serious injury.
DANGER: Ne pas effectuer de dépannnage avec le contact principal activé ou avec l'ali-
mentation électrique appliquée à la machine. Certains éléments de la machine compor-
tent des tensions électriques dangereuses qui peuvent causer un choc électrique et de
graves blessures.
AVVERTENZA: Non effettuare alcuna riparazione con l'alimentazione elettrica inserita.
Figure 1 Dark or Black Image Alcuni componenti contengono corrente ad alta tensione che può provocare forti
scosse e gravi ferite.
VORSICHT: Es dürfen erst Reparaturarbeiten durchgeführt werden, wenn das Gerät aus-
geschaltet ist oder der Netzstecker nicht mehr mit der Stromquelle verbunden ist. Ein-
ige Komponenten des Gerätes sind stromführend und können daher zu ernsthaften
Verletzungen oder Stromschlägen führen.
AVISO: No realice reparaciones con la máquina encendida o conectada a la corriente.
Algunos componentes de la máquina contienen voltajes eléctricos peligrosos que
pueden producir una descarga eléctrica y causar daños graves.
Switch Off the Power. Check the contacts on the LVPS / HVPS PWB and the Print Cartridge for
contamination or damage. The contacts are OK.
Y N
Replace the Print Cartridge. Refer to the WorkCentre® 3025 User Guide, Section 6 Main-
tenance, General Care, for detailed instructions on how to replace the Toner Cartridges.

Check the Transfer Roller for wear or damage. The Transfer Roller is OK.
Y N
Replace the Transfer Roller; (REP 1.17), PL 5.1.

If problem persists, replace the LVPS / HVPS PWB; (REP 1.6), PL 5.1.

June 2014 Image Quality

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 3-7 IQ6, IQ7
 IQ8 Background RAP
Uniform toner contamination appears in most or all non-image areas of the printed sheet (Fig-
ure 1).

Initial Actions
• Check that media type settings are correct.
• Check that the paper meets specifications. Refer to Section 6 for product specifications.
• Check the life of the Print Cartridge, refer to GP 2 Machine Status and Reports.
Replace the Print Cartridge if it is at end of life. Refer to the Workcentre® 3025 User
Guide, Section 6 Maintenance, General Care, for detailed instructions on how to replace
the Print Cartridge.

Procedure
• Switch off the power.
• Clean the contacts on the Print Cartridge and the LVPS / HVPS PWB.
• Switch on the power and make a test print.
The test print looks OK.
Y N
Replace the LVPS / HVPS PWB; (REP 1.6), PL 5.1.

Go to Call Closeout.

Figure 1 Uneven Density

Figure 1 Background

Image Quality June 2014

IQ7, IQ8 3-8 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
IQ9 Residual Image (Ghosting) RAP IQ10 Side 2 Staining
The image from a previous print appears on the current print (Figure 1). Side 2 of a simplex print is stained (Figure 1).

Procedure Procedure
Switch Off the Power. Switch Off the power. Check the Transfer Roller for wear or contamination. The Transfer
Check the Transfer Roller for the following PL 5.1: Roller is OK.
• Wear or damage. Y N
• The left and right tension springs for damage. Replace the Transfer Roll; (REP 1.17), PL 5.1.
• Be sure all parts are installed correctly.
If problem persists, replace the Fuser Module;(REP 1.19), PL 5.2.
The Transfer Roll is OK.
Y N
Replace the Transfer Roll; (REP 1.17), PL 5.1.

If problem persists, Replace components in the following order:

• Print Cartridge, refer to WorkCentre® 3025 User Guide for detailed instructions on how to
replace the Print Cartridge.
• Fuser Module; (REP 1.19), PL 5.2.
• LVPS / HVPS PWB; (REP 1.6), PL 5.1.

Figure 1 Side 2 Staining

Figure 1 Ghost Image

June 2014 Image Quality

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 3-9 IQ9, IQ10
IQ11 Blank Page RAP
The entire image area is blank (Figure 1).

Initial Actions
Check the life of the Print Cartridge, refer to GP 2 Machine Status and Reports.

Replace the Print Cartridge if it is at end of life, refer to the Workcentre® 3025 User Guide,
Section 6 Maintenance, General Care, for detailed instructions on how to replace the Print Car-
tridge.

Procedure
• Switch off the power.
• Check the space between the LSU and Print Cartridge, remove any debris or blockage.
• Clean the contacts on the LVPS / HVPS PWB and the Print Cartridge.
• Switch on the power and make a test print.
The problem continues.
Y N
Go to Call Closeout.

Replace the Print Cartridge, refer to WorkCentre® 3025 User Guide for detailed instructions on
how to replace the Print Cartridge. The problem continues.
Y N
Go to Call Closeout.
Figure 1 Blank Image
Check circuit between the Main PWB and the LVPS / HVPS PWB, refer to BSD 9.1. The cir-
cuit is OK.
Y N
Replace any defective component:
• Main PWB to High Voltage Power Supply Wire Harness.
• Main PWB; (REP 1.7), PL 1.1 and PL 1.2.
• LVPS / HVPS PWB; (REP 1.6), PL 5.1.

Replace the LSU; (REP 1.12), PL 5.6.

Image Quality June 2014

IQ11 3-10 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
IQ12 Partial Image Deletions RAP
Areas of the printed image are light or missing entirely on limited areas of the paper (Figure 1).

Initial Actions
Be sure the printer is installed on a level surface.

Procedure
Procedure
• Switch Off the Power.
• Remove the Print Cartridge.
• Rotate the Print Cartridge side to side for 5 to 6 full rotations to redistribute the toner.
• Reinstall and print 10 test copies.
The problem continues.
Y N
Go to Call Closeout.

Check the Transfer Roller PL 5.1 for the following:

• Wear or damage.
• The left and right tension springs for damage.
• Be sure all parts are installed correctly.

Figure 1 Image Deletions

June 2014 Image Quality

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 3-11 IQ12
Image Quality June 2014
IQ12 3-12 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
 4 Repairs
REP 1.1 Left and Right Side Covers ............................................................................... 4-3
REP 1.2 Front Cover....................................................................................................... 4-4
REP 1.3 Rear Cover ....................................................................................................... 4-5
REP 1.4 Middle Cover..................................................................................................... 4-6
REP 1.5 Control Panel PWB ........................................................................................... 4-8
REP 1.6 LVPS / HVPS .................................................................................................... 4-10
REP 1.7 Main PWB......................................................................................................... 4-12
REP 1.8 Left Frame and Drive Motor.............................................................................. 4-14
REP 1.9 FAX PWB.......................................................................................................... 4-16
REP 1.10 Scanner Module and Support Hinge............................................................... 4-16
REP 1.11 Scanner Drive Motor ....................................................................................... 4-19
REP 1.12 LSU................................................................................................................. 4-21
REP 1.13 Feed Rolls and Retard Pad ............................................................................ 4-23
REP 1.14 Paper Drive Roll and Drive Gear .................................................................... 4-26
REP 1.15 Paper Feed Sensors PWB and Actuators ...................................................... 4-28
REP 1.16 Paper Tray ...................................................................................................... 4-29
REP 1.17 Transfer Roll ................................................................................................... 4-30
REP 1.18 Feed Clutch .................................................................................................... 4-32
REP 1.19 Fuser Module.................................................................................................. 4-33
REP 1.20 WNPC (WiFi) PWB ......................................................................................... 4-36
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

June 2014 Repairs

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-1
Repairs June 2014
4-2 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
REP 1.1 Left and Right Side Covers Replacement
Parts List on PL 1.1 and PL 1.2 Install the components in the reverse of removal.
Removal
1. Switch Off the Printer and disconnect the Power Cord.
2. Remove the Front Cover (REP 1.2).
3. Remove the screw (1) for the Left or Right Side Cover at the rear of the printer (Figure 1).

Right Cover Screw Left Cover Screw

Figure 1 Left and Right Cover Screws (Rear View)

4. Remove the Side Covers being careful not to damage the Fastening Hooks (Figure 2):
a. Pull the bottom of the cover away from the printer to remove it.

Figure 2 Fastening Hooks

June 2014 Repairs

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-3 REP 1.1
REP 1.2 Front Cover 4. Remove the screws (4) (Figure 2).

Parts List on PL 1.1 and PL 1.2

Removal
1. Switch Off the Printer and disconnect the Power Cord.
2. Open the Top Cover and Jam Clearance Cover.
3. Remove the Paper Tray Cover (Figure 1).
Release the Left Hinge, then the Right Hinge.

Screws

Figure 2 Front Cover Screws

5. Remove the Front Cover being careful not to damage the Fastening Hooks (Figure 3):
a. Release the Bottom fasteners.
b. 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 4-4 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
REP 1.3 Rear Cover 5. Remove the Rear Cover screws (4) (Figure 2).

Parts List on PL 1.1 and PL 1.2

Removal Network Data Plate Label
1. Switch Off the Printer and disconnect the Power Cord.
2. Remove the following covers:
a. The Front Cover (REP 1.2).
b. The Left and Right Side Covers Cover (REP 1.1).
3. Release the wires from the wire guides on the Rear Cover (Figure 1).

FAX Screws

Figure 2 Rear Cover Screws and Connector Locations (Rear View 3025 BI)

Wire Guides

Figure 1 Rear Cover Wires to Release

4. Remove the Scanner Module (REP 1.10).

June 2014 Repairs

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-5 REP 1.3
6. Remove the Rear Cover top screws (Figure 3). REP 1.4 Middle Cover
Parts List on PL 1.1 and PL 1.2
Removal
1. Switch Off the Printer and disconnect the Power Cord.
2. Remove the Print Cartridge.
3. Remove the following covers:
a. The Front Cover (REP 1.2).
b. The Left and Right Side Covers Cover (REP 1.1).
c. The Rear Cover (REP 1.3).
4. Remove the Scan Module (REP 1.10).
5. Release the Exit Jam Cover pivots (2).
Use a small screwdriver to move the pivots out of the slots on the cover (Figure 1).

Pivots

Screws

Figure 3 Rear Cover Top Screws (Top View)

7. Remove the Rear Cover.

Replacement
Important: If the Rear Cover is replaced, remove the Data Plate Label from the old Rear
Cover and install it onto the new Rear Cover (Figure 2).

NOTE: If the Rear Cover is being replaced on a 3025 NI, remove the “knockouts” for the FAX
and Network connectors (Figure 2).

NOTE: Tapered Plastic Screws and Round Machine Screws are used to hold the PWB to the
frame. 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 4-6 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
6. Remove the Middle Cover screw (1) on the left side of the printer (Figure 2).

Screw Wire Guides

Screws

Figure 3 Middle Cover Front Screws

8. Lift up and remove the Middle Cover.

Figure 2 Middle Cover Left Side Screw Release the wires from the Main PWB, from the wire guides on the underside of the Mid-
dle Cover (Figure 2).
7. Remove the Middle Cover front screws (2) (Figure 3).

June 2014 Repairs

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-7 REP 1.4
Replacement REP 1.5 Control Panel PWB
1. IMPORTANT Parts List on PL 3.1 and PL 3.2
If the Middle Cover is being replaced, remove the Tag Matrix from the old cover and install
it on to the new Middle Cover (Figure 4).
Removal
1. Switch Off the Printer and unplug the Power Cord.
2. For the 3025 NI, remove the ADF (REP 1.22).
3. Open the Scanner and release the Control Panel from the Scanner (Figure 1).
a. Remove the screws (4).
b. Release the latches (2).

Latches

Tag Matrix

Figure 4 Tag Matrix Location

Screws
NOTE: Tapered Plastic Screws and Round Machine Screws are used to hold the PWB to the
frame. 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 Releasing the Control Panel (Bottom View)

Repairs June 2014

REP 1.4, REP 1.5 4-8 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
4. Disconnect the connectors (3) and remove the Control Panel: 5. Remove the Control Panel PWB:
a. For the 3025 BI refer to (Figure 2). a. Remove the screws (4), release the latches and remove the PWB.
b. For the 3025 NI refer to (Figure 3) For the 3025 BI refer to (Figure 4).
For the 3025 NI refer to (Figure 5).

Connectors
Screws

Figure 4 Control Panel PWB Removal 3025 BI

Figure 2 Control Panel Removal 3025 BI (Front View)

Screws

Figure 3 Control Panel Removal 3025 NI (Front View) Figure 5 Control Panel PWB Removal 3025 NI

Replacement
Install the components in the reverse of removal.

June 2014 Repairs

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-9 REP 1.5
REP 1.6 LVPS / HVPS 4. Remove the Fax PWB (1 screw) and the Metal Shield (6 screws) (Figure 1).

