Xerox C2424 Service Manual
Xerox C2424 - WorkCentre Color Solid Ink Manual
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Xerox C2424 manual content summary:
- Xerox C2424 | Service Manual - Page 1
WorkCentre® C2424 copier-printer Service Manual - Xerox C2424 | Service Manual - Page 2
- Xerox C2424 | Service Manual - Page 3
WorkCentre® C2424 Copier-Printer Service Manual Warning The following servicing instructions are for use by qualified service personnel only. To avoid personal injury, do not perform any servicing other than that contained in the operating instructions, unless you are qualified to do so. First - Xerox C2424 | Service Manual - Page 4
as styles, templates, icons, screen displays, looks, etc. XEROX®, The Document Company®, the digital X®, CentreWare®, FinePoint™, infoSMART®, Made Adobe Systems Incorporated in the United States and/or other countries. Apple®, AppleTalk®, EtherTalk®, LaserWriter®, LocalTalk®, Macintosh®, Mac OS®, - Xerox C2424 | Service Manual - Page 5
detailed parts lists for the WorkCentre C2424 Copier-Printer and the most common Xerox supplies used for this system. Section 10 - Wiring Diagrams This section contains the main wiring diagrams, plug-jack connector maps, and wiring diagrams to aid in troubleshooting the PEST codes. Service Manual - Xerox C2424 | Service Manual - Page 6
, practice or condition that, if not strictly observed, results in damage to, or destruction of, equipment. Warning A warning indicates an operating or maintenance procedure, practice or condition that, if not strictly observed, results in injury or loss of life. ii WorkCentre C2424 Copier-Printer - Xerox C2424 | Service Manual - Page 7
and are specifically instructed to do so. Power should be OFF when performing these installations. Disconnect the power cord when removing covers and guards for installing optional equipment. Except for user-installable options, there are no parts that you can maintain or service behind these - Xerox C2424 | Service Manual - Page 8
instructions marked on, or supplied with, the system, options and supplies. Caution Use of other than Genuine Xerox WorkCentre C2424 Solid Ink may affect print and copy quality and system reliability. It is the only ink designed and manufactured under strict quality controls by Xerox for specific - Xerox C2424 | Service Manual - Page 9
a Power Down Error-Head not Parked message at the system's control panel. This message means the system is not ready to be moved. If the printhead is not locked, the system can be damaged during shipment. ■ Always turn off the system using the power switch, located under the interface cover on the - Xerox C2424 | Service Manual - Page 10
the original packing material and boxes or a Xerox repackaging kit. Additional instructions for repacking the system are provided in the repackaging kit. If you do not have all the original packaging, or are unable to repackage the system, contact your local Xerox service representative. Caution - Xerox C2424 | Service Manual - Page 11
touch the protective material to the chassis or circuit assembly into which the device will be installed. ■ Minimize body motions when handling unpackaged replacement . ■ Pay attention to the direction of parts when mounting or inserting them on Printed Circuit Boards (PCB's). Service Manual vii - Xerox C2424 | Service Manual - Page 12
the printer. You must also disconnect the printer power cord from the AC outlet. Position the power cord so that it is easily accessible during servicing. Warning Do not touch any electrical component unless you are instructed to do so by a service procedure. viii WorkCentre C2424 Copier-Printer - Xerox C2424 | Service Manual - Page 13
Servicing Mechanical Components When servicing mechanical components within the printer, manually rotate drive assemblies, rollers, and gears. Warning Do not try to manually rotate or manually stop the drive assemblies while any printer motor is running. Service Manual ix - Xerox C2424 | Service Manual - Page 14
édicté par le ministere des Communications du Canada, NMB-003. European Union Xerox Corporation declares, under our sole responsibility, that the system to which this declaration relates is in conformity with the following standards and other normative documents: x WorkCentre C2424 Copier-Printer - Xerox C2424 | Service Manual - Page 15
-3-3) "Part 3: Limits - Section 3: Limitation of voltage fluctuations and flicker in low-voltage supply systems for instructions, is neither dangerous for the consumer nor for the environment. A signed copy of the Declaration of Conformity for this product can be obtained from Xerox. Service Manual - Xerox C2424 | Service Manual - Page 16
xii WorkCentre C2424 Copier-Printer - Xerox C2424 | Service Manual - Page 17
Components of the DADF and Scanner 2-3 Document Feeder Functions 2-4 Document Feeder Paper Path and Imaging 2-6 Scanner Assembly Functions 2-7 Scanner and Document Feeder Calibration 2-8 System Electronics 2-10 Exit Module (MEP) Board 2-11 Scanner Power Supply 2-11 Service Manual xiii - Xerox C2424 | Service Manual - Page 18
Fault 3-23 13,0XX.xx Errors - Thermal Faults 3-24 19,0XX.xx Errors - Printhead Calibration faults 3-33 31,0XX.4x Errors - Mechanical Initialization Jam 3-34 33,0XX.xx Errors - Tray Manager Device Faults 3-35 34,0XX.xx Errors - Printhead NVRAM Faults 3-35 xiv WorkCentre C2424 Copier-Printer - Xerox C2424 | Service Manual - Page 19
,000.40 Errors - Drum Maintenance Faults 3-36 37,0XX.xx Errors - PEST Faults 3-37 39,0XX.xx Errors - Document Feeder / Scanner Unit Faults . . . . 3-46 3-Digit Jam Codes 3-49 Jam Code Definition Table 3-50 4 General Troubleshooting Introduction 4-2 Hidden Service Menu 4-2 Service Diagnostics - Xerox C2424 | Service Manual - Page 20
System and Application Problems 4-79 Testing Communications Ports 4-79 Network Problems 4-81 Obtaining Serial Back Channel Trace 4-82 5 Image-Quality Troubleshooting Image-Quality Problems Overview 5-2 Service Technician RIP Procedure 5-3 Isolating a Copy/Scan Malfunction to the Scanner/DADF - Xerox C2424 | Service Manual - Page 21
Drum Temperature Sensor 7-8 Maintenance Kit 7-9 Waste Tray 7-9 Lubrication 7-10 8 Service Parts Disassembly Overview 8-2 Standard Orientation of the System 8-2 General Notes on Disassembly 8-3 Image Input Terminal (DADF and Scanner 8-4 Duplex Automatic Document Feeder 8-4 DADF Front Cover - Xerox C2424 | Service Manual - Page 22
Head Tilt Compound Gear 8-58 Electronics 8-59 Scanner Power Supply 8-59 Exit Module (MEP) Board 8-60 Electronics Module 8-61 Back Frame and Printer Stabilizer 8-63 Wave Amp Board 8-65 I/O Board 8-66 Drum Heater Relay Board 8-67 NVRAM Replacement 8-68 xviii WorkCentre C2424 Copier-Printer - Xerox C2424 | Service Manual - Page 23
the Parts List 9-3 Covers 9-4 Imaging 9-6 Paper Path 9-8 Motors, Gears, Solenoids, Clutches, Sensors, Fans and Backframe 9-10 Electronics Module, Circuit Boards and Cables 9-12 Sensors and Flags (Actuators 9-14 Xerox Supplies 9-16 10 Wiring Diagrams Plug/Jack Locator Table 10-2 Scanner/DADF - Xerox C2424 | Service Manual - Page 24
xx WorkCentre C2424 Copier-Printer - Xerox C2424 | Service Manual - Page 25
General Information In this chapter... ■ System Introduction and Overview ■ System Features and Configurations ■ Routine Maintenance Items and Consumables Life Expectancy ■ Control Panel Layout ■ System Specifications ■ Tray and Media Specifications 1 Section - Xerox C2424 | Service Manual - Page 26
The Xerox WorkCentre® C2424 Copier-Printer Service Manual is the primary document used for repairing, maintaining, and troubleshooting the system. To ensure understanding of this product, complete the Xerox WorkCentre C2424 Service Training Program. s2424-002 1-2 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 27
, see Section 2, "Theory of Operation" on page 2-1. Standard Configurations The WorkCentre C2424 is offered in three configurations. ■ DN = System with 256 MB RAM ■ DP = System with 256 MB RAM, 1 525-sheet high capacity feeder, and a cart. ■ DX = System with 512 MB RAM, 1 525-sheet high capacity - Xerox C2424 | Service Manual - Page 28
8. DADF front cover 9. Duplex Automatic Document Feeder (DADF) 10. Interface (I/O) cover 11. Waste tray/maintenance kit side door 12. Front cover release (product serial number is behind the front cover) 1. Short paper stop 2. Exit cover 3. Ink cover 2424-171 1-4 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 29
View with System Interfaces 1 2 34 1. Maintenance kit 2. Waste tray 3. Power cord connection 4. Power switch 5. Scanner cable connection 6. USB connection 5 7. Configuration card 6 8. Ethernet 10/100 Base-T 7 connection 8 Back View 2424-081 1. RAM slots 2. NVRAM chip 3. Hard drive - Xerox C2424 | Service Manual - Page 30
module in the system, the following components need to be transferred from the old main board. ■ Hard Drive ■ Configuration Card ■ Memory (1 or 2 DIMMs) ■ NVRAM (8-pin socketed chip) Note See the illustrations on page 1-5 for locating the above components. 1-6 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 31
Maintenance Items: Consumable: Extended-Capacity Maintenance Kit 30,000 cycles (0-20% Ink coverage) 20,000 (20-100% coverage) 1220 prints per stick* Standard-Capacity Maintenance Kit 10,000 cycles Waste Tray Empty every 5 Purges (~35 g) DADF Pick Rollers and Separator Pad 50,000 scans - Xerox C2424 | Service Manual - Page 32
■ Displays the system's operating status or errors and warnings. ■ Prompts to load paper, replace supplies, or clear jams. ■ Enables selection settings for print, copy, and scan jobs. ■ Displays menus that enable changing the system's settings and accesses tools to help resolve problems. The control - Xerox C2424 | Service Manual - Page 33
sections in the customers WorkCentre C2424 User Guide. 1. Output button and LEDs (copy only) Press to select Uncollated or Collated for your copies. 2. Color Mode button and LEDs Press to select B/W (black and white) or Color for your copy or scan job. 3. 2-Sided button and LEDs Press to select - Xerox C2424 | Service Manual - Page 34
the System Setup menu 7. Graphic display shows status messages on the graphic display. and menus. 16. Help (?) button 8. Up Arrow button Press to display a help message Scrolls upward. explaining the menu or message shown on the graphic display. 1-10 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 35
shown on the 2. Clear/Clear All button graphic display. Press once to reset the current menu 4. Start button selection; press twice to reset the Press to start a copy or scan job. system. Menu Map The Menu Map is a visual representation of the control panel menu structure. You can - Xerox C2424 | Service Manual - Page 36
System Specifications Physical Dimensions and Clearances Basic System with DADF and Scanner (IIT) Width: Depth: Height: Weight: Print Engine (IOT) only Scanner Unit and DADF Unit Scanner Weight: DADF Weight: Optional 525-Sheet Feeder Weight: Optional Cart Width: Depth: Height: Weight: Minimum - Xerox C2424 | Service Manual - Page 37
FPOT, Color Copy Memory Hard Drive Printer Description Language Print Features Automatic 2-Sided Printing Paper Handling Warm-up time Specification Solid-ink 500 MHz processor Yellow, cyan, magenta, and black ink sticks, each shape-coded. The system uses the subtractive color system to produce the - Xerox C2424 | Service Manual - Page 38
Image Buffer Bit Depth Specification Print Engine Scan to Disk (mailbox) function Scan to PC Flatbed platen and C-shape ADF Charge Coupled Device scan head RGB color pack The scan controller provides 16 bit DMA intrerface for sending image data through the scanner board to the image processor - Xerox C2424 | Service Manual - Page 39
Characteristic Specification Optical Resolution 600 x 300 to 600 x 2400 dpi (FS x SS) Output Resolution from Always equals optical resolution Scanner Calibration Time less than 2 seconds (performed prior to copier and scan operations) Power Saver Mode Scanner and DADF are switched OFF. Also, - Xerox C2424 | Service Manual - Page 40
. ■ If excessive jams occur, use paper, transparencies, or other specialty media from a new package. ■ Custom size paper can be printed only from Tray 1. ■ Xerox Professional Solid Ink Photo Paper, Xerox Professional Solid Ink Glossy Paper, and Xerox Professional Solid Ink Trifold Brochures, can be - Xerox C2424 | Service Manual - Page 41
loose sheets of paper in the document feeder. ■ Adjust the paper guides so they fit against the originals. ■ Insert paper in the document feeder only when the ink on the paper is completely dry. Use the glass rather than the document feeder to copy or scan the following types of originals: ■ Paper - Xerox C2424 | Service Manual - Page 42
-120 g/m2 ● ● (16-32 lb. Bond) (22-45 lb. Cover) 121-220 g/m2 (33-40 lb. Bond) (46-80 lb. Cover) ● ● Special Xerox Phaser Postcards ● ● Xerox Professional Solid Ink ● ● Glossy Paper Xerox Phaser Trifold Brochures ● ● Transparency, Labels ● ● Plain Paper, Card Stock 60-220 g/m2 - Xerox C2424 | Service Manual - Page 43
Supported Envelopes Note All envelopes should be printed single-sided only. Use only paper envelopes. Do not use envelopes with windows in dark, cool, relatively dry locations. Most paper items are susceptible to you are ready to load them into the system. Leave paper in the original packaging. For 19 - Xerox C2424 | Service Manual - Page 44
windows, metal clasps, or adhesives with release strips ■ Padded envelopes ■ CD labels ■ Media that is less than 60 g/m2 or more than 220 g/m2 Media Skew Specification Print Engine (IOT) Charecteristic Specification edge. Media System Skew Specification (IIT/IOT) WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 45
Theory of Operation In this chapter... ■ System Overview ■ Image Input Terminal (IIT) ■ Image Output Terminal (IOT) Sub-Assemblies ■ System Electronics ■ Paper Path and Paper Pick ■ System Motors, Solenoids, and Drive ■ The Print Process ■ Configuration Card "Shadowed" Personality Parameters 2 - Xerox C2424 | Service Manual - Page 46
Terminal (IIT) ■ DADF and paper path ■ The Scanner Assembly with Control Panel ■ System Electronics ■ Electronics Module ■ Scanner Power Supply ■ Exit Module (MEP) Control Board ■ The Print Engine (IOT) ■ Paper Path ■ Sensing ■ Drive ■ Image Process ■ Exiting 2-2 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 47
major subsystems: ■ Duplex Automatic Document Feeder (DADF) ■ Scanner Assembly with Control Panel Major Components of the DADF and Scanner Motor and Drive Media In Sensor Pick Rollers Media Staged Sensor DADF Scan Head Lamp DADF CVT Window & Calibration Strip CVT Window Lamp Input Tray Output Tray - Xerox C2424 | Service Manual - Page 48
Document Feeder Functions The WorkCentre C2424 Copier-Printer includes a Duplexing Automatic Document Feeder (DADF). It is capable of automatically feeding original documents from the input tray and scanning either a single-sided document or both sides of a double-sided document. Input Tray: The - Xerox C2424 | Service Manual - Page 49
or removing media jams from the IOT. In order to unlock the hinges, the IIT must be closed. Note It is possible to continue scan and flatbed copy functions with the document feeder disconnected. In this condition, the control panel displays the error message "Document Feeder Disconnected". Theory - Xerox C2424 | Service Manual - Page 50
the RGB channel data and translates it into a data stream that the print engine controller can understand. This data is either transferred to the engine driver (for copy service) or to the hard drive controller (for scan service) 2-6 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 51
board, main control board, drive motor, and lamp assembly. The lamps are Cold Cathode Flourescent Lamps (same as the lamps in the DADF). CVT Window: This portion of the platen is a part of the DADF media path. The principal function of this window is to allow the lower scanhead to image the first - Xerox C2424 | Service Manual - Page 52
scanner and document feeder: automatic calibration and manual calibration. Automatic Calibration The automatic calibration performed by the sytem is a "white balance" calibration performed during startup and at pre-programmed intervals of operation. This calibration ensures that the system detects - Xerox C2424 | Service Manual - Page 53
under the CVT window. Manual Calibration The manual calibration is a maintenance procedure accessed through the system's control panel. This calibration requires a calibration sheet provided with a new scanner assembly. It is designed to ensure the document feeder and flatbead scan heads are aligned - Xerox C2424 | Service Manual - Page 54
is part of the scanner unit, it receives power from the electronics module power supply. Exit Module (MEP) Board Scanner Power Supply Power Supply Main Board Image Processor Board Hard Drive Configuration Card Power Control Board 2-10 Wave Amplifier s2424-236 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 55
