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Xerox C2424 Service Manual - Page 67

Process Drive

UPC - 095205676532

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Process Drive The process drive is an open loop system that transmits torque to two main camshaft assemblies. One camshaft assembly controls the transfix roller loading, and the other controls the drum maintenance system and printhead tilt system. A small DC servo motor powers the process drive gearbox to rotate the gears to specific positions during the printing process. The process drive is able to actuate each camshaft system independently or concurrently through the use of the swing arm in the gear train. Operation of the transfix and drum maintenance system is controlled by the rotational direction of the motor. When the process motor rotates in one direction, the swing gear engages the lower gears. When the motor rotates in the opposite direction, the upper gears are engaged. Since the system is open loop, special attention to the home position of the process drive gears and the mating camshaft gears is critical. The process drive gearbox is mechanically keyed upon installation via gear orientations. These gear orientations allow the printer subsystems to self home during operation. If either the gearbox or cam gears is out of home during installation, the printer does not function properly. Process Drive Swing Gear Theory of Operation s2424-030 2-23

Section	Page
Copyright	4
Warning Labels	12
Safety Interlocks	12
United States	14
Canada	14
European Union	14
Contents	17
General Information	25
System Introduction and Overview	26
System Features and Configurations	27
Standard Configurations	27
Front View	28
Open View	28
Side View with System Interfaces	29
Back View	29
Electronics Module	30
Routine Maintenance Items and Consumables Life Expectancy	31
Control Panel Layout	32
Menu Map	35
System Specifications	36
Physical Dimensions and Clearances	36
Print Engine (IOT) Functional Specifications	37
System Electrical Specifications	38
System Environmental Specifications	38
Scanner/DADF (IIT) Specifications	38
Tray and Media Specifications	40
Duplex Automatic Document Feeder Guidelines	41
Supported Envelopes	43
Media Storage Guidelines	43
Media that May Damage the System	44
Media Skew Specification Print Engine (IOT)	44
Media System Skew Specification (IIT/IOT)	44
Theory of Operation	45
System Overview	46
System Summaries	46
Image Input Terminal (IIT)	47
Major Components of the DADF and Scanner	47
Document Feeder Functions	48
Document Feeder Paper Path and Imaging	50
Copy/Scan Imaging	50
Scanner Assembly Functions	51
Scanner and Document Feeder Calibration	52
Automatic Calibration	52
Automatic DADF Calibration	52
Automatic Scanner Calibration	53
Manual Calibration	53
System Electronics	54
Exit Module (MEP) Board	55
Scanner Power Supply	55
Electronics Module	55
Power Supply Diagram (Electronics Module)	58
Image Output Terminal (IOT) Sub-Assemblies	59
Sub-Assemblies of the IOT	60
Paper Path and Paper Pick	62
Paper Pick for Tray 1	62
Paper Pick for Trays 2 - 4	63
2-Sided (Duplex) Printing	64
Sensor Locations	65
System Motors, Solenoids, and Drive	66
Process Drive	67
Media Path Drive	68
The Print Process	69
Drum Preparation	70
Printing	70
Ink Loader	71
Printhead	72
Printhead Tilt	75
Drum Assembly	78
Transfix System	80
Drum Maintenance System	81
Purge System	82
Transfixing and Exiting	84
Transfix and Print Speeds	88
Configuration Card Personality Parameters	89
Error Messages and Codes	93
Introduction	94
Power-Up Error Messages and LED Codes	95
BIST Error Reporting	95
POST Error Reporting	96
PEST Error Reporting	99
Fault Code Error Message Troubleshooting	100
Fault Code Error Reporting	100
Interpreting Fault Codes	100
1,000.4x Error - 525-Sheet Feeder Faults	101
2,0XX.4x Error - I/O Circuit Board Fault	102
2,0XX.6x Errors - I/O Board Program Faults	102
3,0XX.6x - IPC Program Faults	102