Parts List on PL 5.1

Removal
WARNING
Do not perform repair activities with the power on or electrical power supplied to the
machine. Some machine components contain dangerous electrical voltages that can
result in electrical shock and possible serious injury.
DANGER: Ne pas effectuer de dépannnage avec le contact principal activé ou avec l'ali-
mentation électrique appliquée à la machine. Certains éléments de la machine compor-
tent des tensions électriques dangereuses qui peuvent causer un choc électrique et de
graves blessures.
AVVERTENZA: Non effettuare alcuna riparazione con l'alimentazione elettrica inserita.
Alcuni componenti contengono corrente ad alta tensione che può provocare forti
scosse e gravi ferite.
VORSICHT: Es dürfen erst Reparaturarbeiten durchgeführt werden, wenn das Gerät aus-
geschaltet ist oder der Netzstecker nicht mehr mit der Stromquelle verbunden ist. Ein-
ige Komponenten des Gerätes sind stromführend und können daher zu ernsthaften
Verletzungen oder Stromschlägen führen.
AVISO: No realice reparaciones con la máquina encendida o conectada a la corriente.
Algunos componentes de la máquina contienen voltajes eléctricos peligrosos que
pueden producir una descarga eléctrica y causar daños graves.
1. Switch Off the Printer and unplug the Power Cord.
2. For a 3025 NI, remove the FAX PWB (REP 1.9) and the Speaker (2 screws). Screws
3. 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
5. Remove the Plastic Shield (2 screws) (Figure 2). NOTE: Be careful not to lose the High Voltage Spring Contacts when removing the SMPS
/ HVPS PWB from the Frame.

6. Remove the LVPS / HVPS PWB (Figure 3).

a. Disconnect the Fuser and Main PWB connectors.
b. Remove the screws (6) and the LVPS / HVPS PWB.

Screws

Screws

Figure 2 Plastic Shield Screws

Connectors Screws

Figure 3 SMPS /HVPS PWB Screws

Replacement
NOTE: Tapered Plastic Screws and Round Machine Screws are used to hold the PWB to the
frame. 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.

June 2014 Repairs

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-11 REP 1.6
REP 1.7 Main PWB 4. Disconnect all the connectors on the Main PWB (Figure 1).

Parts List on PL 1.1 and PL 1.2

Removal Main PWB

WARNING
Do not perform repair activities with the power on or electrical power supplied to the
machine. Some machine components contain dangerous electrical voltages that can
result in electrical shock and possible serious injury.
DANGER: Ne pas effectuer de dépannnage avec le contact principal activé ou avec l'ali-
mentation électrique appliquée à la machine. Certains éléments de la machine compor-
tent des tensions électriques dangereuses qui peuvent causer un choc électrique et de
graves blessures.
AVVERTENZA: Non effettuare alcuna riparazione con l'alimentazione elettrica inserita.
Alcuni componenti contengono corrente ad alta tensione che può provocare forti
scosse e gravi ferite.
VORSICHT: Es dürfen erst Reparaturarbeiten durchgeführt werden, wenn das Gerät aus-
geschaltet ist oder der Netzstecker nicht mehr mit der Stromquelle verbunden ist. Ein-
ige Komponenten des Gerätes sind stromführend und können daher zu ernsthaften
Verletzungen oder Stromschlägen führen.
AVISO: No realice reparaciones con la máquina encendida o conectada a la corriente.
Algunos componentes de la máquina contienen voltajes eléctricos peligrosos que
pueden producir una descarga eléctrica y causar daños graves.
1. Record the machine serial number from the Data Plate (located on the rear cover beneath
the bar code) or from a Configuration Report printed prior to installing the new PWB. (For
information about how to print Configuration Reports refer to GP 2.)
2. Switch Off the Printer and unplug the Power Cord.
Figure 1 Main PWB Connectors
3. Remove the following covers:
a. The Front Cover (REP 1.2).
b. The Right Side Cover (REP 1.1).
c. The Rear Cover (REP 1.3).

Repairs June 2014

REP 1.7 4-12 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
5. Remove the screws (4) and the Main PWB (Figure 2). NOTE: Select the [Check USB] button to ensure that there is a good USB connec-
tion BEFORE entering the serial number. If the connection is good, “USB Success,”
Screws will display in the area above the button. If there is an problem with the USB connec-
tion, “USB Fail“ will display.

Figure 3 PWB Serial Number Tool Screen

4. After successfuly entering the serial number, exit the PWB Serial Number writing applica-
tion.
5. Print a Configuration Report and check that the original machine serial number is dis-
played under the Device Profile heading.
Figure 2 Main PWB Screws
NOTE: There is a function in Diagnostics that allows for entry of the serial number using
Replacement the keypad (3025NI). From Diagnostic Mode, (Ref. GP 1) select: [Data Set Up>Set Serial
Number] then, using the keypad, enter the serial number. Press the <OK> button to con-
NOTE: Tapered Plastic Screws and Round Machine Screws are used to hold the PWB to the firm selections. This function allows numeric entries only. For serial numbers contain-
frame. Make sure that the Plastic Screws go into plastic components and Machine Screws go ing alpha characters (letters), use the serial number writing tool; USB_Serial.V1.02.exe.
into the metal frame.

Install the components in the reverse of removal.

After installing a new Main PWB, the following steps MUST be performed to write the machine
serial number to the new Main PWB:

1. Reconnect the Power Cord. Power On the machine.

2. Connect the PWS to the printer via USB connection.
3. Download the USB Serial Number writing application; USB_Serial.V1.02.exe, to the PWS
from the GSN website (GP 10), and run the application.
a. 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 3.

June 2014 Repairs

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-13 REP 1.7
REP 1.8 Left Frame and Drive Motor 6. Remove the Main Drive Unit (4 screws) (Figure 2).

Parts List on PL 5.4

Removal Screws
1. Switch Off the Printer and unplug the Power Cord.
2. Remove the Print Cartridge.
3. Remove the Middle Cover (REP 1.4).
4. Disconnect the Drive Motor connector (Figure 1).

Figure 2 Main Drive Unit Removal (Left View)

Connector

Figure 1 Drive Motor Connector (Front View)

5. Remove the Fuser Module (REP 1.17).

Repairs June 2014

REP 1.8 4-14 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
7. Remove the Left Frame and Drive Motor (Figure 3): 8. Remove the Guide from the Left Frame (2 screws) (Figure 4).
a. Remove the LSU Cover screw (1).
b. Remove the screws (7) and the Left Frame.

b - Screws a - Screw

Screws

Figure 4 Guide Removal

Replacement
NOTE: Tapered Plastic Screws and Round Machine Screws are used to hold the PWB to the
frame. Make sure that the Plastic Screws go into plastic components and Machine Screws go
Figure 3 Left Frame Removal
into the metal frame.

Install the components in the reverse of removal.

NOTE: The Frame is flexible and can be bowed out if the screws are not tightened in the cor-
rect order.
Reinstall the Frame as follows so it seats flush against the printer internal modules.

1. Align the Left Frame on to the internal modules.

2. Install, but do not tighten, the screws (7) (Figure 3).
3. Tighten the Frame screws from the center of the Frame:
To the Front of the printer, then to the Rear of the Printer.

June 2014 Repairs

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-15 REP 1.8
REP 1.9 FAX PWB REP 1.10 Scanner Module and Support Hinge
Parts List on PL 1.2 Parts List on PL 1.1 and PL 1.2
Removal Removal
1. Switch Off the Printer and unplug the Power Cord. Scanner Module Support Hinge Removal
2. Remove the following covers:
a. The Front Cover (REP 1.2). 1. Open the Scanner Module and release the Latch on the Scanner Support Hinge (Figure
1).
b. The Right Side Cover (REP 1.1).
3. Remove the FAX PWB (Figure):
a. Disconnect the connectors (2) on the FAX PWB (Figure 1)
b. Remove the screws (4) and the PWB.
Hinge Latch

FAX PWB
Figure 1 Scanner Support Hinge (Right Side View)
Figure 1 FAX PWB Removal

Replacement
NOTE: Tapered Plastic Screws and Round Machine Screws are used to hold the PWB to the
frame. 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
 CAUTION Removal
For the 3025 NI with an Automatic Document Feeder (ADF): Scanner Module Removal
Hold the ADF closed when raising the Scanner module to prevent it from opening.
2. Hold the Scanner to prevent it from falling closed. 1. Switch Off the Printer and unplug the Power Cord.
Rotate the hinge up and remove the pivot slot (Figure 2). 2. Remove the following covers:
a. The Front Cover (REP 1.2).
b. The Right Side Cover (REP 1.1).
3. Disconnect the Scanner Module and Control Panel connectors (2) from the Main PWB
(Figure 3).
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

June 2014 Repairs

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-17 REP 1.10
4. Open the Scanner Module and release the Latch on the Scanner Support Hinge (Figure CAUTION
4). For the 3025 NI with an Automatic Document Feeder (ADF):
Hold the ADF closed when raising the Scanner Module to prevent it from opening, or remove
the ADF (REP 1.22).
5. Remove the Scanner Module (Figure 5):
Hinge Latch a. Lift the Scanner Module and release it from the hinges (2).

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
REP 1.11 Scanner Drive Motor 4. Disconnect the connectors (3) and remove the Control Console (Figure 2).

Parts List on PL 4.1 and PL 4.2

Removal Connectors
1. Switch Off the Printer and unplug the Power Cord.
2. Remove the Scanner Module (REP 1.10)
3. Open the Scanner and release the Control Panel from the Scanner (Figure 1).
a. Remove the screws (4).
b. Release the latches (2).

Latches

Figure 2 Control Panel Removal (Front View)

Screws

Figure 1 Control Panel Bottom Screws (Bottom View)

June 2014 Repairs

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-19 REP 1.11
5. Remove the Platen top screws (3) (Figure 3). 6. Remove the Platen from the Scanner Module (Figure 4):
a. Remove the Platen bottom screws (2).
b. 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
7. Remove the Scan Motor (Figure 5): REP 1.12 LSU
NOTE: There is tension on the motor from the ISM Drive Belt, hold the motor down when Parts List on PL 5.6
removing the screws.
Removal
a. Move the Shaft out of the slot. WARNING
b. Remove the screws (3).
Use extreme care when replacing the Raster Output Scanner / LSU (ROS) or touching
c. Remove the Drive Belt from the motor. the high voltage lead. Discharge the laser assembly by touching the high voltage lead to
d. Release the wires from the cable guides. the machine frame. The ROS utilizes a laser assembly that stores a high voltage charge
after the power has been removed and represents a shock hazard that could cause seri-
ous personal injury if not discharged.
DANGER: Faire très attention lors du changement du générateur de balayage / LSU
(ROS) ou lors de la manipulation du câble de haute tension. Décharger le système laser
en touchant le câble HT au bâti machine: le ROS utilise un système laser qui retient une
Drive haute tension après la coupure de l'alimentation, représentant un risque de choc et de
Belt graves blessures.
AVVERTENZA: Fare estrema attenzione nel sostituire il Raster Output Scanner / LSU
(ROS) o nel toccare il cavo di alta tensione. Scaricare il complessivo laser collegando il
cavo di alta tensione col telaio della macchina. Il ROS utilizza un complessivo laser che
ritiene una carica di alta tensione dopo il taglio dell'alimentazione con conseguente
grave pericolo di scossa elettrica e serie ferite.
VORSICHT: Beim Ersetzen der Lasereinheit / LSU (ROS) und beim Umgang mit Hoch-
Screws spannungsleitern ist äußerste Vorsicht geboten. Die Lasereinheit muss durch Berühren
des Hochspannungsleiters mit dem Gehäuse des Geräts entladen werden. Nach Betrieb
der Lasereinheit (ROS) bleibt immer eine Hochspannungsladung zurück, welche ein
hohes Elektroschockrisiko darstellt. Äußerste Vorsicht ist geboten.
Shaft
AVISO: Use extrema precaución para sustituir el Escáner de salida ráster / LSU (ROS) o
tocar el cable de alto voltaje. Descargue el sistema láser tocando el cable de alto voltaje
del bastidor de la máquina. El ROS utiliza un sistema láser que retiene carga de alto
voltaje después de interrumpir la alimentación de energía y representa un grave peligro
que puede ocasionar daños personales graves si no se descarga.
1. Switch Off the Printer and unplug the Power Cord.
2. Remove the Print Cartridge.
3. Remove the Middle Cover (REP 1.4).
Figure 5 Scanner Drive Motor (Top View)

Replacement
NOTE: Tapered Plastic Screws and Round Machine Screws are used to hold the PWB to the
frame. 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.

June 2014 Repairs

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-21 REP 1.11, REP 1.12
4. Perform the following (Figure 1): 5. Remove the top LSU cover screws (2) and the cover (Figure 2).
a. Disconnect the Drive Motor connector (1).
b. Disconnect the LSU flat cables (2).

NOTE: The Flat Cable may be adhered to the LSU, detach it from the LSU and re-
install it on the new LSU in the same location.

c. 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
6. Remove the screws (3) and the LSU (Figure 3). REP 1.13 Feed Rolls and Retard Pad
Parts List on PL 5.3 and PL 5.7
Removal
1. Switch Off the Printer and unplug the Power Cord.
2. Remove the Print Cartridge.
3. Remove the Middle Cover (REP 1.4).
4. Perform the following (Figure 1):
a. Disconnect the Drive Motor connector (1).
b. Remove the inside LSU cover screws (2).