board to the printhead control board (located on the underside of the printhead). These two signals are interpreted by the printhead to properly produce the image on the drum. The main board provides support for Ethernet and USB 2.0 external I/O interfaces. Note The WorkCentre C2424 system does not - Xerox C2424 | Service Manual - Page 56
configurations as low as 64 MB, the WorkCentre C2424 requires a minimum of 256 MB of system memory to operate. The system has been tested with up to 1 GB of memory installed. This memory configuration can be ordered as an option. Hard Drive Support: A hard drive IDE cable is plugged into the main - Xerox C2424 | Service Manual - Page 57
of a "runaway" heater following a hardware failure. The drum and the paper preheater thermal fuses are located on the paper preheater. Additional thermal fuses are located on the printhead and on the ink melting elements. The DC power supply generates + 3.3 V, +/- 15 V, and +/- 50 V. These voltages - Xerox C2424 | Service Manual - Page 58
Power Supply Diagram (Electronics Module) F3 AC Line S1 F2 AC Neutral Line Gnd Ref Neutral D r u m P r e h t H 8 H 9 AC Line AC Neutral Low Interface H 3 H 2 H13 H H12 1 H11 H10 Vcc H9 H8 uProcessor REG H4 H3 H2 H1 Vss s2424-028 2-14 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 59
nine major subsystems: ■ The Process Drive ■ The Media Path Drive ■ The Ink Loader ■ The Printhead ■ The Drum Maintenance System ■ The Preheat and Deskew System ■ The Drum Assembly and Transfix System ■ The Exit Module or Media Exit Path (MEP) ■ The Purge System Note The electronics module is also - Xerox C2424 | Service Manual - Page 60
Sub-Assemblies of the IOT Exit Module Drum Printhead Transfix System Ink Loader Duplex Print Path Paper Preheater (and Deskew) Drum Maintenance Kit Ink Waste Tray Wiper Assembly Paper/Media Tray s2424-008 2-16 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 61
path drive motor also controls the movement of the wiper assembly and the headlock mechanism through a gear train and solenoid on the exit module. The Ink Loader: Melts the solid ink as ink is required by the printhead. The melted ink drops into the ink reservoirs of the printhead underneath the ink - Xerox C2424 | Service Manual - Page 62
capacity ■ Pick roller creates the buckle for the deskew process ■ Pick roller drive disengages when the door is opened and closed ■ Pivoting separator pad to prevent it from binding Drive gear Cam Pick roller Spring loaded lift plate 2-18 Separator pad s8400-190 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 63
are optional 525-Sheet Feeders. To pick a sheet of paper, the media path drive starts the process. The -sheet feeder, paper is pre-picked from the tray and staged in the paper path while the printer is printing . Paper Exit Sensor Transfix Roller Exit Module Elevator Preheat Exit Sensor Preheat - Xerox C2424 | Service Manual - Page 64
-rotating deskew nip, the print continues through the paper preheater and transfix system to the exit tray in the same manner as a single-sided print. Strip Sensor Exit Sensor Preheat Sensor Deskew Sensor Exit Roller Duplex Roller Duplex Roller 2-20 s2424-053 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 65
Sensor Locations Strip Sensor Media Stage Sensor Pick Sensor Paper Exit Sensor Control Panel Sensor Exit Door Sensor Preheater Sensor Front Door Sensor Drum Temperature Sensor Drum Position Encoder Deskew Sensor Pick Sensor (525-Sheet Feeder) Tray Paper Size Sensor Board s2424-004 Theory of - Xerox C2424 | Service Manual - Page 66
System Motors, Solenoids, and Drive DADF Motor Elevator Motor Media Path Motor Media Drive Gearbox Tray Lift Motor Tray 1 Pick Solenoid Y-Axis Motor Paper Drive Motor X-Axis Motor Process Drive Motor s2424-237 2-22 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 67
torque to two main camshaft assemblies. One camshaft assembly controls the transfix roller loading, and the other controls the drum maintenance system and printhead tilt system. A small DC servo motor powers the process drive gearbox to rotate the gears to specific positions during the printing - Xerox C2424 | Service Manual - Page 68
Media Path Drive The media path drive gearbox and motor assembly controls each roller in the paper transport system. A gear train located behind the motor connects it to the exit rollers, which are built into the MEP. Gear trains located within the media path drive assembly, along with two clutches - Xerox C2424 | Service Manual - Page 69
described in this section: ■ Drum Preparation ■ Printing ■ Ink Loader ■ Printhead ■ Drum Assembly ■ Transfix System ■ Purge System ■ Transfix and Exiting Warning Keep your fingers away from the Y-Axis drum rotation drive system; it uses a closed-loop servo drive system and is inherently dangerous - Xerox C2424 | Service Manual - Page 70
"averages out" the variability between jets by interlacing each jet with other jets. In some test prints, the printhead moves to the right and lays down 309 parallel bands of ink. Each band is composed of 15 pixel columns of dots from an individual jet. 2-26 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 71
to install more ink sticks before the current sticks are completely consumed. If the ink level sensors inside the printhead detect that the printhead has run out of ink, but the ink low/out sensors are not activated, the control panel reports an "Ink Jam" error. Ink Loader Door Ink Stick Ink Melt - Xerox C2424 | Service Manual - Page 72
less than 5 mm (0.2 inches), the printhead can print the entire image on the rotating drum. The printhead provides one size ink drop that it uses for all print-quality modes. Reservoir Drum Printhead Head Driver Board Purge Tube Jet Stack s2424-032 2-28 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 73
, piezo-electric crystal-driven diaphragms, which force the ink in droplets out the 1236 corresponding nozzles. Looking at the printhead face, the nozzles are arranged in 12 rows, in color order KYKYKYCMCMCM, where K = black, Y = yellow, C = cyan, and M = magenta. During the printing process - Xerox C2424 | Service Manual - Page 74
drives the printhead in an open-loop. The printhead is driven against the left printer frame for a few seconds, and then reversed a set distance. A tension spring links to the printhead's left shaft, and provides a preloaded tension so the printhead moves smoothly. 2-30 WorkCentre C2424 Service - Xerox C2424 | Service Manual - Page 75
power consumption at a specific phase of rotation. This allows the software to identify a power consumption footprint to alert the system when the head is locked in error. The printhead is tilted away from the drum and locked for shipping. The printhead is locked if the green head lock indicator is - Xerox C2424 | Service Manual - Page 76
. Arrows located on the latching mechanism and on the frame indicate when the printhead is in print position. When the arrows on the latching mechanism and frame align, the printhead is in the print position and the tilt gear disengages from the process drive. 2-32 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 77
As viewed from the left side of the printer, when the arrows do not align, the tilt gear is engaged. Head Tilt Compond Gear Tilt Gear (Engaged) Tilt Drive Gear s2424-036 To accommodate printhead maintenance, the printhead can be tilted back away from the drum. This creates room for the wiper to be - Xerox C2424 | Service Manual - Page 78
heater relay board. A temperature sensor in contact with the drum surface monitors the drum temperature. The main board interprets the sensor's signal and turns on the drum heater and drum fan to heat the drum, or turns on the drum fan alone to cool the drum. 2-34 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 79
Encoder s2424-038 Warning Always keep your fingers away from the drum drive system; it uses a closed-loop servo drive system. Since the motor speeds up if it senses the drum drive system slowing down, fingers caught in the drum belts and gears can be severely injured. Theory of Operation 2-35 - Xerox C2424 | Service Manual - Page 80
is lifted and lowered by the action of the process drive. All gears move to rotate the transfix camshaft to bring the transfix roller into contact with the drum. The gears reverse to Transfix Load Module Transfix Cam Transfix Load Spring Drum s2424-039 2-36 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 81
one direction. This rotates the drum maintenance camshaft and raises the drum maintenance system to the drum. The process drive then rotates in the opposite direction to lower the drum maintenance system. The blade removes oil and drains it back into the maintenance kit drawer through a felt filter - Xerox C2424 | Service Manual - Page 82
perform a printhead maintenance cycle, the printhead is first tilted away from the drum to allow the wiper assembly to pass by. The wiper blade is then raised in front of the printhead. The media path drive governs wiper movement when it engages a clutch on the exit shaft of the printer. The purge - Xerox C2424 | Service Manual - Page 83
cannot vent properly. Warning When servicing the printer be careful of the purge system as it passes the printhead. If a damaged wiper blade of the purge system catches on the printhead, it could propel hot liquid ink upward into your face. Printhead Purge Tube Solenoid Valve Purge Pump - Xerox C2424 | Service Manual - Page 84
the transfix roller into contact with the drum. The transfix roller nip applies the load necessary to transfer the image to the paper from the drum. Once the image is transferred, the drum stops rotating and the transfix roller is lifted by the process drive. 2-40 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 85
Transfix Load Arm Transfix Load Module Transfer Roller Transfix Cam Transfix Load Spring Drum Transfix Roller Gear Transfix Cam Process Drive Theory of Operation ss2424-049 2-41 - Xerox C2424 | Service Manual - Page 86
the paper release guide, the paper release exit module roller. The elevator motor raises the carriage assembly to the top position, where it then stops and the drive motor drives the exit module rollers until the media exits the IOT ending the print cycle. 2-42 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 87
. Release blade Strip solenoid Preheat Exit Sensor Transfix Roller Paper Exit Sensor Engine Exit Sensor Strip Sensor Paper Preheater s2424-052 Theory of Operation 2-43 - Xerox C2424 | Service Manual - Page 88
ppm 7 ppm 13 ppm 6 ppm Auto Duplex, A4 Paper 10 sides per minute (spm) 9 spm 4 spm 3 spm 15 spm 13 spm 11 spm 7 spm 2-44 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 89
printer, the personality parameters are automatically copied to the NVRAM chip. If the configuration card is removed, the system Item version (of the layout of personality parameters) Base Printer Name SysAdmin Contact Printer Location Asset Identifier Host Name Domain Name Network Mask IP Address - Xerox C2424 | Service Manual - Page 90
Configuration Card "Shadowed" Personality Parameters (Continued) NCL Subject IP IP DNS RESOLVER DNS RESOLVER DNS RESOLVER NBNS (WINS) NBNS (WINS) NBNS (WINS) NBNS (WINS) Ethernet HTTP 1 48 4 4 1 1 1 4 4 1 1 1 1 1 11 11 11 11 256 256 1 1 11 11 33 256 1 1 1 1 1 1 2-46 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 91
"USB", "On" and "Enabled" parameters have not been identified as personality parameters. They are not tied to networking. 2. NCL = Nest Configuration Library Theory of Operation 2-47 - Xerox C2424 | Service Manual - Page 92
2-48 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 93
Error Messages and Codes In this chapter... ■ Introduction ■ Power-Up Error Messages and LED Codes ■ BIST Error Reporting ■ POST Error Reporting ■ PEST Error Reporting ■ Fault Code Error Message Troubleshooting ■ 3-Digit Jam Codes 3 Section - Xerox C2424 | Service Manual - Page 94
verify that a specific system component is operating correctly. For information on Service Diagnostics and all internal system test functions, see "Service Diagnostics Menu Functions" on page 4-4. For troubleshooting system problems not associate with, or displaying, an error code or message, such - Xerox C2424 | Service Manual - Page 95
(see "Electrical Troubleshooting" on page 4-58). Also, see "Verifying Power Supply Operation - Print Engine" on page 4-71. Boot loader memory test failure. Ensure the systems RAM chips are properly seated and that the correct RAM type for this system is installed. For specifications on approved RAM - Xerox C2424 | Service Manual - Page 96
Plug in the AC power cable and power on the system electronics module. 3. If the error blink pattern is now different from the original error reported before Step 1, the problem may not be in the electronics module, see "Electrical Troubleshooting" on page 4-58. 3-4 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 97
Soft Soft Soft Soft Soft Soft Hard Communications error. PLD I/O Board serial, link down/bad parity. Communications error. PLD I/O Board serial, mismatch. IDE drive general failure. Reseat IDE cable and power cable. If problem persists, replace the IDE drive. The system will work without the IDE - Xerox C2424 | Service Manual - Page 98
errors. CPU interrupt error, spurious CPU interrupts. CPU interrupt error, missing CPU interrupts. CPU interrupt error, IRQ spurious assertion. CPU interrupt error, timer no assertion. CPU interrupt error, spurious assertion. CPU interrupt error, no assertion. 3-6 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 99
Panel Error Code PS, PE and Control Panel LEDs POST Error Type Description 15.07 15.08 15.09 15.10 15.11 16.01 Flutter and then 15 blinks Flutter and then 15 blinks Flutter and then 15 blinks Flutterand then 15 blinks Flutter and then 15 blinks Flutter only Hard Hard Hard Hard Hard Soft - Xerox C2424 | Service Manual - Page 100
firmware that was executing when the exception occurred: Engine, PostScript, Network, or Operating System. Note A CPU exception can either be caused by hardware or firmware error. Refer to the infoSMART Knowledge Base for descriptions of the most common faults. 3-8 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 101
1,000.4x Error - 525-Sheet Feeder Faults 1,001.46: The upper 525-sheet feeder had an overcurrent condition. The lift motor or clutch may be shorted. 1,002.47: The lower 525-sheet feeder had an overcurrent condition. The lift motor or clutch may be shorted. Troubleshooting Procedure Step Questions - Xerox C2424 | Service Manual - Page 102
"Ensuring Ground Integrity" on page 4-73). c. Replace the EEPROM chip. d. Reboot the system. 3,0XX.6x - IPC Program Faults There is a communication problem between the engine and PostScript regions. a. Reset NVRAM, and then retest. b. Replace the EEPROM chip. 3-10 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 103
control system. The printhead temperature dropped below the head cleaning needed threshold. 4,020.41: This fault code indicates a problem with the process control system. Declared when the printer is booted in FTTR (Fast Time to Ready) mode and the head/cap contact flag is set in NVRAM. The printer - Xerox C2424 | Service Manual - Page 104
to Step 5. Go to Step 4. Replace the problem component. Clean the interior of the sytem and replace clutch if necessary. Go to Step 5. Replace in the following order: ■ Exit module ■ Media drive gearbox ■ Wiper blade Replace the head maintenance clutch. 3-12 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 105
This fault code indicates a problem with the process control system. Cannot succesfully home the drum transfix mechanism. Troubleshooting Procedure Step Questions and Actions Yes No 1 1. Check for obstructions around the printhead. Complete. Look for ink shards in gears of the tilt drive. 2. If - Xerox C2424 | Service Manual - Page 106
were errors during imaging. Possible jets on/off outside of the deadband area. Software fault. a. Reset NVRAM and retest. b. Ensure ground integrity for the system (see "Ensuring Ground Integrity" on page 4-73). c. Replace the EEPROM chip. d. Reboot the system. 3-14 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 107
movement? 2 1. Clear the wiring or ink spill, which is restricting movement of the printhead. 2. Did this correct the problem? 3 1. Inspect the X-axis wiring harness. 2. Is the wiring damaged or faulty? 4 1. Use service diagnostics to test the X-axis drive. 2. Did the test fail? Yes Go to Step - Xerox C2424 | Service Manual - Page 108
Replace the process gearbox. 7,007.49: The process motor stalled while tilting the head. Troubleshooting Procedure Step Questions and Actions Yes 1 1. Check the printhead wiring for proper routing. 2. Remove the printhead and inspect the printhead tilt and drive gears for ink spills. 3. Re-route - Xerox C2424 | Service Manual - Page 109
. "Wiper Alignment" on page 6-2. 2. Did this correct the problem? Go to Step 9. 9 1. Use service diagnostics to run the Wiper Drive Test. 2. Did the test fail? Inspect the maintenance drive system and replace any defective parts. Replace the exit module assembly. Error Messages and Codes 3-17 - Xerox C2424 | Service Manual - Page 110
