Xerox 1632 2240 3535 Color Carrera Manual

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ADJ 9.5
Repairs and Adjustments Prelaunch Training/Review
ADJ 9.5  TRC Adjust (dC924)Purpose
CAUTION
Perform this adjustment only to correct a strong customer complaint. Altering the setpoints will
affect both Print and Copy modes. Also, there is quite a bit of overlap among the low, medium,
and high densities. For these reasons, it is recommended that this procedure not be used
unless absolutely necessary.
To adjust image quality (TRC) to meet the users preference, by increasing or decreasing the
center value of gradation correction for each (YMCK) color, in low density, medium density, and
high density ranges. 
Adjustment1. Connect the PWS to the machine and enter Diagnostic Mode (refer to Entering Diagnostic
Mode using the PWS). 
2. Under the Adjustments tab, select Max Setup.
3. Select the TRC Adjust tab.
4. Type in the desired value; the default is 128, and the range is from 0 to 255.  the results
on the screen.
5. Select Save.
6. Perform a Temporary Call Closeout, then switch the machine power off then on
7. Make 2 prints or copies; the changes are not implemented until the 2nd print is made.
8. Repeat steps 4 through 7 until the customer is satisfied with the image quality. 
						

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ADJ 9.6
Prelaunch Training/Review Repairs and Adjustments
ADJ 9.6   Color Registration (dC685)PurposeTo establish correct horizontal and vertical positioning of the four primary color images
The procedure consists of the following steps, which must be performed in the listed sequence:
1.Belt Edge Learn  - to align the Transfer Belt positioning system.
2.Fine Skew Setup - automatically performs horizontal and vertical alignment, and reports
any skew in the various images caused by ROS misalignment. This skew must be cor-
rected through manual adjustment 
3.IN/OUT Setup - automatically performs magnification adjustment so that scan lines are
the same length for all four colors. Also checks for skew.
4.Center Setup - Aligns the midpoints of  scan lines for all colors, for magnification balance.
There is also a Rough Skew Setup for cases where the skew is outside the measurement
parameters of the Fine Skew test.
This procedure is required if any of the following occur:
ï ROS removal
ï NVM Initialization
ï An Image Quality RAP directed performance of this procedure.CheckNOTE: Excessive toner on the Transfer Belt will prevent completion of the adjustment. Make
sure that there are no Image Quality problems, and that the IBT Cleaner is functioning cor-
rectly. Resolve any Image Quality problems before attempting this adjustment.
1. Open the Front door and cheat the interlock.
2. Connect the PWS to the machine and enter Diagnostic Mode (refer to Entering Diagnostic
Mode using the PWS). 
3. Under the Adjustments tab, select RegiCon.
Set the Belt Edge Alignment
1. Select the Belt Edge Learn Mode tab.
2. Select the Edge Learn Mode button.
3. Select Start.
4. If Edge Learn fails, check: 
ï Installation of IBT Belt Assembly (REP 9.15). 
ï Installation of IBT Edge Sensor (PL 5.4).
ï Installation of IBT Home Sensor (PL 5.4). 
Perform Edge Learn again. If it fails, replace the IBT Edge Sensor (PL 5.4).
If it fails again, replace IBT Home Sensor (PL 5.4).
5. When Edge Learn is successful, select the RegiCon Setup Cycle (dC685) tab.
Check the Fine Skew Setup
1. Select the Skew (Fine) Setup button.
2. Select Start.3. Check the Judgement window. If NG is displayed, perform the Rough Skew Setup then
repeat the Fine Skew check.
4. If OK is displayed in the Judgement window, check the Skew Correction row in the
Skew Values window. If a value greater than 1 is displayed for any color, perform the
Adjustment, then perform the IN/OUT Setup check.
 
Check the IN/OUT Setup
1. Select the IN/OUT Setup button.
2. Select Start
3. Check the Judgement window. If NG is displayed, perform the Adjustment, then perform
the Center Registration check
4. If IN/OUT Setup is OK, check the Center Registration. 
 
