Xerox 1632 2240 3535 Color Carrera Manual

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REP 5.18
Repairs and Adjustments Prelaunch Training/Review
REP 5.18 Rear CoverParts List on PL 20.1 
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
LED harness breakage occurs if Rear Cover is removed without disconnecting LED plug
1. Loosen Screws (3) and remove Rear Cover enough to disconnect LED harness from
DADF Control PWB. 
						

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REP 5.19
Prelaunch Training/Review Repairs and Adjustments
REP 5.19 Platen BeltParts 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.
NOTE: After replacing Platen Belt, reset HFSI counter. Enter DC135 HFSI Counters Diag.
Screen (NVM 005-805).
WARNING
Switch off the power and disconnect power cord.
1. Remove Front Cover (PL 20.1).
2. Remove Document Transport (REP 5.17). 
3. Remove Platen Belt (Figure 2).
a. Loosen screws (2).
b. Move shaft support in direction of arrow.
c. Remove Platen Belt.
Figure 1 Removing Platen Belt
ReplacementNOTE: Lock shaft support by matching hole with frames detent (Figure 3).
Figure 2 Lock shaft support 
						

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REP 5.19
Repairs and Adjustments Prelaunch Training/Review NOTE: Make sure that both sides of Platen Belt are correctly set in pulley (Figure 4).
Figure 3 Install Platen Belt
1. Connect power cord and switch on power.
2. Enter DC330 [5-055].  Press START button and press the Stop button in 15 seconds.
Check the belt position.  If the belt has moved to either side,   
3. Rotate Platen Belt for 15 seconds. Press STOP button. Check the Belt position.  If the belt
moved to either side, check the installation of the Shaft Supports.
CORRECT
INCORRECT 
						

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REP 5.19
Prelaunch Training/Review Repairs and Adjustments 
						

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REP 6.1
Repairs and Adjustments Prelaunch Training/Review
REP 6.1 ROSParts List on PL 3.1
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 Rear Cover (REP 14.2).
CAUTION
Image quality defects result if covers on ROS cleaning openings are removed.
3. Remove ROS (Figure 1).
a. Carefully observe position of wiring harness for later reinstallation.
b. Remove Harness from Harness Clips.
c. Disconnect Harness P/Jís (2).
d. Remove Screws (2).
e. Pull out ROS to remove it.
Figure 1 Removing ROSReplacementAfter machine reassembly perform following:
1. DC956 Belt Edge. 
2. DC685 Color Registration Control (ADJ 9.6).
Harness Clips
P/Jís
Screws (2) 
						

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REP 6.2
Prelaunch Training/Review Repairs and Adjustments
REP 6.2 Platen GlassParts List on PL 18.3 
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 DADF.
2. Remove Platen Glass (Figure 1).
Figure 1 Removing Platen Glass
ReplacementNOTE: Press Platen Glass in direction of arrow A; Press Right Side Plate in direction of arrow
B (Figure 2).
Figure 2 Positioning Platen Glass
1Remove 
screws (2)
2Remove 
Guide3Remove 
Platen 
Glass 
						

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REP 6.3, REP 6.4Repairs and Adjustments Prelaunch Training/Review
REP 6.3  IIT Top CoverRemoval
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 DADF (REP 5.1). 
2. Remove Screws (2) from top front of IIT Top Cover.
3. Loosen Screws (2) under Control Panel, each end.
4. Remove Screw from rear of IIT Top Cover, left side.
5. Remove Document Output Tray.
6. Remove Document Output Tray support bracket Screws (4) and Brackets (2).
7. Lift IIT Top Cover to access harness connectors (2).  Disconnect P/Jís and remove IIT Top
Cover.
REP 6.4 Lens KitParts List on PL 18.4
Removal1. Remove Platen Glass (REP 6.2). 
CAUTION
In the following, do not remove any red screws.
2. Remove the Lens/CCD Chassis (Figure 1).
a. Mark the position of the APS Sensor bracket.
b. Remove the Screw (1) and the APS Sensor with bracket.
c. Remove Lens Cover Screws (6) and Lens Cover.
d. Disconnect CCD Connector (not shown).
e. Remove Lens/CCD Chassis Screws (4) and remove Lens/CCD Chassis.
Figure 1 Removing Lens CoverReplacementNOTE: Align APS Sensor with marks made in step 2a before tightning screw.
NOTE: Perform DC945 IIT Calibration (ADJ 9.7).
APS Sen-
sor Bracket 
and Screw
Lens Cover 
Screws (3)
Lens Cover 
Screws (3)
Lens/CCD 
Chassis 
Screws (2)
Lens/CCD 
Chassis 
Screws (2) 
						

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REP 6.11
Prelaunch Training/Review Repairs and Adjustments
REP 6.11 Carriage CablesParts List on PL 18.5
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.
NOTE: This page describes how to remove Rear Carriage Cable.
NOTE: Do not replace both cables at same time. Remove front and rear cables separately.
1. Remove DADF (REP 5.1).
2. Remove Platen Glass (REP 6.1).
3. Remove IIT Top Cover (REP 6.3).
4. DADF machines: Remove registration gate and plate (Figure 1).
a. 1. Remove screws (2).
b. 2. Remove Registration Gate.
c. 3. Remove screws (2).
d. 4. Remove plate.
Figure 1 Removing Registration Gate and Plate
5. Remove Full Rate Carriage from IIT Frame (REP 6.14). Keep lamp wire harness connec-
tor connected.6. Move Half Rate Carriage so that position of Carriage Cable Ball on Capstan is one of fol-
lowing: (Figure 2).
ï Two Carriage Cable Rolls in front and rear.
ï Carriage Cable Ball is directly above.
Figure 2 Positioning Half Rate Carriage 
						

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REP 6.11
Repairs and Adjustments Prelaunch Training/Review 7. Remove Carriage Cable (Figure 3).
a. Remove spring.
b. Separate spring and cable.
c. Pull out ball from hole.
d. Remove cable.
Figure 3 Removing Carriage Cable
Replacement1. Wind Carriage Cable into pulley (Figure 4).
a. Insert Carriage Cable Ball into groove of pulley. 
Figure 4 Winding Carriage Cable 
						

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REP 6.11
Prelaunch Training/Review Repairs and Adjustmentsb.  Wind cable (spring hook side) onto pulley for 2.5 turns.  Tape and lock cable (on
spring hook) on frame (Figure 5).
Figure 5 Locking Cablec. Wind cable (ball side) onto pulley for 2.4 turns.  Tape and lock cable wound on pulley
(Figure 6).
Figure 6 Locking Cable