Screw

Screws

Figure 3 LSU Removal (Top View)

Replacement
NOTE: Tapered Plastic Screws and Round Machine Screws are used to hold the PWB to the
frame. 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 Motor Connector and LSU Cover Screws (Front View)

June 2014 Repairs

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-23 REP 1.12, REP 1.13
5. Remove the top LSU Cover screws (2) and the cover (Figure 2). 6. Remove the Feed Rolls Assembly screws (2) through the bottom of the Printer (Figure 3).

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
7. Remove the Feed Rolls Assembly (Figure 4): 8. Remove the Retard Pad (Figure 5):
a. Rotate the Feed Roll assembly up to release the locating pins from the frame. Be careful not to lose the Retard Pad Spring.
b. Move the Feed Roll assembly up to the right and remove it. a. From the rear of the printer, release the Pivot Latches (2).
b. 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)

June 2014 Repairs

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-25 REP 1.13
Replacement REP 1.14 Paper Drive Roll and Drive Gear
NOTE: Tapered Plastic Screws and Round Machine Screws are used to hold the PWB to the Parts List on PL 5.3
frame. Make sure that the Plastic Screws go into plastic components and Machine Screws go Removal
into the metal frame.
1. Switch Off the Printer and unplug the Power Cord.
Install the components in the reverse of removal. 2. Remove the following covers:
a. The Front Cover (REP 1.2).
When replacing the Retard Pad make sure the Spring is positioned on the locating post on the
b. The Left and Right Side Covers Cover (REP 1.1).
frame (Figure 5).
c. The Rear Cover (REP 1.3).
When replacing the Feed Rolls Assembly make sure the Locating Pins are positioned in the NOTE: When removing the Main Drive Unit make sure the gears do not slide off their shafts.
frame holes before installing the screws (2) (Figure 6).
3. Remove the Main Drive Unit (4 screws) (Figure 1).

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
4. Release the latch on the Paper Drive Roll Gear and remove it (Figure 2). 5. Remove the Feed Sensor Actuator (Figure 3).
Note the location of the Spring in the frame cutout for reinstallation.
a. 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)

June 2014 Repairs

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-27 REP 1.14
6. Remove the Paper Drive Roll (Figure 4): REP 1.15 Paper Feed Sensors PWB and Actuators
NOTE: Be careful not to lose the Paper Drive Roll Bushing on the Left Frame. Parts List on PL 5.3
a. Remove the E-rings (2). Removal
b. Move the roll to the right and remove it. 1. Switch Off the Printer and unplug the Power Cord.
2. Remove the Rear Cover (REP 1.3).
3. Removing the Feed Sensor PWB (Figure 1):
Bushing a. Unlatch and remove the Sensor PWB.
b. Disconnect the connector (1).

E-rings

Figure 4 Paper Drive Roll Removal (Rear View)

Replacement PWB Latch

NOTE: Tapered Plastic Screws and Round Machine Screws are used to hold the PWB to the
frame. Make sure that the Plastic Screws go into plastic components and Machine Screws go Figure 1 Feed Sensors PWB (Rear View)
into the metal frame.

NOTE: Make sure that the Actuator Spring is location in frame cutout (Figure 3).

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
4. Removing the Feed Sensor Actuator (Figure 2): REP 1.16 Paper Tray
Note the location of the Spring in the frame cutout for reinstallation.
Parts List on PL 5.1
a. Unlatch and remove the actuator.
5. Removing the Width Actuator (Figure 2):
Removal
Note the location of the Spring in the frame cutout for reinstallation. 1. Remove the following covers:

a. Unlatch and remove the actuator. a. The Front Cover (REP).

b. The Left and Right Side Covers Cover (REP).
2. Remove the Paper Tray Screw (1) from the Left Frame (Figure 1).
Spring Spring

Width Sensor Actuator Latch Feed Sensor Actuator

Screw

Figure 2 Sensor Actuators and Springs (Rear View)

Figure 1 Paper Tray Screw (Left View)
Replacement
Install the components in the reverse of removal. NOTE: Use a small screwdriver to help release the Paper Tray from the frame.

3. Remove the Paper Tray (Figure 2).

NOTE: Tapered Plastic Screws and Round Machine Screws are used to hold the PWB to the
a. Release the Paper Tray from the Left Frame.
frame. Make sure that the Plastic Screws go into plastic components and Machine Screws go
into the metal frame. b. Release the Paper Tray from the Right Frame.

NOTE: Make sure that the Actuator Spring is location in frame cutout (Figure 2).

June 2014 Repairs

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-29 REP 1.15, REP 1.16
 REP 1.17 Transfer Roll
Parts List on PL 5.1
Removal
1. Switch Off the Printer and unplug the Power Cord.
2. Remove the Toner Cartridge.
3. Remove the Middle Cover (REP 1.4).
4. Remove the Fuser Module (REP 1.17).
5. From the rear of the printer, using a small screwdriver release the latches (2) and push
the Transfer Roll Bushing into the printer (Figure 1).

Latches

Right Frame
Left Frame

Figure 2 Paper Tray Removal (Front View)

Replacement
NOTE: Tapered Plastic Screws and Round Machine Screws are used to hold the PWB to the
frame. 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.

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
6. Lift the Transfer Roll out of the printer (Figure 2). Replacement
NOTE: Tapered Plastic Screws and Round Machine Screws are used to hold the PWB to the
frame. Make sure that the Plastic Screws go into plastic components and Machine Screws go
into the metal frame.

1. Align the slots in the Transfer Roll Bushing with the Guides on the Printer Frame (Figure
3).
Tilt the top of the Bushing inward to align the Latches while pushing it into place.

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.

June 2014 Repairs

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-31 REP 1.17
REP 1.18 Feed Clutch 5. Release the latch and remove the Feed Clutch (Figure 2).

Parts List on PL 5.3

Removal
1. Switch Off the Printer and unplug the Power Cord.
2. Remove the Middle Cover (REP 1.4).
3. Unplug the Feed Clutch Connector from the Main PWB (Figure 1).
Route the wires through the frame to the left side of the printer.

Latch

Figure 2 Feed Clutch Removal (Left View)

Replacement
NOTE: Tapered Plastic Screws and Round Machine Screws are used to hold the PWB to the
frame. 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 Feed Clutch Connector

4. Remove the Left Frame (REP 1.8).

Repairs June 2014

REP 1.18 4-32 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
REP 1.19 Fuser Module 4. Remove the Metal Shield (4 screws) (Figure 1).

Parts List on PL 5.2

Screws
Removal
WARNING
Do not perform repair activities with the power on or electrical power supplied to the
machine. Some machine components contain dangerous electrical voltages that can
result in electrical shock and possible serious injury.
DANGER: Ne pas effectuer de dépannnage avec le contact principal activé ou avec l'ali-
mentation électrique appliquée à la machine. Certains éléments de la machine compor-
tent des tensions électriques dangereuses qui peuvent causer un choc électrique et de
graves blessures.
AVVERTENZA: Non effettuare alcuna riparazione con l'alimentazione elettrica inserita.
Alcuni componenti contengono corrente ad alta tensione che può provocare forti
scosse e gravi ferite.
VORSICHT: Es dürfen erst Reparaturarbeiten durchgeführt werden, wenn das Gerät aus-
geschaltet ist oder der Netzstecker nicht mehr mit der Stromquelle verbunden ist. Ein-
ige Komponenten des Gerätes sind stromführend und können daher zu ernsthaften
Verletzungen oder Stromschlägen führen.
AVISO: No realice reparaciones con la máquina encendida o conectada a la corriente.
Algunos componentes de la máquina contienen voltajes eléctricos peligrosos que
pueden producir una descarga eléctrica y causar daños graves.
WARNING
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.
DANGER: Ne pas manipuler les éléments du four avant de les laisser refroidir. Certains Figure 1 Metal Shield Screws
éléments du four fonctionnent à des températures très élevées et peuvent causer de
graves blessures s'ils sont touchés.
AVVERTENZA: Non maneggiare i componenti del fusore finché non sono raffreddati.
Alcuni di questi componenti funzionano ad alte temperature e possono provocare gravi
ferite se vengono toccati.
VORSICHT: Die Fixieranlage sollte erst gehandhabt werden, wenn diese genügend
abgekühlt ist. Einige Teile der Fixieranlage erzeugen übermäßige Hitze und führen bei
der Berührung zu schweren Verbrennungen.
AVISO: No manipule los componentes del fusor antes de que se enfríen. Algunos de los
componentes del fusor funcionan a altas temperaturas y pueden ocasionar daños per-
sonales graves si se los toca.
1. Switch Off the Printer and unplug the Power Cord.
2. Remove the Middle Cover (REP 1.4).
3. Remove the Main PWB (REP 1.7).

June 2014 Repairs

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-33 REP 1.19
5. Remove the Plastic Shield (2 screws) (Figure 2). 6. Disconnect the Fuser Connector (Figure 3).
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
NOTE: The top right (viewed from the rear) Tapered Plastic Screw is different than the other 8. Remove the Fuser Module (Figure 5):
plastic screws in the printer, make sure it is installed in the correct location during replacement. Lift the left side of the Fuser (viewed from the top rear), then slide it to the left and remove
7. Remove the screws (3) (Figure 4). it.

Screws

Figure 4 Fuser Screws (Top View) Figure 5 Fuser Removal (Top View)

Replacement
NOTE: Tapered Plastic Screws and Round Machine Screws are used to hold the PWB to the
frame. Make sure that the Plastic Screws go into plastic components and Machine Screws go
into the metal frame.

NOTE: The top right Tapered Plastic Screw (viewed from the rear) is different than the other
plastic screws in the printer, make sure it is installed in the correct location during replacement,
refer to (Figure 4).

Install the components in the reverse of removal.

June 2014 Repairs

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-35 REP 1.19
REP 1.20 WNPC (WiFi) PWB REP 1.21 LSU Cable
Parts List on PL 1.1 and PL 1.2 Parts List on PL 5.6
Removal Removal
1. Switch Off the Printer and unplug the Power Cord. 1. Switch Off the Printer and unplug the Power Cord.
2. Remove the following covers: 2. Remove the Middle Cover (REP 1.4).
a. The Front Cover (REP 1.2). 3. Disconnect the connectors (2) from the LSU (Figure 1).
b. The Right Side Cover (REP 1.1).
3. Remove the WNPC PWB (Figure 1).
The Figure shows the 3025 BI, the PWB is in the same location for the 3025 NI.
a. Disconnect the connector (1).
b. Remove the screw (1) and the PWB.

Connectors

Figure 1 LSU Connectors

4. 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
5. Remove the Black Insulator Sheet and the LSU Cable (Figure 2). REP 1.22 Automatic Document Feeder (ADF)
Parts List on PL 1.2
Removal
LSU Cable 1. Switch Off the Printer and unplug the Power Cord.
Insulator 2. Open and lift the ADF up.
Unlatch and remove the Connector Cover (Figure 1).

ADF Connector Cover

Figure 1 ADF Connector Cover

Figure 2 Insulator Sheet and LSU Cable

Replacement
NOTE: Tapered Plastic Screws and Round Machine Screws are used to hold the PWB to the
frame. 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.

June 2014 Repairs

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-37 REP 1.21, REP 1.22
3. Disconnect the connector and lift the ADF off of the Printer (Figure 2). REP 1.23 Platen Cover
Parts List on PL 1.1
Removal
1. Remove the Platen Cover (Figure 1):
a. Open the Platen Cover.
b. Lift up, releasing the hinged latches.

Hinged Latches

ADF Connector

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
REP 1.24 ADF Feed Separation Pad NOTE: The Separation Pad has spring tension pushing up on it, be careful not to lose the
spring.
Parts List on PL 1.3
2. Release the latches (2) and remove the Separation Pad (Figure 2).
Removal
1. Remove the ADF Cover, release the Rear Pivots and remove the cover (Figure 1).

Rear Pivot Latches

Figure 1 ADF Cover Pivots (Top View)

Figure 2 Separation Pad Latches (Top View)

June 2014 Repairs

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-39 REP 1.24
Replacement REP 1.25 ADF Feed Rolls Assembly
NOTE: Make sure the post on the Separation Pad is positioned inside the Spring (Figure 3). Parts List on PL 1.3
Install the components in the reverse of removal. Removal
1. Remove the ADF Cover, release the Rear Pivots and remove the cover (Figure 1).

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
2. Remove the Document Feed Roll Assembly (Figure 2).
a. Remove the E-Rings (3).
b. Slide the drive shaft out of the Feed Roll Assembly.

E-rings

Figure 2 Feed Roll E-rings

Replacement
Install the components in the reverse of removal.

