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Xerox WORKCENTRE C2424 Service Manual

Manual is about: Service Manual

Summary of WORKCENTRE C2424

  • Page 1

    Workcentre ® c2424 copier-printer service manual.

  • Page 3: Workcentre

    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 prin...

  • Page 4: Copyright

    Copyright copyright © 2005 xerox corporation. All rights reserved. Unpublished rights reserved under the copyright laws of the united states. Contents of this publication may not be reproduced in any form without permission of xerox corporation. Copyright protection claimed includes all forms of mat...

  • Page 5: Organization of This Manual

    Service manual i organization of this manual frontis - introductory, safety and regulatory information this section contains important safety information regarding technical components, regulatory agency requirements, and information about this manual. Section 1 - general information this section ca...

  • Page 6: Manual Terms

    Ii workcentre c2424 copier-printer manual terms various terms are used throughout this manual to either provide additional information on a specific topic or to warn of possible danger present during a procedure or action. Be aware of all symbols and terms when they are used, and always read note, c...

  • Page 7: General Safety

    Service manual iii general safety the system and recommended supplies have been designed and tested to meet strict safety requirements. Attention to the following information will ensure the continued safe operation of the system. Electrical safety ■ use the power cord supplied with the system. ■ pl...

  • Page 8: Maintenance Safety

    Iv workcentre c2424 copier-printer maintenance safety ■ do not attempt any maintenance procedure that is not specifically described in the documentation supplied with your system. ■ do not use aerosol cleaners. The use of supplies that are not approved may cause poor performance and could create a h...

  • Page 9

    Service manual v ■ never move the system if you receive 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 ...

  • Page 10: Symbols Marked On The

    Vi workcentre c2424 copier-printer when shipping the system, repack the system using 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 ...

  • Page 11

    Service manual vii electrostatic discharge (esd) precautions some semiconductor components, and the respective sub-assemblies that contain them, are vulnerable to damage by electrostatic discharge (esd). These components include integrated circuits (ics), large-scale integrated circuits (lsis), fiel...

  • Page 12: Service Safety Summary

    Viii workcentre c2424 copier-printer service safety summary general guidelines for qualified service personnel only: refer also to the preceding power safety precautions. Avoid servicing alone: do not perform internal service or adjustment of this product unless another person capable of rendering f...

  • Page 13

    Service manual ix 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..

  • Page 14: Regulatory Specifications

    X workcentre c2424 copier-printer regulatory specifications united states the equipment described in this manual generates and uses radio frequency energy. If it is not installed properly in strict accordance with xerox' instructions, it may cause interference with radio and television reception or ...

  • Page 15

    Service manual xi following the provisions of the low voltage directive 73/23/eec and its amendments: following the provisions of the electromagnetic compatibility directive 89/336/eec and its amendments: this product, if used properly in accordance with the user's instructions, is neither dangerous...

  • Page 16

    Xii workcentre c2424 copier-printer.

  • Page 17: 1 General Information

    Service manual xiii contents organization of this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I general safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Iii electrostatic discharge (esd) precautions. . . . . . . ....

  • Page 18: 3 Error Messages and Codes

    Xiv workcentre c2424 copier-printer electronics module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 image output terminal (iot) sub-assemblies . . . . . . . . . . . . . . . . . . . 2-15 paper path and paper pick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 19: 4 General Troubleshooting

    Service manual xv 36,000.40 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 . . . . . . . . . . . . . . . ...

  • Page 20

    Xvi workcentre c2424 copier-printer ensuring ground integrity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73 testing motor and solenoid resistances . . . . . . . . . . . . . . . . . . 4-75 paper path and media-based problems . . . . . . . . . . . . . . . . . . . . . . . . 4-76 media-...

  • Page 21: 7 Cleaning and Maintenance

    Service manual xvii white stripes (pinstripes). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 wrinkling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 image is offset or cut-off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34...

  • Page 22

    Xviii workcentre c2424 copier-printer image output terminal (print engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 output paper tray assembly . . . . . . . . . . . . . ....

  • Page 23: 9 Parts Lists

    Service manual xix 9 parts lists serial number format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 using the parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 covers . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 24

    Xx workcentre c2424 copier-printer.

  • Page 25: In This Chapter...

    1 section 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.

  • Page 26

    1-2 workcentre c2424 service manual system introduction and overview 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 servic...

  • Page 27: Standard Configurations

    General information 1-3 system features and configurations this section covers the basic system and its specifications. For more detailed information on the system’s internal components, such as main assemblies, power supply, circuit boards, sensors, paper path, and functions, see section 2, "theory...

  • Page 28: Front View

    1-4 workcentre c2424 service manual front view open view 1. Tray 4 (optional 525-sheet feeder) 2. Tray 3 (optional 525-sheet feeder) 3. Tray 2 (525-sheet capacity) 4. Tray 1 (100-sheet capacity, custom size and manual feed) 5. Output tray 6. Exit cover 7. Control panel 8. Dadf front cover 9. Duplex ...

  • Page 29: Back View

    General information 1-5 side view with system interfaces back view 1. Maintenance kit 2. Waste tray 3. Power cord connection 4. Power switch 5. Scanner cable connection 6. Usb connection 7. Configuration card 8. Ethernet 10/100 base-t connection 1. Ram slots 2. Nvram chip 3. Hard drive 4. Stabilizer...

  • Page 30: Electronics Module

    1-6 workcentre c2424 service manual electronics module the system’s main electronics and power supply are enclosed in a metal case called the electronics module. The rear panel allows access to the electronics module, ram, and nvram chips. The system’s hard drive is mounted on the rear panel. When i...

  • Page 31: Life Expectancy

    General information 1-7 routine maintenance items and consumables life expectancy routine maintenance items: consumable: extended-capacity maintenance kit 30,000 cycles (0-20% coverage) 20,000 (20-100% coverage) ink 1220 prints per stick* standard-capacity maintenance kit 10,000 cycles waste tray em...

  • Page 32: Control Panel Layout

    1-8 workcentre c2424 service manual control panel layout the control panel ■ 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...

  • Page 33: Control Panel Left

    General information 1-9 control panel left the left side of the control panel contains the following copy and scan function buttons and leds. A green led shows the current selection. More details about using these buttons are provided in the copying and scanning sections in the customers workcentre ...

  • Page 34: Control Panel Middle

    1-10 workcentre c2424 service manual control panel middle 1. Original size button press to jump to original size option on the menu. 2. Lighten/darken button press to jump to the lighten/darken option on the menu. 3. Reduce/enlarge button press to jump to reduce/enlarge option on the menu. 4. Paper ...

  • Page 35: Control Panel Right

    General information 1-11 control panel right menu map the menu map is a visual representation of the control panel menu structure. You can use it to see how to access the system settings and information pages. To print the menu map: 1. On the control panel, press the system setup button. 2. Select i...

  • Page 36: System Specifications

    1-12 workcentre c2424 service manual system specifications physical dimensions and clearances basic system with dadf and scanner (iit) value width: 53 cm (20.9 in.) depth: 66 cm (26.2 in.) height: 62 cm (24.4 in.) weight: print engine (iot) only 30.0 kg (66.1 lbs.) scanner unit and dadf unit value s...

  • Page 37

    General information 1-13 print engine (iot) functional specifications characteristic specification printing process solid-ink controller 500 mhz processor color medium yellow, cyan, magenta, and black ink sticks, each shape-coded. The system uses the subtractive color system to produce the colors re...

  • Page 38

    1-14 workcentre c2424 service manual system electrical specifications system environmental specifications scanner/dadf (iit) specifications characteristic specification 115 volt 230 volt primary line voltages 90 - 140 vac 180 - 264 vac primary line voltage frequency range 47 - 63 hz 47 - 63 hz power...

  • Page 39

    General information 1-15 optical resolution 600 x 300 to 600 x 2400 dpi (fs x ss) output resolution from scanner always equals optical resolution calibration time less than 2 seconds (performed prior to copier and scan operations) power saver mode scanner and dadf are switched off. Also, lamps autom...

  • Page 40

    1-16 workcentre c2424 service manual tray and media specifications the system trays accommodate most sizes and types of paper, transparencies, or other specialty media. ■ do not overload the paper tray. Do not load paper above the fill line on the inside of the paper guide. ■ adjust the paper guides...

  • Page 41

    General information 1-17 duplex automatic document feeder guidelines the document feeder accommodates original sizes from 114 x 140 mm (4.5 x 5.5 in.) to 216 x 356 mm (8.5 x 14.0 in.), with weights within the following range: 60–120 g/m 2 (16–32 lb. Bond) (22–45 lb. Cover). Follow these guidelines w...

  • Page 42

    1-18 workcentre c2424 service manual letter (8.5 x 11.0 in.) a4 (210 x 297 mm) special (pre- punched paper, business cards, photo paper, weatherproof paper, carbonless paper, glossy paper) 60–120 g/m 2 (16–32 lb. Bond) (22–45 lb. Cover) ● ● 121–220 g/m 2 (33–40 lb. Bond) (46–80 lb. Cover) ● ● specia...

  • Page 43: Supported Envelopes

    General information 1-19 supported envelopes note all envelopes should be printed single-sided only. Use only paper envelopes. Do not use envelopes with windows, metal clasps, or adhesives with release strips. Some wrinkling and embossing may occur when printing envelopes. Media storage guidelines p...

  • Page 44

    1-20 workcentre c2424 service manual media that may damage the system the system is designed to use a variety of media types for print and copy jobs. However, some media can cause poor output quality, increased paper jams, or damage to the system. Unacceptable media for trays 1–4 include: ■ rough or...

  • Page 45: In This Chapter...

    2 section 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 paramete...

  • Page 46: System Overview

    2-2 workcentre c2424 service manual system overview the system is broken into two main components: the image input terminal (iit - document feeder/scanner) and the image output terminal (iot - print engine). System summaries this section covers the basic theory of operation for all major assemblies ...

  • Page 47: Image Input Terminal (Iit)

    Theory of operation 2-3 image input terminal (iit) the iit generates the image data for copies and scans and is made up of two major subsystems: ■ duplex automatic document feeder (dadf) ■ scanner assembly with control panel major components of the dadf and scanner input tray output tray cvt window ...

  • Page 48: Document Feeder Functions

    2-4 workcentre c2424 service manual 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...

  • Page 49

    Theory of operation 2-5 dadf connector: an electrical connector on the rear of the dadf connects to a receptacle on the rear of the flatbed portion of the iit. The dadf connector communicates with the scanner board and that communication is passed to the iot. The image information is also passed to ...

  • Page 50: Copy/scan Imaging

    2-6 workcentre c2424 service manual document feeder paper path and imaging the pick roller feeds paper from the input tray to the document feeder. The paper then passes between the dadf scanhead and the flatbed scanhead. Mylar strips guide the original document back out the document feeder and into ...

  • Page 51: Scanner Assembly Functions

    Theory of operation 2-7 scanner assembly functions document originals can be placed on the scanner document glass (platen). In this mode of operation the original is stationary and the scanhead moves. Document glass or platen: the scanner platen is used for copying or scanning original documents and...

  • Page 52: Automatic Calibration

    2-8 workcentre c2424 service manual scanner and document feeder calibration there are two types of calibration for the scanner and document feeder: automatic calibration and manual calibration. Automatic calibration the automatic calibration performed by the sytem is a “white balance” calibration pe...

  • Page 53: Manual Calibration

    Theory of operation 2-9 3. The calibration strip holds this position until the charge coupled device (ccd) image reaches a specified luminescence value and is stable. This time varies depending on the starting conditions of the lamp. 4. Once the color stabilizes, the strip retracts back to its home ...

  • Page 54: System Electronics

    2-10 workcentre c2424 service manual system electronics the workcentre c2424 electronics differ from other solid-ink products in that there are two controller boards: the main board and the exit module board. The main board, controls all image processing by way of a daughter board integrated with th...

  • Page 55: Exit Module (Mep) Board

    Theory of operation 2-11 exit module (mep) board the exit module board controls motor and paper path functions for the exit module portion of the iot. Once the print process is complete and the media is ready to exit the iot, the primary controller relinquishes control to the exit module (mep) board...

  • Page 56

    2-12 workcentre c2424 service manual image processor controller board: the image processor board provides the interface between the main board and the scanner. The image processor board includes a complete color image path, taking raw 24-bit rgb scanner data and creating print ready cmyk or b&w bina...

  • Page 57

    Theory of operation 2-13 on a triac to activate a heater, it is turned on for only a fraction of a second. The main board must constantly readdress each heater it wants to remain on. This means if the print engine firmware should fail, the heaters automatically shut off. The printer is also protecte...

  • Page 58

    2-14 workcentre c2424 service manual power supply diagram (electronics module) f3 f2 s1 ac line ac neutral line gnd ref neutral d r u m i n k 4 i n k 3 i n k 2 i n k 1 r e s 2 r e s 1 js r js i p r e h t h 8 h 9 h 1 3 h 1 2 h 1 1 h 1 0 h 4 h 3 h 2 h 1 ac line ac neutral low switcher +3.3 v +15 v -15...

  • Page 59

    Theory of operation 2-15 image output terminal (iot) sub-assemblies the image output terminal (commonly referred to as the print engine) is made up of nine major subsystems: ■ the process drive ■ the media path drive ■ the ink loader ■ the printhead ■ the drum maintenance system ■ the preheat and de...

  • Page 60: Sub-Assemblies of The Iot

    2-16 workcentre c2424 service manual sub-assemblies of the iot exit module s2424-008 duplex print path transfix system paper preheater (and deskew) printhead drum ink loader wiper assembly paper/media tray drum maintenance kit ink waste tray.

