Xerox WorkCentre C2424 Service Manual

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WorkCentre® C2424

copier-printer

Service

Manual

WorkCentre

C2424

Copier-Printer

Service Manual

arning

The following servicing instructions are for use by qualified service personnel only. To a void personal injury, do not perform any servicing other than that contained in the operating instructions, unless you are qualified to do so.

First Printing: March 2005

Part Number: 604E13990

Copyright © 2005 Xerox Corporation. All Rights Reserved. Unpublished rights reserved under the copyright laws of the United States. Contents of this publicatio n may not be reproduced in any form without permission of Xerox Corporation.

Copyright protection claimed includes all forms of matters of copyrightable materials and information now allowed by statutory or jud icial law or hereinafter granted, including without limitation, material generated from the software programs which are displayed on th e screen such as styles, templates, icons, screen displays, looks, etc.

XEROX

, The Document Company®, the digital X®, CentreWare®, FinePoint™, infoSMART®, Made For

Each Other

, Phaser®, PhaserSMART®, and Walk-Up™ are trademarks of Xerox Corporation in the

United States and/or other countries. Acrobat

, Adobe® Reader®, Adobe Type Manager®, ATM™, Illustrator®, PageMaker®, Photoshop®,

PostScript

, Adobe Brilliant® Screens, Adobe Garamond®, Adobe Jenson™, Birch®, Carta®,

IntelliSelect

, Mythos®, Quake®, and Tekton® are trademarks of Adobe Systems Incorporated in the

United States and/or other countries. Apple

, AppleTalk®, EtherTalk®, LaserWriter®, LocalT alk®, Macintosh®, Mac OS®, TrueType®, Apple

Chancery

, Chicago®, Geneva®, Monaco®, New York® , and QuickDraw® are trademarks of Apple

Computer, Inc. in the United States and/or other countries. HP-GL

, HP-UX®, and PCL®are trademarks of Hewlett-Packard Corporation in the United States and/or

other countries. IBM

and AIX® are trademarks of International Business Machines Corporation in the United States and/

or other countries. Windows

, Windows NT®, Windows Server™, and Wingdings® are trademarks of Microsoft Corporation

in the United States and/or other countries. Novell

, NetWare®, NDPS®, NDS®, Novell Directory Services® , IPX™, and Novell Distributed Print

Services

™

are trademarks of Novell, Incorporated in the United States and/or other countries.

Sun

, Sun Microsystems™, and Solaris® are trademarks of Sun Microsystems, Incorporated in the United

States and/or other countries. SWOP

is a trademark of SWOP, Inc.

UNIX

is a trademark in the United States and other countries, licensed exclusively through X/Open

Company Limited. As an E

NERGY STAR

partner, Xerox Corporation has determined that this product with an ES Option

meets the E

NERGY STAR guidelines for energy efficiency. The ENERGY STAR name and logo are registered

U.S. marks.

This product uses code for SHA-1 written by John Halleck, which is being used with his permission. This product includes an implementation of LZW licensed under U.S. Patent 4,558,302.

PANTONE

Colors generated may not match P ANT ONE-identified standards. Consult current PANTONE

Publications for accurate color. PANTONE

and other Pantone, Inc. trademarks are the property of

Pantone, Inc. © Pantone, Inc., 2000.

Service Manual i

Organization of this Manual

Frontis - Introductory, Safety and Regulatory Information

This section contains important safety information re garding technical components, regulatory agency requirements, and information about this manual.

Section 1 - General Information

This section cantains a general overview of the system and basic information regarding the control panel, consumables, and the system’s physical, functional, electrical, environmental, and media specifications.

Section 2 - Theory of Operation

This section contains the basic theory of operation for the entire system. It includes diagrams and detailed operating information regarding the sub-systems (internal components), print processes (media paths and imaging), and electronics (power supply and boards).

Section 3 - Error Codes and Messages

This section provides detailed troubleshooting procedures for the system, utilizing the displayed control panel error codes and messages.

Section 4 - General Troubleshooting

This section covers general start-up, POST, BIST, PEST, and power supply operations of the system to aid in troubleshooting problems not associated with a control panel message or error code. This section also covers the Service Diagnostic functions of the system.

Section 5 - Image-Quality Troubleshooting

This section provides image-quality troubleshooting procedures for the entire system. It also contains the various test prints available to aid in troubleshooting image-quality problems.

Section 6 - Adjustments and Calibrations

This section provides procedures for proper homing of the systems components, system calibrations, ensuring ground integrity of the system, and resetting NVRAM.

Section 7 - Cleaning and Maintenance

This section provides basic information on cleaning and maintaining the system for optimal operation. It also includes printer self-maintenance functions.

Section 8 - Disassembly

This section contains all the disassembly instructions for removing and replacing Xerox spared parts.

Section 9 - Parts List

This section contains exploded diagrams and detailed parts lists for the WorkCentre C2424 Copier-Printer and the most common Xerox supplies used for this system.

Section 10 - Wiring Diagrams

This section contains the main wiring diagrams, plug-jack connector maps, and wiring diagrams to aid in troubleshooting the PEST codes.

ii W orkCentr e 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 al ways read NO TE, CAUTION, and WARNING statements.

Note

A note indicates an operating or maintenance procedure, practice or condition that is neccessary to eff iciently accomplish a task. A note can provide additional information related to a specific subject or add a comment on the results achieved through a previous action.

Caution

A caution indicates an operating or maintenance procedure, practice or condition that, if not strictly observed, results in damage to, or destruction of, equipment.

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A warning indicates an operating or maintenance procedure, practice or condition that, if not strictly observed, results in injury or loss of life.

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.

■ Plug the power cord directly into a properly grounded electrical outlet.

■ Do not use a ground adapter plug to connect the system to an electrical outlet that does not

have a ground connection terminal.

■ Do not use an extension cord or power strip.

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Avoid the potential of electrical shock by ensuring that the system is properly grounded. Electrical products may be hazardous if misused.

■ Do not place the system in an area where people might step on the power cord.

■ Do not place objects on the power cord.

■ Do not block the ventilation openings. These openings are provided to pre vent ov erheating

of the system.

■ Do not drop paper clips or staples into the system.

The power cord is attache d to the system as a plug-in device on the side of the system. If it is necessary to disconnect all electrical power from the system, disconnect the power cord from the electrical outlet.

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Do not remove the co v e rs or guards that are f astened with scre ws unless you are installing optional equipment and are specifically instructed to do so. Power should be OFF when performing these installations. Disconnect the power cord when removing covers and guards for installing optional equipment. Except for user-installable options, there are no parts that you can maintain or service behind these covers.

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The following are hazards to your safety:

■ The power cord is damaged or frayed.

■ Liquid is spilled into the system.

■ The system is exposed to water.

If any of these conditions occur:

1. Turn off the system immediately.

2. Disconnect the power cord from the electrical outlet.

3. Call an authorized service representative.

iv W orkCentr e 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 hazardous condition.

■ Do not burn any consumables or routine maintenance items. For information on Xerox

supplies recycling programs, go to www.xerox.com/gwa

Operational Safety

Your system and supplies were designed and tested to meet strict safety requirements. These include safety agency examination, approval, and complia nce with established environmental standards.

Your attention to the following safety guidelines helps to ensure the continued, safe operation of your system.

System Supplies

■ Use the supplies specifically designed for your system. The use of unsuitable materials

may cause poor performance and a possible safety hazard.

■ Follow all wa rnings and in structions mark ed on , or supplied with, the system, op tions and

supplies.

Caution

Use of other than Genuine Xerox WorkCentre C2424 Solid Ink may affect print and copy quality and system reliability . It is the only ink designed and manufactured under strict quality controls by Xerox for specific use with this system. The Xerox Warranty, Service Agreements, and Total Satisfaction Guarantee do not cover damage, malfunction, or degradation of performance caused by use of non-Xerox supplies or consumables, or the use of Xerox supplies not specified for this system.

Note

The Total Satisfaction Guarantee is available in the United States and Canada. Coverage may vary outside these areas; please contact your local representative for details.

Moving the System

Caution

Parts of the system are hot. To avo id personal injury or damage to the system, allow the ink to solidify. Run the shut-down procedure to cool the system quickly. Wait at least 30 minutes for the system to cool completely before moving or packing it.

■ Always allow the system to cool before it is moved to avoid ink spills which can damage

the system.

■ Use the shut-down procedure at the control panel Shut Down for Moving System for

best results.

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 power switch, located under the interface cover on

the right side of the system, and unplug all cables and cords. Do not turn of f the system by pulling the power cord or using a power-strip with an on/off switch.

■ Always secure the scanhead shipping restraint on the left side of the scanner to lock the

scanhead before removing the scanner portion of the system. Shipping the scanner with the scanhead unlocked can damage the scanner.

■ Always remove the document feeder before shipping the system.

■ Always remove the scanner before shipping the system.

■ The system is heavy and must be lifted by two people. The illustration below shows the

proper technique for lifting the system.

■ Always move the system separately from optional Trays 3 and 4.

2424-107

utput

Color

Mode

2-Sided

lity

ype

i-R

tan

rd F

B/W

Color

Uncollated

Collated

2424-109

42 kg

93 lbs.

vi W orkCentr e 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 to repackage the system, contact your local Xerox service representative .

Caution

Failure to repackage the system properly for shipment ca n result in dama ge to the system. Damage to the system caused by improper moving is not covered by the Xerox warranty, service agreement, or Total Satisfaction Guarantee.

Note

The Total Satisfaction Guarantee is available in the United States and Canada. Coverage may vary outside these areas; please contact your local representative for details.

Operating Safety Guidelines

■ Keep hands, hair, neckties, etc., away from the exit and feed rollers.

■ Do not remove the paper source tray that you selected in either the printer driv er or control

panel.

■ Do not open the doors while the system is busy.

■ Do not move the system while busy.

Symbols Marked on the System

Danger, high voltage.

Use caution (or draws attention to a particular component). See the manual(s) for information.

Avoid pinching fingers in the system. Use caution to avoid personal injury.

Hot surface on or in the system. Use caution to avoid personal injury.

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), field-effect transistors and other semiconductor chip components. The following techniques will reduce the occurrence of component damage caused by static electricity.

Be sure the power is of f to the chassis or circuit board, and observe all other safety precautions.

■ Immediately before handling any semiconductor components assemblies, drain the

electrostatic charge from your body. This can be accomplished by touching an earth ground source or by wearing a wrist strap device connected to an earth ground source. Wearing a wrist strap will also prevent accumulation of additional bodily static charges. Be sure to remove the wrist strap before applying power to the unit under test to avoid potential shock.

■ After removing a static sensitive assembly from its anti-static bag, place it on a grounded

conductive surface. If the anti-static bag is conductive, you may ground the bag and use it as a conductive surface.

■ Do not use freon-propelled chemicals. These can generate electrical ch arges sufficient to

damage some devices.

■ Do not remove a replacem ent component or electrical sub-assembly from its protective

package until you are ready to install it.

■ Immediately before removing the protective material from the leads of a replacement

device, touch the protective material to the chassis or circuit assembly into which the device will be installed.

■ Minimize body motions when handling unpackaged replacement de vices. Motion such as

your clothes brushing together, or lifting a foot from a carpeted floor can generate enough static electricity to damage an electro-statically sensitive device

■ Handle IC’s and EPROM’s carefully to avoid bending pins.

■ Pay attention to the direction of parts when mounting or inserting them on Printed Circuit

Boards (PCB’s).

viii W orkCentr e 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 first aid or resuscitation is present.

Use care when servicing with power: Dangerous voltages may exist at several

points in this product. To avoid personal injury, do not touch exposed connections and components while power is on. Disconnect power before removing the power supply shield or replacing components.

Do not wear jewelry: Remove jewelry prior to servicing. Rings, necklaces, and other

metallic objects could come into contact with dangerous voltages and currents.

Power source: This product is intended to operate from a power source that will not apply

more then 264 volts RMS for a 220 volt AC outlet or 140 volts RMS for a 110 volt AC outlet between the supply conductors or between either supply conductor and ground. A protective ground connection by way of the grounding conductor in the power cord is essential for safe operation.

