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May 2014

702Pxxxxx

WorkCentre 5022/5024
Service Training Student Guide
2014 Xerox Corporation. All rights reserved. XEROX and XEROX and Design are trademarks of Xerox Corporation in the
United States and/or other countries.

Document version 1.0: May 2014


Table of Contents
1. Introduction
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Module Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Module Objective. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Target Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Target Audience Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Course Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Module Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Materials and Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Course Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Laser Safety Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Electrostatic Discharge (ESD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

2. Product Overview
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Module Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Module Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Technical Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Machine Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Technology Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Machine Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Machine Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Connectivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Customer Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Customer Replaceable Unit (CRU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Documentation Supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

3. Service Documentation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Module Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Service Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

4. Power Control
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Module Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Module Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Technical Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Main Printed Wiring Board (PWB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Control Panel PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

WorkCentre 5022/5024 i
Student Guide
5. Paper Supply
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Module Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Module Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Technical Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Paper Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Paper Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Paper Tray 1 Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Paper Tray 2 Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Bypass Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

6. Paper Feed & Registration


Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Module Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Module Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Technical Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Loading the Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Tray Bases Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Tray 1 Feed Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Paper Registration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Tray 2, 3, and 4 Feed Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Bypass Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Paper Tray Drive Trains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Paper Paths. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Removal and Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

7. Scanning
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Module Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Module Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Technical Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Scanning Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Charge Coupled Device (CCD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

8. Xerographics
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Module Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Module Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Technical Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Xerographic Path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Xerographic Process Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Photoreceptor Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Charge Corotron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Raster Output Scanner (ROS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

WorkCentre 5022/5024 ii
Student Guide
Introduction 1
Introduction
Module Overview
Welcome to the Service Training Program.

In this module you will see how to use the materials and resources you need to complete this
course.

Module Objective
When you have completed this module, you will be able to use this Student Guide and Service
Manual to complete the course.

Target Audience
The course is written for Service Providers who have xerographic, copier and printer servicing
skills.

The target audience should be trained on digital products and laser safety. This audience must
be able to use Xerox service documentation, fault analysis procedures and be able to perform
repairs and adjustments a directed in the service documentation.

Target Audience Prerequisites


Before attempting the course you should have completed digital product, electrostatic discharge,
laser safety and basic safety training.

There is no specific product prerequisite but the target audience should be familiar with the
theory of Xerography.

The course contains all the technical information you will need. The course does not contain the
generic technical information that you may need for Xerographics and laser safety.

WorkCentre 5022/5024 1-1


Student Guide
Introduction

Course Objectives
At the completion of the course you should be able to:
Answer questions related to the operation of the machine.
Perform the removal and replacement of major components.
Perform the most critical and frequent adjustments.
Use the service documentation to diagnose and repair electrical and mechanical faults that
could occur in the machine.

Module Structure
The course is structured into eight (8) modules:
1. Introduction
2. Product Overview
3. Service Documentation
4. Power and Control
5. Paper Supply
6. Paper Fed and Registration
7. Scanning
8. Xerographics

Each module has these common elements:


Module Overview
Describes the module contents.
Module Objectives
Tells you what you will know or be able to do at the end of the module.
Technical Overview
Contains the technical content of the module.

Materials and Resources


The User Guide and any Service Documentation needed to complete the course will be provided.

Ensure you have the appropriate resources before starting the course.

Course Guidelines
To complete the course as quickly and effectively as possible, please follow these guidelines:
Complete and understand the material in each module as it is presented.
Be sure you understand the material before moving on to the next module.
Refer to the machine throughout the course to confirm the material presented.

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Student Guide
Introduction

Laser Safety Review

Safety Review - Training Warning


You must have completed basic safety and laser safety training and certification to work on this
product.

You must have completed the Basic Safety and La-


ser Safety Training Program and Certification before
working on this product.

If you have not completed the Laser Safety Program


Tell your Training Administrator Now!

Figure 1-1. Laser Safety Training

Product Certification
This product uses a laser beam to expose the photoreceptor. It is important that all safety
precautions be followed during service procedures.

This product is certified to comply with Laser Product Performance Standards as a Class I
product.

A Class I Product has a laser that does not emit dangerous laser radiation during any mode of
customer operation.

Service Procedure Warnings


During service operation the product is considered a Class 3 product, since the laser beam can
cause eye damage if directed into your eye.

Service procedures must be followed exactly as written without change.

The service representative must observe the established local laser safety precautions while
servicing the product.

Do not place tools on a reflective service in the area of the ROS window.

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Student Guide
Introduction

Eye Damage Warning

WARNING: Permanent eye damage can result if the laser is accidentally directed into your
eye. Do not try to bypass laser interlocks for any reason.

Figure 1-2. Laser Eye Damage

Laser Radiation Safety Warning

WARNING: The use of adjustments or controls other than those specified in the Laser
Safety Training Program may result in an exposure to dangerous laser radiation.

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Student Guide
Introduction

Electrostatic Discharge (ESD)

Cautions

CAUTION: All Electro Static Discharge (ESD) precautions must be following when servicing
this product. Failure to do so could result in damage to the equipment.

All standard Field Electro Static Discharge (ESD)


precautions should be followed whenever servicing
this product.

Figure 1-3. ESD Procedures

WorkCentre 5022/5024 1-5


Student Guide
Introduction

ESD Procedures and Tools


ESD tools including Static Dissipative Bags, ESD Mats, Wrist Straps, etc. must be used when
servicing this equipment.

Figure 1-4. ESD Tools

The electronics in Xerox product have advanced and become very sophisticated to meet the
needs of customers. These advances have increased performance and reduced costs by
allowing more electronic circuits to be contained in smaller areas.

An electrostatic discharge as low as 25 volts can damage equipment.

The sophisticated electronics in this product require the use of all standard ESD procedures to
ensure customer satisfaction and reduce service costs.

If you are not trained on ESD or do not have an ESD kit, tell your Training Administrator now.

1-6 WorkCentre 5022/5024


Student Guide
Product Overview 2
Introduction
Module Overview
In this module you will learn about the different machine configurations and the major
components and technical aspects of each.

Module Objectives
At the completion of the module you will be able to:
Know the major features and options of machine.
Explain the physical and functional differences between the machine configurations.
Know which components can be replaced by the customer.

Technical Overview
Technical aspects of the machine include:
Machine Configurations and Options
User Interface (UI)
Paper Feed Path and Capacity
Machine Features
Machine Operations
Scanning
Document Printing
Document Copying
Connectivity
Customer Maintenance
Customer Replaceable Units
Documentation Supplied

WorkCentre 5022/5024 2-1


Student Guide
Product Overview

Machine Configurations
There a two (2) basic machine configurations:
WorkCentre 5022 which can produce 22 prints per minute.
WorkCentre 5024 which can produce 24 prints per minute.

