Xerox WorkCentre 5022 WorkCentre 5024 Service Manual and Parts Catalog


Accurate, clear and concise text, combined with detailed illustrations, lists of error code, instruction and diagrams, guide you through procedure of repair, remediate, maintenance and adjustments your copier, printer or scanner.
Present manual Xerox WorkCentre 5022 WorkCentre 5024 contain clear instructions and procedures on how to fix the problems occurring in your equipment.
The information contained in this repair manual is necessary for the repair, but also prevention, resulting in a longer life of your equipment.
Format of the manual: PDF, makes it easy to navigate, instant download and print. English language.
To see what contain, please read table of contents:

INTRODUCTION
0.1 Getting to know this Service Manual
0.2 How to use the Service Manual
0.3 Description for Terminology And Symbols

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

2. TROUBLESHOOTING

3. IMAGE QUALITY
3.1 Introduction
3.1.1 Composition of Chapter 3 Image Quality Troubleshooting
3.1.2 Test Pattern
3.1.3 Things to Note when Replacing the Drum Cartridge
3.1.4 Image Quality Troubleshooting
3.2 Image Quality RAPs
IQ1 IOT Image Quality Entry RAP
IQ2 IIT Image Quality Entry RAP
IQ3 Low Image Density RAP
IQ4 Wrinkled Image RAP
IQ5 Residual Image(Ghosting)RAP
IQ6 Background RAP
IQ7 Deletion RAP
IQ8 Skew/Misregistration RAP
IQ9 Process Direction Bands,Streaks,and Smears RAP
IQ10 Unfused Copy/Toner Offset RAP
IQ11 Repeating Bands,Streaks,Spots,and Smears RAP
IQ12 Mottle RAP
IQ13 Spots RAP
IQ14 Black Prints RAP
IQ15 Blank Image RAP
3.3 Image Defect Sample
3.3.1 IOT Image Defect Sample
3.3.2 IIT Image Defect Sample
IDS1 Auger Mark
IDS2 Strobing (27mm or 13.5mm Pitch Density)
IDS3 White Streaks (Process Direction)
IDS4 Black Bands
IDS5 Toner Contamination
IDS6 Toner Splattering
IDS7 White Spots (Irregular)
IDS8 Regular Blank Areas In Process Direction (Spots, Streaks, Bands etc.)
IDS9 Regular Toner Contamination In Process Direction (Spots, Streaks, Bands etc.)
IDS10 Regular Toner Contamination In Process Direction (Side 2)
IDS11 Moire Due to Interference With Copy Documents
IDS12 Light Background Due to Background Suppression in Copies of Documents With Frames
IDS13 Background Smear When Using Platen Copy With Non-Standard Documents
IDS14 Fluctuation In Background Suppression Values for Copies of Documents With Medium Density
IDS15 Defects Related To Scan Print
IDS16 Cold Start Dew
IDS17 Static Electricity Offset
3.4 Fusing Unit Paper Wrinkle Alignment Adjustment
3.5 Cycle Table