NOTE: Install the E-rings in the following order:

1. The E-ring by the gear.

2. The E-ring (center) by the Spring.
3. The E-ring at the end of the shaft.

June 2014 Repairs

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 4-41 REP 1.25
Repairs June 2014
REP 1.25 4-42 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
 5 Parts List
Main
PL 1.1 Main ..................................................................................................................... 5-3
PL 1.2 Main ..................................................................................................................... 5-4

ADF
PL 1.3 ADF (Automatic Document Feeder) .................................................................... 5-5

Middle Cover
PL 2.1 Middle Cover........................................................................................................ 5-6

Control Panel Assembly

PL 3.1 Control Panel Assembly ...................................................................................... 5-7
PL 3.2 Control Panel Assembly ...................................................................................... 5-8

Scanner
PL 4.1 Scanner ............................................................................................................... 5-9
PL 4.2 Scanner ............................................................................................................... 5-10

Frame
PL 5.1 Frame .................................................................................................................. 5-11

Fuser
PL 5.2 Fuser.................................................................................................................... 5-12

Frame Path
PL 5.3 Frame Path .......................................................................................................... 5-13

Left Main Frame

PL 5.4 Left Main Frame................................................................................................... 5-14

Right Main Frame

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

June 2014 Parts List

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 5-1
Parts List June 2014
5-2 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
PL 1.1 Main
Item Part Description
1 002N03188 Platen Cover Assembly
– 002N03189 Platen Cover Assembly (Black)
2 090N00184 Scanner (PL 4.1)
– 090N00185 Scanner (Black) (PL 4.1)
3 – Control Panel Assembly (PL 3.1)
4 – Scanner Support Hinge
5 002N03163 Left Cover
– 002N03164 Left Cover (Black)
6 – Middle Cover (PL 2.1)
7 002N03168 Rear Cover
– 002N03169 Rear Cover (Black)
8 – Frame (PL 5.1)
9 002N03174 Front Cover (Black)
– 002N03173 Front Cover
10 002N03176 Paper Support
– 002N03177 Paper Support (Black)
11 002N03180 Right Cover
– 002N03181 Right Cover (Black)
12 140N63718 PWB-MAIN-3025 BI (USB / Wifi)
13 140N63727 WNPC (WiFi) PWB
14 – Controller Shield
15 – Document Pad

June 2014 Parts Lists

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 5-3 PL 1.1
PL 1.2 Main
Item Part Description
1 022N02799 ADF (PL 1.3)
2 050N00680 Document Pad
3 003N01117 Hinge
4 090N00183 Scanner (PL4.2)
5 – Control Panel (PL 3.2)
6 – Scanner Support Hinge
7 002N03163 Left Cover
8 – Middle Cover (PL 2.1)
9 002N03168 Rear Cover
10 – Frame (PL 5.1)
11 002N03173 Front Cover
12 002N03176 Paper Support
13 002N03180 Right Cover
14 – FAX Board Cover
15 140N63726 Fax PWB
16 140N63717 PWB-MAIN-3025 NI (NW / Wifi)
17 140N63727 WNPC (WiFi) PWB
18 – Speaker
19 – Controller Shield
20 005N01172 Surge Protector (South Africa Only)

Parts Lists June 2014

PL 1.2 5-4 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
PL 1.3 ADF (Automatic Document
Feeder)
Item Part Description
1 022N02801 ADF Feed Roll Assembly
2 127N07864 ADF Drive Motor
3 022N02800 ADF Separation Pad

June 2014 Parts Lists

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 5-5 PL 1.3
PL 2.1 Middle Cover
Item Part Description
1 – Jam Clearance Cover Assembly
2 – Exit Jam Clearance Cover
3 – Top Cover Closed Switch Actuator
4 – Spring
5 – Latch
6 – Spring
7 – Middle Cover
8 002N03185 Middle Cover Assembly
– 002N03186 Middle Cover Assembly (Black)
9 – Output Tray
10 – Output Support

Parts Lists June 2014

PL 2.1 5-6 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
PL 3.1 Control Panel Assembly
Item Part Description
1 – Cover
2 140N63724 Control Panel PWB
3 – Key Holder Cover
4 – LCD Cover
5 – LED Status Indicator
6 – Power Key
7 – Stop Key
8 – Power Saver Key
9 – Start Key
10 140N63732 Control Panel Assembly

June 2014 Parts Lists

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 5-7 PL 3.1
PL 3.2 Control Panel Assembly
Item Part Description
1 – Control Panel Cover
2 – Function Key
3 – FAX Key
4 – Tel Key
5 – LCD Cover
6 140N63722 Control Panel PWB
7 – Key Holder Cover
8 140N63731 Control Panel Assembly

Parts Lists June 2014

PL 3.2 5-8 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
PL 4.1 Scanner
Item Part Description
1 – Upper Scanner Frame
2 – Lower Scanner Frame
3 – Sensor
4 – Flat Cable
5 – Platen Scanner
6 – Scanner Drive Motor
7 – Drive Belt
8 – Contact Image Sensor (CIS)

June 2014 Parts Lists

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 5-9 PL 4.1
PL 4.2 Scanner
Item Part Description
1 – Paper Guide
2 – Upper Scanner Frame
3 – Lower Scanner Frame
4 – Scanner PWB
5 – Flat Cable
6 – Sensor
7 – Platen Scanner
8 – Platen Drive
9 – Drive Belt
10 – Contact Image Sensor

Parts Lists June 2014

PL 4.2 5-10 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
PL 5.1 Frame
Item Part Description
1 – Paper Tray
2 – Middle Frame
3 – Left Frame
4 – Feed Frame
5 – Paper Path Frame
6 022N02794 Transfer Roller
7 – Fuser (PL 5.2)
8 – LSU Cover
9 – Right Frame
10 – HVPS Insulator
11 – HVPS Contacts
12 105N02303 LVPS/HVPS 220V
– 105N02302 LVPS/HVPS 110V
13 – Input Guide
14 – HVPS/SMPS Cover

June 2014 Parts Lists

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 5-11 PL 5.1
PL 5.2 Fuser
Item Part Description
1 – Exit Cover
2 – Screw
3 – Exit Drive Gear
4 – Exit Gear
5 – Exit Shaft Bushing
6 – Spring
7 – Upper Fuser
8 – Exit Roller
9 – Lower Fuser
10 – Fuser Cover
11 – Gear
12 – Jam Lever
13 – Lamp Cover
14 – Gear
15 – Heat Roll
16 – Claw Guide
17 – Spring
18 – Thermostat
19 – Thermistor
20 – Fuser Cover
21 – Bushing
22 – Fuser Lamp
23 – Right Jam Lever
24 – Lamp Cover
25 – Bracket
26 – Bushing
27 – Pressure Roll
28 – Frame
29 – Bracket
30 – Exit Shaft
31 – Rubber Rolls
32 – Exit Roll
33 – Exit Holder
34 – Exit Roll
35 – Spring
36 126N00432 FUSER Module 110V
– 126N00433 FUSER Module 220V

Parts Lists June 2014

PL 5.2 5-12 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
PL 5.3 Frame Path
Item Part Description
1 130N01759 Paper Feed Sensor PWB
2 120N00546 Feed Sensor Actuator
3 – Spring
4 120N00547 Width Sensor Actuator
5 – Spring
6 022N02798 Paper Drive Roll
7 – Plate
8 – Ground Clip
9 – Ground Clip
10 – Paper Path Guide
11 – Feed Roll Shaft
12 121N01246 Feed Clutch
13 007N01801 Feed Gear
14 – Left Bushing
15 – Spring
16 – Right Bushing
17 001N00547 Retard Pad
18 – Path Frame

June 2014 Parts Lists

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 5-13 PL 5.3
PL 5.4 Left Main Frame
Item Part Description
1 – Left Frame
2 – Feed Drive Gear
3 – RDCN OPC Gear
4 – Drive Out Gear
5 – Feed Gear
6 – Drive In Gear
7 – Fuser Drive Gear
8 – RDCN Fuser Gear
9 – RDCN A Gear
10 – Drive Motor
11 – Left Main Frame
12 – Drive Mounting Plate
13 001N00548 Drive Gear Assembly

Parts Lists June 2014

PL 5.4 5-14 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
PL 5.5 Right Main Frame
Item Part Description
1 – Right Frame
2 – CRUM Contacts
3 – Spring
4 – Ground Clip
5 – Washer
6 – Screw
7 – CRUM Cover
8 – Print Cartridge Guide
9 – Main Right Frame Assembly

June 2014 Parts Lists

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 5-15 PL 5.5
PL 5.6 Paper Tray and LSU Frame
Item Part Description
1 001N00549 Paper Tray
2 – LSU Frame
3 – Right Guide
4 – Left Guide
5 – Rubber Friction Pad
6 – Bottom Plate
7 – Pinion Gear
8 – Sponge Damper
9 062N00293 LSU
10 – Motor Cover
11 – LSU Frame
12 117N01971 LSU Flat Cable

Parts Lists June 2014

PL 5.6 5-16 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
PL 5.7 Paper Feed Assembly
Item Part Description
1 – Paper Feed Holder
2 – Feed Roller
3 – Spring
4 – Guide Plate
5 – Left Latch
6 – Paper Stop
7 130N01757 Feed Rolls Assembly
8 – Feed Rolls Housing
9 – Feed Rolls Shaft
10 – Shaft Holder
11 – Bushing
12 – Spring
13 – Collar
14 – Joint Gear
15 – Pickup Clutch
16 – Bushing
17 – Pickup Roller
18 – Washer
19 – Bushing
20 – Sleeve
21 – Spring
22 – Pickup Gear
23 – Feed Gear
24 – Shaft Drive Roller
25 – Right Latch
26 – Sponge Damper

June 2014 Parts Lists

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 5-17 PL 5.7
Part Number Index Table 1 Part Number Index
Part Number Part List
Table 1 Part Number Index
120N00547 PL 5.3
Part Number Part List 121N01246 PL 5.3
001N00547 PL 5.3 126N00432 PL 5.2
001N00548 PL 5.4 126N00433 PL 5.2
001N00549 PL 5.6 127N07864 PL 1.3
002N03163 PL 1.1 130N01757 PL 5.7
002N03163 PL 1.2 130N01759 PL 5.3
002N03164 PL 1.1 140N63717 PL 1.2
002N03168 PL 1.1 140N63718 PL 1.1
002N03168 PL 1.2 140N63722 PL 3.2
002N03169 PL 1.1 140N63724 PL 3.1
002N03173 PL 1.1 140N63726 PL 1.2
002N03173 PL 1.2 140N63727 PL 1.2
002N03174 PL 1.1 140N63727 PL 1.1
002N03176 PL 1.1 140N63731 PL 3.2
002N03176 PL 1.2 140N63732 PL 3.1
002N03177 PL 1.1
002N03180 PL 1.2
002N03180 PL 1.1
002N03181 PL 1.1
002N03185 PL 2.1
002N03186 PL 2.1
002N03188 PL 1.1
002N03189 PL 1.1
003N01117 PL 1.2
005N01172 PL 1.2
007N01801 PL 5.3
022N02794 PL 5.1
022N02798 PL 5.3
022N02799 PL 1.2
022N02800 PL 1.3
022N02801 PL 1.3
050N00680 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
 6 General Procedures and information
General Procedures and Information
General Information ........................................................................................................ 6-3
System Overview ............................................................................................................ 6-3
Product Specifications..................................................................................................... 6-3
Product Overview ............................................................................................................ 6-4
Product Specifications..................................................................................................... 6-7

General Procedures
GP 1 Diagnostics Entry and Exit ..................................................................................... 6-13
GP 2 Machine Reports .................................................................................................... 6-13
GP 3 Machine Counters .................................................................................................. 6-14
GP 4 Machine Firmware Version .................................................................................... 6-15
GP 5 Altitude Adjustment ................................................................................................ 6-15
GP 6 Machine Settings ................................................................................................... 6-16
GP 7 Firmware Upgrade ................................................................................................. 6-17
GP 8 Usage of the Electrostatic Discharge (ESD) Field Service Kit ............................... 6-18
GP 9 DC 305 UI Button Test Sequence (3025NI)........................................................... 6-18
GP 10 Software ServiceTools ......................................................................................... 6-19

6c Diagnostics
Diagnostic Information .................................................................................................... 6-21
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

June 2014 General Procedures and Information

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 6-1
General Procedures and Information June 2014
6-2 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
General Information System Overview
The Xerox® WorkCentre® 3025BI and Xerox® WorkCentre® 3025NI multifunction printers This section provides illustrations of the machine systems. Features and options vary by
use a single-pass laser design offering simplex speeds of up to 21 ppm and output resolution model.
of up to 1200 x 1200 dpi.
• Paper Path - Figure 1 and Figure 2
The WorkCentre® 3025BI features copy, scan, USB device and Wi-Fi functions. In addition to • System Layout - Figure 3
all of the functions of the 3025BI, the WorkCentre 3025NI includes an automatic document
• Print Process - Figure 4
feeder along with fax and network printing capability as standard components.
• Sensor Locations - Figure 5
Refer to Xerox® WorkCentre® 3025BI/3025NI User Guide for detailed feature and configura- • Laser Scanner Unit (LSU) - Figure 6
tion information. • Drives - Figure 7
• Toner System - Figure 8

Product Specifications
This section details product specifications in the following tables:

1. Product Overview
2. General Print Engine Specifications
3. Copy Function Specifications
4. Scan Function Specifications
5. Fax Function Specifications
6. Controller and Software
7. Paper Handling
8. Consumables
9. HFSI’s
10. Reliability and Service
11. Environment

June 2014 General Procedures and Information

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 6-3 General Information, System Overview
Product Overview System Layout
Paper Path The figures below illustrates the mechanical parts of the printer.

