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Xerox WORKCENTRE C2424, Service Manual

The Xerox WORKCENTRE C2424 Service Manual is available for free download at manualshive.com. This comprehensive manual offers detailed instructions and troubleshooting advice to optimize the performance of your Xerox WORKCENTRE C2424 device. Enhance your productivity with this essential manual at your fingertips.

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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) . . . . . . . . . . . . . . . . . . . 10-12
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

Summary of Contents for WORKCENTRE C2424

Page 1: ...WorkCentre C2424 copier printer Service Manual ...

Page 2: ......

Page 3: ...ing servicing instructions are for use by qualified service personnel only To avoid personal injury do not perform any servicing other than that contained in the operating instructions unless you are qualified to do so First Printing March 2005 Part Number 604E13990 ...

Page 4: ...ed 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 ...

Page 5: ... 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 prob...

Page 6: ...ing or maintenance procedure practice or condition that is neccessary to efficiently 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 e...

Page 7: ...ngs are provided to prevent overheating of the system Do not drop paper clips or staples into the system The power cord is attached 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 Warning Do not remove the covers or guards that are fastened with screws unless you a...

Page 8: ... or supplied with the system options and supplies Caution Use of other than Genuine Xerox WorkCentre C2424 Solid Ink may affect print and copy quality and system reliability It is the only ink designed and manufactured under strict quality controls by Xerox for specific use with this system The Xerox Warranty Service Agreements and Total Satisfaction Guarantee do not cover damage malfunction or de...

Page 9: ...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 illustrat...

Page 10: ...ent 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 driver or control pan...

Page 11: ...trap 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 charges sufficient to damage some devices Do not remo...

Page 12: ...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...

Page 13: ...nical Components When servicing mechanical components within the printer manually rotate drive assemblies rollers and gears Warning Do not try to manually rotate or manually stop the drive assemblies while any printer motor is running ...

Page 14: ...e use shielded interface cables 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 res...

Page 15: ...han or equal to 16A per phase EN 61000 3 3 1995 IEC61000 3 3 Part 3 Limits Section 3 Limitation of voltage fluctuations and flicker 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 El...

Page 16: ...xii WorkCentre C2424 Copier Printer ...

Page 17: ...sical 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 ...

Page 18: ... 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...

Page 19: ...p 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 6...

Page 20: ...canner 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 11 Random Light Stripes 5 12 Predominate Light Stripes 5 13 Smudges or Smears 5 14 The Printed Image Is Too Light or Too Dark ...

Page 21: ...eaning 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 Cl...

Page 22: ...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 an...

Page 23: ... 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 10 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 Pa...

Page 24: ...xx WorkCentre C2424 Copier Printer ...

Page 25: ...ormation In this chapter System Introduction and Overview System Features and Configurations Routine Maintenance Items and Consumables Life Expectancy Control Panel Layout System Specifications Tray and Media Specifications ...

Page 26: ...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 002 ...

Page 27: ...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 ...

Page 28: ...eet 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 1 2 3 4 5 6 9 10 11 12 7 8 2424 171 2 3 1 ...

Page 29: ...w 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 1 2 3 4 s2424 267 1 3 4 2 ...

Page 30: ...s 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 the above components ...

Page 31: ...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 1 2 3 4 Document Feed Roller Pad Maintenance Kit Waste Tray Ink Sticks ...

Page 32: ...or 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 2 1 ...

Page 33: ...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 Ty...

Page 34: ...splay 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 ...

Page 35: ...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 for 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 ...

Page 36: ...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 10 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 2...

Page 37: ... 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 NOT...

Page 38: ...Nominal Operating Environment Temperature 10º 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...

Page 39: ... 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 ...

Page 40: ... 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 4 Use Xerox Professional Solid Ink Transparencies print quality may vary with other transparencies When printing photos postcards or brochures some attention to stacki...

Page 41: ...is completely 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 Pr...

Page 42: ... Trifold Brochures Transparency Labels A6 105 x 148 mm Index Cards 3 x 5 in Plain Paper Card Stock 60 220 g m2 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 m2 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...

Page 43: ...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 syste...

Page 44: ...ion 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 th...

Page 45: ... 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 ...

Page 46: ...blies and sub assembly interactions for this system This section is broken down into the following The Image Input Terminal IIT DADF and paper path The Scanner Assembly with Control Panel System Electronics Electronics Module Scanner Power Supply Exit Module MEP Control Board The Print Engine IOT Paper Path Sensing Drive Image Process Exiting s2424 232 Duplex Automatic Document Feeder Scanner Cont...

Page 47: ...t 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 DADF Scan Head Lamp Platen Document Glass Control Panel Media In Sensor Media Staged Sensor Pick Rollers Separator Pad Sensor Motor and Drive ...

Page 48: ...ADF 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 t...

Page 49: ...e 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 IOT In order to unlock the hinges the IIT must be closed Note It is p...

Page 50: ...o 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 same 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 ...

Page 51: ... 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 th...

Page 52: ...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 D...

Page 53: ...otion control 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 a...

Page 54: ...vides 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 exit module drives For more information or block diagrams showing the interaction between the system electronics see the Wiring Diagram section of the manua...

Page 55: ...e 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 betwe...

Page 56: ... 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 configuratio...

Page 57: ...al fuses are located on the printhead and on the ink melting elements The DC power supply generates 3 3 V 15 V and 50 V These voltages 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 EN...

Page 58: ...utral Line Gnd Ref Neutral D r u m I n k 4 I n k 3 I n k 2 I n k 1 r e s 2 r e s 1 js r js I P r e h t H 8 H 9 H 1 3 H 1 2 H 1 1 H 1 0 H 4 H 3 H 2 H 1 AC Line AC Neutral Low Switcher 3 3 V 15 V 15 V 50 V 50 V H13 H12 H11 H10 H9 H8 H4 H3 H2 H1 uProcessor REG Vss Vcc Serial Control Interface s2424 028 ...

Page 59: ...s 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 ...

Page 60: ...24 Service Manual Sub Assemblies of the IOT Exit Module s2424 008 Duplex Print Path Transfix System Paper Preheater and Deskew Printhead Drum Ink Loader Wiper Assembly Paper Media Tray Drum Maintenance Kit Ink Waste Tray ...

Page 61: ...r 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 tran...

Page 62: ...ovided 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 rolle...

Page 63: ...pletes 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 printer is printing previous pages The deskew process uses a reverse buckle deskew for all three paper paths The paper is first driven against non rotating rollers The rollers reverse during simplex causing a buckle in the paper This ensures that the leading e...

Page 64: ...dge 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 053 Exit Roller Duplex Roller Exit Sensor Deskew Sensor Preheat Sensor Duplex Roller Strip Sensor ...

Page 65: ... Exit Door Sensor Control Panel Sensor Strip Sensor Paper Exit Sensor Drum Temperature Sensor Drum Position Encoder Tray Paper Size Sensor Board Preheater Sensor Deskew Sensor Pick Sensor 525 Sheet Feeder Pick Sensor Media Stage Sensor Front Door Sensor ...

Page 66: ... Service Manual System Motors Solenoids and Drive s2424 237 DADF Motor Elevator Motor Media Drive Gearbox Media Path Motor Y Axis Motor Tray 1 Pick Solenoid Tray Lift Motor Paper Drive Motor Process Drive Motor X Axis Motor ...

Page 67: ...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 g...

Page 68: ...to the exit rollers which are built into the MEP Gear trains located within the media path drive assembly along with two clutches and a solenoid allow 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 031 Media Path Drive Swing Gear ...

Page 69: ...ssary 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 Warning Keep your fingers away from the Y Axis drum rotation drive system it uses a closed loop servo drive system and is inherently dangerous the motor speeds up if it senses th...

Page 70: ... 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 down a particular number of pixel columns depending on the print resolution Each jet lays down one pixel ...

Page 71: ...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 activated 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...

Page 72: ... 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 032 Jet Stack Reservoir Purge Tube Drum Printhead Head Driver Board ...

Page 73: ...esponding 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...

Page 74: ...ving 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 tens...

Page 75: ...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 ...

Page 76: ...ther 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 Arro...

Page 77: ...nism 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 drive drives the gears to the tilt compound gear tra...

Page 78: ...d 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 position The drum heater heats the surface of the drum to about 60o C 140o F 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 resistive heat...

Page 79: ...e spring actively adjusts the tension Note The drum rotates in different directions for each process Transfix CW Maintenance CCW Printing CCW Warning Always keep your fingers away from the drum drive system it uses a closed loop servo drive system Since the motor speeds up if it senses the drum drive system slowing down fingers caught in the drum belts and gears can be severely injured s2424 038 Y...

Page 80: ...s to advance the paper during the transfix process The drum continues to advance the paper until the transfix roller is disengaged The transfix roller is lifted and lowered by the action of the process drive All gears move to rotate the transfix camshaft to bring the transfix roller into contact with the drum The gears reverse to rotate the transfix roller back to its original position except when...

Page 81: ...The process drive then rotates in the opposite direction to lower the drum maintenance system The blade removes oil and drains it back into the maintenance kit drawer through a felt filter 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 containin...

Page 82: ...e 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 amount of ink from the jets Following the pressure purge the printhead t...

Page 83: ...not purging a more serious failure can occur if the ink overfills and the reservoir cannot vent properly Warning When servicing the printer be careful of the purge system as it passes the printhead If a damaged wiper blade of the purge system catches on the printhead it could propel hot liquid ink upward into your face s2424 043 Purge Pump Solenoid Valve Purge Tube Printhead Printhead Drum Wiper A...

Page 84: ... is perfectly aligned for transfix to the paper The process drive 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 leve...

Page 85: ...Theory of Operation 2 41 ss2424 049 Drum Transfix Cam Transfix Load Arm Transfix Load Module Transfer Roller Transfix Load Spring Transfix Cam Process Drive Transfix Roller Gear ...

Page 86: ...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 de energized As the process drive lifts the transfix roller the exit 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 rai...

Page 87: ...Theory of Operation 2 43 s2424 052 Release blade Strip solenoid Engine Exit Sensor Preheat Exit Sensor Transfix Roller Paper Preheater Strip Sensor Paper Exit Sensor ...

Page 88: ...fix 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...

Page 89: ...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 NVRA...

Page 90: ...TTP 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...

Page 91: ...SERVER 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 ...

Page 92: ...2 48 WorkCentre C2424 Service Manual ...

Page 93: ...rror Messages and Codes In this chapter Introduction Power Up Error Messages and LED Codes BIST Error Reporting POST Error Reporting PEST Error Reporting Fault Code Error Message Troubleshooting 3 Digit Jam Codes ...

Page 94: ...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 su...

Page 95: ...C 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 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 ...

Page 96: ... 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 d...

Page 97: ...tter 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 r...

Page 98: ...tworking 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 the...

Page 99: ... 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 Resea...

Page 100: ... xx yyy zz 123 when the error occurred xx yyy 4x 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 6x Program faults are indicated by a 6 in the tenths place of the fault code Unfortunately there are too many program faults to enumerate them all an...

Page 101: ...heet 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 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 ...

Page 102: ...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 Pr...

Page 103: ... 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 ...

Page 104: ...2 1 Run the Wiper Drive test 2 Did the test fail Go to Step 3 Go to Step 5 3 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 4 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 ...

Page 105: ...ep 2 2 1 Ensure the wiring around the printhead is routed properly 2 Is the wiring blocking the printhead Re route all wiring to the printhead Go to Step 3 3 1 Remove the waste tray and printhead and look for ink build up in the system 2 Is there ink build up any where in the system Clean any ink or debris which may be restricting movement of the drive train or printhead Go to Step 4 4 1 Check the...

Page 106: ...Ensure ground integrity for the system see Ensuring Ground Integrity on page 4 73 c Replace the EEPROM chip d Reboot the system Troubleshooting Procedure Step Questions and Actions Yes No 1 1 From the service diagnostic Monitor Menu run the Y axis Encoder test 2 Did the test pass Go to Step 2 Go to Step 3 2 1 Inspect the Y axis motor connector 2 Is the wiring faulty Replace the wiring harness or Y...

Page 107: ...h the X axis uninitialized 6 032 68 Could not find a solution to the described home motion profile 6 033 60 Could not allocate memory for X axis move parameters a Reset NVRAM and then retest b Ensure ground integrity for the system see Ensuring Ground Integrity on page 4 73 Troubleshooting Procedure Step Questions and Actions Yes No 1 1 Inspect the printhead power cable and heater wiring 2 Verify ...

Page 108: ...rectly aligned 3 Are the gears damaged Replace the process gearbox Go to Step 4 4 1 Use service diagnostics to run the Process Motor test 2 Did the test fail Replace the process gearbox Go to Step 5 5 1 Use service diagnostics to run the Transfix Drive Slow test 2 Did the test fail Verify the transfix cams are not damaged Replace problem component Replace the process gearbox Troubleshooting Proced...

Page 109: ...erly left and right Go to Step 5 Remove any obstructions or replace any defective parts 5 1 Ensure the gears are correctly aligned and homed see Homing the Process Gear Drive Train on page 6 8 2 Are the gears damaged Replace the process gearbox Go to Step 6 6 1 Use service diagnostics to run the Tilt Axis Drive test 2 Did the test fail Replace the process gearbox Go to Step 7 7 1 Use service diagn...

Page 110: ...ct the problem Complete Go to Step 2 2 1 Ensure the gears are correctly aligned and homed see see Homing the Process Gear Drive Train on page 6 8 2 Did this correct the problem Complete Go to Step 3 3 1 Replace the process gearbox 2 Did this correct the problem Complete Go to Step 4 4 1 Use service diagnostics to run the Head Maintenance Wiper Clutch test 2 Did the test fail Replace the wiper driv...

Page 111: ...1 Use service diagnostics to run the Tilt Axis Drive test 2 Did the test fail Replace the process gearbox Go to Step 7 7 1 Use service diagnostics to run the Process Motor test 2 Did the test fail Replace the process motor Go to Step 8 8 1 Use service diagnostics to run the Head Maintenance Wiper Clutch test 2 Did the test fail Replace the wiper drive clutch Go to Step 9 9 1 Ensure the wiper is pr...

Page 112: ...d while moving the cap wipe DOWN 8 055 44 The media path motor stalled while engaging headtilt Troubleshooting Procedure Step Questions and Actions Yes No 1 For an 8 005 48 error 1 Check for paper in the paper path that is adding drag to the rollers Look for paper or wiring interfering with the take away roller 2 Did this correct the problem Complete Go to Step 4 2 For an 8 007 41 error 1 Check fo...

Page 113: ...e Homing the Printhead Wiper on page 6 4 3 Did this correct the problem Complete Go to Step 7 7 1 Run the Head Maintenance Clutch test 2 Did the test pass Go to Step 8 Replace the maintenance clutch 8 1 Is the head lock mechanism on the right end of the MEP assembly is functioning properly Go to Step 9 Replace the exit assembly 9 1 Are there obstructions or spilled ink on the wiper blade or in the...

Page 114: ...on but the ink does not appear to be dripping 9 009 44 and 900X 6x 9 009 44 This fault code indicates a device failure attempting to access NVRAM a Reset NVRAM and retest b Ensure ground integrity for the system see Ensuring Ground Integrity on page 4 73 Troubleshooting Procedure Step Questions and Actions Yes No 1 1 Are the ink sticks all Xerox branded ink Go to Step 2 Advise customer 2 1 Manuall...

Page 115: ...smatch 11 014 42 Control Panel version mismatch 11 015 43 Printhead PLD version mismatch 11 016 44 Lower 525 sheet feeder PLD version mismatch 11 017 45 Upper 525 sheet feeder PLD version mismatch 11 018 46 Titan version mismatch Troubleshooting Procedure Step Questions and Actions Yes No 1 1 Ensure ground integrity for the system 2 Did this resolve the error Complete Go to Step 2 2 1 Inspect and ...

Page 116: ...t 13 003 42 13 007 46 11 006 43 and 11 015 43 Replace the printhead For all other 11 000 4x errors Replace the electronics module Troubleshooting Procedures Step Questions and Actions Yes No 1 1 Ensure ground integrity for the system 2 Did this correct the problem Complete Go to Step 2 2 1 Reset NVRAM and retest 2 Did this correct the problem Complete Go to Step 3 3 1 Check and reseat all data cab...