Both the WorkCentre 5022 and the WorkCentre 5024 come with the following features as the
standard configuration:
a platen scanner/copier
a document feeder
(1) Paper Tray in a Desk Top Model (which holds 250 sheets)

Both the WorkCentre 5022 and the WorkCentre 5024 can be upgraded with the following options:
a second tray for the desk top model (which holds 500 sheets)
a rolling storage stand for the 2 Tray Model
Paper Trays 3 and 4 for the 2 Tray Model in a rolling stand (which holds 500 sheets each)

WorkCentre 5022 / 5024 Desktop Models

Figure 2-1. WorkCentre 5022 (Standard Configuration and the 2 Tray Desk Top Models)

2-2 WorkCentre 5022/5024


Student Guide
Product Overview

WorkCentre 5022 / 5024 Floor Models

Figure 2-2. WorkCentre 5024 with Tray 3 and 4 and the Storage Stand Configurations

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Student Guide
Product Overview

User Interface (UI)


The Control Panel is commonly referred to as the User Interface (UI).

Some buttons are not available on some models. If you add certain options, you will be able to
use them. For more information, contact the Customer Support Center.

Figure 2-3. Control Panel

Control Panel Components

1. Copy button 10. Job Status button 19 Energy Saver button

2. ID Card Copy button 11. Selection Arrows 20. Clear All button

3. Scan button 12. Log In / Out button 21. Stop button

4. Fax button 13. Back button 22. Start button

5. LCD Display 14. OK button 23. Speed Dial button

6. Lighten / Darker button 15. Address Book button 24. Clear entry button

7. Original Type button 16. Keypad buttons 25. Data Indicator light

8. 2-Sided button 17. Dial Pause button 26. Error Indicator light

9. Collated/Resolution button 18. Machine Status button 27. Jam Clearance areas

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Student Guide
Product Overview

Table 2-1. Control Panel Functions

No. Component Description

1. Copy button

2. ID Card Copy Press this button to use the ID Card Copy feature. While the ID Card Copy
button feature is selected, the button is lit.

3. Scan button

4. Fax button

5. LCD Display

6. Lighten/Darken Press this button to select a copy density level or toner saver mode. The
button selection moves to the right on the machine status diagram every time the
button is pressed.
When the button is pressed while the right-most icon (toner saver mode) is
lit, the selection moves back to the left-most icon.

7. Original Type Press this button to select a document type of the document.
button The selection moves to the right every time the button is pressed.

8. 2 Sided button Press this button to select 1 Sided or 2 Sided copying.


Normally, the icon is off (1 Sided - 1 Sided). The selection moves to the right
from Off (1 Sided -1 Sided) 1 Sided - 2 Sided, 2 Sided - 2 Sided, 2 Sided -
1 Sided every time the button is pressed.
As you press the button when 2 Sided - 2 Sided is selected, the indicator
light goes off again.

9. Collated button Press this button to set collate when copying multiple copies.
The selection switches between sorting and stacking every time the button
is pressed.
When documents are set in the document feeder, this feature is
automatically enabled.

10. Job Status Use to check the progress of active jobs and detailed information about
completed jobs or pending jobs. This area also allows you to delete a job
(cancel printing) and pause jobs.
11. Selection Arrows

12. Log In / Out Press this button to enter or exit System Administration mode. The Log
button In/Out button is lit in System Administration mode.

13. Back button

14. OK button

15. Address Book

16. Numeric keypad Press these numeric buttons to enter numbers, such as the total number of
copies.

17. Dial Pause

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Student Guide
Product Overview

No. Component Description

18. Machine Status Displays error locations, machine status, and other settings.

19. Energy Saver Press this button to enter an energy saver mode when the machine is not in
button use. The button lights up.
Press the Energy Saver button to exit an energy saver mode.

20. Clear All button Press this button to reset the displayed settings of each feature to default
values or to clear the numbers entered. The settings return to the same
condition as when the machine is powered on.

21. Stop button Press this button to cancel a current job or errant job.

22. Start button Press this button to start scanning documents or to confirm the value of
each setting.

23. Speed Dial

24. C (Clear) button Press this button to delete one numeric value that you have entered.

25. Data indicator Blinks while the machine is sending or receiving data.
light

26. Error indicator Blinks when a system error occurs. Lights when an error other than a
light system error (such as paper jam or out of paper) occurs in the machine.

27. Jam Clearance This is a graphic on the control panel to indicate the areas of jam clearance
Areas based on the fault code that is displayed.

Copy Button Functions


Functions Selections

Paper Supply Auto, Tray 1 - 8.5x11 Tray 5 11x17

Reduce / Enlarge Auto, 50%, 70%, 81%, 94%, 122%, 127%, 141%, 200%, Preset 400%,
100%

Pages Per Side Off, 2 pages, 4 pages

Original Size A3 297x420 mm (SEF), A4 297x210 mm (LEF), A4 210x297 mm (SEF),


B4 2 57x364 mm (SEF), B5 257x182 mm (LEF), B5 182x257 mm (SEF),
A5 148x210 mm (SEF), 11x17 (SEF), 8,5x14 (SEF), 8.5x13 (SEF),
8.5x11 (SEF), 8.5x11 (LEF), 8.5x13.4 (SEF),
Custom Size (Y 86x297mm / X 86x432mm)

Original Size - Flip on Long Edge, Flip on Short Edge


Binding Position

Output - Binding Flip on Long Edge, Flip on Short Edge


Position

Edge Erase 0 - 50mm

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Student Guide
Product Overview

Technology Overview
Now that we have seen the basic configuration it is time for a quick overview of the subsystems
that make up the machine.

We will be taking a closer look at each subsystem later in the course.

Paper Feed and Capacity


Trays 1 and 2 capacities are different:
Tray 1 holds up to 250 sheets.
Tray 2 (optional) holds up to 500 sheets.

Both trays can hold papers sizes from A5 (5.5 X 8.5 inches) up to A3 (11 X 17) SEF. The base of
each tray has a motor that raises the tray to the feed position.

The paper feed head contains sets of feed, takeaway and retard rolls.

Note that all paper trays with the exception of the Bypass Tray has an Auto-detect feature.

Bypass Tray and Feed Roll

Bypass Tray

Figure 2-4. Bypass Tray Feed

The bypass tray can hold up to 50 sheets from A5 (5.5 X 8.5 inches) up to A3 (11 X 17).

The bypass tray is suitable for heavier paper, envelops, transparencies and labels.

Paper is feed by a single feed roll.

A retard pad prevents multi-sheet feeding.

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Student Guide
Product Overview

Paper Path Components


The WorkCentre 5022/5024 has a very short paper path. The paper passes a photoreceptor, is
routed through the Fuser, then directed to the output tray.

Figure 2-5. Paper Path Components

2-8 WorkCentre 5022/5024


Student Guide
Product Overview

Machine Features
The WorkCentre 5022/5024 is copier, scanner and printer with the following operational features:
Monochrome copying, scanning and printing.
Scanning and printing via a USB port connection to a laptop computer or PC or Network
Scan with the optional Network Kit.
Copy and print percentage reduction or enlargement processed electronically to achieve the
correct percentage size.
Duplex copying, scanning and printing.