maintenance drive system, replace any defective parts. Replace the exit module assembly. 7,010.43: The printhead is stuck in the tilted position, or is not tilting properly over the CAM, due to problems with the process motor gearbox. 7,011.44: This is a soft fault, and will not halt the printer - Xerox C2424 | Service Manual - Page 111
Go to Step 10. Replace the exit module assembly. 10 1. Use service diagnostics to run the Load Maintenance Clutch test. 2. Did the test fail? Inspect the maintenance drive system, replace any defective parts. 7,0XX.6x Errors - Program Faults a. Reset NVRAM and retest. b. Ensure ground integrity - Xerox C2424 | Service Manual - Page 112
gears. 3. Did this correct the problem? 4 1. Run the Wiper Drive test. 2. Did the test pass? Go to Step 5. 5 1. Run the Wiper Alignment test. 2. Did the test pass? Go to Step 7. No Go to Step 4. Go to Step 4. Go to Step 4. Go to Step 6. Go to Step 6. 3-20 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 113
the inside Replace the wiper blade or in the drive path? of the system exit module and retest. assembly. 8,0XX.6x Errors - Program Faults a. Reset NVRAM, and then retest. b. Ensure ground integrity for the system (see "Ensuring Ground Integrity" on page 4-73). Error Messages and Codes 3-21 - Xerox C2424 | Service Manual - Page 114
the ink stick. Replace the ink loader assembly. 9,009.44 and 900X.6x 9,009.44: This fault code indicates a device failure attempting to access NVRAM. a. Reset NVRAM and retest. b. Ensure ground integrity for the system (see "Ensuring Ground Integrity" on page 4-73). 3-22 WorkCentre C2424 Service - Xerox C2424 | Service Manual - Page 115
3 1. Reset NVRAM and retest. 2. Did this resolve the problem? Complete. Go to Step 4. ■ 11, 001.47 and 11,017.45 Replace Tray 2. ■ 11,002.48 and 11, 016.44 Replace Tray 3. ■ 11,003.49 and 11,0014.42 Replace the control panel. ■ 11,004.41 and 11,013.41 Replace the I/O board. Error Messages - Xerox C2424 | Service Manual - Page 116
Complete. Complete. 13,003.42: 13,007.46: Troubleshooting Procedures Step Questions and Actions 1 1. Ensure ground integrity for the system. 2. Did this correct the problem? Yes Complete. No Go to Step 2. Go to Step 3. Replace the printhead. No Go to Step 2. 3-24 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 117
properly? 3 1. Is the error code associated with an overheat condition? 4 1. Verify system clearance for adequate air flow. 2. Are any of the vents blocked? 5 1. Using service diagnostics, run the Drum Fan Motor test. 2. Did the test pass? Yes Advise customer of specification requirements. Go to - Xerox C2424 | Service Manual - Page 118
drum thermistor circuit is shorted. 13,071.47: The drum thermistor returned a bad reading, or the reading was corrupted by ESD (Electrostatic Discharge). Troubleshooting Procedure Step Questions and Actions 1 1. Using service diagnostics, run the Drum shorted. 3-26 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 119
Troubleshooting Procedure Step Questions and Actions Yes No 1 1. Verify that the ambient temperature of the room is within the systems optimal environmental specification (see "System Environmental Specifications ? preheater board. Replace the wiring harness. Error Messages and Codes 3-27 - Xerox C2424 | Service Manual - Page 120
run the Left Jetstack Temperature test. 2. Did the test pass? Go to Step 4. 4 1. Check and reseat all wiring to the printhead. Complete. 2. Did this correct the problem? No Go to Step 2. Resolve ground integrity. Replace the printhead. Replace the printhead. 3-28 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 121
3 1. Run the Right Jetstack Temperature test. Go to Step 4. 2. Did the test pass? 4 1. Check and reseat all wiring to the printhead. Complete. 2. Did this correct the problem? No Go to Step 2. Resolve ground integrity. Replace the printhead. Replace the printhead. Error Messages and Codes 3-29 - Xerox C2424 | Service Manual - Page 122
printhead Reservoir Temperature Go to Step 4. test. 2. Did the test pass? 4 1. Check and reseat all wiring to the printhead. Complete. 2. Did this correct the problem? No Go to Step 2. Resolve ground integrity. Replace the printhead. Replace the printhead. 3-30 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 123
,583.46: The BLACK thermistor returned a bad reading, or ESD corruption. Troubleshooting Procedure Step Questions and Actions Yes 1 1. Verify that the ambient temperature of the room is within the systems optimal environmental specification (see "System Environmental Specifications" on page 1-14 - Xerox C2424 | Service Manual - Page 124
manager task was expecting initialization message, but received other. 13,008.60: Thermal power manager task received an unexpected message. a. Reset NVRAM and retest. b. Ensure ground integrity for the system (see "Ensuring Ground Integrity" on page 4-73). 3-32 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 125
19,0XX.xx Errors - Printhead Calibration faults. 19,001.46: HFD server failed due to NVRAM operation. This fault only occurs when the system is set in manufacturing mode. Program fault. 19,002.47: Attempted to perform a printhead operation without the printhead NVRAM data being loaded. 19,003.48: - Xerox C2424 | Service Manual - Page 126
the problem? If the media path is clear of debris and the rollers rotate normally, replace the media gearbox. 31,0XX.6x Errors - Program Faults a. Reset NVRAM, and then retest. b. Ensure ground integrity for the system (see "Ensuring Ground Integrity" on page 4-73). 3-34 WorkCentre C2424 Service - Xerox C2424 | Service Manual - Page 127
ink data partition in NVRAM. 34,003.45: An error occurred while attempting read/write access to the printhead data partition in NVRAM. 34,004.46: An error occurred while accessing the printhead NVRAM hardware for the purpose of initialization. The printhead cable may be unplugged. Troubleshooting - Xerox C2424 | Service Manual - Page 128
diagnostics to run the Drum Maintenance/Transfix Home test. 2. Use service diagnostics to run the Drum Maintenance Drive test. If either test fails, Replace the process drive. 36,001.67 Errors a. Replace the pivot plate. b. Replace the drum maintenance unit. 3-36 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 129
, may not supply enough current to properly power up the printer. In these cases, the printer may report printhead jet-stack or reservoir heater disconnect, drum heater, or preheater errors (37,002.47 thru 37,012.48). Verify the AC power source prior to troubleshooting for a system exhibiting any of - Xerox C2424 | Service Manual - Page 130
Troubleshooting Procedure Step Questions and Actions 1 1. Run the appropriate diagnostic test: 37,002.47 = Left Jetstack Heater 37,003.48 = Right Jetstack Heater 37,004.40, 37,005.41 = Reservoir Heater 37,006.42 = Drum Heater 37,008.44 = Preheat Heater 37,009.45 = Ink Melt 1 37,010.46 = Ink Melt 2 - Xerox C2424 | Service Manual - Page 131
power supply test. The 50 V power supply is loaded with the head maintenance clutch and then tested. The expected power from the supply is not being drawn. This error may be caused by a power supply that is faulty or shorted by some other 50 V device. 50V Power Supply Fault Troubleshooting Procedure - Xerox C2424 | Service Manual - Page 132
devices you unplugged earlier. In this case, systematically turn off the printer, plug a wiring harness back in, and turn the printer on until the 50V supply fails. 2. Replace the defective part. Retest the printer. 5 1. To isolate the problem to the I/O board or its Replace the I/O Go to Step - Xerox C2424 | Service Manual - Page 133
the problem wiring harness. Replace the problem component: ■ Head maintenance clutch ■ Media path drive assembly ■ Pick solenoid ■ Strip solenoid 37,021.48: PEST - Tray 1 elevator disconnect. The main tray elevator is not drawing the expected power from the supply. Troubleshooting Procedure - Xerox C2424 | Service Manual - Page 134
from the supply. Troubleshooting Procedures Step Questions and Actions 1 1. Run the Drum Heater Relay test. 2. Did the test pass? 2 1. Check the wiring for damage. Yes No Replace the electronics module. Go to Step 2. Replace the drum heater relay board. 3-42 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 135
) is not drawing the expected power from the supply. 37,031.40: PEST - X-axis motor short. The X-axis motor is drawing too much power from the supply (second phase). Troubleshooting Procedure Step Questions and Actions Yes No 1 1. Run the X-axis Drive test. 2. Did the test pass? Replace the - Xerox C2424 | Service Manual - Page 136
Replace the process drive assembly. 37,038.47: PEST - The power supply did not reset properly as requested. The reset line may not be connected. 37,039.48: PEST - Power supply +5 volt over limit. 37,040.40: PEST - Power supply +5 volt under limit . 37,041.41: PEST - Power supply +1.8 volt over - Xerox C2424 | Service Manual - Page 137
due to a short or disconnected power supply reset line. 37,062.44: PEST - Vss measurement too low. The printhead power cable may be disconnected. 37,063.45: PEST - Vpp measurement too low. The printhead power cable may be disconnected. Troubleshooting Procedure Step Questions and Actions 1 1. Run - Xerox C2424 | Service Manual - Page 138
Home Position Test Error Troubleshooting Procedure Control Panel Message "Release Scanner Shipping Restraint or Scanhead Locked" Step Questions and Actions 1 1. Is the scan head locked? Yes No Unlock and and reboot the system. Replace the scanner assembly. 3-46 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 139
defective motor. 5 1. Leave the exit module motors disconnected Replace the and disconnect the document feeder document assembly. feeder. 2. Does the red LED come on solid? Go to Step 7. 6 1. Is the LED off? Replace in the following order: ■ scanner power supply ■ electronics module Go to - Xerox C2424 | Service Manual - Page 140
the troubleshooting procedure on page 4-77. 39,014.43 Document Feeder Calibration Troubleshooting Procedures Step Questions and Actions 3 1. Cycle power to the system to clear. 2. Did this correct the problem? Yes Complete. No Replace the document feeder. 3-48 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 141
section provides a basis for troubleshooting system problems that occur as the result of misfeeds or jams within the paper path. Refer to the Xerox infoSMART knowledge base at www.xerox.com/office/c2424infoSMART for the latest information on Jam Code interpretation. The system stores the 20 most - Xerox C2424 | Service Manual - Page 142
Not all jam code combinations are documented in this manual, only the codes that occur most commonly. Jam Code Troubleshooting Procedures A2C A2E A2F A2J A2K A2M A2N A2P A2S A2Q A3G A3M Deskew sensor in unexpected state during mechanical recovery. 1. Check the drum maintenance unit NVRAM contacts - Xerox C2424 | Service Manual - Page 143
Jam Code Troubleshooting fault. Preheater exit sensor in unexpected state during stage. 1. Ensure ground integrity of the system (see page 4-73). 2. Check the drum maintenance unit NVRAM contacts during the oiling process for continuity. 3. Check the waste tray. 4. Replace the preheater assembly - Xerox C2424 | Service Manual - Page 144
Ensure ground integrity of the system (see page 4-73). 2. Check the paper tray for overfill. 3. Run the Stripper sensor test. 4. Inspect the stripper blade for damage or debris. 5. Run the Paper Lead Edge Times test. 6. Replace the stripper carriage assembly. 3-52 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 145
thick and that it is supported by the system. 2. Use a less glossy media. 3. If the drum maintenance unit is near the end of its life, replace it. 4. Clean and inspect the exit rollers. 5. Run the Paper Path Drive test. 6. Replace the lower exit guide assembly. Exit flag unexpected event during warm - Xerox C2424 | Service Manual - Page 146
is supported by the system. 2. Use a less glossy media. 3. If the drum maintenance unit is near the end of its life, replace it. 4. Clean and inspect the exit rollers. 5. Check the exit flag for proper installation or damage, replace the flag if necessary. 6. Run the diagnostic Paper Path Drive test - Xerox C2424 | Service Manual - Page 147
Jam Code Troubleshooting Procedures (Continued) F2D F2F F2M F2N F2P F2Q F2R F2S F2T F2V F2W F2X G2M H2N J2M J2P K2A K2B K2C K2D K2E K2F K2T The front door open flag unexpectedly tripped while the system was warming up. The front door open flag unexpectedly tripped while the system was in a fault - Xerox C2424 | Service Manual - Page 148
Jam Code Troubleshooting Procedures (Continued) K2X L2A L2B L2C L2D L2E L2F L2G L2H L2J L2K L2L L2M L2N L2P L2Q L2R L2S L2T L2V L2W Exit module (MEP) malfunction during paper exit. 1. Ensure supported media. 2. Inspect the media path for obstructions. 3. Verify scanner power supply and MEP control - Xerox C2424 | Service Manual - Page 149
path motor stalled during transfix. 1. Verify that the media in the tray is supported by the system. 2. Inspect the paper path for obstructions. 3. Run the Paper Drive Power test. 4. Run the Media Path Motor and Shafts test. 5. Replace the media path drive assembly. Error Messages and Codes 3-57 - Xerox C2424 | Service Manual - Page 150
is correctly aligned. 4. Run the Check Y-Axis Motor test. Replace if necessary. 5. Run the Belt Slip test. 6. Replace the Tray 1 separator pad assembly. 7. Replace the process drive assembly. Y-Axis motor out of position while the system transfixed the print. 3-58 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 151
Jam Code Troubleshooting Procedures (Continued) N5W N6T N7T Y-Axis motor out of position while the system imaged the drum. 1. Inspect the Y-Axis drive belt. 2. Run the Check Drum Y-Axis Encoder test. 3. Run the Check Drum Y-Axis Drive test. 4. Run the Check Drum Y-Axis Belt Slip test. 5. Replace - Xerox C2424 | Service Manual - Page 152
Jam Code Troubleshooting Procedures (Continued) P4T P4V P4W P4X Process motor stalled while the system transfixed the print. Process motor stalled while the system performed a print drum maintenance cycle. Process motor stalled while the system imaged the drum. Process motor stalled while the - Xerox C2424 | Service Manual - Page 153
Jam Code Troubleshooting Procedures (Continued) T2Q The exit door open flag unexpectedly tripped when the system picked from Tray 1. T2R The exit door open flag unexpectedly tripped while the system was duplexing. T2S The exit door open flag unexpectedly tripped while the paper was staging for - Xerox C2424 | Service Manual - Page 154
Jam Code Troubleshooting Procedures (Continued) V2V V2W V2X Tray 2 media size sensor unexpectedly activated while print drum maintenance cycle was being performed. Tray 2 media size sensor unexpectedly activated during system imaging. Tray 2 media size sensor unexpectedly activated while exiting - Xerox C2424 | Service Manual - Page 155
Jam Code Troubleshooting Procedures (Continued) W4S Tray 3 motor stall during pick from Tray 3. 1. Ensure ground integrity of the system (see page 4-73). 2. Ensure the paper guides are correctly set. 3. Run the Monitor Sensors test to test the media size sensor. 4. Replace the 525-Sheet Feeder. X2A - Xerox C2424 | Service Manual - Page 156
drum maintenance cycle was being performed. Tray 3 pick flag sensor timed out while system imaging. Tray 3 pick flag sensor timed out while exiting print. 1. Verify the paper loaded in Tray 3 is supported media. 2. Reduce the amount of media in the tray and reposition the guides to fit snugly - Xerox C2424 | Service Manual - Page 157
Jam Code Troubleshooting Procedures (Continued) Y2T Y2V Y2W Y2X Tray 4 media size sensor unexpectedly activated while transfixing the print. Tray 4 media size sensor unexpectedly activated while the system drum maintenance cycle was being performed. Tray 4 media size sensor unexpectedly activated - Xerox C2424 | Service Manual - Page 158
Tray 4 pick flag sensor timed out while exiting print. 1. Verify the paper loaded in Tray 4 is the correct size and type. 2. Inspect/clean the pick roller assembly. Replace if necessary. 3. Run the Tray 4 Pick Shaft test 4. Replace the Tray 4 525-Sheet Feeder. 3-66 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 159
General Troubleshooting In this chapter... ■ Service Diagnostics ■ Check Menu / Activators Definition Tables ■ Electrical Troubleshooting ■ Ensuring Ground Integrity ■ Paper Path and Media-Based Problems ■ Operating System and Application Problems 4 Section - Xerox C2424 | Service Manual - Page 160
also contains useful troubleshooting information. This page provides general system information, life information for all consumables, printhead cleaning and power cycles, and jam and error code information. Troubleshooting procedures will isolate a problem to a specific component or subassembly - Xerox C2424 | Service Manual - Page 161
Item Reset NVRAM Power Saver Timeout Restart System Head Adjust Adjust X-axis scale Drift Compensation Head-to-Drum Adjust Service Usage Profile Engine Copy Count Head Serial Number Head Cal Date Head Version Engine Firmware Version Center Image Description Provides access to reset the system back - Xerox C2424 | Service Manual - Page 162