  • Page 61

    Theory of operation 2-17 the process drive: an open loop system that transmits 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. The media path drive: the gearbox and motor...

  • Page 62: Paper Path and Paper Pick

    2-18 workcentre c2424 service manual paper path and paper pick for paper picked from the document feeder, see the illustration on "document feeder paper path and imaging" on page 2-6. Paper pick for tray 1 for tray 1, the paper pick process is different than the pick process used by the other trays....

  • Page 63: Paper Pick For Trays 2 - 4

    Theory of operation 2-19 paper pick for trays 2 - 4 note trays 3 and 4 are optional 525-sheet feeders. To pick a sheet of paper, the media path drive starts the process. The pick clutch engages to turn the pick roller and the nudger roller. The nudge roller advances one sheet of paper forward into t...

  • Page 64: 2-Sided (Duplex) Printing

    2-20 workcentre c2424 service manual 2-sided (duplex) printing when duplex printing, the exit rollers pull the paper to a predetermined location. In this position, the trailing edge of the paper is adjacent to the exit rollers. The exit rollers then pull the paper back into the duplex path. From a n...

  • Page 65: Sensor Locations

    Theory of operation 2-21 sensor locations s2424-004 exit door sensor control panel sensor strip sensor paper exit sensor drum temperature sensor drum position encoder tray paper size sensor board preheater sensor deskew sensor pick sensor (525-sheet feeder) pick sensor media stage sensor front door ...

  • Page 66

    2-22 workcentre c2424 service manual system motors, solenoids, and drive s2424-237 dadf motor elevator motor media drive gearbox media path motor y-axis motor tray 1 pick solenoid tray lift motor paper drive motor process drive motor x-axis motor.

  • Page 67: Process Drive

    Theory of operation 2-23 process drive the process drive is an open loop system that transmits 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 powe...

  • Page 68: Media Path Drive

    2-24 workcentre c2424 service manual 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 dri...

  • Page 69: The Print Process

    Theory of operation 2-25 the print process once an image has been processed and a printing bitmap created, the print cycle begins. The printhead and drum are brought up to their operating temperatures and the ink levels in the ink reservoirs are checked. Ink is added from the ink loader, if necessar...

  • Page 70: Drum Preparation

    2-26 workcentre c2424 service manual drum preparation to prepare the drum, a thin coating of silicone oil is applied to the surface of the drum. First the drum is rotated. Next, the oil roller and blade of the drum maintenance system are raised into contact with the drum. To accomplish this, the pro...

  • Page 71: Ink Loader

    Theory of operation 2-27 jet substitution allows a better performing jet to be used in place of a missing or poorly performing neighboring jet. When jet substitution mode is used, the printhead makes a second right-to-left movement to deposit the pixel columns of the substituted jets. See "jet subst...

  • Page 72: Printhead

    2-28 workcentre c2424 service manual printhead the printhead is the heart of the printer, spanning nearly the length of the drum. Using its 1236 jet nozzles (309 jets for each primary color), with a horizontal motion of slightly less than 5 mm (0.2 inches), the printhead can print the entire image o...

  • Page 73

    Theory of operation 2-29 the printhead’s jet stack is fabricated from a stack of chemically etched steel plates which are brazed together to form the jet array. Channels formed by the stacked plates route ink past the 1236 individual, piezo-electric crystal-driven diaphragms, which force the ink in ...

  • Page 74

    2-30 workcentre c2424 service manual the jet array is bonded to a cast aluminum ink reservoir. The reservoir supplies the molten ink to the jet array. Heaters in the reservoir and the jet array maintain the ink at a temperature of about 140 o c for printing. X-axis or lateral movement of the printhe...

  • Page 75: Printhead Tilt

    Theory of operation 2-31 printhead tilt the printhead is able to rotate into four basic positions: 1. Printhead lock / ship position (19.5 degrees): the printhead restraint pins are resting against the right and left locks. In this position, the printhead tilt arm/ follower is free of the tilt cam, ...

  • Page 76

    2-32 workcentre c2424 service manual in the print position (0 degrees), the printhead is forward and resting against the right and left head-to-drum buttons. The head-to-drum buttons define the space between the jet stack and the drum. When the process drive is activated, it drives the drum maintena...

  • Page 77

    Theory of operation 2-33 the latching mechanism is actuated by a small movement of the wiper. Through a follower gear, the compound gear drives the tilt cam gear clockwise. A cam follower, mounted on the lower end of the tilt arm, follows the rotating tilt cam gear and tilts the printhead. After one...

  • Page 78: Drum Assembly

    2-34 workcentre c2424 service manual drum assembly the drum assembly and transfix system form the key portion of the printer where imaging takes place. The drum assembly and transfix system are separate, but interrelated. This section discusses the drum assembly. The next section goes into more deta...

  • Page 79

    Theory of operation 2-35 the drum is driven by a closed-loop servo motor. Through a single reduction belt drive, the servo motor rotates the drum at a high speed for imaging and a constant low speed for image transfer to paper. The y-axis uses an active tension system to allow the pulley to float wh...

  • Page 80: Transfix System

    2-36 workcentre c2424 service manual transfix system the transfix roller applies pressure to the back side of the paper as it moves between the transfix roller and drum. This pressure transfers the image from the drum to the paper. A set of springs determines how much pressure the transfix roller ap...

  • Page 81: Drum Maintenance System

    Theory of operation 2-37 drum maintenance system the drum maintenance system creates a thin, intermediate, liquid transfer surface, a layer of silicone oil, on the surface of the drum prior to printing. The oil keeps the ink from sticking to the drum’s surface and facilitates its transfer to the she...

  • Page 82: Purge System

    2-38 workcentre c2424 service manual purge system proper printhead operation is dependant on the correct operation of the purge system. The purge system uses air pressure and a wiper blade to purge any debris or air bubbles that may be obstructing the printhead nozzles. The waste ink that is expelle...

  • Page 83

    Theory of operation 2-39 the level of the ink in the reservoir is kept at a constant level. If the pressure purge tubing is pinched, the printhead may not purge properly. In addition, because the purge tubing also acts as a vent to atmosphere when not purging, a more serious failure can occur if the...

  • Page 84: Transfixing and Exiting

    2-40 workcentre c2424 service manual transfixing and exiting transfixing and exiting consists of four major functions: 1. Stage the paper for rendezvous with the image on the drum and transfix roller nip. 2. Load the transfix roller and engage the drum stripper blade assembly. 3. Strip the paper fro...

  • Page 85

    Theory of operation 2-41 ss2424-049 drum transfix cam transfix load arm transfix load module transfer roller transfix load spring transfix cam process drive transfix roller gear.

  • Page 86

    2-42 workcentre c2424 service manual after the leading edge of the paper is beyond the paper release guide, the paper release solenoid is de-energized. Once the solenoid is de-energized, the solenoid return spring provides force to move the solenoid plunger out of the solenoid coil which rotates the...

  • Page 87

    Theory of operation 2-43 . S2424-052 release blade strip solenoid engine exit sensor preheat exit sensor transfix roller paper preheater strip sensor paper exit sensor.

  • Page 88: Transfix and Print Speeds

    2-44 workcentre c2424 service manual transfix and print speeds transfix speeds characteristic setpoint, paper media fast color standard enhanced high res/ photo peak transfix speed, simplex tray feed 20 inches per second (ips) 17 ips 13 ips 7 ips peak transfix speed, duplex 5 ips 5 ips 5 ips 5 ips p...

  • Page 89

    Theory of operation 2-45 configuration card personality parameters information stored on the configuration card includes the ethernet address, and personality parameters. The printer model configuration is determined by a combination of printer hardware capabilities. Feature value and ethernet addre...

  • Page 90

    2-46 workcentre c2424 service manual ip autoip 1 ip dhcp vendor class id 48 dns resolver primary name server ip address 4 dns resolver secondary name server ip address 4 dns resolver multicastdns 1 nbns (wins) enable 1 nbns (wins) wins note type 1 nbns (wins) primary wins server 4 nbns (wins) second...

  • Page 91

    Theory of operation 2-47 ipp on 1 ipp enabled 1 mime on 1 mime enabled 1 ethertalk on 1 ethertalk enabled 1 pserver on 1 pserver enabled 1 pserver_ipx enabled 1 notes : 1. “parallel” and “usb”, “on” and “enabled” parameters have not been identified as personality parameters. They are not tied to net...

  • Page 92

    2-48 workcentre c2424 service manual.

  • Page 93: In This Chapter...

    3 section 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.

  • Page 94: Introduction

    3-2 workcentre c2424 service manual introduction this section covers system troubleshooting procedures utilizing control panel error messages and codes. Some procedures require running service diagnostic test functions to verify that a specific system component is operating correctly. For informatio...

  • Page 95: Bist Error Reporting

    Error messages and codes 3-3 power-up error messages and led codes the system has three sets of tests that are run when first powered on: ■ built-in self tests (bist) ■ power on self tests (post) ■ print engine self tests (pest) note bist and post errors are not stored in the fault history logs. Bis...

  • Page 96: Post Error Reporting

    3-4 workcentre c2424 service manual post error reporting post checks the communication paths within the electronics module and to other various system components. Post testing initializes the control panel, and in most cases if an error occurs, a text message is displayed on the control panel along ...

  • Page 97

    Error messages and codes 3-5 post error reporting blink pattern definition table control panel error code ps, pe and control panel leds post error type description 01.01 flutter then 01 blinks hard bad error code. 02.01 flutter then 02 blinks hard failed machine check. 02.02 flutter then 02 blinks h...

  • Page 98

    3-6 workcentre c2424 service manual 10.02 flutter only soft pld power control link invalid, mismatch error. 11.01 flutter and then 11 blinks hard eeprom read failure. 1. Check eeprom orientation. 2. Replace eeprom. 11.02 flutter and then 11 blinks hard eeprom write failure. 1. Check eeprom orientati...

  • Page 99: Pest Error Reporting

    Error messages and codes 3-7 pest error reporting pest tests occur after post tests have been run and postscript has been initialized. Pest checks the connections and operation of various system components. Error codes for pest tests are displayed on the control panel and are all in the 37,xxx.Xx se...

  • Page 100: Fault Code Error Reporting

    3-8 workcentre c2424 service manual fault code error message troubleshooting fault code error reporting fault codes are saved to nvram and can be retrieved from the system’s fault history. All procedures that ask for a test to be run are referencing tests from within the “hidden” service diagnostics...

  • Page 101

    Error messages and codes 3-9 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. 1,0xx.6x error...

  • Page 102

    3-10 workcentre c2424 service manual 2,0xx.4x error - i/o circuit board fault 2,001.47: the print engine cannot detect the presence of the i/o circuit board. 2,0xx.6x errors - i/o board program faults 2,001.69: the electronics module failed to initialize. 2,002.61: this fault code indicates a proble...

  • Page 103

    Error messages and codes 3-11 4,0xx.4x errors - process control system fault 4,017.47: this fault code indicates a problem with the process control system. The ambient temperature is considered too cold to warm up the system. (less than 10 o c). 4,018.48: this fault code indicates a problem with the...

  • Page 104

    3-12 workcentre c2424 service manual 4,024.42: this fault code indicates a problem with the wiper. The wiper is not aligned properly and engaged the headtilt while in the waste lock position. Troubleshooting procedure step questions and actions yes no 1 1. Run the check wiper alignment test. 2. Did ...

  • Page 105

    Error messages and codes 3-13 4,025.46: this fault code indicates a problem with the process control system. Cannot succesfully home the drum transfix mechanism. 4,0xx.6x process control software fault a. Reset nvram and then retest. B. Ensure ground integrity for the system (see "ensuring ground in...

  • Page 106

    3-14 workcentre c2424 service manual 5,0xx.4x errors - y-axis sub-system fault 5,001.41: the drum turned one full revolution without seeing the drum home sensor activate. 5,002.42: the y-axis encoder is not working properly or the drum has stalled. 5,003.43: there is a general problem with the y-axi...

  • Page 107

    Error messages and codes 3-15 6,0xx.4x errors - x-axis fault 6,000.41: an x-axis motor current error occured. 6,0xx.6x errors - program faults 6,001.64: the x-axis task recieved an unexpected message. 6,002.65: attempt to home the x-axis from a state where homing is not allowed. 6,008.62: attempt to...

  • Page 108

    3-16 workcentre c2424 service manual 7,0xx.4x errors - process motor gearbox faults 7,002.44: there is a problem with the process motor sub-system. The process motor stalled during operation. 7,007.49: the process motor stalled while tilting the head. Troubleshooting procedure step questions and act...

  • Page 109

    Error messages and codes 3-17 7,008.41: the head tilt is not engaged, or the printhead is stuck in the tilt position by the tilt arms. Troubleshooting procedure step questions and actions yes no 1 1. Reboot the system . 2. Did this correct the problem? Go to step 2. Complete. 2 1. Inspect the system...

  • Page 110

    3-18 workcentre c2424 service manual 7,009.42: the printhead is tilted back but not properly restrained in the park arms. 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, ...

  • Page 111

    Error messages and codes 3-19 7,0xx.6x errors - program faults a. Reset nvram and retest. B. Ensure ground integrity for the system (see "ensuring ground integrity" on page 4-73). 4 1. Check the process gearbox for obstructions or damaged. 2. Ensure the gears are correctly aligned and homed. 3. Veri...

