Xerox 1632 2240 3535 Color Carrera Manual

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REP 6.11
Repairs and Adjustments Prelaunch Training/Reviewd. Check orientation of ends and number of carriage cable windings (front/rear) (Figure
7).  Reconfigure as required.
Figure 7 Carriage Cable Windings2. Install Carriage Cable (ball side) (Figure 8).
a. Hook cable to pulley (from bottom to top).
b. Hook cable to large pulley in Half Rate Carriage (from top to bottom).
c. Insert ball into frame hole.
Figure 8 Installing Carriage Cable (ball side) 
						

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REP 6.11
Prelaunch Training/Review Repairs and Adjustments 3. Install Carriage Cable (spring hook side) (Figure 9).
a. Hook cable to pulley (from bottom to top).
b. Hook cable to small pulley in Half Rate Carriage (from bottom to top).
c. Hook cable to stud (from bottom to top).
d. Install spring on cable (spring hook side).
e. Hook spring onto frame.
Figure 9 Installing Carriage Cable (spring hook side)4. Remove tape from cable.
5. Install Full Rate Carriage in IIT Frame.
6. Adjust positions of Full Rate/Half Rate Carriages (ADJ 6.1). 
7. Manually move Full Rate Carriage to make sure it moves smoothly.
8. Install remaining parts. 
						

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REP 6.12
Repairs and Adjustments Prelaunch Training/Review
REP 6.12 Carriage MotorParts 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.
1. Remove DADF (REP 5.1).
2. Remove Platen Glass (REP 6.2).
3. Remove IIT Top Cover (REP 6.3).
4. Remove Carriage Motor (Figure 1).
a. Release clamps (2).
b. Disconnect connector.
c. Remove screws (3).
d. Remove spring.
e. Remove Carriage Motor.
Figure 1 Removing Carriage Motor 
						

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REP 6.13
Prelaunch Training/Review Repairs and Adjustments
REP 6.13 Exposure LampParts List on PL 18.6
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.
CAUTION
Avoid touching exposure lamp with your bare hands during removal or installation. Oil from
your hands will contaminate surface of lamp. 
1. Open DADF (REP 5.1).
2. Remove Platen Glass (REP 6.2).
3. Move Full Rate Carriage to frame notch.
4. Remove Exposure Lamp (Figure 1).
a. Disconnect connector.
b. Remove screw.
c. Remove Exposure Lamp.
Figure 1 Removing Exposure Lamp 
						

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REP 6.14
Repairs and Adjustments Prelaunch Training/Review
REP 6.14 Lamp Wire HarnessParts List on PL 18.6
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 DADF (REP 5.1).
2. Remove Platen Glass (REP 6.2).
3. Remove IIT Top Cover (REP 6.3).
4. Disconnect Lamp Wire Harness connector and release Clamp Hook (Figure 1).
a. Disconnect connector.
b. Release clamp.
c. Remove clamp.
d. Release hook.
Figure 1 Disconnecting Lamp Wire Harness5. Remove Full Rate Carriage (Figure 2).
a. Remove screws (2).
b. Remove Full Rate Carriage.
Figure 2 Removing Full Rate Carriage 
						

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REP 6.14
Prelaunch Training/Review Repairs and Adjustments 6. Remove Lamp Wire Harness from Full Rate Carriage (Figure 3).
a. Flip Full Rate Carriage.
b. Remove screw.
c. Remove guide.
d. Disconnect connector.
e. Remove Lamp Wire Harness.
Figure 3 Removing Lamp Wire Harness
ReplacementNOTE: After reinstalling parts, adjust positions of Full Rate/Half Rate Carriages (ADJ 6.1).  
						

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REP 7.1
Repairs and Adjustments Prelaunch Training/Review
REP 7.1 Tray 5Parts List on PL 2.2
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 Power Switch Cover (REP 14.6).
3. Remove Upper Rear Left Cover (REP 14.4). 
4. Close Left Door Transport.
5. Remove Tray 5 (Figure 1). 
a. Observe position of harness for later reinstallation.
b. Disconnect Tray 5 connector.
c. Disconnect harness Clip from frame.
d. Remove Screws (2).
e. Pull out Tray 5 while applying a small amount of lifting force to right side.
Figure 1 Removing Tray 5Replacement
CAUTION
Duplex Paper Guide must be in up position before installing Tray 5.  
1. Open Left Door Transport.  Pivot and hold Duplex Paper Guide against Left Door Trans-
port and then close Left Door Transport.2. Install Tray 5.
HarnessClipScrews (2) 
						

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REP 7.2
Prelaunch Training/Review Repairs and Adjustments
REP 7.2 Tray 5 Feed RollParts List on PL 2.14
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 Power Switch Cover (REP 14.6).
3. Remove Upper Rear Left Cover (REP 14.4). 
4. Close Left Door Transport.
5. Remove Tray 5 (REP 7.1). 
6. Remove Chute (Figure 1). 
a. Remove Screws (3).
b. Lift to remove Chute.
Figure 1 Removing Chute
7. Remove Feed Roll (Figure 2). 
a. Release Locking Tab from groove on shaft and slide Lock Roll away from Feed Roll.
b. Slide Feed Roll to disengage drive pin and remove Feed Roll.Figure 2 Removing Feed Roll
ReplacementEnsure Arrow is positioned as shown (Figure 3). 
Figure 3 Installing Feed Roll
Screws (3)
Chute
Locking 
Ta bLock Roll
Feed 
RollArrow 
						

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REP 7.3, REP 7.4Repairs and Adjustments Prelaunch Training/Review
REP 7.3 Tray 1 FeederParts List on PL 2.3
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. Pull out Tray 1 to paper loading position.
2. Open Tray 1 Left Door. 
3. Remove Tray 1 Feeder (Figure 1). 
Figure 1 Removing Tray 1 Feeder
REP 7.4 Tray 1 Feed/Lift MotorParts List on PL 2.4
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. Pull out Tray 1 to paper loading position.
2. Open Tray 1 Left Door. 
3. Remove Tray 1 Feeder (REP 7.3). 
4. Remove Tray 1 Feed Motor (Figure 1). 
Figure 1 Removing Tray 1 Feed Motor
1Disconnect 
Harness2Remove 
Screws (2)
3Remove 
Feeder
Remove Screws 
(2) and motor 
						

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REP 7.5, REP 7.6
Prelaunch Training/Review Repairs and Adjustments
REP 7.5 Tray 1 Paper Size SensorParts List on PL 2.1
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 (REP 4.3).
6. Remove Tray 1 Paper Size Switch (Figure 1).
a. Disconnect P/J.
b. Remove Screws (2) and remove Tray 1 Paper Size Switch.
Figure 1 Removing Tray Paper Size Switch
REP 7.6 Tray 3Parts List on PL 16.1
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. Open HCF Left Door. 
2. Remove Tray 3 (Figure 1).
a. Pull out Tray 3.
b. Remove Screw.
c. Pivot bottom of Tray Lock away from Tray 3 and pull out Tray 3 to remove it.
Figure 1 Removing Tray 3
P/J
Screws (2)
ScrewBottom of 
Tray Lock