Warning Labels

Read and obey all posted warning labels. Throughout the printer, warning labels are displayed on potentially dangerous components. As you service the printer, check to make certain that all warning labels remain in place.

Safety Interlocks

Make sure all covers and the system’s control pane l are in place and all interlock switches are functioning correctly after you have completed a service call. If you bypass an interlock switch during a service call, use extreme caution when working on or around the system.

Servicing Electrical Components

Before starting any service procedure, switch off the printer power and unplug the power cord from the wall outlet. If you must service the system with power applied, be aware of the potential for electrical shock.

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Turning the power off by using the On/Off switch does not completely de-energize the printer. You must also disconnect the printer power cord from the AC outlet. Position the power cord so that it is easily accessible during servicing.

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Do not touch any electrical component unless you are instructed to do so by a service procedure.

Service Manual ix

Servicing Mechanical Components

When servicing mechanical components within the printer, manually rotate drive assemblies, rollers, and gears.

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Do not try to manually rotate or manually stop the drive assemblies while any printer motor is running.

x W orkCentr e 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 may not function properly due to interference from another device. However, there is no guarantee that interference will not occur in a particular installation. If this equipment do es cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

■ Reorient or relocate the receiver (device being interfered with).

■ Increase the separation between the system and the receiver.

■ Connect the system into an outlet on a circuit dif ferent from tha t which the recei ve r is

connected.

■ Route the interface cables on the system away from the receiver

■ Consult the dealer, Xerox service, or an experienced radio/television technician for

help.

Changes or modifications not expressly approved by Xerox can affect the emission and immunity compliance and could void the user's authority to operate this product. To ensure compliance, use shielded interfac e ca bles. A shielded parallel cable can be purchased directly from Xerox at www.xerox.com/office/supplies

Xerox has tested this product to internationally accepted electromagnetic emission and immunity standards. These standards are designed to mitigate interference caused or received by this product in a normal office environment. This product is also suitable for use in a residential environment based on the levels tested.

In the United States this product complies wit h the requiremen ts of an unintentional radiato r in part 15 of the FCC rules. Operation is subject to the following two conditions: (1) this de vice may not cause harmful interference; (2) this device must accept any interference received, including interference that may cause undesired operation.

Canada

This digital apparatus does not exceed the Class B limits for radio noise emissions from digit al apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications, ICES-003.

Le présent appareil numérique n'émet pas de bruits radioélectrique dépassant les limits applicables aux appareils numériques de la classe B prescrites dans le Réglement sur le brouillage radioélectrique édicté par le ministere des Communications du Canada, NMB-003.

European Union

Xerox Corporation declares, under our sole responsibility, that the system to which this declaration relates is in conformity with the following standards and other normative documents:

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 for the consumer nor for the environment. A signed copy of the Declaration of Conformity for this product can be obtained from Xerox.

EN 60950 (IEC

60950)

"Safety of Information Technology Equipment including Electrical Business Equipment"

EN 55022:1998 (CISPR 22)

"Limits and Methods of measurement of radio interference characteristics of Information Technology Equipment." Class B.

EN 61000-3-2:1995 +A1:1998+A2:1998 (IEC61000-3-2)

"Part 3: Limits - Section 2: Limits for harmonic current emissions (equipment input current less than or equal to 16A per phase)."

EN 61000-3-3:1995 (IEC61000-3-3)

"Part 3: Limits - Section 3: Limitation of voltage fluctuations and flic ker in low-voltage supply systems for equipment with rated current less than or equal to 16A."

EN 55024:1998 (CISPR 24)

"Information technology equipment - Immunity characteristics - Limits and methods of measurement. "

CISPR 24 Immunity Phenomena Basic Standard Test Specification

Electrostatic Discharge

IEC 61000-4-2:1995 6 kV Contact, 10 kV Air

Radio-Frequency Electromagnetic Field (radiated)

IEC 61000-4-3:1995 80-1000 MHz, 3 V/m, 80% AM @ 1 KHz

Fast Burst Transients

IEC 61000-4-4:1995 5/50 Tr/Th ns, 5 kHz Rep. Freq

0.5 kV Signal Lines 1 kV AC Mains

Line Surge IEC 61000-4-5:1995 Combination wave

2.0 kV Common mode

2.0 kV Differential mode

Radio-Frequency Electromagnetic Field (Conducted)

IEC 61000-4-6:1996 0.15 - 80 MHz, 3 V, 80% AM @ 1 kHz

Line voltage dips IEC 61000-4-11:1994 >95% dip for ½ cycle @ 50 Hz

30% dip for 25 cycles @ 50 Hz

Line voltage dropout

IEC 61000-4-11:1994 >95% dropout for 250 cycles @ 50 Hz

Service Manual xiii

Contents

Organization of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Electrostatic Discharge (ESD) Precautions. . . . . . . . . . . . . . . . . . . . . . . . .vii

Service Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii

Regulatory Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .x

1 General Information

System Introduction and Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

System Features and Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Standard Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Front View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Open View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Side View with System Interfaces. . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Back View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Electronics Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

Routine Maintenance Items and Consumables Life Expectancy . . . . . . . 1-7

Control Panel Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Menu Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Physical Dimensions and Clearances . . . . . . . . . . . . . . . . . . . . . 1-12

Print Engine (IOT) Functional Specifications. . . . . . . . . . . . . . . .1-13

System Electrical Specifications. . . . . . . . . . . . . . . . . . . . . . . . .1-14

System Environmental Specifications. . . . . . . . . . . . . . . . . . . . . 1-14

Scanner/DADF (IIT) Specifications . . . . . . . . . . . . . . . . . . . . . . . 1-14

Tray and Media Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16

Duplex Automatic Document Feeder Guidelines. . . . . . . . . . . . . 1-17

Supported Envelopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19

Media Storage Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

Media that May Damage the System. . . . . . . . . . . . . . . . . . . . . . 1-20

2 Theory of Operation

System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

System Summaries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Image Input Terminal (IIT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Major Components of the DADF and Scanner. . . . . . . . . . . . . . . .2-3

Document Feeder Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Document Feeder Paper Path and Imaging. . . . . . . . . . . . . . . . . . 2-6

Scanner Assembly Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Scanner and Document Feeder Calibration. . . . . . . . . . . . . . . . . . 2-8

System Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

Exit Module (MEP) Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Scanner Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

xiv W orkCentre C2424 Copier-Printer

Electronics Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Image Output Terminal (IOT) Sub-Assemblies . . . . . . . . . . . . . . . . . . . 2-15

Paper Path and Paper Pick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Paper Pick for Tray 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Paper Pick for Trays 2 - 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

2-Sided (Duplex) Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Sensor Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

System Motors, Solenoids, and Drive. . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Process Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Media Path Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

The Print Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Drum Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

Ink Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Drum Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

Transfix System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

Drum Maintenance System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37

Purge System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

Transfixing and Exiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

Transfix and Print Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

Configuration Card Personality Parameters. . . . . . . . . . . . . . . . . . . . . . 2-45

3 Error Messages and Codes

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Power-Up Error Messages and LED Codes . . . . . . . . . . . . . . . . . . . . . . . 3-3

BIST Error Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

POST Error Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

PEST Error Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Fault Code Error Message Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 3-8

Fault Code Error Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Interpreting Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

1,000.4x Error - 525-Sheet Feeder Faults . . . . . . . . . . . . . . . . . . 3-9

2,0XX.4x Error - I/O Circuit Board Fault. . . . . . . . . . . . . . . . . . . 3-10

3,0XX.6x - IPC Program Faults . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

4,0XX.4x Errors - Process Control System Fault . . . . . . . . . . . . 3-11

5,0XX.4x Errors - Y-Axis Sub-System Fault. . . . . . . . . . . . . . . . 3-14

6,0XX.4x Errors - X-Axis Fault . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

7,0XX.4x Errors - Process Motor Gearbox Faults. . . . . . . . . . . . 3-16

8,0XX.xx Error - Wiper/Media Path Gearbox Faults . . . . . . . . . . 3-20

9,0XX.xx Errors - Ink Loader Faults. . . . . . . . . . . . . . . . . . . . . . 3-22

11,0XX.xx Errors - Electronics Module Interface Fault. . . . . . . . 3-23

13,0XX.xx Errors - Thermal Faults. . . . . . . . . . . . . . . . . . . . . . . 3-24

19,0XX.xx Errors - Printhead Calibration faults.. . . . . . . . . . . . . 3-33

31,0XX.4x Errors - Mechanical Initialization Jam. . . . . . . . . . . . 3-34

33,0XX.xx Errors - Tray Manager Device Faults. . . . . . . . . . . . . 3-35

34,0XX.xx Errors - Printhead NVRAM Faults . . . . . . . . . . . . . . . 3-35

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49

Jam Code Definition Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

4 General Troubleshooting

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Hidden Service Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Service Diagnostics Menu Functions . . . . . . . . . . . . . . . . . . . . . . 4-4

Entering Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Service Diagnostic Menu Definition Tables. . . . . . . . . . . . . . . . . . 4-6

Check Menu / Activators Definition Tables. . . . . . . . . . . . . . . . . . . . . . . 4-15

Check / Activators Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

Check Shafts Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Check Fans Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Check Heaters Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Check Paper Path Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27

Check Drive Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

Check Drum Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-40

Check Motors Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45

Check Misc Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48

System Power-Up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-54

Mechanical Initialization of the Print Engine . . . . . . . . . . . . . . . . 4-55

Head Cleaning Cycle Performance . . . . . . . . . . . . . . . . . . . . . . .4-57

Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58

Electronics Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-58

Document Feeder Lamp Does Not Turn ON . . . . . . . . . . . . . . . . 4-59

Document Feeder Does Not Feed Media. . . . . . . . . . . . . . . . . . . 4-59

Scanner Scanhead Does Not Move. . . . . . . . . . . . . . . . . . . . . . . 4-60

Scanhead Motion is Not Smooth and Continuous . . . . . . . . . . . 4-60

Scanner Lamp Does Not Turn On. . . . . . . . . . . . . . . . . . . . . . . . 4-60

Control Panel is Malfunctioning . . . . . . . . . . . . . . . . . . . . . . . . . 4-60

Exit Module (MEP) is Malfunctioning . . . . . . . . . . . . . . . . . . . . .4-62

System Fails to Power-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-62

System Energy Star Mode Troubleshooting . . . . . . . . . . . . . . . . 4-64

System Reports Missing Maintenance Kit . . . . . . . . . . . . . . . . . 4-65

System Reports Missing Waste Tray . . . . . . . . . . . . . . . . . . . . . 4-65

System Features Not Available . . . . . . . . . . . . . . . . . . . . . . . . . .4-65

525-Sheet Feeder Does Not Function . . . . . . . . . . . . . . . . . . . . .4-66

Non-Specific Electronics Failure. . . . . . . . . . . . . . . . . . . . . . . . .4-67

Verifying Scanner Power Supply Operation . . . . . . . . . . . . . . . .4-70

Verifying Power Supply Operation - Print Engine . . . . . . . . . . . . 4-71

Measuring AC Power Supply Voltages . . . . . . . . . . . . . . . . . . . . 4-72

Measuring DC Power Supply Voltages . . . . . . . . . . . . . . . . . . . . 4-73

xvi W orkCentr e C2424 Copier-Printer

Ensuring Ground Integrity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73

Testing Motor and Solenoid Resistances. . . . . . . . . . . . . . . . . . 4-75

Paper Path and Media-Based Problems . . . . . . . . . . . . . . . . . . . . . . . . 4-76

Media-Based Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76

Checking the Process and Media Path Drive . . . . . . . . . . . . . . . 4-78

Operating System and Application Problems . . . . . . . . . . . . . . . . . . . . 4-79

Testing Communications Ports . . . . . . . . . . . . . . . . . . . . . . . . . 4-79

Network Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81

Obtaining Serial Back Channel Trace . . . . . . . . . . . . . . . . . . . . . 4-82

5 Image-Quality Troubleshooting

Image-Quality Problems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Service Technician RIP Procedure. . . . . . . . . . . . . . . . . . . . . . . . 5-3

Isolating a Copy/Scan Malfunction to the Scanner/DADF. . . . . . . 5-3

DADF Image-Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Dark Streaks on the Copied Image. . . . . . . . . . . . . . . . . . . . . . . . 5-4

Skewed Copy Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Copy Image is Lighter/Darker than the Original . . . . . . . . . . . . . 5-5