The following diagrams display the path that the paper follows during the printing process.

Figure 1 Paper Path Figure 3 System Layout

Figure 2 Automatic Document Feeder (ADF) 3025NI Model

General Procedures and Information June 2014

Product Overview 6-4 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
Print Process Sensors
Figure 4 presents a general layout of the fusing and printing components used in the print pro- 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

June 2014 General Procedures and Information

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 6-5 Product Overview
Laser Scanner Unit (LSU) Drives
The Scanner Unit receives image data from the HVPS PWB and scans the surface of the pho- The Drive System consists of the Main (BLDC) Motor, Registration and Pick-up Clutches along
toreceptor drum (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 6-6 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
Toner System Product Specifications
The WorkCentre® 3025 printer uses a integrated toner system. The toner cartridge, photore-
ceptor and developer units are contained within the Print Cartridge. Table 1 Product Overview WorkCentre® 3025BI/NI
Feature Specification
Speed Up to 20 ppm (A4), 21 ppm (8.5 x 11 in.)
Print Resolution 600 x 600 dpi
1200 x 1200 dpi effective output
Processor 600 MHz
Printer Language Emulation SPL
Memory 128MB
Interface • High speed USB 2.0
• 10/100 BaseTX network connector
• 802.11b/g/n wireless LAN (2070W/ 2070FW)
• Wireless models support NFC (Near Field
Communcation) printing
Print Cartridge - Initial 700 images
Print Cartridge - Standard/ 1,500 images
High Yield

Table 2 General Print Engine Specifications

Item Mode WorkCentre 3025BI/NI
Engine Speed Simplex 20 ppm (A4), 21 ppm (8.5
Figure 8 Integrated Toner System x 11 in.)
Warmup time From Power Save Mode Less than 14 seconds
First Copy Out Time From Platen in Standby Mode 14 seconds
(FCOT) 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

June 2014 General Procedures and Information

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 6-7 Product Overview, Product Specifications
 Table 4 Scan Function Specifications WorkCentre® 3025BI/NI
Item
Table 3 Copy Function Specifications WorkCentre® 3025BI/NI
Specification
Item Specification
Resolution Optical 1200 x 1200 dpi
Copy Speed 1 to 1 copying 20 ppm (A4) 21 ppm (8.5 x 11 in.) Enhanced 4800 x 4800 dpi
FCOT (B&W) From Standby Less than 14 seconds (from Document Glass) Halftone 256 levels
Copy Resolution Text • From Document Feeder Scan Size Max. Document 216 mm (8.5 in.)
Scan: 300 x 300 dpi, Printing: 600 x 600 dpi Width
• From Document Glass Effective Scan 208 mm (8.2 in.)
Scan: 600 x 300 dpi, Printing: 600 x 600 dpi Width
Text/Photo • From ADF Max. Document ADF: 356 mm (14 in.)
Length Document Glass: 297 mm (11.7 in.)
Scan: 300 x 300 dpi, Printing: 600 x 600 dpi
Effective Scan ADF: 348 mm (13.7 in.)
• From Document Glass
Length Document Glass: 289 mm (11.4 in.)
Scan: 600 x 300 dpi, Printing: 600 x 600 dpi
Scan Depth Color Internal: 16 bit x 3, External: 8 bit x 3
Photo • From Document Feeder
Mono 1 bit for Lineart and Halftone
Scan: 600 x 300 dpi, Printing: 600 x 600 dpi
8 Bits for Gray scale
• From Document Glass
ADF (3025NI) Capacity 40 sheets @ 80gsm
Scan: 600 x 600 dpi, Printing: 600 x 600 dpi
Document size Width : 142 to 216 mm (8.5 in.)
Original Type Factory Default Text/ Photo Length : 148 to 356 mm (14 in.)
Max Original Size Document Glass A4
Document Feeder Legal (8.5 x 14 in.)
(ADF)
Basic Copy Multi Copy 1 to 99
Automatic Paper No
Selection
Manual Paper No
Selection
Duplex Copy No
Darkness Control 11 levels
Magnification 25% - 400%

Table 4 Scan Function Specifications WorkCentre® 3025BI/NI

Item
Specification
Scan Method Color CIS cpm
Compatibility TWAIN, WIA
Scan Speed Lineart, Halftone 15 ipm on Document Glass, 15 ipm from ADF @
(mono) 300dpi
Gray (mono) 23 ipm on Document Glass, 26 ipm from ADF @
300dpi
Color • 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 6-8 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
 Table 5 Fax Function Specifications (WorkCentre® 3025NI only) Table 6 Controller and Software WorkCentre® 3025BI/NI
Item Specification Item Specification
Compatibility ITU-T G3, ECM Processor 600 MHz (A1500 CPU)
Communication System Standard public telephone analog switched or Memory Standard 128 MB
equivalent. PSTN/ PABX Maximum N/A
Modem Speed 33.6 Kbps Printer Languages SPL
Transmission Speed (Tx speed) Approx. 3 sec (Mono/ Standard/ ECM-MMR/ Fonts Windows
ITU-T G3 No.1 chart)
Print Driver Default Driver SPL
Compression MH/ MR/ MMR/ JBIG/ JPEG (Tx only)
Install SPL
Color Fax Yes (Tx only)
Supporting OS Windows® XP (32/64bits)
ECM Yes Windows® Vista (32/64bits)
Resolution (mono) Standard 203 x 98 dpi Windows® 2003 Server (32/64bits)
Fine 203 x 196 dpi Windows® 2008 Server (32/64bits)
Windows® 7 (32/64bits)
S. Fine 300 x 300 dpi
Windows® 2008 Server R2 (64bits)
Telephone Features Handset No Windows® 8 (32/64bits)
On Hook Dial Yes Linux
Search Yes (Phone Book) Red Hat Enterprise Linux 5, 6
Speed Dial 200 locations Fedora 11-19
Group Dial 100 Groups OpenSuSE 11.0, 11.1, 11.2, 11.3, 11.4,
12.1, 12.2, 12.3
TAD I/F Yes
Ubuntu 10.04, 10.10, 11.04, 11.10,
Tone/Pulse Yes (Selectable in Tech Mode) 12.04, 12.10, 13.04
Pause Yes SuSE Linux Enterprise Desktop 10, 11
Auto Redial Yes Debian 5.0, 6.0, 7.0, 7.1
Last Number Yes Mint 13, 14, 15
Redial Mac OS X 10.5 through 10.9
Caller ID No WHQL Windows® Vista(32/64bit)
Windows® 8 (32/64bit)
External Phone Yes
Windows® 7 (32/64bit)
Interface
Compatibility 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)

June 2014 General Procedures and Information

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 6-9 Product Specifications
 Table 6 Controller and Software WorkCentre® 3025BI/NI Table 6 Controller and Software WorkCentre® 3025BI/NI
Item Specification Item Specification
Scan Driver TWAIN Yes Wireless Network Protocol 802.11 b/g/n Wireless LAN
WIA Yes Supporting OS Same as wired network
ICDM Yes
Application Easy Printer Windows and Macintosh
Supporting OS Windows® 2000/ XP (32/64bits)
Manager
Windows® Vista (32/64bits)
Windows® 2003 Server (32/64bits) Smart Panel Linux
Windows® 2008 Server (32/64bits) Network Manage- CentreWare Internet Services
Windows® 7 (32/64bits) ment
Windows® 2008 Server R2 (64bits) Interface Parallel N/A
Windows® 8 (32/64bits)
USB High speed USB 2.0
Linux
Red Hat Enterprise Linux 5, 6
Fedora 11, 12, 13, 14, 15, 16, 17, 18
OpenSuSE 11.0, 11.1, 11.2, 11.3, 11.4,
12.1, 12.2, 12.3
Ubuntu 10.04, 10.10, 11.04, 11.10,
12.04, 12.10
SuSE Linux Enterprise Desktop 10, 11
Debian 5.0, 6.0
Mint 13, 14
Mac OS X 10.5 through 10.8
Wired Network (3025NI) Protocol TCP/IP v4/ IPv6, HTTP, SNMP v1/ v2c/
v3, DNS/WINS, DDNS, DHCP, BOOTP,
AutoIP, Standard TCP/IP printing, LPR,
IPP, UPnP (SSDP), Bonjour, WSD, SLP,
SetIP
Supporting OS Windows® 2000/ XP (32/64bits)
Windows® Vista (32/64bits)
Windows® 2003 Server (32/64bits)
Windows® 2008 Server (32/64bits)
Windows® 7 (32/64bits)
Windows® 2008 Server R2 (64bits)
Windows® 8 (32/64bits)
Linux
Red Hat® Enterprise Linux WS 5,6 (32/
64 bit)
Fedora 11-19 (32/64 bit)
SuSE Linux 10, 11 (32 bit)
OpenSuSE 11.0, 11.1, 11.2, 11.3, 11.4,
21.1, 12.2, 12.3 (32/64 bit)
Mint 13, 14, 15
Ubuntu 10.04, 10.10, 11.04, 11.10,
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
 Table 7 Paper Handling
Item Specification
Standard Capacity Multi-Purpose Tray 150 sheets @ 80gsm
Max. Capacity 150 sheets @ 80gsm
Printing Minimum size 8.5 x 14.02 in. (216 x 356 mm)
Maximum size 3.0 x 7.2 in. (76 x 183 mm)
Standard Paper Tray N/A
Multi-purpose Tray Capacity • Plain paper: 150 sheets @ 80 gsm
(Bin type) • Envelope: 1 sheet @ 80 gsm
Media sizes A4, A5, 8.5 x 11 in.(letter), 8.5 x 14 in. (legal),
Executive, Folio, Oficio, B5 ISO, B5 JIS,
Envelope (No 10, Monarch, DL, C5), Custom
Media type Plain, Heavy-weight, Light-weight, Cotton,
Recycled, Archive, Colored, Pre-printed,
Label, Bond, Cardstock, Envelopes
Media weight 16 to 43 lb (60 to 163 gsm)
Sensing N/A
Optional Cassette Tray N/A
Output Stacking Capacity Face down: 100 sheets @ 80 gsm
Output Full Sensing N/A
Duplex Supporting N/A
Printable Area Non-Printable Area 3 mm (0.12 in.) from edge (top, bottom, left,
right)

June 2014 General Procedures and Information

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 6-11 Product Specifications
 Table 11 Environment
Item Specification
Table 8 Consumables
Acoustic Noise Level* Ready mode Less than 26 dB
Item Specification Approx yield (See note) (Sound Power/Pressure) Print mode Less than 50 dB
Print Cartridge MLT-D111S 1500 images (Ships with 700 page Starter
Copy mode • Document Glass: Less than 52 dB
Print Cartridge)
• Document Feeder: Less than 51 dB
Scan mode • Document Glass: Less than 52 dB
NOTE:
• Document Glass: Less than 53 dB
Declared yield value in accordance with ISO/IEC 19752.
Power Rating** 110 Volt models 110-127 VAC
Depending on the options and job mode used, the Print Cartridge’s lifespan may differ.
220 Volt models 220-240 VAC
When replacing the Print Cartridge, check model number and consumables code. Refer to the
WorkCentre® 3025 User Guide for information regarding ordering consumables. Power Consumption Avg. Operating Less than 230 W
Mode
Table 9 HSFI’s Ready Mode Less than 35 W

Item Specification Approx. yield Power Save Less than 1.0 W

Mode
Fuser Unit JC91-01077A (220V) 30,000 pages
Power Off mode Less than 0.45 W (0.1 w***)
JC91-01076A (110V)
Transfer Roll JC66-02709A 30,000 pages
NOTE:
Pick-Up Roll Assy JC66-00525A 30,000 pages
* Sound Pressure Level, ISO 7779. Configuration tested: basic machine installation, A4 paper,
Friction Pad JC66-00522A 30,000 pages simplex printing.
** See the rating label on the machine for the correct voltage, frequency (Hz) and type of cur-
rent.
*** If equipped with a power switch.
Table 10 Reliability and Service
Item Specification
Printing Volume (SET AMPV) 75 pages/ month
MPBF 20,000 pages
MTTR 30 minutes
SET Life Cycle 30,000 pages or 5 years (whichever comes first)

Table 11 Environment
Item Specification
Dimension (W x D x H) SET 13.7 x 13.3 x 7.7 in.
348 x 338 x 197 mm
Weight Machine (with • 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
GP 1 Diagnostics Entry and Exit GP 2 Machine Reports
Purpose Purpose
This procedure describes the following items: This procedure is used to access and print machine reports. The information within the reports
• How to enter Diagnostics may be useful for troubleshooting problems.
• The Diagnostic screen
• How to exit Diagnostics
Procedure
To access machine status and reports, follow the steps below:
Procedure
Enter Diagnostics from the 3025NI model: From the Control Panel:
1. Make sure the machine is in Ready mode.
2. Enter the Diagnostic (Tech) Mode from the Control Panel. Press the following buttons in 1. Press the <Info> Button, then select: [Information Pages>Reports] to print the following
quick succession: <Menu>#>1934>OK>. reports.
3. In the Diagnostic Mode, use the navigation buttons to scroll to the desired sub-menu.
4. Press the <OK> button to confirm menu selections. 3025BI:
• Configuration
To enter Diagnostics from the 3025BI model: • Demo Page
1. Make sure the machine is in Ready mode. • Network Configuration
2. Enter the Diagnostic (Tech) Mode from the Control Panel. Press the following buttons in • Supplies Information
quick succession: <Menu>Back>Up arrow>Down arrow>OK>Stop. • Usage Counter
• Press the [Menu] button to access Diagnostics.
3. In the Diagnostic Mode, use the navigation buttons to scroll to the desired sub-menu. 3025NI:
4. Press the <OK> button to confirm selections. • Configuration
• Demo Page
• Network Configuration
To exit Diagnostics:
• Supplies Info
1. From the Diagnostics menu, use up and down arrows to scroll to <Exit Diagnostics>.
• Usage Counter
2. Press the <OK> button.
• Fax Received
Refer to Section 6, Diagnostics for a listing of available functions within Diagnostic Mode.
• Fax Sent
• (Fax) Scheduled Jobs
• Fax Confirm
• Junk Fax
• Address Book

From a networked PC:

1. Open Easy Printer Manager.

2. Select the [Settings] tab then select the [CentreWare Internet Services] button.
3. 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.

June 2014 General Procedures and Information

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 6-13 GP 1, GP 2
4. Select the [Status] tab then, [Current Settings, Print Information] to access: GP 3 Machine Counters
• Machine Information
Purpose
• Security Information
Use this procedure to access the Machine Counters.
• Print Information and Reports:
– Configuration NOTE: If frequent paper jams or printing problems are occurring, check the number of pages
– Network Configuration the machine has printed or scanned. Replace worn parts as needed.
– Supplies Info
Procedure
– Usage Counters
From the Control Panel:

Refer to the following sections of the WorkCentre® 3025BI/NI User Guide for: 1. Press the <Information> button
2. Use the up/down arrows to scroll to <Info Pages>, then press the <OK> button.
• Information on machine reporting and configuration using the Control Panel and Centre-
3. Scroll to <Usage Counter> then press the <OK> button to print a Usage Counter report.
Ware Internet Services (CWIS) including:
or
• Section 6 Maintenance: Checking the Status of Consumables.
• Section 7 Troubleshooting, Machine Status Indicators, for:
1. Enter Diagnostics Mode, select <Diagnostics> then press the <OK> button
– LED color and status descriptions
2. Use the up/down arrows to select <Report>, then press <OK>.
– Printing machine reports
3. 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
GP 4 Machine Firmware Version GP 5 Altitude Adjustment
Purpose Purpose
Use this procedure to check the firmware version of the machine. Print quality is affected by atmospheric pressure, which is determined by the height of the
machine above sea level.
Procedure
From the Control Panel: Requirements
• WiFi or Network connection
1. Press the <Information> button. Procedure
2. Use the up/down arrows to scroll to Info Pages, then press the <OK> button.
1. Determine altitude of machine placement:
3. Use the up/down arrows to scroll to Configuration then press the <OK> button to print a
configuration report. Table 1 Altitude Values
or: Altitude Value

1. From Diagnostics Mode: 0 - 1000 M Normal

0 - 3,280 ft.
2. Use the up/down arrows to select <Report> then press <OK>.
1000 - 2000 M High 1
3. Use the up/down arrows to select <Configuration> then press <OK>, then <OK> again
3,280 - 6,561 ft.
to print a configuration report.
2000 - 3000M High 2
6,561 - 9,842 ft.
The firmware version is listed under Device Setup/ System. 3000 - 4000 M High 3
9,842 - 13,123 ft.
4000 - 5000 M High 4
13,123 - 16,404 ft.

2. Press the <Information> button on the Control Panel to go to Machine Status.

3. Using the up/down arrows, naviagate to: [System Setup>Machine Setup>Altitude
Adjustment]. Press the <OK> button to confirm selections.
4. Select the correct altitude value for the placement of the machine. Table 1.
5. Press <OK>.
or:

1. Open Easy Printer Manager. Select: [Machine Settings, System Altitude Adjustment].
2. Select the correct altitude value for the placement of the machine. Table 1. Press <OK>.

June 2014 General Procedures and Information

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 6-15 GP 4, GP 5
GP 6 Machine Settings 4. Select [Properties] then select from the following menu items to change the machine set-
tings:
Purpose • Firmware
Use this procedure to configure machine settings from the Control Panel, Easy Print Manager,
• System
and CWIS.
• Printer
Procedure • Copy

From the Conrol Panel • Fax

• Scan
1. Press the <Information> button. • E-mail Notification
2. Use the up/down arrows to scroll to the following menu items: • Network Settings
• Feature Default • Security
• Fax Setup
• System Setup
• Network

To change settings Using Easy Print Manager (EPM):

1. Connect to the WorkCentre® 3025 Printer with a USB cable.

2. Open Easy Print Manager from the PWS.
3. Select [Advanced Mode] then select [Machine Settings].
4. Select from the following menu items to change the machine settings.
• System
• Earth Smart
• Input Tray
• Layout
• Printer
• Emulation
• Copy
• Fax
• Scan
• Network Setttings

From CWIS:
1. Connect to the WorkCentre® 3025 Printer with a USB cable or wirelessly.
2. Open Easy Print Manager and select the [CWIS] icon.
3. 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
GP 7 Firmware Upgrade b. Locate and select the correct firmware upgrade .hd file.
c. Select [Open].
Purpose
12. Select [Next]. The firmware will now be verified and display information about the
Use this procedure to update the machine firmware using the USB port or via the network.
upgrade.
13. Select [Next] to continue. The upgrade should take approximately 10 minutes.
Requirements
14. The machine will reboot automatically when the upgrade has completed.
• Wired or wireless connection to upgrade using the network.
15. Print a Configuration Report and verify that the firmware has been successfully upgraded.
• The usblist2.exe tool, located in the GSN website, installed on the PWS device. (Ref. GP
X)
• Correct firmware file for update.
• Firmware Upgrade must be enabled in the machine settings on the printer.
• Complete or delete all jobs in the printer queue before initiating a firmware upgrade.

Procedure
Upgrading the Firmware using a USB Port:

1. Connect a USB cable from the PWS to the USB port on the printer.
2. Confirm that the printer is the Ready status.
3. To enable firmware upgrades on the device:
• Drag the SWUPGRADE_ON.prn file and drop it onto usblist2.exe.
or
• In Diagnostic Mode, select [Data Setup>F/W Upgrade>On]. Press the <OK> button
to confirm menu selections.
4. Drag and drop the firmware file onto usblist2.exe. The firmware update will start automat-
ically.
5. The printer will reboot when upgrade is complete.

Upgrading the Firmware using the Network:

1. Open a web browser and enter the machine’s IP address.

2. Select [Enter]. The CentreWare Internet Services window will open.
3. Select the [Login] link at the top of the screen.
4. Enter the Administrator username (admin) and password (1111). The Firmware Upgrade
window will open.

NOTE: It may be necessary to obtain the username and password from the customer if
they have been changed.

5. Click on the [Properties] tab.

6. In the [Security link], select [System Security].
7. Select the [Feature Management] link in the directory tree.
8. Select the [Firmware Upgrade Enable] box.
9. Click [Apply] to save the changes.
10. Select the [Support] tab.
11. In the [Firmware Upgrade] link, select the [Upgrade Wizard] button.
a. In the Firmware File area, select [Browse].

June 2014 General Procedures and Information

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 6-17 GP 7
GP 8 Usage of the Electrostatic Discharge (ESD) Field GP 9 DC 305 UI Button Test Sequence (3025NI)
Service Kit Purpose
Purpose Use this procedure to access and run the DC 305 UI Button Test
The purpose of the Electrostatic Discharge (ESD) Field Service Kit is to preserve the inherent
reliability and quality of sensitive electronic components handled by the service representative. Procedure
The kit should be used whenever handling the circuit boards or any other ESD sensitive com- 1. Enter the Diagnostic (Tech) Mode from the Control Panel. Press the following buttons in
ponents. quick succession: <Menu>#>1934>OK>.
2. In the Diagnostic Mode, use the navigation buttons to scroll to the Machine Test sub-
Procedure menu.
1. Switch off the machine power and disconnect the machine power cords. 3. Press any button to start the LDC test.
2. Assemble the kit: 4. Press the OK button 2 times. A series of black boxes will be shown on the Control Panel
a. Place the static dissipative work surface mat on a flat surface in close proximity to display. [Figure 1].
the machine or the component
b. Connect the snap end of the green grounding cord to the snap on the static dissipa-
tive work surface mat. Connect the male end (plug) to the frame.
c. Connect the small snap end of the blue cord to the top snap on the green grounding
cord.
d. Connect the small snap end of the blue cord to the snap on the adjustable cloth wrist
strap or the ESD wristwatch.
e. Install the adjustable wrist strap or ESD wristwatch securely on the wrist.
First display
3. The circuit boards (PWBs) and ESD sensitive components can now be handled without
causing any ESD related damage. Place all of the components removed from the
machine onto the static dissipative work surface mat.
4. New replacement components, as well as defective components, should be handled dur-
ing unpacking and repacking using the ESD Field Service Kit. During transfer from or to
the packing material or container, the PWB should be placed on the static dissipative work
surface mat.

Second display

Figure 1 Control Panel Display

5. Press the OK button until PRESS BELOW Copy Mode 00 is displayed on the Control
Panel. Press the Copy Mode button to continue.
6. 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
 NOTE: The <OK> button does not have an indicator light. It is depicted by a series of GP 10 Software ServiceTools
black boxes displayed when the Menu button is pressed. [Figure 2]. Press the OK button
to test the button and return to the test sequence. Purpose
Use this procedure access and download the software service tools.

Procedure
1. To access the software tools file go to:
• GSN Library #7387
• https://www.xrxgsn.com/secure/main.pl?catid=13991
• Software_tools.zip
2. Download the Software_tools.zip file onto the PWS.
3. Open the zip folder and extract the tool files.
4. The WorkCentre® 3025 uses the following tools:
• SWUPGRADE_ON.prn - to enable the machine to accept software downloads
• usblist2.exe - to download software via USB connection.
• USB_Serial_V1.02.exe - tool used to write the machine serial number to the Main
PWB.
OK Button Indication NOTE: There is a function in Diagnostics that allows for entry of the serial number
using the keypad (3025NI). From Diagnostic Mode, (Ref. [GP 1]) select: [Data Set
Up>Set Serial Number] then, using the keypad, enter the serial number. Press the
Figure 2 OK Button Indication <OK> button to confirm selections. This function allows numeric entries only. For
serial numbers containing alpha characters (letters) use the serial number writing
7. Press the <Stop> button to end the test. All control panel lights are illuminated. tool; USB_Serial.V1.02.exe.
8. Continue pressing the <Stop> button until all control panel indicator lights are turned off
and the machine is returned to Copy mode.

June 2014 General Procedures and Information

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 6-19 GP 9, GP 10
General Procedures and Information June 2014
GP 9, GP 10 6-20 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
Diagnostic Information Entering Diagnostic Mode (Tech Mode)
This section of the Service Documentation contains information about Diagnostic Procedures. To enter Diagnostic (Tech) Mode, use the steps listed below.
This section also contains various other product-specific information that may be useful and/or
needed for product servicing. For Model 3025 NI:
1. From the Control Panel, press the <Menu> button.
2. Press the <#> button
3. On the keypad, enter 1934
4. Press <OK>
For Model 3025 BI:
1. From the Control Panel, press the following buttons in quick succession: <Menu > Back >
Up Arrow > Down Arrow > OK >Stop
2. Press the <Menu> button
3. Select [Diagnostics]

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

June 2014 General Procedures and Information

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 6-21 Diagnostic Information, Entering Diagnostic Mode
 NOTE: NOTE:
* Indicates features included in the 3025NI model only.
** Indicates that there is a function in Diagnostics that allows for entry of the serial number
using the keypad (3025NI). From Diagnostic Mode, (Ref. GP 1) select: [Data Set Up>Set
Table 1 Diagnostic Mode Menu - Data Setup Serial Number] then, using the keypad, enter the serial number. Press the <OK> button to
Level 1 Level 2 Level 3 Level 4 confirm selections. This function allows numeric entries only. For serial numbers containing
Data Setup *Send Level 9-15 12 alpha characters (letters) use the serial number writing tool; USB_Serial.V1.02.exe.

*DTMF Level (High) 0-15 (Low) 0-15

*Pause Time 1-9
*Dial Mode Tone/Pulse

*Modem Speed 33.6

28.8
14.4
12.0
9.6
4.8
*Error Rate 10%
5%
Clear All Memory Set options Clearing Memory
Toner Low Level 1-30%
Clear Counts Enter <1934> ADF Scan
Platen Scan
Fuser
Transfer Roller
Pickup Roller
ADF Roller
ADF Rubber Pad
Engine Footer Off/On

*Dial Tone Off/On

*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
 Table 2 Diagnostic Mode Menu - Machine Test
Level 1 Level 2 Level 3 Level 4 Level 5 Level 6
Machine Test DC305 UI Test Press any key to start NOTE: Refer to GP 9 for test
procedure
*Modem Test Fsk ? Press <Stop> button to cancel
DRAM Test DRAM Test OK
ROM Test Press <OK>
*Continuous DTMF DTMF # Line1
DTMF *Line1
Shading Test Shading & Print Print? Yes/No
Scan Aging (Internal Eng. test) P.1...P.2, etc. Press <Stop> button to cancel
EDC Mode DC330 Component Control 100 Motor Feed Motor Status:
Off/On
Feed Motor Slow Status:
Off/On
101 Clutch Tray 1 Pickup Status:
Off/On
102 Sensor Feed Sens Status:
Low
Width Sens Status:
Low
105 Charger K MHV Bias Status:
Off/On
106 Development K Dev Bias Status:
Off/On
K Dev AC Status:
Off/On
107 Transfer K THV Bias Status:
Off/On
K THV - Bias Status:
Off/On
109 Fuser Temp A Status:
[0]
110 LSU LSU Mot1 Run Status:
Off/On
LD Power4 Status:
Off/On
LSU HSync4 Status:
Low

June 2014 General Procedures and Information

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 6-23 Entering Diagnostic Mode
 Table 3 Diagnostic Mode Menu - Report Data Setup
Level 1 Level 2 Level 3 The following items can be modified:
Report Protocol Dump (3025NI only) Yes • Send Level
Supplies Info Yes The level of the transmission signal (Tx). The Tx signal can be set to a value between
Configuration Yes 9dBm and 15 dBm. Normally, the Tx level should be less than 12 dBm.
Error Info Yes • DTMF Level
Usage Counter Yes The value of the High level tone and the Low level tone in DTMF mode. (Not dial mode).
Both High and Low can be set to a value between 0 and 15.
Component Check Yes
• Pause Time
Fax Options (3025NI only) Yes
The delay time when receiving the pause input at auto dial. The pause time can be set to
Service Support Yes
a value between 1 and 9 seconds.
• Dial Mode
The type of dial method, either Tone or Pulse. The default setting is Tone.
• Modem Speed
The modem speed is automatically set to a slower speed when communicating with a
slower speed modem, as communication is done on the standard of the side where
modem speed is low for transmission/reception. Available settings are 33.6 Kbps, 28.8
Kbps, 14.4 Kbps, 12.0 Kbps, 9.6 Kbps, and 4.8 Kbps. It is recommended to maintain the
default setting of 33.6 Kbps.

• Error Rate
When the error rate is about exceed the set value, the Baud rate automatically adjusts to
2400 bps. This ensures that the error rate remains below the set value. The error rate can
be set to 5% or 10%.
• Clear All Memory
To reset the system to factory default settings when the product is functioning abnormally.
All system settings are returned to the default values, including all customer settings.

NOTE: Clear All Memory must be performed after replacing the Main PWB. Failure to do
so could negatively effect machine performance.

• Toner Low Level

This is used to set up when the customer is notified to replace the Toner Cartridge. The
time can be set from 1 to 30%.
• Clear Counts
Use this function to reset the copy counters for the following operations or components:
– Platen Scan
– Document Feeder Scan
– Fuser
– Transfer Roll
– 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
• Engine Footer Machine Test
This function is used to display the print engine status on the bottom of a printed page. It
The following machine tests are available:
is set to either On or Off.
• Switch Test
• Dial Tone
The Switch Test is used to test the Control Panel buttons. When a functioning button is
On or Off. pressed, the LCD will indicate that it is functioning. Refer to GP 9.
• Caller ID • Modem Test
On or Off. The Modem Test transmits signals from the MODEM to a telephone. If no transmission
• Busy Tone sound is heard, the modem segment of the Main PWB has malfunctioned.
On or Off. • DRAM Test
• Wrap Jam Clear Use this feature to test the system DRAM. The test result will be shown on the LCD dis-
This function is used to cancel the Wrap Jam fault. play.
Yes or No. • ROM Test
• F/W Upgrade Use this feature to test the system ROM. The test result will be shown on the LCD display.
This function is used to upgrade the printer firmware via USB port by using the • Continuous DTMF Test
“usblist2.exe” tool, or by using a network connection with a web browser. Refer to General Dual Tone Multi-Frequency Signal (DTMF) tests the line for the volume of the dialing and
Procedures, GP 7 for detailed instructions on how to update firmware. dial tone for machines equipped with a fax option.
• Set Serial Number • Shading Test
The Machine Serial Number must be re-entered manually after installing a new Main The Shading Test is performed to asses and optimize image quality by checking the Con-
PWB. Refer to REP 1.7. tact Image Sensor.
• Scan Aging
An internal Engineering tool that tests the reliability of the Scanner Motor. (Not a field
diagnostic function.)

June 2014 General Procedures and Information

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 6-25 Data Setup, Machine Test
Report EDC (Diagnostic) Mode
The following printed reports can be generated by the machine: The following diagnostic routines can be accessed in EDC Mode:
• Protocol • NVM Initialize
The Protocol report is used to check for send and receive errors. It shows the sequence The NVM Initialize routine provides the capability to initialize (set to default) machine con-
of the CCITT group 3 T.30 protocol during the most recent sending or receiving operation. trol parameters stored in Non-Volatile Memory (NVM). Refer to Table 1.
• Supplies Info • NVM Read/Write
The Supplies Information report shows Toner Cartridge information such as toner remain- The NVM Read/Write routine provides the capability to review and modify machine con-
ing, toner capacity, and toner product date. trol parameters stored in Non-Volatile Memory (NVM). Refer to Table 1.
• Configuration
Table 1 NVM Codes and values
The Configuration report shows the status of user-selectable options, and should be
printed to confirm changes made to machine settings. NVM Code LCD Definition Default Min Max
• Error Info 105 MHV Bias Charger HV Black DC Duty 210 50 250
The Error Info report shows a list of all machine errors since the last service call. 106 Deve Bias Deve DC Black 190 50 250
• Usage Page 107 ATTR Bias Transfer2 HV 130 50 250
The Usage Page report shows the number of duplex and simplex prints since the last ser- 109 Fuser Heat Standby target temperature 10 0 15
vice call. 110 LSU LSU Power at Normal Speed 450 50 600
• Component Check
The Component Check report shows the results of component testing while in Diagnostic • DC330 Test Routines
Mode.
This routine provides the capability to verify component functionality by monitoring input
signals and controlling output states. Refer to Table 2.

Table 2 Input/Output Components

Diagnostic Input/ State
Code Displayed name Definition Output Displayed
100-Motor Feed Motor Feed Motor is On/Off Output On [Off]
Feed Motor Slow Detect if Feed Motor Input High [Low]
runs at normal speed
101-Clutch Tray1 Pick-Up Engages drive to pick Output On [Off]
up a paper from tray1

102 Sensor Feed Sens Detects when a paper Input High [Low]
is at Feed sensor.
Width Sensor

105 Charger K MHV Bias Black MHV bias volt- Output On [Off]
age on at normal drive
level
106 Develop- K Dev Bias Black Dev bias voltage Output On [Off]
ment on at normal drive level
107 Transfer K THV Bias Black THV bias voltage Input On [Off]
on at normal drive level
K THV(-) Bias Black THV bias voltage Input On [Off]
on at normal drive level
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
 Table 2 Input/Output Components
Diagnostic Input/ State
Code Displayed name Definition Output Displayed
110 LSU LSU Motor1 Rdy Detects if LSU motor1 Input High [Low]
runs at normal speed
LSU Motor1 Run 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]

June 2014 General Procedures and Information

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 6-27 EDC (Diagnostic) Mode
General Procedures and Information June 2014
EDC (Diagnostic) Mode 6-28 Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
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.
Table 1 Glossary Grayscale Varying shades of gray pixels ranging from black to white that repre-
sent different tones of an image.
Term/Acronym Definition
Halftone The reprographic technique that simulates continuous tone imagery
802.11 802.11 is a set of standards for wireless local area network (WLAN) through the use of dots, varying in either size, shape or spacing.
communications, developed by the IEEE LAN/MAN Standards Com-
IP address Internet Protocol Address. A unique number that devices use to iden-
mittee (IEEE 802).
tify and communicate with each other over a network utilizing the IP
802.11b/g/n 802.11b/g/n refers to specifications within the 802.11 family. 802.11b standard.
is also referred to as High-Rate or Wi-Fi, 802.11g is used for transmis-
IPP The Internet Printing Protocol. A standard protocol that can be used
sion over short distances and 802.11n adds multiple-input multiple-
locally or over the internet to create and manage print jobs, and to
output.
support access control, authentication, and encryption.
Access point A device that connects wireless communication devices on wireless
IPX/SPX Internet Packet Exchange/Sequenced Packet Exchange. A network-
local area networks (WLAN). Also acts as a central transmitter and
ing protocol to provide connection services similar to TCP/IP, with the
receiver of WLAN radio signals.
IPX protocol having similarities to IP, and SPX having similarities to
ADF Automatic Document Feeder. Scanning device that automatically TCP.
feeds a document or stack of documents.
ISO International Standardization Organization. An international standard-
BOOTP Bootstrap Protocol. Used by a network client to obtain an IP address setting body that develops and promotes world-wide industrial and
from a configuration server. During computer startup, a BOOTP con- commercial standards.
figuration server assigns an IP address to each client from a pool of
ITU-T International Telecommunication Union (Telecommunications sector).
addresses.
Established to standardize and regulate international radio and tele-
Control Panel Area where control or monitoring instruments are displayed, typically communications.
located in the front area of the machine.
ITU-T standard Chart Standardized test chart published by ITU-T for document facsimile
Default The value or setting that is in effect when the printer/copier is first number 1 transmissions.
installed, reset, or initialized.
JBIG Joint Bi-level Image Experts Group (JBIG), is lossless (no loss of
DHCP The Dynamic Host Configuration Protocol. A standardized networking accuracy or quality) bi-level image compression standard. It’s widely
protocol used by servers on an IP computer network to allocate implemented in fax machines, but can also be used for other images.
assigned IP addresses to a computer requesting an IP address.
JPEG Joint Photographic Experts Group. A commonly used standard
DNS Domain Name Server. The Domain Name Server translates alpha- method of lossy (compressing data by losing some of it) compression
betic domain names into a corresponding IP address. for photographic images.
DPI Dots Per Inch. The measure of the resolution of an image displayed LED A Light-Emitting Diode. A semiconductor device used to display
on a screen or on a printed page, in dots or pixels. machine status.
Duplex In printing, the capability to automatically turn over a sheet of paper so MFP Multi Function Printer. A machine that includes multiple functions in
that the machine can print both sides of the sheet during one print one device such as; printing, copying, faxing, and scanning functions.
cycle.
MH Modified Huffman. A compression method for decreasing the amount
Duty Cycle The proportion of time during which a device is active. (E.g., if the duty of data that needs to be transmitted between fax machines to transfer
cycle for a printing device is 48,000 pages per month for 20 working the image.
days, the output that device can reliably produce is 2,400 pages a
MMR Modified Modified READ. A compression method recommended by
day.)
ITU-T T.6.
ECM Error Correction Mode. A transmission mode built into fax machines
Modem Modulator-Demodulator. A device that modulates an analog carrier
or fax modems to automatically detect and correct errors in the trans-
signal to encode digital information, and demodulates a carrier signal
mission process.
to decode the transmitted information.
Emulation Hardware and/or software that emulates the functions of one com-
MR Modified Read. A compression method that encodes the first scanned
puter system (the guest) in another computer system (the host).
line (using MH), then compares the next line to the first, determines
Fuser The Fuser subsystem permanently affixes toner onto print media by the differences, then encodes and transmits those differences.
applying heat and pressure.

June 2014 General Procedures and Information

Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 6-29 Glossary of Terms
 Table 1 Glossary Table 1 Glossary
Term/Acronym Definition Term/Acronym Definition
NFC Printing Near Field Communication Printing. Allows printing and scanning USB Universal Serial Bus. A hardware interface that connects computers
directly from NFC enabled cell phones. (Does not require print driver and peripherals. The USB is designed to concurrently connect a sin-
installation or connection to an access point.) gle computer USB port to multiple peripherals.
OPC Organic Photo Conductor. A mechanism that creates a virtual image WEP Wired Equivalent Privacy. A protocol for wireless local area networks
for print using a laser beam emitted from a laser printer. Also referred that provides security by encrypting data over radio waves so that it is
to as Photoreceptor Drum. protected as it is transmitted from one end point to another.
Originals The original is the first example of a document, photograph, chart, or WIA Windows Imaging Architecture. A still image acquisition platform
any combination of these, used to produce others. that allows different imaging/graphics applications to interact with dif-
PABX Private Automatic Branch Exchange. An automatic telephone switch- ferent scanners without requiring customized applications or drivers
ing system within a private enterprise. for each combination.
PCL Printer Command Language. A page description language developed Wi-Fi A technology that uses radio waves to provide high-speed internet
to provide an efficient way to control printer features across various and network connections.
printing devices. WPS The Wi-Fi Protected Setup. A standard for establishing a wireless
PostScript (PS) A page description and programming language used primarily in the home network, allowing easy wireless network connection without a
electronic and desktop publishing areas to generate high-resolution computer.
images.
Printer Driver A program used to send commands and transfer data from the com-
puter to the printer.
Print Media Material such as paper, envelopes, labels, and transparencies which
can be used in printers, scanners, fax machines, or copiers.
PPM Prints Per Minute. Used to measure printer speed. The number of
copies or prints produced in one minute.
Protocol A convention or standard that controls or enables the connection,
communication, and data transfer between two computing endpoints.
PSTN Public Switched Telephone Network. The aggregate of the world's cir-
cuit-switched telephone networks providing infrastructure and ser-
vices for public telecommunication.
Resolution The sharpness of an image, measured in Dots Per Inch (DPI).
TCP/IP Transmission Control Protocol (TCP) / Internet Protocol (IP). The suite
of protocols for communication between computers, used as a stan-
dard for transmitting data over networks.
TIFF Tagged Image File Format (TIFF) is a bit mapped image format used
for storing raster graphics images, typically from scanners. TIFF
images make use of tags, keywords defining the characteristics of the
image that is included in the file.
Toner Cartridge A bottle or container used in a xerographic copier/printer that contains
the powder used to form the text and images on the printed paper.
TWAIN An applications programming interface and communications protocol
that regulates communications between software and digital imaging
devices.
URL Uniform Resource Locator. The global address of documents and
resources on the 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
 Xerox® WorkCentre® 3025 TABLE OF CONTENTS
BLOCK SCHEMATIC DIAGRAMS
June, 2014
CHAIN 1 POWER
1.1 AC / LOW VOLTAGE and HIGH VOLTAGE POWER /
INTERLOCKS

This document contains wiring and mechanical power data for the Xerox® WorkCentre® 3025. These CHAIN 3 COMMUNICATIONS
block schematic diagrams are supplemental to the diagnostic and troubleshooting information found 3.1A PRINTER COMMUNICATION
in the Xerox WorkCentre 3025 Service Manual. 3.1B PRINTER COMMUNICATION

CHAIN 4 MAIN DRIVE

Every effort has been made to achieve accuracy on these schematics. However, if a difference is 4.1 MAIN DRIVE
noted between these schematics and the Xerox service documentation, the service documentation
takes precedence. CHAIN 5 AUTOMATIC DOCUMENT FEEDER
5.1A ADF
5.1B ADF

CHAIN 6 LSU
6.1 LSU

CHAIN 7 PAPER FEED AND REGISTRATION

7.1 PAPER FEED AND REGISTRATION

CHAIN 9 XEROGRAPHICS
9.1 PRINT MODULE

CHAIN 10 FUSING
10.1 FUSING

CHAIN 14 DOCUMENT SCANNING

14.1 SCANNING

Prepared by:

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..
 THIS PAGE INTENTIONALLY BLANK

June 2014
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 A B C D E F G H J
1.1 AC / LOW VOLTAGE and HIGH VOLTAGE POWER / INTERLOCKS

LVPS / HVPS PWB MAIN PWB

PL 5.1 PL 1.1 - 1.2

TOP COVER
INTERLOCK
+3.3 VDC
SWITCH +24 VDC Off
J6 P6 Sleep Mode
9
2

COVER CLOSED
(H) +3.3 VDC P6 J6
5 16

DC COM
18 3

DC COM
13 8
3
DC COM
14 7
DC COM DC COM
+24VDC
+24 VDC Off
Sleep Mode P1 J1 +24 VDC
12 19 2
DC POWER
GENERATION +24 VDC
17 4

4 J2 15
+24 VDC
6

ACH
+24 VDC
DC COM
ACN 11 10
DC COM DC COM
+5VDC
+5 VDC

5 +5 VDC

+5 VDC

DC COM

+24 VDC +3.3 VDC

POWER
GENERATION

DC COM
+3.3 VDC
6 7 14
+3.3 VDC +3.3 VDC +3.3 VDC

June 2014
Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 7-1 BSD’s
 A B C D E F G H J
3.1A COMMUNICATIONS (1 of 2)
MAIN PWB WNPC (WiFi) PWB
PL 1.1 - 1.2 PL 1.1
J3 P3 +3.3 VDC
1 11
1 USB J1 +3.3 VDC +3.3 VDC
3
2 10

2 DC COM
3 9
DC COM DC COM
1 SIGNAL
4 8

4 SIGNAL
6 6
DC COM
SIGNAL
2 7 5

DC COM
8 4
J2 SIGNAL DC COM DC COM
1 SIGNAL
9 3
SIGNAL
2 DC COM
10 2
SIGNAL
3 DC COM DC COM
+3.3 VDC
11 1
TERMINATE +3.3 VDC +3.3 VDC
3 4

5 TERMINATE

SIGNAL 3025 BI
6 CONTROL PANEL PWB
ROUTER PL 3.1
TERMINATE
7 J11 P11 SIGNAL
5 9
TERMINATE
8
4 LED G ENABLE DC COM POWER LED
6 8
9

LED G ANODE
10
POWER KEY
7 7
LED Y ENABLE
11
LED Y ANODE DC COM
12 8 6
DC COM DC COM
13
5 +5 VDC
9 5
14
+5 VDC +5 VDC
DC COM

+3.3 VDC SIGNAL

10 4

J14 SIGNAL
1 11 3

6 2 SIGNAL
12 2
WIDTH SENSOR
3

FEED SENSOR
4

June 2014
BSDs Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
7- 2
 K L M N P R S T U

3.1B COMMUNICATIONS (2 of 2)
MAIN PWB FAX PWB
PL 1.1 - 1.2 PL 1.2
J12 P12 MODEM SIGNAL SPEAKER
1 1 1

MODEM SIGNAL
2 2 1

MODEM INIT
3 3
2
MODEM SIGNAL
4 4

MODEM SIGNAL
5 5

6
MODEM SIGNAL 2
6

MODEM SIGNAL 7
7

MODEM RESET
8 8

DC COM
9 9
DC COM DC COM
+3.3 VDC
10 10
+3.3 VDC +3.3 VDC 3

CONTROL PANEL PWB 3025 NI

PL 8.1

J11 P11 ECO LED

1 1

ECO KEY
2 2

WPS LED 4
4 4

WPS KEY
5 5

POWER LED
6 6

POWER KEY
7 7

DC COM
8 8 5
DC COM DC COM
+5 VDC
9 9
+5 VDC +5 VDC
CANCEL KEY
10 10

11 READY LED 11

ERROR LED 6
12 12

TONER LED
13 13

June 2014
Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 7-3 BSD’s
 A B C D E F G H J

4.1 MAIN DRIVE

MAIN PWB
PL 1.1 - 1.2

2
+24 VDC

DRIVE MOTOR
PL 5.4
MOTOR
DRIVER
J8 P8 PHASE A
1

PHASE B
2

3 PHASE C MOT
3

PHASE D
4

June 2014
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 A B C D E F G H J

5.1A AUTOMATIC DOCUMENT FEEDER (1 OF 2)

ADF PWB MAIN PWB
PL 1.1 - 1.2
ADF COVER SENSOR
+3.3 VDC
1 COVER OPEN
(H) +3.3 VDC
COVER OPEN P13 J13
3 10

DC COM
2
DC COM
+3.3 VDC
1
+3.3 VDC
2

PAPER POSITION
SENSOR
+3.3 VDC
PAPER POSITION
(H) +3.3 VDC
PAPER POSITION
3 9

DC COM
2
3 DC COM
+3.3 VDC
1
+3.3 VDC

PAPER PRESENT
SENSOR +3.3 VDC
PAPER PRESENT
(H) +3.3 VDC
PAPER PRESENT
4 3 12 J13 P13 +3.3 VDC
5

DC COM
2 +3.3 VDC
6
DC COM
+3.3 VDC
1 +3.3 VDC
7
+3.3 VDC
+3.3 VDC
+3.3 VDC DC COM
8
5
+3.3 VDC DC COM
11
+3.3 VDC DC COM

+3.3 VDC
DC COM

DC COM

DC COM

6 DC COM

DC COM

+3.3 VDC

+3.3 VDC

+3.3 VDC

June 2014
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 K L M N P R S T U

5.1B AUTOMATIC DOCUMENT FEEDER (2 OF 2)

2
MAIN PWB
PL 1.1 - 1.2

ADF PWB
+24 VDC

ADF MOTOR
PL 3.1
MOTOR
DRIVER
J13 P13 PHASE A PHASE A 3
1 1 1
PHASE B PHASE B
2 2

PHASE C PHASE C MOT

3 3

PHASE D PHASE D
4 4

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 A B C D E F G H J

6.1 LSU
MAIN PWB LSU
PL 1.1 - 1.2 PL 5.1

J5 P5 +24 VDC
1 1 5

+24 VDC +24 VDC

DC COM
2 4
DC COM DC COM

MOTOR ENABLED
3 3

2
MOTOR READY
4 2

MOTOR CLOCK
5 1

POWER
3 8 9

LSU
MOTOR
SIGNAL
9 8

SIGNAL
10 7

4
DC COM
11 6
DC COM DC COM

SIGNAL
12 5

SIGNAL
13 4
5
DC COM
14 3
DC COM DC COM

SYNC SIGNAL
15 2

+3.3 VDC
6 16 1
+3.3 VDC +3.3 VDC

June 2014
Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 7-7 BSD’s
 A B C D E F G H J

7.1 PAPER FEED AND REGISTRATION

1
MAIN PWB
PL 1.1 - 1.2

FEED SENSOR PWB

PL 5.3

+3.3 VDC
FEED SENSOR
PAPER AT FEED
CN1 SENSOR (L) +3.3 VDC CN SENSOR
2 1
2

DC COM
1 5
DC COM
+3.3 VDC
3 4
+3.3 VDC

+3.3 VDC
WIDTH SENSOR
3 PAPER AT REG
SENSOR (L) +3.3 VDC
4 3

+3.3 VDC
5 2
+3.3 VDC

4
FEED
CLUTCH
PL 5.3
+24 VDC FEED CLUTCH ON
J9 P9 (L) +24 VDC
1

2
DC COM
5

June 2014
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 A B C D E F G H J

9.1 XEROGRAPHICS

1
MAIN PWB LVPS / HVPS PWB
PL 1.1 - 1.2 PL 5.1

J6 P6 DEVELOPER ON
11 10 PRINT MODULE

TRANSFER ON DEVELOPER
12 9 ROLL
CHARGE

DEVELOPER ENABLED
13 8
2
DEVELOPER AC
15 6

DEVELOPER DC
17 4

TRANSFER ENABLED
18 3
SUPPLY
PR DRUM
3 ROLL
CHARGE ENABLED
19 2
TRANSFER
CHARGE ON ROLL
20 1

CRUM

J7 P7 +3 VDC
1 1
+3.3 VDC
5 CRUM SIGNAL
2 2

CRUM SIGNAL
3 3

DC COM
4 4
DC COM

June 2014
Xerox® WorkCentre® 3025 Multifunction Printer Service Manual 7-9 BSD’s
 A B C D E F G H J

10.1 FUSER

1
MAIN PWB LVPS / HVPS PWB
PL 1.1 - 1.2 PL 5.1
FUSER MODULE
PL 5.1

FUSER
THERMISTOR
RT10-001 Fuser Temperature Enable Fuser
Signal P16 J16 Relay
1 J6 P6
2 1 20

Fuser Relay
+3.3 VDC On
3 5 16 FUSER MODULE
+3.3 VDC PL5.2

OVERTEMPERATURE
THERMOSTAT
Heat Lamp
On ACH T1 T2
CN1 CN
L
3

ACH HEAT LAMP

ACN

June 2014
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 A B C D E F G H J
14.1 SCANNING
MAIN PWB SCANNER PWB
PL 1.1 - 1.2 PL 4.2
J10 P10 SIGNAL
1 1
1
SCAN CONTROL
2 2

DC COM
3 3
DC COM DC COM

+3.3 VDC
4 4
+3.3 VDC +3.3 VDC

SIGNAL
2 5 5

SCAN SIGNAL
6 6

CLOCK SIGNAL
7 7

+6.6 VDC
8 8
3 +6.6 VDC +6.6 VDC
BLUE
9 9

GREEN
10 10

RED
11 11

DC COM
12 12
4 DC COM DC COM

CONTROL PANEL PWB

PL 3.2
J11 P11 PHASE A
1 13
+ 24VDC
PHASE B
2 12 SCAN MOTOR
PL 4.1
PHASE C MOTOR
5 3 11 DRIVER
PHASE A
PHASE D 1
4 10
PHASE B
SCAN HOME 2
SENSOR SIGNAL MOT
SCANNER HOME 13 1 PHASE C
+5 VDC 3
SENSOR
SCANNER HOME PHASE D
(H) +5 VDC 4
3 13

6
DC COM
2 2
DC COM
+5 VDC
1 1
+5VDC

June 2014
BSDs Xerox® WorkCentre® 3025 Multifunction Printer Service Manual
7-11
©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..