to aid in troubleshooting problems with the system components. The Service Diagnostics menu provides a means to test sensors, motors, switches, clutches, solenoids, fans, and power supplies. Diagnostics also contain functions to report system status and some NVRAM access. Service diagnostics are to - Xerox C2424 | Service Manual - Page 163
to diagnostics while keeping the system warm. 1. Display the Hidden Service menu as described in "Hidden Service Menu" on page 4-2. 2. Scroll down to Enter Diagnostics and press the Enter button. From System OFF to Diagnostics: 1. Turn the system power ON. 2. Wait for the Xerox logo to begin moving - Xerox C2424 | Service Manual - Page 164
the test functions for the DADF. Control (Front) Panel Menu This menu contains the test functions for the control panel. * The exit module, scanner, and doc handler are separate subsystems with their own firmware. In these tests, the service diagnostic firmware commands the subsystem to perform - Xerox C2424 | Service Manual - Page 165
Exercise Roller Drive Rotates the exit path transport rollers clockwise, then counter-clockwise, performs a seek home command, and then reports final status. Ready Error Reset Exit Module This test power cycles the IIT unit (MEP, Scanner, DADF). Ready or Not Ready General Troubleshooting 4-7 - Xerox C2424 | Service Manual - Page 166
test. The test will fail if the scan head is locked. Tests the scanner subsystem DRAM. Runs the scanner axis seek home procedure. The axis moves or Fail. Cover open or closed. (The cover must be open approximately 60 degrees before the test preports a change.) 4-8 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 167
version. Report Status Checks then reports the current status as reported by the DADF unit firmware. Ready or Not Ready Lamp: ON, OFF, Warming Up, Warmup test not done, Test fail Error: OK, Paper Jam, Cover Open, Internal failure, Test fail, Data Capture test fail, Cal Device test fail. Report - Xerox C2424 | Service Manual - Page 168
subsystem to move the calibration strip into the scanning window. OK or Fail. Monitor Sensors Paper or no paper. Exercise feed motion Exercises the transport rollers in the DADF. Monitors the paper present sensor. You can manually excercise the sensor flags and verify the results. OK or Fail - Xerox C2424 | Service Manual - Page 169
Jetstack RJ = Right Jetstack RE = Reservoir DR = Drum PH = Preheater Line Voltage Provides the current voltage readings for AC Power. You can run this test overnight to record supply voltage settings. This test will not record spike voltages. Minimum: Now: Maximum: General Troubleshooting 4-11 - Xerox C2424 | Service Manual - Page 170
Cam Shaft ■ Drum Maintenance Cam Shaft ■ Deskew Shaft ■ Wiper Shaft ■ Tray 1 Pick Shaft ■ Tray 2 Pick Shaft ■ Tray 3 Pick Shaft ■ Tray 0 lift motor ■ Tray 3 Lift Motor ■ Tray 3 Motor & Shafts ■ Tray 4 Pick Shaft ■ Tray 4 Lift Motor ■ Tray 4 Motor & Shafts 4-12 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 171
a group of tests that perform specific measurements on portions of the print engine and report measured values to the control panel. These values may then be compared with range limits documented in the service manual, or using service bulletins on the service website (if the values were unavailable - Xerox C2424 | Service Manual - Page 172
with defaults at the next power-up. Clear PE NVRAM A restricted function that clears the PE NVRAM to be rebuilt with defaults at the next power-up. Set PE NVRAM to Defaults A restricted function that sets the PE NVRAM parameters to the default values. 4-14 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 173
ink or maintenance kit life. The diagnostics routines are not designed to address all of these conditions consistently. If a test result differs significantly from the typical values defined in the following tables, check the entire system containing the problem . General Troubleshooting 4-15 - Xerox C2424 | Service Manual - Page 174
to -0.4 Reports the min power following power off. 3 Peak Power Time (sec) 0.05 to 0.19 Reports time after solenoid power on that the peak power occurred. 4 Initial Average Power (watts) 15 the average power during the constant portion of the profile. 4-16 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 175
the average power during the constant portion of the profile. Drum Heater Relay Gathers data on the performance of the drum heater dual relay assembly by energizing each relay for a short time and capturing power occurred. Reports the average power following power on. General Troubleshooting 4-17 - Xerox C2424 | Service Manual - Page 176
steady state drive requirements, bearing the deskew shaft assembly or a indicate particles in the gears or non uniform contamination system to react to the sudden addition of the deskew shaft load. Larger values may indicate a slipping or slow to engage clutch. 4-18 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 177
the time it takes the MP motor servo system to "settle down" after the sudden release of the deskew shaft load. A larger value could indicate a dragging or slow to release clutch. Wiper Shaft Runs the media path drive train and engages the head maintenance clutch on the fly then disengages the - Xerox C2424 | Service Manual - Page 178
8 CW On fe settling time (sec). 0.01 to 0.20 Reports the time it takes the MP motor servo system to "settle down" following the sudden addition of the wiper shaft load. A longer time could indicate a looseness in the wiper shaft assembly or a slipping clutch. 4-20 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 179
the missing tooth gear engaged more slowly than usual, which could be a problem with the lift plate spring tension, the condition of the sliding surfaces between the cams and the followers, drag on the pick shaft, or problems with the drive gears (missing teeth, etc.). General Troubleshooting 4-21 - Xerox C2424 | Service Manual - Page 180
on the fly. The pick shaft goes through 2 full revolutions while drive requirements are determined. R# Definition Typical Value Actions 2 Initial average MP fe gear. This value should be the same as R0 if the missing tooth gear successfully relatched. 4-22 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 181
a binding shaft, missing pressure springs, hard/dirty rollers, or extra friction in the pick truck assembly. Reports the variation of effort required a problem with the lifting mechanism (which could effect the following friction measurement), or media left in the tray. General Troubleshooting 4- - Xerox C2424 | Service Manual - Page 182
path motor is used and for the 525-Sheet Feeders the corresponding pick/transport motor is used. Test , missing nudger assembly pressure spring, or glazed/dirty roller/pad. Check Fans Menu Drum Fan and Electronics drive or extra drag (bearings, brushes, blade). 4-24 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 183
, Drum Heater, Ink Melt 1 (yellow) Heater, Ink Melt 2 (cyan) Heater, Ink Melt 3 (magenta) Heater, Ink Melt 4 (Black) Heater supply, indicating a more robust supply may be required. Reports the time after power is applied to the specified heater that the temperature begins to rise. For printhead - Xerox C2424 | Service Manual - Page 184
effected than others by cross talk from other heaters (and the chassis generally warming). Shows the heat dissipation at the thermistor during cooling. Might indicate problems with airflow. 4-26 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 185
Check Paper Path Menu Paper Drive Power Test picks paper from selected tray (test currently supports picking from Tray 2 only) and moves it through either the simplex or duplex paper the interval from the Tray 3 Pick sensor activation until the Deskew sensor activates. General Troubleshooting 4-27 - Xerox C2424 | Service Manual - Page 186
until the Preheat sensor activates. (part way through the stage paper motion). Reports the interval from the time the engine software is commanded to start the transfix process until the Strip sensor activates. (part way through the paper transfix motion). 4-28 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 187
until the Exit sensor activates (part way through the paper transfix motion). Reports the interval from the time the engine software is commanded to start the exit process until the Exit sensor deactivates. tray 3 pick process until the Tray 3 pick sensor deactivates. General Troubleshooting 4-29 - Xerox C2424 | Service Manual - Page 188
the time the engine software is commanded to start the exit process until the strip sensor deactivates. (part way through the paper exit motion). Reports the interval from the time the engine software MFG Only Reports the tray from which the paper was picked. 4-30 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 189
Preheat Bounce Interval (us) MFG Only 6 Strip Bounce Interval (us) MFG Only 7 Exit Bounce Interval MFG (us) Only Reports size of the picked paper. Reports the interval during during which the exit sensor bounces following the passage of the paper trailing edge. General Troubleshooting 4-31 - Xerox C2424 | Service Manual - Page 190
until the preheat sensor activates. (part way through the stage paper motion). Reports the interval from the time the engine software is commanded to start the transfix process until the strip sensor activates. (part way through the paper transfix motion). 4-32 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 191
engine software is commanded to start the exit process until the strip sensor deactivates. (part way through the paper exit motion). Reports the interval from the time the engine software is commanded to start the duplex pick process until the exit sensor deactivates. General Troubleshooting 4-33 - Xerox C2424 | Service Manual - Page 192
if simplex or duplex path was selected. R# Definition Typical Value Actions 7 Exit Bounce Interval MFG (us) Only 8 Duplex Deskew MFG Bounce Interval (us) interval during which the exit sensor bounces following the passage of the paper trailing edge. 4-34 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 193
upper limit of travel at which the wiper first encounters the lower travel limit. 12 Turnaround 0.001 to Reports the time following the start of the Recovery time (sec) 0.25 turnaround motion that the motion drive error return to normal in the opposite direction. General Troubleshooting 4-35 - Xerox C2424 | Service Manual - Page 194
power level needed to move the printhead from the right hard stop to the left hard stop. An abnormal value may indicate a problem with roughness in the drive mechanism or an interference with the printhead motion. Same as R2 except for the other direction of motion. WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 195
the Roll With Transfix Roller Down interval. Reports the difference between the max and min Y-axis following errors during the Roll With Transfix Roller Down interval. Reports the time from the unload command to the engine until the drum indicates no further contact. General Troubleshooting 4-37 - Xerox C2424 | Service Manual - Page 196
difference between the max and the min Y-axis following error during the Roll With Blade Loaded interval. 9 Blade Disengaged MFG Time (sec) Only Reports the time from the unload blade command to the engine until the drum indicates no further blade contact. 4-38 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 197
error at the post wipe peak location. Tray 2, Tray 3, Tray 4, Lift Plate Drive This test raises the lift plate to verify motion and sensor operation. If the test is requested for a 525-sheet feeder that is not installed Troubleshooting 4-39 - Xerox C2424 | Service Manual - Page 198
power during the overlifting interval. Check Drum Menu Y-axis Encoder Uses the sine and cosine sum data to determine the characteristics of the encoder disk and encoder sensors. R# Definition Typical from the notch min as reflected in the Sin Sum data. 4-40 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 199
determine the characteristics of the encoder disk and encoder sensors. R# Definition drum or motor). Reports the ratio of the FFT power amplitude of the second most powerful FFT frequency (not including the drum or motor), to the FFT power amplitude of the drum frequency. General Troubleshooting - Xerox C2424 | Service Manual - Page 200
it takes the following error value to enter the idle ripple band. 7 HAHVN Delta Print 0.02 to Velocity Settle Time 0.10 (sec) Reports the time following the start of motion that it takes the Y-axis delta velocity to enter the CCW delta velocity ripple band. 4-42 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 201
frequency is recorded while the drum is advanced for two revolutions. Checks for correct belt tension and for variations in tension locate the min frequency configuration. Reports the amount of additional Y-axis rotation required to locate the min frequency configuration. General Troubleshooting - Xerox C2424 | Service Manual - Page 202
blade begins to withdraw from the drum (see R2). 6 Releasing Period (sec) -1 to 1 Reports the time between the disengagement of the stripper sol and the point when the reaction of the drum to the withdrawal of the blade fades back into the ripple (see R2). 4-44 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 203
-12.3 to Reports the magnitude of the reaction of the (mpts) 5.85 drum to the blade withdrawal (see R3). Drum Maintenance Contact This test uses the drum servo error signal to indicate when the drum is contacted by the roller blade. R# Definition Typical Value Actions 0 Initial Contact - Xerox C2424 | Service Manual - Page 204
interval. 4 Motor drive power ripple (watts) 1.03 to 3.6 Reports amount of variation of the motor drive power over the recording interval. 5 Motor drive power average (watts) 0 to 5 Reports the motor drive power average value of the recording interval. 4-46 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 205
recording drive data. The test is the same for each motor. Requesting a test for a 525-sheet feeder that is not installed will generate motor drive power over the last half of the run interval. Reports the average motor brake power over the stop with brake interval. General Troubleshooting 4-47 - Xerox C2424 | Service Manual - Page 206
drive data. The test is the same for each motor. Requesting a test for a 525-sheet feeder that is not installed string of 0's and 1's (one digit for each sensor state) and is listed below from most significant bit to least significant bit. 1 = an item door open 4-48 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 207
state) and is listed below from most exit sensor 14 - 31 unused, always 0 13 - No media present 0 - 12 width value 9 - 31 unused 8 - No tray 7 - No paper 6 - plate not lifted 5 - Paper at tray pick sensor 4 - media length top 3 - media length bottom 2 - Media width top General Troubleshooting - Xerox C2424 | Service Manual - Page 208
1's (one digit for each sensor state) and is listed below from most significant bit to least significant bit. 1 Status This test scans the thermocouples and reports Drum Temp 5 Ink Melt 1 Temp 6 Ink Melt 2 Temp 7 Ink Melt 3 Temp 8 Ink Black (usually off) 4-50 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 209
results will report as 0. This avoids having ink extrude out of the faceplate and onto the drum, requiring both a wipe and a chase to R1). This is the first value to reflect the system pressure. If the volume is normal (hose/printhead), then the drop is large and the pressure Troubleshooting 4-51 - Xerox C2424 | Service Manual - Page 210
Definition Typical Value Actions 0 The engage wiper position (min) MFG Only 1 Upper hard stop MFG wiper position (min) Only Reports the distance from wipe home to the tilt engage position. Reports the distance from wipe to home to the upper hard stop. 4-52 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 211
Drum Maint/Transfix Home This test drives the process motor a short distance in each direction to verify that the dmfix drive unit was in its Only Reports the height of the initial peak when starting rotation of the dm drive gear. Reports the time since the start of CCW motion until the peak was - Xerox C2424 | Service Manual - Page 212
Cold printers only. 10:16 22. Control panel displays "Printing page 1 of 4" --- Cold printers only. 11:12 23. Cleaning page exits --- Cold printers only. 11:48 24. Startup page exits (if enabled). 11:58 25. Control panel displays "Ready To Print". 11:59 4-54 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 213
Recovery POWER ON Set FIRMWARE states: CapState = UNKNOWN Head Tilt State = UNKNOWN DmfixState = UNKNOWN YaState = HOMELESS Xa State = HOMELESS Home the Y-Axis 5001, 5002 YES Is the head tilt Cam engaged (head tilted?) Valves in the NVRAM are used to determine if the printhead and wiper have - Xerox C2424 | Service Manual - Page 214
