Xerox WorkCentre C2424 Copier-Printer 2005 Service Manual (P/N 604E13990)

This 432-page PDF contains Xerox's OEM WorkCentre C2424 Copier-Printer Service Manual, Part Number 604E13990, first printing March 2005. It covers the DN, DP, and DX configurations and is written for technicians handling shop-floor diagnosis, maintenance, and repair.

• Coverage: Scanner/DADF Image Input Terminal (IIT), Image Output Terminal (IOT), high-capacity feeder and cart hardware, plus configuration-card, NVRAM, memory, and hard-drive service considerations.
• Architecture: Shows how the main board, image processor board, power control board, scanner power supply, Exit Module (MEP) board, control panel, scanner, DADF, and print engine interact.
• Print engine: Details the printhead and X/Y-axis motion, ink loader, drum assembly, transfix, drum maintenance, purge, paper preheater/deskew, duplex path, process drive, media-path drive, and exit module.
• Diagnostics: Includes the Hidden Service Menu, BIST/POST/PEST reporting, monitor/exercise/check functions, electrical testing, fault history, and common three-digit jam-code troubleshooting.
• Repair procedures: Covers removal and replacement of the DADF, scanner, control panel, printhead, drum, wiper, transfix components, purge pump, paper-path assemblies, drives, sensors, boards, and electronics module.
• Adjustments and references: Provides wiper alignment, component homing, head-tilt and process-drive timing, DADF-to-scanner calibration, jet substitution, NVRAM reset, test prints, exploded views, connector maps, and wiring diagrams.

Configuration Coverage

Xerox lists three standard versions. DN uses 256 MB RAM. DP adds one 525-sheet high-capacity feeder and a cart. DX uses 512 MB RAM and adds the same feeder/cart package plus ScanSoft applications. Optional lower-tray diagnosis covers feeder lift motors, pick clutches, sensors, and media-size circuits.

The specification sections include physical clearances, electrical and environmental data, print/copy/scan functions, DADF limits, media compatibility, duplex support, maintenance-item life, and consumable information. These tables are tied to theory-of-operation coverage of document feeding, scanning, imaging, transfixing, duplexing, and paper exit.

System Architecture & Print Engine Mechanics

The IIT material explains the DADF, Constant Velocity Transport imaging path, flatbed scanner, scanheads, lamps, sensors, drive, calibration targets, and image-data path. The IOT chapters follow the solid-ink process from drum preparation and ink loading through printhead jetting, transfix, stripping, duplex routing, and exit-module handoff.

The electronics section documents the C2424's two-controller arrangement: the main board handles image processing and overall system control, while the MEP board controls the exit module. Electronics-module repair is assembly-level rather than board-level; the hard drive, configuration card, memory, and NVRAM are transferred to the replacement module.

Technical Data & Component Troubleshooting

Service diagnostics can monitor or exercise sensors, encoders, solenoids, clutches, heaters, fans, shafts, motors, drum functions, and power supplies, with check tables for measured results. Fault sections cover process control and motion axes, process and media-path drives, ink-loader and thermal circuits, electronics interfaces, printhead calibration/NVRAM, drum maintenance, feeder hardware, and scanner/DADF faults.

Image-quality diagnosis separates scanner/DADF defects from IOT problems. Symptoms include light stripes, smears, color mismatch, ghosting, repeating defects, incomplete transfer, duplex-side ink smears, wrinkling, image offset, and poor adhesion. Service test prints, the Service Technician RIP procedure, and the appendix On-Site Printhead Troubleshooting Checklist support repair decisions before major parts are replaced.

Parts, Wiring Diagrams & Shop Notes

Section 8 supplies field replacement procedures for Xerox-spared assemblies. Section 9 pairs exploded diagrams with part-number lists for imaging, paper path, drives, electronics, sensors, supplies, and options, and explains the revision-coded serial-number format used for parts ordering.

Section 10 includes the Plug/Jack Locator Table, Scanner/DADF Functional Diagrams, Main Block Wiring Diagram, Scanner/Exit Module Power Supply and MEP Board diagram, and side-specific internal wiring layouts. These drawings show harness routing and associate connector locations with PEST fault families.

The recommended-tools list identifies Xerox P/N 003082700 adjustable torque screwdriver, 003086600 T20 bit, 006799700 approved grease, and 109K01910 scanner calibration page. Network and intermittent-fault material also covers USB/Ethernet checks, event and runtime logs, configuration pages, and a serial back-channel trace.

Important repair cautions are machine-specific: incorrectly seated printhead flex cables can short the Wave Amp, while powering up with the wiper, head-tilt gear, or process drive out of home can grind the drive gears. Unspecified grease or threadlocking chemicals can deteriorate plastic parts.

Scope note: The jam-code section covers the combinations encountered most commonly, not every possible code. Some printhead, wiper, and transfix procedures refer to videos on a separate WorkCentre C2424 Product Training CD-ROM; those videos are not embedded in this PDF.

Safety: This publication is for qualified service personnel. The power switch does not fully disconnect AC power; unplug the machine before removing covers, follow ESD precautions, and account for hot solid ink, heater circuits, and the closed-loop drum drive.