Xerox WorkCentre C2424 Service Manual, 2005 (P/N 604E13990)

Xerox’s WorkCentre C2424 Copier-Printer Service Manual, P/N 604E13990, covers the DN, DP, and DX configurations. This is the first printing, dated March 2005.

Finding Service Information in the PDF

Text search and bookmarks: The manual has searchable text and embedded bookmarks for the service chapters and appendix. Small connector labels in dense wiring diagrams are easier to read when zoomed in. Two heater callouts on the Inside Top Wiring Diagram are clipped at the left edge (PDF p. 410).

The single printable PDF contains 432 pages, including the front and back covers, title and copyright pages, six pages without body content, the 10-page appendix, and the 8-page index.

Solid-Ink Print Engine and Scanner Service

These are selected topics from the manual. The appendix also includes a control panel menu map and a paper weight equivalence table.

• Scanner and document feeder: Flatbed and duplex automatic document feeder (DADF) operation, scanhead and lamp diagnosis, assembly replacement, and DADF-to-scanner calibration.
• Solid-ink print engine: X-axis printhead motion, Y-axis drum drive, ink loading and purging, transfix, paper preheating and deskew, and duplex routing through the exit module.
• Fault isolation: Hidden Service Menu, BIST and POST LED patterns, PEST fault codes, and built-in tests for motors, sensors, heaters, clutches, and power supplies.
• Field replacement: Illustrated, step-by-step procedures for the control panel, printhead, drum, wiper, transfix assemblies, purge pump, paper-path drives, and serviceable circuit boards.
• Adjustments: Wiper alignment, printhead and head-tilt homing, process-drive timing, jet substitution, and NVRAM reset.
• Cleaning and maintenance: Paper-pick and preheater cleaning, maintenance-kit life and replacement messages, and lubrication guidance for replacement parts.
• Parts and wiring: Exploded views with part numbers, the Plug/Jack Locator Table, and wiring diagrams that tie connector locations to PEST fault codes.

Xerox wrote the servicing instructions for qualified technicians handling diagnosis, maintenance, and repair.

Configurations and Controller Layout

The DP and DX add a high-capacity feeder and cart, and the DX also includes ScanSoft applications. Optional lower-tray diagnosis covers lift motors, pick clutches, sensors, and media-size circuits. The specification tables cover clearances, electrical and environmental requirements, DADF limits, supported media, duplex operation, and consumables.

The Image Input Terminal (IIT) section follows the Constant Velocity Transport path and explains the scanheads and calibration targets. The main board handles image processing through its daughterboard and controls the system. The Exit Module (MEP) board controls the exit mechanism, and the diagrams show how the power control board, scanner power supply, and control panel connect.

Fault Codes and Image Quality

The Monitor, Exercise, and Check functions cover encoders, solenoids, fans, and shafts. Fault tables address drive, ink-loader, heater, electronics-interface, printhead calibration, and drum maintenance faults. The jam tables cover the most common code combinations.

Startup diagnostics, fault history, and ground and voltage checks help trace intermittent faults. Communications troubleshooting includes USB and Ethernet checks, configuration pages, event and runtime logs, and a serial back-channel trace.

The image-quality checks help distinguish flatbed or DADF defects from print-engine faults before parts are replaced. The manual covers light stripes, smears, color mismatch, ghosting, repeating defects, incomplete transfer, duplex-side ink smears, wrinkling, image offset, and poor adhesion. It provides service test prints, the Service Technician RIP procedure, and an on-site printhead troubleshooting checklist.

Assembly Replacement and Shop Tools

The electronics module is serviced as a unit. The replacement procedure covers transferring the hard drive, configuration card, memory, and NVRAM. The printhead procedure warns that poorly seated flex cables can short the Wave Amp. The homing section explains how an out-of-position wiper, head-tilt gear, or process drive can cause gear grinding at startup.

The tool list identifies adjustable torque screwdriver 003082700, T20 bit 003086600, approved grease 006799700, and scanner calibration page 109K01910. The lubrication notes warn that unsuitable grease or threadlockers can damage plastic. The referenced printhead, wiper, and transfix videos are on the separate WorkCentre C2424 Product Training CD-ROM.

The safety section covers AC isolation at the power cord, ESD precautions, and hazards from hot ink, heater circuits, and the drum drive.

Parts Lists and Wiring Maps

The parts lists pair exploded views with part numbers for imaging, paper handling, drives, electronics, sensors, supplies, and options. The ordering notes explain the revision digit in the machine serial number.

The Scanner/DADF Functional Diagrams and Main Block Wiring Diagram show the system connections. The Scanner/Exit Module Power Supply and MEP Board diagram covers that power supply and controller, while the Right-Side and Left-Side Wiring Diagrams trace harness routing.

Motor Resistance and Fastener Torque Examples

For disconnected motor windings, the resistance table gives approximately 12.5 ohms per phase for the X-axis motor (red to yellow and blue to orange) and 1.5 ohms per phase (±20%) for the media path motor.

The disassembly notes specify 12 in-lb for screws threaded into plastic and 15 in-lb for screws threaded into metal, unless a procedure gives a different torque.