Check the Center Registration
1. Remove the Waste Toner Cartridge.
2. Move MOB sensor to the center position (Figure 1).
Figure 1 Moving MOB Sensor to Center Position
3. Reinstall the Waste Toner Cartridge.
1Remove 
Screw
2Remove 
Cleaning 
Tool from 
Front Cover
3Pull out MOB 
Sensor slightly 
with needle nose 
pliers (pliers not 
shown). 
Hook end of 
Cleaning Tool to 
MOB Sensor.
4Push in MOB Sensor until sensor stops.
Tool will be positioned as shown (Stop Tab 
on tool should be flush with frame).5Remove ToolNOTE:
Stop Tab
NOTE:
Stop Tab 
						

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ADJ 9.6
Repairs and Adjustments Prelaunch Training/Review 4. Select the Center Setup button.
5. Select Start.
CAUTION
Make sure not to hook the wiring harness when moving the MOB Sensor.
6. If Center Setup is OK, dC685 is complete. Use the Cleaning Tool to pull the MOB Sensor
back to the original position, and fasten the screw. 
If Center Setup fails, ensure MOB Sensor is positioned to the rear. Go back to step 1 of
the Center check.
 
Check the Rough Skew Setup
1. Select the Skew (Rough) Setup button.
2. Select Start.
3. Check the Judgement window. If NG is displayed, there is a problem with the ROS, the
IBT Assembly, or the MOB Sensor.
4. If OK is displayed in the Judgement window, check the Skew Correction row in the
Skew Values window. If a value greater than 1 is displayed for any color, perform the
Adjustment, then repeat the Fine Skew Setup check.
 
Adjustment1. In the Skew Values window, record  the value for each color  in the Skew Correction
row. This is the required number of rotations of the adjustment screw. 
WARNING
To avoid exposure to laser light, reinstall the Waste Cartridge before attempting to
recheck the adjustment. 
2. Remove the Waste Toner Cartridge (REP 9.4). 
3. For each color, rotate the appropriate (CYMK) adjustment screw (Figure 2) in + (CW), or -
(CCW) direction the number of clicks recorded in step 1. Figure 2 Adjusting Skew
4. Reinstall Waste Toner Cartridge (REP 9.4). 
Check IOT Lead Edge/Side Edge (ADJ 9.9) after performing this adjustment. 
						

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ADJ 9.7, ADJ 9.8
Prelaunch Training/Review Repairs and Adjustments
ADJ 9.7   IIT Calibration (dC945)Purposeï To calculate and set up the White Reference Correction Coefficient. 
ï To correct the IIT sensitivity dispersion (CCD Calibration).
ï Adjust the light axis correction data when replacing the Lens unit.Adjustment1. Clean the Optics:
a. Switch off the power and allow the Exposure Lamp to cool off.
b. Using the optical Cleaning Cloth, clean the front and rear of the Document Glass,
Document Cover, White Reference Strip, Reflector, and Mirror. 
c. Clean the Exposure Lamp with a clean cloth and Film Remover.
d. Clean the Lens with Lens and Mirror Cleaner and lint free cloth. 
2. Connect the PWS to the machine and enter Diagnostic Mode (refer to Entering Diagnostic
Mode using the PWS). 
3. Under the Adjustments tab, select Max Setup.
4. Select the IIT Calibration  tab.
5. Select  the White Reference Adjustment button. 
6. Press Start.
7. Follow the instructions on the PWS screen, then select OK. 
8. Select the Read button.
9. The setup values are displayed on the White Reference Setup Value screen.
10. When White Reference setup is done, select the CCD Calibration button.
11 . P r e s s  Start.
12. Follow the instructions on the screen, then select OK.
13. The obtained data is displayed in the b* Calibration Coefficients window.
14. Select [Close] to return to the Color Image Quality Adjustment screen.
NOTE: Do not select Optical Axis Calibration unless replacing the Lens Kit (PL 18.4). Refer to
REP 6.4.
ADJ 9.8  Hard Disk Diagnostics/Setup (dC355)Purpose
CAUTION
This  procedure does not work as described  in the current tool; the spec is being rewritten.
This  description is an attempt to document the new spec. DO NOT USE.
To perform the diagnostics in the hard disk and setup (initialization) of each partition. 
NOTE: Perform this procedure only after the customers approval is obtained.  Check what
kind of data are stored in each partition according to the list below since some partitions store
fonts etc. that the customer has installed.
NOTE: Setup function is only available from customers mode or UI-Diag mode in Partition A.
Adjustment1. Connect the PWS to the machine and enter Diagnostic Mode (refer to Entering Diagnostic
Mode using the PWS). 
2. Under the Diagnostics tab, select System Test.
3. Select the Hard Disk Diag. Program tab.
4. Select the appropriate Partition (see Table 1.)
5. Select the Diag Type (see Table 2).
6. Press Start.Table 1  Partition Content
Display of appropriate 
hard disk columnSize 
(GB) Stored information and usages
MP All All All the items in Partition 1~6
MP Partition 1 (a) 2.0 Font, Form/Logo, SMB Folder (Config. txt, driver), 
Job Template
MP Partition 2 (b) 2.0 Printing range
MP Partition 3 (c) 1.2 Scan, Report, Mailbox, Security - Print
MP Partition 4 (d) 2.0 PLD, Others
MP Partition 5 (e) 2.0 Copying range
MP Partition 6 (f) 0.5 Spool Cont Control Information, Log
Table 2 
Work Item Details
Setup Initialize the file system.  It is required when the management data 
of the file system corrupts and when read errors occur.
Hard Disk Test
Read Verify)Perform the Read verify diagnostics of all the sectors in designated 
partitions.  Sector numbers where a read error is occurring will 
appear.
Troubleshooting Perform the hard disk ROM check and controller diagnostics.
Trouble Prediction Perform the SMART (Self-monitoring analysis and reporting tech-
nology) to predict latent troubles on the hard disk. 
						

