Xerox 1632 2240 3535 Color Carrera Manual

							6/02
4-87 DC1632/2240
REP 9.22
Repairs and Adjustments Prelaunch Training/Review 11. Pull out BUR ROLL Housing from Hole below and move it in arrow direction (Figure 8)
a. Pull Housing.
b. Turn Housing to move it.
Figure 8 Pulling Out BUR Roll Housing
12. Remove Transfer Belt (Figure 9)Figure 9 Removing Transfer Belt 
						

							6/02
4-88DC1632/2240
REP 9.22
Prelaunch Training/Review Repairs and Adjustments
Replacement1. Install Transfer Belt with Reflector at rear (Figure 10). 
Figure 10 Installing Transfer Belt 2. After installing Transfer Belt, move it to center of IBT Frame (exposed parts of IBT Drive
Roll are same at In and Out sides) (Figure 11). 
Figure 11 Positioning Transfer Belt
Reflector 
						

							6/02
4-89 DC1632/2240
REP 9.22
Repairs and Adjustments Prelaunch Training/Review 3. If Transfer Belt is skewed or wrinkled, perform following steps:  (Figure 12)
a. Relax tension of Belt. 
b. Rotate Gear in arrow direction and move Transfer Belt.
Figure 12 Re-positioning Transfer Belt 
						

							6/02
4-90DC1632/2240
REP 9.23, REP 9.24
Prelaunch Training/Review Repairs and Adjustments
REP 9.23  1st BTR RollParts List on PL 5.4
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. Open Front Cover.
2. Release and move Xerographic Release Lever down.
3. Open Right Side Door. 
4. Remove IBT Assembly (REP 9.15). 
5. Remove Transfer Belt (REP 9.22). 
6. Remove 1st BTR Roll (Figure 1). 
Figure 1 Removing 1st BTR Roll
REP 9.24 2nd BTR RollParts 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 2nd BTR (Figure 1). 
a. Open Left Cover Assembly.
b. Remove Screws (4).
c. Remove 2nd BTR  with Support Brackets
Figure 1 Removing 2nd BTR
1Remove 
Screw
2Remove 
Support and 
1st BTR Roll
NOTE: Front 
axle is long-
est
Front 
Axle
Screws 
(2) Screws (2)
Transfer Roll 
Assembly
Support 
Bracket
Support 
Bracket 
						

							6/02
4-91 DC1632/2240
REP 9.26
Repairs and Adjustments Prelaunch Training/Review
REP 9.26 ATC SensorParts List on PL 6.2 
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 Front Cover (REP 14.7).
2. Remove Drum Cartridges.
3. Remove Waste Cartridge (REP 9.4). 
4. Remove Waste Cartridge Cover (REP 9.3). 
5. Remove Fuser Front Cover (REP 14.8). 
6. Release and move Xerographic Release Lever half way down.
7. Remove Dispenser Assembly Cover (REP 9.6).
8. Remove all Dispenser Assemblies (REP 9.7). 
NOTE: In next step, do not remove sensor.
9. Remove housing for Waste Cartridge Full Sensor (REP 9.5).  
NOTE: In next step, it may not be necessary to disconnect harnesses for Plate Assembly (PL
4.2) to remove a developer housing.
10. Remove Plate Assembly (REP 9.8). 
11. Remove Developer Housing (REP 9.9). 
12. Release Harness from Harness Clips (Figure 1).
Figure 1 Removing Harness form Clips13. Remove ATC Sensor (Figure 2).
Figure 2 Removing ATC Sensor
2Release Tab and 
remove wires
3Lift Tab and remove wires
1Carefully notice posi-
tion of wires
1Lift Lock 
and move 
end away 
from Tab
2Remove Seal 
from under 
Sensor 
						

							6/02
4-92DC1632/2240
REP 9.26
Prelaunch Training/Review Repairs and Adjustments
ReplacementNOTE: Remove ATC Sensor Setup Data Tag from new sensor.  On tag, highlight K, C, M, or Y
as required for color of developer housing.  Raise Xerographic Release Lever and install Tag in
position shown (Figure 3). 
Figure 3 Installing ATC Sensor Setup Data Tag
NOTE: Perform dC921 ATC Sensor Setup (ADJ 9.2). 
1Raise Xerographic 
Release Lever
2Position Tag in correct location Tag with K 
highlighted
Tag with C 
highlightedTag with M 
highlightedTag with Y 
highlighted 
						

							6/02
4-93 DC1632/2240
REP 9.27
Repairs and Adjustments Prelaunch Training/Review
REP 9.27 Retract ShaftParts List on PL 5.4
ReplacementNOTE: Cam and Flag must be aligned as shown, both on the same side (Figure 1).
Figure 1 Cam and Flag Alignment
Correct 
Alignment Incorrect 
Alignment 
						

							6/02
4-94DC1632/2240
REP 9.27
Prelaunch Training/Review Repairs and Adjustments 
						

							6/02
4-95 DC1632/2240
REP 10.1, REP 10.2
Repairs and Adjustments Prelaunch Training/Review
REP 10.1 FuserParts List on PL 7.1
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.
WARNING
Personal injury may result from grasping hot areas of Fuser Module. If a hot Fuser Mod-
ule must be removed, grasp Fuser Module by black plastic frame component, shown in
figure (Figure 1). 
CAUTION
Damage to work surface may result if a hot Fuser Module is removed and positioned on an
unprotected work surface. Place a hot fuser on ten sheets of paper.
1. Open Left Cover Assembly.
2. Remove Fuser Module (Figure 1).
a. Loosen Screws (2). (PL 1.1) 
WARNING
If machine was making copies within 30 minutes, Fuser Module is hot. Grasp
Fuser Module using Grip Rings.
b. Use Grip Rings to pull Fuser Module out.
Figure 1 Removing Fuser Module
REP 10.2 Fuser FanParts List on PL 8.1
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.
WARNING
Personal injury may result from grasping hot areas of Fuser Module. If a hot Fuser Mod-
ule must be removed, grasp Fuser Module by black plastic frame component, shown in
figure (Figure 1). 
CAUTION
Damage to work surface may result if a hot Fuser Module is removed and positioned on an
unprotected work surface. Place a hot fuser on ten sheets of paper.
1. Open Front Cover.
2. Remove Right Cover (REP 14.3). 
3. Remove Top Cover (REP 14.1). 
4. Remove Rear Cover (REP 14.2). 
5. Remove Fuser Cooling Fan (Figure 1).
a. Disconnect P/J.
b. Remove Screws (2) and lift to remove Fuser Cooling Fan.
Figure 1 Removing Fuser Cooling Fan
Grip Rings
Screws (2)
P/J
Screws (2) 
						

							6/02
4-96DC1632/2240
REP 10.3
Prelaunch Training/Review Repairs and Adjustments
REP 10.3  Main/Sub Heater RodParts List on PL 7.2
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 the Fuser Assembly (REP 10.1).
2. Remove the following parts:
ï Front Cover (REP 14.7)
ï Handle (PL 7.2)
ï Rear Cover (PL 7.2)
ï Handle (PL 7.2)
3. Disconnect P/Jís (2) at rear of Fuser (Figure 1). 
Figure 1 Disconnecting Connectors4. Prepare Fuser at front  (Figure 2). 
Figure 2 Preparing Fuser at Front
Disconnect 
P/Jís (2)
2Remove Screw 
and Heat Rod 
Support1Disconnect 
P/Jís (2)