WorkCentre C2424 Service Manual 4-56 _head Parked On? Last Power Down? YES Move Cap/Wiper to the Park ARMS- and restrain head again. 8035,7009 Device Fault Codes 80xx - Wiper 7002 - PM stalled 70xx - Headtilt 7014 - Head Not Restrained 31001 - Media Path 5001 - YA Home Timer 5002 YA - Encoder ( - Xerox C2424 | Service Manual - Page 215
to its print position to check the ink levels. If the ink level is low, ink is melted into the appropriated reservoirs. 3. The printhead tilts to the standby position and moves the wiper assembly to the purge position in front of the printhead faceplate. 4. The purge pump begins the pressure purge - Xerox C2424 | Service Manual - Page 216
the exception of the NVRAM, memory, configuration card, and hard drive; no individual board troubleshooting is needed. The system contains many self test routines to aid in diagnosing problems. The system backframe contains the scanner and exit module power supply and the scanner control board. Note - Xerox C2424 | Service Manual - Page 217
list of supported media. 5. Clean or replace the pick rollers and separator pad. 6. Check the document feeder front cover and upper cover for obstructions or damage. 7. Print a Usage Profile and look for repeating document feeder or scanner errors that may be causing the problem. Note If the system - Xerox C2424 | Service Manual - Page 218
appears functional after operating the door, advise client that failure may have been due to an ESD event. Thoroughly test system for any other problems. c. Skip the rest of this section if the system now appears functional, otherwise continue troubleshooting. 4-60 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 219
history for any error codes that may be causing the system to reboot. Troubleshoot any error codes reported. e. Turn the system off and unplug the document feeder. If the system powers on normally, replace the document feeder. f. Turn the system off and unplug the scanner. If the system powers on - Xerox C2424 | Service Manual - Page 220
and lower correctly. a. Is there scanner power supply working properly? Lift the document feeder and observe the scanner lamps. If the lamps are on and the scanhead moves, the scanner power supply is supplying +24 volts. b. Check the exit module board LED's, see "Scanner/Exit Module Power Supply and - Xerox C2424 | Service Manual - Page 221
right (J400) ■ Printhead data cable (J130) ■ Waveamp signal (J790) ■ Power Control left (J390) ■ Y-Axis motor (J280) ■ Scanner power supply ■ Exit module data cable ■ Door sensor(s) Exit cover and Front door e. Plug in power cord and power on the system f. If the PE and PS indicators do not - Xerox C2424 | Service Manual - Page 222
to discharge. d. Unplug power cord and remove system's covers. e. Replace the electronics module. f. Plug in all cables removed during service. g. Trace through all service steps performed to reattach any cables that were unplugged during troubleshooting. 4-64 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 223
If the power supply fails to shut off, the system may appear to be in energy star mode but its power consumption will be about 70 Watts higher than it should be. System Reports Missing Maintenance Kit 1. Maintenance kit missing or not fully seated. a. Fully install maintenance kit. 2. Connector is - Xerox C2424 | Service Manual - Page 224
self resetting device, power cycling ensures the fuse cools enough to reset itself. 2. 525-Sheet Feeder is faulty. a. Turn off system and wait 30 seconds for power supply capacitors to discharge. b. Replace the 525-Sheet Feeder. c. Perform full test of system. 4-66 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 225
the Scanner cable from the electronics module and power on. a. Double check PS and PE indicators for any error code information. The system self test is usually able to detect a failure that would cause this symptom. Looking up the error code may save troubleshooting time. b. If the PS & PE - Xerox C2424 | Service Manual - Page 226
, see the "Fault Code Error Message Troubleshooting" on page 3-8 for a definition of the problem and the procedures needed to solve the problem. 2. Repeat the following procedures to check all circuits connected to the I/O board: a. Turn off system and wait 30 seconds for power supply capacitors to - Xerox C2424 | Service Manual - Page 227
made during this step, plug in all connectors to system and retest. If system is fixed, reattach covers to system and perform a full test. If no defects are found in this step, replace electronics module, test system, reattach covers to system and perform a full test. General Troubleshooting 4-69 - Xerox C2424 | Service Manual - Page 228
problem with the document feeder, scanner power supply or exit module board. 3. Isolate the problem board: a. Turn the system off and disconnect the document feeder. Turn the system back on. If the LED is still blinking the problem is not with the document feeder. b. Disconnect the scanner assembly - Xerox C2424 | Service Manual - Page 229
. 2. Inspecting the power supply fuses. 3. Testing for a shorted motor or solenoid driver, which shuts down the power supply. +50 V Supply Active LED (take 20 seconds to drain off) +3.3 V Supply Active LED +15 High side +12 Power +5 Supply Active LED s2424-068 General Troubleshooting 4-71 - Xerox C2424 | Service Manual - Page 230
a heater shorts, F2 or F3 opens. The power supply does NOT shut down; however, a Service Required error code is displayed on the control panel. Detecting condition of Fuse F2 and F3 1. The drum and preheater connect to F2. 2. The printhead and ink loader connect to F3. 3. Turn the power switch off - Xerox C2424 | Service Manual - Page 231
or missing ground connections can result in minor interferences in the system. As examples: ■ control panel display can be affected (blank) ■ I/O board errors ■ False jam reporting ■ Erroneous thermistor readings ■ Major interruptions ■ Damage to the electrical boards General Troubleshooting 4-73 - Xerox C2424 | Service Manual - Page 232
the IOT that need to be checked. There is also one grounding point in the backframe Transfix Roller I/O Board Ground Ground Springs DM Ground Clip Exit Module Ground Media Exit Path Motor Ground 4-74 X-Axis Return Spring Ground Y-Axis Motor Ground s2424-069 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 233
resistance, test each motor's windings for correct resistance (disconnected from the system). Rotate the motor's drive shaft slightly while taking the measurement. Motor and Solenoid Resistances Motor or 20% ohms/phase 132 ohms +/- 15% 186 ohms +/- 15% 124 ohms +/- 5% General Troubleshooting 4-75 - Xerox C2424 | Service Manual - Page 234
problems, first check the displayed error codes using the Error Code Definition Table beginning on page 3-8 to help determine where the error is occurring. Run paper path diagnostics to help eliminate problems with system components. Media-Based Problems . 4-76 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 235
for more information. 4. Remove all media, open and close the document feeder jam access cover then try copying again. Document Feeder Pick Problems 1. Verify supported media for the system. 2. Clean or replace the document feeder pick rollers and separator pad, see "Pick Roller Cleaning Methods" on - Xerox C2424 | Service Manual - Page 236
, as required, the preheater and/or take away rollers. Also make sure that the front door is properly closed. 8. The system should be installed on a flat, level surface. 9. Ensure the paper preheater assembly is clean and properly seated into the system frame. 4-78 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 237
to ensure the problem is not system related. There is additional help available at www.xerox.com/office/support. You can access the infoSMART Knowledge Base, PhaserSMART Technical Support, Technical Support via email, driver downloads, and much more. PhaserSMART Technical Support is an automated - Xerox C2424 | Service Manual - Page 238
to cause AutoIP to assign a new IP address (cycle power or select Restart system from the Shutdown menu). 5. After the system's IP address is set, test communication by sending the "PING" command. 6. If the test fails, install a different cable and retest. 4-80 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 239
the CD-ROM. Once the files have been located, the computer installs the driver and automatically configures it to match the system's feature set. 5. To test the connection, click the START button. 6. Select SETTINGS and then systemS. 7. Locate the WorkCentre C2424 Service Manual icon and display its - Xerox C2424 | Service Manual - Page 240
:Communications:HyperTerminal). Ensure the serial port settings, usually COM1: is correct. 6. Turn on the system. The trace should appear in the terminal dialog window. Examine the trace to troubleshoot the problem. Save the trace as a file, if necessary. 4-82 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 241
Image-Quality Troubleshooting In this chapter... ■ Image-Quality Problems Overview ■ Isolating a Copy/Scan Malfunction to the Scanner/DADF ■ Diagnosing IOT (Print Engine) Print-Quality Problems ■ Analyzing Service Test Prints 5 Section - Xerox C2424 | Service Manual - Page 242
problems: 1. Verify the media being used and the environment for the system are within specification. 2. Isolate the print-quality defect to either a malfunction of the DADF/scanner (IIT) or a malfunction of the print engine (IOT), and once identified: ■ Troubleshoot the DADF/Scanner ■ Troubleshoot - Xerox C2424 | Service Manual - Page 243
-Xerox Ink in OpenUp Time. 8. Review proper operation of the system using a customer file, if possible. 9. Review with the customer all work performed. Also, discuss the need for 90% IPA, a cleaning kit, and how to properly care for their system. Isolating a Copy/Scan Malfunction to the Scanner/DADF - Xerox C2424 | Service Manual - Page 244
through the document feeder. 4. Does the strip extend and retract properly? 3 1. Check and remove any paper debris obstructing the DADF lamp. 2. Did this correct the problem? Complete. No Go to Step 3. Replace the document feeder. Replace the document feeder. 5-4 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 245
"Media System Skew Specification Complete. (IIT/IOT)" on page 1-20. 2. Is the skew within specification? 4 1. Perform the "Manual DADF to Scanner Calibration" on page 6-9. 2. Did this correct the problem? Complete. No Use the platen. Go to Step 3. Go to Step 4. Replace the document feeder. Copy - Xerox C2424 | Service Manual - Page 246
Settings section to aid in adjusting copy settings. 2. Did this correct the problem? Go to Step 6. 6 1. Use the flatbed to make a copy of the embedded page printed in Step 2. 2. Did this correct the problem? Replace the scanner assembly. Replace the DADF. 5-6 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 247
correct the problem? 3 1. Perform the "Manual DADF to Scanner Calibration" on page 6-9. 2. Did this correct the problem? Complete. 4 1. Replace the document feeder. 2. Did this correct the problem? Complete. 5 1. Inspect the cable connection between the Replace the scanner assembly and the - Xerox C2424 | Service Manual - Page 248
1. See the "Media System Skew Specification Complete. (IIT/IOT)" on page 1-20. 2. Is the skew within specification? 2 1. Perform the "Manual DADF to Scanner Calibration" on page 6-9. 2. Did this correct the problem? Complete. No Go to Step 2. Replace the scanner assembly. Copied Image is Lighter - Xerox C2424 | Service Manual - Page 249
correct the problem? 3 1. Perform the "Manual DADF to Scanner Calibration" on page 6-9. 2. Did this correct the problem? Complete. 4 1. Replace the document feeder. 2. Did this correct the problem? Complete. 5 1. Inspect the cable connection between the Replace the scanner assembly and the - Xerox C2424 | Service Manual - Page 250
Settings section to aid in adjusting copy settings. 2. Did this correct the problem? Go to Step 6. 6 1. Use the flatbed to make a copy of the embedded page printed in Step 2. 2. Did this correct the problem? Replace the scanner assembly. Replace the DADF. 5-10 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 251
occurs, and usually selfcorrects within a few printed pages. If a print quality problem is not resolved with the information provided in the Diagnosing Print-Quality Problems section, see the specific problem in "Analyzing Service Test Prints" on page 5-35. Image-Quality Troubleshooting 5-11 - Xerox C2424 | Service Manual - Page 252
replace the maintenance kit. 2. Did this correct the problem? 5 1. Download the latest Jet Fix snippet from the Complete. customer support site and follow the readme text instructions. 2. Did this correct the problem? Go to Step 4. Go to Step 5. Go to Step 6. 5-12 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 253
)" on page 5-32. Step Questions and Actions Yes 1 1. Clean the system's exit path, including wiping the paper release blade with a lintfree cloth. 2. Did this correct the problem? Complete. 2 1. Remove the drum maintenance kit and wipe Complete. the clear plastic wiper blade with a lint-free - Xerox C2424 | Service Manual - Page 254
free from damage. 2. Verify the cam rollers for the drum maintenance are working properly. 3. Replace any defective parts. 4. Did this correct the problem? Complete. No Go to Step 2. Complete. Go to Step 4. Go to Step 5. Go to Step 6. Replace the preheater. 5-14 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 255
a part of normal operation. Step Questions and Actions Yes 1 1. Inspect the area around the printhead and Complete. drum and remove any media or bits of paper jammed between the printhead and drum. 2. Did this correct the problem? 2 1. Follow the instructions on the "Printhead Troubleshooting - Xerox C2424 | Service Manual - Page 256
"13-19: Black, Red, Green, Blue, Cyan, Magenta, and Yellow Solid Fills" on page 5-42. 1. Purge the printhead up to three times. If some improvement is seen, the ink could be discolored due to a long period of time without use. 2. Did this correct the problem? 2 1. Clean the maintenance kit wiper - Xerox C2424 | Service Manual - Page 257
replace the maintenance kit. 2. Did this correct the problem? Complete. 3 1. Check the exit area, exit frame, the Complete. preheater, maintenance kit, and the printhead (including the paper release blade) to see if there is anything touching the drum assembly. 2. Reseat any system component - Xerox C2424 | Service Manual - Page 258
jet. Print the solid fill test Complete. print, see "13-19: Black, Red, Green, Blue, Cyan, Magenta, and Yellow Solid Fills" on page 5-42. 2. Did this correct the problem? 7 1. The X-axis drive is not functioning correctly. Complete. If the X-Axis Drive does not move the printhead smoothly and evenly - Xerox C2424 | Service Manual - Page 259
on the lower portion of the image. s2424-076 Step Questions and Actions Yes 1 1. Check the exit area, the preheater, Complete. maintenance kit, and the printhead (including the paper release blade) to see if there is anything touching the drum assembly. 2. Reseat any system component - Xerox C2424 | Service Manual - Page 260
Change the paper pick guide, front door, or maintenance kit. 3. Did this correct the problem? Go to Step 5. problem? Go to Step 7. 7 1. Inspect all paper guides inside the system Clean or replace any defective for nicks, cuts, or debris. paper guide(s). 5-20 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 261
2. If necessary replace the maintenance kit. 3. Did this correct the problem? 3 1. Clean the paper release blade, it may be contaminated with ink. 2. Run the Remove Print Smears from the system's control panel. 3. Did this correct the problem? Complete. 4 1. Run service diagnostics to verify the - Xerox C2424 | Service Manual - Page 262
x-axis movement is not impeded. Complete. 2. See "White Stripes (Pinstripes)" on page 5-32 for troubleshooting this problem. 3. Did this correct the problem? No Go to Step 2. Go to Step 3. Go to Step 4. Go to Step 5. Replace the drum assembly. Go to Step 7. 5-22 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 263
Step Questions and Actions Yes 7 1. Verify the printhead is tilted forward against Complete. the drum in the proper print position. 2. Did this correct the problem? No Follow the instructions on the "On-Site Printhead Troubleshooting Checklist" on page A-7. Image-Quality Troubleshooting 5-23 - Xerox C2424 | Service Manual - Page 264
Yellow Solid Fills" on page 5-42. 2. Did this correct the problem? Complete. No Go to Step 2. Replace the drum assembly. Replace the Xaxis motor or electronics module. Follow the instructions on the "On-Site Printhead Troubleshooting Checklist" on page A-7 5-24 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 265
. 2. If necessary, replace the maintenance kit. 3. Did this correct the problem? 4 1. Run service diagnostics to verify the drum Complete. maintenance system is operating correctly. 2. Inspect or replace the following parts: ■ Drum maintenance pivot plate ■ Drum maintenance cam shaft 3. Did this - Xerox C2424 | Service Manual - Page 266