Machine Operations
This machine performs three (3) basic tasks:
Document Scanning
Document Printing
Document Copying

Document Scanning
Images can be scanned to a computer through a scanning driver called a TWAIN DRIVER or via
the Network with the Optional Network Kit.

Documents to a maximum size of A3 (11 X 17 inches) can be scanned for copy by placing them
on the document glass or DADF.

The maximum scanning resolution is 600 X 600 dots per inch (dpi).

Color Image Scanning and Monochrome Prints.

The scanner contains a single Scan Carriage that houses all the optical components including
the CCD.

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Student Guide
Product Overview

Scanning Process
1. Place the document on the document glass or the DADF.
2. Press the scan button on the UI Control Panel.
3. The scanner moves under the document to scan it.

Carriage
Assembly

Document
Glass

Figure 2-6. Document Scanning

Document Printing
The imaging components are contained in four (4) major subassemblies:
Drum Module
Dual Beam ROS - writes the image onto the photoreceptors
Transfer Cortron - transfers the image onto paper
Fuser Module - fixes the toner to the copy paper surface using heat and pressure rollers

Document printing will be covered in detail later in this course.

Document Copying
The WorkCentre 5022 / 5024 is also equipped with a Document Feeder. Multi-page documents
can be placed in the feeder.
When the Copy button is pushed the Scan Carriage Assembly moves under the platen glass
and scans the image as document pages are feed into the machine.

Document copying will be covered in more detail later in the course.

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Student Guide
Product Overview

Connectivity
The USB Port provides laptop or PC connectivity and is used for upgrading firmware and local
printing.

There is an Optional Network Kit which enables scan and print via the network. A Fax Option with
a Keypad Kit will also be available.

Network
Port

USB Port

Figure 2-7. USB Port

WorkCentre 5022/5024 2-11


Student Guide
Product Overview

Customer Maintenance
The user is instructed in the Maintaining the Product Cleaning section of the User Guide to
perform various cleaning activities.

The most important cleaning task include:


Constant Velocity Glass
Document Glass
CVT and Document Covers

CVT and
Document
Covers

Document
Glass

Constant
Velocity
Glass

Figure 2-8. Cleaning

Dirt, dust and ink can contaminate these surfaces and will produce image quality defects such as
streaks and spots.

Clean these surfaces using lens and mirror cleaner identified in Section 6, General Procedures
and Information, of the Service Documentation.

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Student Guide
Product Overview

Customer Replaceable Unit (CRU)


There are two (2) CRUs associated with the WorkCentre 5022/5024:
a Toner Cartridge
and the Drum Assembly. Note that the Drum Assembly no longer has a Crum. NVM has to
be reset manually.

Toner
Cartridge

Drum

Figure 2-9. Customer Replaceable Units

Documentation Supplied
The customer is supplied with a User Guide and an Installation Guide
User Guide
This guide contains instructions to the customer on printing, scanning and maintenance.
Installation Guide
This guide contains information about how to connect the machine and enable all
connected features.

WorkCentre 5022/5024 2-13


Student Guide
Product Overview

2-14 WorkCentre 5022/5024


Student Guide
Service
Documentation
3
Introduction

Module Overview
This module overview of the various sections of the service manual and the information each
section contains will familiarize you with how to use the service documentation to perform your
job.

Objectives
At the completion of the module you will be able to:
Understand the structure and content of the Service Manual.

WorkCentre 5022/5024 3-1


Student Guide
Service Documentation

Work Centre 5022/5024 Service Manual

Introduction
The Introduction consists of these sections:
Getting to Know this Service Manual
Discusses how the content is organized.
How to use the Service Manual
Describes standard procedures for servicing the machine.
Description of Terminology and Symbols
Explains the terms and symbols used throughout this service manual including safety
Danger Warning and Caution.

The categories for the Introduction section are:


Getting to know the Service Manual
How to use the Service Manual
Description of Terminology and Symbols

Section 1 - Service Call Procedures:


The Service Call Procedures describe the general work and servicing procedures for the
maintenance of the WorkCentre 5022/5024.

It is recommended that you print a copy of the Configuration Report at the end of each service
call.

Store the printed report with the machine Service Log book.

The categories for the Service Call Procedures are:


Before Starting the Servicing
Service Call Procedure
Detailed Contents of the Service Call
TRIM Check List
Periodic Replacement Parts/Consumables List

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Student Guide
Service Documentation

Section 2 - Troubleshooting
This section describes the troubleshooting procedures for the WorkCentre 5022/5024, other than
image quality troubleshooting which is covered in Section 3.

The actions taken direct you to a repair activity.

The categories for the Troubleshooting section are:


Introduction
Product FIP
Level 1 FIP
Level 2 FIP
Various Chains from 3 through 134
Other Failure FIP
Generic FIP
NET System Fault Check
Software Download

Section 3 - Image Quality Troubleshooting


The section describes the image quality trouble hooting procedures for the WorkCentre
5022/5024. It is divided into three subsections, Introduction, Image Quality RAPs and Image
Defect Samples.

This section detail the actions required to remove and replace component in the machine, as well
as any Warnings and Cautions that pertain.

The Adjustment subsection includes mechanical adjustments that may be required to restore
proper operation.

The categories for the IQ Troubleshooting section are:


Introduction
Image Quality RAPs
Image Defect Sample

WorkCentre 5022/5024 3-3


Student Guide
Service Documentation

Section 4 - Disassembly/Assembly and Adjustment


This section detail the actions required to remove and replace component in the machine, as well
as any Warnings and Cautions that pertain.

The Adjustment subsection includes mechanical adjustments that may be required to restore
proper operation.

The categories for the Disassembly / Assembly section are:


Introduction
IIT / UI
ROS
Drive
NOHAD
Transfer
Fuser Unit
Xero / Deve
Feeder Tray (Tray 1)
One Tray Module (Tray 2)
Two Tray Module (Tray 3 / 4)
MSI
L/H Cover
Registration
Exit
Electrical
Cover
DADF
Safety Critical Components

3-4 WorkCentre 5022/5024


Student Guide
Service Documentation

Section 5 - Parts List


This section includes all available spare parts with exploded diagrams to assist in identification.