Fuzzy Text/Image. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Copied Image Colors Do Not Match the Original . . . . . . . . . . . . . 5-7

Scanner Image Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Dark Streaks on the Copied Image. . . . . . . . . . . . . . . . . . . . . . . . 5-8

Copied Image is Skewed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Copied Image is Lighter/Darker than the Original . . . . . . . . . . . . 5-8

Copy Image Colors Do Not Match the Original. . . . . . . . . . . . . . . 5-9

Fuzzy Text/Image. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Diagnosing IOT (Print Engine) Print-Quality Problems . . . . . . . . . . . . . 5-1 1

Random Light Stripes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Predominate Light Stripes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Smudges or Smears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

The Printed Image Is Too Light or Too Dark . . . . . . . . . . . . . . . 5-15

No Image is Being Printed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Color is Uneven or Color is Wrong . . . . . . . . . . . . . . . . . . . . . . 5-16

Streaks or Lines Down the Print . . . . . . . . . . . . . . . . . . . . . . . . 5-17

Scratches or Marks Parallel to the Long Axis of Printing,

Particularly with Transparencies . . . . . . . . . . . . . . . . . . . . . 5-19

There is ink on the White Portion of the Printed Page . . . . . . . . 5-21

Fuzzy Text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

Poor Primary Color Fills. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

Ghosting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

Poor Small Text Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

Vertical Lines Appear Wavy . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

Oil Streaks on Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

Incomplete Image Transfer to Paper . . . . . . . . . . . . . . . . . . . . . 5-29

Ink Smears on First Printed Side of Duplex Print. . . . . . . . . . . . 5-30

Repeating Print Defects on Print . . . . . . . . . . . . . . . . . . . . . . . . 5-31

Service Manual xvii

White Stripes (Pinstripes). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

Wrinkling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

Image is Offset or Cut-Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-34

Poor Ink Adhesion, Poor Image Durability . . . . . . . . . . . . . . . . . 5-3 4

Analyzing Service Test Prints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-35

Test Print Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

6 Adjustments and Calibrations

System Alignments and Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Wiper Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

Print Engine Component Home Positions and Indicators. . . . . . . . . . . . . 6-4

Homing the Printhead Wiper. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

Homing the Head Tilt Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Homing the Process Gear Drive Train. . . . . . . . . . . . . . . . . . . . . . 6-8

Manual DADF to Scanner Calibration . . . . . . . . . . . . . . . . . . . . . . 6-9

Jet Substitution Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Resetting NVRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

7 Cleaning and Maintenance

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

System Self-Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Printhead Maintenance Cycle (Eliminate Light Stripes). . . . . . . . .7-3

Paper Preheater Cleaning (Remove Print Smears). . . . . . . . . . . .7-4

Transfix Roller Oiling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4

Drum Cleaning - Chase Page . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4

Service Cleaning and Maintenance Procedures . . . . . . . . . . . . . . . . . . . .7-5

Cleaning for Print-Quality Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Media Jams and Paper Pick Cleaning Procedures . . . . . . . . . . . . 7-7

Pick Roller Cleaning Methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

Cleaning the Drum Temperature Sensor. . . . . . . . . . . . . . . . . . . . 7-8

Maintenance Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Waste Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

8 Service Parts Disassembly

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2

Standard Orientation of the System . . . . . . . . . . . . . . . . . . . . . . . 8-2

General Notes on Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .8-3

Image Input Terminal (DADF and Scanner) . . . . . . . . . . . . . . . . . . . . . . . 8-4

Duplex Automatic Document Feeder. . . . . . . . . . . . . . . . . . . . . . . 8-4

DADF Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Scanner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

xviii W orkCentr e C2424 Copier-Printer

Image Output Terminal (Print Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

Output Paper Tray Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

Front Door / Tray 1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

Right and Left Side Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

Rear Cover and EMI Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

Imaging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

Ink Loader Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

Y-Axis Drum Belt, Y-Axis Tension Spring,

and Y-Axis Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 8-14

Printhead Assembly, Right and Left Printhead Restraints . . . . . 8-16

X-Axis Bias Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23

Printhead Wiper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24

Media Release Blade (Stripper) Carriage Assembly,

and Transfix Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26

Paper Preheater and Deskew Assembly. . . . . . . . . . . . . . . . . . . 8-27

Duplex Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29

Transfix Load Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30

Transfix Camshaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34

Drum Maintenance Camshaft Assembly . . . . . . . . . . . . . . . . . . 8-35

Drum Maintenance Pivot Plate Assembly . . . . . . . . . . . . . . . . . 8-36

Drum Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37

Purge Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41

Paper Path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42

Exit Module Assembly (MEP). . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42

Paper Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44

Take Away Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48

Pick Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49

Tray Lift Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51

Motors, Gears, Solenoids, Clutches, and Fans . . . . . . . . . . . . . . . . . . . 8-52

Media Drive Gearbox with Two Clutches and Solenoid . . . . . . . 8-52

Tray 1 (MPT) Pick Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54

Process Drive Motor and Gearbox. . . . . . . . . . . . . . . . . . . . . . . 8-55

X-Axis Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-57

Head Tilt Compound Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58

Electronics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-59

Scanner Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-59

Exit Module (MEP) Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-60

Electronics Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-61

Back Frame and Printer Stabilizer . . . . . . . . . . . . . . . . . . . . . . . 8-63

Wave Amp Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-65

I/O Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-66

Drum Heater Relay Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-67

NVRAM Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-68

Service Manual xix

9 Parts Lists

Serial Number Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Using the Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

Imaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-8

Motors, Gears, Solenoids, Clutches, Sensors, Fans

and Backframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

Electronics Module, Circuit Boards and Cables. . . . . . . . . . . . . . 9-12

Sensors and Flags (Actuators) . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14

Xerox Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16

10 Wiring Diagrams

Plug/Jack Locator Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

Scanner/DADF Functional Diagrams. . . . . . . . . . . . . . . . . . . . . .10-5

Main Block Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

Main Block Wiring Diagram (Continued) . . . . . . . . . . . . . . . . . . 10-7

Scanner/Exit Module Power Supply

and MEP (Exit Module) Board . . . . . . . . . . . . . . . . . . . . . . . 10-8

Right-Side Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9

Right-Side Wiring Diagram (Continued). . . . . . . . . . . . . . . . . .10-10

Left-Side Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-11

Left-Side Wiring Diagram (Continued) . . . . . . . . . . . . . . . . . . .1 0-12

Inside Front Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13

Inside Top Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14

Inside Top Wiring Diagram (continued) . . . . . . . . . . . . . . . . . . 10-15

Electronics Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-16

A Appendix

Control Panel Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Control Panel Menu Map -continued-. . . . . . . . . . . . . . . . . . . . . .A-3

Control Panel Menu Map -continued-. . . . . . . . . . . . . . . . . . . . . .A-4

Media Margin Specification Table. . . . . . . . . . . . . . . . . . . . . . . . .A-5

Paper Weight Equivalence Table. . . . . . . . . . . . . . . . . . . . . . . . . .A-6

On-Site Printhead Troubleshooting Checklist . . . . . . . . . . . . . . . . A-7

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

1-2 W orkCentr e 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 Service Training Program.

s2424-0

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 of Operation" on page 2-1.

Standard Configurations

The WorkCentre C2424 is offered in three configurations.

■ DN = System with 256 MB RAM

■ DP = System with 256 MB RAM, 1 525-sheet high capacity feeder, and a

cart.

■ DX = System with 512 MB RAM, 1 525-sheet high capacity feeder, cart,

plus Scansoft applications.

1-4 W orkCentr e 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 Automatic Document

Feeder (DADF)

10. Interface (I/O) cover

11. Waste tray/maintenance kit side

door

12. Front cover release (product serial number is behind the front cover)

1. Short paper stop

2. Exit cover

3. Ink cover

2424-080

10 11

2424-1

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

2424-081

5 6

7 8

s2424-267

1-6 W orkCentr e 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 installing a new electronics module in the system, the following components need to be transferred from the old main board.

■ Hard Drive

■ Configuration Card

■ Memory (1 or 2 DIMMs)

■ NVRAM (8-pin socketed chip)

Note

See the illustrations on page 1-5 for locating th e above components.

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 Empty every 5 Purges

(~35 g)

DADF Pick Rollers and Separator Pad

50,000 scans

*Consumable capacity is based on 5% coverage per color on plain A4/Letter paper.

s2424-005

Document Feed Roller

Pad

Maintenance Kit

Waste Tray

Ink Sticks

1-8 W orkCentr e 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 system’s settings and accesses tools to

help resolve problems.

The control panel is divided into three major areas.

Left side:

Copying and scanning function buttons and LEDs

Middle:

Graphic display screen, mode buttons, menu navigation, shortcut buttons and status LEDs

Right side

Numeric keypad, Clear/Clear All, Stop, and Start buttons

2424-1

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 C2424 User Guide.

1. Output button and LEDs (copy only) Press to select Uncollated or Collated for your copies.

2. Color Mode button and LEDs Press to select B/W (black and white) or Color for your copy or scan job.

3. 2-Sided button and LEDs Press to select whether the original is 2-sided and whether you want the output 2-sided.

4. Output Quality button and LEDs Press to select the output quality for the copy job.

5. Output Type button and LEDs Press to select the type of original for your copy or scan job.

2424-173

1-10 W orkCentr e 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 Supply button Press to jump to the Paper Supply option on the menu.

5. Copy button Press to display the Copy menu on the graphic display.

6. Scan button Press to display the Scan menu on the graphic display.

7. Graphic display shows status messages and menus.

8. Up Arrow button Scrolls upward.

9. Enter button The menu option selected.

10. Status Indicator LED: Blinking green = System is busy or in

Standby or PowerSaver mode

Steady green = Ready

11. Down Arrow button

Scrolls downward.

12. Status Indicator LED: Blinking red = Error condition, stops job Steady red = Warning, continues job

13. Back button

Returns to the previous menu item.

14. Print button Press to display the Print menu on the graphic display.

15. System Setup button Press to display the System Setup menu on the graphic display.

16. Help (?) button Press to display a help message explaining the menu or message shown on the graphic display.

2424-174

11 10

1213

General Information 1-11

Control Panel Right

Menu Map

The Menu Map is a visual representation of the control panel menu structure. Y ou 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 Information, then press the Enter button.

3. Select Menu Map, then press the Enter button to print.

The menu map can also be found in the appendix of this manual. See, "Control Panel Menu Map" on page A-2.

1. Number keys Press to enter a number, such as f or the number of copies or a numeric password.

2. Clear/Clear All button Press once to reset the current menu selection; press twice to reset the system.

3. Stop button Press to pause the printing of the current copy or print job. To then cancel the job, follow the instructions shown on the graphic display.

4. Start button Press to start a copy or scan job.

2424-1

1-12 W orkCentr e 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

Scanner Weight: 6.3 kg (14 lbs.) DADF Weight: 4.8 kg (10.6 lbs.)

Optional 525-Sheet Feeder Value

Weight: 5 kg (11 lbs.)

Optional Cart Value

Width: 50 cm (19.7 in.) Depth: 67 cm (26 in.) Height: 36 cm (14.2 in.) Weight: 22 kg (48 lbs.)

Minimum Clearances

60 cm

(24 in.)

37 cm

(14.5 in.)

0 cm

(

4 in.)

100 cm (40 in.)

88 cm

(35 in.)

92 cm

(36 in.)

142 cm

(56 in.

)

13.5 cm (5.3 in.)

36 cm

(14 in.)

24 cm

(9.5 in.)

s2424-231

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 red, green, and blue.

Color Management Automatic, Black & White,

Office: sRGB, Vivid Color, None, Press: Commercial, Euroscale, SWOP

Print Speed Up to 24 ppm print and copy

Up to 20 ppm scan Up to 18 ppm document feeder

Resolutions 2400 FinePoint print

Standard 300 x 300 dpi scan resolution

600 x 600 dpi copy resolution up to 600 x 2400 for 400% zoom FPOT < 6 seconds from Ready. FPOT, Color Copy < 15 seconds per page/1st copy

subsequent copies at printer speed. Memory 2 slots; minumum 256 MB, maximum 512 MB, PC133 DRAM

256 MB RAM standard, upgradable to 1 GB Hard Drive Standard 40 GB Printer Description

Language

137 PostScript 3

81 PCL5c Print Features Intelligent Ready, Collation, Secure Printing, Proof Print, Saved

Print, Job Pipeling

NOTE: Does not support direct PDF printing.