4. REPAIRS AND ADJUSTMENTS
4.1 Introduction
4.1 Introduction
1. IIT/UI
REP 1.2.1 IIT Top Cover
REP 1.3.1 IIT Carriage
REP 1.3.2 IIT Carriage Belt
REP 1.4.1 Carriage Motor
REP 1.5.1 LED Lamp PWB
REP 1.10.1 LCD Display
2. ROS
REP 2.1.1 ROS Assembly
3. Drive
REP 3.1.1 Main Drive Motor
REP 3.1.2 Main Drive Housing
4. NOHAD
REP 4.1.1 NOHAD Fan
6. Transfer
REP 6.1.1 BTR Roll
7. Fusing Unit
REP 7.1.1 Fusing Unit
8. Xero./Deve.
REP 8.1.1 Drum Cartridge
REP 8.2.1 Cartridge Guide
REP 8.2.2 Dispense Drive
9. Feeder,Tray (Tray 1)
REP 9.1.1 Tray 1 Feed Clutch
REP 9.1.2 Tray 1
REP 9.1.3 Tray 1 Size Sensor
REP 9.2.1 Tray 1 Feed Roll and Tray 1 Retard Pad
10. One Tray Module (Tray 2)
REP 10.1.1 Tray 2 Feeder
REP 10.3.1 Tray 2 Feed/Retard/Nudger Roll
REP 10.6.1 STM PWB
REP 10.6.2 STM Takeaway Motor
11. Two Tray Module
REP 11.1.1 Tray 3 Feeder
REP 11.1.2 Tray 4 Feeder
REP 11.3.1 Tray 3 Feed/Retard/Nudger Roll
REP 11.3.2 Tray 4 Feed/Retard/Nudger Roll
REP 11.6.1 2TM PWB
REP 11.6.2 2TM Takeaway Motor
13. MSI
REP 13.1.1 MSI
REP 13.3.1 MSI Nudger/Feed Roll
REP 13.3.2 MSI Retard Pad
14. L/H Cover
REP 14.1.1 L/H Cover
15. Registration
REP 15.1.1 Registration Chute
REP 15.1.2 Registration Roll
17. Exit
REP 17.1.1 Exit Cover
REP 17.1.2 Exit Roll
18. Electrical
REP 18.1.2 HVPS
REP 18.1.3 LVPS
REP 18.3.1 Net I/F PWB
REP 18.3.2 ESS/MCU PWB
19. Cover
REP 19.1.1 Front Cover
REP 19.1.2 Top Cover
REP 19.4.1 Rear Cover
56. DADF
REP 56.1.1 DADF
REP 56.1.2 DADF Platen Cushion
REP 56.2.1 DADF Front Cover
REP 56.2.2 DADF Rear Cover
REP 56.2.3 DADF PWB
REP 56.2.4 Upper Feeder
REP 56.2.5 DADF Feeder Assembly
REP 56.3.1 Left Counter Balance
REP 56.3.2 Right Counter Balance
REP 56.5.1 DADF Feed/Nudger Roll
REP 56.6.1 Harness Guide and Wire Harness
REP 56.6.2 DADF Feed Motor
REP 56.7.1 DADF Drive Belt
REP 56.9.1 Document Tray
REP 56.9.2 Retard Chute
REP 56.9.3 Invert Chute
REP 56.10.1 DADF Takeaway Roll
REP 56.10.2 Sensor Bracket
REP 56.13.1 DADF Retard Pad
1. IIT/UI
ADJ 1.3.1 IIT Lead Edge Registration
ADJ 1.3.2 IIT Side Registration
8. Xero./Deve.
ADJ 8.1.1 ATC Sensor Read & Tone Up/Down
18. Electrical
ADJ 18.1.2 IOT Lead Edge/Side Edge Registration
ADJ 18.1.3 Edge Erase Value Adjustment
ADJ 18.2.1 Things to take note when replacing Important Information Stored Components (ISC)
ADJ 18.2.3 Firmware Version Upgrade
56. DADF
ADJ 56.1.1 DADF Lead-Skew Adjustment
ADJ 56.1.2 DADF Side Registration
ADJ 56.1.3 DADF Lead Edge Registration

