Xerox 1632 2240 3535 Color Carrera Manual

							6/02
4-7 DC1632/2240
REP 1.8, REP 1.9Repairs and Adjustments Prelaunch Training/Review
ReplacementEnsure Screws (2) are positioned in slots as shown before tightening Screws (2) (Figure 2). 
Figure 2 Installing Interface PWB
REP 1.9 24 V LVPS BracketParts List on  PL 9.1 
Removal
WARNINGTo avoid personal injury or shock, do not perform repair or adjustment activities with
the power switch on or electrical power applied to the machine.
1. Remove Rear Cover (REP 14.2).
2. Remove Upper Rear Left Cover (REP 14.4).
3. Remove 24 V LVPS (REP 1.5).
4. Remove 24 VDC LVPS Chassis (Figure 1).
a. Remove Top Screw.
b. Remove upper harnesses from Harness Clips (2).
c. Disconnect Fan P/J and remove harness from Harness Clip.
d. Loosen Screws (4).
e. Remove 24 VDC LVPS Chassis.
Figure 1 Removing 24 VDC LVPS Bracket Assembly
Screws (2)
Slot
Slot
Harness 
Clips
Harness 
ClipFan P/J
Screws (2)Screws (2)
Top 
Screw 
						

							6/02
4-8DC1632/2240
REP 1.10, REP 1.11
Prelaunch Training/Review Repairs and Adjustments
REP 1.10 HVPS T6Parts List on  PL 9.1
Removal
WARNINGTo avoid personal injury or shock, do not perform repair or adjustment activities with
the power switch on or electrical power applied to the machine.
1. Remove Rear Cover (REP 14.2).
2. Remove 24 V LVPS (REP 1.5).
3. Remove 24 VDC LVPS Chassis (REP 1.9).
4. Remove HVPS T6 (Figure 1).
a. Disconnect P/Jís (4).
b. Disconnect Harness P/Jís (2).
c. Remove Screws (2) and remove High Voltage Power Supply with chassis.
d. Remove High Voltage Power Supply from chassis.
Figure 1 Removing HVPS T6
REP 1.11 AC Drive PWBParts List on  PL 9.2
Removal
WARNINGTo avoid personal injury or shock, do not perform repair or adjustment activities with
the power switch on or electrical power applied to the machine.
1. Remove Rear Cover (REP 14.2).
2. Remove 24 V LVPS (REP 1.5).
3. Remove 24 VDC LVPS Chassis (REP 1.9).
4. Remove HVPS T6 (REP 1.10).
5. Remove AC Drive PWB (Figure 1).
a. Remove Screws (2) and Bracket.
b. Carefully observe position of wiring harnesses and AC Wires for later reinstallation
c. Disconnect AC Harness P/Jís (3) and AC Wires (6).
d. Disconnect DC Harness P/Jís (2).
e. Release harness from Harness Clip.
f. Remove Mounting Screws (3)
g. Disengage rear clip (not shown) and remove AC Drive PWB.
Figure 1 Removing AC Drive PWB
1st BTR 
P/Jís (4)Harness 
P/Jís (2)
Screws 
(2)
K
C
M
Y
Screws (2) 
and 
Bracket
AC Har-
ness P/Jís 
(3) and 
AC wires 
(6)Mounting 
Screw
Mounting 
ScrewDC Har-
ness P/Jís
Harness 
Clip
Mounting 
Screw
P42
Blue
P43
WhiteP46 
						