problem? 3 1. Verify the X-axis drive system is correctly assembled and lubricated, see "X-Axis Motor Assembly" on page 8-57 for more information. 2. Did this correct the problem? Complete. No Go to Step 2. Go to Step 3. Replace the x-axis motor assembly. 5-26 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 267
, replace the maintenance kit. 4. Did this correct the problem? 2 1. Check the motion of the X-axis and verify Complete. there is nothing interfering such as a poorly dressed cable or screw. 2. Replace any defective parts. 3. Did this correct the problem? 3 1. Use service diagnostics to run - Xerox C2424 | Service Manual - Page 268
to verify the drum Complete. maintenance cam roller and pivot plate are operating correctly. 2. Did this correct the problem? No Go to Step 2. Go to Step 3. Go to Step 4. Go to Step 5. Replace the pivot plate or drum maintenance cam roller if damaged. 5-28 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 269
one side of the page. 4 1. Use service diagnostics to verify the drum Complete. maintenance cam roller and pivot plate are operating correctly. Replace any defective parts. 2. Did this correct the problem? 5 1. Inspect and clean the maintenance kit wiper Complete. blade. 2. If necessary, replace - Xerox C2424 | Service Manual - Page 270
debris, or damage. 2. Clean or replace defective parts. 3. Did this correct the problem? Complete. 3 1. Run the Remove Print Smears routine from Complete. the system control panel. 2. Did this correct the problem? No Go to Step 2. Go to Step 3. Go to Step 4. 5-30 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 271
4 1. Use service diagnostics to check . Transfix Roller defects show up as light spots in solid fill areas. s2424-077 Step Questions and Actions Yes drum. 2. Clean the drum assembly. 3. Did this correct the problem? No Go to Step 2. Replace the drum assembly. Image-Quality Troubleshooting - Xerox C2424 | Service Manual - Page 272
of the printhead. 2. Redress any faulty wiring. 3. Repair or replace any defective part or interference with the printhead. 4. Did this correct the problem? No Complete. The problem is not with the print engine. Go to Step 3. Replace the X-axis drive. 5-32 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 273
media is supported for this system. Complete. maintenance Complete. kit. 2. Did this correct the problem? Go to Step 4. 4 1. Inspect the transfix components. Replace in the following order: ■ transfix roller ■ transfix cam ■ transfix load arm ■ transfix load module. Image-Quality Troubleshooting - Xerox C2424 | Service Manual - Page 274
Verify the paper preheater temperature using diagnostics. 3. The drum is too cold or too hot. Verify the drum temperature using diagnostics. Ensure that the drum temperature sensor is properly positioned and has no contamination between it and the drum surface. 5-34 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 275
if practical). Then perform a clean/ purge cycle again. There may be a problem in the purge pump assembly or the wiper assembly may not be compliant. Verify that the printer is using Xerox ink. Follow the instructions on the "Printhead Troubleshooting Checklist". 74 75 76 77 78 79 80 Weak jet s2424 - Xerox C2424 | Service Manual - Page 276
can also be caused by color-to-color misregistration. Use service diagnostics to ensure that the printhead and drum thermals are correct. Follow the instructions on the "Printhead Troubleshooting Checklist". < current setpoint s2424-093 Banding s2424-094 5-36 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 277
printhead is producing properly-sized drops of ink and that the drum temperature is not too high. NOTE: This print should be made with the system covers closed and in place. The heat loss without the covers can hide the "too-hot" thermal problem drum temperature sensor. Ensure the printhead drive - Xerox C2424 | Service Manual - Page 278
using the transparency that is supported for this system. Clean or replace the paper release blade. For more information about scratches, see "Scratches or Marks Parallel to the Long Axis of Printing, Particularly with Transparencies" on page 5-19. 9923-117 5-38 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 279
the maintenance kit. 2. If there is ink on the top and bottom margin of the page or ink on the back of the page, it may be caused by the roller remaining down during the print. You may hear an unusual noise if the Transfix Roller stays down and rubs against the drum. Inspect the Drive - Xerox C2424 | Service Manual - Page 280
. As a last resort to fix wrinkling, replace the transfix roller, transfix load module, and transfix load arm. 9: Drum Seal This print is not supported for this system. 10: Manuf. Paper Path These prints are used by manufacturing and engineering only. 9923-119 5-40 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 281
in previous solid ink systems. There is no head-to-drum adjustment possible in this system. If the gap is suspect, check that the printhead is correctly and completely installed. EFGHIJKLMNOPQ EFGHIJKLMNOP EFGHIJKLMNOPQR EFGHIJKLMNOPQ EFGHIJKLMNOP EFGHIJKLMNOP 12: Manuf X-Axis (Scanner) This print - Xerox C2424 | Service Manual - Page 282
the worn load arm assembly. 4. If there are repeating white stripes on the print, there may be a problem with the X-Axis motion, see "White Stripes (Pinstripes)" on page 32. 20: OHP Color Bands This print is used by Manufacturing and Engineering. s2424-098 5-42 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 283
Fills 10x This item enables you to print 10 cyan solid fill prints, 10 magenta solid fill prints, 10 yellow solid fill prints, or 10 black solid fill prints. These prints can be used to determine if the drum or transfix roller have a defect. Drum defects do not move in the X-position print-to-print - Xerox C2424 | Service Manual - Page 284
Evaluate with the following formula: Skew Spec (mm) = 998.4*(width12.5)^(-1.02), where Specification in the Appendix. NOTE: The measurement for skew and margin for Side 1 and Side 2 may not match Check: The media must be supported for the tray. The side and rear guides WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 285
by Manufacturing. 24: Head Roll This print is used by Manufacturing. 25: Head Height This print is drum, transfix roller, and paper path. 29: Oil Bar Chase This print is used by Manufacturing. 30: Purge Efficiency This print is used by Manufacturing and Engineering. Image-Quality Troubleshooting - Xerox C2424 | Service Manual - Page 286
Test Print Examples (Continued) 31: Cleaning (Chase) Page This page is automatically printed following a purge. It is used to flush the jet nozzles of any possible contamination or color mixed jets. It can also be printed on its own. s2424-100 5-46 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 287
Adjustments and Calibrations In this chapter... ■ System Alignments and Adjustments ■ Print Engine Component Home Positions and Indicators ■ Manual DADF to Scanner Calibration ■ Jet Substitution Mode ■ Resetting NVRAM 6 Section - Xerox C2424 | Service Manual - Page 288
procedures that begin on page 8-8. 2. With the swing arm in the unlocked position, remove the K-clip from the drive shaft and remove the left drive gear. If the printhead is installed, it must be tilted back first. Left Idler Gear Left Drive Gear s2424-014 6-2 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 289
way to the bottom of its travel and the gears cannot be rotated any further. Note Rotating the left and right gears together ensures that the wiper stays parallel and does not pop out of the belts. Idler Gears 4. Replace the left drive gear and the KL-clip. s2424-015 Adjustments and Calibrations - Xerox C2424 | Service Manual - Page 290
After servicing the system, manually set the following assemblies to their home position before powering on the system. If the assemblies are not home, gears in the process drive assembly can grind or the system will generate errors. ■ Printhead wiper (bottom of travel) ■ Head tilt gear (disengaged - Xerox C2424 | Service Manual - Page 291
Homing the Head Tilt Gear When the Printhead Is NOT Installed 1. Manually move the tilt gear, located on the inside of the left frame, to its disengaged position. When disengaged, the arrows on the left frame point to each other. Tilt Gear (Disengaged) Tilt Gear (Engaged) s2424-018 Adjustments - Xerox C2424 | Service Manual - Page 292
, manually assist the movement of the printhead. There is an audible click when the gear disengages. Note The hole on the drum maintenance camshaft drive gear should be at the 6:00 position after the rotation. Insert screwdriver and rotate clockwise. s2424-017 6-6 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 293
When the tilt gear is disengaged, the two arrows on the left side of the printer are pointing at each other, see also the illustration on page 6-5. Drum Printhead DM Cam Gear Tilt gear (disengaged) Tilt Gear Adjustments and Calibrations s2424-016 6-7 - Xerox C2424 | Service Manual - Page 294
must align with the arrow on the frame. ■ The hole in the transfix camshaft gear aligns with the hole on the frame. Hole in gear aligns with arrow on frame 6-8 Holes in process drive frame aligns with holes in gears Hole in gear aligns with arrow on frame s2424-019 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 295
, see "Xerox Supplies" on page 9-16 for the part number, or use the page that came with the replacement part. Calibrate the scanner using the Scanner Calibration page that came with your replacement scanner or document feeder. Calibrating the scanner is a two-step process: ■ The first step scans the - Xerox C2424 | Service Manual - Page 296
document feeder. 3. In the menu, select Document Glass Step, and then press the Enter button to scan the calibration page. 4. When the scan 5. Remove the Scanner Calibration page from the platen. 6. Continue with the Document Feeder Steps on page 6-11. 6-10 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 297
is aligned correctly and the paper guides are adjusted to fit against the paper. If the page is misaligned, the calibration procedure fails. 2. In the menu, select Document Feeder Step, and then press the Enter button to scan the calibration page. 3. When the scan completes, check the control panel - Xerox C2424 | Service Manual - Page 298
solved. At the bottom of the page, a Service Mode key summarizes the number of substituted jets for each color. Note The Configuration Page indicates the date when the service mode was entered. The Printer Status Page provides a list of jets in Service Mode. 6-12 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 299
for all jets. Resetting NVRAM Resetting NVRAM returns all the Image Processor Board NVRAM-stored parameters to their factory default values. The print counts and the Adobe firmware serial number are not affected by this reset. You can reset the PostScript NVRAM using the Service Tools Menu or the - Xerox C2424 | Service Manual - Page 300
6-14 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 301
Cleaning and Maintenance In this chapter... ■ Inspection ■ System Self-Maintenance ■ Service Cleaning and Maintenance Procedures ■ Cleaning for Print-Quality Problems ■ Maintenance Kit ■ Lubrication 7 Section - Xerox C2424 | Service Manual - Page 302
or replace the part if damaged or if these problems occur: ■ Dirt, debris or scratches on the platen ■ Document feeder pick rollers or separator pad is damaged or dirty. ■ Clear any foriegn objects or clean dirt or debris from the CVT window on the scanner. 7-2 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 303
. For DADF/Scanner automatic-calibration, see "Scanner and Document Feeder Calibration" on page 2-8. ■ Printhead Maintenance Cycle (Eliminate Light Stripes) ■ Paper Preheater Cleaning (Remove Print Smears) ■ Transfix Roller Oiling ■ Drum Cleaning (Chase Page) Printhead Maintenance Cycle (Eliminate - Xerox C2424 | Service Manual - Page 304
processed the same as a regular print, except that the drum is not oiled and no image is printed on the drum (since an image is already printed on the drum). A chase page is also run during startup/recovery if the system believes that there is ink on the drum. 7-4 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 305
picks occur at the media tray. ■ Persistent paper jams inside the system, DADF, or at the media tray if the rollers are visibly dirty. ■ Wiggly vertical stripes caused by too much oil created by a dirty maintenance kit blade. ■ Most print-quality problems can be corrected by running the cleaning - Xerox C2424 | Service Manual - Page 306
(drum fluid) on top edge of print. Select the automated procedure Remove Print Smears from the control panel. Check the maintenance kit for ink and paper-dust buildup on the wiper blade. Select the automated procedure Remove Print Smears from the control panel. 7-6 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 307
See the jam codes in "3-Digit Jam Codes" on page 3-49. Problem Type Paper-pick or jamming problems tray 1. Paper jamming problems at the front door. Paper jamming problems within the exit path. Paper jamming problems at the exit. Paper-pick or jamming problems at the Optional 525-Sheet Feeder, Tray - Xerox C2424 | Service Manual - Page 308
Sensor With a dry swab, clean any buildup around the drum temperature sensor. You can access the sensor through the opened exit cover. Also make sure the sensor rides evenly on the drum surface. You can remove the sensor, if necessary, to clean under it. 7-8 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 309
the installation instructions included with the maintenance kit. Note The maintenance kit oil poses no known adverse health effects. See the Material Safety Data Sheet at www.xerox.com/office/msds. Waste Tray (PL 1.23) The waste tray collects ink that has been purged from the printhead's ink jets - Xerox C2424 | Service Manual - Page 310
the WorkCentre C2424 system. The grease part number is 006-7997-00. Caution Plastic parts will deteriorate when unspecified grease and chemicals are used, such as WD-40® and Locktite® Threadlocker. To avoid damage, use only the grease specified in the Lubrication section of the Service Manual. 7-10 - Xerox C2424 | Service Manual - Page 311
Service Parts Disassembly In this chapter... ■ Overview ■ General Notes on Disassembly ■ Image Input Terminal (DADF and Scanner) ■ Image Output Terminal (Print Engine) ■ Ink Loader Assembly ■ Back Frame and Printer Stabilizer ■ Imaging ■ Paper Path ■ Motors, Gears, Solenoids, Clutches, and Fans ■ - Xerox C2424 | Service Manual - Page 312
. Standard Orientation of the System When needed, the orientation of the system is called out in the procedure for locating printer parts. Refer to the system orientation graphic for locating the right, left, front and back sides of the printer. s2424-002 8-2 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 313
a screw or a printer part. ■ If using a power driver to install a screw into plastic, start the screw by hand. ■ If you strip out threads in the plastic chassis, a silver-blue-tinted thread repair screw (included in the hardware kit) can be used to correct the problem. ■ If you remove a silver - Xerox C2424 | Service Manual - Page 314
the document feeder from the scanner assembly. 3. Lift straight up on the document feeder to remove. Note You must perform the scanner calibration procedure after replacing the document feeder. "Manual DADF to Scanner Calibration" on page 6-9. 2 1 s2424-240 8-4 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 315
DADF Front Cover (PL 1.13) 1. Remove 3 screws securing the cover. 2. Lift and remove. s2424-241 Service Parts Disassembly 8-5 - Xerox C2424 | Service Manual - Page 316
prior to shipment. Make sure to power down the system when the DADF is closed. When the DADF is open, the platen scanhead is not in the home position and cannot be locked. 1. Remove the document feeder (page 8-4). 2. Disconnect the scanner assembly cable from the print engine. 3. Place the scanhead - Xerox C2424 | Service Manual - Page 317
covers can be done while the document feeder and scanner assemblies are still in place; however, removing the assemblies improves access to other printer components. For all IOT disassembly, the document feeder and scanner assembly are shown removed from the system. Service Parts Disassembly - Xerox C2424 | Service Manual - Page 318
Covers & Ink Loader" is available with instructions for removing the document feeder, scanner assembly, covers, and ink loader. Videos are located on the WorkCentre C2424 Product Training CD-ROM. 1. Disconnect all interface cables, including the power cord. 2. Remove the DADF and scanner assembly - Xerox C2424 | Service Manual - Page 319
2. Pry up on the left and right side of the output tray and the two tabs on the bottom to remove the tray from the system. s2424-244 Service Parts Disassembly 8-9 - Xerox C2424 | Service Manual - Page 320
Tray 1. 2. Disconnect and free the wiring from Tray 1. 3. Carefully remove the front door/tray 1 assembly, by releasing the left hinge pin from the printer frame and sliding the assembly to the right to remove it. Stay Retainer 2 1 Stay Retainer 3 s2424-147 8-10 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 321