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ADJ 9.9
Repairs and Adjustments Prelaunch Training/Review
ADJ 9.9 IOT Registration Series (dC129)PurposeThe purpose is to adjust the position of the printed image on the page. This is done by chang-
ing the value in the appropriate NVM location in dC129. This controls where the ROS writes
the image. IntroductionThis series consists of 4 procedures:
Lead Edge Registration (Trays 1-4)
Side Edge Registration (Trays 1-5)
Duplex (Side 2) Registration 
Lead Edge Registration for Tray 5
All procedures must be checked.Lead Edge Registration (Paper Trays 1 - 4)
PurposeTo correctly set the lead edge of the image in relation to the edge of the paper. There is one
lead edge setting for Trays 1 - 4.Check1. Connect the PWS to the machine and enter Diagnostic Mode (refer to Entering Diagnostic
Mode using the PWS). Select dC129 from the DC Quick menu
2. Load Tray 1 with the largest paper used by the customer.
3. Select ALL in the Lead Edge column.
4. Press the Start button on the screen. As the prints are made, mark each to indicate the
lead edge.
5. Take the third pattern that was printed and measure from the lead edge to point ëAí on Fig-
ure 1 (the intersection of the 7th line from the left edge and the first line from the lead
edge).
Figure 1 Measurement points
6. If the measured value is not 21.6mm±0.5, perform the Adjustment.
Adjustment1. Use the Right and Left Arrow buttons to move the image toward or away from the lead
edge of the paper. Each click on the button moves the image 0.25mm. The cumulative
amount of shift is indicated in the Lead Reg. box.
2. After adjusting the registration, click Set Adjust Value.
NOTE: Changes made to the NVM  for LE registration are not implemented unless the
machine exits Diagnostic Mode.
3. Go to the Service Exit tab and select Temporary Closeout.
4. After the machine reboots and is ready to copy, reconnect the PWS.
5. Select Start.
6. Repeat the check/adjustment until the specifications are met.
7. Select Save [LR] to save the new NVM settings.
8. Proceed to Side Edge Registration for Paper Trays 1 - 5.
LEAD EDGE
SIDE 
EDGE 
						