Page 117: ... system see Ensuring Ground Integrity on page 4 73 2 Are all components grounded properly Go to Step 3 Resolve ground integrity 3 1 Is the error code associated with an overheat condition Go to Step 4 Go to Step 6 4 1 Verify system clearance for adequate air flow 2 Are any of the vents blocked Advise customer of clearance specification Go to Step 5 5 1 Using service diagnostics run the Drum Fan Mo...

Page 118: ... 133 46 The preheater thermistor circuit is shorted 8 1 Using service diagnostics run the Drum Heater test 2 Did the test pass Replace the drum assembly Replace the drum temperature sensor Troubleshooting Procedure Step Questions and Actions Yes No 1 1 Using service diagnostics run the Drum Temperature Sensor test 2 Did the test pass Go to Step 2 Replace the drum temperature sensor 2 1 Inspect the...

Page 119: ... room is within the systems optimal environmental specification see System Environmental Specifications on page 1 14 2 Is the room too cold or too hot Advise customer of specification requirements Go to Step 2 2 1 Run the Preheater test 2 Did the test pass Replace the I O board Go to Step 3 3 1 Check the wiring from the preheater 2 Is the wiring connected properly and sound Replace the preheater b...

Page 120: ...ambient temperature of the room is within the systems optimal environmental specification see System Environmental Specifications on page 1 14 2 Is the room too cold or too hot Advise customer of environmental specification requirements Go to Step 2 2 1 Ensure ground integrity of the system see Ensuring Ground Integrity on page 4 73 2 Are all components grounded properly Go to Step 3 Resolve groun...

Page 121: ...Verify that the ambient temperature of the room is within the system s optimal environmental specification see System Environmental Specifications on page 1 14 2 Is the room too cold or too hot Advise customer of specification requirements Go to Step 2 2 1 Ensure the ground integrity of the system see Ensuring Ground Integrity on page 4 73 2 Are all components grounded properly Go to Step 3 Resolv...

Page 122: ...at the ambient temperature of the room is within the system s optimal environmental specification see System Environmental Specifications on page 1 14 2 Is the room too cold or too hot Advise customer of specification requirements Go to Step 2 2 1 Ensure ground integrity of the system see Ensuring Ground Integrity on page 4 73 2 Are all components grounded properly Go to Step 3 Resolve ground inte...

Page 123: ...it is shorted 13 519 45 The YELLOW thermistor returned a bad reading or ESD corruption 13 520 46 The BLACK heater got too hot 13 522 48 The BLACK heater took too long to reach its setpoint 13 579 42 The BLACK thermistor circuit is open 13 581 44 The BLACK thermistor circuit is shorted 13 583 46 The BLACK thermistor returned a bad reading or ESD corruption Troubleshooting Procedure Step Questions a...

Page 124: ...D that did not exist 13 006 67 Thermal code tried to command a segment ID that did not exist 13 007 68 Thermal power manager task was expecting initialization message but received other 13 008 60 Thermal power manager task received an unexpected message a Reset NVRAM and retest b Ensure ground integrity for the system see Ensuring Ground Integrity on page 4 73 4 1 Inspect and reseat the wiring to ...

Page 125: ...M and then retest b Replace the NVRAM chip 21 000 69 Errors Diagnostic Code Version Mismatch a The diagnostic firmware does not match the engine firmware Update the diagnostic firmware for the system If a code updated ROM daughter board is installed on the main board remove the board so the preheater boots using the main board s code and diagnostics 22 0XX 6x Errors Jam Codes a For jam codes see 3...

Page 126: ...edure Step Questions and Actions Yes No 1 1 Verify that all the main tray paper path sensor wires are clear of the takeaway rollers 2 Are any wires damaged Replace the wiring harness Go to Step 2 2 1 Are the takeaway rollers dirty contaminated or damaged Replace the take away roller Go to Step 3 3 1 Run the Paper Path Drive test 2 Did the test pass Go to Step 5 Go to Step 4 4 1 Remove the media dr...

Page 127: ... to the printhead data partition in NVRAM 34 004 46 An error occurred while accessing the printhead NVRAM hardware for the purpose of initialization The printhead cable may be unplugged Troubleshooting Procedure Step Questions and Actions Yes No 1 1 Check the wiring and connectors from the front door to the I O board 2 Are the wires connected properly Go to Step 2 Replace the wiring harness 2 1 Ru...

Page 128: ...ity on page 4 73 2 Did this correct the problem Complete Go to Step 2 2 1 Inspect pivot plate for cracks 2 Check the drum maintenance cam rollers for damage or improper movement 3 If the pivot plate or cam rollers are faulty replace 4 Did this correct the problem Complete Go to Step 3 3 1 Use service diagnostics to run the Drum Maintenance Transfix Home test 2 Use service diagnostics to run the Dr...

Page 129: ... 37 003 48 PEST Right jetstack disconnect The right jetstack is not drawing the expected power from the supply 37 004 40 PEST Reservoir 0 disconnect Reservoir 0 is not drawing the expected power from the supply 37 005 41 PEST Reservoir 1 disconnect Reservoir 1 is not drawing the expected power from the supply 37 006 42 PEST Drum disconnect The drum heater is not drawing the expected power from the...

Page 130: ... 45 Ink Melt 1 37 010 46 Ink Melt 2 37 011 47 Ink Melt 3 37 012 48 Ink Melt 4 2 Did the test pass Go to Step 3 Go to Step 2 2 1 Check the wiring running from the problem component to the printhead 2 Is the wiring damaged or not working properly Replace the problem wiring harness Replace in the following order Drum assembly Preheater Printhead Ink loader Troubleshooting Procedure Step Questions and...

Page 131: ... The test point is located on the power control board below the main board RAM DIMMs 4 Is the power supply within specification Go to Step 2 Go to Step 2 2 1 Unplug the following electronics module connectors This step disconnects all other external circuits so the electronics module can be tested alone Power Control to I O board J800 gray ribbon cable on right side Power Control right J400 16 wir...

Page 132: ...e problem to the I O board or its related cabling unplug the I O board connectors Umbilical Right J1 Waste Tray Sense J110 Stripper Solenoid J250 Paper Tray Sense J610Ink load Signal J910 DMU Sense J860 Drum Thermistor J870 Exit Module J680 Heater Relay Control J950 2 Test the resistance of the I O board 3 Is the resistance still less than 1K ohm Replace the I O board Go to Step 6 6 1 Plug in the ...

Page 133: ...wer from the supply Troubleshooting Procedure Step Questions and Actions Yes No 1 1 Run the appropriate diagnostic test 37 016 43 Head Maintenance Clutch 37 017 44 Deskew Clutch 37 018 45 Pick Clutch 37 019 46 Pick Solenoid 37 020 47 Strip Solenoid 2 Did the test pass Go to Step 3 Go to Step 2 2 1 Check the wring for the problem clutch or solenoid 2 Is the wiring damaged or not working properly Re...

Page 134: ...wing the expected power from the supply Troubleshooting Procedure Step Questions and Actions Yes No 1 1 Run the Pressure Pump Motor test 2 Did the test pass Replace the electronics module Go to Step 2 2 1 Check the purge pump assembly wiring 2 Is the wiring damaged Replace the pressure pump motor Troubleshooting Procedure Step Questions and Actions Yes No 1 1 Run the Purge Vent Solenoid test 2 Did...

Page 135: ...r from the supply 37 033 42 PEST Y axis motor short The Y axis motor is drawing too much power from the supply Troubleshooting Procedure Step Questions and Actions Yes No 1 1 Run the X axis Drive test 2 Did the test pass Replace the electronics module Go to Step 2 2 1 Check the X axis motor wiring for damage Replace the X axis motor Troubleshooting Procedure Step Questions and Actions Yes No 1 1 R...

Page 136: ...limit 37 042 42 PEST Power supply 1 8 volt under limit 37 043 43 PEST Power supply 2 5 volt over limit 37 044 44 PEST Power supply 2 5 volt under limit 37 045 45 PEST Power supply 3 3 volt over limit 37 046 46 PEST Power supply 3 3 volt under limit 37 047 47 PEST Power supply 12 volt over limit Troubleshooting Procedure Step Questions and Actions Yes No 1 1 Run the Media Path Motor test 2 Did the ...

Page 137: ...r supply 15 volt under limit 37 059 41 PEST Power supply 15 volt over limit 37 060 42 PEST Power supply 15 volt under limit 37 061 43 PEST Power supply high switch will not activate 12 15 and 50 volt missing This may be due to a short or disconnected power supply reset line 37 062 44 PEST Vss measurement too low The printhead power cable may be disconnected 37 063 45 PEST Vpp measurement too low T...

Page 138: ...orrect the problem Complete Replace the scanner assembly 39 003 41 Scanner Optical Test Failure Troubleshooting Procedures Step Questions and Actions Yes No 1 1 Cycle power to the system to clear 2 Did this correct the problem Complete Replace the scanner assembly 39 004 42 Home Position Test Error Troubleshooting Procedure Control Panel Message Release Scanner Shipping Restraint or Scanhead Locke...

Page 139: ...eplace the scanner assembly Go to Step 3 3 1 Is the red LED blinking Go to Step 4 Go to Step 6 4 1 Remove the side covers and disconnect both exit module MEP motors 2 Does the red LED come on solid Replace the exit module or defective motor Go to Step 5 5 1 Leave the exit module motors disconnected and disconnect the document feeder assembly 2 Does the red LED come on solid Replace the document fe...

Page 140: ...r 2 Did this correct the problem NOTE You can disconnect the document feeder and the system will still scan from the platen Complete Replace the document feeder assembly 39 012 41 Document Feeder Optical Test Failure Troubleshooting Procedure Step Questions and Actions Yes No 1 1 Cycle power to the system to clear 2 Did this correct the problem Complete Replace the document feeder 39 013 42 Docume...

Page 141: ...skew Flag B Preheat Flag C Strip Flag D Exit Flag E Tray 1 Width Sensor F Front Door Event G Tray 2 Media Present Sensor H Tray 3 Media Present Sensor J Tray 4 Media Present Sensor K Exit Module L IIT Cover M Paper Path Motor N Y Axis Motor P Process Motor T Exit Door Event V Tray 2 Event W Tray 3 Event X Tray 3 Pick Flag Y Tray 4 Event Z Tray 4 Pick Flag 2 Sensor Event 3 Timeout 4 Motor Stall 5 M...

Page 142: ...ler oiling A2M The deskew flag tripped unexpectedly while the system was picking paper from Tray 2 A2N The deskew flag tripped unexpectedly while the system was picking paper from Tray 3 A2P The deskew flag tripped unexpectedly while the system was picking paper from Tray 4 A2S Deskew sensor in unexpected state during media stage for transfix A2Q The deskew flag tripped unexpectedly while the syst...

Page 143: ...dition of the exit rollers and the duplex roller 3 Check the Front Door for obstructions or damage replace the Front Door if necessary 4 Test the operation of the exit roller and the duplex roller using diagnostic Duplex Paper Lead Edge Times test 5 Test the deskew sensor using the diagnostic Sensors test B2C Preheat exit sensor unexpected state during mechanical recovery 1 Clear jam and let syste...

Page 144: ...n good condition 6 Run the Deskew Clutch test 7 Run the Paper Path Drive test 8 Replace the pre heater then retest C2C Strip flag unexpected event during mechanical recovery C2D Strip flag unexpected state during warm up C2E Strip flag unexpected event during system ready C2F Strip flag unexpected event during fault C2K Strip flag unexpected event during transfix roller oiling C2M The strip flag a...

Page 145: ...rrectly homed see page 6 8 4 Ensure that the stripper carriage moves freely Run the Stripper Contact test 5 Run the Transfix Drive Slow and Transfix Drive Fast tests C3X Strip flag time out during exit 1 Open the exit cover and ensure that the springs for the idler rollers are present and installed correctly they should be the same for all 5 rollers 2 Verify that the metal bar is installed on top ...

Page 146: ...recovery D3M Exit flag timed out following Tray 2 Pick D3N Exit flag timed out following Tray 3 Pick D3P Exit flag timed out following Tray 4 Pick D3Q Exit flag timed out following Tray 1 Pick D3R Exit flag timed out during duplexing D3T Exit flag time out during transfix 1 Inspect the exit path for obstructions 2 Inspect and clean the exit roller ensure the exit roller rotates 3 Inspect and clean...

Page 147: ...ing the drum during a print job F2W The front door open flag unexpectedly tripped while the system was imaging during a print job F2X Front door sensor unexpectedly actuated during exit 1 Ensure the media is supported 2 Ensure ground integrity of the system see page 4 73 3 Run the diagnostic Sensors test to test the door sensor 4 Check that the doors and covers are properly closed and seated 5 Run...

Page 148: ...arm up L2E IIT cover open while in ready state L2F IIT cover open while in a fault state L2G IIT cover open during auto drum maintenance cycle L2H IIT cover open during printhead maintenance cycle L2J IIT cover open during printhead purge L2K IIT cover open during transfix L2L IIT cover open in standby mode L2M IIT cover open during pick from Tray 2 L2N IIT cover open during pick from Tray 3 L2P I...

Page 149: ...h motor stalled while the system performed an auto drum maintenance cycle M4H Paper path motor stalled while the system performed printhead maintenance M4J Paper path motor stalled while the system performed printhead purge M4K Paper path motor stalled while the system performed an oil transfix roller cycle M4L Paper path motor stalled while the system was in standby mode M4M Paper path motor stal...

Page 150: ...e the system performed an auto drum maintenance cycle N4H Y Axis motor stalled while the system performed printhead maintenance N4J Y Axis motor stalled while the system performed printhead purge N4K Y Axis motor stalled while the system performed an oil transfix roller cycle N4L Y Axis motor stalled while the system was in standby mode N4S Y Axis motor stalled while the system staged for transfix...

Page 151: ...unning one sheet at a time 4 Run the diagnostic Check Drum Y Axis Encoder test 5 Replace the Pick Assembly and retard roller 6 Run the clean ink smears and check the preheater exit flag for debris 7 Replace the Tray 1 Separator Pad Assembly P4A Process motor stalled on abnormal shutdown P4B Process motor stalled on power up following a normal system shutdown P4C Process motor stalled during mechan...

Page 152: ...he system was performing a mechanical recovery T2D The exit door open flag unexpectedly tripped while the system was warming up T2E The exit door open flag unexpectedly tripped while the system was ready T2x continued T2F The exit door open flag unexpectedly tripped while the system was in a fault state T2G The exit door open flag unexpectedly tripped while the system was performing an automatic d...

Page 153: ...k debris 6 Replace the drum maintenance unit 7 Replace the transfix roller V2D Tray 2 media size sensor unexpectedly activated during warm up V2E Tray 2 media size sensor unexpectedly activated during system ready V2F Tray 2 media size sensor unexpectedly activated while system was in a fault state V2K Tray 2 media size sensor unexpected event during oil transfix V2L Tray 2 media size sensor unexp...

Page 154: ...ing from Tray 2 W2N Tray 3 media size sensor unexpectedly activated while picking from Tray 3 W2P Tray 3 media size sensor unexpectedly activated while picking from Tray 4 W2Q Tray 3 media size sensor unexpectedly activated while picking from Tray 1 W2R Tray 3 media size sensor unexpectedly activated while duplexing W2V Tray 3 media size sensor unexpectedly activated while print drum maintenance c...

Page 155: ...ggered unexpectedly while picking from Tray 3 X2P Tray 3 pick flag triggered unexpectedly while picking from Tray 4 X2Q Tray 3 pick flag triggered unexpectedly while picking from Tray 1 X2R Tray 3 pick flag triggered unexpectedly while duplexing X2S Tray 3 pick flag triggered unexpectedly while transfixing X2V Tray 3 pick flag triggered unexpectedly while print drum maintenance cycle was being per...

Page 156: ... Tray 3 Pick Shaft test 5 Ensure ground integrity of the system see page 4 73 6 Push up on the nudger roller until it is captured by the actuator arm 7 Run the Pick Clutch test replace the pick clutch 8 Run the Media Path Drive test 9 Replace the pick roller assembly 10 Replace the Tray 3 525 sheet feeder Y2D Tray 4 media size sensor unexpectedly activated during warm up Y2E Tray 4 media size sens...