  • Page 112

    3-20 workcentre c2424 service manual 8,0xx.Xx error - wiper/media path gearbox faults 8,005.48: the media path motor gearbox stalled while moving the wiper to the home position. 8,006.49: the wiper cannot verify the home position. 8,007.41: the wiper stalled finding home. 8,008.42: the wiper stalled...

  • Page 113

    Error messages and codes 3-21 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). 6 1. Inspect the wiper system for improper operation, obstructions, or damage (broken gear or belt). 2. Ensure the...

  • Page 114: 9,009.44 and 900X.6X

    3-22 workcentre c2424 service manual 9,0xx.Xx errors - ink loader faults 9,000.44: these fault indicate a problem with the ink loader. 9,005.49: ink loader fault. The cyan ink melt heater is on, but the ink does not appear to be dripping. 9,006.41: ink loader fault. The magenta ink melt heater is on...

  • Page 115

    Error messages and codes 3-23 11,0xx.Xx errors - electronics module interface fault 11,001.47: upper 525-sheet feeder broken serial link detected. 11,002.48: lower 525-sheet feeder broken serial link detected. 11,003.49: control panel broken serial link detected. 11,004.41: control panel or i/o boar...

  • Page 116

    3-24 workcentre c2424 service manual 11,100.60 - temperature error 11.100.60: the root problem for this error is temperature sensitivity with the power supply’s opto isolator chips. Ensure room temperature is not too high. Ensure also that the electronics fan runs correctly. If ok, then replace the ...

  • Page 117

    Error messages and codes 3-25 13,008.47: the drum heater is too hot. 13,010.49: the drum heater took too long to reach its setpoint. 2 1. Reset nvram and retest. 2. Did this correct the problem? Complete. Replace in the following order: ■ nvram ■ electronics module. Troubleshooting procedure step qu...

  • Page 118

    3-26 workcentre c2424 service manual 13,067.43: the drum thermistor circuit is open. 13,069.45: the drum thermistor circuit is shorted. 13,071.47: the drum thermistor returned a bad reading, or the reading was corrupted by esd (electrostatic discharge). 13,072.48: the preheater got too hot. 13,074.4...

  • Page 119

    Error messages and codes 3-27 13,135.48: the preheater thermistor returned a bad reading, or the reading was corrupted by esd. 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 (s...

  • Page 120

    3-28 workcentre c2424 service manual 13,136.49: the left jetstack heater is too hot. 13,138.42: the left jetstack heater took too long to reach its setpoint. 13,195.45: the left jetstack thermistor circuit is open. 13,197.47: the left jetstack thermistor circuit is shorted. 13,199.49: the left jetst...

  • Page 121

    Error messages and codes 3-29 13,200.41: the right jetstack heater is too hot. 13,202.43: the right jetstack heater took too long to reach its setpoint. 13,259.46: the right jetstack thermistor circuit is open. 13,261.48: the right jetstack thermistor circuit is shorted. 13,263.41: the right jetstac...

  • Page 122

    3-30 workcentre c2424 service manual 13,264.42: the reservoir heater got too hot. 13,266.44: the reservoir heater took too long to reach its setpoint. 13,323.47: the reservoir thermistor circuit is open. 13,325.49: the reservoir thermistor circuit is shorted. 13,327.42: the reservoir thermistor retu...

  • Page 123

    Error messages and codes 3-31 13,328.43: the cyan heater is too hot. 13,330.45: the cyan heater took too long to reach its setpoint. 13,387.48: the cyan thermistor circuit is open. 13,389.41: the cyan thermistor circuit is shorted. 13,391.43: the cyan thermistor returned a bad reading, or was corrup...

  • Page 124

    3-32 workcentre c2424 service manual 13,000.6x errors - program faults 13,001.62: thermals failed to read from system nvram. 13,002.63: value is not in valid range. 13,003.64: thermal control task received an unexpected message. 13,004.65: thermal control task was expecting initialization message, b...

  • Page 125: 19,0Xx.6X - Errors

    Error messages and codes 3-33 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 da...

  • Page 126

    3-34 workcentre c2424 service manual 27,0xx.6x errors - profile library a. Ensure the ground integrity of the system (see "ensuring ground integrity" on page 4-73). 29,0xx.6x errors - jam manager a. Reset nvram, and then retest. B. Replace the nvram. 31,0xx.4x errors - mechanical initialization jam ...

  • Page 127

    Error messages and codes 3-35 33,0xx.Xx errors - tray manager device faults 33,001.42: tray 1 width value too low. 33,002.43: tray 1 width value too high. 34,0xx.Xx errors - printhead nvram faults 34,001.43: an error occurred while attempting read/write access to the printhead calibration partition ...

  • Page 128: 36,001.67 Errors

    3-36 workcentre c2424 service manual 36,000.40 errors - drum maintenance faults 36,001.67 errors a. Replace the pivot plate. B. Replace the drum maintenance unit. Troubleshooting procedure step questions and actions yes no 1 1. Ensure ground integrity (see "ensuring ground integrity" on page 4-73. 2...

  • Page 129

    Error messages and codes 3-37 37,0xx.Xx errors - pest faults ac power supplied by power sources such as uninterruptible power supplies (ups’s) or dc-to-ac inverter systems, may not supply enough current to properly power up the printer. In these cases, the printer may report printhead jet-stack or r...

  • Page 130

    3-38 workcentre c2424 service manual 37,013.40: pest - electronics module cooling fan disconnect. The electronics cooling fan is not drawing the expected power from the supply. 37,014.41: pest - drum cooling fan disconnect. The drum cooling fan is not drawing the expected power from the supply. Trou...

  • Page 131

    Error messages and codes 3-39 37,016.43: pest 50 v 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 devic...

  • Page 132

    3-40 workcentre c2424 service manual 4 1. If the 50v power supply led (viewed thru the cooling grill below the power cord receptacle) illuminates, the short is on one of the external devices you unplugged earlier. In this case, systematically turn off the printer, plug a wiring harness back in, and ...

  • Page 133

    Error messages and codes 3-41 37,017.44: pest - main tray (tray 1) deskew clutch disconnect . The main tray deskew clutch is not drawing the expected power from the supply. 37,018.45: pest - main tray (tray 1) pick clutch disconnect. The main tray pick clutch is not drawing the expected power from t...

  • Page 134

    3-42 workcentre c2424 service manual 37,022.40: pest - pressure pump motor disconnect. The pressure pump motor is not drawing the expected power from the supply. 37,023.41: pest - purge valve disconnect. The purge valve is not drawing the expected power from the supply. 37,024.42: pest - drum heater...

  • Page 135

    Error messages and codes 3-43 37,027.45: pest - x-axis motor disconnect. The x-axis motor is not drawing the expected power from the supply (both phases). 37,028.46: pest - x-axis motor disconnect. The x-axis motor (first phase) is not drawing the expected power from the supply. 37,029.47: pest - x-...

  • Page 136

    3-44 workcentre c2424 service manual 37,034.43: pest - media path motor disconnect. The media path motor is not drawing the expected power from the supply. 37,035.44: pest - media path motor short. The media path motor is drawing too much power from the supply. 37,036.45: pest - process motor discon...

  • Page 137

    Error messages and codes 3-45 37,048.48: pest - power supply +12 volt under limit. 37,049.40: pest - power supply -12 volt over limit. 37,050.41: pest - power supply -12 volt under limit. 37,051.42: pest - power supply current over limit. 37,052.43: pest - power supply current under limit. 37,053.44...

  • Page 138: Faults

    3-46 workcentre c2424 service manual 39,0xx.Xx errors - document feeder / scanner unit faults note document feeder and scanner faults are only recorded in the usage profile report. 39,002.40 (scanner) dram test failure troubleshooting procedures step questions and actions yes no 1 1. Cycle power to ...

  • Page 139

    Error messages and codes 3-47 39,005.43 “scanner missing” troubleshooting procedures step questions and actions yes no 1 1. Reseat the scanner cable connection, verify the scan head lock is in the unlocked postion and reboot the sytem. 2. Did this correct the problem? Complete. Go to step 2. 2 1. Op...

  • Page 140

    3-48 workcentre c2424 service manual 39,010.8 document feeder disconnected troubleshooting procedure control panel message: “document feeder disconnected or dadh missing” step questions and actions yes no 1 1. Reseat the document feeder cable connector. 2. Wait at least one full minute. 3. Did this ...

  • Page 141: 3-Digit Jam Codes

    Error messages and codes 3-49 3-digit jam codes this 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 c...

  • Page 142: Jam Code Definition Table

    3-50 workcentre c2424 service manual jam code definition table not all jam code combinations are documented in this manual, only the codes that occur most commonly. Jam code troubleshooting procedures a2c deskew sensor in unexpected state during mechanical recovery. 1. Check the drum maintenance uni...

  • Page 143

    Error messages and codes 3-51 a3n the deskew flag timed out waiting for the paper picked from tray 3. A3p the deskew flag timed out waiting for the paper picked from tray 4. A3q the deskew flag timed out waiting for the paper picked from tray 1. 1. Verify media is appropriate for the tray. 2. Verify...

  • Page 144

    3-52 workcentre c2424 service manual b2q the preheat flag tripped unexpectedly while the system was picking paper from tray 1. 1. Test the preheat flag using the diagnostic sensors test. 2. Ensure ground integrity of the system (see page 4-73). B3m the preheat flag timed out waiting for the paper pi...

  • Page 145

    Error messages and codes 3-53 c2x strip flag unexpected event during exit. 1. Ensure that the media is not too thick and that it is supported by the system. 2. Use a less glossy media. 3. Ensure that the guides in the tray are snug against the media. 4. If the drum maintenance unit is near the end o...

  • Page 146

    3-54 workcentre c2424 service manual d2r d2t the exit flag actuated unexpectedly when duplexing. The exit flag actuated unexpectedly when transfixing. 1. Ensure ground integrity of the system (see page 4-73). 2. Run the sensors test to test the exit sensor. 3. Run the paper lead edge times test. 4. ...

  • Page 147

    Error messages and codes 3-55 f2d the front door open flag unexpectedly tripped while the system was warming up. F2f the front door open flag unexpectedly tripped while the system was in a fault state. F2m the front door open flag unexpectedly tripped when the system pick from tray 2. F2n the front ...

  • Page 148

    3-56 workcentre c2424 service manual k2x 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 board operation, see page 4-70. 4. Inspect the exit module for defects or damaged components...

  • Page 149

    Error messages and codes 3-57 l2x iit cover open while paper exits the iot. 1. Test the iit cover open sensor with a magnet or magnetic screwdriver, the exit module will home and the message should clear. 2. Check the wiring to the iit cover open sensor, (see "main block wiring diagram" on page 10-6...

  • Page 150

    3-58 workcentre c2424 service manual n2t y-axis motor event during transfix (tray 1 only- probably a multi-pick). 1. Verify that the media in the tray is supported by the system. 2. Try a heavier media. 3. Inspect tray 1 separator pad. Replace if necessary. 4. Send a snippet to turn off the multi-pi...

  • Page 151

    Error messages and codes 3-59 n5w 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 the y-axis motor or drum asse...

  • Page 152

    3-60 workcentre c2424 service manual p4t process motor stalled while the system transfixed the print. P4v process motor stalled while the system performed a print drum maintenance cycle. P4w process motor stalled while the system imaged the drum. P4x process motor stalled while the print exited the ...

  • Page 153

    Error messages and codes 3-61 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 the transfix cycle. T2t...

  • Page 154

    3-62 workcentre c2424 service manual v2v tray 2 media size sensor unexpectedly activated while print drum maintenance cycle was being performed. V2w tray 2 media size sensor unexpectedly activated during system imaging. V2x tray 2 media size sensor unexpectedly activated while exiting print. 1. Ensu...

  • Page 155

    Error messages and codes 3-63 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 tray 3 pick flag t...

  • Page 156

    3-64 workcentre c2424 service manual x3m tray 3 pick flag sensor timed out while picking from tray 2. X3n tray 3 pick flag sensor timed out while picking from tray 3. X3p tray 3 pick flag sensor timed out while picking from tray 4. X3q tray 3 pick flag sensor timed out while picking from tray 1. X3r...

  • Page 157

    Error messages and codes 3-65 y2t tray 4 media size sensor unexpectedly activated while transfixing the print. Y2v tray 4 media size sensor unexpectedly activated while the system drum maintenance cycle was being performed. Y2w tray 4 media size sensor unexpectedly activated while system imaging. Y2...

  • Page 158

    3-66 workcentre c2424 service manual z2z tray 4 pick flag triggered unexpectedly while exiting print. 1. Ensure ground integrity of the system (see page 4-73). 2. Run the monitor sensors test to test the media size sensor. 3. Replace the 525-sheet feeder. 4. Replace the pivot arm. Z3b tray 4 pick fl...

  • Page 159: In This Chapter...

    4 section 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.

  • Page 160: Introduction

    4-2 workcentre c2424 service manual introduction this section covers troubleshooting general start-up, mechanical, and electrical or power supply problems not associated with a control panel error message or code. For troubleshooting problems associated with an error code or control panel error mess...

  • Page 161

    General troubleshooting 4-3 reset nvram provides access to reset the system back to its factory- default settings and erase all network settings. If possible, print the configuration page before resetting nvram. Power saver timeout selects the power saver timeout, the amount of time the system must ...

  • Page 162: Service Diagnostics

    4-4 workcentre c2424 service manual service diagnostics the system has built-in diagnostics 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 ...

  • Page 163: Entering Service Diagnostics

    General troubleshooting 4-5 entering service diagnostics from customer mode to diagnostics: this method of entering diagnostics is to allow a transistion 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...

  • Page 164

    4-6 workcentre c2424 service manual service diagnostic menu definition tables service diagnostics main menu definition table menu item description main menu menu help displays information on how to use the control panel menus. Exit diagnostics exits service diagnostics and runs through post to ready...

  • Page 165

    General troubleshooting 4-7 main menu --> exit module menu test name description results report fw version reports the current firmware version. Report status displays the current status as reported by the exit module firmware. Monitor sensors monitors all sensors associated with the exit module ass...

  • Page 166

    4-8 workcentre c2424 service manual main menu --> scanner menu test name description results report fw version reports the current firmware version. Report status checks then reports the current status as reported by the scanner unit firmware. Ready or not ready lamp: on, off, warming up, warmup tes...

  • Page 167

    General troubleshooting 4-9 test name description results exercise lamp this tests commands the scanner to cycle the lamp on, then off. The lamp is then left on. The lamp status must be observed. Ok fail exercise axis motion the scanner axis moves to the maximum of its travel position, then back to ...

  • Page 168

    4-10 workcentre c2424 service manual test name description results test data capture performs the built-in optical test procedure to determine if the system can capture scan dats, the calibration device, the lamp, optics and electronics are functional. Ok or fail. Test cal motion commands the dadf s...

  • Page 169

    General troubleshooting 4-11 service diagnostic print engine menu functions print engine monitor menu functions main menu --> print engine menu --> monitor menu the monitor test functions report current values (temperatures, positions, etc.), and demonstrate the ability to read the values without ch...

  • Page 170

    4-12 workcentre c2424 service manual print engine exercise menu functions this submenu contains a group of functions intended to stimulate a specific portion of the print engine system in such a way that the test can be observed. Listening observations may be required for certain tests and will prom...

  • Page 171

    General troubleshooting 4-13 heaters menu allows the heaters to be forced to an on or off condition or to be toggled from one condition to the other. Also provides monitoring to observe the resulting heater power or temperature. ■ monitor heaters ■ monitor temperatures ■ all heaters on (warmup to no...

  • Page 172

    4-14 workcentre c2424 service manual print engine function menu functions this submenu contains a group of functions that either perform higher-level exercise functions involving multiple print engine subsystems, or special purpose functions requiring sofware support, such as working with nvram. Mai...

  • Page 173: Check / Activators Menu

    General troubleshooting 4-15 check menu / activators definition tables the check menu contains a set of extensive tests that return measured mechanism parameters for comparison against stated limits. Refer to the table associated with each test for their normal operating ranges. In cases where insuf...

  • Page 174

    4-16 workcentre c2424 service manual tray 1 pick solenoid gathers data on the performance of the tray 1 pick solenoid coil and flapper. R# definition typical value actions 0 peak power (watts) 0 to 1.5 reports the profile max power value. 1 average power (watts) 18 to 26.5 reports the average power ...

  • Page 175

    General troubleshooting 4-17 purge vent solenoid gathers data on the performance of the purge vent solenoid coil. R# definition typical value actions 0 peak power (watts) -0.65 to 1.2 reports the profile max power value. 1 average power (watts) 0.03 to 1.29 reports the average power during the const...

  • Page 176: Check Shafts Menu

    4-18 workcentre c2424 service manual check shafts menu deskew shaft runs the media path drive train and engages the deskew clutch on the fly then disengages the clutch. The test is repeated in both directions to determine clutch characteristics, steady state drive requirements, bearing status, etc. ...

  • Page 177

    General troubleshooting 4-19 7 cw on peak fe. -950 to -450 reports the peak effort required to accelerate the deskew shaft load. A smaller value could indicate a slipping clutch. 8 cw on fe settling time (sec). 0.010 to 0.20 reports the time it takes the mp motor servo system to "settle down" after ...

  • Page 178

    4-20 workcentre c2424 service manual 1 ccw on peak fe. 25 to 100 reports the peak effort required to accelerate the wiper shaft load. A smaller value could indicate a slipping clutch. 2 ccw on fe settling time (sec). -2.1 to 0.25 reports the time it takes the mp motor servo system to "settle down" f...

  • Page 179

    General troubleshooting 4-21 9 cw on average fe. -50 to 15 reports the average effort required to rotate the wiper shaft in the cw direction at a constant velocity. An unusual value could indicate a difference in the composition and/or number of the rollers, the nip pressure, or out of range mechani...

  • Page 180

    4-22 workcentre c2424 service manual 2 initial average mp fe. (mpts). Mfg only reports the average mp fe immediately following the pick shaft engagement. A higher value of r2 could indicate extra friction between the cams and the lift plate followers (wear, contamination, etc.), as well as high lift...

  • Page 181

    General troubleshooting 4-23 tray 2, tray 3, and tray 4 pick shaft test is the same for each pick shaft although for tray 2 the media path motor is used and for the 525-sheet feeders the corresponding pick/transport motor is used. Test determines if the shaft can be driven by the clutch, if the nudg...

  • Page 182: Check Fans Menu

    4-24 workcentre c2424 service manual check fans menu 7 plate lifted average fe. Mfg only reports the peak effort required to drive the pick shaft when the nudger roller is in contact with the separator pad. A smaller value could indicate a slipping clutch, missing nudger assembly pressure spring, or...

  • Page 183: Check Heaters Menu

    General troubleshooting 4-25 check heaters menu reservoir heater, jetstack left heater, jetstack right heater, paper preheater, drum heater, ink melt 1 (yellow) heater, ink melt 2 (cyan) heater, ink melt 3 (magenta) heater, ink melt 4 (black) heater this test sequentially applies power to each of th...

  • Page 184

    4-26 workcentre c2424 service manual 5 peak temperature (deg c) mfg only reports the peak temperature after the heating interval ends. Normally the beginning temp would be subtracted. Indicates how much heat was produced during the heating interval and propagated to the thermistor. 6 peak temperatur...

  • Page 185: Check Paper Path Menu

    General troubleshooting 4-27 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 path to determine paper path power requirements. R# definition typical value actions 0 t...

  • Page 186

    4-28 workcentre c2424 service manual tray 3 pick 2 unused mfg only 3 tray 3 pick interval (us) mfg only reports the interval from the time the engine software is commanded to start the tray 3 pick process until the tray 3 pick sensor activates. 4 tray 3 transport interval (us) mfg only reports the i...

  • Page 187

    General troubleshooting 4-29 7 exit interval (us) mfg only reports the interval from the time the engine software is commanded to start the transfix process until the exit sensor activates (part way through the paper transfix motion). Simplex path 8 exited interval (us) mfg only reports the interval...

  • Page 188

    4-30 workcentre c2424 service manual 3 unused mfg only tray 1 pick 2 unused mfg only 3 unused mfg only common 4 deskew trailing edge interval (us) mfg only reports the interval from the time the engine software is commanded to start the transfix process until the deskew sensor deactivates. (part way...

  • Page 189

    General troubleshooting 4-31 1 paper size mfg only reports size of the picked paper. Tray 4 pick 2 tray 4 pick bounce interval (us) mfg only reports the interval during which the tray 4 pick sensor bounces following the passage of the paper trailing edge. Tray 3 pick 3 tray 3 pick bounce interval (u...

  • Page 190

    4-32 workcentre c2424 service manual duplex 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 path to determine paper path power requirements. R# definition typical value actions 0 tray mfg...

  • Page 191

    General troubleshooting 4-33 12 duplex exit interval (us) mfg only reports the interval from the time the engine software is commanded to start the transfix process until the exit sensor activates (part way through the paper transfix motion). 13 duplex exited interval (us) mfg only reports the inter...

  • Page 192

    4-34 workcentre c2424 service manual duplex paper sensor bounce times paper is picked and moved through either the duplex paper path to determine the paper trailing edge bounce interval at each paper path sensor. R values have alternate definitions or are unused depending on the pick tray and if sim...

  • Page 193: Check Drive Menu

    General troubleshooting 4-35 check drive menu wiper drive this test moves the wiper drive mechanism through the complete range of its motion in each direction and does an “on-the-fly” reversal to verify operability. R# definition typical value actions 0 up motion drive error (uin) 120 to 275 reports...

  • Page 194

    4-36 workcentre c2424 service manual paper path drive this test moves the gear train in one direction while capturing data, does a reversal to capture reversal transient data, and then operates in the other direction. R# definition typical value actions 0 cw average power (watts) 0 to 15 reports the...

  • Page 195

    General troubleshooting 4-37 5 left right traverse power ripple (watts) mfg only same as r3 except for the other direction of. Motion. 6 turnaround power blip width (watts) 4.3 to 10.85 reports the width of the momentary drop in the required drive power when the printhead motion is being reversed. A...

  • Page 196

    4-38 workcentre c2424 service manual drum maintenance drive with the y-axis rotating, the drum maintenance unit is loaded against the drum for a short time in each configuration (roller and blade/blade only). R# definition typical value actions 0 time to blade first contact (sec) .01 to .35 reports ...

  • Page 197

    General troubleshooting 4-39 tilt drive this test drives the printhead tilt mechanism through one cycle to determine if it is controllable and operating as expected. R# definition typical value actions 0 tilt engage cap position (min) mfg only reports the distance from the cap home position to the t...

  • Page 198: Check Drum Menu

    4-40 workcentre c2424 service manual check drum menu 4 lift contact time (sec) mfg only reports the interval from the motor start time until the required lift power starts to increase due to the initial contact with the nudger roller assembly. 5 lift time (sec) mfg only reports the interval from the...

  • Page 199

    General troubleshooting 4-41 7 amplitude ripple (sun sum units) mfg only reports the ripple in the sin sum amplitude values. Excludes the neighborhood of the home notch (a distance of +/- 50 samples from the home notch min location. 8 max position ripple (mpts) mfg only reports the max variation in ...

  • Page 200

    4-42 workcentre c2424 service manual 7 frequency 2 frequency (hz) mfg only reports the frequency of the second most powerful fft frequency (not including the drum or motor). Y-axis drive this procedure performs a “4 corner” test using the minimum and maximum velocity and acceleration used during pri...

  • Page 201

    General troubleshooting 4-43 y-axis belt slip this test does a chase using a special sheet of preprinted media and records the y-axis following error. R# definition typical value actions 0 initial peak y-axis fe (mpts) 3500 to 6900 reports the amplitude of the first y-axis following error peak. 1 ma...

  • Page 202

    4-44 workcentre c2424 service manual stripper contact this test holds the drum stationary while the stripper solenoid is activated and released. The drum servo error signal illustrates activation/deactivation timing and how strongly the drum was contacted by the blade. R# definition typical value ac...

  • Page 203: Check Motors Menu

    General troubleshooting 4-45 check motors menu 7 releasing amplitude (mpts) -12.3 to 5.85 reports the magnitude of the reaction of the 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...

  • Page 204

    4-46 workcentre c2424 service manual x-axis motor this test turns on the x-axis motor and runs it very slowly for one revolution. R# definition typical value actions 0 motor voltage a ripple (volts). Mfg only reports amount of variation of the motor phase a drive voltage over the recording interval....

  • Page 205

    General troubleshooting 4-47 media path motor this test turns on the media path motor and runs it very slowly for one revolution. R# definition typical value actions 0 motor fe ripple (ticks) .4 to 1.3 reports amount of variation of the motor following error over the recording interval. 1 motor fe a...

  • Page 206: Check Misc Menu

    4-48 workcentre c2424 service manual check misc menu tray 3 and tray 4 pick/feed motor this test turns on the specified motor and runs it at constant velocity for approximately 25 revolutions while recording drive data. The test is the same for each motor. Requesting a test for a 525-sheet feeder th...

  • Page 207

    General troubleshooting 4-49 0 mfg only 3 - paper at deskew sensor 0 mfg only 2 - paper at preheat exit sensor 0 mfg only 1 - paper at strip sensor 0 mfg only 0 - paper at exit sensor 1 tray 1 mfg only 14 - 31 unused, always 0 1 mfg only 13 - no media present 1 mfg only 0 - 12 width value 2, 3, 4 tr...

  • Page 208

    4-50 workcentre c2424 service manual 2, 3, 4 mfg only 1 - media width middle 2, 3, 4 mfg only 0 - media width bottom temperature status this test scans the thermocouples and reports data on the current temperature with the goal of providing a picture of the current temperature state of the system. A...

  • Page 209

    General troubleshooting 4-51 purge pump this test determines if the purge pump system (pump/hose/purge valve/printhead) is operating normally. R# definition typical value actions 0 jetstack temperature (deg) mfg only reports current jetstack temperature. If the temperature is above current threshold...

  • Page 210

    4-52 workcentre c2424 service manual voltages this test determines averaged readings for key system voltages. R# definition typical value actions main board voltages 0 5 volts (volts) ~4.79 to 5.0 1 1.8 volts (volts) ~1.68 to 1.76 2 2.5 volts (volts) ~2.38 to 2.46 3 3.3 volts (volts) ~3.17 to 3.24 4...

  • Page 211

    General troubleshooting 4-53 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 home position. R# definition typical value actions 0 dm initial fe peak (pm motor counts) mfg only reports the height of the init...

  • Page 212: System Power-Up Sequence

    4-54 workcentre c2424 service manual system power-up sequence use the power-up sequence timing chart to troubleshoot failures that occur during the power-on sequence. The chart provides typical timing of mechanical events that occur relative to power-on, assuming the printer is cold and was shutdown...

  • Page 213

    General troubleshooting 4-55 mechanical initialization of the print engine the following chart does not include initialization of the exit module. Start the thermals 13,xxx unbind media path motor and home the mpt 31,000 home the y -axis 5001, 5002 w ait for the head to read ok_to_wipe temperatures ...