4,0XX.4x Errors - Process Control System Fault	103
4,0XX.6x Process Control Software Fault	105
5,0XX.4x Errors - Y-Axis Sub-System Fault	106
5,0XX.6x Errors - Program Faults	106
6,0XX.4x Errors - X-Axis Fault	107
6,0XX.6x Errors - Program Faults	107
7,0XX.4x Errors - Process Motor Gearbox Faults	108
7,0XX.6x Errors - Program Faults	111
8,0XX.xx Error - Wiper/Media Path Gearbox Faults	112
8,0XX.6x Errors - Program Faults	113
9,0XX.xx Errors - Ink Loader Faults	114
9,009.44 and 900X.6x	114
11,0XX.xx Errors - Electronics Module Interface Fault	115
11,100.60 - Temperature Error	116
12,000.60 Errors - Program Faults	116
13,0XX.xx Errors - Thermal Faults	116
13,000.6x Errors - Program Faults	124
19,0XX.xx Errors - Printhead Calibration faults.	125
19,0XX.6x - Errors	125
21,000.69 Errors - Diagnostic Code Version Mismatch	125
22,0XX.6x Errors - Jam Codes	125
23,0XX.6x Errors - NVRAM Fault	125
26,0XX.6x Errors - Printing Faults	125
27,0XX.6x Errors - Profile Library	126
29,0XX.6x Errors - Jam Manager	126
31,0XX.4x Errors - Mechanical Initialization Jam	126
31,0XX.6x Errors - Program Faults	126
33,0XX.xx Errors - Tray Manager Device Faults	127
34,0XX.xx Errors - Printhead NVRAM Faults	127
36,000.40 Errors - Drum Maintenance Faults	128
36,001.67 Errors	128
37,0XX.xx Errors - PEST Faults	129
39,0XX.xx Errors - Document Feeder / Scanner Unit Faults	138
3-Digit Jam Codes	141
Jam Code Definition Table	142
General Troubleshooting	159
Introduction	160
Hidden Service Menu	160
Service Diagnostics	162
Service Diagnostics Menu Functions	162
Important Information While Performing Service Diagnostics	162
Entering Service Diagnostics	163
From Customer Mode to Diagnostics:	163
From System OFF to Diagnostics:	163
Service Diagnostic Menu Definition Tables	164
Service Diagnostic Print Engine Menu Functions	169
Check Menu / Activators Definition Tables	173
Check / Activators Menu	173
Check Shafts Menu	176
Check Fans Menu	182
Check Heaters Menu	183
Check Paper Path Menu	185
Check Drive Menu	193
Check Drum Menu	198
Check Motors Menu	203
Check Misc Menu	206
System Power-Up Sequence	212
Mechanical Initialization of the Print Engine	213
Head Cleaning Cycle Performance	215
Electrical Troubleshooting	216
Electronics Module	216
Document Feeder Lamp Does Not Turn ON	217
Document Feeder Does Not Feed Media	217
Scanner Scanhead Does Not Move	218
Scanhead Motion is Not Smooth and Continuous	218
Scanner Lamp Does Not Turn On	218
Control Panel is Malfunctioning	218
System Continuously Resets or Resets Unexpectedly	219
Control Panel Is Blank and the PS and PE Indicators are Flashing an Error Code	219
Exit Module (MEP) is Malfunctioning	220
System Fails to Power-Up	220
System Energy Star Mode Troubleshooting	222
System Reports Missing Maintenance Kit	223
System Reports Missing Waste Tray	223
System Features Not Available	223
525-Sheet Feeder Does Not Function	224
Non-Specific Electronics Failure	225
Verifying Scanner Power Supply Operation	228
Verifying Power Supply Operation - Print Engine	229
Measuring AC Power Supply Voltages	230
Detecting condition of Fuse F2 and F3	230
Measuring DC Power Supply Voltages	231
Ensuring Ground Integrity	231
Testing Motor and Solenoid Resistances	233
Paper Path and Media-Based Problems	234
Media-Based Problems	234
Paper-Pick Errors - Trays 2, 3, and 4	234
Paper-Pick Errors - Tray 1	235
Document Feeder Pick Problems	235
Preheater and Transfix Jams	235
Checking the Process and Media Path Drive	236
Media Skews Passing Through the Paper Path	236
Operating System and Application Problems	237
Testing Communications Ports	237
Ethernet Port Verification	237
Ethernet Port Verification for Default Assigned IP Address 169.254.xxx.xxx	238
USB Port Verification	239
Network Problems	239
To print an Event Log or Runtime Log:	239
Obtaining Serial Back Channel Trace	240
Image-Quality Troubleshooting	241
Image-Quality Problems Overview	242
Service Technician RIP Procedure	243
Isolating a Copy/Scan Malfunction to the Scanner/DADF	243