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ADJ 9.9
Prelaunch Training/Review Repairs and Adjustments
Side Edge Registration for Paper Trays 1 - 5
PurposeNOTE: Each Paper Tray has a separate setting for side edge registration.
To correctly position the side edge of the image in relation to the outboard edge of the paper.Check1. Check that paper is loaded in all trays, and that the paper guides are adjusted correctly.
For Tray 1 and Tray 2, use 11 x 17 in. or A3 paper if available.
2. Select Tray  1 in the Side Edge column.
3. Press the Start button on the screen. As the prints are made, mark each to indicate the
lead edge.
NOTE: Print All prints from each tray in numerical sequence from Tray 1 through Tray 6
(HCF - if installed). Make sure to keep the sheets in the correct sequence.
4. Take  the third pattern that was printed and measure the following: perform the Adjust-
ment for that tray.
For paper larger than letter size: from the intersection between the 1st line from the
left top edge and the 10th line from the lead edge of the paper (point ëB2í on Figure
1).
For paper letter size (A4/8.5 x 11) or smaller: from the intersection between the 1st
line from the left top edge and the 5th line from the lead edge of the paper (point ëB1í
on Figure 1).
5. If the measured value is not 21.6mm±0.5, perform the Adjustment.
6. If the measurement is within specifications, repeat the Check for Trays 2 - 5. Perform the
Adjustment for any tray that is not within specifications. 
7. If all trays are within specifications, proceed to Duplex (Side 2) Registration. Adjustment1. Select the paper tray to be adjusted from the Side Edge column. 
2. Use the Up and Down Arrow buttons to move the image toward or away from the out-
board edge of the paper. Each click on the button moves the image 0.21 mm. The cumu-
lative amount of shift is indicated in the Side Reg. box.
3. After adjusting the registration, click Set Adjust Value.
4. Select Start.
5. Repeat the check/adjustment until the specifications are met.
6. Select Save [SR] to save the new NVM settings.
7. Repeat steps 1 through 6 for each tray that requires adjustment.
8. Proceed to Duplex (Side 2) Registration.
Duplex (Side 2) Registration  
PurposeThe purpose of this procedure is to correctly position the lead edge and side edge of the image
in relation to the edge of the paper.Check1. Ensure that Paper Tray 1 contains paper and that the paper guides are adjusted correctly.
If available, load the tray with 11 x 17 in. or A3 paper.
2. Select Duplex (Side 2) in the Lead Edge column.
NOTE:  Side 2 will be face down in the output tray.
3. Press the Start button on the screen. As the prints are made, mark each to indicate the
lead edge.
4.Check Lead Edge:
Check the Side 2 Lead Edge Registration (Figure 1). If the measured value is not
21.6mm±0.5, perform the Adjustment.
5.Check Side Edge:
Check the Side Edge Registration (Figure 1). If the measured value is not 21.6mm±0.5,
perform the Adjustment.AdjustmentDuplex Lead Edge:
1. Use the Right and Left Arrow buttons to move the image toward or away from the lead
edge of the paper. Each click on the button moves the image 0.25mm. The cumulative
amount of shift is indicated in the Lead Reg. box.
2. After adjusting the registration, click Set Adjust Value.
NOTE: Changes made to the NVM  for LE registration are not implemented unless the
machine exits Diagnostic Mode.
3. Go to the Service Exit tab and select Temporary Closeout.
4. After the machine reboots and is ready to copy, reconnect the PWS
5. Select Start.
6. Repeat the check/adjustment until the specifications are met.
7. Select Save [LR] to save the new NVM settings.
Duplex Side Edge:
1. Select Duplex (Side 2) in the Side Edge column
2. Use the Up and Down Arrow buttons to move the image toward or away from the out-
board edge of the paper. Each click on the button moves the image 0.21mm. The cumula-
tive amount of shift is indicated in the Side Reg. box.
3. After adjusting the registration, click Set Adjust Value.
4. Select Start.
5. Repeat the check/adjustment until the specifications are met.
6. Select Save [SR] to save the new NVM settings. 
						