  • Page 214

    4-56 workcentre c2424 service manual _head parked on? Last power down? Move cap/wiper to the park arms- and restrain head again. 8035,7009 home dmfix 7002 jog the x axis in order to release the head t ilt arms. Move head to the p ark position, 7007, 7008, 8005, 8055, 8007, 8008, 8009, 7014 if not in...

  • Page 215

    General troubleshooting 4-57 head cleaning cycle performance if the printhead, ink reservoirs, or jetstack temperature are below purge threshold, the system performs a head clean cycle. 1. The system waits for the printhead to reach its purge temperature. 2. The system moves the wiper to the bottom ...

  • Page 216: Electrical Troubleshooting

    4-58 workcentre c2424 service manual electrical troubleshooting electronics module the electronics module contains the power supply, main board containing the image processor controller board, and the power control board. If a component of the electronics module fails, and service is necessary, the ...

  • Page 217

    General troubleshooting 4-59 document feeder lamp does not turn on 1. Is there power at the document feeder? Place media into the document feeder input tray. If the paper feeds the document feeder has power, the lamp circuit is faulty, replace the document feeder. 2. Is there power at the scanner? L...

  • Page 218

    4-60 workcentre c2424 service manual scanner scanhead does not move 1. Verify the scanhead shipping lock is in the “unlocked” position. Reboot the system. 2. Is there power to the scanner assembly? Lift the document feeder and verify the document feeder lamp is on. If so, the scanner power supply is...

  • Page 219: Error Code

    General troubleshooting 4-61 d. With power cord connected, touch the metal electronics module to discharge any static electricity. Esd damage to the system may occur if static electricity is discharged to system electronics. E. Turn off system and wait 30 seconds for power supply capacitors to disch...

  • Page 220: System Fails to Power-Up

    4-62 workcentre c2424 service manual exit module (mep) is malfunctioning 1. The exit module elevator does not raise 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 ...

  • Page 221

    General troubleshooting 4-63 d. Unplug the following electronics module connectors: this step removes all other circuits so the electronics module can be tested alone (see also "plug/ jack locator table" on page 10-2). ■ power control to i/o board (j800) ■ power control right (j400) ■ printhead data...

  • Page 222

    4-64 workcentre c2424 service manual ■ exit module j680 ■ heater relay control j950 (no cable) c. Retest the resistance of the i/o board. If the resistance is still less than 1k ohm, replace the i/o board, reinstall all cables and retest system. D. If the i/o board resistance is ok, plug in the i/o ...

  • Page 223

    General troubleshooting 4-65 h. Attach the system covers. I. Perform full test of system. 3. Power supply problems in the energy star mode. A. In the energy star mode, the 2nd power supply is turned off via a signal from the image processor board. B. If the power supply fails to shut off, the system...

  • Page 224

    4-66 workcentre c2424 service manual a. Verify configuration card is properly oriented and fully inserted. B. Clean configuration card contacts with isopropyl alcohol, reinstall, and then retest. C. Swap configuration card with a known working card to test operation. D. The configuration card enable...

  • Page 225

    General troubleshooting 4-67 non-specific electronics failure 1. Disconnect 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...

  • Page 226

    4-68 workcentre c2424 service manual m. Plug in the i/o board connector ('p' / j800) in the electronics module. This step adds the i/o board and control panel to the electronics module. N. Turn on power to the system. O. If the electronics module, i/o board and control panel are working, the error c...

  • Page 227

    General troubleshooting 4-69 f. If repairs are 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 perfo...

  • Page 228

    4-70 workcentre c2424 service manual verifying scanner power supply operation 1. Open the electronics module and observe the +24 vdc led. If the led is on, the scanner power supply is operational. 2. If the led is blinking, there is a problem with the document feeder, scanner power supply or exit mo...

  • Page 229

    General troubleshooting 4-71 verifying power supply operation - print engine the power supply is divided into two sections: the ac section used for heaters and the dc section for control logic, printhead drivers and motors. Verifying thepower supply involves three steps: 1. Checking for proper ac vo...

  • Page 230

    4-72 workcentre c2424 service manual measuring ac power supply voltages ac line voltages are present on the power supply and possibly in the system, via the heaters, while the system is plugged into an ac outlet. The power switch is detected by software and proper shut down is followed by a power of...

  • Page 231: Ensuring Ground Integrity

    General troubleshooting 4-73 measuring dc power supply voltages 1. Check the power supply status leds, they should be bright. 2. If the system is operational, use the diagnostic test monitor voltages. Ensuring ground integrity intermittent or missing ground connections can result in minor interferen...

  • Page 232: Key Ground Connections

    4-74 workcentre c2424 service manual key ground connections the following illustration shows the grounding points in the iot that need to be checked. There is also one grounding point in the backframe s2424-069 transfix roller ground springs i/o board ground dm ground clip x-axis return spring groun...

  • Page 233

    General troubleshooting 4-75 testing motor and solenoid resistances 1. Turn off the system and disconnect the power cord. 2. With a dmm set for measuring resistance, test each motor's windings for correct resistance (disconnected from the system). Rotate the motor's drive shaft slightly while taking...

  • Page 234: Media-Based Problems

    4-76 workcentre c2424 service manual paper path and media-based problems for paper path and media-based 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 elimi...

  • Page 235: Paper-Pick Errors - Tray 1

    General troubleshooting 4-77 8. Run the paper path test. 9. Replace the pick roller if damaged. 10. Inspect the rollers, bushings and gears of the paper path. Paper-pick errors - tray 1 1. Verify the media being used is the correct size and weight. 2. Clean or replace the document feeder pick roller...

  • Page 236

    4-78 workcentre c2424 service manual checking the process and media path drive 1. Determine if the process motor runs. If it does not rotate, go to step 2. If it does rotate, go to step 4. 2. Measure to determine if +50 vdc is being supplied to the motor. If power is applied, go to step 3. If it is ...

  • Page 237: Testing Communications Ports

    General troubleshooting 4-79 operating system and application problems print an internal test print from the system’s control panel 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, phasersmar...

  • Page 238: 169.254.Xxx.Xxx

    4-80 workcentre c2424 service manual 7. Using the system control panel, disable dhcp/bootp and autoip so that the system can be configured manually. 8. Select an ip address for the system that matches the computer, except for the last field, which must be unique. 9. Edit the system’s gateway and sub...

  • Page 239: Usb Port Verification

    General troubleshooting 4-81 usb port verification 1. Verify that the system is ready to print . 2. Insert the system installer and utilities cd-rom into the computer. 3. If the installer autoruns, exit the installer window. 4. Connect a usb cable between the system and computer usb ports. The compu...

  • Page 240

    4-82 workcentre c2424 service manual 5. The page should now print. Note to print the connection setup page or configuration page, select the system setup menu. Obtaining serial back channel trace in rare cases the system may exit unusual behavior that is difficult to troubleshoot. In such cases, if ...

  • Page 241: In This Chapter...

    5 section 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.

  • Page 242

    5-2 workcentre c2424 service manual image-quality problems overview image-quality defects can be attributed to the following: ■ system hardware components or communication ■ consumables ■ media ■ internal or external software applications ■ environmental conditions to successfully troubleshoot print...

  • Page 243

    Image-quality troubleshooting 5-3 service technician rip procedure 1. Clean all pick rollers only when ink or debris is visible. 2. Clean feed rollers, exit rollers, and guides only when ink or debris is visible. 3. Inspect the wiper blade. If the wiper blade is damaged, replace the wiper assembly. ...

  • Page 244: Dadf Image-Quality Problems

    5-4 workcentre c2424 service manual dadf image-quality problems dark streaks on the copied image voids in the copied image step questions and actions yes no 1 1. Reseat all connections to the dadf and scanner assembly. 2. Copy another page. 3. Did this correct the problem? Complete. Go to step 2. 2 ...

  • Page 245: Skewed Copy Image

    Image-quality troubleshooting 5-5 skewed copy image copy image is lighter/darker than the original step questions and actions yes no 1 1. Ensure the original copy being used is supported by this system and undamaged. Go to step 2. Use the platen. 2 1. Ensure the paper guides are adjusted securely ag...

  • Page 246: Fuzzy Text/image

    5-6 workcentre c2424 service manual fuzzy text/image step questions and actions yes no 1 1. Cycle power to the system, this will cause an automatic calibration cycle. 2. Does the text or image still appear fuzzy? Go to step 2. Complete. 2 1. Print the graphics demo for a fuzzy image or the configura...

  • Page 247

    Image-quality troubleshooting 5-7 copied image colors do not match the original note there can be slight color variations from an original copy to a solid ink print resulting from the physical properties of the original, (i.E., ink jet copy, laser toner copy, etc.) step questions and actions yes no ...

  • Page 248: Copied Image Is Skewed

    5-8 workcentre c2424 service manual scanner image quality problems dark streaks on the copied image copied image is skewed copied image is lighter/darker than the original step questions and actions yes no 1 1. Reseat the cable connection from the scanner assembly to the electronics module. 2. Clean...

  • Page 249

    Image-quality troubleshooting 5-9 copy image colors do not match the original note there can be slight color variations from an original copy to a solid ink print resulting from the physical properties of the original, (i.E., ink jet copy, laser toner copy, etc. Step questions and actions yes no 1 1...

  • Page 250: Fuzzy Text/image

    5-10 workcentre c2424 service manual fuzzy text/image step questions and actions yes no 1 1. Cycle power to the system, this will cause an automatic calibration cycle. 2. Does the text or image still appear fuzzy? Go to step 2. Complete. 2 1. Print the graphics demo for a fuzzy image or the configur...

  • Page 251: Problems

    Image-quality troubleshooting 5-11 diagnosing iot (print engine) print-quality problems when analyzing a print-quality defect from a print engine malfunction, determine if the defect occurs: ■ in all colors ■ in only one color ■ as a repeating or random defect the troubleshooting print-quality page ...

  • Page 252: Random Light Stripes

    5-12 workcentre c2424 service manual random light stripes one or more color bars are missing on the test page. This is probably caused by a weak or clogged printhead jet. Step questions and actions yes no 1 1. At the system’s control panel, select the eliminate light stripes function and follow the ...

  • Page 253: Predominate Light Stripes

    Image-quality troubleshooting 5-13 predominate light stripes all four color bars are missing on the test page. The probable cause for light stripes is something scraping the image off the drum before transfixing. Note: if there are a series of regularly spaced white lines approximately 6 mm (.25 in....

  • Page 254: Smudges Or Smears

    5-14 workcentre c2424 service manual smudges or smears smudges or smears appear on the page. The probable cause is ink residue in the paper path. The residue can be found on the roller, on the paper guide ribs, or inside the paper preheater. Step questions and actions yes no 1 1. Clean the system’s ...

  • Page 255: No Image Is Being Printed

    Image-quality troubleshooting 5-15 the printed image is too light or too dark no image is being printed the system processes a sheet of paper, but no image is printed on it. Note blank sheets accompanying multi-picks or chase pages following a jam are a part of normal operation. Step questions and a...

  • Page 256

    5-16 workcentre c2424 service manual color is uneven or color is wrong this may be due to incorrect colors in the ink loader, old ink in the printhead, color mixing at the faceplate, or drum thermal problems. Note : using non-xerox ink may cause unpredictable color results. Step questions and action...

  • Page 257

    Image-quality troubleshooting 5-17 streaks or lines down the print there are several possible causes of streaks running down the length of a print. Step questions and actions yes no 1 1. Check for and remove any media, jammed paper, or debris found in the systems exit path. 2. Did this correct the p...

  • Page 258

    5-18 workcentre c2424 service manual 6 1. Possible discolored jet. Print the solid fill test print, see "13-19: black, red, green, blue, cyan, magenta, and yellow solid fills" on page 5-42. 2. Did this correct the problem? Complete. Go to step 7. 7 1. The x-axis drive is not functioning correctly. I...

  • Page 259

    Image-quality troubleshooting 5-19 scratches or marks parallel to the long axis of printing, particularly with transparencies usually caused by debris in the paper path. The scratch or mark may extend into non-printed areas or be more pronounced on the lower portion of the image. Step questions and ...

  • Page 260

    5-20 workcentre c2424 service manual 4 1. If there is no visible scratch on the transparency the defect occurred during paper pick or early transport from trays 2, 3, or 4. 2. Change the paper pick guide, front door, or maintenance kit. 3. Did this correct the problem? Complete. Go to step 5. 5 a sc...

  • Page 261

    Image-quality troubleshooting 5-21 there is ink on the white portion of the printed page color on a print where no color should be printed is often called a latent image. A latent image remains on the drum when it should have been transferred to its sheet of paper. An insufficient amount of oil on t...

  • Page 262: Fuzzy Text

    5-22 workcentre c2424 service manual fuzzy text text appears indistinct and difficult to read. There are three typical reasons for fuzzy text, as called out in this illustration. Top left image displays a y-axis drum rotation problem. Lower left image displays the wrong drum temperature problem. Low...

  • Page 263

    Image-quality troubleshooting 5-23 7 1. Verify the printhead is tilted forward against the drum in the proper print position. 2. Did this correct the problem? Complete. Follow the instructions on the "on-site printhead troubleshooting checklist" on page a-7. Step questions and actions yes no.

  • Page 264: Poor Primary Color Fills

    5-24 workcentre c2424 service manual poor primary color fills primary fills appear banded and inconsistent. Step questions and actions yes no 1 1. Banded and inconsistent primary fills may indicate a missing, weak, or discolored jet. 2. Print the service test print 1: weak/missing jet. 3. If there a...