Before troubleshooting image-quality problems:	243
DADF Image-Quality Problems	244
Dark Streaks on the Copied Image	244
Skewed Copy Image	245
Copy Image is Lighter/Darker than the Original	245
Fuzzy Text/Image	246
Copied Image Colors Do Not Match the Original	247
Scanner Image Quality Problems	248
Dark Streaks on the Copied Image	248
Copied Image is Skewed	248
Copied Image is Lighter/Darker than the Original	248
Copy Image Colors Do Not Match the Original	249
Fuzzy Text/Image	250
Diagnosing IOT (Print Engine) Print-Quality Problems	251
Random Light Stripes	252
Predominate Light Stripes	253
Smudges or Smears	254
The Printed Image Is Too Light or Too Dark	255
No Image is Being Printed	255
Color is Uneven or Color is Wrong	256
Streaks or Lines Down the Print	257
Scratches or Marks Parallel to the Long Axis of Printing, Particularly with Transparencies	259
There is ink on the White Portion of the Printed Page	261
Fuzzy Text	262
Poor Primary Color Fills	264
Ghosting	265
Poor Small Text Resolution	266
Vertical Lines Appear Wavy	267
Oil Streaks on Print	268
Incomplete Image Transfer to Paper	269
Ink Smears on First Printed Side of Duplex Print	270
Repeating Print Defects on Print	271
White Stripes (Pinstripes)	272
Wrinkling	273
Image is Offset or Cut-Off	274
Poor Ink Adhesion, Poor Image Durability	274
Analyzing Service Test Prints	275
Test Print Examples	275
1: Weak/Missing Jet	275
2: X-Axis Motion (Drop Mass Evaluation)	276
3: Color Bands, RGBK Dither	276
4: Reverse Text	277
5: Big Bands OHP	278
6: Gray Fill, Dot Size Uniformity	279
7: Manuf. Five Duplex GSF	279
8: YMCKRGB Solid Fills	280
9: Drum Seal	280
10: Manuf. Paper Path	280
11: Head-to-Drum Check	281
12: Manuf X-Axis (Scanner)	281
13-19: Black, Red, Green, Blue, Cyan, Magenta, and Yellow Solid Fills	282
20: OHP Color Bands	282
21: Primary Solid Fills 10x	283
22: Manuf. Skew Margins	284
23: Manuf. Banding	285
24: Head Roll	285
25: Head Height	285
26: X Dot Position	285
27: Y Dot Position	285
28: Chase Pages	285
29: Oil Bar Chase	285
30: Purge Efficiency	285
31: Cleaning (Chase) Page	286
Adjustments and Calibrations	287
System Alignments and Adjustments	288
Wiper Alignment	288
Print Engine Component Home Positions and Indicators	290
Homing the Printhead Wiper	290
Homing the Head Tilt Gear	291
When the Printhead Is NOT Installed	291
Homing the Process Gear Drive Train	294
Manual DADF to Scanner Calibration	295
Starting the Calibration Procedure	295
Scanner Platen Steps	296
Document Feeder Steps	297
Jet Substitution Mode	298
Enabling Jet Substitution Mode	298
Disabling Jet Substitution Mode	299
Resetting NVRAM	299
Cleaning and Maintenance	301
Inspection	302
System Self-Maintenance	303
Printhead Maintenance Cycle (Eliminate Light Stripes)	303
Paper Preheater Cleaning (Remove Print Smears)	304
Transfix Roller Oiling	304
Drum Cleaning - Chase Page	304
Service Cleaning and Maintenance Procedures	305
Supplies Required	305
Cleaning for Print-Quality Problems	306
Scan or Copy Print-Quality Problem	306
Light Stripes or Missing Colors	306
Ink Smears, Oil Spots, or Random Ink Streaks	306
Media Jams and Paper Pick Cleaning Procedures	307
Pick Roller Cleaning Methods	307
Tray 1 Pick Rollers	307
Cleaning the Drum Temperature Sensor	308
Maintenance Kit	309
Maintenance Kit Life	309
Waste Tray	309
Lubrication	310
Service Parts Disassembly	311
Overview	312
Standard Orientation of the System	312
General Notes on Disassembly	313
Special Notes Regarding Screws Used in This Equipment.	313
Notations in the Disassembly Text	313
Image Input Terminal (DADF and Scanner)	314
Duplex Automatic Document Feeder	314
DADF Front Cover	315
Scanner Assembly	316
Control Panel	317
Image Output Terminal (Print Engine)	317
Covers	318
Output Paper Tray Assembly	318
Front Door / Tray 1 Assembly	320
Right and Left Side Covers	321
Rear Cover and EMI Shield	322
Imaging	323
Ink Loader Assembly	323
Replacement Notes:	323
Y-Axis Drum Belt, Y-Axis Tension Spring, and Y-Axis Motor Assembly	324