Page 157: ...anical recovery Z2D Tray 4 pick flag triggered unexpectedly during warm up Z2E Tray 4 pick flag triggered unexpectedly while system ready Z2F Tray 4 pick flag triggered unexpectedly while system in fault state Z2L Tray 4 pick flag triggered unexpectedly while system in standby Z2M Tray 4 pick flag triggered unexpectedly while pick from Tray 2 Z2N Tray 4 pick flag triggered unexpectedly while pick ...

Page 158: ...ay 2 Z3N Tray 4 pick flag sensor timed out while pick from Tray 4 Z3P Tray 4 pick flag sensor timed out while pick from Tray 4 Z3Q Tray 4 pick flag sensor timed out while pick from Tray 1 Z3R Tray 4 pick flag sensor timed out while duplexing Z3V Tray 4 pick flag sensor timed out while the system drum maintenance cycle was being performed Z3W Tray 4 pick flag sensor timed out while system imaging Z...

Page 159: ...roubleshooting In this chapter Service Diagnostics Check Menu Activators Definition Tables Electrical Troubleshooting Ensuring Ground Integrity Paper Path and Media Based Problems Operating System and Application Problems ...

Page 160: ...lies are supposed to function Hidden Service Menu The Hidden Service menu provides access to a large group of information pages and functions usable for diagnosing and correcting system malfunctions and accessing special features Display the Hidden Service menu as follows 1 From the System Setup menu go to Information Troubleshooting Service Tools menu 2 With the cursor at the top of the Service T...

Page 161: ...d Adjust This is for manufacturing or engineering use only Adjust X axis scale This is for manufacturing or engineering use only Drift Compensation This is for manufacturing or engineering use only Head to Drum Adjust This is for manufacturing or engineering use only Service Usage Profile Prints pages with detailed system usage information Engine Copy Count Displays engine copy count Head Serial N...

Page 162: ...e to run diagnostics under this condition Important Information While Performing Service Diagnostics Heaters and Thermals When entering diagnostics if the printhead temperature is approximately 32o Celcius the system is assumed to be warm and the heaters are turned ON to maintain the warmed up state Otherwise they will remain OFF Utilize the Exercise Heaters function if it is necessary to turn ON ...

Page 163: ...se these tests are duplicated in the hidden Service Diagnostics menu the customer diagnostics are not detailed in this manual Service Diagnostics Control Panel Button Descriptions Button Function BACK Returns to the prior higher level menu structure if available Cancels the display of test results on the control panel and allows the current test to complete If help text is displayed on the control...

Page 164: ...iagnostic firmware commands the subsystem to perform the built in test and reports the results on the display Each subsystem is tested separately with an electronic reset performed when switching the testing focus from one subsystem to another Main Menu Print Engine Menu Monitor Menu A submenu containing a set of functions for passively viewing or monitoring system mechanical parameters See the mo...

Page 165: ...over Open or Not Open Output Tray Full sensor Full or Not Full Error Exercise Elevator Home Sequence Exercises the exit path elevator home position and reports final status Ready Error Exercise Elevator Lift Sequence Moves the pinch roller over its range of travel then reports final status Ready Error Exercise Roller Drive Rotates the exit path transport rollers clockwise then counter clockwise pe...

Page 166: ...e several minutes to complete Test DRAM Tests the scanner subsystem DRAM OK or Fail This operation may take several minutes to complete Test Homing Runs the scanner axis seek home procedure The axis moves a short distance to the left then moves right to the home sensor OK or Fail Test Axis Unlock The axis attempts to move a short distance to the right The test will make strange noises if the scan ...

Page 167: ... Reports the current firmware version Report Status Checks then reports the current status as reported by the DADF unit firmware Ready or Not Ready Lamp ON OFF Warming Up Warmup test not done Test fail Error OK Paper Jam Cover Open Internal failure Test fail Data Capture test fail Cal Device test fail Report Paper Status Reports the presence of paper in the DADF unit Paper or no paper Perform Self...

Page 168: ...s OK or Fail There should not be media present to perform this test Exercise Lamp Cycles the DADF lamp on then off The lamp is then left ON OK or Fail The lamp state must be manually observed Reset Doc Handler This test power cycles the IIT unit MEP Scanner DADF Ready or Not Ready Main Menu Control Panel Menu Test Name Description Results Report FW Version Reports the current firmware version Moni...

Page 169: ...lows H Open or de actuated L Closed Present Actuated Encoders Monitors each of the non temperature analog sensors Tray 1 Media Width Y Axis Position Media Path Motor Position Process Motor Position Temps Monitors each of the thermal sensors Shows the current thermal control setpoint first value and the current sensor temperature second value LJ Left Jetstack RJ Right Jetstack RE Reservoir DR Drum ...

Page 170: ...Solenoid Tray 2 Pick Clutch Tray 3 Pick Clutch Tray 4 Pick Clutch Deskew Clutch Strip Solenoid Head Maintenance Clutch Purge Vent Solenoid 110 V and 220 V Drum Heater Relays All test results toggle ON and then OFF on the display Motors Shafts Menu The motor and shaft functions drive the specified motor or shaft enough to generate enough motion to be easily observed usually 1 revolution without mak...

Page 171: ...lues may then be compared with range limits documented in the service manual or using service bulletins on the service website if the values were unavailable at the time of printing Main Menu Print Engine Menu Check Menu Test Name Description Results Check Menu See the individual table descriptions starting on page 4 15 for all Check Activator menu items Check All Activators Menu Shafts Menu Fans ...

Page 172: ...quence The result is an oil print of the contact of the DM unit with the drum about 2 3 of the way down the page Display Fault History A function that displays the current contents of the Fault History NVRAM store Access PE NVRAM Parameters A restricted function that provides read write access to selected PE NVRAM parameters Clear Fault History A restricted function that clears the Fault History N...

Page 173: ...nce kit life The diagnostics routines are not designed to address all of these conditions consistently If a test result differs significantly from the typical values defined in the following tables check the entire system containing the problem component to ensure a problem within the system is not influencing the test results The Check All selection will run all check tests taking 1 5 hours to co...

Page 174: ...erage Power watts 15 to 25 Reports the average power following power on Tray 2 Tray 3 Tray 4 Pick Clutch Gathers data on the performance of the pick clutch coil for Trays 2 through 4 The same type of clutch is used for each tray R Definition Typical Value Actions 0 Peak Power watts 45 to 0 95 Reports the profile max power value 1 Average Power watts 2 5 to 5 5 Reports the average power during the ...

Page 175: ...s MFG Only Reports the average power during the constant portion of the profile 2 220 V Coil Min Power watts MFG Only Reports the min power following power off 3 220 V Coil Peak Power Time sec MFG Only Reports time after solenoid power on that the peak power occurred 4 220 V Coil Initial Average Power watts MFG Only Reports the average power following power on 5 110 V Coil Peak Power watts MFG Onl...

Page 176: ... or a slipping clutch 3 CCW On average fe 250 to 600 Reports the average effort required to rotate the deskew shaft in the CCW direction at a constant velocity An unusual value could indicate a difference in the composition and or number of the rollers the nip pressure or out of range mechanical dimensions due to wear or contamination such as paper dust increasing the effective diameter of a rolle...

Page 177: ...tant velocity A larger value could indicate particles in the gears or non uniform contamination of a roller causing a lump 11 CW Off fe settling time sec 0 01 to 0 20 Reports the time it takes the MP motor servo system to settle down after the sudden release of the deskew shaft load A larger value could indicate a dragging or slow to release clutch Wiper Shaft Runs the media path drive train and e...

Page 178: ...in the gears or non uniform contamination of a roller causing a lump 5 CCW Off fe setting time sec 0 01to 0 20 Reports the time it takes the MP motor servo system to settle down after the sudden release of the wiper shaft load A larger value may show a dragging or slow to release clutch 6 Time to CW On peak fe sec 0 005 to 0 20 Reports how long it takes the MP motor servo system to react to the su...

Page 179: ...uns the media path drive train and engages the Tray 1 pick solenoid on the fly The pick shaft goes through 2 full revolutions while drive requirements are determined R Definition Typical Value Actions 0 Off average MP fe mpts MFG Only Reports the average MP fe during the run in interval before the pick shaft is engaged 1 On response time sec MFG Only Reports the time between pick solenoid activati...

Page 180: ...friction and or lift plate spring strength 4 Contact average fe MFG Only Reports the average MP fe while the pick roller is contacting the separator pad This value should reflect the coefficient of friction between the separator pad and the pick roller This value may be effected by contamination or glazing 5 Pushdown MP fe max MFG Only Reports the peak MP fe during the interval when the pick cams ...

Page 181: ...me could indicate looseness in the Tray 2 pick shaft assembly or a slipping clutch 3 On average fe MFG Only Reports the average effort needed to rotate the Tray 2 pick shaft in the pick direction at a constant velocity An unusual value could indicate a binding shaft missing pressure springs hard dirty rollers or extra friction in the pick truck assembly 4 On fe ripple MFG Only Reports the variatio...

Page 182: ...elocity Power watts 0 to 8 25 0 to 10 Reports the power drawn by the fan while running a constant velocity Should be proportional to the final fan RPM due to the back EMF 2 Constant Velocity Power Ripple watts 0 to 5 0 to 5 Reports the power ripple while the fan is running at constant velocity Could indicate a bad winding commutator segment 3 Constant Velocity Time sec 0 to 7 0 to 5 Reports the ti...

Page 183: ...urrent during the specified heating interval For heaters with multiple elements in parallel a significantly different value can indicate a partial failure The nominal values could change with operating hours 2 Average Voltage Change volts MFG Only Reports the difference from baseline AC volts during the specified heating period Normally the changes should be small Negative changes for high current...

Page 184: ...t time from heater power application This value could be more effected than others by cross talk from other heaters and the chassis generally warming Shows the heat dissipation at the thermistor during cooling Might indicate problems with airflow Reservoir Heater Jetstack Left Heater Jetstack Right Heater Paper Preheater Drum Heater Ink Melt 1 yellow Heater Ink Melt 2 cyan Heater Ink Melt 3 magent...

Page 185: ... simplex or duplex paper path to determine leading edge arrival time at each paper path sensor R values have alternate definitions or are unused depending on the pick tray and if simplex or duplex path was selected R Definition Typical Value Actions Common 0 Tray MFG Only Reports the tray from which the test paper was picked 1 Paper Size MFG Only Reports the size of the picked paper Tray 4 Pick 2 ...

Page 186: ...ly Reports the interval from the time the engine software is commanded to start the Tray 1 pick process until the Deskew sensor activates Common 5 Stage Interval us MFG Only Reports the interval from the time the engine software is commanded to start the stage process until the Preheat sensor activates part way through the stage paper motion 6 Transfix Interval us MFG Only Reports the interval fro...

Page 187: ...ical Value Actions Common 0 Tray MFG Only Reports the tray from which the test paper was picked 1 Paper Size MFG Only Reports the size of the picked paper Tray 4 Pick 2 Tray 4 Pick Trailing Edge Interval us MFG Only Reports the interval from the time the engine software is commanded to start the tray 4 pick process until the Tray 4 Pick sensor deactivates Tray 3 Pick 3 Tray 3 Pick Trailing Edge In...

Page 188: ...the paper exit motion Simplex Path 7 Exit Trailing Edge Interval us MFG Only Reports the interval from the time the engine software is commanded to start the duplex pick process until the Exit sensor deactivates Paper Sensor Bounce Times Paper is picked and moved through either the simplex paper path to determine the paper trailing edge bounce interval at each paper path sensor R values have alter...

Page 189: ...es following the passage of the paper trailing edge 5 Preheat Bounce Interval us MFG Only Reports the interval during which the Preheat sensor bounces following the passage of the paper trailing edge 6 Strip Bounce Interval us MFG Only Reports the interval during which the Strip sensor bounces following the passage of the paper trailing edge 7 Exit Bounce Interval us MFG Only Reports the interval ...

Page 190: ...h sensor R values have alternate definitions or are unused depending on the pick tray and if simplex or duplex path was selected R Definition Typical Value Actions 8 Duplex Turnaround Interval us MFG Only Reports the interval from the time the engine software is commanded to start the duplex exit process until the strip sensor deactivates 9 Duplex Pick Interval us MFG Only Reports the interval fro...

Page 191: ...l us MFG Only Reports the interval from the time the engine software is commanded to start the transfix process until the deskew sensor deactivates part way through the paper transfix motion 9 Duplex Preheat Trailing Edge Interval us MFG Only Reports the interval from the time the engine software is commanded to start the transfix process until the preheat sensor deactivates part way through the p...

Page 192: ...g the passage of the paper trailing edge during duplex turnaround 8 Duplex Deskew Bounce Interval us MFG Only Reports the interval during which the deskew sensor bounces following the passage of the paper trailing edge 9 Duplex Preheat Bounce Interval us MFG Only Reports the interval during which the preheat sensor bounces following the passage of the paper trailing edge 10 Duplex Strip Bounce Int...

Page 193: ... head lock latch engages 5 Lock Engage Peak uin 1570 to 2083 Reports the peak following error at the point the latch engages 6 Down Motion Drive Error uin MFG Only Reports the average following error while move the wiper up from the low limit to the lock encounter point 7 Down Motion Drive Error Ripple uin MFG Only Reports the difference between the max and min following error over the same interv...

Page 194: ...irm operational goals R Definition Typical Value Actions 0 Right Stall Power Level watts 4 3 to 10 85 Reports the motor drive electronics stall power An abnormal level may indicate a motor motor drive problem 1 Left Right Distance in 0 to 0 5 Reports the distance between the left and right stall points An abnormal value may indicate an problem that restricts the range of motion pinched cable etc 2...

Page 195: ... 29 MFG Only Reports the time from the load command to the engine until the drum indicates contact with the pressure roller 1 Loaded average Y axis following error mpts 2600 to 3800 MFG Only Reports the average Y axis following error during the Roll With Transfix Roller Down interval 2 Loaded Y axis following error ripple mpts 150 to 1100 MFG Only Reports the difference between the max and min Y a...

Page 196: ...uring the Roll With Both Loaded interval 4 Roller Average Period sec 50 to 1600 Reports the average period of the Y axis following error ripple during the Roll With Both Loaded interval This variation would be due to the dmu roller rolling along the drum surface 5 Roller Revs 0 to 55 Reports the number of Y axis following error ripple peaks during the Roll With Both Loaded interval 6 Roller Diseng...

Page 197: ...d be in degrees but currently units scaling are unverified 4 Post Wipe peak Magnitude pm ticks MFG Only Reports the pm motor following error at the post wipe peak location Tray 2 Tray 3 Tray 4 Lift Plate Drive This test raises the lift plate to verify motion and sensor operation If the test is requested for a 525 sheet feeder that is not installed an Option Not Detected message is generated R Defi...

Page 198: ...tween the max and min Cosine Sum average amplitude values 2 Sin Sum Data Offset sin sum units MFG Only Reports average of the max and min Sin Sum average amplitude values 3 Cosine Sum Data Offset cosine sum units MFG Only Reports average of the max and min Cosine Sum average amplitude values 4 Home Notch Depth Ratio none MFG Only Reports the ratio between the notch bottom amplitude and the max amp...

Page 199: ...1 Drum Frequency hz MFG Only Reports the current drum frequency 2 Motor FFT Power Ratio none MFG Only Reports the ration of the FFT power amplitude of the motor frequency to the FFT power amplitude of the drum frequency 3 Motor Frequency hz MFG Only Reports the current motor frequency 4 FFT Power Ratio 1 none MFG Only Reports the ratio of the FFT power amplitude of the most powerful FFT frequency ...

Page 200: ...80 to 380 Reports following error ripple during the last half of the second period 4 HAHVN Start Fe Settle time sec 0 08 to 1 0 Reports the time following the start of motion that it takes the following error value to enter the CCW ripple band 5 HAHVN Reverse Fe Settle time sec 0 17 to 1 1 Reports the time following the start of motion reversing that it takes the following error value to enter the...