The categories for the Parts Lists are:


Introduction
IIT / UI
ROS
Drive
NOHAD
Transfer
Fuser Unit
Xero / Deve
Feeder Tray (Tray 1)
One Tray Module (Tray 2)
Two Tray Module
MSI
L/H Cover
Registration
Exit
Electrical
Cover
DADF
Screws
Adjustments / Consumable Area Code List
Parts Navigation

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Student Guide
Service Documentation

Section 6 - General
This section includes various General Procedures (GP) and service information necessary to
support the WorkCentre 5022/5024. It contains these five (5) subsections:
Specifications
Tools/Service Consumables/Consumables
Service Data
Service Mode
KO PROGRAM# LIST

The categories for General Procedures are:


Specifications
Tools/Service Consumables/Consumables
Input Component Check List
Output Component Check List
Analog Monitor Code List
HFSI Counters
NVM Lists
How to Enter the CE DIAG Mode/How to Exit from the CE DIAG Mode
How to Use the CE DIAG Mode
Fax Related Information
Protocol Trace
Super G3 Fax

Section 7 - Wiring Data


This section includes wiring diagrams to aid in tracing wiring faults and to compliment the circuit
diagrams in the Repair Analysis Procedures (RAPs).

The location and pin assignments for all Printed Wiring Board (PWB) connectors are shown.

The categories for Wiring Data are:


Plug/Jack Location List
Wirenet Drawings
BSDs
Electrical Component Locations

Section 9 - Installation and Removal


This section contains installation and removal procedures for the WorkCentre 5022/5024 and the
options that are specific to it.

3-6 WorkCentre 5022/5024


Student Guide
Power Control 4
Introduction
Module Overview
In this module you will learn about power and control functions of the machine.

This will cover the location and purpose of the PWBs, the low and high voltage power generation
and distribution components and mechanical drives.

Module Objectives
At the completion of this module you will be able to:
Identify the major electrical components of the machine.
Describe the mechanical drive system for the major components.

WorkCentre 5022/5024 4-1


Student Guide
Power Control

Technical Overview
Cover Removal
Most power components are mounted on a panel inside the Rear Cover of the machine.

Access to these components require the removal of the Rear Cover, which is held on by five (5)
screws.

Figure 4-1. Rear Cover Removal

4-2 WorkCentre 5022/5024


Student Guide
Power Control

Power Components Overview


Removing the Rear Cover provides access to these components:
Main PWB
Fuser Exhaust Fan
Main Motor
Paper Feed Clutches
High Voltage Power Supply (HVPS)
Low Voltage Power Supply (LVPS)
Toner Dispense Motor

Main PWB Fuser Exhaust Fan HVPS

Main Motor

Paper
Feed
Clutches

LVPS Toner Dispense Motor

Figure 4-2. Rear Cover Component Access

WorkCentre 5022/5024 4-3


Student Guide
Power Control

The Source Power Input Socket and Power ON/OFF Switch are located on the right side of the
machine.
The Power Input Socket accepts 110 or 220 VAC at 50 or 60 Hz.
The Power ON/OFF Switch isolates the machine from the main source power supply.

Power
ON/OFF
Switch

Input
Power

Figure 4-3. Power Input

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Student Guide
Power Control

WARNING: AC power is still applied to the input side of the Main Power Switch even when
the switch is turned off.

Figure 4-4. Input Power Wiring Diagram

HVPS Power Generation


The HVPS generates the high voltages required by the Xerographic Subsystem, including:
Charge Corotron power
Transfer Corotron power

The high voltage components are described in the Xerographics Module of this course.

LVPS Power Generation


The LVPS generates the low voltages required throughout the machine:
Available low voltage output voltage levels include 3.3 VDC, 5 VDC and 24 VDC.

The LVPS also supplies power to the fuser:


The Main PWB (AIOC) monitors the fuser thermostat and sends control signals to the LVPS.

WorkCentre 5022/5024 4-5


Student Guide
Power Control

Main Printed Wiring Board (PWB)

Main PWB Overview


The Main PWB is the functional control center of the machine. It controls most machine
operations including:
Scan
Printer operation
Sensor detection
Power levels in standby and power save modes

The Main PWB memory is used for system data such as configuration data and NVM settings.
The Main PWB is unique due to software upgrades.

The Main PWB monitors the fuser temperature via a thermostat that contacts the heat roll and
sends control signal to the LVPS to regulate power supply to the fuser.

Figure 4-5. Main PWB

The Main PWB uses 3.3 VDC, 5 VDC and 24 VDC supplied by the LVPS.

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Student Guide
Power Control

USB Port Access


A USB Port located on the Main PWB can be accessed on the right side of the machine:
The USB port can be connected to a lap top or PC for local printing and scanning.
The USB port is also used by engineering and technical support personnel for
software installation and upgrade using lap top or PC.

There is an Optional Network Kit which enables scan and print via the network. A Fax Option with
a Keypad Kit will also be available.

Network
Port

USB Port

Figure 4-6. USB Port Access

Control Panel PWB


The Control Panel PWB is located under the Control Panel and is commonly referred to as the
User Interface (UI).

Control
Panel

Figure 4-7. Control Panel

WorkCentre 5022/5024 4-7


Student Guide
Power Control

The Control Panel PWB controls the UI and communicates user input to the Main PWB.

Control Panel PWB

Figure 4-8. Control Panel PWB

Left Side Cover Interlock


Opening the left side cover de-actuates the electrical interlock allowing the Xerographic Module
to be removed.
This prevents damage to the photoreceptor if removal is attempted with the side cover
closed.

When the left side cover is opened the UI will display a statement Close Cover A.

4-8 WorkCentre 5022/5024


Student Guide
Power Control

Electrical
Interlock

Figure 4-9. Side Cover Electrical Interlock

WorkCentre 5022/5024 4-9


Student Guide
Power Control

Front Cover Interlock


The front cover has an electrical interlock which de-actuates when the front cover is opened.

When the front cover is opened the UI will display a statement Close Front Door.

Front
Cover
Interlock

Figure 4-10. Front Cover Electrical Interlock

Main Drive Motor


The Main Drive Motor provides mechanical power to the paper feed components for Tray 1.
Paper Tray 2 and the scanner have their own drive motors. Details will be provided later in the
course.

Main Motor

Figure 4-11. Main Drive Motor

4-10 WorkCentre 5022/5024


Student Guide
Power Control

Drive Assembly
The Drive Assembly houses the Main Drive Motor and a number of other drive components:
The gear train located on the inside of the Drive Assembly transmits drive to various
components in the machine.
A Toner Dispense Motor mounted on the rear panel is actuated when required to rotate the
shaft in the Toner Cartridge to dispense toner into the developer housing.

Figure 4-12. Drive Assembly

WorkCentre 5022/5024 4-11


Student Guide
Power Control

4-12 WorkCentre 5022/5024


Student Guide
Paper Supply 5
Introduction
Module Overview
In this module you will learn about the paper supply systems.

Module Objectives
At the completion of this module you will be able to:
Identify the various paper supply areas of the machine.

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Student Guide
Paper Supply

Technical Overview
Paper Supply
Paper can be supplied from any paper tray or bypass feeder.

The route taken by the paper, after entering the machine, is common to both areas.

