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WorkCentre

C2424

Copier-Printer

Service Manual

arn

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 Printing: March 2005

Part Number: 604E13990

Main Page

Organization of this Manual5
General Safety7
Electrostatic Discharge (ESD) Precautions11
Service Safety Summary12
Regulatory Specifications14
Table of Contents17
General Information25
System Introduction and Overview26
System Features and Configurations27
Standard Configurations27
Front View28
Open View28
Side View with System Interfaces29
Back View29
Electronics Module30
Routine Maintenance Items and Consumables Life Expectancy31
Control Panel Layout32
Menu Map35
System Specifications36
Physical Dimensions and Clearances36
Print Engine (IOT) Functional Specifications37
System Electrical Specifications38
System Environmental Specifications38
Scanner/Dadf (IIT) Specifications38
Tray and Media Specifications40
Duplex Automatic Document Feeder Guidelines41
Supported Envelopes43
Media Storage Guidelines43
Media that May Damage the System44
Theory of Operation45
System Overview46
System Summaries46
Image Input Terminal (IIT)47
Major Components of the DADF and Scanner47
Document Feeder Functions48
Document Feeder Paper Path and Imaging50
Scanner Assembly Functions51
Scanner and Document Feeder Calibration52
System Electronics54
Exit Module (MEP) Board55
Scanner Power Supply55
Electronics Module55
Image Output Terminal (IOT) Sub-Assemblies59
Paper Path and Paper Pick62
Paper Pick for Tray 162
Paper Pick for Trays 2 - 463
2-Sided (Duplex) Printing64
Sensor Locations65
System Motors, Solenoids, and Drive66
Process Drive67
Media Path Drive68
The Print Process69
Drum Preparation70
Ink Loader71
Printhead72
Drum Assembly78
Transfix System80
Drum Maintenance System81
Purge System82
Transfixing and Exiting84
Transfix and Print Speeds88
Configuration Card Personality Parameters89
Error Messages and Codes93
Introduction94
Power-Up Error Messages and LED Codes95
BIST Error Reporting95
POST Error Reporting96
PEST Error Reporting99
Fault Code Error Message Troubleshooting100
Fault Code Error Reporting100
Interpreting Fault Codes100
1,000.4X Error - 525-Sheet Feeder Faults101
2,0Xx.4X Error - I/O Circuit Board Fault102
3,0Xx.6X - IPC Program Faults102
4,0Xx.4X Errors - Process Control System Fault103
5,0Xx.4X Errors - Y-Axis Sub-System Fault106
6,0Xx.4X Errors - X-Axis Fault107
7,0Xx.4X Errors - Process Motor Gearbox Faults108
8,0Xx.XX Error - Wiper/Media Path Gearbox Faults112
9,0Xx.XX Errors - Ink Loader Faults114
11,0Xx.XX Errors - Electronics Module Interface Fault115
13,0Xx.XX Errors - Thermal Faults116
19,0Xx.XX Errors - Printhead Calibration Faults125
31,0Xx.4X Errors - Mechanical Initialization Jam126
33,0Xx.XX Errors - Tray Manager Device Faults127
34,0Xx.XX Errors - Printhead NVRAM Faults127
36,000.40 Errors - Drum Maintenance Faults128
37,0Xx.XX Errors - PEST Faults129
39,0Xx.XX Errors - Document Feeder / Scanner Unit Faults138
3-Digit Jam Codes141
Jam Code Definition Table142
General Troubleshooting159
Introduction160
Hidden Service Menu160
Service Diagnostics162
Service Diagnostics Menu Functions162
Entering Service Diagnostics163
Service Diagnostic Menu Definition Tables164
Check Menu / Activators Definition Tables173
Check / Activators Menu173
Check Shafts Menu176
Check Fans Menu182
Check Heaters Menu183
Check Paper Path Menu185
Check Drive Menu193
Check Drum Menu198
Check Misc Menu206
System Power-Up Sequence212
Mechanical Initialization of the Print Engine213
Head Cleaning Cycle Performance215
Electrical Troubleshooting216
Electronics Module216
Document Feeder Lamp Does Not Turn on217
Document Feeder Does Not Feed Media217
Scanner Scanhead Does Not Move218
Scanhead Motion Is Not Smooth and Continuous218
Scanner Lamp Does Not Turn on218
Control Panel Is Malfunctioning218
Exit Module (MEP) Is Malfunctioning220
System Fails to Power-Up220
System Energy Star Mode Troubleshooting222
System Reports Missing Maintenance Kit223
System Reports Missing Waste Tray223
System Features Not Available223
525-Sheet Feeder Does Not Function224
Non-Specific Electronics Failure225
Verifying Scanner Power Supply Operation228
Verifying Power Supply Operation - Print Engine229
Measuring AC Power Supply Voltages230
Measuring DC Power Supply Voltages231
Ensuring Ground Integrity231
Testing Motor and Solenoid Resistances233
Paper Path and Media-Based Problems234
Media-Based Problems234
Checking the Process and Media Path Drive236
Operating System and Application Problems237
Testing Communications Ports237
Network Problems239
Obtaining Serial Back Channel Trace240
Image-Quality Troubleshooting241
