Xerox 1632 2240 3535 Color Carrera Manual

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4-57 DC1632/2240
REP 7.7, REP 7.8Repairs and Adjustments Prelaunch Training/Review
REP 7.7 Tray 4Parts 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. Pull out Tray 4.
2. Remove Tray 4 (Figure 1). 
a. Pull out Tray 4.
b. Remove Transport Screws (2).
c. Remove Tray Lock Screws (2).
d. Remove Tray Lock.
e. Pull out Tray 4 to remove it.
Figure 1 Removing Tray 4
REP 7.8 Tray 1Parts 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. Pull out Tray 1.
2. Lift end of tray to disengage lock on rail (not visible) and remove tray. 
Transport 
Screws (2)
Tray Lock
Tray 
Lock 
Screws 
(2) 
						

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4-58DC1632/2240
REP 7.9
Prelaunch Training/Review Repairs and Adjustments
REP 7.9 Tray 2Parts List on PL 16.2
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. Pull out Tray 2.
2. Lift end of tray to disengage lock on rail (not visible) and remove tray.  
						

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4-59 DC1632/2240
REP 7.10
Repairs and Adjustments Prelaunch Training/Review
REP 7.10  Tray 2 FeederParts List on 
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 2.
2. Remove the Left Lower Cover.  (PL 16.16)
3. Remove the Tray 2 Feeder (Figure 1).
Figure 1 Removing the Tray 2 Feeder
1Loosen 
Screw and 
move 
Bracket
2Release 
Wire Har-
ness from 
Clamp and 
disconnect 
P/J
3Remove 
Screws (2) 
and Feeder 
						

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4-60DC1632/2240
REP 7.11
Prelaunch Training/Review Repairs and Adjustments
REP 7.11 Tray 3 FeederParts List on 
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 Tray 2. 
2. Pull out Tray 3 and Tray 4.
3. Open the Left Cover. 
4. Remove the Lower Chute.
5. Remove the Tray 3 Feeder Assembly (Figure 1).
Figure 1 Removing the Tray 3 Feeder Assembly6. Remove the Tray 3 Feeder from mounting bracket (Figure 2). 
Figure 2 Removing Tray 3 Feeder from Bracket
1Remove 
Screws (2)
2Release Wire 
Harness and 
disconnect P/J
3Loosen 
Screw (1)
4Remove Screws 
(2) and Tray 3 
Feeder Assembly
Remove the 
Screws (2) 
and Bracket 
						

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4-61 DC1632/2240
REP 7.12
Repairs and Adjustments Prelaunch Training/Review
REP 7.12  Tray 4 FeederParts List on 
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 the Tray 2. 
2. Pull out the Tray 3/4.
3. Remove the Stud Bracket (Figure 1). 
Figure 1 Removing Stud Bracket4. Remove the Tray 4 Feeder Assembly (Figure 2). 
Figure 2 Removing the Tray 4 Feeder Assembly
Remove Screw 
and Bracket
1Disconnect 
P/J
2Loosen 
Screw
3Remove Screw and 
Feeder Assembly 
						

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4-62DC1632/2240
REP 7.12
Prelaunch Training/Review Repairs and Adjustments 5. Remove the Tray 4 Feeder Guides (Figure 3). 
Figure 3 Removing the Guides6. Remove Brackets from Tray 4 Feeder Assembly (Figure 4). 
Figure 4 Removing the Brackets
1Remove Screws (2) 
and Upper Guide
2Remove Screws (2) 
and Lower Guide
1Remove 
Screws (2) 
and Bracket
2Remove Screw 
and Bracket
3Remove Screw 
and Bracket 
						

							6/02
4-63 DC1632/2240
REP 8.1
Repairs and Adjustments Prelaunch Training/Review
REP 8.1 Left Cover AssemblyParts List on PL 2.9
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 14.2). 
2. Remove Power Switch Cover (REP 14.6).
3. Remove Upper Rear Left Cover (REP 14.4). 
4. Close Left Cover Assembly.
5. Remove Tray 5 (REP 7.1).
6. Remove Fuser Front Cover (REP 14.8). 
7. Disconnect Electrical Connectors (3) (Figure 1).
Figure 1 Disconnecting Electrical Connectors (3)
1Disconnect (3)
2Remove Screw 
and Cover
3Move Harnesses 
into this space 
						

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4-64DC1632/2240
REP 8.1
Prelaunch Training/Review Repairs and Adjustments 8. Remove Left Cover Assembly (Figure 2). 
Figure 2 Removing Left Cover Assembly
ReplacementInstall Left Cover Assembly on hinge pins, manually align marks on Motion Damper, then tip
up transport to engage Motion Damper gears and connect stop arm on Stop Pin (Figure 3). CAUTION
Before closing Left Cover Assembly to connect harness, hold up black plastic Duplex Baffle
while closing transport.
Figure 3 Aligning Marks on Motion Damper
1Remove Clip and 
disconnect Stop2Support Left Cover 
Assembly while per-
form steps 3 and 4  
3Remove 
Screw and 
lift up Stop 
Arm
4Lower Left Cover Assembly and then 
lift to disengage hinges and remove it
Hinge 
Pin
Marks on 
Motion 
Damper
Stop Pin 
						

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4-65 DC1632/2240
REP 8.2
Repairs and Adjustments Prelaunch Training/Review
REP 8.2 Duplex ChuteParts List on PL 2.8
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.
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 Cover Assembly.
5. Remove Tray 5 (REP 7.1).
6. Open and close Left Cover Assembly to allow Duplex Paper Guide to swing down. 
7. Swing Duplex Paper Guide back and forth while carefully pushing Duplex Paper Guide
toward rear.  Key in front hinge pin will enter hinge pin slot and front hinge pin will disen-
gage hinge pin hole.  Move Duplex Paper Guide toward front to disengage rear hinge pin.ReplacementInstall Left Cover Assembly on hinge pins, manually align marks on Motion Damper, then tip
up transport to engage Motion Damper gears and connect stop arm on Stop Pin (Figure 3). CAUTION
Before closing Left Cover Assembly to connect harness, hold up black plastic Duplex Baffle
while closing transport.
Figure 1 Aligning Marks on Motion Damper
Hinge 
Pin
Marks on 
Motion 
Damper
Stop Pin 
						

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REP 8.3, REP 8.5
Prelaunch Training/Review Repairs and Adjustments
REP 8.3 Duplex Transport AssemblyParts List on  PL 2.7 
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 Duplex Transport Assembly (Figure 1). 
a. Remove Clip and Left Upper Cover.
b. Loosen Screws and remove Duplex Transport Assembly.
Figure 1 Removing Duplex Transport AssemblyReplacement
REP 8.5 Inverter TransportParts List on PL 11.1 
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 Left Cover Assembly.
2. Remove Inverter Transport (Figure 1). 
a. Remove E-rings (2), Bearings (2), and Transport Shaft.
b. Remove Screws (2).
c. Remove Inverter Transport. 
Figure 1 Removing Inverter Transport
Screws 
(2)Le
ft Upper 
Cover Clip
Screw 
(1) Screw 
(1)
Inverter 
Transport
E-Ring and 
Bearing
E-Ring and 
Bearing
Transport 
Shaft