							6/02
4-9 DC1632/2240
REP 1.11, REP 1.12
Repairs and Adjustments Prelaunch Training/Review
Replacement
CAUTION
Ensure White connector P43 and Blue connector is P42.   Other connectors are different sizes
to ensure correct connection.  
REP 1.12  ESS PWBParts List on PL 13.1 
Removal
WARNINGTo avoid personal injury or shock, do not perform repair or adjustment activities with
the power switch on or electrical power applied to the machine.
CAUTION
The ESS PWB has a lithium battery.  Dispose of the used battery following the manufacturers
instructions after replacing.  Do not throw it away at customers site.
1. Remove Right Cover (REP 14.3). 
2. Remove Top Cover (REP 14.1).
3. Remove Rear Cover (REP 14.2).
4. Remove ESS Top Cover (PL 13.1).
CAUTION
Protect Hard Drive Harness.  Hard Drive is mounted to ESS Top Cover.  Hard Drive har-
ness remains connected to ESS PWB while removing ESS Top Cover.
a. Remove screws (11) from ESS Top Cover. 
b. Lift ESS Top Cover and place it upside down on Toner Cartridges.
c. Disconnect Hard Drive harness from ESS PWB. 
						

							6/02
4-10DC1632/2240
REP 1.12
Prelaunch Training/Review Repairs and Adjustments NOTE: 5 mm tool may be required.
5. Remove ESS PWB (Figure 1). 
Figure 1 Removing ESS PWB
2Remove 
ESS 
NVM3Remove 
Postscript 
Font ROM
4Remove ESS 
Firmware 
EPROMS
5Remove 
RAM
1Remove 
MAC 
ROM
6Disconnect 
P/J
9Disconnect 
Fan P/J
10Remove Screws (9) and 
remove ESS PWB
8Remove 
jacks from 
plate7Remove 
RAM 
						

							6/02
4-11 DC1632/2240
REP 1.13
Repairs and Adjustments Prelaunch Training/Review
REP 1.13  ESS NVM PWBParts List on PL 13.1 
Removal1. Download ESS NVM values to machine floppy.  If download is not possible, most recent
NVM values will be downloaded during replacement step 3.
WARNING
To avoid personal injury or shock, do not perform repair or adjustment activities with
the power switch on or electrical power applied to the machine.
2. Remove Right Cover (REP 14.3). 
3. Remove Top Cover (REP 14.1).
4. Remove Rear Cover (REP 14.2).
5. Remove ESS Top Cover (PL 13.1).
CAUTION
Protect Hard Drive Harness.  Hard Drive is mounted to ESS Top Cover.  Hard Drive har-
ness remains connected to ESS PWB while removing ESS Top Cover.
a. Remove screws (11) from ESS Top Cover. 
b. Lift ESS Top Cover and place it upside down on Toner Cartridges.CAUTION
The ESS PWB has a lithium battery.  Dispose of the used battery following the manufacturers
instructions after replacing.  Do not throw it away at customers site.
6. Remove the ESS NVM PWB (Figure 1). 
Figure 1 Removing the ESS NVM PWB
Replacement1. Connect the PSW and enter DC132.
2. Match the Billing, following the steps of DC132. 
3. Enter all the NVM values described in the NVM List that comes with the machine or down-
load NVM values from machine floppy.
ESS NVM 
PWB 
						

							6/02
4-12DC1632/2240
REP 1.13
Prelaunch Training/Review Repairs and Adjustments 
						

							6/02
4-13 DC1632/2240
REP 4.1
Repairs and Adjustments Prelaunch Training/Review
REP 4.1 Main Drive Motor AssemblyParts List on  PL 1.1 
Removal
WARNINGTo avoid personal injury or shock, do not perform repair or adjustment activities with
the power switch on or electrical power applied to the machine.
1. Remove Fuser Module (REP 10.1). 
2. Remove Tray 5 (REP 7.1).
3. Remove Rear Cover (REP 14.2).
4. Remove 24 V LVPS (REP 1.5).
5. Remove 24 VDC LVPS Chassis (REP 1.9).
6. Remove Developer High Voltage Power Supply (REP 1.10).
7. Remove AC Drive PWB (REP 1.11).
8. Remove Main Drive Motor Assembly (Figure 1). 
a. Carefully observe position of wiring harnesses for later reinstallation
b. Disconnect Harness P/Jís (5).
c. Disconnect Harness P/Jís (3).
d. Remove harness from Harness Clips (3).
e. Disconnect HV Wire.
NOTE: In next step, do not remove small round head screws that appear to secure Main Drive
Motor Assembly to machine.
f. Remove Screws (5) and remove Main Drive Motor Assembly.
Figure 1 Removing Main Drive Motor
Harness Clips (3) 
(2 not shown)
Harness 
P/Jís (3)
HV 
Wire
Harness 
P/Jís (5) 
						

							6/02
4-14DC1632/2240
REP 4.2, REP 4.3
Prelaunch Training/Review Repairs and Adjustments
REP 4.2 IBT MotorParts List on PL 1.1
Removal
WARNINGTo avoid personal injury or shock, do not perform repair or adjustment activities with
the power switch on or electrical power applied to the machine.
1. Remove Rear Cover (REP 14.2).
2. Pivot down High Voltage Power Supply Chassis (REP 1.6).
3. Remove Photoreceptor Module Drive Motor.
a. Disconnect Cooling Fan P/J.
b. Remove screws (2) and remove Cooling Fan.
c. Disconnect Photoreceptor Module Drive Motor P/J.
d. Remove Photoreceptor Module Drive Motor screws (3) and remove Photoreceptor
Module Drive Motor.
Figure 1 Removing Photoreceptor Module Drive Motor
REP 4.3 Developer Drive MotorParts List on PL 1.1
Removal
WARNINGTo avoid personal injury or shock, do not perform repair or adjustment activities with
the power switch on or electrical power applied to the machine.
1. Remove Rear Cover (REP 14.2).
2. Remove High Voltage Power Supply Chassis (REP 1.6).
NOTE: Step 3 can be omitted if Low Voltage Power Supply P/Jís are disconnected before per-
forming step 4.
3. Remove 3.3 VDC and 5 VDC Low Voltage Power Supply (REP 1.4). 
4. Remove Chassis for 3.3 VDC and 5 VDC Low Voltage Power Supply.
a. Release harnesses from harness clips (3).
b. Remove screws (4) and remove Chassis.
5. Remove Developer Drive Module (Figure 1).
a. Disconnect P/J.
b. Remove harness from Harness Clip.
c. Remove Screws (2) and remove Developer Drive Module.
Figure 1 Removing Developer Drive Module
Cooling Fan
Photoreceptor 
Module Drive 
Motor
Harness Clip
Screw
Screw
P/J 
						

							6/02
4-15 DC1632/2240
REP 4.4
Repairs and Adjustments Prelaunch Training/Review
REP 4.4 Drum Motor AssemblyParts List on PL 1.1
Removal
WARNINGTo avoid personal injury or shock, do not perform repair or adjustment activities with
the power switch on or electrical power applied to the machine.
1. Remove Right Cover (REP 14.3). 
2. Remove Top Cover (REP 14.1).
3. Remove Rear Cover (REP 14.2).
CAUTION
Machine problems will result from careless harness routing during reassembly.  Carefully
observe position of wiring harnesses for later reinstallation.
NOTE: Step 6 can be omitted if Low Voltage Power Supply P/Jís are disconnected before per-
forming step 7.
4. Remove 24 V LVPS (REP 1.5).
5. Remove 24 VDC LVPS Chassis (REP 1.9).
6. Remove Control Chassis (REP 1.3).
7. Remove High Voltage Power Supply Chassis (REP 1.6). 
NOTE: In next step, do not disconnect P/Jís.
8. Loosen Interface PWB chassis mounting screws (2) and move chassis up (REP 1.8). 
9. Remove Photoreceptor Module Drive Motor (REP 4.2). 
10. Remove Developer High Voltage Power Supply (REP 1.10).
11. Remove 3.3/5 VDC Power Supply Chassis (REP 1.1). 
12. Remove Print Cartridge Drive Module (Figure 1). 
a. Release harness from Harness Clips (3)
b. Remove screws (2) to release Connector from frame.
c. Disconnect P/J.
d. Remove Screws (8) and remove Print Cartridge Drive Module.
Figure 1 Removing Print Cartridge Drive Module
Harness 
Clips (3)Con-
nector
P/J
Screws (8) 
						

							6/02
4-16DC1632/2240
REP 4.4
Prelaunch Training/Review Repairs and Adjustments