Automatic 2-Sided Printing

Supported from Trays 1, 2, 3, and 4

- Duplex automatic 2-sided copy, supported from DADF tray

Paper Handling Tray 1 = 100-sheet capacity

Tray 2 = 525-sheet capacity

Optional Tray 3 = 525-sheet capacity

Optional Tray 4 = 525-sheet capacity

- Duplex Automatic Document Feeder = 50-sheet capacity

Warm-up time From Off (cold start): 12 minutes

From power saver: 4 minutes

1-14 W orkCentr e 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 Consumption 1250 W (peak)

175 W (idle) 230 W (average during printing)

1250 W (peak) 175 W (idle)

230 W (average during printing) ENERGY STAR® 70 W 70 W Scanner Power Supply 30 W 30 W

Nominal Operating Environment

Temperature

- 32º C / 50º - 90º F operating

Humidity 10% - 80% RH Non-Condensing operating

Characteristic Specification

Printing Process Print Engine Scan to Capabilities Scan to Disk (mailbox) function

Scan to PC

Scan/copy Process Flatbed platen and C-shape ADF

Charge Coupled Device scan head RGB color pack The scan controller provides 16 bit DMA intrerface for sending image data through the scanner board to the image processor board

in the electronics module. Copies per Minute DADF: 20 ppm simplex, 10 ppm duplex Memory 2 MB (1M x 16 SDRAM Image Buffer 32 MB SDRAM for Platen

128 MB SDRAM for DADF Bit Depth Reading: 48 bits

Output: 24 bits

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 automatically

turn off after after 20 minutes.

Noise Standby: < or equal to 45 dB

Scanning: < or equal to 50 dB

Characteristic Specification

1-16 W orkCentr e 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 to fit the paper size. For Trays 2, 3, and 4, the paper

guides click into place when they are adjusted correctly.

■ If excessive jams occur, use paper, transparencies, or other specialty media from

a new package.

■ Custom size paper can be printed only from Tray 1.

■ Xerox Professional Solid Ink Photo Paper, Xerox Professional Solid Ink Glossy

Paper, and Xerox Professional Solid Ink Trifold Brochures, can be printed from any tray, although they exceed the recommended weight guidelines for Trays 2–

■ Use Xerox Professional Solid Ink Transparencies; print quality may vary with

other transparencies.

■ When printing photos, postcards, or brochures, some attention to stacking in the

output tray may be required.

■ Use only paper envelopes. Do not use envelopes with windows, metal clasps, or

adhesives with release strips.

■ Do not print CD labels in this system.

■ When using pre-punched paper, load the paper so that the holes are on the right

side of the tray. Adjust print and copy margins to accommodate the pre-punched holes.

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

(16–32 lb. Bond) (22–45 lb. Cover).

Follow these guidelines when loading originals into the document feeder:

■ Load originals faceup, so the top of the document enters first.

■ Place only loose sheets of paper in the document feeder.

■ Adjust the paper guides so they fit against the originals.

■ Insert paper in the document feeder only when the ink on the pap er is completel y

dry.

Use the glass rather than the document feeder to copy or scan the following types of originals:

■ Paper with paper clips or staples attached

■ Paper with wrinkles, curls, folds, tears, or notches

■ Coated or carbonless paper, transparencies, or items other than paper such as

cloth or metal

■ Envelopes

Supported Papers, Transparencies, and Other Specialty Media

Any Tray

Tray 1 Only

Auto 2-Sided Printing

1-Sided Printing Only

Paper Sizes Paper Types Paper Weight/Description

Letter (8.5 x 11.0 in.) A4 (210 x 297 mm) Legal (8.5 x 14.0 in.) Executive (7.25 x 10.5 in.) A5 (148 x 210 mm) Statement (5.5 x 8.5 in.) US Folio (8.5 x 13 in.) B5 ISO (176 x 250 mm) B5 JIS (182 x 257 mm)

Plain Paper, Letterhead, Card Stock

60–120 g/m

(16–32 lb. Bond) (22–45 lb. Cover)

●

121–220 g/m2 (33–40 lb. Bond) (46–80 lb. Cover)

● ●

1-18 W orkCentr e 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

(16–32 lb. Bond) (22–45 lb. Cover)

●

121–220 g/m2 (33–40 lb. Bond) (46–80 lb. Cover)

● ●

Special Xerox Phaser Postcards ●

●

Xerox Professional Solid Ink Glossy Paper

● ●

Xerox Phaser Trifold Brochures

● ●

Transparency, Labels

● ●

A6 (105 x 148 mm)

Index Cards (3 x 5 in.)

Plain Paper, Card Stock

60–220 g/m

(16–40 lb. Bond) (22–80 lb. Cover)

● ●

Custom Width: 140–216 mm (5.5–

8.5 in.) and Height: 210–356 mm (8.3–

14.0 in.)

●●

Width: 76–139 mm (3.0–5.4 in.) or Height: 127–209 mm (5.0–

8.2 in.)

● ●

Weight: 60–120 g/m

(16–32 lb. Bond) (22–45 lb. Cover)

●●

Weight: 121–220 g/m2 (33–40 lb. Bond) (46–80 lb. Cover)

● ●

Supported Papers, Transparencies, and Other Specialty Medi a (Conti nued)

Any Tray

Tray 1 Only

Auto 2-Sided Printing

1-Sided Printing Only

Paper Sizes Paper Types Paper Weight/Description

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 pri nting envelopes.

Media Storage Guidelines

Providing a good environment, and safe handling and storage conditions for your paper and other media contributes to optimum print quality.

■ Store paper in dark, cool, relatively dry locations. Most paper items are

susceptible to damage from ultraviolet (UV) and visible light. UV radiation, which is emitted by the sun and fluorescent bulbs, is particularly damaging to paper items. The intensity and length of exposure to visible light on paper items should be reduced as much as possible.

■ Maintain constant temperatures and relative humidity.

■ Avoid light, heat, and dampness.

■ Avoid attics, kitchens, garages, and basements for storing paper. Inside walls are

drier than outside walls where moisture can collect.

■ Store paper flat. Paper should be stored on pallets, cartons, shelves, or in

cabinets.

■ Avoid having food or drinks in the area where paper is stored or handled.

■ Do not open sealed packages of paper until you are ready to load them into the

system. Leave paper in the original packaging. For most commercial cut-size grades, the ream wrapper contains an inner lining that protects the paper from moisture loss or gain.

■ Some specialty media is packaged inside resealable plastic bags. Leave the media

inside the bag until you are ready to use it; reinsert unused media in the bag and reseal it for protection.

Tray Size/Description

Print these envelopes from any tray

■ #10 Commercial (4.12 x 9.5 in.)

■ DL (110 x 220 mm)

■ C5 (162 x 229 mm)

Print these envelopes from Tray 1 only

■ #5 ½ Baronial (4.375 x 5.75 in.)

■ #6 ¾ Commercial (3.625 x 6.5 in.)

■ Monarch (3.87 x 7.5 in.)

■ #6 ½ Booklet (6 x 9 in.)

■ Lee (5.25 x 7.25 in.)

1-20 W orkCentr e 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. Howev er , some media can cause poor output quality , increased paper jams, or damage to the system. Unacceptable media for Trays 1–4 include:

■ Rough or porous media

■ Plastic media

■ Paper that has been folded or wrinkled

■ Paper that has been photocopied

■ Paper with staples inserted

■ Envelopes with windows, metal clasps, or adhesives with release strips

■ Padded envelopes

■ CD labels

■ Media that is less than 60 g/m

or more than 220 g/m

Media Skew Specification Print Engine (IOT)

Media System Skew Specification (IIT/IOT)

Charecteristic Specification

Printed Left Side Margin 5.0 mm + 2.0 mm (0.197 in. + .080 in.) Leading Edge Margin 5.0 mm +

1.3 mm (0.197 in. + .050 in.)

Image Area Tolerance Zone Image Skew, Envelopes 11.5 milli-radians measured across the width of leading edge. Image Skew, Index Card 14.0 milli-radians measured across the width of leading edge. Image Skew, All other sizes 7.0 milli-radians measured across the width of leading edge.

Charecteristic Specification

Printed Left Side Margin 5.0 mm + 4.0 mm (0.197 in. + .157 in.) Leading Edge Margin 5.0 mm +

3.3 mm (0.197 in. + .130 in.)

Image Area Tolerance Zone Image Skew, Envelopes 11.5 +

4 milli-radians measured across the width of

leading edge.

Image Skew, Index Card 14.0 +

4 milli-radians measured across the width of

leading edge.

Image Skew, All other sizes 7.0 +

4 milli-radians measured across the width of

leading edge.

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 Parameters

2-2 W orkCentr e 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 and subassembly interactions for this system. This section is broken down into the following:

■ The Image Input Terminal (IIT)

■ DADF and pap e r path

■ The Scanner Assembly with Control Panel

■ System Electronics

■ Electronics Module

■ Scanner Power Supply

■ Exit Module (MEP) Control Board

■ The Print Engine (IOT)

■ Paper Path

■ Sensing

■ Drive

■ Image Process

■ Exiting

s2424-232

uplex Automatic

ocument Feeder

canner

ontrol Panel

rint Engine

Image Input Termina

Image Output Termin

Optional Lower Trays

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

Lamp

Scanner Flatbed Scan Head

DADF Hinges

DADF Connector

s2424-235

DADF CVT

Window &

Calibration

Strip

ADF Scan Head

Lamp

Platen/Document Glass

Control Panel

Media In Sensor

Media Staged Sensor

Pick Rollers

Separator Pad

Sensor

Motor and Drive

2-4 W orkCentr e 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-sided document.

Input Tray: The input tray feeds document originals into the DADF for simplex

(single-sided) or duplex (double-sided) scanning. It has a capacity of 50 originals.

Output Tray: Original documents fed through the DADF exit to the output tray. Media Present Sensor/Media In Sensor: The media in sensor detects the

presence of original documents in the input tray. After a delay to allow for adjusting the feed guides, the media will stage to the this media staged sensor.

Media Staged Sensor: This sensor, located within the DADF scanhead, detects

whether media has been fed into the DADF to a predetermined (staged) point. When the scanner detects this point, it starts collecting data from the Charge Coupled Device (CCD).

DADF Cover Open Sensor: This optical sensor detects the status of the DADF

access cover. When the cover is open, DADF operation is inhibited; given sufficient time, an error message appears on the control panel display instructing the user to close the access cover.

Pick Roller and Separator Pad: The pick roller is the first of several feed rollers.

It is designed to work with the separator pad to ensure that only one sheet of media is fed at a time.

Feed Rollers and Idler Rollers: Three additional feed rollers in the DADF are

responsible for media transport through the media path. They include associated idler rollers to maintain proper media tension. This ensures proper imaging while providing the minimal chance for damage to the original document(s).

Drive Motor: A stepper motor is housed in the DADF to drive the pick and feed

rollers, and moves the calibration shutter into position. The connection is through a toothed belt and gear drive. This connection and the vibration mounts that the motor is mounted to help reduce vibrations introduced into the system.

DADF scanhead and Lamp: The DADF utilizes a stationary scanhead containing

the imaging CCD. This scanhead is only for scanning the second side of a duplex original. The lamp is a Cold Cathode Flourescent Lamp (CCFL).

Note

The CCFL is powered through a chopper board. It is supplied with a variable DC input (Up to +24 VDC) and generates +600 VDC to +900 VDC depending on the supply voltage.

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 the scanner board and then sent to the IOT. There is no direct communication from the DADF to the IOT

DADF Hinges: Mechanical connection between the DADF and the scanner portion

of the IIT consists of a set of hinges. These hinges allow for the DADF to lift from the platen glass to facilitate book copying. The hinges are designed to lock when the IIT is opened for adding consumables or removing media jams from the IO T. In order to unlock the hinges, the IIT must be closed.

Note

It is possible to continue scan and flatbed copy functions with the document feeder disconnected. In this condition, the control panel displays the error message “Document Feeder Disconnected”.

2-6 W orkCentr e 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 the output tray.