of the right side cover. 3. Remove one screw, on the back of the system, securing the right side cover. 4. Using a cover. 5. There are tabs on the inner front side of each side cover that latch to the exit module assembly, release these tabs and remove the cover. Right Cover Latch Service Parts - Xerox C2424 | Service Manual - Page 322
tab securing the back cover. 3. Remove 2 screws securing the EMI shield. 4. Using a flatblade screwdriver, release the tab securing the EMI shield. 5. Slide the EMI shield straight back to remove from the system. EMI Shield Rear Cover Back Frame s2424-263 8-12 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 323
Imaging Ink Loader Assembly (PL 2.1) A video entitled "Replacing Covers & Ink Loader" is available with instructions for removing the ink loader. Videos are located on the WorkCentre C2424 Product Training CD-ROM. 1. Remove the right and left side covers (page 8-10). 2. Ensure the media exit - Xerox C2424 | Service Manual - Page 324
Y-Axis Drum Belt, Y-Axis Tension Spring, and Y-Axis Motor Assembly (Belt PL 2.4) ( Tension Spring PL 2.14) (Motor PL 4.11) 1. Remove the left side cover (page 8-11). 2. Relieve tension on the belt by pulling the end of the spring arm toward the front of the printer using your fingers. 3. While - Xerox C2424 | Service Manual - Page 325
from the printer. 7. Remove 4 screws (three coarse thread and one fine thread) from the spring arm. The three screws securing the arm to the motor remain in place. 20 in-lbs. Y-Axis Motor Assembly s2424-152 Replacement Notes: Note Ensure the spring arm screws are in the right locations and that - Xerox C2424 | Service Manual - Page 326
the document feeder, scanner assembly, output paper tray assembly, right and left side covers, and the ink loader assembly (see page 4 thru page 13). Caution Place several sheets of paper between the printhead and the drum to protect the drum from damage. 2. On the right side of the printer, snap - Xerox C2424 | Service Manual - Page 327
Wiper Assembly Lock Gear Printhead Restraint Printhead Restraint Arm 1 2 Printhead 3 3 Printhead Restraint Printhead Restraint Arm s2424-153 3. Rotate the gears as shown by #2 above to lower the wiper all the way down. Caution When the printhead is parked, it is held in place by pins - Xerox C2424 | Service Manual - Page 328
6. Disconnect the air hose from the purge pump. Purge Pump Bias Spring Hook 1 2 s2424-022 8-18 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 329
-155 Note Adjust printhead position as required to remove the right restraint. Printhead Shaft Roll Block s2424-156 Caution The roll block stays hot 10 to 15 minutes after the printer is shut down. 8. Remove the roll block on the left end of the printhead shaft. Service Parts Disassembly 8-19 - Xerox C2424 | Service Manual - Page 330
Heater Cable Heater Harness Plug s2424-157 10. Lift the printhead out of its mounting position and place the shaft ends in the cradle notches near the top of the chassis frame. Cradle Notches s2424-276 11. Disconnect the data cable from the print head. 8-20 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 331
damage observe the following order when reinstalling the printhead: 1. Ensure that the tilt gear is in the home position (page 6-5). 2. Rest the printhead on the cradle notches provided (see the previous illustration) while reconnecting the cable and ZIF connectors. Service Parts Disassembly 8-21 - Xerox C2424 | Service Manual - Page 332
7009 and 4025 fault codes. Caution Before reinstalling the printhead, move the wiper all the way down. 5. Lower the printhead into its mounts. The printhead should be tilted forward in the print position. 6. Route the air hose through the frame and connect it to the purge pump. 7. Install the Roll - Xerox C2424 | Service Manual - Page 333
and the spring to ensure that you do not damage the drum. 2. Using your hands, a spring hook, or pliers, remove the X-axis bias spring from inside the printer cavity. X-Axis Bias Spring Replacement Note: Note Do not rotate the spring more than 1/4 turn. s2424-158 Service Parts Disassembly 8-23 - Xerox C2424 | Service Manual - Page 334
. 4. While holding the wiper, rotate the small drive gear to lower the left end of the wiper. One end of the wiper will travel down the guide, allowing you to slide the wiper belt off of the wiper clip. KL-Clip Large Drive Gear 8-24 Wiper Clip Wiper Belt s2424-159 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 335
ends are all the way down following reassembly (see "Wiper Alignment" on page 6-2). Note Make sure the metal portion of the blade is nearest the drum and that the plastic clip is attached to the pulley side nearest the drum. Service Parts Disassembly 8-25 - Xerox C2424 | Service Manual - Page 336
Release Blade (Stripper) Carriage Assembly and Transfix Roller (Carriage PL 2.12) (Roller PL 2.13) Videos are available with instructions for replacing the Transfix Roller. Videos are located on the WorkCentre C2424 Product Training CD-ROM. 1. Remove the right side cover (page 8-10). 2. Disconnect - Xerox C2424 | Service Manual - Page 337
inner simplex guide (page 8-44). 3. Release the lock on the back of the AC connector and unplug the AC and sensor flag connectors from the bottom of the preheater. The connectors are located on the backside of the assembly. AC Connector Sensor Flag Connector s2424-269 Service Parts Disassembly - Xerox C2424 | Service Manual - Page 338
by (3). Replacement Note: Note The fingers on the inner simplex guide go over the segmented roller. First snap the left retainer into place, then the right. Note Be sure you do not dislodge the optical sensors while replacing or reconnecting the pre-heater. 8-28 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 339
Roller (PL 3.4) 1. Open the front door. 2. Remove the outer duplex paper guide (with sensors) and the lower inner duplex guide (page 8-44). 3. To allow removal of the duplex roller, remove the left KL right frame during removal. (3). KL-Clip 3 1 2 Bearing s2424-162 Service Parts Disassembly 8-29 - Xerox C2424 | Service Manual - Page 340
instructions for replacing the Transfix Load Module. Videos are located on the WorkCentre C2424 Product Training CD-ROM. 1. Remove the inkloader (page 8-13). 2. Remove the media drive gearbox (page 8-52). 3. Remove the exit module assembly Load Module 8-30 s2424-163 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 341
carriage assembly will be removed as a single part. 9. Remove the clevis pins from the left and right sides, securing the transfix load arms to the chassis. 10. Carefully lift each transfix load arm from the system. Clevis Pin Transfix Load Arm Add Grease s2424-164 Service Parts Disassembly - Xerox C2424 | Service Manual - Page 342
11. Remove the grounding springs from the transfix load module to avoid bending them. Grounding Springs s2424-165 12. Remove 2 screws securing each end of the transfix load module to the chassis. Transfix Load Module 8-32 s2424-166 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 343
After installing the EMA, perform the Wiper Alignment on (page 6-2). The printer may report error code 7,009.4x if the wiper assembly is misaligned. Note When replacing grounding springs on the transfix load module, make sure the springs rest below the camshaft assembly. Service Parts Disassembly - Xerox C2424 | Service Manual - Page 344
(page 8-55). 3. Slide the shaft to the right (1) and make sure the bearing slides over to the gear, move the shaft down and slightly to the right (2) and then up and to the left (3) to remove it from the printer chassis. Transfix Camshaft 2 1 3 s2424-168 8-34 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 345
toward the rear of the printer, lift the shaft through the slot, and pull it out to the right through the large hole. Drum Maintenance Camshaft Bushing s2424-169 Replacement Notes: Note Be sure to replace the KL-clips on the outside groves of the camshaft. Service Parts Disassembly 8-35 - Xerox C2424 | Service Manual - Page 346
Drum Maintenance Pivot Plate Assembly (PL 2.16) 1. Remove the drum maintenance kit (page 9-5). 2. Remove both the right and left side covers (page the cable into the printer while sliding the drum maintenance pivot plate out the drum maintenance drawer cavity. Metal WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 347
available with instructions for replacing the Drum Assembly. Videos are located on the WorkCentre C2424 Product training CD-ROM. 1. Remove the DADF, scanner assembly, output tray assembly, left and right side covers and the ink loader (see page 4 thru page 13). 2. Ensure that the printhead is in - Xerox C2424 | Service Manual - Page 348
. 1. Gently seat the drum assembly into the chassis. 2. Align the screw holes in the left and right labyrinth seals to holes in the chassis sides. 3. Install 1 screw at the rear position to hold the left labyrinth seal and torque the screw to 25 in.-lbs. 8-38 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 349
in.-lbs. 14. Pull the lower end of the Y-axis spring arm toward the front of the printer and install the Y-axis belt first on the motor pulley and then on the drum pulley. (It is not necessary to align the belt on the drum pulley.) Ensure that the grooves of the belt align in the grooves of - Xerox C2424 | Service Manual - Page 350
gearbox. 22. Reinstall the drum fan assembly and secure it with 3 lower inner duplex guide on the 4 mounting pins on the chassis. 24. Install the ink loader assembly (page 8-13). 25. Reinstall all covers and doors. 26. Reinstall the DADF and Scanner assemblies. 8-40 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 351
Pump (PL 2.7) 1. Remove the left cover (page 8-11). 2. Disconnect the air hose from the purge pressure pump. 3. Disconnect the wiring harness from the purge pressure pump. 4. Remove 3 screws and remove the purge pressure pump. Purge Pressure Pump Air Hose Service Parts Disassembly s2424-023 8-41 - Xerox C2424 | Service Manual - Page 352
Paper Path Exit Module Assembly (MEP) (PL 3.7) 1. Remove the DADF, scanner assembly, side covers, and inkloader, pages 4 thru page 13. s2424-219 2. Right side instructions ■ Remove right front screw. ■ Remove the pulley and belt from the elevator roller to access and remove the right rear screw. ■ - Xerox C2424 | Service Manual - Page 353
remove the left front screw (see illustration above). ■ Remove the left rear and side screws. ■ Disconnect the following connectors: back frame, paper full sensor, IIT (scanner) closed sensor, lift motor, and the connector to the MEP elevator. Service Parts Disassembly s2424-271 8-43 - Xerox C2424 | Service Manual - Page 354
of the mounting boss and remove the guide. Lower Exit-Guide Assembly with Strip Flag (PL 3.13) 1. Open the exit cover. 2. Lift upward on the center of the guide, then flex the left retainer inward to remove it. 3. Remove the right retainer and remove the guide. 8-44 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 355
s2424-274 Upper Duplex Guide with Solenoid (PL 3.5) 1. Remove the right side cover (page 8-11). 2. Remove the outer duplex paper guide (see instructions above). 3. Disconnect the solenoid connector from the I/O board and remove the harness from the right side frame. Service Parts Disassembly 8-45 - Xerox C2424 | Service Manual - Page 356
4. Remove the upper duplex guide from the printer. Hole for Solenoid Lever Solenoid Lever Upper Duplex Guide 8-46 s2424-275 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 357
Route the solenoid harness through the right side frame when replacing the upper duplex guide. Also, you must route the guide under the edges of the exit module assembly (EMA) frame. Note Verify that the solenoid lever engages the hole in the Paper Release Guide. Service Parts Disassembly 8-47 - Xerox C2424 | Service Manual - Page 358
Take Away Roller (PL 3.3) 1. Remove the left and right side covers from the printer (page 8-11). 2. Remove the media drive gearbox (page 8-52). 3. Remove the lower simplex guide (page 8-44). 4. Remove the KL-clip from the right end of the shaft. 5. Remove the KL-clip and bushing from the left end of - Xerox C2424 | Service Manual - Page 359
Pick Assembly (PL 3.18) 1. Remove Tray 2 from the system. 2. Reach into the tray cavity and release the light-colored catch holding the pick roller in place. Note The catch is located on you replace the pick assembly. This roller is located in the Tray 2 media tray. Service Parts Disassembly 8-49 - Xerox C2424 | Service Manual - Page 360
be facing you. Position the roller back about 2 inches (5 cm.) in the tray cavity, feel for a large plastic clip on the right and the mating gear for the pick assembly on the left. Rotate the pick assembly up and back to latch it in place. 2 1 1 2 s2424-177 8-50 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 361
the media tray lift motor to the printer frame. 7. Remove the media tray lift motor from the outside of the printer. Lift Motor Gear Push Nut s2424-179 Replacement Note: a 3/8 in. nut driver (approx.) over the nut and press firmly to seat the nut on the shaft. Service Parts Disassembly 8-51 - Xerox C2424 | Service Manual - Page 362
Gears, Solenoids, Clutches, and Fans Media Drive Gearbox with Two Clutches and Solenoid (PL 4.14) Videos are available with instructions for replacing the media drive gearbox. Videos are located on the WorkCentre C2424 Product training CD-ROM. 1. Remove the output paper tray and left side cover - Xerox C2424 | Service Manual - Page 363
media drive gearbox, first remove the paper tray. Rotate the pick roller shaft until the pick clutch seats, and then work upwards, rotating the duplex feed rollers until the other shafts seat. Ensure that the media drive gearbox is correctly positioned on the side frame. Service Parts Disassembly - Xerox C2424 | Service Manual - Page 364
Tray 1 (MPT) Pick Solenoid (PL 4.12) 1. Remove the left side cover (page 8-11). 2. Disconnect the solenoid cable. 3. Remove 1 screw from the solenoid, and remove the solenoid from the media drive gearbox. Tray 1 Pick Solenoid s2424-181 8-54 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 365
Motor and Gearbox (PL 4.7) Videos are available with instructions for replacing the process drive motor and gearbox. Videos are located on the WorkCentre C2424 Product Training CD-ROM. 1. Remove the right side cover (page 8-10). 2. Disconnect the drum heater wiring harness from the relay board to - Xerox C2424 | Service Manual - Page 366
gears in the correctly aligned and "pinned" positions, the printer will not function correctly and could be damaged. Note Ensure that the drum heater harness, Y-axis encoder harness, and the drum fan harness are replaced in the cable restraint on the gearbox. 8-56 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 367
X-Axis Motor Assembly (PL 4.5) 1. Remove the right side cover (page 8-11). 2. Disconnect the wiring harness. 3. Remove 4 screws securing the motor to the chassis and remove the motor out from the side of the cone nut on the motor shaft, is engaged with the side rail. Service Parts Disassembly 8-57 - Xerox C2424 | Service Manual - Page 368
s2424-185 Replacement Notes: Note On reassembly, the leaf spring on the back side of the chassis must be behind the gear to engage. Note On reassembly, lubricate the curved (cam) surfaces of the gear using a small quantity of Rheolube 768 grease (P/N 00679900). 8-58 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 369
the rear cover and EMI shield (page 8-12). 5. Disconnect all wiring cables to the power supply board. 6. Remove 4 short screws connecting the scanner supply board to the back frame. 7. List and remove the scanner power supply. Scanner Assembly Power Supply Board Service Parts Disassembly s2424 - Xerox C2424 | Service Manual - Page 370
tray (page 8-8). 3. Remove the left and right side covers (page 8-11). 4. Remove the rear cover and EMI shield (page 8-12). 5. Disconnect all wiring to the exit module board. 6. Remove 2 screws securing the board to the back frame. Exit Module Board 8-60 s2424-212 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 371
the DADF and scanner assemblies (page 8-4). 2. Remove the output tray (page 8-8). 3. Remove the left and right side covers (page 8-11). 4. Remove the ink loader assembly (page 8-13). 5. Disconnect the 3 wiring harnesses from the top of the electronics module. 6. Disconnect the 2 printhead cables - Xerox C2424 | Service Manual - Page 372
11. Remove the electronics module. Electronics Module s2424-186 Replacement Note: Note When replacing the electronics module, transfer the Configuration Card, NVRAM, SODIMM RAM, and hard drive to the new module. 8-62 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 373
Frame and Printer Stabilizer ( Stabilizer PL 3.14) (Backframe PL 5.24) Caution If replacing a back frame, perform the following procedure on a flat surface. 1. Remove the DADF and scanner assemblies (page 8-4). 2. Remove the output tray (page 8-8). 3. Remove the left and right side covers (page 8-11 - Xerox C2424 | Service Manual - Page 374
