Xerox 1632 2240 3535 Color Carrera Manual

							6/02
4-147 DC1632/2240
REP 14.7, REP 14.8
Repairs and Adjustments Prelaunch Training/ReviewFigure 1 Removing Front Cover
REP 14.8 Fuser CoverParts List on PL 10.2
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. Open Front Cover.
2. Remove Fuser Cover (Figure ).
a. Remove Screws (2).
b. Move cover up to release Hidden Tabs (3) and pull out to remove cover.
Figure 1 Removing Fuser Cover
Support 
Str a p
Hinge Pin 
:Locks
Hidden 
Tabs 
						

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4-148DC1632/2240
REP 14.9, REP 14.10
Prelaunch Training/Review Repairs and Adjustments
REP 14.9 Rear CoverParts List on PL 16.16
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 Thumbscrews (4).
2. Remove Screws (4) and remove Lower Rear Cover.
REP 14.10 Inner CoverParts 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.
1. Open Front Cover.
2. Remove Fuser Front Cover (REP 14.8).
3. Remove Waste Cartridge Cover (REP 9.3). 
4. Remove Inner Cover (Figure 1).
a. Open Harness Clip and remove harness from Clip.
b. Remove Screw and remove Harness Cover.
Figure 1 Removing Inner Cover
Harness Clip
Inner 
CoverScrew 
						

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4-149 DC1632/2240
REP 14.11, REP 14.12
Repairs and Adjustments Prelaunch Training/Review
REP 14.11 Left Cover AssemblyParts List on PL 16.13
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 Lower Cover (REP 14.12). 
2. Remove Left Cover Assembly (Figure 1).
a. Remove Screws (2) and Straps (2) from frame.
b. Remove Screw (1) and Pivot Support and remove Left Cover Assembly.
Figure 1 Removing Left Cover Assembly
REP 14.12 Lower CoverParts List on PL 16.16
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 Lower Cover (Figure 1).
a. Remove Screws (4).
b. Open Left Cover Assembly.
c. Remove Lower Cover.
Figure 1 Removing Lower Cover
Left Cover 
Assembly
1Remove 
Screws (2)
Screws (2) 
						

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4-150DC1632/2240
REP 14.11, REP 14.12
Prelaunch Training/Review Repairs and Adjustments 
						

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4-151 DC1632/2240
ADJ 5.1
Repairs and Adjustments Prelaunch Training/Review
ADJ 5.1  DADF Side RegistrationPurposeAlign image scanned from document with left side edge of paper. Check1. Make two copies from the Platen Glass to be used as DADF originals. 
a. Register Test Chart 82E8220 on Platen with side edge metrics SE1 through SE4
against rear registration guide.
b. Select the following:
ï 1 to 1 sided 
ï A3 or 11 x 17 Paper Supply
ï 100% Reduce/Enlarge
ï 2 Copies
c. Press Start and write DADF Original 1 on first copy and DADF Original 2 on second
copy.
2. Verify side edge registration of DADF Originals.
a. On DADF Original 2 measure and record the distance between the side edge and
the reference line and write A next to this measurement (Figure 1).
b. Check that A is 10.0 ±0.5mm.  If A is 10.0 ±0.5 mm, go to step 3. 
If A is not 10.0 ±0.5 mm, check both of the following and then return to the beginning
of this procedure.
i. DC129 IOT Lead Edge/Side Edge Registration (ADJ 9.9). 
ii. IIT Side Edge Registration (ADJ 9.11)
Figure 1 Verifying Side Edge Registration of DADF Originals
3. Check DADF Side Edge Registration for Side 1.
a. Load both DADF Originals in DADF, 1 on top, with side edge metrics SE1 through
SE4 against rear registration guide.  Check that side guide touches documents.
b. Select the following:ï 1 to 1-sided
ï A3 or 11 x 17 Paper Supply
ï 100% Reduce/Enlarge
ï 2 Copies
c. Press Start and discard the first copy.
d. On side 1 of copy 2 measure and record the distance between the side edge and the
reference line and write B next to this measurement (Figure 2).
Figure 2 Checking Side Edge Registration of DADF
e. Compare B to A.  B must be within ±1.1 mm of A.
If the difference between B and A is greater than 1.1 mm, go to step 1 of the adjust-
ment.
Otherwise go to step 4.
4. Check DADF Side Edge Registration for Side 2.
a. Make a 2-sided test pattern.
i. Load DADF originals 1 and 2 face up, 1 on top, with side edge metrics toward
rear of DADF.
ii. Select 1 to 2-sided and press Start to make the 2-sided test pattern
b. Make test copies.
i. Load 2-sided test pattern with side 1 edge metrics up and toward rear of DADF. 
ii. Select the following:
ï 2 to 1 sided
ï A3 or 11 x 17 Paper Supply
ï 100% Reduce/Enlarge
ï 1 Copy
iii. Press the Start button.
c. Check that side edge metrics are same distance from edge of paper for both copies.
If the difference is greater than ±1.1 mm, go to step 2 of the adjustment.
Otherwise DADF Side Registration is good.
Paper 
Feed 
Direction
AManually 
labeled 2Edge of 
Copy10.0 
±0.5m
m
Paper 
Feed 
Direction
Edge of 
Copy
B 
						