The imaging path of the DADF is referred to as a Constant Velocity Transport (CVT) design. This design compensates for differences in the operating speed of any of the drive rollers, thereby reducing the chance of damage to the original or of varying the distance between the imaging device and the target document.

Copy/Scan Imaging

When using the document feeder for a copy or a scan, the DADF scanhead scans the second side of the original at the sam e time the flatbed scanhead scans the first side of the original. The scanhead in the document feeder is stationary.

Data is transferred from the IIT to the IOT through the electrical connections to an image processing board in the electronics module. This processing board receives the RGB channel data and translates it into a data stream that the print engine controller can understand. This data is either transferred to the engine driver (for copy service) or to the hard drive controller (for scan service)

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 images. The platen functions well for media outside the operating range of the DADF (16 lb.-32 lb.), fragile or damaged originals, photographs, or large (or bound) items such as books or periodicals.

scanhead and Lamp: The Flatbed portion of the IIT contains a moveable scanhead

that includes the CCD imaging board, main control board, drive motor, and lamp assembly. The lamps are Cold Cathode Flourescent Lamps (same as the lamps in the DADF).

CVT Window: This portion of the platen is a part of the DADF media path. The

principal function of this window is to allow the lower scanhead to image the first side of an original being fed through the DADF.

IIT Connector: An electrical connection on the rear of the Flatbed portion of the IIT

connects to a receptacle on the IOT completing the signal path for image data from the IIT, power to the IIT, and system communications between the three components.

Control Panel: The control panel is the user interface with the system.

2-8 W orkCentr e 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 performed during startup and at pre-programmed intervals of operation. This calibration ensures that the system detects the response to a giv en calibration spot and determines the effects of lamp temperature and age on the image quality of the system.

Automatic calibration uses built in targets of the system. The target for the flatbed is on the back of the diverter strip; the target for the DADF is located on the back of a moveable flap, internal to the DADF. The calibration is automatic at power-up, when coming out of energy star mode, and at a predetermined schedule based on the length of time the lamps have been on continuously.

Automatic DADF Calibration

Calibration for the DADF is performed at initial power-up and “as required” with normal usage of the DADF. The steps are the same for both conditions.

1. The lamps turn on.

2. The calibration strip moves back slightly from the home position, to confirm the

home position, then extends into the image path.

s2424-2

alibration Strip

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 position.

Automatic Scanner Calibration

1. Lamps turn on.

2. The scanhead drives toward the automatic calibration target to ensure that the

head lock is released.

3. Scanhead moves back to the home position flag, out, and back in to confirm

operation.

4. Scanhead moves under the calibration target until the CCD achieves a

predetermined image quality and stability.

5. Scanhead moves toward platen glass to confirm motion cont rol.

6. Scanhead moves back to the home position under the CVT window.

Manual Calibration

The manual calibration is a maintenance procedure accessed through the system’s control panel. This calibration requires a calibration sheet provided with a new scanner assembly. It is designed to ensure the document feeder and flatbead scan heads are aligned to the system (motion control), the scan heads are aligned to one another (duplex scanning alignment), and that certain white, black and gray scale calibrations are performed. This calibration is performed:

■ At the factory during initial system setup.

■ Whenever the document feeder or scanner assembly, or both, are replaced.

■ If troubleshooting determines that the calibration has drifted or that the

calibration data has been erased from the system (ESD event).

Note

The manual calibration procedure is detailed in "Manual DADF to Scanner Calibration" on page 6-9.

2-10 W orkCentr e 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 the main board. The main board also controls network functionality, PS and PCL interpretation, memory , job management, de vice management interfaces and a host of other services. The MEP board, or exit module board, provides low level motor control for the exit module components.

The system also contains a second (scanner) power supply located next to the exit module MEP board contained in the backframe. This supplies power to the scanner, document feeder, and the e xit module drives.

For more information, or block diagrams showing the interaction between the system electronics, see the Wiring Diagram section of the manual starting on page 10-1.

Note

Although the control panel is part of the scanner unit, it receives power from the electronics module power supply.

s2424-236

Power Supply

Hard Drive

Scanner Power Supp

Exit Module (MEP) Board

Main Board

Image Processor Board

Power Control Board

Wave Amplifier

Configuration Card

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. The exit module board is also the connection point for the stack full sensor, cover open sensor, exit module elevator carriage, and exit sensors and flags.

Scanner Power Supply

The scanner power supply board supplies power to the scanner and exit module assemblies using the following voltages:

■ +24 V to the scanner

■ +24 V and +5 V to the exit module board

The electronics module enables or disables the scanner power supply using the power supply enable line for functions such as Intelligent Ready and standby functions. The control panel receives power from the power supply contained in the electronics module.

Electronics Module

The electronics module includes the main board, image processing board, the power control board, hard disk drive, and the power supply. The electronics module is replaced as one assembly.

Main Board: The main board controls the operation of all the mechanical and

electrical systems in the IOT. Through the power control and I/O boards, signals are passed to the different gear trains, heater controls, and drive motors and signals are received from sensors for proper operation of the IOT.

The imaging process is a "three way" communication between the electronics module, printhead, and wave amplifier board. Imaging data is received from either the print or scan function and is processed through the imaging path portion of the main board. This data then is split into two paths. One of these paths is through the power control board to the wave amplifier board. This data controls the operation of the wave amp with regard to the drive algorithm to use for driving the jet stacks (discussed later in the printhead section). The second path is through a ribbon cable from the main board to the printhead control board (located on the underside of the printhead). These two signals are interpreted by the printhead to properly produce the image on the drum.

The main board provides support for Ethernet and USB 2.0 external I/O interfaces.

Note

The WorkCentre C2424 system does not support a parallel connection.

2-12 W orkCentr e 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 binary data, 8-bit RGB data, or 8-bit grayscale data.

NVRAM: The NVRAM memory device, located on the main board, stores control

panel defaults, network settings, IOT calibration data, copy counts, usage profile data, and the printer serial number, which is also referred to as the engine tracking number (ETN). When the electronics module is replaced, the NVRAM must be transferred to the main board in the replacement electronics module.

Memory: The main board supports two PC133 compatible SO-DIMM SDRAM

memory modules (64 to 512 MB). While the main board will support memory configurations as low as 64 MB, the WorkCentre C2424 requires a minimum of 256 MB of system memory to operate. The system has been tested with up to 1 GB of memory installed. This memory configuration can be ordered as an option.

Hard Drive Support: A hard drive IDE cable is plugged into the main board from

the hard drive board. A separate power cable must be plugged into the power control board from the hard dri ve board to make the hard drive functional. The WorkCentre C2424 requires that a hard drive be installed for proper operation.

Configuration Card: The conf iguration card is a thumbnail-sized device that plugs

into the side of the electronics module. This device stores printer information and interacts with the printer's NVRAM chip. The configuration card supports the transfer of network configuration information from a failed printer to a replacement printer. When the electronics module is replaced, the configuration card must be transferred to the replacement electronics module. For more information on the configuration card, see "Configuration Card Personality Parameters" on page 2-45.

Power Control Board: The power control board dist ributes drive voltages to

operate the printer’s various motors, solenoids and clutches. The power control board also provides the interface that returns information from the printer's sensors to the main board. The sensors are used to track mechanical and thermal functions, such as the position and temperature of the printhead. The power control board also generates regulated +/- 12 V and 5 V from unregulated +/-15 V power.

Power Supply (Electronics Module): There are no field adjustments necessary

on the power supply. In general, the power supply has two main, yet interrelated sections: the AC section and the DC section. In the AC section, power is routed to 10 triacs. Under the main board lo gic cont rol, the triacs supply AC power to the 10 heaters in the printer.

Two fuses provide current protection to the triacs. Fuse F2 and F3 protect the power supply from, most often, a shorted triac caused by a defective heater. If the F2 or F3 fuses blow, it is best to replace the electronics module (and, of course, the defective heater), rather than the fuse. Otherwise uncontrolled, with the fuse replaced but the triac shorted, AC power may be applied to the heater. Each time the main board turns

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 protected by thermal fuses. A thermal fuse opens in the unlikely event of a “runaway” heater following a hardware failure. The drum and the paper preheater thermal fuses are located on the paper preheater. Additional thermal fuses are located on the printhead and on the ink melting elements.

The DC power supply ge nerates + 3.3 V, +/- 15 V, and +/- 50 V. These voltages are used directly or regulated to other voltage values as needed by various circuits in the printer. The power control board regulates +/- 15 V to +/- 12 and other voltages. The main board also has regulators providing + 5 V, + 2.5 V, and + 1.8 V. The power supply outputs + 3.3 V in ENERGY STAR mode. Fuse F1 provides protection for the switching power supply in the DC section.

arning

Do not touch the power supply; AC line voltages are present. The power switch does not disconnect power from the printer. The power switch signals the supply and the printer logic to begin a shutdown sequence.

2-14 W orkCentr e C2424 Service Manual

Power Supply Diagram (Electronics Module)

AC Line

AC Neutral

Line

Gnd Ref

Neutral

r u

I n k

r e s

jsrjs

r e h

H 1 3

H 1 2

1 1

1 0

H 3

H 2

H 1

AC Line

AC Neutral

Low

Switcher

+3.3 V

+15 V

-15 V

+50 V

-50 V

H13 H12 H11 H10

H9 H8 H4 H3 H2 H1

uProcessor

REG

Vss

Vcc

Serial

Control

Interface

s2424-028

Theory of Operation 2-15

Image Output Terminal (IOT) Sub-Assemblies

The Image Output T erminal (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 Deskew System

■ The Drum Assembly and Transfix System

■ The Exit Module or Media Exit Path (MEP)

■ The Purge System

Note

The electronics module is also a subsystem of the IOT but was discussed previously. For more information on the electronics module, see "System Electronics" on page 2-10.

2-16 W orkCentr e C2424 Service Manual

Sub-Assemblies of the IOT

Exit Module

s2424-008

uplex Print Path

Transfix System

aper Preheater

(

and Deskew)

Printhead

Drum

Ink Loader

Wiper Assembly

Paper/Med

Tray

Drum Maintenance Kit

Ink Waste Tray

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 assembly controls each roller in the

paper transport system. The paper transport system consists of a drive motor, a gearbox assembly and three solenoids. The media path drive motor also controls the movement of the wiper assembly and the headlock mechanism through a gear train and solenoid on the exit module.

The Ink Loader: Melts the so lid ink as ink is required by the printhead. The melted

ink drops into the ink reservoirs of the printhead underneath the ink loader.

The Printhead: inteRfaces with the electronics of the system to jet ink onto the

drum surface to create an image. The printhead includes 1236 interleaved jets (309 of each primary color) to provide the ability to electronically turn off a weak or missing jet to restore image quality.

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 sheet of paper or transparency film.

The Preheat and Deskew System: Serves to ensure that the print media (paper,

envelope, or transparency film) aligns properly to the drum and that the media is sufficiently warms to facilitate transfer of the image fr om the drum to the media.

The Drum Assembly and Transfix System: Form the key portion of where

imaging takes place. The image is first printed as a "mirror" image on the rotating drum. A sheet of warmed media feeds from the preheater and passes between the drum and the transfix roller. The process gear train then loads the transfix system and presses the paper to the drum to adhere the image as the drum spins in the transfix direction.

The Exit Module or Media Exit Path (MEP): Receives control signals from the

exit module (MEP) board, which contains its own firmware, for proper handling of media exiting the IOT. The exit module takes transport control of the media, lifting it from the area of the ink loader and delivering it to the output tray at the front of the IOT.

The Purge System: Uses air pressure and a wiper blade to remove an y debris or air

bubbles that may be obst ructing the printhead nozzles.

2-18 W orkCentr e 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. To pick a sheet of paper, the Tray 1 solenoid is fired, and the drive gear rotates slightly to engage with the drive train. A bias force provided by the lift plate force against a cam causes the roller to rotate enough so the missing tooth gear engages the drive train. The pick roller rotates to pick the paper, and the separator pad assembly prevents multiple sheets from being picked by the pick roller.