Replacement Notes:	325
Printhead Assembly, Right and Left Printhead Restraints	326
Replacement Notes:	331
X-Axis Bias Spring	333
Replacement Note:	333
Printhead Wiper	334
Replacement Note:	335
Media Release Blade (Stripper) Carriage Assembly and Transfix Roller	336
Paper Preheater and Deskew Assembly	337
Replacement Note:	338
Duplex Roller	339
Transfix Load Module	340
Replacement Notes:	343
Transfix Camshaft Assembly	344
Drum Maintenance Camshaft Assembly	345
Replacement Notes:	345
Drum Maintenance Pivot Plate Assembly	346
Drum Assembly	347
Replacement Notes:	348
Purge Pressure Pump	351
Paper Path	352
Exit Module Assembly (MEP)	352
Replacement Note:	354
Paper Guides	354
Inner Simplex	354
Replacement Note:	354
Lower Inner Duplex	354
Lower Exit-Guide Assembly with Strip Flag	354
Upper Duplex Guide with Solenoid	355
Replacement Notes:	357
Take Away Roller	358
Pick Assembly	359
Replacement Note:	360
Tray Lift Motor	361
Replacement Note:	361
Motors, Gears, Solenoids, Clutches, and Fans	362
Media Drive Gearbox with Two Clutches and Solenoid	362
Replacement Note:	363
Tray 1 (MPT) Pick Solenoid	364
Process Drive Motor and Gearbox	365
Replacement Notes:	366
X-Axis Motor Assembly	367
Replacement Note:	367
Head Tilt Compound Gear	368
Replacement Notes:	368
Electronics	369
Scanner Power Supply	369
Exit Module (MEP) Board	370
Electronics Module	371
Replacement Note:	372
Back Frame and Printer Stabilizer	373
Wave Amp Board	375
Replacement Note:	375
I/O Board	376
Replacement Note:	376
Drum Heater Relay Board	377
Replacement Note:	377
NVRAM Replacement	378
Parts Lists	379
Serial Number Format	380
The serial number is coded as follows:	380
Serial Number Example:	380
Using the Parts List	381
Covers	382
Imaging	384
Paper Path	386
Motors, Gears, Solenoids, Clutches, Sensors, Fans and Backframe	388
Electronics Module, Circuit Boards and Cables	390
Sensors and Flags (Actuators)	392
Xerox Supplies	394
Wiring Diagrams	397
Plug/Jack Locator Table	398
Scanner/DADF Functional Diagrams	401
Main Block Wiring Diagram	402
Main Block Wiring Diagram (Continued)	403
Scanner/Exit Module Power Supply and MEP (Exit Module) Board	404
Right-Side Wiring Diagram	405
Right-Side Wiring Diagram (Continued)	406
Left-Side Wiring Diagram	407
Left-Side Wiring Diagram (Continued)	408
Inside Front Wiring Diagram	409
Inside Top Wiring Diagram	410
Inside Top Wiring Diagram (continued)	411
Electronics Module	412
Appendix	413
Control Panel Menu Map	414
Control Panel Menu Map -continued-	415
Control Panel Menu Map -continued-	416
Media Margin Specification Table	417
Paper Weight Equivalence Table	418

Match case Limit results 1 per page

Theory of Operation

2-23

Process Drive

The process drive is an open loop system that transmits torque to two main camshaft

assemblies. One camshaft assembly controls the transfix roller loading, and the other

controls the drum maintenance system and printhead tilt system. A small DC servo

motor powers the process drive gearbox to rotate the gears to specific positions during

the printing process. The process drive is able to actuate each camshaft system

independently or concurrently through the use of the swing arm in the gear train.

Operation of the transfix and drum maintenance system is controlled by the rotational

direction of the motor.

When the process motor rotates in one direction, the swing gear engages the lower

gears. When the motor rotates in the opposite direction, the upper gears are engaged.

Since the system is open loop, special attention to the home position of the process

drive gears and the mating camshaft gears is critical. The process drive gearbox is

mechanically keyed upon installation via gear orientations. These gear orientations

allow the printer subsystems to self home during operation. If either the gearbox or

cam gears is out of home during installation, the printer does not function properly.

s2424-030

Process Drive

Swing Gear