Paper Specifications

Paper Trays 1 and 2


Paper Tray 1 has a paper weight range of 60 to 90 gsm (16 to 24 lbs.). Paper Tray 2 has a paper
weight range of 60 to 216 gsm (16 to 80 lbs.).

Both trays can accommodate paper sizes B5 LEF, B5 SEF, A4 LEF, A4 SEF, 8.5 X11 LEF, 8.5 x
11 SEF, 8.5 X 13 SEF, 8.5 X 13.4 SEF, 8.5 X 14 SEF, B4, A3 SEF AND 11 X 17 SEF.

Paper Trays 1 and 2 have different capacities of 70 gsm (20 lb.) paper:
Tray 1 holds up to 250 sheets
Tray 2 holds up to 500 sheets.

Bypass Tray
Suitable paper weight range is 60 to 216 gsm (16 to 80 lb.).

The Bypass Tray is also suitable for heavier paper, envelopes and transparencies.

The paper stack height must not exceed 10 mm (0.4 inches).

The Bypass Tray can accommodate paper sizes B5 LEF, B5 SEF, A4 LEF, A4 SEF, 8.5 X11 LEF,
8.5 x 11 SEF, 8.5 X 13 SEF, 8.5 X 13.4 SEF, 8.5 X 14 SEF, B4 SEF, A3 SEF AND 11 X 17 SEF.

Figure 5-1. Paper Trays

5-2 WorkCentre 5022/5024


Student Guide
Paper Supply

Paper Trays 3 and 4


Paper Trays 3 and 4 have a paper weight range of 60 to 216 gsm (16 to 80 lbs.).

Both trays can accommodate paper sizes B5 LEF, B5 SEF, A4 LEF, A4 SEF, 8.5 X11 LEF, 8.5 x
11 SEF, 8.5 X 13 SEF, 8.5 X 13.4 SEF, 8.5 X 14 SEF, B4, A3 SEF AND 11 X 17 SEF.

Paper Trays 3 and 4 holds up to 500 sheets each.

Tray 3

Tray 4

Figure 5-2. Tray 1 Module

WorkCentre 5022/5024 5-3


Student Guide
Paper Supply

Paper Tray 1 Module

Operation
1. The paper is stacked on the Bottom Plate of the paper tray.
2. The Bottom Plate is pivoted on one end of the paper stack and raised into the feed position
on the other end.

Tray
Bottom
Plate

Bottom
Plate
Pivots

Figure 5-3. Tray 1 Module

Paper Stack
The paper stack is raised up by springs as it is used.

Tray 1 Feed Roll

Paper

Pad

Spring Bottom Plate

Figure 5-4. Paper Stack Positioning

5-4 WorkCentre 5022/5024


Student Guide
Paper Supply

Tray Empty Sensor


The Tray Empty Sensor consists of a No Paper Empty Actuator and a No Paper Empty Sensor.

No Paper
Empty Sensor

No Paper
Empty Sensor
Actuator

Figure 5-5. Tray Empty Sensor

When the last sheet of paper leaves the tray, the Tray Empty Sensor Actuator drops into a cutout
in the paper tray Bottom plate, de-actuating the sensor.
A message is sent to the UI informing the user that the paper tray is empty.

Paper Tray and Size Adjustment


The Paper Tray has adjustable Front and Rear Paper Guides and an adjustable Paper Length
Guide.

Front and Rear Paper Length


Adjustable Guide
Paper Guides

Figure 5-6. Tray Size Adjustments

WorkCentre 5022/5024 5-5


Student Guide
Paper Supply

Registration
Front to rear registration of the paper is fixed by the position of the Front and Rear Paper Guides.

The paper is registered to the center of the paper path.

Adjustment
The Paper Length Guide is adjusted to the length of the paper in the tray.

Paper Tray 2 Module


Paper Tray 2 uses the same components as the Paper Tray 1 Module but there are some
differences:
Tray 2 holds 500 sheets of 70 gsm (20 lb.) versus 250 sheets.
Tray 2 has its own paper size sensing assembly.
Tray 2 Bottom Plate will drop when tray is opened.

Figure 5-7. Paper Tray 2

The Paper Tray 2 Module is optional except that configurations using the stand option must also
have a Paper Tray 2 Module.

Paper Tray 3 / 4 Module


Paper Trays 3 and 4 in the optional stand has the same characteristics as Tray 2.
Tray 3 / 4 holds 500 sheets of 70 gsm (20 lb.)
Tray 2 has its own paper size sensing assembly.

5-6 WorkCentre 5022/5024


Student Guide
Paper Supply

Bypass Tray

Description
The Bypass Tray is installed on the left side of the machine.

Paper is fed into the paper path just above the main paper tray feed position.

Components include a Bypass Paper Present Sensor and a Bypass Feed Roller.

Operation
With the Bypass Tray the user aligns the tray front and rear paper guides to match the paper
size.

Front and
Rear Guides

Figure 5-8. Bypass Tray Paper Alignment

The machine does not monitor the width of the paper.

When paper is loaded into the Bypass Tray the paper stack actuates a Bypass Paper Present
Sensor indicating that the paper is in the tray.

WorkCentre 5022/5024 5-7


Student Guide
Paper Supply

5-8 WorkCentre 5022/5024


Student Guide
Paper Feed &
Registration
6
Introduction
Module Overview
In this module you will learn about paper feeding and registration as well as how the paper
travels through the machine.

The paper tray feeders in the machine and the paper tray modules use the same feed principle
and are almost identical.

The bypass feeder has differences and will be described separately.

Module Objectives
At the completion of this module you will be able to:
Identify paper feed components.
Be aware of the most common repair procedures for the Paper Feed and Registration
subsystem.

WorkCentre 5022/5024 6-1


Student Guide
Paper Feed & Registration

Technical Overview
Loading the Paper
Refer to the User Guide for instructions on how to load the paper.

Tray Bottom Plates


The paper stack is positioned on the Paper Tray Bottom Plate.

Tray 1
Bottom
Plate

Figure 6-1. Tray 1 Bottom Plate

The Tray 1 Bottom Plate is raised by spring action to the feed position.

6-2 WorkCentre 5022/5024


Student Guide
Paper Feed & Registration

Tray 1 Feed Sequence

Tray 1 Feed Roll

Paper

Pad

Spring Bottom Plate

Figure 6-2. Feed Sequence

When paper feed is required from Tray 1:


1. The paper tray feed roll begins to rotate and feeds the top sheet of paper.
2. Tray 1 has a passive retard pad that works in conjunction with the Tray 1 Feed roll to offer
greater frictional force to the top sheet of paper than the second sheet so that only the top
sheet will be transported.

Feed Roll

Retard Pad

Figure 6-3. Tray 1 Retard Pad

3. The paper feed process continues until the job is completed.

WorkCentre 5022/5024 6-3


Student Guide
Paper Feed & Registration

Paper Registration
Paper Registration Sensor actuation causes the Main PWB to start the ROS imaging of the
photoreceptor.