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ADJ 9.9, ADJ 9.10Repairs and Adjustments Prelaunch Training/Review
Lead Edge Registration for Tray 5 (MSI)
PurposeNOTE: There are three settings for Tray 5 Lead Edge; one for standard weight paper, one for
heavyweight stock, and one for extra-heavyweight stock. 
To correctly set the lead edge of the image in relation to the edge of the paper.Check1. Load Tray 5 with the largest standard weight paper used by the customer.
2. Select Tray 5 (MSI) in the Lead Edge column.
3. Press the Start button on the screen. As the prints are made, mark each to indicate the
lead edge. 
4. Take the third pattern that was printed and measure from the lead edge to point ëAí on Fig-
ure 1 (the intersection of the 7th line from the left edge and the first line from the lead
edge).
5. If the measured value is not 21.6mm±0.5, perform the Adjustment.
6. If the customer uses heavyweight or extra-heavyweight stock, load Tray 5 with the stock.
Select Tray 5 (HW) or Tray 5 (XHW), as appropriate. Repeat the check. Adjustment1. Use the Right and Left Arrow buttons to move the image toward or away from the lead
edge of the paper. Each click on the button moves the image 0.25mm. The cumulative
amount of shift is indicated in the Lead Reg. box.
2. After adjusting the registration, click Set Adjust Value.
NOTE: Changes made to the NVM for LE registration are not implemented unless the machine
exits Diagnostic Mode.
3. Go to the Service Exit tab and select Temporary Closeout.
4. After the machine reboots and is ready to copy, reconnect the PWS.
5. Select Start.
6. Repeat the check/adjustment until the specifications are met.
7. Select Save [LR] to save the new NVM settings.
ADJ 9.10  IIT Lead Edge RegistrationPurposeTo adjust the IIT scan timing in the Slow Scan direction and to correct the copy position.Check
CAUTION
Perform this adjustment only if absolutely required; the IIT Lead Edge Registration affects the
precision of the document size detection.
NOTE: Before performing this procedure, make sure that the IOT Lead Edge Registration is
correct. Refer to ADJ 9.9, IOT Side/Lead Edge Registration.
1. Place the Geometric Test Pattern on the Platen Glass correctly and make a copy with the
following settings:
ï Copy Mode: Black
ï Paper Size: 11 x 17 in or A3
ï Magnification: 100%
ï No. of Copies: 2
2. On the 2nd copy, check that the distance from the lead edge to the top of Step 3 on the
LE2 scale is 10.0mm +/- 2.1mm (Figure 1). 
Figure 1 Checking IIT Side Registration
3. If the value is not within the specified range, Perform the Adjustment:
Lead Edge
10.0mm 
+/- 2.1mm 
						

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ADJ 9.10, ADJ 9.11
Prelaunch Training/Review Repairs and Adjustments
Adjustment1. Enter dC131 [715-301].
2. Change the value:
ï Each bit represents  0.036 mm
ï Increase the value to move the image toward the lead edge.
ï Decrease the value to move the image away from the lead edge.
ADJ 9.11  IIT Side Edge RegistrationPurposeTo adjust the IIT scan timing in the Fast Scan direction and to correct the copy position.Check
CAUTION
Perform this adjustment only if absolutely required; the IIT Lead Edge Registration affects the
precision of the document size detection.
NOTE: Before performing this procedure, make sure that the IOT Side Edge Registration is
correct. (Refer to ADJ 9.9, IOT Side/Lead Edge Registration.)
1. Load 11 x 17 in. or A3 paper into Tray 2.
2. Place the Geometric Test Pattern on the Platen Glass correctly and make a copy with the
following settings:
ï Copy Mode: Black
ï Paper Tray: Tray 2
ï Magnification: 100%
ï No. of Copies: 2
3. On the 2nd copy, check that the distance from the lead edge to the top of Step 3 on the
SE2 and SE3 scales is 10.0mm +/- 1.6mm (Figure 1). 
Figure 1 Checking IIT Side Edge Registration
10.0mm 
+/- 2.1mm Lead Edge 
						

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ADJ 9.11, ADJ 9.12
Repairs and Adjustments Prelaunch Training/Review 4. If the value is not within the specified range, perform the Adjustment:
Adjustment
Purpose1. Enter dC131 [715-014].
2. Change the value:
ï Each bit represents  0.036 mm
ï Increase the value to move the image toward the edge.
ï Decrease the value to move the image away from the edge.
ADJ 9.12  IIT Vertical/Horizontal MagnificationPurposeTo correct the horizontal (fast scan)/vertical (slow scan) magnification ratio for a 100% copy.Check
CAUTION
Perform this procedure only if absolutely required; changing IIT magnification may adversely
affect resolution due to ASIC shift, and may cause a color shift.  
NOTE: Before performing this procedure, make sure that the IOT horizontal/vertical magnifica-
tion ratios are correct.
1. Place the Geometric Test Pattern on the Platen Glass and make a copy using the follow-
ing copy mode settings:
ï Copy Mode: Black
ï Document Type: Text/Photo
ï Paper: 11 x17 in. or A3
ï Magnification: 100%
ï No. of Copies: 2
2. Check the 2nd copy for the following:  
3.Check horizontal magnification (Figure 1): 
Measure the 200mm line running from near LE1 to near LE3. If the dimension is not
200mm ±1mm, perform the Adjustment. 
						

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ADJ 9.12
Prelaunch Training/Review Repairs and AdjustmentsFigure 1 Checking Horizontal Magnification
Lead Edge
200mm
+/-1mm