Back Frame s2424-214 8-64 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 375
ZIF connectors on the wave amp and printhead. If the cables are inserted incorrectly, they can damage the wave amp Board. Route the ribbon cables carefully through the slots. Ensure that the T-shaped strain relief on the cable is nearest the wave amp on installation. Service Parts Disassembly 8-65 - Xerox C2424 | Service Manual - Page 376
8-10). 2. Disconnect the wires to the I/O Board. 3. Remove 2 screws attaching the I/O Board to the printer. 4. Remove the I/O Board. I/O Board Ground Tab s2424-027 Replacement Note: Note Ensure the corner of the board is behind the ground tab on reassembly. 8-66 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 377
5.19) Warning This is an AC board, shut off power to the printer and disconnect the power cord before starting this procedure. 1. Remove the right side cover (page 8-10). 2. Disconnect 3 wires to the drum heater relay board. 3. Remove the 2 screws securing the drum heater relay board to the system - Xerox C2424 | Service Manual - Page 378
the system, either download the snippet titled "setsn.ps" from infoSMART or get it from the Product Training CD-ROM. 5. Edit the snippet to include the printer serial number, using a text editor. 6. Download the edited file to the printer using an FTP program. 8-68 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 379
Parts Lists In this chapter... ■ Serial Number Format ■ Using the Parts List ■ Xerox Supplies 9 Section - Xerox C2424 | Service Manual - Page 380
Xerox products are made to accommodate improved components as they become available. It is important when ordering parts to include the following information: ■ Component's part number ■ Product type or model number ■ Serial number of the printer = Serial number 9-2 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 381
used to order specific parts. 3. Qty: This number represents the parts per printer, not the number of parts supplied in the actual part order. 4. Name/Description: Details the name of the part to be ordered and the number of parts supplied per order. 5. Parts identified throughout this manual are - Xerox C2424 | Service Manual - Page 382
Covers PL 1.11 (With 8-12) 12 11 10 9 8 7 13 14 15 PL 1.15 (With 13-19) 16 17 19 18 20 21 6 2 3 5 22 2 4 23 3 25 24 4 1 26 s2424-149 9-4 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 383
802K87660 DADF Upper Cover 1 802K87820 Duplex Automatic Document Feeder Assembly (includes 1 PL 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19) DADF Input Tray 1 DADF Pick Roller and Pad Kit 1 004K07270 050K59960 604K30540 Separator Pad (part of PL 1.17) 1 DADF Hinge Rear Cover 1 003K19520 - Xerox C2424 | Service Manual - Page 384
Imaging 1 2 4 3 5 19 18 20 6 7 12 21 8 13 14 15 16 17 11 10 9 18 s2424-193 9-6 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 385
16 17 18 19 20 21 Name/Description Ink Loader Assembly and Door Printhead Assembly Drum Assembly Belt, Y-Axis Drum Printhead Wiper Belt, Wiper Drive Purge Pressure Pump Left Printhead Restraint Right Printhead Restraint Transfix Camshaft Assembly Drum Maintenance Camshaft Assembly Stripper Carriage - Xerox C2424 | Service Manual - Page 386
Paper Path 8 7 10 11 6 5 9 8 10 11 13 12 4 3 2 14 1 15 19 18 16 17 s2424-194 9-8 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 387
, MEP (Exit Module) Belt, MEP (Exit Module) Roller, Idler, Exit Lower Exit Guide Assembly Printer Stabilizer 525-Sheet Feeder (HCF) Stabilizer 525-Sheet Feeder (HCF) with Tray 525-Sheet Tray, Adjustable to Legal Pick Assembly and Retard Roller Kit Separator Pad Kit Qty Part Number 1 351111480 - Xerox C2424 | Service Manual - Page 388
Motors, Gears, Solenoids, Clutches, Sensors, Fans and Backframe 1 2 15 14 12 10 11 9 10 3 13 7 8 4 5 6 s2424-195 9-10 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 389
ASM, Motor (DADF) DADF Belt Kit Fan, (Scanner) Power Supply, Cooling Electric Clutch, Wiper X-Axis Motor Assembly Drum Cooling Fan Gearbox and Motor, Process Drive MEP (Drive) Motor MEP (Elevator) Motor Tray Lift Motor Kit Motor Assembly, Y-Axis (Drive) Pick Solenoid, Tray 1 Compound Gear, Head Tilt - Xerox C2424 | Service Manual - Page 390
Electronics Module, Circuit Boards and Cables 1 2 24 23 21 22 20 9-12 6 5 3 4 7 8 11 12 13 19 17 18 9 10 14 15 16 s2424-196 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 391
12 13 14 15 16 17 18 19 20 21 22 23 24 Name/Description PCBA, Malibu MEP (Exit Module Board) Power Supply, Scanner Cable, Wave Amp Signal Wave Amp Board Electronics Module Stripped (no RAM, NVRAM, or Configuration Card) Cable, Printhead Interface Hard Drive Assembly 256 MB SDRAM 512 MB SDRAM 8-pin - Xerox C2424 | Service Manual - Page 392
Sensors and Flags (Actuators) 1 2 3 4 5 11 10 9 8 7 6 s2424-197 9-14 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 393
Switch (Mech) Engine Exit Flag Drum Temperature Sensor Assembly Exit Module (MEP) Sensor Assembly Waste Tray Sensor (optical) Sensor Assembly, Paper Tray Optical Sensor (Generic Snap-In) Paper Present Flag Paper Full Sensor Kit Flag, MEP (Exit Module) Qty Part Number 1 960K20680 1 119645580 - Xerox C2424 | Service Manual - Page 394
Xerox Supplies Miscellaneous Kits, Supplies, and Options Description Part Number Mechanical Kit -C2424 (Hardware) DADF/Scanner Hinge screws - M4x12 - 5 each Scanner PS & MEP Board screws - M4x6 5 each Backframe Cable Clamps - 2 each MEP KL clips - 5mm - 5 each MEP Plastic washers - 2 each - Xerox C2424 | Service Manual - Page 395
-Capacity Maintenance Kit, WorkCentre C2424 Genuine Xerox Solid Ink 8400 Black (3 sticks) Genuine Xerox Solid Ink 8400 Cyan (3 sticks) Genuine Xerox Solid Ink 8400 Magenta (3 sticks) Genuine Xerox Solid Ink 8400 Yellow (3 sticks) Genuine Xerox Solid Ink 8400 Black (6 sticks) Rainbow Pack (1 Cyan - Xerox C2424 | Service Manual - Page 396
Dutch Overlay Kit, Swedish Overlay Kit, Brazilian-Portuguese Overlay Kit, Russian Service Manual Software CD-ROM User Documentation CD-ROM Part Number 650K24020 650K24030 650K24040 650K24050 650K24060 650K24070 650K24080 650K24300 604E13990 063346900 063346800 9-18 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 397
Wiring Diagrams In this chapter... ■ Scanner/DADF Functional Diagrams ■ Main Block Wiring Diagram ■ Right-Side Wiring Diagram ■ Left-Side Wiring Diagram ■ Inside Front Wiring Diagram ■ Inside Top Wiring Diagram ■ Electronics Module 10 Section - Xerox C2424 | Service Manual - Page 398
Sensor MEP Drive Motor MEP Elevator Motor Waste tray sensor (3) Paper height opto (3) Pick sense opto (3) Paper out opto (3) Pick Clutch (2) Printhead driver ECB Media Tray Sense ECB P/J No. J790 (14) J160 (6) J910 (10) J400 (10) J3AC J2 CN1 J3 J4 J180 (26) J1 10-2 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 399
No. Printhead driver ECB Power Supply ECB Relay ECB Inkload ECB Printhead driver ECB Printhead driver ECB I/O ECB Power Control ECB Power Supply ECB Main ECB Hard Drive ECB Main ECB Power Control ECB Power Supply ECB I/O ECB Power Control ECB (16) Power Control ECB Power Supply ECB Hard Drive ECB - Xerox C2424 | Service Manual - Page 400
Power Supply ECB Media Present (MPT) sensors (5) Printhead driver ECB Printhead driver ECB Strip/Exit Bib opto (6) Power HM clutch (2 Wave Amp ECB I/O ECB Paper pre-heater Hard Drive ECB Ethernet RCV/XMT ribbon cable I/O ECB Maintenance kit missing sensor (2) Hard Drive ECB Drum print thermister - Xerox C2424 | Service Manual - Page 401
Amp s2424-255 Document Feeder Timing Synchronization Scanner Integrated ASIC and Line Drivers Cmd/ Status Video Scanner Integrated ASIC and Line Drivers Scanner Scanner Control Panel Cmd/ Status Video FP Interface Scanner / Exit Module Power Supply 24V 5V PS Enable Scanner Interface FPGA - Xerox C2424 | Service Manual - Page 402
Paper Full Sensor Exit Cover Sensor Power Supply 120VAC Scanner Power J1 Supply JP22 +24VDC +5VDC JP22 JP22 Cooling Fan MEP Board CN2 CN1 +24VDC CN1 +5VDC CN4 Scanner Bridge Board J1/J2 J3 IIT Sensor MEP Elevator Motor MEP Drive Motor System Front Panel Printhead Driver ECB 660-0004 - Xerox C2424 | Service Manual - Page 403
3 JDC1 J3AC Power Supply ECB Rev. F 7 AC J2AC (in Electronics 3 Module) Generates: ±50V ±12V Unreg 4 +3.3V J4AC J1AC 5 4 Printhead AC Resv. Heaters (2) AC Jetstack Heaters (2) Drum Heater Series/Parallel Heater 2 J2 3 J3 3 Relay ECB 660-0019-03 J1 Printer Ambient Temperature 2 J280 - Xerox C2424 | Service Manual - Page 404
Sensors To Left Side Wiring Harness +24 Volts MEP Serial Communication +5 +24V Serial-In AC Main Scanner Assembly Ground Wire Power Supply Board MEP Sensors Exit Module Board Motor Power +5 +24V Out (Elevator/Drive on MEP) +5V LED +24V LED 10-8 s2424-277 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 405
-Through J680 13067.4x MEP Drive Motor J250 37020.4x Strip Solenoid J910 13387.4 J400 Drum Heater J110 Waste Tray Ground Clip J600 Add Paper Tray J610 No Handfeed 37006.4x Drum Heater 37016.4x HM Clutch Wiring Harness Pass-Through J870 13067.4x J860 Maintenance Kit Missing J840 Dead Power Ground - Xerox C2424 | Service Manual - Page 406
) The lines indicate which connectors you should look at for the Pest codes. The Pest codes are displayed on the control panel. Signal Cable (Routes to Bottom of Channel) 13387.4x J4AC 37006.4x 37027.4x X-Motor J800 Dead Power J480 37027.4x s2424-201 10-10 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 407
The lines indicate which connectors you should look at for the Pest codes. The Pest codes are displayed on the control panel. To Scanner Power Supply 37023.4x Purge Valve 37022.4x Purge Motor J280 37032.4x Y-Motor J790 37062.4x Head VSS J390 37034.4x MP Motor 37021.4x MT Elevator 37013.4x - Xerox C2424 | Service Manual - Page 408
The Pest codes are displayed on the control panel. Exit Module Sensor Assembly MEP Elevator Motor 37034.3x MP Motor IIT Sensor Paper Full Sensor Exit Cover Sensor 37017.4x Deskew Clutch Ground Clip 37018.4x Pick Clutch 37019.4x Pick Solenoid s2424-203 10-12 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 409
Front Wiring Diagram The lines indicate which connectors you should look at for the Pest codes. The Pest codes are displayed on the control panel. 37036.4x Process Motor 37008.4x Preheat Power (AC Connector) Paper Jam Load Paper (Open Front Cover) J860 13131.41 Sensor Flag s2424-204 10-13 - Xerox C2424 | Service Manual - Page 410
at for the Pest codes. The Pest codes are displayed on the control panel. 37010.4x Ink 1 Heater J2AC 37002.4x JSL Heater J1AC 37009.4x (Ink Load Power) J180 34062.4x (Data Cable) +24 Volts To MEP Board Door Sensors MEP Serial Communication s2424-205 10-14 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 411
Inside Top Wiring Diagram (continued) The lines indicate which connectors you should look at for the Pest codes. The Pest codes are displayed on the control panel. Cable Restraint Out of Ink J180 32064.4x Heater Cable J110 37062.4x Head VSS J140 37063.4x Head VPP s2424-206 10-15 - Xerox C2424 | Service Manual - Page 412
Right Umbilical Power Cable Y Axis Motor Left Umbilical Connector Wave Amp Data Exit Module Serial Port Door Sensors Data Cable +24 Volt (from Scanner Assembly Power Supply to IIT Connector) Ink Load Power Connector Heater Cable Connector s2424-218 10-16 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 413
Appendix Contents... ■ Control Panel Menu Map ■ Media Margin Specification Table ■ Paper Weight Equivalence Table ■ On-Site Printhead Troubleshooting Checklist A Appendix - Xerox C2424 | Service Manual - Page 414
or menu. Scan Menu: Scan file capacity on the hard drive. Copy Ready to Scan 25% Full Print Scan Scan To... Scan Resolution... Scanning Guide Original Size... Public Folder 300x300 Tray/Auto System Setup Ready to Scan Scan To Destinations on C2424 or PC. Scan Resolution Scanning Guide - Xerox C2424 | Service Manual - Page 415
Sample Pages Supplies Info Billing Meters (continued) Print System Setup Maintenance Kit Life Total Print Count Serial # Total Impressions Color Impressions Black Impressions Troubleshooting Help Guide Paper Jams Print Quality Problems Network Log Pages Service Tools Model Printer Name Print - Xerox C2424 | Service Manual - Page 416
Original Type Paper Supply Reduce/Enlarge Lighten/Darken Auto Suppression Contrast Color Balance Reset Copy Defaults Setup Paper Handling Setup PostScript Setup PCL Setup Use when installing a Windows printer driver. Shutdown Power Saver (Recommended) Restart System Power Down To minimize - Xerox C2424 | Service Manual - Page 417
Media Margin Specification Table Media Size Width (mm) Legal 215.9 Folio 215.9 A4 210 A 215.9 Executive 184.15 B5 JIS 182 B5 ISO 176 #10 Envelope 104.775 - Xerox C2424 | Service Manual - Page 418
97 105 110 113 120 135 US Tag Weight (lb.) 37 39 46 49 55 61 65 68 74 83 91 92 100 104 108 117 122 125 133 150 Metric Weight (g/m2) 60 64 75 80 90 100 105 110 120 135 148 150 163 170 176 190 199 203 216 244 A-6 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 419
On-Site Printhead Troubleshooting Checklist PRINTHEAD TROUBLESHOOTING CHECKLIST Phaser 8400/WorkCentre C2424 Version 1.1 IMPORTANT! This checklist outlines proper printhead troubleshooting procedures. All Xerox service employees and any other service personnel on any job involving a printhead - Xerox C2424 | Service Manual - Page 420
Usage Profile. It is located in the front panel menu Troubleshooting - Service Tools. Does the printer display an error code indicating a problem with the printhead? YES NO Circle one If Line 631 Printhead ID lists a date, record the date (month day year) here: Printhead ID: 00-09 10-29 30 - Xerox C2424 | Service Manual - Page 421
by downloading the appropriate snippet (such as 8400_jetfix_c.ps for a missing cyan jet) to the printer. The snippets are available on the Customer Support Resources website in the Phaser 8400 web pages. Refer to Service Bulletin 640. x If the jet is still missing, replace the printhead. The - Xerox C2424 | Service Manual - Page 422
printheads replace because of an error code) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 9923-114 Xerox Phaser 8400 Printhead Checklist - Version 1.1 075-0882-01 Page 4 A-10 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 423
basic inspection, 7-2 belts tension, check menu, 4-43 wiper drive, parts list (imaging), 9-7 y-axis drum, parts list (imaging), 9-7 BIST Error Codes, 3-3 C cable, right umbilical, 9-13 calibration faults, 3-33, 3-35 calibration page, 6-10 camshaft assembly, 2-23 center image, service menu, 4-3 chase - Xerox C2424 | Service Manual - Page 424
parts list (covers), 9-5 doc handler menu, diagnostics, 4-6 document feeder Document Feeder Step, 6-11 guidelines, 1-17 scanner platen steps, 6-10 dot size variations, 5-39 down arrow button, 1-10 drift compensation, service menu, 4-3 drop mass evaluation, 5-36 drum assembly instructions, 8-37 parts - Xerox C2424 | Service Manual - Page 425
connection problems, 4-73 ground connection terminal, 1-iii grounding, 4-73 guidelines document feeder, 1-17 media, 1-16 operating safety, 1-vi H hard drive, 2-12 hard drive assembly, parts list (circuit boards), 9-13 head adjust, service menu, 4-3 head cal date, service menu, 4-3 head maintenance - Xerox C2424 | Service Manual - Page 426
), 9-9 lower inner duplex guide parts list (paper path), 9-9 removal, 8-44 removing duplex roller, 8-29 M main board, 2-11 maintenance kit, 6-6, 7-9 maintenance kit, parts list (covers), 9-5 manual terminology, 1-ii Manual Terms, 1-ii media storage, 1-19 supported, 1-17 unsupported, 1-20 media drive - Xerox C2424 | Service Manual - Page 427
storage, 1-19 supported papers, transparencies, and other media, 1-17 paper full sensor, 8-43 paper full sensor kit, parts list (sensors), 9-15 paper path document feeder, 2-6 problems, 4-76 sensors, check menu, 4-48 paper pick errors troubleshooting, 4-76 paper pick process, 2-18 paper preheater - Xerox C2424 | Service Manual - Page 428
assembly (paper tray), parts list, 9-15 sensors, 2-12 separator pad consumables, 1-7 kit, parts list, 9-9 parts list (covers), 9-5 Service Safety Summary, 1-viii service usage profile, service menu, 4-3 silicone oil, 2-37 skew problems, 5-44 skew specifications, 1-20 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 429
list (covers), 9-5 Smudges or smears, 5-14 SODIMM RAM, 8-62 Software and Documentation, 9-17 solid fill problems, 5-40 spring arm, 8-14 start button, 1-11 startup maintenance kit, 1-7 startup page, service menu, 4-2 status indicator LED, 1-10 status page, 4-2 stop button, 1-11 storing media, 1-19 - Xerox C2424 | Service Manual - Page 430
, parts list, 9-7 X-axis faults, 3-15, 3-16 Y y-axis belt removal, 8-14 drive, 4-42 faults, 3-14 motor assembly, parts list, 9-11 motor cable, parts list, 9-13 motor, check menu, 4-45 rotating, check menu, 4-38 tension spring, 8-14 tension spring, parts list, 9-7 WorkCentre C2424 Service Manual - Xerox C2424 | Service Manual - Page 431
- Xerox C2424 | Service Manual - Page 432
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WorkCentre
®
C2424
copier-printer
Service
Manual