Registration
Sensor

Figure 6-4. Registration Sensor

Tray 2, 3, and 4 Feed Sequence


The paper feed sequence for Tray 2, 3, and 4 differs from Tray 1.

When paper feed is required from Tray 2, 3, or 4:


1. The Bottom Plate raises when the tray is closed to the proper feed height.
2. The paper tray feed roll begins to rotate and feeds the top sheet of paper in the correct feed
direction.
3. The Retard Rolls rotates in the opposite direction of the Tray Feed Roll and is pressed
against it by the support assembly and spring.
4. If more than one sheet is fed, the Retard Roll actively drives the second sheet back into the
paper tray.
5. The paper feed process continues until the job is completed.

6-4 WorkCentre 5022/5024


Student Guide
Paper Feed & Registration

Tray Feed Roll


Paper

Retard
Roll

Lift Shaft
Bottom Plate

Figure 6-5. Tray 2 Feed Process

Tray 2 Feed Motor


Tray 2 has its own independent Feed Motor that drives these components:
Clutch
Roll Drive Gear
Paper Feeder Drive Gears

Paper Feed
Motor Roll Drive
Gear

Paper Feed
Drive Gears

Clutch

Figure 6-6. Tray 2 Paper Feed Motor

WorkCentre 5022/5024 6-5


Student Guide
Paper Feed & Registration

Tray 3/4 Feed Motor


Tray 3/4 has its own Feed Motor that drives these components:
Clutch
Roll Drive Gear
Paper Feeder Drive Gears

Clutch

Roll Drive
Gear

Paper Feed
Motor

Paper Feed
Drive Gears

Figure 6-7. Tray 3/4 Paper Feed Motor

Tray 1-4 Paper Size Switch


All 4 Paper Trays has a Paper Size Switch that sets the tray properties.

Figure 6-8. Paper Size Switches

6-6 WorkCentre 5022/5024


Student Guide
Paper Feed & Registration

Bypass Tray
The Bypass Tray is installed on the left side of the machine.

Bypass
Tray

Figure 6-9. Bypass Tray

Paper is fed into the paper path just above the main paper tray feed position.

The bypass tray has an input sensor which is actuated by paper placed in the tray.

Input
Sensor

Bypass Feed
Roller

Figure 6-10. Bypass Tray Components

The Bypass feeder is driven by the Main Drive Motor.

The Main PWB energizes the bypass feed clutch, connecting drive to the bypass feed roller
shaft.

WorkCentre 5022/5024 6-7


Student Guide
Paper Feed & Registration

Bypass Feed Sequence


1. The bypass clutch is energized by a control signal from the Main PWB.
2. The Bypass Feed Rolls starts to rotate.
3. The Nudger plate presses the top of the sheet of paper against the bypass feed roll and into
the paper path, actuating the Registration Sensor.
4. If more than one sheet is fed, the Retard Pad actively drives the second sheet back into the
paper tray.

Paper Tray Drive Trains


Paper feed roll drive for Tray 1 and the Bypass Tray is provide by the Main Motor through gears
and clutches on command from the Main PWB.

Bypass Tray
Drive Train
Exit Roll
Main Motor

Tray 1
Drive Train

Bypass Tray
Feed Roll Tray 2
Drive Train

Tray 1 Feed Roll

Tray 2 Feed Roll Tray 2 Feed Motor

Figure 6-11. Paper Tray Drive Trains

For Tray 2 paper feed roll drive is provided by a separate and dedicated Feed Motor though
gears and clutches on command from the Main PWB.

6-8 WorkCentre 5022/5024


Student Guide
Paper Feed & Registration

Paper Path Motors

Invert Motor

Main Motor

Bypass Tray
Tray 1

Tray 2 Feed Motor

STM Takeaway Motor


Tray 2

Figure 6-12. Paper Path Motors

WorkCentre 5022/5024 6-9


Student Guide
Paper Feed & Registration

Paper Paths

Overview
Paper is transported through the machine from the paper trays and bypass feeder.

Regardless of the paper source once the paper reaches the Registration Sensor, the paper exit
route is the same.

2
12

9 11
6

7
10 5

Figure 6-13. Paper Paths

Cover Switch Paper Size Sensor Paper Path Sensor

1. Front Cover Switch 5. Tray 2 Paper Size Sensor 6. Tray 1 No Paper Sensor

2. Front Cover Interlock Switch 7. Tray 2 Nudger Level Sensor

3. L/H Cover Interlock Switch 8. Tray 2 No paper Sensor

4. STM Left Cover Switch 9. MSI No Paper Sensor

10. Feedout Sensor 2

11. Registration Sensor

12. Fusing Unit Exit Sensor

6-10 WorkCentre 5022/5024


Student Guide
Paper Feed & Registration

Paper Path Sequence


1. Paper is supplied from the paper trays or bypass tray.
2. The paper actuates the Registration Sensor and the Registration Roller drive the paper onto
the Xerographic drum.
3. Paper is transported past the Xerographic Drum where the drum image is transferred onto
the paper.
4. The paper passes through the fuser where the image is fixed.
5. The copies or prints are stacked in the output tray.

The collated or non-collated option can be selected from the Control Panel

DADF Document Path


The Duplex Automatic Document Feeder (DADF) provides automatic duplex capability for
WorkCentre 5022 / 5024 configurations.

Feed Motor Feed Clutch


Feed Roll
Nudger Roll
T/A
Clutch

T/A
Roll

Exit Roll
Registration
Out Roll
Roll

Figure 6-14. DADF Document Path

WorkCentre 5022/5024 6-11


Student Guide
Paper Feed & Registration

Paper Jam Detection


The WorkCentre 5022/5024 is equipped with a number of sensors to detect document and paper
jams.

If a document jams in the document feeder, and the machine stops, Open Document Feeder
and remove paper appears on the Control Panel Display.

If a sheet of paper jams somewhere in the paper path one of two faults will be displayed on the
Control Panel Display:
Paper Jam left cover/Tray 2 (open Cover A and remove the paper)
Paper Jam left cover/Bypass (open Cover A and remove the paper)

For complete details on paper jams and clearing paper jams refer to the User Manual.

DADF Path Sensors and Cover Interlock

10 3
7 2
1

9 4, 5, 6
8

Figure 6-15. DADF Document Path

Sensors (SNR) and Interlocks

1. DADF Document Set SNR 5. DADF Tray Set Guide SNR 2 9. DADF Invert SNR

2. Document Tray Size SNR 1 6. DADF Tray Set Guide SNR 3

3. Document Tray Size SNR 2 7. DADF Pre-reg SNR 10. DADF Document Set SNR

4. DADF Tray Set Guide SNR 1 8. DADF Reg SNR

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Paper Feed & Registration

Output Tray
Copies and prints are sent to the output area beneath the scanner.