Page 201: ... Y axis Belt Tension This test modifies the y Axis servo loop so that it is unstable and oscillates The oscillation frequency is recorded while the drum is advanced for two revolutions Checks for correct belt tension and for variations in tension during operation R Definition Typical Value Actions 0 Min Resonant Frequency hz MFG Only Reports the min resonant frequency over the data set 1 Max Reson...

Page 202: ...rts out of tolerance mis assembled bent etc causing an incorrect blade to drum gap 2 Engaging Period sec 0 to 0 11 Reports time between stripper solenoid engagement and the point when the reaction of the drum to the contact of the blade fades back into the ripple noise Another indication of blade to drum interaction The profile shape R2 R2 could be a dynamic indication of the blade drum interactio...

Page 203: ...t of variation of the motor following error over the recording interval 1 Motor fe average ticks 0 3 to 0 8 Reports the motor following error average value of the recording interval 2 Motor drive voltage ripple volts 0 34 to 1 3 Reports amount of variation of the motor drive voltage over the recording interval 3 Motor drive voltage volts 75 to 1 5 Reports average value of motor drive voltage over ...

Page 204: ...er over the recording interval 5 Motor Drive Power Average watts 9 to 13 Reports the motor drive power average value of the recording interval Process Motor This test turns on the process motor and runs it very slowly for one revolution R Definition Typical Value Actions 0 Motor fe ripple ticks 2 8 to 6 0 Reports amount of variation of the motor following error over the recording interval 1 Motor ...

Page 205: ... 0 8 to 6 Reports amount of variation of the motor drive power over the recording interval 5 Motor drive power average watts 1 9 to 7 Reports the motor drive power average value of the recording interval Tray 2 Tray 3 Tray 4 Lift Motor This test turns on the specified motor and runs it at constant velocity for approximately 20 revolutions while recording drive data The test is the same for each mo...

Page 206: ...erval 3 Motor drive voltage volts MFG Only Reports the motor drive voltage average value of the recording interval 4 Motor drive power ripple watts MFG Only Reports amount of variation of the motor drive power over the recording interval 5 Motor drive power average watts MFG Only Reports motor drive power average value over the recording interval Paper Path Status This test enters the paper path s...

Page 207: ...Paper at tray pick sensor 2 3 4 MFG Only 4 media length top 2 3 4 MFG Only 3 media length bottom 2 3 4 MFG Only 2 Media width top Paper Path Status Continued This test enters the paper path sensors to identify if anything would prevent a page from printing The control panel will display messages indicating if anything unexpected is found for R0 upper paper path R1 tray 1 R2 tray 2 R3 tray 3 and R4...

Page 208: ...o Reports the current temperature 4 Drum Temp 60o Reports the current temperature 5 Ink Melt 1 Temp 50o Yellow usually off 6 Ink Melt 2 Temp 50o Cyan usually off 7 Ink Melt 3 Temp 50o Magenta usually off 8 Ink Melt 4 Temp 50o Black usually off Paper Path Status Continued This test enters the paper path sensors to identify if anything would prevent a page from printing The control panel will displa...

Page 209: ... printhead then the drop is large and the pressure rises slowly If the volume is small hose pinched plugged near the pump then the drop is minimal and the pressure rises quickly 3 Max Pressure Pumping Power MFG Only Reports average pumping power just before maximum pressure is reached May indicate the efficiency of the pump leaks and or the setting of the pressure relief valve 4 Pumping Time To Ma...

Page 210: ...o 2 47 6 unregulated Negative 12 Volts volts 13 1 to 12 26 Control Board Voltages 7 DC Power watts 20 to 27 4 8 50 Volts 47 to 52 9 Negative 50 Volts 47 to 52 10 Unregulated Negative 15 Volts 16 5 to 13 5 11 Unregulated 15 Volts MFG Only 12 AC Volts 120V 90 to 140 AC Volts 240V 180 to 275 Wiper Alignment R Definition Typical Value Actions 0 The engage wiper position min MFG Only Reports the distan...

Page 211: ...ounts MFG Only Reports the height of the initial peak when starting rotation of the dm drive gear 1 DM Initial FE Peak Time sec MFG Only Reports the time since the start of CCW motion until the peak was detected 2 TF Initial FE Peak pm motor counts MFG Only Reports the height of the initial peak when starting rotation of the tf drive gear 3 TF Initial FE Peak Time sec MFG Only Reports the time sin...

Page 212: ...03 4 Scrolling Xerox logo 5 Control panel displays WorkCentre C2424 Power on Self Test 00 04 6 Control panel displays Test Complete Initializing 00 11 7 Power supply fan starts turning 00 20 8 Control panel displays Initializing Complete 00 23 9 Control panel displays XEROX logo LED turns green 00 24 10 Print Engine Self Tests PEST begin with solenoids and clutches 00 26 11 Print Engine Self Test ...

Page 213: ...d Tilt Cam 8005 8007 8008 8009 YES NO If the NVRAM valve cap HT Spring On is set the wiper will move up 100 milli inches to determine if it is in the spring if it is it will use a special algorthm to get out of the restraint spring if not it just homes the wiper normally Valves in the NVRAM are used to determine if the printhead and wiper have contact or if the head was parked on last power down I...

Page 214: ...ove Head to the Home Print position 7010 Start YA Slew 5003 Rehome XA 6000 RECOVERY ROUTINE Try to recover from Process Motor Stall Home XA 6000 Move XA to Left Side Hard Stop 6000 Move XA to Tilt Position 6000 home Dmfix again 4025 Warmup is responsible for moving the head to the print position after the wipe and purge are performed NO YES YES YES NO NO Device Fault Codes 80xx Wiper 7002 PM stall...

Page 215: ...cates the system is performing the cleaning process 7 The printhead is moved left to the tilt zone where the printhead can tilt back without interference and the media path motor moves the wiper to the bottom of its travel to engage the printhead tilt cam The process motor rotates the printhead tilt gears which tilt in order to move the printhead to the forward print position 8 After the print eng...

Page 216: ...ain fault conditions the system may reboot up to three times before displaying an error code This is an attempt to correct the problem and reduce the number of unnecessary service calls Following the suggested troubleshooting procedures in the specified sequence generally provides better test coverage than performing tests in a different order If either the scanner turns on or the exit module init...

Page 217: ...dia 1 Is there power at the document feeder Lift the document feeder and verify the document feeder lamp is on and the calibration strip moves into position If so the scanner power supply is operating correctly 2 If there is not power at the document feeder perform Steps 2 through 4 from Document Feeder Lamp Does Not Turn ON on page 4 59 3 Using service diagnostics run the Paper Present and Feed M...

Page 218: ... is no scanhead motion replace the scanner assembly Scanner Lamp Does Not Turn On 1 Is there power to the scanner assembly Lift the document feeder and verify the scanhead moves If so the scanner power supply is operating correctly 2 Is there power being to the scanner power supply See Verifying Scanner Power Supply Operation on page 4 70 3 Replace the scanner assembly Control Panel is Malfunction...

Page 219: ...i Attach system covers j Perform full test of system System Continuously Resets or Resets Unexpectedly a Check the main AC voltage For troubleshooting AC voltages see page 4 72 b Disconnect the network cable if this corrects the problem go to Network Problems on page 4 81 c Try entering Service Diagnostics see page 4 4 d If you are able to enter service diagnostics view the fault history for any e...

Page 220: ...ed through the vent holes close to the AC power switch see the illustration on page 4 71 a Inspect the power cord b Verify AC outlet voltage and current capacities are within specifications c If necessary move the system to a different outlet and retest 2 Disconnect the scanner assembly 3 Transient on AC line tripped protective circuitry in system power supply a Cycle power to system to reset prot...

Page 221: ... steps The I O board needs to be isolated from other systems in the system to be effectively tested b Turn off system and wait 30 seconds for power supply capacitors to discharge Damage to circuits within the electronics module may occur if the power supply capacitors are not allowed to fully discharge c Plug in the Power Control to I O board connector J800 This step adds the I O board back to the...

Page 222: ...capacitors to discharge Damage to circuits within the electronics module may occur if the power supply capacitors are not allowed to fully discharge d Plug in the printhead interface connector J130 to the electronics module e Power on the system f If the PE and PS indicators do not flash the short is on the printhead Replace the printhead and retest the system Skip the rest of Step 8 if the PE and...

Page 223: ...Reports Missing Waste Tray 1 Waste tray missing or not fully seated a Fully install waste tray 2 Connector not fully seated a Check I O board connector J110 for proper mating see Plug Jack Locator Table on page 10 2 b Verify the waste tray sensor is operating correctly System Features Not Available Note Before performing the following steps check and reinstall scanner cables if necessary Make a co...

Page 224: ...o test operation d The configuration card enables miscellaneous features in the system 525 Sheet Feeder Does Not Function 1 Thermal safety fuse blown a Power cycle system b The safety fuse is a self resetting device power cycling ensures the fuse cools enough to reset itself 2 525 Sheet Feeder is faulty a Turn off system and wait 30 seconds for power supply capacitors to discharge b Replace the 52...

Page 225: ... g Unplug the following electronics module connectors see Plug Jack Locator Table on page 10 2 Power Control to I O board J800 Power Control right J400 Printhead data J130 Waveamp signal J790 Power Control left J390 Y Axis motor J280 h This step removes all other circuits so the electronics module can be tested alone i Plug in power cord and turn on power to the system j The PE and PS indicators s...

Page 226: ... steps C and D for each connector c Turn on system and wait for the error code 34 001 43 Check that the three voltage indication LEDs INSIDE the electronics module visible through the vent holes of the electronics module near the AC power switch are lit d If the proper error code and LED doesn t appear after each I O connector is reconnected repair or replace the faulty circuit e If the proper cod...

Page 227: ...uring this step plug in all connectors to system and retest If system is fixed reattach covers to system and perform a full test If no defects are found in this step replace electronics module test system reattach covers to system and perform a full test ...

Page 228: ... feeder b Disconnect the scanner assembly Turn the system back on if the LED is still blinking the problem is not with the scanner assembly c Check the exit module MEP board LEDs see Scanner Exit Module Power Supply and MEP Exit Module Board on page 10 8 If the 24 V and 5 V LEDs are on the exit module MEP board is operating correctly d If the 24 VDC LED is still blinking replace the scanner power ...

Page 229: ...ivers and motors Verifying thepower supply involves three steps 1 Checking for proper AC voltage 2 Inspecting the power supply fuses 3 Testing for a shorted motor or solenoid driver which shuts down the power supply Required tools TORX T 20 screwdriver Digital Multi Meter DMM s2424 068 50 V Supply Active LED take 20 seconds to drain off 3 3 V Supply Active LED 15 High side 12 Power 5 Supply Active...

Page 230: ...e is displayed on the control panel Detecting condition of Fuse F2 and F3 1 The drum and preheater connect to F2 2 The printhead and ink loader connect to F3 3 Turn the power switch off and wait for the system to shut down 4 Unplug the power cord 5 Remove the Ink loader Assembly and Door as specified on page 8 13 6 From the back of the system you will see one heater cable connector on the left nea...

Page 231: ...operational use the diagnostic test Monitor Voltages Ensuring Ground Integrity Intermittent or missing ground connections can result in minor interferences in the system As examples control panel display can be affected blank I O board errors False jam reporting Erroneous thermistor readings Major interruptions Damage to the electrical boards ...

Page 232: ...ion shows the grounding points in the IOT that need to be checked There is also one grounding point in the backframe s2424 069 Transfix Roller Ground Springs I O Board Ground DM Ground Clip X Axis Return Spring Ground Y Axis Motor Ground Exit Module Ground Media Exit Path Motor Ground ...

Page 233: ...ing the measurement Motor and Solenoid Resistances Motor or Solenoid Resistance Approximate Process motor 4 3 ohms 15 Difficult to measure due to variability at the brush commutator interface Y axis motor 1 4 ohms 15 Difficult to measure due to variability at the brush commutator interface X axis motor 12 5 ohms phase red to yellow and blue to orange Media path motor 1 5 20 ohms phase Wiper drive ...

Page 234: ...the system the size of media being used Ensure that the media guides in the tray are set correctly 6 Inspect the paper for bent torn or folded corners 7 Check to ensure no small pieces of paper are in the paper path 8 Run the paper path status test in service diagnostics to ensure all sensors are operating correctly 9 Try printing from a fresh unopened ream of paper Paper Pick Errors Trays 2 3 and...

Page 235: ...Specifications on page 1 14 4 Remove all media open and close the document feeder jam access cover then try copying again Preheater and Transfix Jams 1 Remove the preheater and check for and remove any small paper scraps that may be present 2 Check for excessive media skews 3 Check for ink shards on top of the preheater next to the flag see page 8 27 4 Using diagnostics run the media drive path te...

Page 236: ...nce drive test 7 Run the transfix fast and transfix slow 8 Run the process motor and media drive motor tests 9 Inspect the gears and mating cam gears for stripped or damaged gear teeth 10 Replace the Process Drive Gearbox 11 Replace the media path drive gearbox Media Skews Passing Through the Paper Path 1 Ensure the media is supported 2 Ensure that the side guides are properly adjusted 3 Do not ov...

Page 237: ...ommunication ports can isolate communication problems to the computer network or software Test the communications ports after the system is installed or when the electronics module has been replaced Test the communications ports as follows Ethernet Port Verification Note The Ethernet port can be tested without connecting to the network by using a crossover cable and the PING command 1 Connect a cr...

Page 238: ... been configured for a specific network default to a LOCAL LINK value within the 169 254 xxx xxx range Note To comply with industry standards WorkCentre C2424 systems cannot be manually configured for IP addresses within the LOCAL LINK range Note Always print the Configuration Page to obtain a record of the system settings before changing the IP address After testing the system be sure to restore ...

Page 239: ...8 From the General tab click the Print Test Page button to generate the test print If the test page prints the USB port is functioning normally Network Problems The WorkCentre C2424 system maintains 6 logs in memory detailing network functions The logs contain TCP IP NetWare and AppleTalk initialization events The logs can also be accessed remotely via CentreWare The logs list events chronological...

Page 240: ...dapter part number 174 3493 00 Same adapter used to run PC based diagnostic on Phaser 340 360 and Phaser 840 systems To obtain a trace 1 Connect the serial cable to your PC Serial port settings are 19 2 kbaud 8 bits no parity 1 stop bit and hardware control 2 Turn off the system 3 Remove the rear panel to access the main board 4 Connect the serial cable with adapter to the 5 pin connector labeled ...

Page 241: ...Image Quality Troubleshooting In this chapter Image Quality Problems Overview Isolating a Copy Scan Malfunction to the Scanner DADF Diagnosing IOT Print Engine Print Quality Problems Analyzing Service Test Prints ...

Page 242: ...hat has been tested and approved for use in this system The paper should be from an unopened ream that has been acclimated to room temperature If the print quality defect is still present when printing on approved media from an unopened ream of paper other conditions need to be researched The following steps should be performed for diagnosing print quality problems 1 Verify the media being used an...

Page 243: ...w with the customer all work performed Also discuss the need for 90 IPA a cleaning kit and how to properly care for their system Isolating a Copy Scan Malfunction to the Scanner DADF Scanner software computer applications hardware malfunctions or communication between the IIT and IOT can cause scan copy print quality issues that reside within the document feeder or scanner unit and not from the pr...

Page 244: ...ibration on page 6 9 2 Did this correct the problem Complete Go to Step 5 5 1 Replace the document feeder 2 Did this correct the problem Complete Replace the scanner assembly Step Questions and Actions Yes No 1 1 Does the void run along the entire length of one side of the image Go to Step 2 Go to Step 3 2 1 Open the document feeder and ensure the automatic calibration strip fully extends the lamp...

Page 245: ...0 2 Is the skew within specification Complete Go to Step 4 4 1 Perform the Manual DADF to Scanner Calibration on page 6 9 2 Did this correct the problem Complete Replace the document feeder Step Questions and Actions Yes No 1 1 Ensure supported media is being used 2 Check and or adjust the control panel copy settings Print the Troubleshooting Print Quality information page from the control panel a...

Page 246: ...age printed in Step 2 using the document feeder 2 Does the text or image still appear fuzzy Go to Step 4 Go to Step 5 4 1 Perform the Manual DADF to Scanner Calibration on page 6 9 2 Does the text or image still appear fuzzy Go to Step 5 Complete 5 1 Check and or adjust the control panel copy settings Print the Troubleshooting Print Quality information page from the control panel and review Output...