  • Page 265: Ghosting

    Image-quality troubleshooting 5-25 ghosting the image from a previous print is on the current print. Step questions and actions yes no 1 1. This problem can occur from prints being stacked in the output tray, causing the pressure of the stack and the heat of the system to cause “blocking” which has ...

  • Page 266: Poor Small Text Resolution

    5-26 workcentre c2424 service manual poor small text resolution small characters appear heavy and “plug up.” step questions and actions yes no 1 1. Try using a higher quality print mode. 2. Did this correct the problem? Complete. Go to step 2. 2 1. Run service diagnostics to check the temperature of...

  • Page 267: Vertical Lines Appear Wavy

    Image-quality troubleshooting 5-27 vertical lines appear wavy straight vertical lines appear to be wavy and ill-formed. Step questions and actions yes no 1 1. There may be too much oil on the drum. 2. Inspect and clean the maintenance kit wiper blade. 3. If necessary, replace the maintenance kit. 4....

  • Page 268: Oil Streaks On Print

    5-28 workcentre c2424 service manual oil streaks on print oil stains the edge of the print. Step questions and actions yes no 1 1. There may be too much oil on the drum. 2. Inspect and clean the maintenance kit wiper blade. 3. If necessary, replace the maintenance kit. 4. Did this correct the proble...

  • Page 269

    Image-quality troubleshooting 5-29 incomplete image transfer to paper all of the image does not transfer to the paper. Media that is not smooth enough or too light can cause this problem. This problem can also occur on watermarked paper. Step questions and actions yes no 1 1. Verify the media is sup...

  • Page 270

    5-30 workcentre c2424 service manual ink smears on first printed side of duplex print preheater temperature is too high. 7 1. Is the incomplete image transfer on the left and right sides of the print, but fine through the center? 2. This indicates incomplete transfix cam rotation. Check for a damage...

  • Page 271

    Image-quality troubleshooting 5-31 repeating print defects on print the distance between each artifact of a repeating image defect reveals which imaging component is causing the defect. Transfix roller defects show up as light spots in solid fill areas. 4 1. Use service diagnostics to check the pape...

  • Page 272: White Stripes (Pinstripes)

    5-32 workcentre c2424 service manual white stripes (pinstripes) this print-quality problem has a series of regularly spaced white stripes approximately 6 mm (.25 in.) apart. If the x-axis drive does not move the printhead smoothly and evenly during printing, vertical lines appear in the print. Step ...

  • Page 273: Wrinkling

    Image-quality troubleshooting 5-33 wrinkling the print is usually damaged in a corner with solid fills. This problem is more often seen on short-grain media. Some wrinkling on envelopes flaps is an acceptable limitation of this system. You may see wrinkling on the second side of a 2-sided print on t...

  • Page 274: Image Is Offset Or Cut-Off

    5-34 workcentre c2424 service manual image is offset or cut-off 1. Print an information page from the system’s control panel. This is to verify the driver settings or image file is not the cause of the problem. If the defect is not visible on the information page, the problem is not hardware related...

  • Page 275: Test Print Examples

    Image-quality troubleshooting 5-35 analyzing service test prints a variety of test prints are available in the hidden service menu to aid in determining the quality of output from the system and to assist in troubleshooting problems. This section shows how to select and analyze all test prints avail...

  • Page 276: 2: X-Axis Motion (Drop Mass

    5-36 workcentre c2424 service manual 2: x-axis motion (drop mass evaluation) for x-axis motion problems, see service test prints 13-19 (solid fill prints). This print is used by engineering and manufacturing. The print must be printed on xerox photo paper. Using a lower grade paper results in inaccu...

  • Page 277: 4: Reverse Text

    Image-quality troubleshooting 5-37 4: reverse text the print indicates if the 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 “t...

  • Page 278: 5: Big Bands Ohp

    5-38 workcentre c2424 service manual 5: big bands ohp this print allows you to evaluate transparency printing. It prints two transparencies from tray 1: one with primary color fills and one with secondary color fills and a band of 50% blue. This is a popular background color for overhead transparenc...

  • Page 279: 7: Manuf. Five Duplex Gsf

    Image-quality troubleshooting 5-39 6: gray fill, dot size uniformity this print is made up of a 66% black fill. It reveals variations in the ink-drop-spread caused by thermal variations, transfix roller pressure variations, or drum oiling variations. Look for: 1. There is a large area of differences...

  • Page 280: 8: Ymckrgb Solid Fills

    5-40 workcentre c2424 service manual 8: ymckrgb solid fills these seven prints show uniformity of fill. If colors are uneven or wrong, see "color is uneven or color is wrong" on page 5-16. Look for: 1. There are even, uniform fills throughout each print. 2. Wrinkles or deformity of the paper itself ...

  • Page 281: 11: Head-to-Drum Check

    Image-quality troubleshooting 5-41 11: head-to-drum check these prints indicate if the gap between the printhead and the drum is correct. Lines: the horizontal lines of the print are made up of long and short dashes. Inspect the first and last 1/2 in. (12 mm) of the black lines for the vertical dist...

  • Page 282: Fills

    5-42 workcentre c2424 service manual 13-19: black, red, green, blue, cyan, magenta, and yellow solid fills this prints show uniformity of fill. Look for: 1. There are even, uniform fills throughout the print. 2. There should be no wrinkling or deformity of the paper throughout the print. 3. You may ...

  • Page 283: 21: Primary Solid Fills 10X

    Image-quality troubleshooting 5-43 21: primary solid 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 ...

  • Page 284: 22: Manuf. Skew Margins

    5-44 workcentre c2424 service manual 22: manuf. Skew margins this print consists of an image used by manufacturing to gauge skew and margin on 2- sided prints. Skew to measure skew: the measurement between the edge of the paper and the magenta frame should be within tolerance along the entire length...

  • Page 285: 23: Manuf. Banding

    Image-quality troubleshooting 5-45 23: manuf. Banding this print is used by manufacturing. 24: head roll this print is used by manufacturing. 25: head height this print is used by manufacturing and engineering. 26: x dot position this print is used by manufacturing and engineering. 27: y dot positio...

  • Page 286: 31: Cleaning (Chase) Page

    5-46 workcentre c2424 service manual 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. Test print examples (continued) s2424-100

  • Page 287: In This Chapter...

    6 section 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.

  • Page 288: Wiper Alignment

    6-2 workcentre c2424 service manual system alignments and adjustments wiper alignment 1. Remove the system covers using the 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 in...

  • Page 289

    Adjustments and calibrations 6-3 3. Rotate the left and right idler gears until the wiper is all the 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. 4...

  • Page 290: Indicators

    6-4 workcentre c2424 service manual print engine component home positions and indicators 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...

  • Page 291: Homing The Head Tilt Gear

    Adjustments and calibrations 6-5 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. S2424-018 tilt gear (engaged) tilt ge...

  • Page 292

    6-6 workcentre c2424 service manual when the printhead is in the printer 1. Remove the maintenance kit. 2. Insert a flat blade screwdriver into the end of drum maintenance cam shaft and rotate clockwise one revolution. If the printhead is engaged, manually assist the movement of the printhead. There...

  • Page 293

    Adjustments and calibrations 6-7 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. S2424-016 drum printhead tilt gear tilt gear (disengaged) dm cam gear.

  • Page 294

    6-8 workcentre c2424 service manual homing the process gear drive train examine the process gear drive train for the following: ■ the holes in the process drive frame must align with the holes in the gear. ■ the hole in the drum maintenance camshaft gear must align with the arrow on the frame. ■ the...

  • Page 295

    Adjustments and calibrations 6-9 manual dadf to scanner calibration note perform this calibration procedure when replacing the scanner unit or dadf assembly. It is best to start this procedure with the scanner having just made a duplex copy, this ensures the lamps are on and ready. If the lamps need...

  • Page 296: Scanner Platen Steps

    6-10 workcentre c2424 service manual scanner platen steps 1. Place the scanner calibration page on the platen with the top edge to the left as shown. Note make sure the calibration page is aligned correctly. If the page is misaligned, the calibration procedure fails. 2. Close the document feeder. 3....

  • Page 297: Document Feeder Steps

    Adjustments and calibrations 6-11 document feeder steps 1. Place the scanner calibration page in the document feeder so that the top edge enters first (as shown). Adjust the paper guides so they fit against the page. Note make sure the calibration page is aligned correctly and the paper guides are a...

  • Page 298: Jet Substitution Mode

    6-12 workcentre c2424 service manual jet substitution mode the jet substitution mode provides a temporary solution for print-quality problems when weak or missing jets cannot be recovered. Jet substitution mode reduces the maximum imaging speed by 50% or more and has other limitations that affect pr...

  • Page 299: Resetting Nvram

    Adjustments and calibrations 6-13 disabling jet substitution mode after the printhead is replaced, disable jet substitution mode to restore normal operation. Using the hidden jet substitution mode menu, select jet select . 1. First press system setup , and then enter the information menu. 2. From th...

  • Page 300

    6-14 workcentre c2424 service manual.

  • Page 301: In This Chapter...

    7 section cleaning and maintenance in this chapter... ■ inspection ■ system self-maintenance ■ service cleaning and maintenance procedures ■ cleaning for print-quality problems ■ maintenance kit ■ lubrication.

  • Page 302: Inspection

    7-2 workcentre c2424 service manual inspection rollers: replace the rollers when you see any of the following defects: ■ flat spots ■ out of roundness ■ cracked rubber ■ loss of traction (tackiness) causing pick or feed failures gears: replace gears that show any signs of wear or breakage. Look for ...

  • Page 303: System Self-Maintenance

    Cleaning and maintenance 7-3 system self-maintenance to maintain peak operation, reliability, and print quality, the system has several automatic or semi-automatic maintenance functions. These functions may be started automatically after a certain number of prints or during system power on, or they ...

  • Page 304: Transfix Roller Oiling

    7-4 workcentre c2424 service manual paper preheater cleaning (remove print smears) the paper preheater cleaning procedure is a function selected on the control panel by the user. This procedure cleans ink out of the paper preheater that may have been deposited there. Heavier-weight, high-grade quali...

  • Page 305: Supplies Required

    Cleaning and maintenance 7-5 service cleaning and maintenance procedures ■ clean dust build-up on the exterior of the system. ■ inspect the vents on the exterior of the system for excessive dust and build up. Clean if necessary. ■ clean the pick rollers as described in this section. ■ clean the scan...

  • Page 306

    7-6 workcentre c2424 service manual cleaning for print-quality problems appropriate cleaning procedures, as listed in the following tables, should be performed when specific print-quality or paper transport problems occur. All cleaning procedures are detailed in the system’s user guide. Scan or copy...

  • Page 307: Pick Roller Cleaning Methods

    Cleaning and maintenance 7-7 media jams and paper pick cleaning procedures pick roller cleaning methods tray 1 pick rollers tray 1 pick rollers can be cleaned with an alcohol moistened swab. 1. Open the front cover. 2. Rotate the roller and clean it with an alcohol-moistened swab. 3. Rotate the roll...

  • Page 308

    7-8 workcentre c2424 service manual trays 2 through 4 pick rollers use off-the-shelf clear packaging tape and follow the procedures listed below to clean the pick roller and pick pad for trays 2-4. This cleaning method has been found to be extremely effective for removing debris. Isopropyl alcohol, ...

  • Page 309: Maintenance Kit

    Cleaning and maintenance 7-9 maintenance kit (pl 1.24) the system uses a maintenance kit as part of its self-maintenance routine to coat the print drum with oil before each print. For a detailed explanation on the functions of the maintenance kit, see "drum maintenance system" on page 2-37. Maintena...

  • Page 310: Lubrication

    7-10 workcentre c2424 service manual lubrication the system is lubricated during assembly at the factory and requires no periodic lubrication. Certain system components require lubrication following replacement. These parts are identified in the replacement procedures. When lubricating during replac...

  • Page 311: In This Chapter...

    8 section 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...

  • Page 312: Overview

    8-2 workcentre c2424 service manual overview this section contains the removal and replacement procedures for selected parts of the printer according to the field replaceable units (service parts) parts list. In general, replacement procedures are not given because re-installing a part is simply a r...

  • Page 313: General Notes On Disassembly

    Service parts disassembly 8-3 general notes on disassembly caution follow the steps of all disassembly procedures in the order given to avoid damaging printer components. 1. Before servicing the printer, switch off the printer power, wait until the printer completely shuts down, and disconnect the p...

  • Page 314

    8-4 workcentre c2424 service manual image input terminal (dadf and scanner) duplex automatic document feeder (pl 1.15) 1. Disconnect the document feeder cable from the scanner assembly. 2. You must depress the locking mechanism (2) on the back hinges to release the document feeder from the scanner a...

  • Page 315: Dadf Front Cover

    Service parts disassembly 8-5 dadf front cover (pl 1.13) 1. Remove 3 screws securing the cover. 2. Lift and remove. S2424-241.

  • Page 316: Scanner Assembly

    8-6 workcentre c2424 service manual scanner assembly (pl 1.11) caution you must lock the scanhead 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 317: Control Panel

    Service parts disassembly 8-7 control panel (pl 1.9) 1. Remove 4 screws securing the control panel to the scanner assembly. 2. Release the 6 tabs securing the control panel and carefully lift to access the connector. 3. Disconnect the control panel connector from the scanner assembly. 4. Remove the ...

  • Page 318: Covers

    8-8 workcentre c2424 service manual covers a video entitled “replacing 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 cable...