Output
Tray

Figure 6-16. Output Tray

Removal and Replacement Procedures


Chapter 1, Service Call Procedures, of the Service Manual identifies cleaning and check
intervals as well as the recommended intervals for replaceable of components.

The most frequent service activities include cleaning and replacing are Feed Rolls, Nudger Rolls,
Retard Rolls, Retard Pads and Bypass Feed Tray Components (In the bypass tray the feed roll
and retard pad may need cleaning or replacing).
Note
The Feed Roll is more easily accessed when the Bypass Assembly is removed from the
machine.

Figure 6-17. Removal and Replacement

WorkCentre 5022/5024 6-13


Student Guide
Paper Feed & Registration

6-14 WorkCentre 5022/5024


Student Guide
Scanning 7
Introduction
Module Overview
In this module you will learn about the components used in the scanner.

The module describes how documents are fed through the document feeder and scanned.

Module Objectives
At the completion of this module you will be able to:
Identify the scanner components.
Describe the sequence of operation of the scanner.
Understand the most frequently performed maintenance procedures.

WorkCentre 5022/5024 7-1


Student Guide
Scanning

Technical Overview

General Description
The machine scans the document once to memory then prints the number of copies or sets
requested.

The scanned document images are stored as electronic data.

Process Overview
1. The document is placed on the document glass or in the DADF.
2. The copy button on the Control Panel is pushed.
3. The scan carriage assembly moves under the platen glass to scan the image.

Scan
Carriage
Assembly

Document
Glass

Figure 7-1. Scan Image

7-2 WorkCentre 5022/5024


Student Guide
Scanning

Scanning Overview

Description
The scanner assembly in the machine operates similar to modern scanners that connect to a
personal computer. Light reflected from the document is converted to a digital image by the
Charge Coupled Device (CCD) mounted on the scanner assembly.

Scan Drives and Carriage


When documents are scanned from the document glass the scan carriage moves and the
documents are scanned by the movement of the scan carriage under the platen glass.

Optical Path
The Scan Carriage Assembly houses all the optical components. The document is illuminated by
a Xenon exposure lamp mounted within the Scan Carriage Assembly.

The image is reflected from the document through mirrors focused by the lens and projected onto
the CCD (Charge Coupled Device).

The document width is always scanned at the same size and resolution. Any reduction or
enlargement is processed electronically to achieve the correct percentage size.

The document length (the process direction) is scanned at a speed appropriate to the reduction
or enlargement selected. A fast scan indicates a reduction, a slow scan, a magnification.

Starting Point

Document

Exposure
Lamp

Mirror
Mirror
Scan Carriage
Assembly
Mirror

CCD PWB Mirror


Lens

Figure 7-2. Scanning Image

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Scanning

Scan Drive Motor


The Scan Drive Motor is a stepper motor that moves the scan carriage at precise speeds.
The scan speed varies depending on the scan options selected.

The scan speed determines the size of the image in the scan direction.
A slow scan speed equals a large image and a fast scan speed a smaller image.

The higher the magnification, the slower the scan speed.

Scan Drive
Motor

Figure 7-3. Scan Drive Motor

The Home Sensor detects when the Scan Carriage is in the home position.

Home Sensor

Figure 7-4. Scan Drive Motor

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Scan Operating Sequence


4. The Main PWB initiates the scanning operation.
5. The carriage moves to the right with the exposure lamps switched on, reading and calculating
the shading correction.
6. The document is scanned at a speed determined by the reduction or enlargement selected.
7. The carriage returns to the home position.
8. The image is stored in memory.

The document is only scanned once even when multiple copies are required.

Charge Coupled Device (CCD)

Description
The CCD in this machine prints only in monochrome.

The CCD contains arrays of light sensitive devices.


The number of devices in the arrays determines the resolution of the image across the
document from front to back.
In this machine the resolution is 600 DPI (Dots Per Inch).

Scanned
graphics
and text
Analog Data Digital Data

EIUDFSOIUYKJ

Scanned Analog to
Document CCD Digital
Converter

Figure 7-5. Charged Coupled Device

Each light sensitive device in each array produces one picture element (pixel) of information.

Each pixel represents one spot corresponding to the image on the document.

The analog voltage signals are converted to a digital signal on the CCD PWB before being sent
to the Main PWB for image processing.

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Image Processing
The digital image is sent to the Main PWB for processing.

Various image corrections factors are applied to the image to give, for example, sharper outlines.

Digital Data
Infra-red Laser
Data
ROS

Main PWB

Figure 7-6. Image Processing

The image is also modified according to user selections such as image type, reduction, etc.

The image is printed.

Initialization
The CCD must be optimized before scanning starts.

Auto Initialization Sequence


1. The Scan Cartridge moves to the home position, under the white reference strip.
2. The exposure lamps are switch on providing light to the CCD.
3. Automatic Gain Control (AGC) - CCD gain is adjusted to compensate for any variation in the
lamp exposure output or optical system.
4. The exposure lamps are switch off and the Automatic Offset Control (AOC) is set.

Note: This sets the output of the CCD when no light is present, which is the equivalent of a black
image.

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Cleaning the Optics


The upper surface of the document glass should be cleaned regularly.

CVT and
Document
Covers

Document
Glass

Constant
Velocity Glass

Figure 7-7. Cleaning the Glass

The underside of the document glass is only accessible after dismantling numerous parts of the
machine.

Only materials listed in the service procedures should be used to clean components.
Refer to Chapter 1, Service Call Procedures, in the Service Manual.

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Xerographics 8
Introduction
Module Overview
This module describes the components and processed used to place an image on paper.

The modules assumes you know the theory of Xerography.

Module Objectives
At the completion of this module you will be able to:
Identify the location and purpose of the components of the Xerographic process.
Be aware of the most common repair procedures in the Xerographic subsystem.

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Technical Overview

Xerographic Path
This machine uses conventional Xerographic processes, with some innovative adaptations.

The paper path in the Xerographic area includes:


Charging
Exposure
Development
Transfer
Fusing

DADF
Exposure Lamp
IIT
CCD

IOT

Duplex
Fuser
Finger
Cleaning Blade USB 2.0

BCR Toner AIO


DTS Cartridge Controller
PWB
Drum ROS
BTR

Auger
Magnet
Network
MSI (Option)

STM

Figure 8-1. Xerographic Path Overview

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Xerographic Process Components


The Xerographic Process is contained within four (4) major assemblies:
Drum Module
Raster Output Scanner (ROS)
Transfer Corotron
Fuser

Electrical and mechanical power, high voltage and the Main Drive Motor are also required.

Drum Module

Overview
The Toner Cartridge contains enough toner for approximately 9000 prints/copies of 5% area
coverage.

The Toner Empty Sensor monitors the toner level and warns the user when enough toner
remains for approximately 100 prints.