Page 247: ...djust the control panel copy settings NOTE Print the Troubleshooting Print Quality information page from the control panel and review Output Quality and Color Settings section to aid in adjusting copy settings 1 Does adjusting the copy settings correct the problem Complete Go to Step 3 3 1 Perform the Manual DADF to Scanner Calibration on page 6 9 2 Did this correct the problem Complete Go to Step...

Page 248: ...1 1 See the Media System Skew Specification IIT IOT on page 1 20 2 Is the skew within specification Complete Go to Step 2 2 1 Perform the Manual DADF to Scanner Calibration on page 6 9 2 Did this correct the problem Complete Replace the scanner assembly Step Questions and Actions Yes No 1 1 Ensure supported media is being used 2 Check and or adjust the control panel copy settings NOTE Print the Tr...

Page 249: ...just the control panel copy settings NOTE Print the Troubleshooting Print Quality information page from the control panel and review Output Quality and Color Settings section to aid in adjusting copy settings 1 Does adjusting the copy settings correct the problem Complete Go to Step 3 3 1 Perform the Manual DADF to Scanner Calibration on page 6 9 2 Did this correct the problem Complete Go to Step ...

Page 250: ...g the DADF of the embedded page printed in Step 2 2 Does the text or image still appear fuzzy Go to Step 4 Go to Step 5 4 1 Perform the Manual DADF to Scanner Calibration on page 6 9 2 Did this correct the problem Complete Go to Step 5 5 1 Check and or adjust the control panel copy settings Print the Troubleshooting Print Quality information page from the control panel and review Output Quality an...

Page 251: ...s Enter 4 Scroll to Troubleshooting Print Quality Page and then press Enter Note The Troubleshooting Print Quality Page includes instructions for printing the Eliminate Light Stripes test print These instructions are also provided on the next page of this manual The Eliminate Light Stripes test print indicates individual weak or missing jets or an obstruction in the imaging path that affects a ver...

Page 252: ...low stripe has discolored jets therefore you would print the yellow solid fill For instructions on printing solid fill test prints see 13 19 Black Red Green Blue Cyan Magenta and Yellow Solid Fills on page 5 42 Discolored jets usually clear after two or three prints using the problem jets 3 1 Clean the print engine exit path and wipe the paper release blade with a lint free cloth 2 Did this correc...

Page 253: ...Turn on the system and if necessary repeat Step 1 3 Did this correct the problem Complete Follow the instructions on the Printhead Troubleshooting Checklist Step Questions and Actions Yes No 1 1 Clean the system s exit path including wiping the paper release blade with a lint free cloth 2 Did this correct the problem Complete Go to Step 2 2 1 Remove the drum maintenance kit and wipe the clear plas...

Page 254: ...eheater and exit rollers 3 Reprint test pages Do you still see smudges Go to Step 3 Complete 3 1 Repeat Step 2 up to 3 times if the smears still appear 2 Verify supported media is being used 3 Open a fresh ream of supported paper and reprint the test page 4 Did this correct the problem Complete Go to Step 4 4 1 Remove the drum maintenance kit and wipe the clear plastic wiper blade with a lint free...

Page 255: ...over an extended period of time 2 Insert new ink and print a solid fill test print Run the test print until the affected color returns to normal 3 Did this correct the problem Complete Go to Step 4 4 1 If the problem is occuring for only one color purge the ink up to 10 times to clear the ink or until discoloration is cleared 2 Did this correct the problem Complete Replace the printhead Step Quest...

Page 256: ...en the ink could be discolored due to a long period of time without use 2 Did this correct the problem Complete Go to Step 2 2 1 Clean the maintenance kit wiper blade or replace the maintenance kit 2 Did this correct the problem Complete Go to Step 3 3 1 Check the thermal regulation of the drum 2 Run the service diagnostics drum thermal check test see Check Heaters Menu on page 4 25 3 Are the drum...

Page 257: ...ding the paper release blade to see if there is anything touching the drum assembly 2 Reseat any system component interfering or touching the drum assembly 3 Clean the paper release blade 4 Did this correct the problem Complete Go to Step 4 4 1 If there are streaks on the front side only of a 2 sided print the preheater may be scraping ink off the print 2 Look for ink shavings along the streaks on...

Page 258: ...lines appear on the print For information about X Axis Drive problems see White Stripes Pinstripes on page 5 32 2 Did this correct the problem Complete Go to Step 8 8 1 Smears on a duplex print can be caused by the paper preheater operating at a temperature that is too high or debris is in the duplex roller or duplex paper path guides 2 Run the service diagnostics Duplex Path test to check the pap...

Page 259: ...ade 4 Did this correct the problem Complete Go to Step 2 2 1 Inspect the drum maintenance kit If the defect is a thin line that is glossier than the surrounding area it may be due to a defect on the maintenance kit wiper blade 2 Clean the wiper blade or replace the maintenance kit 3 Did this correct the problem Complete Go to Step 3 3 1 Using transparency media print from Tray 1 to see if the scra...

Page 260: ...from the system s control panel 2 Did this correct the problem Complete Go to Step 6 6 1 Force a sheet of thick 65 to 80 lb paper through the paper preheater to buff the paper preheater heating surfaces 2 With the leading and trailing ends of the sheet of paper extending from the entry and exit of the paper preheater gently pull the sheet of paper back and forth several times and then remove the p...

Page 261: ...Step 2 2 1 Inspect and clean the maintenance kit wiper blade 2 If necessary replace the maintenance kit 3 Did this correct the problem Complete Go to Step 3 3 1 Clean the paper release blade it may be contaminated with ink 2 Run the Remove Print Smears from the system s control panel 3 Did this correct the problem Complete Go to Step 4 4 1 Run service diagnostics to verify the system termperatures...

Page 262: ... print mode 2 Did this correct the problem Complete Go to Step 3 3 1 This problem can occur after a printhead has been replaced Verify the dot on the printhead roll block is positioned to match the label on the left frame Adjust if necessary 2 Did this correct the problem Complete Go to Step 4 4 1 Run service diagnostics to check the temperature of the drum 2 Verify the drum termperature sensor is...

Page 263: ...rify the printhead is tilted forward against the drum in the proper print position 2 Did this correct the problem Complete Follow the instructions on the On Site Printhead Troubleshooting Checklist on page A 7 Step Questions and Actions Yes No ...

Page 264: ...he Y axis encoder is operating normally 2 Is the Y axis encoder working properly Go to Step 3 Replace the drum assembly 3 1 If the bands are uniform or in a corduroy pattern use diagnostics to check the X axis motion 2 Ensure the x axis movement is not impeded 3 See White Stripes Pinstripes on page 5 32 for troubleshooting this problem 4 Did this correct the problem Go to Step 4 Replace the X axis...

Page 265: ... roller ghosting is inherent to the system but will improve with multiple prints 2 Does this correct the problem Complete Go to Step 3 3 1 Inspect and clean the maintenance kit wiper blade 2 If necessary replace the maintenance kit 3 Did this correct the problem Complete Go to Step 4 4 1 Run service diagnostics to verify the drum maintenance system is operating correctly 2 Inspect or replace the f...

Page 266: ...ete Go to Step 2 2 1 Run service diagnostics to check the temperature of the drum 2 Verify the drum termperature sensor is clean and properly positioned 3 Did this correct the problem Complete Go to Step 3 3 1 Verify the X axis drive system is correctly assembled and lubricated see X Axis Motor Assembly on page 8 57 for more information 2 Did this correct the problem Complete Replace the x axis mo...

Page 267: ...he motion of the X axis and verify there is nothing interfering such as a poorly dressed cable or screw 2 Replace any defective parts 3 Did this correct the problem Complete Go to Step 3 3 1 Use service diagnostics to run the Y axis encoder test 2 Is the Y axis encoder functioning properly Go to Step 4 Replace the drum assembly 4 1 Use service diagnostics to verify the drum maintenance cam roller ...

Page 268: ...nce unit to drum maintenance shaft to drum fan ground clip 3 Did this correct the problem Complete Go to Step 3 3 1 Run pages through the printer to clean the drum by using the Remove Print Smears routine from the system s control panel 2 Did this correct the problem Complete Go to Step 4 4 1 Clean the paper release blade and the exit guides 2 Did this correct the problem Complete Go to Step 5 5 1...

Page 269: ... Complete Go to Step 3 3 1 Poor drum oiling can cause the image transfer to be incomplete on one side of the page 4 1 Use service diagnostics to verify the drum maintenance cam roller and pivot plate are operating correctly Replace any defective parts 2 Did this correct the problem Complete Go to Step 5 5 1 Inspect and clean the maintenance kit wiper blade 2 If necessary replace the maintenance ki...

Page 270: ...gnostics verify the paper preheater temperature is within normal operating range 2 Replace the paper preheater if necessary Complete Replace the transfix load assembly and transfix load arm Step Questions and Actions Yes No 1 1 Clean or replace the paper release blade 2 Did this correct the problem Complete Go to Step 2 2 1 Inspect the duplex paper path for obstructions contamination debris or dam...

Page 271: ...g order preheater electronics module Step Questions and Actions Yes No 1 1 Repeating defects that occur every 11 6 cm 4 58 in are caused by the transfix roller 2 Clean the transfix roller The defect does not move in the X position 3 Replace if necessary 4 Did this correct the problem Complete Go to Step 2 2 1 A single repeating defect that has a different Y position on each page but the same X pos...

Page 272: ...for more information 2 Are the pinstripes apparent on the test prints Go to Step 2 Complete The problem is not with the print engine 2 1 Verify the X axis motion is operating correctly and that poorly dressed cables loose screws or mechanical failures are not interfering 2 Remove any obstructions or redress cables 3 Did this correct the problem Complete Go to Step 3 3 1 Verify there are no wiring ...

Page 273: ...ions Yes No 1 1 Verify the media is supported for this system 2 Print from an unopened fresh ream of paper 3 Try a higher quality or heavier media type 4 Did this correct the problem Complete Go to Step 2 2 1 Increase the margin size of the image Wrinkling generally occurs in solid fills near the print s edge 2 Did this correct the problem Complete Go to Step 3 3 1 Inspect clean or replace the mai...

Page 274: ...ay 4 Check the application for the correct image sizing and orientation Poor Ink Adhesion Poor Image Durability Follow these steps if the ink is flaking off the print after the print is complete 1 If a specialty coated paper is being used for example glossy media try a different paper Xerox transparency film provides the best ink adhesion versus off the shelf transparency film 2 Verify the paper p...

Page 275: ...added to them This tints them green to make them more visible Look for No interlacing is used in this print expect light dark variation between jets Use Look for much lighter colored vertical bands in the horizontal bars Weak jets in the yellow band are distinguished by a cyan tint Causes A jet may be partially clogged Perform printhead clean purge cycles on the printhead to remove contaminants fr...

Page 276: ... on the Printhead Troubleshooting Checklist Test Print Examples Continued s2424 093 This is a text print This is a text print This is a text print This is a text print This is a text print This is a text print This is a text print This is a text print This is a text print This is a text print This is a text print This is a text print This is a text print This is a text print This is a text print T...

Page 277: ...t Times Roman ABCDEFGHIJKLMNOPQRSTUVWXYZabcdefghijklmnopqrstuvwxyz1234567890 10 point Times Roman ABCDEFGHIJKLMNOPQRSTUVWXYZabcdefghijklmnopqrstuvwxyz1234567890 8 point Times Roman ABCDEFGHIJKLMNOPQRSTUVWXYZabcdefghijklmnopqrstuvwxyz1234567890 6 point Times Roman ABCDEFGHIJKLMNOPQRSTUVWXYZabcdefghijklmnopqrstuvwxyz1234567890 5 point Times Roman ABCDEFGHIJKLMNOPQRSTUVWXYZabcdefghijklmnopqrstuvwxyz1...

Page 278: ...n the print Uniformity of fill with no scratching Evaluate the print on an overhead projector Some print artifacts visible on the print do not show when projected Likewise some defects do not show until projected Causes Confirm that you are using the transparency that is supported for this system Clean or replace the paper release blade For more information about scratches see Scratches or Marks P...

Page 279: ... every 11 63 cm 4 58 in down the length of the page are caused by a defective transfix roller The roller has a soft spot that is not pushing the ink into the paper as well as the rest of the roller If you observe variations in the glossiness of the print replace the maintenance kit 2 If there is ink on the top and bottom margin of the page or ink on the back of the page it may be caused by the rol...

Page 280: ...inkling appears in the secondary colors See the blue and green solid fills in the illustration to the right Causes 1 Weak jets or uneven drum heating may cause uneven fills 2 To solve wrinkling try different print media Replace the maintenance kit to correct streaking Check the drum temperature sensor for debris build up on the sensor Check to see if the sensor is in improper contact with the drum...

Page 281: ...or differences between the quality of the characters on the left and right ends of the print A difference indicates the printhead gaps at each end of the printhead are not equal The ends of this system s printhead rests on two spacers on the ends of the drum that hold the head to drum gap under much tighter control than in previous solid ink systems There is no head to drum adjustment possible in ...

Page 282: ...orrect streaking Check the drum temperature sensor for debris build up on the sensor or the sensor is not in proper contact with the drum See the test print Reverse Text 3 If there is poor transfer on one side check to see if the transfix load arm assemblies are moving easily Clean any contamination that may be interfering with the transfix arm assembly movement If either of the transfix load arm ...

Page 283: ...etermine if the drum or transfix roller have a defect Drum defects do not move in the X position print to print but it does move into the Y position print to print drum defects do not repeat down the page Transfix Roller defects do not move in the X direction but these defects repeat every 4 58 in 11 63 cm down the length of the page Many Transfix Roller defects are the most visible on duplex soli...

Page 284: ... the following formula Skew Spec mm 998 4 width 12 5 1 02 where width is in millimeters To measure margin measure from the magenta frame to the edge of the paper at the midpoint on the top and left edge margin right side of paper left side of system of the paper The tolerance for margin is the margin 2 See the Media Margin Specification in the Appendix NOTE The measurement for skew and margin for ...

Page 285: ... X Dot Position This print is used by Manufacturing and Engineering 27 Y Dot Position This print is used by Manufacturing and Engineering 28 Chase Pages A blank piece of paper is used to remove contamination from the drum transfix roller and paper path 29 Oil Bar Chase This print is used by Manufacturing 30 Purge Efficiency This print is used by Manufacturing and Engineering Test Print Examples Co...

Page 286: ...l 31 Cleaning Chase Page This page is automatically printed following a purge It is used to flush the jet nozzles of any possible contamination or color mixed jets It can also be printed on its own Test Print Examples Continued s2424 100 ...

Page 287: ...ion Adjustments and Calibrations In this chapter System Alignments and Adjustments Print Engine Component Home Positions and Indicators Manual DADF to Scanner Calibration Jet Substitution Mode Resetting NVRAM ...

Page 288: ...1 Remove the system covers using the procedures that begin on page 8 8 2 With the swing arm in the unlocked position remove the K clip from the drive shaft and remove the left drive gear If the printhead is installed it must be tilted back first s2424 014 Left Idler Gear Left Drive Gear ...

Page 289: ...e wiper is all the way to the bottom of its travel and the gears cannot be rotated any further Note Rotating the left and right gears together ensures that the wiper stays parallel and does not pop out of the belts 4 Replace the left drive gear and the KL clip Idler Gears s2424 015 ...

Page 290: ...avel Head tilt gear disengaged from process drive train arrows on left frame point to each other Printhead tilted forward and disengaged from tilt gear Process drive assembly holes on transfix camshaft and drum maintenance camshaft line up with marks on frame large gears within assembly line up with holes in assembly housing Homing the Printhead Wiper When the wiper is homed the wiper should be mo...

Page 291: ...t Gear When the Printhead Is NOT Installed 1 Manually move the tilt gear located on the inside of the left frame to its disengaged position When disengaged the arrows on the left frame point to each other s2424 018 Tilt Gear Engaged Tilt Gear Disengaged ...

Page 292: ... of drum maintenance cam shaft and rotate clockwise one revolution If the printhead is engaged manually assist the movement of the printhead There is an audible click when the gear disengages Note The hole on the drum maintenance camshaft drive gear should be at the 6 00 position after the rotation s2424 017 Insert screwdriver and rotate clockwise ...