5. PARTS LIST
5.1 Introduction
5.1.1 How to Use the Parts List
5.1.2 Precautions
5.1.3 Plate Composition
5.1.4 Terminology and Symbols
5.1.5 Using Parts Navigation
Parts Lists
IIT/UI
PL 1.4 Carriage Motor
PL 1.5 IIT Carriage
PL 1.6 Control Panel
PL 1.8 Top Cover (with Platen Glass), Front Cover
PL 1.9 IIT Base Frame Component
ROS
PL 2.1 ROS
Drive
PL 3.1 Main Drive Motor
PL 3.2 Main Drive Housing
NOHAD
PL 4.1 NOHAD
Transfer
PL 6.1 Transfer
Fusing Unit
PL 7.1 Fusing Unit
XERO./DEVE
PL 8.1 Drum Cartridge,Toner Cartridge
PL 8.2 Toner System
PL 8.3 Dispense Drive
Feeder; Tray( Tray1)
PL 9.1 Tray 1,Tray Drive
PL 9.3 Tray 1 Component
One Tray Module ( Tray 2)
PL 10.1 Tray 2 ,Feeder
PL 10.2 Tray 2 Component
PL 10.3 Tray 2 Feeder
PL 10.4 Left Cover
PL 10.5 Takeaway Roll
PL 10.6 Electrical
PL 10.7 Cover
Tray Module (Tray 3, Tray4)
PL 11.1 Tray 3/4, Feeder
PL 11.2 Tray 3/4 Component
PL 11.3 Tray 3/4 Feeder
PL 11.4 Left Cover
PL 11.5 Takeaway Roll
PL 11.6 Electrical
PL 11.7 Cover
MSI
PL 13.1 MSI
PL 13.2 MSI Component
PL 13.3 MSI Lower Feeder
L/H Cover
PL 14.1 Duplex L/H Cover
PL 14.3 Duplex L/H Cover-Chute,Latch
PL 14.4 Duplex L/H Cover-Roll,Gear
Registration
PL 15.1 Registration
Exit
PL 17.1 Duplex Exit
Electrical
PL 18.2 Wire Harness
PL 18.3 Electrical
PL 18.4 Fax Box Assembly
PL 18.5 Fax Box Assembly
Cover
PL 19.1 Cover-Front,Top,Right
PL 19.2 Cover-Rear,Left Rear
DADF
PL 56.1 DADF Accessory
PL 56.2 DADF Component
PL 56.3 DADF Base Frame
PL 56.4 Upper Feeder
PL 56.5 Feed Roll Nudger Roll Assembly
PL 56.6 DADF Feed Motor,Harness Guide
PL 56.7 DADF Feeder Rear Frame
PL 56.8 DADF Feeder Front Frame
PL 56.9 DADF Tray,Chute
PL 56.10 DADF Roll,Sensor Bracket
PL 56.11 Document Tray
PL 56.12 Invert Chute
PL 56.13 Retard Chute
PL 56.14 Sensor Bracket
Common Hardware
Common Hardware
Part Number Index
5.3 Parts Navi
Navi 1.1 Processor + Option
Navi 2.1 IOT
Navi 2.2 One Tray Module
Navi 2.3 DADF
Navi 2.4 2 Tray Module