Toner
Cartridge

Figure 8-2. Toner Cartridge

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Components
The Drum Module contains these components:
Charge Device
Photoreceptor Drum
Developer System
Cleaning Components

Drum
Module

Figure 8-3. Drum Module

Note: the Left Side Cover (A) needs to be open to remove the Drum Module.

The Drum Module no longer has a Crum. After replacement of the module, you will have to
manually enter an NVM value to reset the counter.

To initialize the counter:


1. Enter the System Admin Mode on the UI by pressing and holding the Log In/Out Button for 4
seconds
2. Select System Settings from Tools list using arrows to navigate and press OK button.
3. Select Maintenance from System Settings list using arrows to navigate and press OK button.
4. Enter "950807" using the numeric keypad on Maintenance screen and press Start button.
5. Press Start button if the Drum Cartridge has been replaced with a new unit or press Clear All
to cancel this action.
6. Log out of System Administration Mode by pressing Log In/Out button.

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Photoreceptor Drum
The photoreceptor consists of an aluminum tube coated with an organic photoconductive layer.

The photoconductive layer retains a static charge in darkness but becomes conductive and loses
its static charge to ground when exposed to light from the laser beam.

The aluminum drum is connected to the machine frame through a contacts at the end of the
Drum Module (CRU).

When the CRU is placed in the machine the contacts connect with a drum contact on the
machine frame.

Contacts

Photoreceptor

Figure 8-4. Photoreceptor

Machine Return Contact


Check the Drum Contact on the machine frame every time the Drum Module (CRU) is removed
from the machine. A poor/intermittent contact will significantly affect image quality.

Drum
Contacts (2)

Drum Drive

Interior view with


Drum removed.

Figure 8-5. Drum Contact

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Charge Corotron

Overview
The Charge Corotron, located alongside the Drum Module, charges the surface of the
photoreceptor with high voltage.

The Charge Corotron is an internal Drum Module component and is replaced as part of the Drum
Module.

Charge Corotron
(Internal component)

Figure 8-6. Charge Corotron

Operation
The Corotron is connected to the HVPS by contactors on the top of the Drum Module (CRU).

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Raster Output Scanner (ROS)

Overview
The ROS is located to the left of the HVPS and under the paper receiving area.

ROS

Figure 8-7. ROS

The HVPS provides power to the ROS on command from the Main PWB.

The ROS is a sealed unit that is not repairable.

ROS Components
The ROS contains these components:
Laser Diode
Polygon Mirror
Motor
Mirror to direct the laser beam onto the drum
Glass Window

Note: The laser beam leaves the ROS through a glass window adjacent to the photoreceptor.

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Exposure
Exposure is the process of creating a latent image of the document on the drum using a laser
beam from the Raster Output Scanner (ROS).

Polygon Mirror
Motor

Photoreceptor

Laser Diode

SOS Sensor

Note:
Generic ROS Unit The colored laser beams are for illus-
tration purposes only. The machine
only prints in monochrome.

Figure 8-8. ROS Operation

Operation
1. The printer receives a signal to print or copy a document.
2. The Polygon Mirror and Main Motor starts.
3. Paper is fed from the selected paper tray.
4. The beam from the laser diode is reflected from the rotating Polygon Mirror causing the beam
to travel across the surface of the drum.
5. The Start of Scan Sensor (SOS) is triggered as the laser beam starts a new line and triggers
the input of the next line of data to the laser beam. This SOS should not be confused with the
Start of Scan Sensor in the Scanner which monitors the position of the scan carriage.
6. As the drum rolls, the scanner laser beam creates the latent image of the document on the
surface of the drum.
7. The laser beam is switched on and off according to the image data being received from the
Main PWB:
a. When the laser beam is switched on, the charge on the drum will be discharged where
the laser strikes the surface of the drum. This is the image (black printing) area of the
print.
b. When the laser beam is switched off, the charge will remain on the drum. This is the
background (white printing) area of the image.

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Development
The latent image is developed by the Magnetic Developer Roller.

Process Overview
the Toner Supply Auger and Developer Mixer Roller rotate in the same direction causing the
toner particles to be agitated.
the agitation creates a negative charge on the tone particles so they are attracted by the
developer. This is called Tribo Electric Charge.

Cleaning
The photoreceptor cleaning function consists of a cleaning blade, an auger and an erase lamp
within the Xerographic CRU.

The final stage of cleaning is the erase lamp which dissipates any remaining charge on the
photoreceptor.

The Erase Lamp is an internal Drum Module component and is replaced as part of the Drum
Module.

Erase Lamp
(Internal component)

Figure 8-9. Erase Lamp

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Used toner, removed from the photoreceptor, is carried by an auger system back to the waste
container on the CRU.

Toner Dispense Assembly


(From Toner Cartridge)

Figure 8-10. Toner Dispense Assembly

The Toner is fed from the Toner Cartridge though the Toner Dispense Assembly into a matching
receptacle on the Drum Module.

Drum Module
Toner Receptacle

Figure 8-11.

When the Drum Module is installed into the machine the Toner Cartridge part of the Toner
Dispense Assembly matches up to a Feed Receptacle on the Drum Module.

Waste toner is circulated back into the Toner Cartridge.

When the toner has exceeded it useful life the Toner Cartridge (CRU) is replaced.

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Fusing

Description
The toner image on the paper is fixed to the surface of the paper by heat and pressure.
The Heat Roll and Pressure Roll are held in constant contact with each other by spring
tension.
The spring tension exerts approximately 4kg of pressure, via the Pressure Roll, onto the
paper that passes between them.

Duplex Clutch

Heat Roller

Pressure Roller

Drum

Figure 8-12. Fuser Path Operation

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The Fuser Assembly has a Jam Clearance lever that separates the Fuser rollers when the right
hand cover is opened. This allows paper removal in the event of a paper jam.

Fuser Rollers
Jam Clearance
Lever

Fuser Assembly

Figure 8-13. Fuser

Power and Control


Fuser lamp power is generated by the LVPS located behind the rear panel of the machine.

LVPS

Figure 8-14. LVPS

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Control Logic
Control logic is part of the Main PWB.

Main PWB
Data Thermistor

AC Input Fuser Lamp

LVPS

Data
Overheat
Thermostat
Fuser Module
Electrical Connection

Figure 8-15. Control Logic

Operation
the thermistor monitors the temperature of the fuser lamp and sends this information to the
Main PWB.
the Main PWB instructs the LVPS to switch the fuser lamp on or off to maintain the correct
temperature.
if the temperature exceeds the threshold the control logic disconnects the power supply from
the LVPS to the Fuser Lamp and a fuser error is displayed on the Control Panel.

Ventilation
The Fuser and Xerographic components are cooled by the NOHAD Fan located behind the rear
cover of the machine.
NOHAD
Fan

Figure 8-16. NOHAD Fan

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