Page 293: ...ations 6 7 When the tilt gear is disengaged the two arrows on the left side of the printer are pointing at each other see also the illustration on page 6 5 s2424 016 Drum Printhead Tilt Gear Tilt gear disengaged DM Cam Gear ...

Page 294: ...drive frame must align with the holes in the gear The hole in the drum maintenance camshaft gear must align with the arrow on the frame The hole in the transfix camshaft gear aligns with the hole on the frame s2424 019 Hole in gear aligns with arrow on frame Holes in process drive frame aligns with holes in gears Hole in gear aligns with arrow on frame ...

Page 295: ...s procedure see Xerox Supplies on page 9 16 for the part number or use the page that came with the replacement part Starting the Calibration Procedure 1 On the control panel press the System Setup button 2 Select the Information menu 3 In the menu select Troubleshooting and then press the Enter button 4 Select Service Tools and then press the Enter button 5 Select Calibrate Scanner and then press ...

Page 296: ...r 3 In the menu select Document Glass Step and then press the Enter button to scan the calibration page 4 When the scan completes check the control panel message If the control panel indicates Success select Continue press the Enter button and then continue with Step 5 If the control panel indicates Failure select Continue press the Enter button and then repeat Steps 1 4 5 Remove the Scanner Calib...

Page 297: ...re adjusted to fit against the paper If the page is misaligned the calibration procedure fails 2 In the menu select Document Feeder Step and then press the Enter button to scan the calibration page 3 When the scan completes check the control panel message If the control panel indicates Success select Continue and then press the Enter button The calibration procedure is complete If the control pane...

Page 298: ...hooting and then press the OK button 3 Scroll to Print Quality Problems and then press the OK button 4 Press and hold the Up Arrow button and then press the Back button The Jet Substitution Mode is now displayed on the control panel To correct print quality problems refer to the Eliminate Light Stripes test page to determine which jets are weak or missing 1 Scroll to Jet Substitution Mode and then...

Page 299: ...oblems and then press the OK button 4 Press and hold the Up Arrow button and then press the Back button 5 Scroll to Turn Jet Substitution Mode Off and then press the OK button 6 Print the Eliminate Light Stripes test page to verify that Service Mode is disabled for all jets Resetting NVRAM Resetting NVRAM returns all the Image Processor Board NVRAM stored parameters to their factory default values...

Page 300: ...6 14 WorkCentre C2424 Service Manual ...

Page 301: ...7 Section Cleaning and Maintenance In this chapter Inspection System Self Maintenance Service Cleaning and Maintenance Procedures Cleaning for Print Quality Problems Maintenance Kit Lubrication ...

Page 302: ... crack Belts There are five rubber belts in the system Y axis belt that rotates the drum Two small belts for the exit module exit rollers rotation and lift Two belts on the printhead wiper Inspect the belts for wear and look for these problems Loose rubber particles below the belts indicate a worn belt Missing teeth in the belts Cracking or moderate fraying is inevitable so look for other signs of...

Page 303: ...nt Smears Transfix Roller Oiling Drum Cleaning Chase Page Printhead Maintenance Cycle Eliminate Light Stripes The printhead maintenance cleaning cycle removes bubbles or foreign matter that cause printhead jets to malfunction A maintenance cycle is performed At system power on If the ink reservoir has cooled to the point a cleaning cycle is triggered When the user selects the Eliminate Light Strip...

Page 304: ...bility is enabled 5 sheets of paper go through the simplex paper path and up to 20 sheets go through the duplex paper path 4 The system returns to the Print Quality Problems menu Because of the higher paper temperatures involved this function can also be used to clean the drum surface of ink deposits caused by a contaminated blade on the drum maintenance system Transfix Roller Oiling Oiling the tr...

Page 305: ...lors appear in prints Ink smears or random streaks appear on the front or back of prints Oily spots appear along the tops of prints Mispicks or multiple picks occur at the media tray Persistent paper jams inside the system DADF or at the media tray if the rollers are visibly dirty Wiggly vertical stripes caused by too much oil created by a dirty maintenance kit blade Most print quality problems ca...

Page 306: ...is with the IOT or IIT Also clean the glass platen the CVT window and the pick feed rollers Light Stripes or Missing Colors Problem type Solution Missing or light colored stripes on prints Select the automated procedure Eliminate Light Stripes from the control panel Ink Smears Oil Spots or Random Ink Streaks Problem type Solution Ink smears on the front back or edges of a page Select the automated...

Page 307: ...e Pick Roller Cleaning Methods on page 7 7 Paper jamming problems at the front door Clean the transport rollers Paper jamming problems within the exit path Clean the elevator rollers Paper jamming problems at the exit Clean the exit rollers and paper release blade Paper pick or jamming problems at the Optional 525 Sheet Feeder Tray 3 or Tray 4 Clean the appropriate tray assembly feed roller Duplex...

Page 308: ... 2 Peel off a strip of tape Stretch the tape across the table with the sticky side up Fasten it to the table at both ends 3 Remove the roller 4 Roll the roller across the tape to remove the debris from the roller 5 Locate a clean section of the tape rub it onto the surface of the pick pad for the paper tray then remove it 6 Replace the roller 7 Reinsert the tray Cleaning the Drum Temperature Senso...

Page 309: ...replaced before continued printing is possible See the installation instructions included with the maintenance kit Note The maintenance kit oil poses no known adverse health effects See the Material Safety Data Sheet at www xerox com office msds Waste Tray PL 1 23 The waste tray collects ink that has been purged from the printhead s ink jets A control panel message indicates when the waste tray is...

Page 310: ...t These parts are identified in the replacement procedures When lubricating during replacement use the grease approved for the WorkCentre C2424 system The grease part number is 006 7997 00 Caution Plastic parts will deteriorate when unspecified grease and chemicals are used such as WD 40 and Locktite Threadlocker To avoid damage use only the grease specified in the Lubrication section of the Servi...

Page 311: ... chapter Overview General Notes on Disassembly Image Input Terminal DADF and Scanner Image Output Terminal Print Engine Ink Loader Assembly Back Frame and Printer Stabilizer Imaging Paper Path Motors Gears Solenoids Clutches and Fans Electronics ...

Page 312: ...a part is simply a reversal of the disassembly Replacement procedures are included where this is not the case and special steps are required Replacement notes are included when they can help ease or shorten the reassembly process Standard Orientation of the System When needed the orientation of the system is called out in the procedure for locating printer parts Refer to the system orientation gra...

Page 313: ...s Always use the correct type and size screw coarse thread brass colored screws into plastic and fine thread silver colored screws into metal Using the wrong screw can damage tapped holes Do not use excessive force to remove or install either a screw or a printer part If using a power driver to install a screw into plastic start the screw by hand If you strip out threads in the plastic chassis a s...

Page 314: ...le from the scanner assembly 2 You must depress the locking mechanism 2 on the back hinges to release the document feeder from the scanner assembly 3 Lift straight up on the document feeder to remove Note You must perform the scanner calibration procedure after replacing the document feeder Manual DADF to Scanner Calibration on page 6 9 2 1 s2424 240 ...

Page 315: ...Service Parts Disassembly 8 5 DADF Front Cover PL 1 13 1 Remove 3 screws securing the cover 2 Lift and remove s2424 241 ...

Page 316: ...s open the platen scanhead is not in the home position and cannot be locked 1 Remove the document feeder page 8 4 2 Disconnect the scanner assembly cable from the print engine 3 Place the scanhead in the shipping restraint locked position 4 Using a pen or screwdriver release the hinge latches 5 Slide the scanner assembly towards the rear of the system and then lift up to remove s2424 242 ...

Page 317: ...control panel connector from the scanner assembly 4 Remove the control panel Image Output Terminal Print Engine Note Accessing and removing exterior covers can be done while the document feeder and scanner assemblies are still in place however removing the assemblies improves access to other printer components For all IOT disassembly the document feeder and scanner assembly are shown removed from ...

Page 318: ...ng the document feeder scanner assembly covers and ink loader Videos are located on the WorkCentre C2424 Product Training CD ROM 1 Disconnect all interface cables including the power cord 2 Remove the DADF and scanner assembly Output Paper Tray Assembly PL 1 6 1 Open the front cover Tab Tab Output Paper Tray Front Cover s2424 268 ...

Page 319: ...Service Parts Disassembly 8 9 2 Pry up on the left and right side of the output tray and the two tabs on the bottom to remove the tray from the system s2424 244 ...

Page 320: ... and unsnap the right and left stay retainers from Tray 1 2 Disconnect and free the wiring from Tray 1 3 Carefully remove the front door tray 1 assembly by releasing the left hinge pin from the printer frame and sliding the assembly to the right to remove it 1 3 2 s2424 147 Stay Retainer Stay Retainer ...

Page 321: ...er 3 Remove one screw on the back of the system securing the right side cover 4 Using a flatblade screwdriver insert the screwdriver into the channel and lift up to release the tab securing the right side cover 5 There are tabs on the inner front side of each side cover that latch to the exit module assembly release these tabs and remove the cover s2424 261 Latch Right Cover ...

Page 322: ...overs page 8 11 2 Using a flatblade screwdriver release the tab securing the back cover 3 Remove 2 screws securing the EMI shield 4 Using a flatblade screwdriver release the tab securing the EMI shield 5 Slide the EMI shield straight back to remove from the system Back Frame s2424 263 Rear Cover EMI Shield ...

Page 323: ...and left sides of the ink loader to release from the system then lift the ink loader assembly clear of the chassis and hold it in position against the rear of the system to allow access to the connectors 4 Disconnect the 2 connectors from the system and remove the ink loader Replacement Notes Note The gray cable must be routed between the Ink Loader and the printer side The white cable must be rou...

Page 324: ...fingers 3 While keeping the tension with one hand on the spring use your other hand to slide the loosened belt off the pulley Caution This is a strong spring that can cause damage if it slips during removal use extreme caution when removing 4 Using a spring hook or pliers remove the Y axis tension spring from the chassis retainer and the spring arm Brace the printer to keep it from moving during r...

Page 325: ... Replacement Notes Note Ensure the spring arm screws are in the right locations and that the arm floats freely Note If replacing the motor remove 3 motor screws to separate the motor from the arm and remove the spring arm Torque the screws connecting the spring arm to the motor to 20 in lbs Caution Ensure that the ground lug is replaced on the mounting screw see figure above during replacement s24...

Page 326: ...llow the printhead to cool for 30 minutes before starting the removal procedure Caution Perform the steps in this procedure in the order given to prevent damage to the system 1 Remove the document feeder scanner assembly output paper tray assembly right and left side covers and the ink loader assembly see page 4 thru page 13 Caution Place several sheets of paper between the printhead and the drum ...

Page 327: ...k slightly on the printhead to keep it away from the drum surface unlock push down the right and left printhead restraint arms 3 above then slowly allow the spring loaded printhead to tilt forward 5 On the left side of the printer pull the X Axis bias spring and hook out slightly and shift to the side rotate down see 1 and 2 in the following illustration Allow the spring hook to rest against the d...

Page 328: ...8 18 WorkCentre C2424 Service Manual 6 Disconnect the air hose from the purge pump s2424 022 1 2 Bias Spring Hook Purge Pump ...

Page 329: ...tly toward the rear of the printer to remove Note Adjust printhead position as required to remove the right restraint Caution The roll block stays hot 10 to 15 minutes after the printer is shut down 8 Remove the roll block on the left end of the printhead shaft s2424 155 Printhead Restraint Printhead Restraint Roll Block Printhead Shaft s2424 156 ...

Page 330: ... 10 Lift the printhead out of its mounting position and place the shaft ends in the cradle notches near the top of the chassis frame 11 Disconnect the data cable from the print head s2424 157 Heater Cable Data Cable Cradle Notch Finger Holes Cable Restraint Heater Harness Plug Flex Cables Cradle Notches s2424 276 ...

Page 331: ... the printhead free of the printer chassis Replacement Notes Caution To avoid damage observe the following order when reinstalling the printhead 1 Ensure that the tilt gear is in the home position page 6 5 2 Rest the printhead on the cradle notches provided see the previous illustration while reconnecting the cable and ZIF connectors s2424 154 Data Cable Cradle Notch Printhead Finger Holes ...

Page 332: ...e tilted forward in the print position 6 Route the air hose through the frame and connect it to the purge pump 7 Install the Roll Block on the left end of the printhead Shaft The Roll Block must be oriented as shown on the paper label on the left side of the printer frame Caution Ensure that the printhead restraint does not obstruct the Roll Block 8 Install the left and right printhead restraints ...

Page 333: ...close proximity to the drum Be careful with the removal tools and the spring to ensure that you do not damage the drum 2 Using your hands a spring hook or pliers remove the X axis bias spring from inside the printer cavity Replacement Note Note Do not rotate the spring more than 1 4 turn s2424 158 X Axis Bias Spring ...

Page 334: ...between the printhead and the drum to protect the drum from damage 2 Using the gears position the wiper blade all the way to the top of its travel 3 On the left side of the printer remove the KL clip and large drive gear 4 While holding the wiper rotate the small drive gear to lower the left end of the wiper One end of the wiper will travel down the guide allowing you to slide the wiper belt off o...

Page 335: ...Note Position the wiper so both ends are all the way down following reassembly see Wiper Alignment on page 6 2 Note Make sure the metal portion of the blade is nearest the drum and that the plastic clip is attached to the pulley side nearest the drum ...

Page 336: ...ectronics Module Circuit Boards and Cables on page 9 12 slide the board towards the rear and move the board out of the way 4 Loosen 1 screw securing the transfix roller shaft restraint and remove the restraint Caution Hold the transfix roller and the media release blade with one hand during removal to prevent the roller from damaging the printer or the roller itself 5 Use the end of the transfix r...

Page 337: ...ove the lower duplex guide and the white inner simplex guide page 8 44 3 Release the lock on the back of the AC connector and unplug the AC and sensor flag connectors from the bottom of the preheater The connectors are located on the backside of the assembly AC Connector Sensor Flag Connector s2424 269 ...

Page 338: ...5 Slide the preheater off the shelves and out of the printer as shown by 3 Replacement Note Note The fingers on the inner simplex guide go over the segmented roller First snap the left retainer into place then the right Note Be sure you do not dislodge the optical sensors while replacing or reconnecting the pre heater 1 2 2 1 3 s2424 161 Latches ...

Page 339: ...44 3 To allow removal of the duplex roller remove the left KL clip on the shaft 4 Slide the shaft toward the left 2 to free the right end of the shaft 5 Finally pull the shaft out from the top Once the shaft is free from the right frame you lift the right end of the shaft up so it can clear the top of the right frame during removal 3 s2424 162 1 3 2 KL Clip Bearing ...

Page 340: ...e with solenoid page 8 44 6 Insert a T 20 Torxbit through the slotted hole in the transfix load module on the outside of the plastic arm through the backside of the housing 7 Rotate the screwdriver toward the center of the system to release the spring hook Caution Ensure that you lever the spring cam towards the center Applying the pressure in the wrong direction can damage the transfix load modul...

Page 341: ... and stripper carriage assembly will be removed as a single part 9 Remove the clevis pins from the left and right sides securing the transfix load arms to the chassis 10 Carefully lift each transfix load arm from the system s2424 164 Add Grease Clevis Pin Transfix Load Arm ...

Page 342: ... Manual 11 Remove the grounding springs from the transfix load module to avoid bending them 12 Remove 2 screws securing each end of the transfix load module to the chassis s2424 165 Grounding Springs s2424 166 Transfix Load Module ...

Page 343: ...ube 768 grease P N 00679900 in the groove on the end of each transfix load arm before reattaching the spring hooks Note After installing the EMA perform the Wiper Alignment on page 6 2 The printer may report error code 7 009 4x if the wiper assembly is misaligned Note When replacing grounding springs on the transfix load module make sure the springs rest below the camshaft assembly s2424 167 Trans...

Page 344: ... module removal procedure page 8 30 2 Remove the process drive gearbox assembly page 8 55 3 Slide the shaft to the right 1 and make sure the bearing slides over to the gear move the shaft down and slightly to the right 2 and then up and to the left 3 to remove it from the printer chassis s2424 168 1 2 3 Transfix Camshaft ...