Key differences in the Tray 1 pick process include:

■ Lift plate force is optimized to support heavier paper

■ 100-sheet capacity

■ Pick roller creates the buckle for the deskew process

■ Pick roller drive disengages when the door is opened and closed

■ Pivoting separator pad to prevent it from binding

s8400-190

Spring loaded lift plate

Cam

Drive gear

Pick roller

Separator pad

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 the pick nip. The retard roller prevents two sheets from advancing. The sheet of paper continues past the take away rollers until the sheet completes the deskew process. When using the optional 525-sheet feeder, paper is pre-picked from the tray and staged in the paper path while the pr in ter is printing previous pages.

The deskew process uses a re v erse/b uckle de skew for all three paper paths. The paper is first driv en against non-rotating rollers. The rollers reverse during simplex, causing a buckle in the paper. This ensures that the leading edge is straight to prevent ske wing. The deskew rollers will not reverse during du plex printing.

s2424-045

Preheat Exit Sensor

Preheat Entry

(

Deskew) Sensor

Transfix Roller

Paper Preheater

Strip

Sensor

Paper Exit Sensor

Exit Module Elevat

2-20 W orkCentr e 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 non-rotating deskew nip, the print continues through the paper preheater and transfix system to the exit tray in the same manner as a single-sided print.

s2424-0

Exit Roller

Duplex Rolle

Exit Sensor

Deskew Sensor

Preheat Sensor

Duplex Roller

Strip Sensor

Theory of Operation 2-21

Sensor Locations

s2424-0

Exit Door Sensor

ontrol Panel Sensor

Strip Sensor

Paper Exit Sensor

Drum Temperatu

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 Sensor

2-22 W orkCentr e C2424 Service Manual

System Motors, Solenoids, and Drive

s2424-2

DADF Motor

levator Motor

Media Drive Gearb

Media Path Motor

Y-Axis Motor

Tray 1 Pick Soleno

Tray Lift Motor

Paper Drive Mot

Process Drive Motor

X-Axis Motor

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 powers the process driv e gearbox to rotate the gears to specific positions during the printing process. The process drive is able to actuate each camshaft system independently or concurrently through the use of the swing arm in the gear train. Operation of the transfix and drum maintenance system is controlled by the rotational direction of the motor.

When the process motor rotates in one direction, the swing gear engages the lower gears. When the motor rotates in the opposite direction, the upper gears are engaged.

Since the system is open loop, special attention to the home position of the process drive gears and the mating camshaft gears is critical. The process drive gearbox is mechanically keyed upon installation via gear orientations. These gear orientations allow the printer subsystems to self home during operation. If either the gearbox or cam gears is out of home during installation, the printer does not function properly.

s2424-0

Process Drive

Swing Gear

2-24 W orkCentr e 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 drive assembly , along with tw o clutches and a solenoid, allo w the motor to control the pick, take away, duplex, and deskew rollers.

A unique swing gear allows the pick roller and takeaway roller to rotate in the same direction regardless of the direction the motor is rotating

s2424-03

Media Path Drive

Swing Gear

Motor

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 necessary.

In the ready state, the print process consists of the following steps, which are described in this section:

■ Drum Preparation

■ Printing

■ Ink Loader

■ Printhead

■ Drum Assembly

■ Transfix System

■ Purge System

■ Transfix and Exiting

arning

Keep your fingers away from the Y-Axis drum rotation drive system; it uses a closed-loop servo drive system and is inherently dangerous; the motor speeds up if it senses the drive system slowing down, and fingers caught in the belts and gears can be severely injured.

2-26 W orkCentr e 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 process drive rotates the drum maintenance camshaft lifting the oil and wiper blade to the drum . The cams on the ends of the camshaft push against followers on each side of the drum maintenance system, forcing the oil roller and blade against the drum. The drum is rotated against the oil saturated roller.

Printing

To print, the drum starts rotating at a speed dependent upon print resolution. As the drum reaches the correct speed, the jets begin to fire to deposit the image on the oiled portion of the drum. As the jets fire, the printhead moves from right to left to complete the image on the drum.

When printing, the printer performs a “six-jet interlace, ” in which each jet lays do wn a particular number of pixel columns, depending on the print resolution. Each jet lays down one pixel column for each drum rotation, which varies from eight to 16 rotations, depending on the print resolution. Interlacing “averages out” the variability between jets by interlacing each jet with other jets. In some test prints, the printhead moves to the right and lays down 309 parallel bands of ink. Each band is composed of 15 pixel columns of dots from an individual jet.

s2424-0

Drum

Maintenance Roller

Drum Maintenance Pivot Plate

rum Maintenance

amshaft

Blade

Oil On Dru

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 Substitution Mode" on page 6-12.

Ink Loader

The ink loader consists of four parallel channels with an ink melting element at the end of each channel. Ink sticks, one color loaded in each channel, are pressed by coil spring pressure into the melting elements. As ink is required by the printhead, the appropriate color’s melting element is activ ated and the end of the ink stick is melted. The melted ink drips into the ink reservoirs of the printhead underneath. Sensors in the ink loader alert the customer to install more ink sticks before the current sticks are completely consumed.

If the ink level sensors inside the printhead detect that the printhead has run out of ink, but the ink low/out sensors are not activated, the control panel reports an “Ink Jam” error.

Ink Loader Door

Ink Stick

nk Melt Units

Ink Low Sensors

Ink Out Sensors

Printhead

s2424-0

2-28 W orkCentr e 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 on the rotating drum. The printhead provides one size ink drop that it uses for all print-quality modes.

s2424-0

Jet Stack

Reservoir

Purge Tube

Drum

Printhead

Head Driver Board

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 b y the stacked plates route ink past the 1236 individual, piezo-electric crystal-driven di aphragms, which force the ink in droplets out the 1236 corresponding nozzles. Looking at the printhead face, the nozzles are arranged in 12 rows, in color order KYKYKYCMCMCM, where K = black, Y = yellow, C = cyan, and M = magenta. During the printing process, the printhead would only have to travel approximately 14 pixels horizontally to provide complete coverage. However, the printhead travels much further, depending on print resolution, to interlace each jet with the output of neighboring jets.

Black

Yellow

Cya

Magenta

Ink Loader

Printhead

Ink

Funnel Filter

Purge Valve

s2424-0

Level Sense Probe

2-30 W orkCentr e 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

C for printing.

X-Axis or lateral movement of the printhead is accomplished using a stepper motor driving a fine-thread screw system. The printhead, mounted to the X-Axis shaft, moves laterally across the surface of the drum.

To find the printhead home position, the X-Axis system drives the printhead in an open-loop. The printhead is driven against the left printer frame for a few seconds, and then reversed a set distance. A tension spring links to the printhead’s left shaft, and provides a preloaded tension so the printhead moves smoothly.

s2424-034

Tension Spring

X-Axis Shaft

X-Axis Hook

X-Axis Shaft

X-Axis Mot

Drum

Printhead

Nose Cone Gear

Theory of Operation 2-31

Printhead Tilt

The printhead is able to rotate into fou r 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, and the head is secured for shipping.

2. Wipe position (12 degrees): the printhead tilt arm/follower is engaged with the

tilt cam, and the head overload spring contact is engaged with the overload spring-plate to provide the correct force for the wiper.

3. Standby position (20.9 degrees): allows the wiper to clear the printhead in order

to be in the start wipe printhead position, and also allow the printhead locks to pivot and lock or unlock the printhead. In this position, the printhead tilt arm/ follower is engaged at the standby position of the tilt cam.

4. Print position (0 degr ees): 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.

The tilt cam tilts the head into the basic fou r posit ion s listed above. The cam has five special features and associated functions:

1. The cam is combined with a missing tooth gear that allows the cam to be inacti ve

in the print position. This frees the process drive to perform other printer operations.

2. The cam has a latching feature to unlatch and latch the missing tooth gear to

engage the printhead tilt drive train.

3. The cam profile has a standby dwell (the portion of the cam that has a constant

radius). This holds the printhead back in the standby position

4. The cam profile has a wipe dwell that holds the printhead back in the wipe

position.

5. The cam profile increases the power consumption at a specific phase of rotation.

This allows the software to identify a power consumption footprint to alert the system when the head is locked in error.

The printhead is tilted away from the drum and locked for shipping. The printhead is locked if the green head lock indicator is above the level of the tray. When the printhead is locked in the shipping position there are three key restraining elements:

1. The printhead is restrained from rotating from the shipping position by pins

extending from both ends of the printhead into a pocket. These pockets are defined by dampening pads that limit motion to the back and polycarbonate locks that pivot into the lock position and limit forward motion toward the drum. The locks are held in the lock position by the wiper carriage, and are spring-loaded to normally be unlocked.

2. The printhead is restrained at the X-Axis shafts by the right and left head

restraints that limit motion at both ends of the printhead.

3. The printhead is limited to the nominal motion of 1.7 mm in the X-Ax is (left /

right side motion when the printhead is back and locked) by the right lock and the left home stop on the left side frame.

2-32 W orkCentr e 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 dri ve is activated, it drives the drum maintenance camshaft to engage the tilt gear train. The tilt cam tilts the printhead into the print position. The cam is combined with a missing tooth gear that allows the cam to be inactive in the print position, freeing the process drive to perform other printer operations.

The cam has a latching mechanism to unlatch and latch the missing tooth gear to engage the printhead tilt drive train. The cam’s latching mechanism also holds the tilt gear in place. A leaf spring applies constant pressure to engage the gear when the latching mechanism is released. The arm of the latching mechanism is inside the frame; the rest is visible, outside the frame. Arrows located on the latching mechanism and on the frame indicate when the printhead is in pr in t position. When the arrows on the latching mechanism and frame align, the printhead is in the print position and the tilt gear disengages from the process drive.

Drum

Printhead

Tilt Gear

Tilt Gear (Engaged)

Printhead Restraint

s2424-03

M Cam Gear

Theory of Operation 2-33

The latching mechanism is actuated by a small movement of the wiper. Through a follower gear, the compound gear dri ves 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 revolution of the tilt gear, the latching mechanism is pulled back into position by the return spring.

As viewed from the left side of the printer, when the arrows do not align, the tilt gear is engaged.

To accommodate printhead maintenance, the printhead can be tilted back away from the drum. This creates room for the wiper to be moved into position in front of the printhead faceplate. The process driv e dri v es the gears to the tilt compound gear train. The drum maintenance camshaft drives the gear train to tilt the printhead.

Tilt Gear (Engaged)

Head Tilt Compond Gear

Tilt Drive Gear

s2424-03

2-34 W orkCentr e 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 detail on the transfix system.

In operation, the image to be printed on paper is first “printed” on the rapidly rotating drum. The paper preheater heats a sheet of paper or transparency film to prepare it for the image transfer process. The heated paper is then passed between the drum (now rotating much more slowly) and the transfix roller. Under the pressure between the drum and the transfix roller , the image is transferred to the sheet of paper. An encoder disk and sensor on the left end of the drum monitors the drum’s speed and posit ion.

The drum heater heats the surface of the drum to about 60

C (140oF) for imaging. The drum heater does not rotate. The heater is inside the drum, and is controlled by the drum heater relay board. The drum heater consists of two resisti ve heater coils that operate in series for 220 V and in parallel for 110 V operation. The series/parallel operation is controlled by the drum heater relay board. A temperature sensor in contact with the drum surface monitors the drum temperature. The main board interprets the sensor’s signal and turns on the drum heater and drum fan to heat the drum, or turns on the drum fan alone to cool the drum.

aper Preheater

Transfix Roller

Paper Pa

Dru

Drum Heater

s2424-0

Theory of Operation 2-35

The drum is driven by a closed-loop servo motor. Through a single reduction belt drive, the serv o 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 while the spring actively adjusts the tension.

Note

The drum rotates in different directions for each process.

■ Transfix CW

■ Maintenance CCW

■ Printing CCW

arning

Always keep your fingers away from the drum drive system; it uses a closed-loop servo drive system. Since the motor speeds up if it senses the drum drive system slowing down, fingers caught in the drum belts and gears can be severely injured.

s2424-03

Y-Axis Motor

Tension Spring

Fan

Y-Axis Encoder

Drum Temperature Sensor

Single Reduction Belt Drive

Pulley

2-36 W orkCentr e 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 applies in the load module against the drum. The pressure must be uniform across the length of the transfix roller to avoid paper wrinkles and light spots on the prints.