Image-Quality Problems Overview242
Service Technician RIP Procedure243
Isolating a Copy/Scan Malfunction to the Scanner/Dadf243
DADF Image-Quality Problems244
Dark Streaks on the Copied Image244
Skewed Copy Image245
Copy Image Is Lighter/Darker than the Original245
Fuzzy Text/Image246
Copied Image Colors Do Not Match the Original247
Scanner Image Quality Problems248
Dark Streaks on the Copied Image248
Copied Image Is Skewed248
Copied Image Is Lighter/Darker than the Original248
Copy Image Colors Do Not Match the Original249
Fuzzy Text/Image250
Diagnosing IOT (Print Engine) Print-Quality Problems251
Random Light Stripes252
Predominate Light Stripes253
Smudges or Smears254
The Printed Image Is too Light or too Dark255
No Image Is Being Printed255
Color Is Uneven or Color Is Wrong256
Streaks or Lines down the Print257
Scratches or Marks Parallel to the Long Axis of Printing, Particularly with Transparencies259
There Is Ink on the White Portion of the Printed Page261
Fuzzy Text262
Poor Primary Color Fills264
Ghosting265
Poor Small Text Resolution266
Vertical Lines Appear Wavy267
Oil Streaks on Print268
Incomplete Image Transfer to Paper269
Ink Smears on First Printed Side of Duplex Print270
Repeating Print Defects on Print271
White Stripes (Pinstripes)272
Wrinkling273
Image Is Offset or Cut-Off274
Poor Ink Adhesion, Poor Image Durability274
Analyzing Service Test Prints275
Test Print Examples275
Adjustments and Calibrations287
System Alignments and Adjustments288
Wiper Alignment288
Print Engine Component Home Positions and Indicators290
Homing the Printhead Wiper290
Homing the Head Tilt Gear291
Homing the Process Gear Drive Train294
Manual DADF to Scanner Calibration295
Jet Substitution Mode298
Resetting NVRAM299
Cleaning and Maintenance301
Inspection302
System Self-Maintenance303
Printhead Maintenance Cycle (Eliminate Light Stripes)303
Paper Preheater Cleaning (Remove Print Smears)304
Transfix Roller Oiling304
Drum Cleaning - Chase Page304
Service Cleaning and Maintenance Procedures305
Cleaning for Print-Quality Problems306
Media Jams and Paper Pick Cleaning Procedures307
Pick Roller Cleaning Methods307
Cleaning the Drum Temperature Sensor308
Maintenance Kit309
Waste Tray309
Lubrication310
Service Parts Disassembly311
Overview312
Standard Orientation of the System312
General Notes on Disassembly313
Image Input Terminal (DADF and Scanner)314
Duplex Automatic Document Feeder314
DADF Front Cover315
Scanner Assembly316
Control Panel317
Image Output Terminal (Print Engine)317
Covers318
Output Paper Tray Assembly318
Front Door / Tray 1 Assembly320
Right and Left Side Covers321
Rear Cover and EMI Shield322
Imaging323
Ink Loader Assembly323
Y-Axis Drum Belt, Y-Axis Tension Spring, and Y-Axis Motor Assembly324
Printhead Assembly, Right and Left Printhead Restraints326
X-Axis Bias Spring333
Printhead Wiper334
Media Release Blade (Stripper) Carriage Assembly336
And Transfix Roller336
Paper Preheater and Deskew Assembly337
Duplex Roller339
Transfix Load Module340
Transfix Camshaft Assembly344
Drum Maintenance Camshaft Assembly345
Drum Maintenance Pivot Plate Assembly346
Drum Assembly347
Purge Pressure Pump351
Paper Path352
Exit Module Assembly (MEP)352
Paper Guides354
Take Away Roller358
Pick Assembly359
Tray Lift Motor361
Motors, Gears, Solenoids, Clutches, and Fans362
Media Drive Gearbox with Two Clutches and Solenoid362
Tray 1 (MPT) Pick Solenoid364
Process Drive Motor and Gearbox365
X-Axis Motor Assembly367
Head Tilt Compound Gear368
Electronics369
Scanner Power Supply369
Exit Module (MEP) Board370
Electronics Module371
Back Frame and Printer Stabilizer373
Wave Amp Board375
I/O Board376
Drum Heater Relay Board377
NVRAM Replacement378
Parts Lists379
Serial Number Format380
Using the Parts List381
Covers382
Imaging384
Paper Path386
Motors, Gears, Solenoids, Clutches, Sensors, Fans388
Electronics Module, Circuit Boards and Cables390
Sensors and Flags (Actuators)392
Xerox Supplies394
Wiring Diagrams397
Plug/Jack Locator Table398
Scanner/Dadf Functional Diagrams401
Main Block Wiring Diagram402
Main Block Wiring Diagram (Continued)403
Scanner/Exit Module Power Supply and MEP (Exit Module) Board404
Right-Side Wiring Diagram405
Right-Side Wiring Diagram (Continued)406
Left-Side Wiring Diagram407
Left-Side Wiring Diagram (Continued)408
Inside Front Wiring Diagram409
Inside Top Wiring Diagram410
Inside Top Wiring Diagram (Continued)411
Electronics Module412
A Appendix413
Control Panel Menu Map414
Control Panel Menu Map -Continued416
Media Margin Specification Table417
Paper Weight Equivalence Table418
On-Site Printhead Troubleshooting Checklist419

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