Page 345: ...aft to the right Caution The ground plate firmly holds the bushing in place Be careful when pulling out 1 Carefully pry the bushing out of the right ground plane 2 Rotate the left end of the shaft slightly toward the rear of the printer lift the shaft through the slot and pull it out to the right through the large hole Replacement Notes Note Be sure to replace the KL clips on the outside groves of...

Page 346: ...g clip on the right end of the pivot plate shaft 6 Remove the pivot plate shaft 7 Disconnect the connector from the I O Board connector J860 8 Feed the cable into the printer while sliding the drum maintenance pivot plate out the drum maintenance drawer cavity Note Lightly grease the metal plates on which the cams ride using a small quantity of Rheolube 768 grease P N 00679900 Also fill the pocket...

Page 347: ...belt Relieve tension on the belt by pulling the end of the spring arm toward the front of the printer using your fingers See the figure on page 14 then slide the belt off the pulley 6 Remove 3 screws from the drum fan note the location of the ground clip and allow the fan to hang free 7 Unplug the drum heater cable from the relay board and free the cable from the retaining hook 8 Unplug the drum e...

Page 348: ...The transfix load arms and the media release blade carriage assembly can be installed on the drum assembly either before the drum is installed in the printer or after This procedure installs these components after the drum is installed Note After installing the EMA perform the Wiper Alignment page 6 2 The printer may report error code 7 009 4x if the wiper assembly is misaligned 1 Gently seat the ...

Page 349: ...ge the transfix load module 11 Insert a T 20 Torxbit through the right side slotted hole in the transfix load module engage the hole on the back of the module and lever the module s spring cam toward the center of the printer while connecting the spring hooks to the transfix load arms Repeat for the other side 12 Install the front lower screw no washer and then the front upper screw into the right...

Page 350: ...ure it with 3 screws Torque the top screw into the labyrinth seal to 20 in lbs and the other two screws into the chassis to 12 in lbs 23 Pass the media release blade solenoid cable through the right side of the chassis and seat the lower inner duplex guide on the 4 mounting pins on the chassis 24 Install the ink loader assembly page 8 13 25 Reinstall all covers and doors 26 Reinstall the DADF and ...

Page 351: ...p PL 2 7 1 Remove the left cover page 8 11 2 Disconnect the air hose from the purge pressure pump 3 Disconnect the wiring harness from the purge pressure pump 4 Remove 3 screws and remove the purge pressure pump s2424 023 Purge Pressure Pump Air Hose ...

Page 352: ... pages 4 thru page 13 2 Right side instructions Remove right front screw Remove the pulley and belt from the elevator roller to access and remove the right rear screw Remove the screw on the right side connecting backframe to exit module and grounding wire Disconnect 3 connectors 2 on I O board and 1 to the front cover open sensor s2424 219 ...

Page 353: ...path gearbox to access and remove the left front screw see illustration above Remove the left rear and side screws Disconnect the following connectors back frame paper full sensor IIT scanner closed sensor lift motor and the connector to the MEP elevator s2424 270 s2424 271 ...

Page 354: ...and forward to remove Replacement Note Note The fingers on the Inner Simplex Guide go over the segmented roller First snap the left retainer into place then the right Lower Inner Duplex PL 3 2 1 Open the front door 2 Pull out on the tabs at the bottom of the guide and let the guide swing free 3 Pry inward toward the center of the printer on the right upper retainer until it is free of the mounting...

Page 355: ...ove the output tray 3 Remove the side covers 4 Open the exit cover and remove the outer duplex guide Upper Duplex Guide with Solenoid PL 3 5 1 Remove the right side cover page 8 11 2 Remove the outer duplex paper guide see instructions above 3 Disconnect the solenoid connector from the I O board and remove the harness from the right side frame s2424 274 Outer Duplex Guide ...

Page 356: ...8 46 WorkCentre C2424 Service Manual 4 Remove the upper duplex guide from the printer s2424 275 Hole for Solenoid Lever Solenoid Lever Upper Duplex Guide ...

Page 357: ...oute the solenoid harness through the right side frame when replacing the upper duplex guide Also you must route the guide under the edges of the exit module assembly EMA frame Note Verify that the solenoid lever engages the hole in the Paper Release Guide ...

Page 358: ...e the KL clip from the right end of the shaft 5 Remove the KL clip and bushing from the left end of the shaft Move the take away roller shaft to the left side of the printer to release it from the right side frame rotate the shaft forward and remove it to the right Pressure from the idler rollers makes it difficult to move the take away roller shaft to the right during removal s2424 175 Take Away ...

Page 359: ...Note The catch is located on the ceiling of the tray cavity about 1 4 of the way across the unit from the right side and about 5 in 12 5 cm back When you pull forward on the catch the roller swings down 3 Pull down to remove the roller Note Replace the retard roller at the same time you replace the pick assembly This roller is located in the Tray 2 media tray s2424 026 2 1 s2424 024 ...

Page 360: ...at the top and toward the left the grey rollers should be facing you Position the roller back about 2 inches 5 cm in the tray cavity feel for a large plastic clip on the right and the mating gear for the pick assembly on the left Rotate the pick assembly up and back to latch it in place 1 2 2 1 s2424 177 ...

Page 361: ... this nut use a new one see replacement note 5 Remove the gear from the shaft 6 Remove the 2 screws holding the media tray lift motor to the printer frame 7 Remove the media tray lift motor from the outside of the printer Replacement Note Note Ensure that the two tabs of the bushing are seated in the chassis Position the push nut so the fingers on the nut are pointed away from the end of the shaft...

Page 362: ...entre C2424 Product training CD ROM 1 Remove the output paper tray and left side cover page 8 11 2 Disconnect the media path motor deskew clutch pick clutch and Tray 1 pick solenoid wiring harnesses 3 Remove 6 screws securing the media drive gearbox and remove the entire assembly Caution Do NOT remove the screw for the Tray 1 pick solenoid Media Drive Gearbox Pick Clutch s2424 025 Duplex Roller Sh...

Page 363: ...e media drive gearbox first remove the paper tray Rotate the pick roller shaft until the pick clutch seats and then work upwards rotating the duplex feed rollers until the other shafts seat Ensure that the media drive gearbox is correctly positioned on the side frame ...

Page 364: ... Manual Tray 1 MPT Pick Solenoid PL 4 12 1 Remove the left side cover page 8 11 2 Disconnect the solenoid cable 3 Remove 1 screw from the solenoid and remove the solenoid from the media drive gearbox s2424 181 Tray 1 Pick Solenoid ...

Page 365: ...arnesses from the gearbox cable restraint 3 If you will be re installing this gearbox pin the gears in position to ensure correct alignment on replacement Caution Replacement gear boxes come with two pins to hold the gears in position Use either the pins that come with replacement gear boxes or a paper clip bent into a U shape to hold the gears in their proper position during removal and replaceme...

Page 366: ...ilt system is in the home position page 9 11 Be sure you seat the process drive motor with all three screws before torquing the screws to final tightness Torquing the screws individually before seating all components can put undue strain on the mounting bosses Caution When reinstalling the gearbox the hole in the bottom mating gear should be aligned with the arrow embossed on the ground plane The ...

Page 367: ...isconnect the wiring harness 3 Remove 4 screws securing the motor to the chassis and remove the motor Replacement Note Note When reinstalling the X axis motor ensure that the fork extending out from the side of the cone nut on the motor shaft is engaged with the side rail s2424 184 Side Rail X Axis Motor ...

Page 368: ...sconnecting the sensor wiring harness page 9 15 4 Reach into the waste tray cavity and remove the head tilt compound gear Replacement Notes Note On reassembly the leaf spring on the back side of the chassis must be behind the gear to engage Note On reassembly lubricate the curved cam surfaces of the gear using a small quantity of Rheolube 768 grease P N 00679900 s2424 185 Remove KL Clip Head Tilt ...

Page 369: ...canner assemblies page 8 4 2 Remove the output tray page 8 8 3 Remove the left and right side covers page 8 11 4 Remove the rear cover and EMI shield page 8 12 5 Disconnect all wiring cables to the power supply board 6 Remove 4 short screws connecting the scanner supply board to the back frame 7 List and remove the scanner power supply s2424 211 Scanner Assembly Power Supply Board ...

Page 370: ...canner assemblies page 8 4 2 Remove the output tray page 8 8 3 Remove the left and right side covers page 8 11 4 Remove the rear cover and EMI shield page 8 12 5 Disconnect all wiring to the exit module board 6 Remove 2 screws securing the board to the back frame s2424 212 Exit Module Board ...

Page 371: ...t 1 Remove the DADF and scanner assemblies page 8 4 2 Remove the output tray page 8 8 3 Remove the left and right side covers page 8 11 4 Remove the ink loader assembly page 8 13 5 Disconnect the 3 wiring harnesses from the top of the electronics module 6 Disconnect the 2 printhead cables 7 Remove 5 screws from the back of the electronics module 8 Remove 2 screws from inside the printer chassis 9 ...

Page 372: ...24 Service Manual 11 Remove the electronics module Replacement Note Note When replacing the electronics module transfer the Configuration Card NVRAM SODIMM RAM and hard drive to the new module Electronics Module s2424 186 ...

Page 373: ...mblies page 8 4 2 Remove the output tray page 8 8 3 Remove the left and right side covers page 8 11 4 Remove the scanner power supply and MEP control board page 8 42 5 Remove the Electronics Module page 8 61 6 Remove 2 screws securing the stabilizers to the system and remove the stabilizer 7 Remove Ink loader page 8 13 8 Remove 4 screws from the top 9 Remove 7 screws from the rear of the back fram...

Page 374: ...8 64 WorkCentre C2424 Service Manual s2424 214 Back Frame ...

Page 375: ... the wave amp board through the back of the printer Replacement Note Caution Ensure that the ribbon cables are fully and squarely inserted into the ZIF connectors on the wave amp and printhead If the cables are inserted incorrectly they can damage the wave amp Board Route the ribbon cables carefully through the slots Ensure that the T shaped strain relief on the cable is nearest the wave amp on in...

Page 376: ...right side cover page 8 10 2 Disconnect the wires to the I O Board 3 Remove 2 screws attaching the I O Board to the printer 4 Remove the I O Board Replacement Note Note Ensure the corner of the board is behind the ground tab on reassembly s2424 027 Ground Tab I O Board ...

Page 377: ...0 2 Disconnect 3 wires to the drum heater relay board 3 Remove the 2 screws securing the drum heater relay board to the system 4 Remove the drum heater relay board Replacement Note Warning Ensure that no wires are routed behind the drum heater relay board during reinstallation Some of these wires carry AC line voltage and a short could result in AC being shorted to accessible locations s2424 189 D...

Page 378: ...e the orientation of the NVRAM chip before removing it and use this as a guide for proper replacement 2 Remove the old NVRAM from its socket in the Electronics Module page 1 4 3 Insert the new NVRAM chip into the socket Ensure that the notch on the chip is on the left side 4 After powering ON the system either download the snippet titled setsn ps from infoSMART or get it from the Product Training ...

Page 379: ...9 Section Parts Lists In this chapter Serial Number Format Using the Parts List Xerox Supplies ...

Page 380: ...te the modification level of the printer the date of its manufacture and the sequence number of the printer produced on that day The serial number is coded as follows The text S N followed by the serial number in the barcode The barcode does not include a field identifier The nine digit serial number is based on the following format PPPRSSSSS R Single digit numeric revision digit To be rolled when...

Page 381: ... up of the individual parts called out in parentheses 7 The notation with X Y following a part name indicates an assembly that is made up of components X through Y For example 1 with 2 4 means part 1 consists of part 2 part 3 and part 4 8 An asterisk following a part name indicates the page contains a note about this part 9 The notation NS next to a part indicates that particular part is not spare...

Page 382: ...9 4 WorkCentre C2424 Service Manual Covers 4 4 6 3 2 5 2 3 1 7 9 11 s2424 149 22 23 21 20 25 15 16 17 13 14 12 19 18 8 24 26 10 PL 1 11 With 8 12 PL 1 15 With 13 19 ...

Page 383: ...luded 1 109K01870 12 Upper Housing including platen glass 1 802K87650 13 DADF Front Cover 1 802K87660 14 DADF Upper Cover 1 802K87820 15 Duplex Automatic Document Feeder Assembly includes PL 1 13 1 14 1 15 1 16 1 17 1 18 1 19 1 004K07270 16 DADF Input Tray 1 050K59960 17 DADF Pick Roller and Pad Kit 1 604K30540 18 Separator Pad part of PL 1 17 1 19 DADF Hinge 1 003K19520 20 Rear Cover 1 802E82550 ...

Page 384: ...9 6 WorkCentre C2424 Service Manual Imaging s2424 193 1 2 3 7 12 13 14 15 16 17 8 11 10 9 4 19 20 21 18 18 5 6 ...

Page 385: ...280 9 Right Printhead Restraint 1 343167180 10 Transfix Camshaft Assembly 1 384187480 11 Drum Maintenance Camshaft Assembly 1 401100380 12 Stripper Carriage Assembly 1 386735281 13 Transfix Roller 1 022E32290 14 Y Axis Tension Spring 1 214499680 15 Transfix Load Module 1 386739380 16 Drum Maintenance Pivot Plate Assembly 1 367053181 17 Preheater and Deskew Assembly 1 119641980 18 Transfix Arm Asse...

Page 386: ...9 8 WorkCentre C2424 Service Manual Paper Path s2424 194 6 7 8 8 9 5 13 17 18 19 16 12 4 2 1 3 15 14 10 11 11 10 ...

Page 387: ...351113680 7 Exit Module Assembly MEP 1 441224480 8 Spring Carriage 2 809E68760 9 Spring Carriage Roller 4 809E68750 10 Pulley MEP Exit Module 4 020E47770 11 Belt MEP Exit Module 2 023E30530 12 Roller Idler Exit 1 022E32230 13 Lower Exit Guide Assembly 1 038K16410 14 Printer Stabilizer 1 674E00750 15 525 Sheet Feeder HCF Stabilizer 1 674E00760 16 525 Sheet Feeder HCF with Tray 1 650433100 17 525 Sh...

Page 388: ...9 10 WorkCentre C2424 Service Manual Motors Gears Solenoids Clutches Sensors Fans and Backframe 6 8 1 2 9 7 10 12 13 5 4 10 15 14 11 s2424 195 3 ...

Page 389: ... 401096180 5 X Axis Motor Assembly 1 650429400 6 Drum Cooling Fan 1 119641780 7 Gearbox and Motor Process Drive 1 401100080 8 MEP Drive Motor 1 127K53270 9 MEP Elevator Motor 127E14830 10 Tray Lift Motor Kit 1 650429500 11 Motor Assembly Y Axis Drive 1 147101780 12 Pick Solenoid Tray 1 1 119640880 13 Compound Gear Head Tilt 1 401097880 14 Gearbox Media Drive with 2 Clutches 1 401098480 15 Electron...

Page 390: ...9 12 WorkCentre C2424 Service Manual Electronics Module Circuit Boards and Cables 7 8 9 10 1 2 6 3 11 5 12 17 14 18 20 4 22 21 15 16 23 s2424 196 19 13 24 ...

Page 391: ...n NVRAM 1 156476800 10 Configuration Card Programmed 1 537E65920 11 Cable ZIF Wave Amp Drive 1 174448680 12 Cable Right Side Power Control 1 174446680 13 I O Board 1 671529180 14 Cable Combined Right 1 174451180 15 Cable Scanner PSU to Printer PSU 1 117E28380 16 Cable Scanner PSU TI IP MEP and FAN 1 117E28390 17 Cable I O Board Data 1 174447480 18 Cable Right Umbilical 1 174448180 19 Drum Heater R...

Page 392: ...9 14 WorkCentre C2424 Service Manual Sensors and Flags Actuators s2424 197 2 3 4 5 6 7 8 9 10 11 1 ...

Page 393: ...19645580 3 Engine Exit Flag 1 137E11880 4 Drum Temperature Sensor Assembly 1 119643080 5 Exit Module MEP Sensor Assembly 1 119648180 6 Waste Tray Sensor optical 1 119648780 7 Sensor Assembly Paper Tray 1 441223780 8 Optical Sensor Generic Snap In 1 119640580 9 Paper Present Flag 1 386731280 10 Paper Full Sensor Kit 604K30550 11 Flag MEP Exit Module 1 137E11890 ...