  • Page 319

    Service parts disassembly 8-9 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.

  • Page 320: Front Door / Tray 1 Assembly

    8-10 workcentre c2424 service manual front door / tray 1 assembly (pl 1.1) 1. Open the front door assembly and unsnap the right and left stay retainers from 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...

  • Page 321: Right and Left Side Covers

    Service parts disassembly 8-11 right and left side covers (right pl 1.21, left pl 1.7) 1. Remove the output paper tray. 2. Open the front door to allow removal of the right side cover. 3. Remove one screw, on the back of the system, securing the right side cover. 4. Using a flatblade screwdriver, in...

  • Page 322: Rear Cover and Emi Shield

    8-12 workcentre c2424 service manual rear cover and emi shield (pl 1.20) 1. Remove the left and right side covers (page 8-11). 2. Using a flatblade screwdriver, release the tab securing the back cover. 3. Remove 2 screws securing the emi shield. 4. Using a flatblade screwdriver, release the tab secu...

  • Page 323: Imaging

    Service parts disassembly 8-13 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...

  • Page 324: Motor Assembly

    8-14 workcentre c2424 service manual 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 print...

  • Page 325: Replacement Notes:

    Service parts disassembly 8-15 6. Disconnect the motor wiring harness connector 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. Replacement notes: note ensure the spring arm screws are...

  • Page 326: Restraints

    8-16 workcentre c2424 service manual printhead assembly, right and left printhead restraints ( printhead pl 2.2) (restraints pl 2.8, 2.9) videos are available with instructions for replacing the printhead assembly. Videos are located on the workcenter c2424 product training cd-rom. Warning the print...

  • Page 327

    Service parts disassembly 8-17 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 that are captured by left and right printhead restraints. If the restraints are released, the printhead tilt spring will push...

  • Page 328

    8-18 workcentre c2424 service manual 6. Disconnect the air hose from the purge pump. S2424-022 1 2 bias spring hook purge pump.

  • Page 329

    Service parts disassembly 8-19 7. Remove left and right printhead restraints. Remove 1 screw, pull inward towards the printhead, and then lift up slightly toward the rear of the printer to remove. Note adjust printhead position as required to remove the right restraint. Caution the roll block stays ...

  • Page 330

    8-20 workcentre c2424 service manual 9. Disconnect the heater cable and free the cable harness from its restraint. 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. 11. Disconnect the data cable from the print head. ...

  • Page 331: Replacement Notes:

    Service parts disassembly 8-21 12. Disconnect the 2 flex cables from the printhead. Warning do not pinch or tear the air hose while removing the printhead as this can damage the printer. 13. Lift the printhead free of the printer chassis. Replacement notes: caution to avoid damage observe the follow...

  • Page 332

    8-22 workcentre c2424 service manual 3. Insert the ribbon cables fully and squarely into the zif connectors. Caution ensure that the flex cables are inserted into the zif connectors on the printhead fully and squarely. If the cables are inserted incorrectly, they can short out the wave amp. 4. Conne...

  • Page 333: X-Axis Bias Spring

    Service parts disassembly 8-23 x-axis bias spring (pl2.21) 1. Remove the printhead (page 8-16). Caution the spring is in close proximity to the drum. Be careful with the removal tools and the spring to ensure that you do not damage the drum. 2. Using your hands, a spring hook, or pliers, remove the ...

  • Page 334: Printhead Wiper

    8-24 workcentre c2424 service manual printhead wiper (pl 2.5) videos are available with instructions for replacing the printhead wiper. Videos are located on the workcentre c2424 product training cd-rom. 1. Remove the printhead (page 8-16). Caution place several sheets of paper between the printhead...

  • Page 335: Replacement Note:

    Service parts disassembly 8-25 replacement note: note position the wiper so both 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 ...

  • Page 336: Transfix Roller

    8-26 workcentre c2424 service manual media 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 ri...

  • Page 337

    Service parts disassembly 8-27 paper preheater and deskew assembly (pl 2.17) 1. Open the front door. 2. Remove the lower duplex guide and the white 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...

  • Page 338: Replacement Note:

    8-28 workcentre c2424 service manual 4. Slide the latches in and forward to latch in their slots as shown by (1) and (2) in the following illustration. 5. Slide the preheater off the shelves and out of the printer as shown by (3). Replacement note: note the fingers on the inner simplex guide go over...

  • Page 339: Duplex Roller

    Service parts disassembly 8-29 duplex 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-clip on the shaft. 4. Slide the shaft toward the left (2) to ...

  • Page 340: Transfix Load Module

    8-30 workcentre c2424 service manual transfix load module (pl 2.15) videos are available with 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...

  • Page 341

    Service parts disassembly 8-31 in the next step, the 2 transfix load arms and stripper 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 syste...

  • Page 342

    8-32 workcentre c2424 service manual 11. Remove the grounding springs from the transfix load module to avoid bending them. 12. Remove 2 screws securing each end of the transfix load module to the chassis. S2424-165 grounding springs s2424-166 transfix load module.

  • Page 343: Replacement Notes:

    Service parts disassembly 8-33 13. The transfix load module fits tightly in the chassis. Rotate the bottom inwards and pull it forward to remove it from the frame. Replacement notes: note place a small amount of rheolube 768 grease (p/n 00679900) in the groove on the end of each transfix load arm be...

  • Page 344: Transfix Camshaft Assembly

    8-34 workcentre c2424 service manual transfix camshaft assembly (pl 2.10) 1. Perform steps 1 through 6 of the transfix load module removal procedure (page 8-30). 2. Remove the process drive gearbox assembly (page 8-55). 3. Slide the shaft to the right (1) and make sure the bearing slides over to the...

  • Page 345: Replacement Notes:

    Service parts disassembly 8-35 drum maintenance camshaft assembly (pl 2.11) 1. Remove the drum maintenance pivot plate assembly (page 8-36). 2. Remove the process drive gearbox assembly (page 8-55). 3. Slide the shaft to the right, free the bushing, and pull out the shaft to the right. Caution the g...

  • Page 346

    8-36 workcentre c2424 service manual 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 8-10). 3. Remove the paper preheater (page 8-27). 4. Remove the kl-clip on the left end of the pivot plate shaft. 5....

  • Page 347: Drum Assembly

    Service parts disassembly 8-37 drum assembly (pl 2.3) videos are 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 ...

  • Page 348: Replacement Notes:

    8-38 workcentre c2424 service manual 11. Remove 3 screws and 2 washers from the right side of the drum assembly. 12. Remove 3 screws and 3 washers from the left side of the drum assembly. 13. Using the metal grips, lift the drum assembly straight up to remove it from the system. Caution to prevent d...

  • Page 349

    Service parts disassembly 8-39 4. Install 1 screw at the rear position to hold the right labyrinth seal and torque the screw to 25 in.-lbs. 5. Pull outward on the left labyrinth seal handle and the right chassis side to spread the chassis and seat the left drum bearing. 6. Align the clevis on the tr...

  • Page 350

    8-40 workcentre c2424 service manual 21. Ensure that the drum heater cable and drum encoder cable are dressed correctly and secured by the retainer hook at the process gearbox. 22. Reinstall the drum fan assembly and secure it with 3 screws. Torque the top screw into the labyrinth seal to 20 in.-lbs...

  • Page 351: Purge Pressure Pump

    Service parts disassembly 8-41 purge pressure 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. S2424-023 purge pressure pu...

  • Page 352: Paper Path

    8-42 workcentre c2424 service manual paper path exit module assembly (mep) (pl 3.7) 1. Remove the dadf, scanner assembly, side covers, and inkloader, pages 4 thru page 13. 2. Right side instructions ■ remove right front screw. ■ remove the pulley and belt from the elevator roller to access and remov...

  • Page 353

    Service parts disassembly 8-43 3. Left side instructions ■ loosen the media path gearbox to access and 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...

  • Page 354: Replacement Note:

    8-44 workcentre c2424 service manual replacement note: after installing the mep, perform the wiper alignment (page 6-2). The printer may report error code 7,009.4x if the wiper assembly is misaligned. Paper guides inner simplex (pl 3.1) 1. Open the printer front door to access the guide. 2. Using a ...

  • Page 355

    Service parts disassembly 8-45 outer duplex paper guide with sensors (safety interlocks) (pl 3.6) 1. Remove the output tray assembly and disconnect the two wiring harnesses. 2. Remove the output tray. 3. Remove the side covers. 4. Open the exit cover and remove the outer duplex guide. Upper duplex g...

  • Page 356

    8-46 workcentre c2424 service manual 4. Remove the upper duplex guide from the printer. S2424-275 hole for solenoid lever solenoid lever upper duplex guide.

  • Page 357: Replacement Notes:

    Service parts disassembly 8-47 replacement notes: note 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 pa...

  • Page 358: Take Away Roller

    8-48 workcentre c2424 service manual 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-...

  • Page 359: Pick Assembly

    Service parts disassembly 8-49 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 the ceiling of the tray cavity about 1/4 of the way across the unit from the right...

  • Page 360: Replacement Note:

    8-50 workcentre c2424 service manual replacement note: note insert the replacement with the metal shaft at the top and toward the left, the grey rollers should 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...

  • Page 361: Tray Lift Motor

    Service parts disassembly 8-51 tray lift motor (pl 4.10) 1. Remove the electronics module (page 8-61). 2. Remove tray 2. 3. Disconnect the wiring harness from the media tray lift motor. 4. From the rear of the printer, inside the cavity, remove the push nut (this is a press fit and you will need to ...

  • Page 362

    8-52 workcentre c2424 service manual motors, 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 t...

  • Page 363: Replacement Note:

    Service parts disassembly 8-53 replacement note: note to replace the 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...

  • Page 364: Tray 1 (Mpt) Pick Solenoid

    8-54 workcentre c2424 service manual 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. S2424-181 tray 1 pick solenoid.

  • Page 365

    Service parts disassembly 8-55 process drive 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 hea...

  • Page 366: Replacement Notes:

    8-56 workcentre c2424 service manual 4. Remove 3 screws and remove the process drive motor and gearbox. 5. Disconnect the wiring harness from the process drive motor. Replacement notes: caution if replacing the process gear drive, see "homing the process gear drive train" on page 6-8). Caution be ca...

  • Page 367: X-Axis Motor Assembly

    Service parts disassembly 8-57 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. Replacement note: note when reinstalling the x-axis motor, ensure that the fork, exte...

  • Page 368: Head Tilt Compound Gear

    8-58 workcentre c2424 service manual head tilt compound gear (pl 4.13) 1. Remove the printhead assembly (page 8-16). 2. On the left side of the system, remove the kl-clip as shown. 3. Remove the waste tray frame, without disconnecting the sensor wiring harness (page 9-15). 4. Reach into the waste tr...

  • Page 369: Electronics

    Service parts disassembly 8-59 electronics scanner power supply (pl 5.2) warning unplug the power cord. The scanner power supply connects directly to the ac line. 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 (pag...

  • Page 370: Exit Module (Mep) Board

    8-60 workcentre c2424 service manual exit module (mep) board (pl 5.1) 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). 4. Remove the rear cover and emi shield (page 8-12). 5. Disconnect all wiring to the...

  • Page 371: Electronics Module

    Service parts disassembly 8-61 electronics module (pl 5.5) videos are available with instructions for replacing the electronics module. Videos are located on the workcentre c2424 product training cd-rom. Caution touch the back of the electronics module before starting this procedure to discharge any...

  • Page 372: Replacement Note:

    8-62 workcentre c2424 service manual 11. Remove the electronics module. Replacement note: note when replacing the electronics module, transfer the configuration card, nvram, sodimm ram, and hard drive to the new module. Electronics module s2424-186.

  • Page 373

    Service parts disassembly 8-63 back 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 l...

  • Page 374

    8-64 workcentre c2424 service manual s2424-214 back frame.

  • Page 375: Wave Amp Board

    Service parts disassembly 8-65 wave amp board (pl 5.4) 1. Remove electronics module (page 8-61). 2. Remove the printhead (page 8-16). 3. Remove 3 screws (see illustration below). Caution route the ribbon cables carefully through the slots. 4. Remove the wave amp board through the back of the printer...

  • Page 376: I/o Board

    8-66 workcentre c2424 service manual i/o board (pl 5.13) 1. Remove the right side cover (page 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. Replacement note: note ensure the corner of the board is behind the groun...

  • Page 377: Drum Heater Relay Board

    Service parts disassembly 8-67 drum heater relay board (pl 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 ...

  • Page 378: Nvram Replacement

    8-68 workcentre c2424 service manual nvram replacement (pl 5.9) 1. Remove the back cover from the electronics module. Caution some semiconductor components, such as the nvram chip, are vulnerable to damage by electrostatic discharge (esd). Review the “electrostatic discharge (esd) precautions” on pa...

  • Page 379: In This Chapter...

    9 section parts lists in this chapter... ■ serial number format ■ using the parts list ■ xerox supplies.

  • Page 380: Serial Number Format

    9-2 workcentre c2424 service manual serial number format changes to 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 ...

  • Page 381: Using The Parts List

    Parts lists 9-3 using the parts list 1. No.: the callout number from the exploded part diagram. 2. Part number: the material part number 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:...

  • Page 382: Covers

    9-4 workcentre c2424 service manual covers 4 4 6 3 2 5 2 3 1 7 9 11 s2424-149 22 23 21 20 25 15 16 17 13 14 12 19 18 8 24 26 10 pl 1.11 (with 8-12) pl 1.15 (with 13-19).

  • Page 383

    Parts lists 9-5 parts list 1.0 covers no. Name/description qty part number 1 front door mpt asm 1 200467880 2 front door stay retainer (w/clip) 2 131714380 3 clip (part of pl 1.2) 2 4 hinge pins, front door 2 131713880 5 front door stay with spring 2 386740780 6 lower paper tray (output paper tray) ...

  • Page 384: Imaging

    9-6 workcentre c2424 service manual imaging s2424-193 1 2 3 7 12 13 14 15 16 17 8 11 10 9 4 19 20 21 18 18 5 6.

  • Page 385

    Parts lists 9-7 parts list 2.0 imaging no. Name/description qty part number 1 ink loader assembly and door 1 200471180 2 printhead assembly 1 650435400 3 drum assembly 1 105115080 4 belt, y-axis drum 1 214498780 5 printhead wiper 1 367053480 6 belt, wiper drive 1 214501280 7 purge pressure pump 1 11...

  • Page 386: Paper Path

    9-8 workcentre c2424 service manual paper path s2424-194 6 7 8 8 9 5 13 17 18 19 16 12 4 2 1 3 15 14 10 11 11 10

  • Page 387

    Parts lists 9-9 parts list 3.0 paper path no. Name/description qty part number 1 inner simplex guide 1 351111480 2 lower inner duplex guide 1 351112081 3 take away roller 1 401094780 4 duplex roller 1 401091880 5 upper duplex paper guide with solenoid 1 351113280 6 outer duplex paper guide with sens...

  • Page 388: Backframe

    9-10 workcentre c2424 service manual motors, gears, solenoids, clutches, sensors, fans and backframe 6 8 1 2 9 7 10 12 13 5 4 10 15 14 11 s2424-195 3.

  • Page 389

    Parts lists 9-11 parts list 4.0 motors, gears, solenoids, clutches, and fans no. Name/description qty part number 1 asm, motor (dadf) 1 127k53220 2 dadf belt kit 1 604k31090 3 fan, (scanner) power supply, cooling 1 105e18240 4 electric clutch, wiper 1 401096180 5 x-axis motor assembly 1 650429400 6 ...

  • Page 390

    9-12 workcentre c2424 service manual electronics module, circuit boards and cables 7 8 9 10 1 2 6 3 11 5 12 17 14 18 20 4 22 21 15 16 23 s2424-196 19 13 24.

  • Page 391

    Parts lists 9-13 parts list 5.0 circuit boards no. Name/description qty part number 1 pcba, malibu mep (exit module board) 1 960k19990 2 power supply, scanner 1 105e18250 3 cable, wave amp signal 1 174446580 4 wave amp board 1 671522380 5 electronics module stripped (no ram, nvram, or configuration ...

  • Page 392

    9-14 workcentre c2424 service manual sensors and flags (actuators) s2424-197 2 3 4 5 6 7 8 9 10 11 1.

  • Page 393

    Parts lists 9-15 parts list 6.0 sensors and flags (actuators) no. Name/description qty part number 1 pcba, iit sensor 1 960k20680 2 safety interlock switch (mech) 1 119645580 3 engine exit flag 1 137e11880 4 drum temperature sensor assembly 1 119643080 5 exit module (mep) sensor assembly 1 119648180...

  • Page 394: Xerox Supplies

    9-16 workcentre c2424 service manual 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 ...

  • Page 395

    Parts lists 9-17 cable assembly swiss 220/240 v, 50 hz 161015400 cable assembly pwr. Danish, 250 v 161024000 cable assy pwr, prc 161030400 cable power, 240 v, argentina 161030700 recommended tools description part number torque screwdriver, adjust 003082700 bit, screwdriver; 0.25 hexdrive, t20 00308...

  • Page 396

    9-18 workcentre c2424 service manual overlay kit, french 650k24020 overlay kit, italian 650k24030 overlay kit, german 650k24040 overlay kit, spanish 650k24050 overlay kit, dutch 650k24060 overlay kit, swedish 650k24070 overlay kit, brazilian-portuguese 650k24080 overlay kit, russian 650k24300 servic...

  • Page 397: In This Chapter...

    10 section 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.

  • Page 398: Plug/jack Locator Table

    10-2 workcentre c2424 service manual plug/jack locator table plug/jack locator table p/j no. Connected to... P/j no. J0660 (2) pre-heat ecb pre-heat sense opto j0670 (3) pre-heat ecb pre-heat temp therm j0800 (14) wave amp ecb power control ecb j790 (14) j1 (6 media tray sense ecb main ecb j160 (6) ...

  • Page 399

    10-3 j180 (26) printhead driver ecb main processor ecb j130 (26) j1ac power supply ecb inkload ecb j2 (5) j2 (2) relay ecb power supply ecb j4ac (4) j2 (5) inkload ecb power supply ecb j1ac j210 (30) printhead driver ecb wave amp ecb j630 (30) j240 (30) printhead driver ecb wave amp ecb j670 (30) j2...

  • Page 400

    10-4 workcentre c2424 service manual j610 (5) i/o ecb media present (mpt) sensors (5) j630 (30) wave amp ecb printhead driver ecb j210 (30) j670 (30) wave amp ecb printhead driver ecb j240 (30) j680 (8) i/o ecb strip/exit bib opto (6) power hm clutch (2 j790 (14) power control ecb wave amp ecb j0800...

  • Page 401

    10-5 scanner/dadf functional diagrams power control board mp motor mp encoder purge pump drum fan mpt pick clutch x-axis motor 2 2 2 2 2 2 2 2+2 2+2 2+2 4 2 4 2 32 mhz bus 3.3. Main board titan power supply ± 50, ± 15, 3.3v hard drive +15v pld regulates: ± 12v, +5v 1 mhz bus +50. 3.3v hcf i/o board ...

  • Page 402: Main Block Wiring Diagram

    10-6 workcentre c2424 service manual main block wiring diagram 40, connector i/o ecb 660-0079-11 main fan cooling fan printhead driver ecb 660-0004-05 purge pump power control ecb 660-0074-13 (in electronics module) ± 50v ± 12v unregulated +3.3v generates: ± 12v regulated +5v printer ambient tempera...

  • Page 403

    10-7 main block wiring diagram (continued) inkload ecb 660-0077-05 heaters (4) ink out opto ink low opto door open opto thermistor (4) process motor with encoder y-axis motor drum fan x-axis motor power supply ecb rev. F ac (in electronics module) generates: ± 50v ± 12v unreg +3.3v printhead ac resv...

  • Page 404: Module) Board

    10-8 workcentre c2424 service manual scanner/exit module power supply and mep (exit module) board s2424-277 exit module board scanner assembly power supply board mep serial communication +5 +24v serial-in door sensors +24 volts motor power (elevator/drive on mep) mep sensors ac main ground wire +5 +...

  • Page 405: Right-Side Wiring Diagram

    10-9 right-side wiring diagram the lines indicate which connectors you should look at for the pest codes. The pest codes are displayed on the control panel. Wiring harness pass-through wiring harness pass-through 37016.4x hm clutch j680 13067.4x j870 13067.4x j860 maintenance kit missing j400 drum h...

  • Page 406

    10-10 workcentre c2424 service manual right-side 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. 13387.4x 37027.4x x-motor signal cable (routes to bottom of channel) j800 dead power j4ac 37006.4x...

  • Page 407: Left-Side Wiring Diagram

    10-11 left-side wiring diagram the lines indicate which connectors you should look at for the pest codes. The pest codes are displayed on the control panel. S2424-202 37023.4x purge valve 37022.4x purge motor 37013.4x electric fan j280 37032.4x y-motor j790 37062.4x head vss j390 37034.4x mp motor 3...

  • Page 408

    10-12 workcentre c2424 service manual left-side 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. 37034.3x mp motor 37017.4x deskew clutch 37019.4x pick solenoid 37018.4x pick clutch ground clip me...

  • Page 409: Inside Front Wiring Diagram

    10-13 inside 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. S2424-204 37036.4x process motor 37008.4x preheat power (ac connector) j860 13131.41 sensor flag paper jam (open front cover) load paper.

  • Page 410: Inside Top Wiring Diagram

    10-14 workcentre c2424 service manual inside top wiring diagram the lines indicate which connectors you should look at for the pest codes. The pest codes are displayed on the control panel. Mep serial communication door sensors +24 volts s2424-205 37010.4x ink 1 heater j180 34062.4x (data cable) j1a...

  • Page 411

    10-15 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. S2424-206 heater cable cable restraint out of ink j180 32064.4x j140 37063.4x head vpp j110 37062.4x head vss.

  • Page 412: Electronics Module

    10-16 workcentre c2424 service manual electronics module s2424-218 factory only ps pe usb ethernet tp rcv xmt scanner connector (iit) power switch ac connector i/o ribbon connector data cable usb port config card ethernet port heater cable connector ink load power connector power to preheater and dr...

  • Page 413: Contents...

    A appendix appendix contents... ■ control panel menu map ■ media margin specification table ■ paper weight equivalence table ■ on-site printhead troubleshooting checklist.

  • Page 414: Control Panel Menu Map

    A-2 workcentre c2424 service manual control panel menu map copy scan print system setup 2: letter 8.5x11 100% 0 tray/auto paper supply... Reduce/enlarge... Lighten/darken... Original size... Ready to copy 1 copy scan print system setup public folder 300x300 tray/auto scan to... Scan resolution... Sc...

  • Page 415

    A-3 control panel menu map -continued- system setup copy scan print system setup 2: letter 8.5x11 paper supply... Walk-up printing ready to print 1 copy scan print system setup information configuration page connection setup general setup job defaults setup system setup information menu map troubles...

  • Page 416

    A-4 workcentre c2424 service manual control panel menu map -continued- (system setup continued) job defaults setup general setup shutdown power saver (recommended) restart system power down select for installation copy defaults setup scan defaults setup print defaults setup control panel setup syste...

  • Page 417

    A-5 media margin specification table media size width (mm) length (mm) side margins (mm) top/ bottom margin (mm) image width (mm) image length (mm) legal 215.9 355.6 5 5 205.9 345.6 folio 215.9 330.2 5 5 205.9 320.2 a4 210 297 5 5 200 287 a 215.9 279.4 5 5 205.9 256.7 executive 184.15 266.7 5 5 174....

  • Page 418

    A-6 workcentre c2424 service manual paper weight equivalence table us postcard thickness (mm) us bond weight (lb.) us text book weight (lb.) us cover weight (lb.) us bristol weight (lb.) us index weight (lb.) us tag weight (lb.) metric weight (g/m 2 ) 16 41 22 27 33 37 60 17 43 24 29 35 39 64 20 50b...

  • Page 419

    A-7 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 re...

  • Page 420

    A-8 workcentre c2424 service manual step 2 print the service usage profile. It is located in the front panel menu troubleshooting – service tools. If line 631 printhead id lists a date, record the date (month day year) here: printhead id: 00-09: _______________ 10-29: _______________ 30-99 _________...

  • Page 421

    A-9 6 cap/wipe/ purge assembly correctly aligned? Yes no circle one faceplate)? If yes, perform the wiper alignment procedure as described in the phaser 8400 color printer service guide. Step 7 print service test print 2: weak and missing jets. Is severe color mixing apparent? Yes no circle one is t...

  • Page 422

    A-10 workcentre c2424 service manual 12 experiencing vertical bands (not light stripes) in solid color areas? Yes no circle one and/or location over the 10 prints, the customer is experiencing stagnant ink discoloration. Continue to print solid fills of the offending color until the output is unifor...

  • Page 423: Numerics

    Service manual index – 1 numerics 525-sheet tray, parts list (paper path) , 9-9 8-pin nvram, parts list (circuit boards) , 9-13 a adjust x-axis scale, service menu , 4-3 b back button , 1-10 back channel trace , 4-82 back frame assembly cable, parts list (circuit boards) , 9-13 assembly, parts list ...

  • Page 424

    Workcentre c2424 service manual index – 2 ink loader assembly , 8-13 paper path , 8-42 dm access cover, 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...

  • Page 425

    Service manual index – 3 exit rollers , 2-20 , 2-42 extension cord , 1-iii f fan, check menu , 4-24 fault codes , 3-8 fault history, service menu , 4-2 faulty colors , 5-16 field replaceable units , 8-2 front door cable, parts list (circuit boards) , 9-13 hinge pins, parts list (covers) , 9-5 mpt as...

  • Page 426

    Workcentre c2424 service manual index – 4 j jam codes , 3-49 jam history, service menu , 4-2 jet array , 2-30 jet substitution , 2-27 jet substitution mode , 6-12 l left printhead restraint, parts list (imaging) , 9-7 left side cover, parts list (covers) , 9-5 lift motor , 8-43 lift motor, check men...

  • Page 427

    Service manual index – 5 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...

  • Page 428

    Workcentre c2424 service manual index – 6 print-quality page , 5-11 process control faults , 3-11 process drive assembly , 6-4 function , 2-17 gear drive train , 6-8 gearbox , 2-23 gearbox, parts list (motors and fans) , 9-11 motor replacement , 8-55 motor, check menu , 4-46 theory , 2-23 purge pres...

  • Page 429

    Service manual index – 7 sm (lamp), parts 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 statu...

  • Page 430

    Workcentre c2424 service manual index – 8 sensor, parts list (sensors) , 9-15 wave amp board removal , 8-65 board, parts list , 9-13 cable, parts list , 9-13 zif cable, parts list , 9-13 wavy vertical lines , 5-27 wiper assembly lock , 8-16 wiper blade , 8-24 wiper drive, check menu , 4-35 wiper fau...

  • Page 432

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