After the transfix roller is engaged, the drum rotates to advance the paper during the transfix process. The drum continues to adv ance the paper until the transfix roller is disengaged. The transfix roller is lifted and lowered by the action of the process driv e. All gears move to rotate the transfix camshaft to bring the transfix roller into contact with the drum. The gears reverse to rotate the transfix roller back to its original position, except when printing from Tray 1 or on envelopes. The transfix load springs and double lever arms increase the force when the camshaft is engaged.

arning

Never attempt to adjust or increase the transfix pressure on the springs.

Drum

Transfix Cam

Transfix Load Arm

s2424-03

ransfix Load Module

Transfer Roller

Transfix Load Spring

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 surf ace and facilitates its transfer to the sheet of paper or transparency film. The oil is contained in a porous foam roller.

Prior to each print, the process motor drives a cam to raise the pivot plate, which raises the oil roller against the rotating drum. The same cam raises the compliant wiper blade to assure that the oil film is smooth and even across the drum’s surface. The process drive rotates in one direction. This rotates the drum maintenance camshaft and raises the drum maintenance system to the drum. The process driv e then rotates in the opposite direction to lower the drum maintenance system. The blade removes oil and drains it back into the maintenance kit drawer through a felt filter. The oil roller can then reuse the oil. As the drum completes one rotation, the rotating cam lowers the oil roller and then lowers the blade.

The drum has a floating deadband, the narrow section of the drum containing excess oil and other debris. The oil bar is left on the drum surface when the blade is remo ved from the drum. This oil bar location is controlled to keep it outside of the print area.

An EEPROM chip, built-in to the maintenance kit, stores the number of oiling cycles performed by the drum maintenance system. The EEPROM stores the number of prints remaining to track consumable life. At printer startup, four oiling cycles are performed to condition the drum.

s2424-040

Drum

Maintenance Roller

Drum Maintenance Pivot Plate

rum Maintenance

amshaft

Blade

Oil On Dru

2-38 W orkCentr e 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 expelled during the purge is funneled into the waste tray . Following the purge, a wipe operation is performed on the faceplate using the wiper blade. After the wipe, a cleaning page is printed.

To perform a printhead maintenance cycle, the printhead is first tilted away from the drum to allow the wiper assembly to pass by . The wiper blade is then raised in front of the printhead. The media path drive governs wiper movement when it engages a clutch on the exit shaft of the printer. The purge pump applies pressure to the ink reservoir for approximately 2.5 seconds. Valves in the reservoir seal when pressure is applied. The pressurization ejects a small amou nt of ink from the jets. Following the pressure purge, the printhead tilts into the wiper assembly and the wipe cycle begins. The pump runs again with the solenoid for approximately 30 seconds, creating a neutral balance between pressure and ink. The wiper blade lowers and wipes excess ink from the jets into the ink waste tray. A proper purge co v ers the length of the waste tray with a single layer of ink about 20 mm wide.

s2424-0

Wiper Blade

Printhead

Purge Pump

Purge Tube

2.5 Sec

Theory of Operation 2-39

The level of the ink in the reservoir is kept at a constant level. If the pressure pur g e tubing is pinched, the printhead may not purge properly. In addition, be cause the purge tubing also acts as a vent to atmosphere when not purging, a more serious failure can occur if the ink overfills and the reservoir cannot vent properly.

arning

When servicing the printer be careful of the purge system as it passes the printhead. If a damaged wiper blade of the purge system catches on the printhead, it could propel hot liquid ink upward into your face.

s2424-043

Purge Pump

Solenoid Valve

Purge Tube

Printhead

Drum

Wiper Assembly

Wiper

30 Sec

(Open During Wiper Action)

2-40 W orkCentr e C2424 Service Manual

Transfixing and Exiting

Transfixing an d exiting consis ts 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 from the drum.

4. Exit the paper from the system, or exit the paper for 2-sided printing.

Tripping the preheat exit sensor sets up a series of events that occur on a predetermined schedule. Paper is transported through the preheater to thermally prepare it for transfixing. The preheat sensor detects the paper’s presence and accurately references the leading edge of the paper with the image on the drum. Based on the timing information from the paper preheater exit sensor, the transfix roller lowers onto the leading edge of the media in the nip. Timing is based on the sensor ensuring the image is perfectly aligned for transfix to the paper. The process dri ve lifts and lowers the transfix roller.

At the point which the transfix roller is loaded, but before the drum begins to rotate, the paper stripper solenoid is engaged. The paper stripper is actuated by energizing the paper stripper solenoid. The solenoid mounts on the upper inner duplex guide and activates the strip solenoid lever. The lever rotates the paper release carriage until it hits the transfix ground pins, causing the paper release blade to momentarily drop onto the deadband of the drum. This action catches the leading edge of the sheet of paper and guides the paper to the rotating exit rollers.

After the transfix roller is engaged, the drum rotates to adv anc e the paper and transf ix the image. All gears move to rotate the drum transfix camshaft to bring the transfix roller into contact with the drum. The transfix roller nip applies the load necessary to transfer the image to the paper from the drum. Once the image is transferred, the drum stops rotating and the transfix roller is lifted by the process drive.

Theory of Operation 2-41

ss2424-04

Drum

Transfix Cam

Transfix Load Arm

Transfix Load Module

Transfer Roller

Transfix Load Spring

Transfix Cam

Process Drive

Transfix Roller Gear

2-42 W orkCentr e 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-en e rgized, the solenoid return spring provides force to move the solenoid plunger out of the solenoid coil which rotates the paper release carriage back to its ready position.

The deskew rollers are not driven during transfixing. The media path drive rotates the exit rollers in the correct direction to pull the paper out with the deskew clutch deenergized.

As the process drive lifts the transfix roller , the e xit rollers transport the paper into the exit module. The media is then fed out over the ink loader until the trailing edge is at the nip of the exit module roller. The elevator motor raises the carriage assembly to the top position, where it then stops and the drive motor drives the exit module rollers until the media exits the IOT ending the print cycle.

Theory of Operation 2-43

s2424-0

Release blade

Strip solenoid

Engine Exit Senso

reheat Exit Sensor

Transfix Roller

Paper Preheater

Strip

Sensor

Paper Exit Sensor

2-44 W orkCentr e 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 Peak Transfix Speed, Legal 20 ips 17 ips 13 ips 7 ips Peak Transfix Speed, Tray 1 13 ips 7 ips 7 ips 7 ips First sheet transfix speed 7 ips 7 ips 7 ips 7 ips

Setpoint, OHP Media

Peak Transfix Speed 5 ips

Approximate Print Speeds

Tray (source) / Resolution Simplex, A4 Paper Auto Duplex, A4 Paper

Tray 1

Fast Color (300 x 300 dpi) 10 pages per minute

(ppm)

10 sides per minute (spm)

Standard (300 x 450 dpi) 9 ppm 9 spm Enhanced (563 x 400 dpi) 8 ppm 4 spm High Res/Photo (525 x 2400) 6 ppm 3 spm PCL 600 x 300 Mode

PCL 600 x 600 Mode

6.5 ppm 3 ppm

Tray 2 - 4

Fast Color (300 x 300 dpi) 24 ppm 15 spm Standard (300 x 450 dpi) 18 ppm 13 spm Enhanced (563 x 400 dpi) 12 ppm 11 spm Hi Res photo (525 x 2400 dpi) 7 ppm 7 spm PCL 600 x 300 Mode

PCL 600 x 600 Mode

13 ppm

6 ppm

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 address are configured at the factory, and are “read only”. The feature value is fixed in the configuration card, and does not change. Ethernet address is stored only on the configuration card, and cannot be rewritten. The ethernet address is not written to the NVRAM chip.

Personality parameters are a subset of network configuration parameters, which are populated to the configuration card over time as the system is configured b y the customer. The personality parameters are copied, or “shadowed”, from the main board's NVRAM chip to the configuration card during the normal operation of the printer. When the configuration card is inserted into a new printer, the personality parameters on the configuration card are written into the NVRAM chip of the new printer. When a printer is powered on, if it contains the configuration card of another printer, the personality parameters are automatically copied to the NVRAM chip. If the configuration card is removed, the system will reboot as a "B" (non-networking, non-duplexing) model..

Configuration Card “Shadowed” Personality Parameters

NCL Subject NCL Item Size (bytes)

N/A “version” not NCL parameter

version (of the layout of personality

parameters)

NEST Base Printer Name 48 NEST SysAdmin Contact 128 (truncated from 256) NEST Printer Location 128 (truncated from 256) NEST Asset Identifier 128 (truncated from 256) IP Host Name 64 IP Domain Name 256 IP Network Mask 4 IP IP Address 4 IP Default Gateway 4 IP BOOTP/DHCP 1 IP DDNS 1 IP SMTP Server 256 IP IP Source 1 IP TCP/IP 1

2-46 W orkCentr e 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) Secondary WINS Server 4 Ethernet Speed 1 HTTP On 1 HTTP Information Forwarding 1 HTTP SMTP Server Automatic 1 HTTP Legal Settings 1 HTTP Admin_Password 11 HTTP Admin_Username 11 HTTP KeyUser_Password 11 HTTP KeyUser_Username 11 HTTP Admin_HostAccessList 256 HTTP KeyUser_HostAccessList 256 Notify On 1 IPP Authentication Scheme 1 IPP IPP user name 11 IPP IPP password 11 FTP Login Password 33 Security Print Hosts 256 AppSocket On 1 AppSocket Enabled 1 LPR On 1 LPR Enabled 1 FTP On 1 FTP Enabled 1

Configuration Card “Shadowed” Personality Parameters (Continued)

NCL Subject NCL Item Size (bytes)

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 networking.

2. NCL = Nest Configuration Library

Configuration Card “Shadowed” Personality Parameters (Continued)

NCL Subject NCL Item Size (bytes)

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

3-2 W orkCentr e 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 information on Service Diagnostics and all internal system test functions, see "Service Diagnostics Menu Functions" on page 4-4.

For troubleshooting system problems not associate with, or displaying, an error code or message, such as startup or system power on, media, paper path, print-quality or image problems, and electrical failures see "General Troubleshooting" on page 4-1 or see "Image-Quality Troubleshooting" on page 5-1.

When checking for error codes from the control panel, be sure to check the Copy, Scan, and Print main menus (major mode buttons) for current status and error conditions.

■ Status Page

■ Usage Profile

■ Fault History

■ Diagnostic History

Erro r 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 hist ory logs.

BIST Error Reporting

BIST verifies basic electronics module CPU operation and reports failures by utilizing the rear interface panel PS and PE LEDs. These tests occur immediately at power-up, before POST tests are run or the control panel is initialized.

The following table defines the blink patterns associated with a failure.

BIST Error Reporting Blink Pattern Definition Table

PE LED PS LED Description

Off or 1 Blink, and then off

The power supply could not remain regulated when DC power was applied so it was shut down. Follow the troubleshooting procedures for electrical shorts (see "Electrical Troubleshooting" on page 4-58 and check the power supply fuses).

On Solid (dimly)

Initialization failure. The system is held in reset mode. This can be caused by an electronics module fault or a +3.3 V power supply regulation failure (see "Electrical Troubleshooting" on page 4-58). Also, see "Verifying Pow er Supply Operation - Print Engine" on page 4-71.

Off PS and

control panel 1/2 sec. blink

Boot loader memory test failure. Ensure the systems RAM chips are properly seated and that the correct RAM type for this system is installed. For specifications on approved RAM types for this system, see "System Specifications" on page 1-12.

1Rapid

blinking

CPU bridge and/or PCI bus is not communicating. Reboot the printer, if the error still occurs, replace the electronics module.

2Rapid

blinking

ROM not responding. Reboot the printer, if the error still occurs, replace the electronics module.

3-4 W orkCentr e 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 with an LED blink code flashing on all three LEDs (control panel LED, PS LED and PE LED). If initialization of the control panel fails, POST errors will still report using the LED blink patterns. The sum of the flashes, blinking in increments of 5, equal the error code. For example, 7 flashes equals error code 7.

“Soft” POST errors, that do not prevent the system from powering up Complete.ly, are displayed on the control panel for 5 seconds and then the system continues through the remainder of POST. There are no rear panel LED codes associated with soft errors. Most soft errors will cause the system to print a Startup Page with the error message on it.