6. GENERAL PROCEDURES
6.1 Specifications
6.1.1 Product Name/Product Code/Serial No
6.1.2 Configuration
6.1.3 Operating Modes
6.1.4 Machine Sizes and Basis Weights
6.1.5 Installation Space
6.1.6 Levelness
6.1.7 Operating Air Pressure
6.1.8 Electrical Specification
6.1.10 Installation Environment
6.1.11 Warm Up Time
6.1.12 FCOT
6.1.13 Print Speed
6.1.14 Tray (Paper Feed)
6.1.15 Tray Size Factory Settings
6.1.16 Classifications and Functions
6.1.17 Auto 2 Sided Printing
6.1.18 Output Function
6.1.19 Resolution/Gradation
6.1.20 Image Loss
6.1.21 Print Area
6.1.22 Alignment Specification
6.1.23 I/F Specification
6.1.24 Print Feature
6.1.25 Scan Feature Specifications
6.1.26 Fax Feature
6.1.27 Document Feeder (DADF)
6.1.28 Billing Counter
6.1.29 Environmental Feasibility (Energy Star Program)
6.2 Tools/Service Consumables/Consumables
6.2.1 Tools and Service Consumables
6.2.2 Consumables
6.3.1 Input Component Check List
6.3.1.1 DADF Input Component Check List
6.3.1.2 IIT Input Component Check List
6.3.1.4 IOT Input Component Check List
6.3.2 Output Component Check List
6.3.2.1 DADF Output Component Check List
6.3.2.2 IIT Output Component Check List
6.3.2.4 IOT Ouput Component Check List
6.3.3 Analog Monitor Code List
6.3.3.2 Analog Monitor List
6.3.4 HFSI Counters
6.3.4.1 DADF HFSI List
6.3.4.2 IIT HFSI List
6.3.4.4 IOT HFSI List
6.3.4.5 IOT HFSI List – System Administrator Mode Version
6.3.5 NVM DADF
6.3.5 NVM DADF
6.3.6 NVM IIT
6.3.6.2 NVM IIT
6.3.8 NVM DRIVE NOHAD
6.3.8.2 NVM DRIVE & NOHAD
6.3.7 NVM DIAG
6.3.7.2 NVM DIAG
6.3.9 NVM PH
6.3.9.2 NVM PH
6.3.10 NVM Fusing
6.3.10 NVM Fusing
6.3.11 NVM Xfer
6.3.11.2 NVM X’fer
6.3.13 NVM ROS
6.3.13.2 NVM ROS
6.3.12 NVM XERO
6.3.12 NVM XERO
6.3.15 NVM SYSTEM
6.3.15.2 NVM SYSTEM
6.3.14 NVM PROCON
6.3.14.2 NVM PROCON
6.3.16 NVM NET
6.3.16 NVM NET
6.3.18 NVM JOB ATTRIBUTE
6.3.18.2 NVM JOB ATTRIBUTE
6.3.17 NVM IPS
6.3.17 NVM IPS
6.3.19 NVM ACCOUNT MODE
6.3.19 NVM ACCOUNT MODE
6.3.20 NVM Jam Counter Clear Initialize HFSI
6.3.20 NVM Jam Counter Clear & Initialize HFSI
6.3.21 NVM FAX
6.3.21 NVM FAX
6.5 Service Mode
6.5.1 How to Enter the CE DIAG Mode/How to Exit from the CE DIAG Mode
6.5.1.1 UI CE Diag Mode Structure
6.5.1.2 How to Enter the CE Diag Mode
6.5.1.3 How to Exit from the CE Diag Mode
6.5.2 How to Use the CE DIAG Mode
6.5.2.1 Shutdown History
6.5.2.2 NVM Read / Write
6.5.2.3 Analog Monitor
6.5.2.4 NVM Initialize
6.5.2.5 Component Check
6.5.2.6 Maintenance Report
6.5.2.7 HFSI Counter Clear/Initialize
6.5.2.8 DATA All Delete
6.5.2.9 Test Pattern Print
6.5.2.10 ATC Check
6.5.2.11 Tone Up / Down
6.5.2.12 Read Temperature
6.5.2.13 IIT Calibration
6.5.2.14 IIT Breakdown Diagnosis
6.5.2.15 DADF Size Detect Auto Adjust
6.5.2.16 Self Test Settings (Fax)
6.5.2.17 Self Test Request (Fax)
6.5.2.18 Checking and Repairing the Billing Counter (621-400)
6.8 Fax Related Information
6.8.1 Activity Report (User Mode)
6.8.2 Activity Report (CE Mode)
6.8.3 Protocol Monitor
6.8.4 Protocol Trace
6.8.4.1 Protocol Trace
6.8.4.2 FCF/FIF Description
6.8.4.3 Bit 7 Description
6.8.4.4 Bit 6 Description
6.8.4.5 Bit 16 Description
6.8.4.6 Bit 15 Description
6.8.4.7 Bit 14~11 Description
6.8.4.8 Bit 10 Description
6.8.4.9 Bit 9 Description
6.8.4.10 Bit 24, 32, 40, 48, 56, 64, 72, 80, 88, 96, 104, 112 Description
6.8.4.11 Bit 21~23 Description
6.8.4.12 Bit 19, 20 Description
6.8.4.13 Bit 17, 18 Description
6.8.4.14 Bit 31 Description
6.8.4.15 Bit 28 Description
6.8.4.16 Bit 27 Description
6.8.4.17 Bit 26 Description
6.8.4.18 Bit 25 Description
6.8.4.19 Bit 1, 3, 33~38, 47, 49~51, 53~55, 57, 59, 60, 62, 65~71, 73~75, 81~84, 87, 92~95, 97~99, 101, 102 Description
6.8.4.20 Bit 46 Description
6.8.4.21 Bit 45 Description
6.8.4.22 Bit 44 Description
6.8.4.23 Bit 43 Description
6.8.4.24 Bit 42 Description
6.8.4.25 Bit 41 Description
6.8.4.26 Bit 79 Description
6.8.4.27 Bit 78 Description
6.8.4.28 Bit 77 Description
6.8.4.29 Bit 76 Description
6.8.4.30 Bit 105~109 Description
6.8.5 Super G3 Fax
6.8.5.1 Super G3 Fax
6.8.5.2 V.8 CM/JM Signal
6.8.5.3 V.8 Operation / Auto Send
6.8.5.4 V.8 Operation/Manual Send
6.8.5.5 Troubleshooting of Super G3 Fax

7. WIRING DATA
7.1 Plug/Jack Location List
7.1.1 Plug/Jack Location List
7.1.2 Plug/Jack Location
7.2 Wirenet Drawings
7.2.1 IOT/IIT
7.2.1.1 IOT ACH
7.2.1.2 IOT ACN
7.2.1.3 +24VDC-1
7.2.1.4 +24VDC-2
7.2.1.5 +5VDC/SLP +5VDC/+3.3VDC
7.2.1.6 +3.3VDC/SLP +3.3VDC
7.2.1.7 DC COM-1 (5V RTN)
7.2.1.8 DC COM-2 (5V RTN)
7.2.1.9 DC COM-3 (24V RTN)
7.2.56 DADF
7.2.56.1 DADF +5VDC
7.2.56.2 DADF +24VDC
7.2.56.3 DADF DC COM
7.3 BSD
7.3.1 Introduction
1. How to Use BSDs
2. Symbology
3. Signal Name
4. DC Voltage
5. Other Descriptions
7.3.3 BSD
Chain 1 Standby Power
CH1.1 Main Power On & M/C Power Control
CH1.2 DC Power Generation
CH1.3 IIT/DADF DC Power Distribution
CH1.4 Power Interlock Switching
CH1.5 Fuse & LED Location
Chain 2 Mode Selection
CH2.1 Control Panel
Chain 3 Machine Run Control
CH3.1 PWBS Communication (IIT/DADF)
CH3.2 PWBS Communication (STM/2TM)
CH3.3 PWBS Communication (NET)
CH3.4 Electric Billing
Chain 4 Start Print Power
CH4.1 Main Drive
Chain 5 Document Transportation
CH5.1 DADF Interlock and Document Setting
CH5.2 Document Size Sensing (1/2)
CH5.3 Document Size Sensing (2/2)
CH5.4 Document Feeding
CH5.5 Document Scan, Invert & Exit Transportation
CH5.6 Document Path & Drive Transmission
Chain 6 Imaging
CH6.1 Document Size Sensing
CH6.2 Document Illumination
CH6.3 Carriage Control
CH6.4 Image Input
CH6.5 Laser Scanning
Chain 7 Paper Supplying
CH7.1 Tray 1 Paper Size Sensing
CH7.2 Tray 2 Paper Size Sensing (1TM)
CH7.3 Tray 3 Paper Size Sensing (2TM)
CH7.4 Tray 4 Paper Size Sensing
CH7.5 Tray 1 Paper Stacking
CH7.6 Tray 2 Paper Stacking
CH7.7 Tray 3 Paper Stacking
CH7.8 Tray 4 Paper Stacking
CH7.9 MSI Paper Stacking
Chain 8 Paper Transportation
CH8.1 Tray 1 & MSI Paper Feeding
CH8.2 Tray 2 Paper Feeding & STM Paper Transportation
CH8.3 Tray 3/4 Paper Feeding & 2TM Paper Transportation
CH8.4 Registration
CH8.5 Paper Path & Drive Transmission
Chain 9 Marking
CH9.1 Charging, Exposure & Development
CH9.2 Toner Dispense & Toner Life Control
CH9.3 Image Transfer & Stripping
Chain 10 Fusing Paper Transportation
CH10.1 Fusing Heat (1/2)
CH10.2 Fusing Heat (2/2)
CH10.3 Fusing
CH10.4 Paper Exit & Duplex Transportation
Chain 34 FAX
CH34.1 Fax
7.4 Electrical Component Location
7.4.1 Sensor Location (DADF)
7.4.2 Sensor Location (IIT)
7.4.3 Sensor Location (L/H & Fusing)
7.4.5 Sensor Location (IOT Front)
7.4.7 Sensor Location (IOT Rear)

INSTALLATION/REMOVAL
9.1 Installation
9.1.1 Installation of Main Unit
9.1.5 One Tray Module
9.1.6 Stand
9.1.7 Two Tray Module
9.1.8 Fax Kit
9.1.9 Network Print Kit
9.1.10 Tray Lock Kit
9.2 Removal
9.2 Removal

Number of pages: 698.