Page 394: ... M4 x 32 partial thread flanged hex 5 each M4 x 12 taptite flanged 5 each ASMO clip lift motor 2 each E ring bent M6 5 mm 5 each Bushing 6 mm 2 each Cable Restraint 2 each Frame Replace Screw silver blue tint 5 each 650429700 Cleaning Kit 016184500 Repackaging Kit 695K17720 Printer Stabilizer 674E00750 HCF 525 Sheet Feeder Stabilizer 674E00760 Cart 137E11900 Stopper Retainer 003E77400 Clip Retaine...

Page 395: ...andard Capacity Maintenance Kit WorkCentre C2424 108R00656 Extended Capacity Maintenance Kit WorkCentre C2424 108R00657 Genuine Xerox Solid Ink 8400 Black 3 sticks 108R00663 Genuine Xerox Solid Ink 8400 Cyan 3 sticks 108R00660 Genuine Xerox Solid Ink 8400 Magenta 3 sticks 108R00661 Genuine Xerox Solid Ink 8400 Yellow 3 sticks 108R00662 Genuine Xerox Solid Ink 8400 Black 6 sticks 108R00664 Rainbow ...

Page 396: ...man 650K24040 Overlay Kit Spanish 650K24050 Overlay Kit Dutch 650K24060 Overlay Kit Swedish 650K24070 Overlay Kit Brazilian Portuguese 650K24080 Overlay Kit Russian 650K24300 Service Manual 604E13990 Software CD ROM 063346900 User Documentation CD ROM 063346800 Software and Documentation Description Part Number ...

Page 397: ...iring Diagrams In this chapter Scanner DADF Functional Diagrams Main Block Wiring Diagram Right Side Wiring Diagram Left Side Wiring Diagram Inside Front Wiring Diagram Inside Top Wiring Diagram Electronics Module ...

Page 398: ...y Main Power Control J3AC J2 Scanner Power Supply Cooling Fan J2 Scanner Power Supply Image Processor Controller Board J2 J2 Scanner Power Supply MEP Board CN1 J1 J2 Scanner Bridge Board Image Processor Controller Board J3 J3 Scanner Bridge Board Control Panel CN1 MEP Board Image Processor Controller Board J4 CN2 MEP Board Exit Module Sensor Paper Full Sensor Exit Cover Sensor IIT Sensor CN4 MEP B...

Page 399: ... Main ECB Transport motor negative J390 34 Power Control ECB Main ECB 8 Main tray elevator plate 2 Main tray pick clutch 2 MPT Solenoid 3 Deskew Clutch 2 Purge pump 6 Main fan 2 Media motor and encoder 7 Media path motor fan 2 J400 8 J3AC 3 Power Supply ECB Auxiliary J400 14 I O ECB Main tray paper opto 3 Main paper height opto 3 Pre heater ECB 6 Relay ECB 2 J860 J1 J400 16 Power Control ECB 16 X ...

Page 400: ...00 Ethernet RCV XMT ribbon cable I O ECB J840 J720 2 Pre Heat ECB Paper pre heater J820 4 Power Control ECB Hard Drive ECB J390 J840 I O ECB Ethernet RCV XMT ribbon cable J800 J860 Pre heat ECB I O ECB J400 J860 2 I O ECB Maintenance kit missing sensor 2 J860 80 Main Processor ECB Hard Drive ECB J580 80 J870 2 I O ECB Drum print thermister 2 J910 10 I O ECB Inkload ECB J1 10 JDC1 Power Supply ECB ...

Page 401: ...Image Processing Controller 1 Existing Printer Front Panel NOT INSTALLED USB Image Processor Scanner Control Panel FP Interface FP Interface Scanner Part of Print Engine Printer IP Controller Board PCI Plugin Board Notes 1 With additional internal PCI Connector and additional FW ROM I O ASIC IDE Disk Document Feeder Video Exit Module Controller Motor Drivers Exit Module Board Scanner Exit Module P...

Page 402: ... Drum Temp Thermistor 14 2 14 80 6 2 34 2 2 2 3 14 2 5 Hard Drive 7 DMU Life i Button 6 MPT Solenoid 8 HCF Connector Transport Motor 8 2 3 3 3 2 HCF Module 3 10 8 8 HCF Connector 11 30 14 30 Vss Vpp 8 Generates 24V PWM 2 VssD VppD Gnd Sense WaveAmp Enable 50V 12V Unregulated Gnd 6 JET0 JET1 JET2 CLK ADCTX ADCRX 12V Regulated 3 3V Gnd 9 Spares Vss Vpp HCF_ RD HCF_TD HCF_CLK 50V 3 3V Gnd 3 50V 3 3V ...

Page 403: ...CB Deskew Entry Sense Opto Waste Tray Opto Main Tray Paper Height Opto Main Tray Paper Out Opto Process Home Optional 5 2 10 3 16 7 3 3 3 NOTE The numbers shown at the circuitboard perimeters are for the actual connectors Some have extra n c pins added to prevent misplugging errors 3 Preheat Sense Opto 2 3 2 Paper Preheater Preheat Temp Therm 5 Relay ECB 660 0019 03 3 To Scanner Power Supply 3 I O...

Page 404: ...and MEP Exit Module Board s2424 277 Exit Module Board Scanner Assembly Power Supply Board MEP Serial Communication 5 24V Serial In Door Sensors 24 Volts Motor Power Elevator Drive on MEP MEP Sensors AC Main Ground Wire 5 24V Out 5V LED 24V LED To Left Side Wiring Harness ...

Page 405: ...rness Pass Through Wiring Harness Pass Through 37016 4x HM Clutch J680 13067 4x J870 13067 4x J860 Maintenance Kit Missing J400 Drum Heater J600 Add Paper Tray J250 37020 4x Strip Solenoid J110 Waste Tray Ground Clip Ground Clip J610 No Handfeed J910 13387 4 J840 Dead Power 37006 4x Drum Heater 5002 42 37014 4x Drum Fan Paper Full Sensor MEP Drive Motor s2424 200 ...

Page 406: ...agram Continued The lines indicate which connectors you should look at for the Pest codes The Pest codes are displayed on the control panel 13387 4x 37027 4x X Motor Signal Cable Routes to Bottom of Channel J800 Dead Power J4AC 37006 4x J480 37027 4x s2424 201 ...

Page 407: ...or the Pest codes The Pest codes are displayed on the control panel s2424 202 37023 4x Purge Valve 37022 4x Purge Motor 37013 4x Electric Fan J280 37032 4x Y Motor J790 37062 4x Head VSS J390 37034 4x MP Motor 37021 4x MT Elevator Channel Connected to Ground Strap To Scanner Power Supply ...

Page 408: ...connectors you should look at for the Pest codes The Pest codes are displayed on the control panel 37034 3x MP Motor 37017 4x Deskew Clutch 37019 4x Pick Solenoid 37018 4x Pick Clutch Ground Clip MEP Elevator Motor IIT Sensor Paper Full Sensor Exit Cover Sensor Exit Module Sensor Assembly s2424 203 ...

Page 409: ...indicate which connectors you should look at for the Pest codes The Pest codes are displayed on the control panel s2424 204 37036 4x Process Motor 37008 4x Preheat Power AC Connector J860 13131 41 Sensor Flag Paper Jam Open Front Cover Load Paper ...

Page 410: ...cate which connectors you should look at for the Pest codes The Pest codes are displayed on the control panel MEP Serial Communication Door Sensors 24 Volts s2424 205 37010 4x Ink 1 Heater J180 34062 4x Data Cable J1AC 37009 4x Ink Load Power J2AC 37002 4x JSL Heater To MEP Board ...

Page 411: ...nued The lines indicate which connectors you should look at for the Pest codes The Pest codes are displayed on the control panel s2424 206 Heater Cable Cable Restraint Out of Ink J180 32064 4x J140 37063 4x Head VPP J110 37062 4x Head VSS ...

Page 412: ...bbon Connector Data Cable USB Port Config Card Ethernet Port Heater Cable Connector Ink Load Power Connector Power to Preheater and Drum Power to Scanner Assembly Power Supply Service Port Right Umbilical Power Cable Y Axis Motor Left Umbilical Connector Wave Amp Data Exit Module Serial Port Door Sensors 24 Volt from Scanner Assembly Power Supply to IIT Connector ...

Page 413: ...A Appendix Appendix Contents Control Panel Menu Map Media Margin Specification Table Paper Weight Equivalence Table On Site Printhead Troubleshooting Checklist ...

Page 414: ...mSetup Enter Back Lighten Darken Stop Start Clear ClearAll Reduce Enlarge PaperSupply Ready to Copy Paper Supply Reduce Enlarge Lighten Darken Original Size Edge Erase Margin Shift Auto Center Book Copy Auto Suppression Covers Blank Separators Create Booklet Repeat Image N Up Contrast Color Balance Ready to Scan Scan To Scan Resolution Scanning Guide Original Size Auto Suppression Clear Folder Cop...

Page 415: ...monstration Print Mode Demonstration CMYK Sampler Pages RGB Sampler Pages Model Printer Name Print Server IP Address Serial Activation Date Serial Total Impressions Color Impressions Black Impressions Maintenance Kit Life Total Print Count Paper Tips Page Troubleshoot Jams Paper Path Test System Status Page Engine Error History Jam History Diagnostics History Calibrate Scanner Enter Diagnostic Mod...

Page 416: ...Security Startup Page Auto Clear Timeout Power Saver Timeout Date and Time Intelligent Ready Default Service Color Copy Password Print Job Interrupt Metric Defaults Reset System Controls Paper Source 2 Sided Printing Tray 1 Setup Tray 2 Paper Type Tray 3 Paper Type Tray 4 Paper Type Load Paper Timeout Custom Units Cleaning Page Source Reset Paper Handling Setup Output Color Mode 2 Sided Copying Ou...

Page 417: ...0 5 5 166 240 10 Envelope 104 775 241 3 5 15 94 775 211 3 C5 Envelope 162 229 5 20 157 189 DL Envelope 110 220 5 20 100 180 Statement 139 7 215 9 5 5 129 7 205 9 A5 148 210 5 5 138 200 Monarch Envelope 98 425 190 5 5 15 88 425 160 5 A7 Lee Envelope 133 35 184 2 5 15 123 35 154 2 6 75 Envelope 92 075 165 1 5 15 82 075 135 1 A6 105 148 5 5 95 138 5 5 Baronial 111 125 146 5 15 101 125 112 9 3 x 5 Ind...

Page 418: ...43 24 29 35 39 64 20 50b 28 34 42 46 75 21 54 30 36 44 49 80 24 60b 33 41 50 55 90 27 68 37 45 55 61 100 28 70b 39 49 58 65 105 29 74 41 50 61 68 110 32 80b 44 55 67 74 120 36 90 50 62 75 83 135 0 18 39 100 55 67 82 91 148 40 101 55 68 83 92 150 0 20 43 110 60 74 90 100 163 45 115 63 77 94 104 170 0 23 47 119 65 80 97 108 176 51 128 70 86 105 117 190 53 134 74 90 110 122 199 54 137 75 93 113 125 2...

Page 419: ...mplete Value or Result What to look for Step 1 Do you suspect or have evidence of use of generic ink YES NO Circle one 1a Did the customer state that they have used generic ink in this printhead YES NO 1b Did you observe generic sticks or related packaging at the site YES NO 1c Are there generic ink sticks in the ink loader YES NO 1d Does the service history indicate possible use of generic ink YE...

Page 420: ...259 46 13 261 48 13 323 47 13 325 49 is displayed or a PEST error code 37 002 47 37 003 48 37 004 40 or 37 005 41 perform the following steps 3c Inspect and reseat the printhead interface cable gray ribbon cable and retest 3d Replace the electronics module and retest 3e Replace the printhead 3f Perform Wiper Purge Checklist with new printhead Visually inspect the ink reservoirs Do they all contain...

Page 421: ... the waste tray 9b Select Eliminate Light Stripes from the printer front panel and run one cleaning cycle 9c Remove the waste tray and examine how much ink was purged A single purge should resemble the illustration Is the purge mass noticeably less than what is pictured If YES inspect the purge hoses for splits or tears Step 11 Print Service Test 2 Weak and Missing Jets Are there weak or missing j...

Page 422: ...ror code x This Printhead Troubleshooting Checklist filled out x Inventory control Green Tag filled out x Sample prints that clearly show the observed print quality defect not applicable for printheads replace because of an error code Service Print 1 1 2 3 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 5...

Page 423: ... covers 9 5 color mode button 1 9 communication port testing 4 79 compound gear head tilt parts list motors and fans 9 11 configuration card electronics module 1 6 8 62 parts list circuit boards 9 13 printer information 2 12 configuration card parameters 2 45 Consumables 9 17 diagram 1 7 life counters 1 7 control panel 8 7 layout 1 8 menu map 1 11 A 2 parts list covers 9 5 control panel buttons 1 ...

Page 424: ...haft 2 40 Duplex Automatic Document Feeder guidelines 1 17 duplex paper path check menu 4 32 duplex printing theory 2 20 duplex roller removal 8 29 duplex roller parts list paper path 9 9 E electric clutch wiper parts list motors and fans 9 11 electrical safety 1 iii electrical specifications 1 14 electronics module connectors 10 16 main system electronics 1 6 parts list circuit boards 9 13 replac...

Page 425: ...date service menu 4 3 head maintenance clutch check menu 4 15 head serial number service menu 4 3 head tilt compound gear removal 8 58 head tilt gear 6 5 head version service menu 4 3 head to drum adjust service menu 4 3 head to drum check 5 41 heaters check menu 4 25 help button 1 10 hidden service menu 4 2 home position check menu 4 53 I I O access cover parts list covers 9 5 I O board cables pa...

Page 426: ...theory 2 24 2 42 Media Exit Path MEP 2 17 media jams 7 7 media margin specifications A 5 media path faults 3 34 media path motor check menu 4 47 media release blade 8 26 media release blade removal 8 26 media tray lift motor removal 8 51 media based problems 4 76 memory 2 12 menu help diagnostics 4 6 menu map 1 11 MEP control board 8 63 MEP elevator carriage motor parts list motors and fans 9 11 M...

Page 427: ...fans 9 11 pick feed motor check menu 4 48 pivot plate 2 37 plug and jack locator 10 2 POST Error Codes 3 5 power control board 2 12 power control cable parts list circuit boards 9 13 Power Cord Parts List 9 16 Power Safety Precautions 1 vii power saver timeout service menu 4 3 power supply verification procedures 4 71 Predominate light stripes problem 5 13 preheat sensor 2 40 preheater jams 4 77 p...

Page 428: ...5 right side cover removal 8 11 roll block 8 19 8 22 roller exit idler parts list 9 9 Routine 1 7 Routine Maintenance Items diagram 1 7 Runtime Log 4 81 S Safety electrical components 1 viii hazards 1 iii mechanical components 1 ix operation 1 iv Power 1 vii requirements 1 iii service summary 1 viii symbols 1 vi safety electrical safety 1 iii operational safety 1 iv safety interlock switch parts l...

Page 429: ... 31 tilt drive check menu 4 39 tilt gear 2 33 Tools List 9 17 total satisfaction guarantee 1 iv 1 vi Transfix and exit functions 2 40 transfix arm assembly parts list imaging 9 7 transfix camshaft assembly parts list imaging 9 7 transfix camshaft gear 6 8 transfix camshaft removal 8 34 transfix load module replacement 8 30 transfix load module parts list imaging 9 7 transfix roller check menu 4 37...

Page 430: ... side wiring 10 11 main wiring 10 6 right side wiring 10 9 scanner DADF 10 5 wrinkling 5 33 X x axis bias spring 8 17 8 23 bias spring hook parts list 9 7 bias spring parts list 9 7 motor assembly parts list 9 11 motor removal 8 57 motor check menu 4 36 4 46 roll adjuster spring parts list 9 7 X axis faults 3 15 3 16 Y y axis belt removal 8 14 drive 4 42 faults 3 14 motor assembly parts list 9 11 ...

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Page 432: ...604E13990 ...

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