Note

* Before replacing the electronics module for any POST errors, do the

following:

1. Unplug all wiring and/or cables to the electronics module.

2. Plug in the AC power cable and power on the system electronics module.

3. If the error blink pattern is now different from the original error reported before

Step 1, the problem may not be in the electronics module, see "Electrical Troubleshooting" on page 4-58.

3Rapid

blinking

System hangs during code initialization.

1. Unplug all cables from the electronics module.

2. Plug in the power cable.

3. Power on the electronics module (system).

4. If the problem still occurs, reseat the RAM DIMMs.

5. Replace the electronics module. For disassembly, see

"Electronics Module" on page 8-61. For replacement, go to the parts list on page 9-12.

BIST Error Reporting Blink Pattern Definition Table (Continued)

PE LED PS LED Description

Erro r 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

Hard System panic.

03.01 Flutter only Soft ID read failure.

03.02 Flutter then 03 blinks

Hard Mismatch.

03.03 Flutter only. Soft Version mismatch.

03.04 Flutter then 03 blinks

Hard Access failure.

04.01 Flutter and then 04 blinks

Hard ID read failure.

04.02 Flutter and then 04 blinks

Hard ID mismatch.

04.03 Flutter and then 04 blinks

Hard TMVL mismatch, write/read failed.

04.04 Flutter and then 04 blinks

Hard TMVH mismatch, write/read failed.

05.01 Flutterand then 05 blinks

Hard Communications error. PLD I/O Board serial,

link down/bad parity.

05.02 Flutter only Soft Communications error. PLD I/O Board serial,

mismatch.

6.08 N/A Soft IDE drive general failure. Reseat IDE cable and

power cable. If problem persists, replace the IDE drive. The system will work without the IDE drive.

07.01 Flutter only Soft Control panel link is invalid or bad parity.

07.02 Flutter only Soft Control panel version mismatch.

08.01 Flutter only Soft Control panel failed to initialize , POST soft error.

09.01 Flutter only Soft Control panel data path failure, bad data

returned.

10.01 Flutter and then 10 blinks

Hard PLD power control link down.

3-6 W orkCentr e 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 orientation.

2. Replace EEPROM.

11.03 Flutter and then 11 blinks

Hard EEPROM re-read failure.

1. Check EEPROM orientation.

2. Replace EEPROM.

11.04 Flutter and then 11 blinks

Hard EEPROM data failure, mismatch error.

1. Check EEPROM orientation.

2. Replace EEPROM.

12.xx Flutter only Soft Configuration card test failure.

1. Check card orientation.

2. Reseat then replace the configuration card.

NOTE: System will work as a base model

(without networking) without the configuration card.

13.01 Flutter and then 13 blinks

Hard PHY reset failure, reset stuck low.

13.02 Flutter and then 13 blinks

Hard PHY ID error, mismatch erro.

14.xx Flutterand then 14 blinks

Hard USB ASIC test errors, N2280 netchip read,

write, and mismatch errors, POST hard errors.

15.01 Flutter and then 15 blinks

Hard CPU interrupt error, spurious CPU interrupts.

15.02 Flutter and then 15 blinks

Hard CPU interrupt error, missing CPU interrupts.

15.03 Flutter and then 15 blinks

Hard CPU interrupt error, IRQ spurious assertion.

15.04 Flutter and then 15 blinks

Hard CPU interrupt error, timer no assertion.

15.05 Flutter and then 15 blinks

Hard CPU interrupt error, spurious assertion.

15.06 Flutter and then 15 blinks

Hard CPU interrupt error, no assertion.

POST Error Reporting Blink Pattern Definition Table (Continu ed)

Control Panel Error Code

PS, PE and Control Panel LEDs

POST Error Type Description

Erro r 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 series. For troubleshooting PEST error codes, see "37,0XX.xx Errors PEST Faults" on page 3-37.

15.07 Flutter and then 15 blinks

Hard CPU interrupt error, spurious assertion.

15.08 Flutter and then 15 blinks

Hard CPU interrupt error, no assertion.

15.09 Flutter and then 15 blinks

Hard CPU interrupt error, spurious assertion.

15.10 Flutterand then 15 blinks

Hard CPU interrupt error, no assertion.

15.11 Flutter and then 15 blinks

Hard CPU interrupt error, IRQ spurious assertion.

16.01 Flutter only Soft Real time clock read failure.

16.02 Flutter only Soft Real-time clock write failure.

16.03 Flutter only Soft Real-time clock re-read failure.

16.04 Flutter only Soft Real-time clock does not tick.

17.01 Flutter and then 17 blinks

Hard Memory test, less than 128 MB of RAM

detected. This is the minimum RAM required. Add more RAM. Reseat the RAM SODIMM(s), then replace the RAM SODIMM(s).

18.01 Flutter and then 18 blinks

Hard IPCB ID read failure.

18.02 Flutter and then 18 blinks

Hard IPCB ID mismatch.

18.03 Flutter and then 18 blinks

Hard IPCB PCI configuration failure.

18.04 Flutter only Soft IPCB version mismatch.

19.01 Flutter and then 19 blinks

Hard Check and reseat cables. Replace hard drive, if

necessary.

POST Error Reporting Blink Pattern Definition Table (Continu ed)

Control Panel Error Code

PS, PE and Control Panel LEDs

POST Error Type Description

3-8 W orkCentr e C2424 Service Manual

Fault Code Error Message Troubleshooting

Fault Code Error Reporting

Fault codes are saved to NVRAM and can be retrie ved 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 menu. For more information on service diagnostics tests, their results, and how to enter into diagnostic mode, see "Service Diagnostics" on page 4-4.

In normal customer mode, the system will reboot each time an error occurs. If three of the same errors occur within 72 hours, or 1000 pages, the fault will be displayed on the system’s control panel.

Interpreting Fault Codes

■ Failing system (XX,yyy.zz)

■ Failing subsystem (xx,YYY.zz)

■ Checksum (xx,yyy.zZ

■ Type of problem (xx,yyy.Zx)

■ Print engine copy count (xx,yyy.zz:123) when the error occurred

(xx,yyy.4

x) Device faults are indicated by a 4 in the tenths place of the

fault code. This indicates a hardware problem. The most common device faults

troubleshooting procedures are documented in this section.

(xx,yyy.6

x) Program faults are indicated by a 6 in the tenths place of the

fault code. Unfortunately , there are too man y program faults to enumerate them all

and most program faults will not mean anything unless you are intimately familiar with the code base. Some of the more common program faults are documented in this section.

(xx,yyy.7

z) CPU exceptions are indicated by a 7 in the tenths place of the

fault code. The error code indicates both the PowerPC exception number and the

region of firmware that was executing when the exception occurred: Engine, PostScript, Network, or Operating System.

Note

A CPU exception can either be caused by hardware or firmware error. Refer to the infoSMART Knowledge Base for descriptions of the most common faults.

Erro r Messages and Codes 3-9

1,000.4x Error - 525-Sheet Feeder Faults

1,001.46: The upper 525-sheet feeder had an ove rcurrent condition. The lift motor or

clutch may be shorted.

1,002.47: The lower 525-sheet feeder had an ov ercurrent condition. The lift motor or

clutch may be shorted.

1,0XX.6x Errors - 525-Sheet Feeder program faults

a. Reseat the system onto the 525-sheet feeder. b. Ensure ground integrity for the system (see "Ensuring Ground Integrity" on

page 4-73).

c. Reset NVRAM. d. Replace the 525-sheet feeder.

Troubleshooting Procedure

Step Questions or Actions Yes No

1. Unplug all connectors to the optional 525-

sheet feeder.

2. Remove the feeder and inspect the connector.

3. Replace any damaged connectors either on the 525-sheet feeder or engine.

4. Reseat and reconnect the 525-sheet feeder to the system.

5. Did this correct the problem?

Complete. Go to Step 2.

1. Inspect the pick rollers in the 525-sheet

feeder tray(s).

2. Are the pick rollers damaged, dirty, or not moving freely?

Replace the pick assembly.

Go to Step 3.

1. Run the Tray [3]/[4] Pick Clutch test.

2. Does the pick clutch operate correctly?

Go to Step 4. Replace the

525-sheet feeder.

1. Run the Tray [3]/[4] Lift Motor test.

2. Does the lift motor operate correctly?

Go to Step 5. Replace the

525-sheet feeder.

1. Check the wiring from the 525-sheet feeder

to the Electronics Module (J390).

2. Is the wiring defective?

Replace the wiring and go to Step 3.

Replace the 525-sheet feeder.

3-10 W orkCentr e 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 problem with the system program. The engine

firmware was unable to initialize the queues used for inter-task communication.

2,003.62: This fault code indicates a problem with the system program. The engine

firmware was unable to start the service diagnostics tasks.

2,004.63: Failure to start the print engine in suspend mode . 2,005.64: This fault code indicates a problem with the system program. ROM could

not be opened for reading (idiags).

2,006.65: This fault code indicates a problem with the system program. ROM could

not be loaded (idiags).

2,007.66: This fault code indicates a problem with the system program (idiags) entry

point cannot be found.

a. Reset NVRAM and retest. b. Ensure ground integrity for the system (see "Ensuring Ground Integrity" on

page 4-73).

c. Replace the EEPROM chip. d. Reboot the system.

3,0XX.6x - IPC Program Faults

There is a communication problem between the engine and PostScript regions.

a. Reset NVRAM, and then retest. b. Replace the EEPROM chip.

Troubleshooting Procedure

Step Questions or Actions Yes No

1. Are all wiring connections to and from the

I/O Board properly seated?

Go to Step 3. Go to Step 2.

1. Reseat the connections.

2. Power on the sytem.

3. Did the error reoccur?

Go to Step 3. Complete.

1. Test the wiring from the I/O board J840 to

the power control board J800.

Replace the I/O Board.

Erro r 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

C).

4,018.48: This fault code indicates a problem with the process control system. The

printhead temperature dropped below the head cleaning needed threshold.

4,020.41: This fault code indicates a problem with the process control system.

Declared when the printer is booted in FTTR (Fast Time to Ready) mode and the head/cap contact flag is set in NVRAM. The printer cannot run in FTTR mode with head/cap in contact because it would be unwise to separate the two when cold (could tear wiper.) Service requested that this be a device fault in order to alert the service person to this condition.

4,021.42: This fault code indicates a problem with the process control system.

Declared when the printer is booted in FTTR mode and the drum is dirty. Cleaning the drum when very cold could increase the chance of gluing media to the drum surface and creating an ungly mess around the stripper fingers. Service requested that this be a device fault in order to alert the service person to this condition .

Troubleshooting Procedure

Step Questions and Actions Yes No

1. V erify the temperature of the room where the

system is located (see "System Environmental Specifications" on page 1-14) is operating within specification.

2. Is the room temperature too cold for proper operation of the sytem?

3. Ensure the printer is acclimated to the room temperature.

4. Did this correct the problem?

Complete. Go to Step 2.

1. Run the Monitor Heaters tests with all heaters ON.

2. Are the heaters operating correctly and

within specification?

Replace the electronics module.

Go to Step 3.

1. Inspect the wiring harness to the failed

heater.

2. Is the wiring harness damaged or not working properly?

Replace the wiring harness to the failed heater.

Replace the problem component.

3-12 W orkCentr e 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. Run the Check Wiper Alignment test.

2. Did the test fail?

Perform the Wiper Alignment Procdure and test again. Go to Step 2 if the test fails again.

Go to Step 2.

1. Run the Wiper Drive test.

2. Did the test fail?

Go to Step 3. Go to Step 5.

1. Inspect the wiper drive system and wiper

lock system. Look for ink in the belts.

2. Is the wipe system operating correctly?

Go to Step 4. Replace the

problem component.

1. Inspect the head maintenance clutch.

2. Is there the presence of oil or

contamination?

Clean the interior of the sytem and replace clutch if necessary.

Go to Step 5.

1. Run the Head Maintenance Clutch test.

2. Is the head maintenance clutch operating

correctly?

Replace in the following order:

■ Exit module

■ Media drive

gearbox

■ Wiper blade

Replace the head maintenance clutch.

Xerox WorkCentre C2424 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual