Xerox 1632 2240 3535 Color Carrera Manual

							6/02
4-27 DC1632/2240
REP 5.10
Repairs and Adjustments Prelaunch Training/Review
REP 5.10 Set Gate Solenoid AssemblyParts List on PL 20.5
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. Open Top Cover.
2. Remove following:
a. Front Cover (PL 20.1).
b. Entrance Tray (PL 20.1). 
3. Remove Lower Chute Assembly (REP 5.8).
4. Remove Set Gate Solenoid Assembly (Figure 1).
Figure 1 Removing Set Gate Solenoid Assembly
Replacement1. Engage pin with slot  (Figure 2).
Figure 2 Engaging Pin with Slot
2Disconnect
3Release clamp 
and remove wire
4Loosen screws 
(2) and remove 
solenoid
1Make note of pin 
engagement
PinSlot 
						

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4-28DC1632/2240
REP 5.10
Prelaunch Training/Review Repairs and Adjustments 2. Install Set Gate Solenoid Assembly (Figure 3)
Figure 3 Installing Set Gate Solenoid Assembly
1Position Solenoid 
on Screws
2Move Solenoid as 
shown and tighten 
Screws (2)3Connect and secure 
harness in clip 
						

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4-29 DC1632/2240
REP 5.11
Repairs and Adjustments Prelaunch Training/Review
REP 5.11 Registration SensorParts List on PL 20.5
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. Open Top Cover.
2. Remove following:
a. Front Cover (PL 20.1).
b. Entrance Tray (PL 20.1). 
3. Remove Lower Chute Assembly (REP 5.8).
4. Disconnect P/J580 and remove Registration Sensor (Figure 1).
Figure 1 Removing Registration Sensor
Replacement1. When installing Registration Sensor align holes with bumps and tighten screw (Figure 2).
Figure 2 Installing Registration Sensor
1Loosen 
screw
2Remove 
Registration 
Sensor and 
disconnect 
						

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4-30DC1632/2240
REP 5.12
Prelaunch Training/Review Repairs and Adjustments
REP 5.12 Size Sensors 1/2 (Rear/Front)Parts List on PL 20.5
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. Open Top Cover.
2. Remove following:
a. Front Cover (PL 20.1).
b. Entrance Tray (PL 20.1). 
3. Remove Lower Chute Assembly (REP 5.8).
4. Remove Set Gate Solenoid Assembly (REP 5.10).
5. Remove Size Sensors 1/2 (front/rear) (Figure 1).
Figure 1 Removing Size Sensors 1/2
1Remove 
screws (2)
2Disconnect plugs
3Remove screws (2) and 
sensors 
						

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4-31 DC1632/2240
REP 5.13
Repairs and Adjustments Prelaunch Training/Review
REP 5.13 DADF Belt Motor AssemblyParts List on PL 20.6
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 5.18). 
2. Remove DADF Belt Motor Assembly (Figure 2).
Figure 1 Removing DADF Belt Motor Assembly
ReplacementNOTE: Align motor bracket with marks on frame before tightening screws.
1Mark position of motor bracket on frame 
near all four mounting screws
2Disconnect 
motor con-
nector
3Loosen 
screws (4)
4Remove 
Belt from 
motor pulley 
and remove 
motor 
						

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4-32DC1632/2240
REP 5.14
Prelaunch Training/Review Repairs and Adjustments
REP 5.14 Duplex SensorParts List on PL 20.7
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 following:
a. Front Cover (PL 20.1) 
b. Rear Cover (REP 5.18) 
c. Top Cover (PL 20.2)
2. Loosen screws (2) and remove Feed Motor from mounting (REP 5.5).
3. Remove Duplex Sensor (Figure 1).
a. Remove screws (2).
b. Lift Duplex Chute to disengage lower mounts.
c. Lift rear end of Duplex Chute so that Duplex Sensor is visible.  Harness remains
connected.
d. Remove screw and remove Duplex Sensor.
Figure 1 Removing Duplex Sensor
Screws
Lower Mounts 
						

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4-33 DC1632/2240
REP 5.15
Repairs and Adjustments Prelaunch Training/Review
REP 5.15 Registration Pinch RollParts List on PL 20.8
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.
NOTE: Do not damage or scratch surface of Registration Pinch Roll. (Scratches may cause
skewing.)
1. Remove following:
a. Front Cover (PL 20.1)  
b. Rear Cover (REP 5.18).
c. Registration Gate Solenoid (REP 5.2).
2. Remove Gate (Figure 1).
Figure 1 Removing Gate
2Remove 
screws (4)
4Remove 
Gate3Remove 
Screws (2)
1Remove Belt from Pulley.  Remove 
E-Ring and Pulley 
						

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REP 5.15
Prelaunch Training/Review Repairs and Adjustments 3. Remove Gate (Figure 2).
Figure 2 Removing Gate4. Remove Registration Pinch Roll (Figure 3).
Figure 3 Removing Registration Pinch Roll
1Observe position 
of Springs
3Remove 
Screws (2)
4Remove Gate while 
containing Springs
2Close DADFCAUTION
Plastic edge on 
Gate is fragile
2Remove 
C Clip 
and 
longer 
Spring1Remove C 
Clip, shorter 
Spring, and 
Bearing
3Remove Regis-
tration Pinch Roll 
						

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4-35 DC1632/2240
REP 5.16
Repairs and Adjustments Prelaunch Training/Review
REP 5.16 Exit Motor AssemblyParts List on PL 20.9
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 5.18).
2. Remove Exit Motor Assembly (Figure 1).
a. Disconnect connector.
b. Release clamps (2) and remove wire.
c. Loosen screws (2).
d. Remove belt.
e. Remove Exit Motor Assembly.
Figure 1 Removing Exit Motor Assembly
ReplacementNOTE: Belt should be tight but not stretched before tightening motor mounting screws (Figure
2).
Figure 2 Tightening Exit Motor Assembly Mounting Screws
1Disconnect
2Release wires 
from Clamps
3Loosen 
Screws (2)
4Remove 
Exit Motor 
Assembly 
and Belt 
						

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4-36DC1632/2240
REP 5.17
Prelaunch Training/Review Repairs and Adjustments
REP 5.17 Document TransportParts List on PL 20.10 
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 Front Cover (PL 20.1).
2. Remove Document Transport (Figure 1).
a. Loosen screws (3).
CAUTION
Document Handler rises quickly after lowering when Document Transport is removed.
b. Support bottom of Document Transport and remove it by pulling up and off mounting
screws.
Figure 1 Removing Document Transport