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4-152DC1632/2240
ADJ 5.1
Prelaunch Training/Review Repairs and Adjustments
Adjustment1. Adjust Side 1 DADF Side Registration.
a. Enter NVM Rear/Write (DC131) [715-015].
NOTE: Increasing value moves side edge metrics SE1 through SE4 toward edge.
b. If B is more than A, increase the NVM value (15 = approx. 1 mm).
If B is less than A, decrease the NVM value (15 = approx. 1 mm).
c. Check results of adjustment and adjust if required.
2. Adjust Side 2 DADF Side Registration.
a. Enter NVM Rear/Write (DC131) [715-128].
NOTE: Increasing value moves side edge metrics SE1 through SE4 toward edge.
b. If copy 2 edge metric is farther away from edge than copy 1, increase the NVM value
(15 = approx. 1 mm).
If copy 2 edge metric is closer to edge than copy 1, decrease the NVM value (15 =
approx. 1 mm).
c. Check results of adjustment and adjust as required. 
NOTE: 2 to 2-sided or 2 to 1-sided must be selected to view a change in [715-128].
[715-128] produces no change in 1 to 2-sided copying.
NOTE: Total lead edge deviation for DADF is  ±1.6 mm.  Total lead edge deviation for IIt is ±0.5
mm.  This leaves ±1.1 mm for DADF when a copy paper test pattern is made for use in DADF. 
						

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4-153 DC1632/2240
ADJ 5.2
Repairs and Adjustments Prelaunch Training/Review
ADJ 5.2  DADF CounterbalancePurposeCorrect DADF opening and closing action.Check1. Check DADF opening and closing action.
a. Raise DADF and check that it remains in fully raised position.
b. Check that the DADF closes from a height of 100 ±50mm by its own weight without
excessive noise (Figure 1). 
Figure 1 Checking DADF Height
Adjustment
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
When removing the Rear Cover, disconnect LED Connector on DADF PWB.
1. Remove the Rear Cover.  (REP 5.18)
2. Adjust the Left Counterbalance  (Figure 2).
NOTE: Rotate in A direction for stronger spring pressure
Rotate in B direction for weaker spring pressure
a. Loosen the nut.
b. Rotate the Set Screw for the adjustment.
c. Tighten the nut.
Figure 2 Adjusting Left Counterbalance
100 mm +/- 50 mm
A
B 
						

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4-154DC1632/2240
ADJ 5.3
Prelaunch Training/Review Repairs and Adjustments
ADJ 5.3  DADF ParallelismPurposeEnable parallel Document placement and image scan.Check
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 Entrance Tray.  (PL 20.1)
3. Remove the Document Transport.  (REP 5.17 )
4. Check DADF Parallelism.
a. Manually hold down the DADF.
b. Check that the distance between the DADF Rear Frame and the Rear Registration
Edge  is 20 ±1 mm (Figure 1).
c. Perform the same check at the left end of the DADF.
If 20 ±1 mm is not measured in each check, or the measurements are different, go to
the adjustment.
Otherwise DADF Parallelism is good.
Figure 1 Checking DADF Parallelism
Adjustment
CAUTION
The DADF Parallelism must be made within ±1mm of the specified range. 
CAUTION
When removing the Rear Cover, disconnect LED Connector on DADF PWB.
1. Remove Rear Cover (REP 5.18). 
2. Adjust DADF Parallelism (Figure 2).
Figure 2 Adjusting DADF Parallelism
3. Adjust Left Counterbalance if required.
4. Repeat the check.
DADF Rear Frame20 mm
Rear Regis-
tration Edge
Scale
Right End 
of DADF
DADF Moves 
to Rear
DADF Moves 
to Front
1Loosen 
Screws (4)
2Loosen 
Screws (2)
3Adjust Screw
4Tighten 
Screws (6) 
						

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4-155 DC1632/2240
ADJ 5.4
Repairs and Adjustments Prelaunch Training/Review
ADJ 5.4  Document Transport  HeightPurposeEnable document feed at the correct speed and free of skew.Check
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. Entrance Tray (PL 20.1).
3. Check Document Transport Height (Figure 1).
a. At left end of Document Transport, check that there is 24.5 ±0.3 mm between top of
Document Transport Frame and Top of Rear Registration Edge.
b. At Right end of Document Transport, check that there is 24.5 ±0.3 mm between top
of Document Transport Frame and Top of Rear Registration Edge.
c. If there is more or less than specified, perform the adjustment on the counterbalance
for the side that is not in specification.  Adjust both counterbalances if required.
Otherwise, Document Transport Height is good.
Figure 1 Checking Document Transport Height
Adjustment
CAUTION
When removing the Rear Cover, disconnect LED Connector on DADF PWB.
1. Remove Rear Cover (REP 5.18). 
2. Raise DADF and loosen the Screws (2) (Figure 2). 
Figure 2 Loosening Screws
Document Transport Frame
To p  o f  
Rear Reg-
istration 
Edge
24.5 ±0.3 mm
Left End of Document Transport
Right End of 
Document 
Transport
Screws 
						

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4-156DC1632/2240
ADJ 5.4
Prelaunch Training/Review Repairs and Adjustments 3. Adjust Document Transport Height (Figure 3). 
Figure 3 Adjusting Document Transport Height
4. Repeat check.
Lower Document 
Transport Frame
Raise Docu-
ment Trans-
port Frame
2Adjust 
Screw
!Lower DADF
3Raise 
DADF
4Tighten 
Screws