Xerox 1632 2240 3535 Color Carrera Manual

							6/02
3-1 DC1632/2240Image Quality Prelaunch Training/Review
3 Image Quality
IQ1 IOT Image Quality Entry RAP .................................................................................. 3-3
IQ2 IIT Image Quality Entry RAP .................................................................................... 3-4
IQ3 Low Image Density RAP .......................................................................................... 3-5
IQ4 Wrinkled Image RAP ................................................................................................ 3-5
IQ5 Residual Image (Ghosting) RAP .............................................................................. 3-6
IQ6 IOT Background RAP ............................................................................................... 3-8
IQ7 Deletions RAP .......................................................................................................... 3-8
IQ8 Color-to-Color Misregistration RAP .......................................................................... 3-10
IQ9 Skew/Misregistration RAP ........................................................................................ 3-10
IQ12 Process Direction Bands, Streaks, and Smears RAP ............................................ 3-11
IQ13 Unfused Copy RAP ................................................................................................ 3-12
IQ14 Repeating Bands, Streaks, Spots, and Smears RAP............................................. 3-12
IQ15 Mottle RAP ............................................................................................................. 3-13
IQ16 Spots RAP .............................................................................................................. 3-13
IQ20 1st BTR Checkout RAP .......................................................................................... 3-14
IQ21 Developer Bias RAP............................................................................................... 3-16
IQ22 2nd BTR Checkout RAP......................................................................................... 3-18
IQ23 BCR Checkout RAP ............................................................................................... 3-20
Image Quality Specifications ........................................................................................... 3-21 
						

							6/02
3-2DC1632/2240 Prelaunch Training/Review Image Quality 
						

							6/02
3-3 DC1632/2240
IQ1
Image Quality Prelaunch Training/Review
IQ1 IOT Image Quality Entry RAPThe purpose of this RAP is to serve as the entrance vehicle into the Image Quality RAPs sec-
tion. All Image Quality RAPs must be accessed through this RAP. 
The RAP will have you evaluate the copies made during the Call Flow procedure for image
quality defects. It will refer you to the Image Quality Analysis RAPs, the Image Quality Defect
section in order to diagnose and repair any image quality problems. 
Initial ActionsCheck for the presence of the defect in Copy mode and in Print mode. If the problem occurs in
Copy mode only, go to the IQ2 RAP. ProcedureGo to Table 1. Compare the prints for any of the listed defects. Perform the corrective action
that is listed. 
Table 1 Image Quality Defects
DefectDescription Corrective Action
Background
See Defect Sample ____.Undesirable toner deposits on the copy or print. The toner deposits can be localized or may cover the entire copy or print. Depend-
ing on the density of the background, it is referred to as low, medium, high, or very high background. It may occur in all colors, sin-
gle colors, or any combination of single colors.Go to the IQ6 RAP
Color Misregistration 
See Defect Sample ____.Multi-colored images that should be superimposed are offset. This offset may be in the process direction or perpendicular to pro-
cess direction.Go to the IQ8 RAP
Deletions
Debris-Centered
See Defect Sample ____.
Nonuniform Streak
See Defect Sample ____.The undesirable absence of toner from the copy or print. This defect can show as white, light, or untrue colored areas on the copy 
or print. The most common example is a deletion caused by the ì tentingî  of paper from mishandling or moisture, or by dents or 
defects in the Transfer Belt. 
ïDebris-Centered: Deletions in the areas surrounding toner agglomerates.
ïNonuniform Streak: A deletion in the form of a single streak that runs from the lead edge to the trail edge of the copy.Go to the IQ7 RAP 
High Frequency Bands
See Defect Sample ____.Repeating interval bands that are most noticeable in low density (20-30%) halftone areas of the copy. These bands run perpendic-
ular to process direction.Go to the IQ14 RAP
Irregular Streak in Process Direc-
tion
See Defect Sample ____.Streaks: Usually medium-width streaks of (or shifts in) color most noticeable in low density 20-30%) halftone areas of the copy.
A deletion in the form of a single streak that runs from the lead edge to the trail edge of the copy.Go to the IQ12 RAP
Low Image Density A condition that results when too little toner of a single color or combination of colors is developed on the copy or print. This results 
in lighter copies or prints for the single-color toner or the color that results from the combination of color toners.Go to the IQ3 RAP
Misregistration/Skew  The position and/or alignment of the image relative to the top edge and side edge of the paper is not within specification. Go to the IQ9 RAP
Missing Colors One or more of the primary colors are missing from the image.
Mottle
See Defect Sample ____.Areas of solid, or high density coverage that are reproduced with a surface that resembles marble. Go to the IQ15 RAP
Regular (repeating) Bands, 
Streaks, or SmearsA defect that repeats at an interval from14 to 264 mm, is most noticeable in low density (20-30%) halftone areas of the copy, and 
runs perpendicular to process direction. 
Lines and bands are generally uniform in shape from one end to the other. 
Streaks are generally shorter than lines and are of nonuniform width along their length. They may have a more ragged or fuzzy 
appearance than lines.Go to the IQ14 RAP
Residual Image A toner image that remains on the photoreceptor or Transfer Belt after cleaning. The next image is placed on top of the residual 
image and both images are transferred to the next copy.Go to the IQ5 RAP
Spots Generally circular in shape, these defects can be caused by an absence of toner in a desired area, or a deposit of toner in an 
undesired areaGo to the IQ16 RAP
Unfused prints Image can be rubbed off with little or no pressureGo to the IQ13 RAP
Wrinkled Image
See Defect Sample ____.Go to the IQ4 RAP 
						

							6/02
3-4DC1632/2240
IQ2
Prelaunch Training/Review Image Quality
IQ2 IIT Image Quality Entry RAPThis RAP is for troubleshooting IIT (Scanner/ADF) problems only. Before proceeding, verify
that the defect is present in Copy mode only. If the defect is present in Print mode, go to the
IQ1 RAP. 
Initial ActionsClean the Lens, the top and bottom surface of the Platen Glass, and all Mirrors with Lens and
Mirror Cleaner and a soft, lint-free cloth.ProcedureCompare the defective copies with the descriptions listed in Ta b l e  1. Perform the corrective
action listed for that defect. 
Table 1 
DefectCorrective Action
Background Clean the Platen Belt.
Calibrate the IIT (ADJ 9.7).
Blurred or Streaked Copy Ensure that the Platen Glass is installed correctly.
Check/adjust the carriage alignment (ADJ 6.1). 
R/E error Check/adjust IIT magnification (ADJ 9.12). 
Deletions Clean the Lens, the top and bottom surface of the Platen Glass, and all Mirrors with Lens and Mirror Cleaner and a soft, lint-free cloth. 
If the problem persists, replace the Lens Kit (PL 18.4). 
Misregistration/Skew Go to the IQ9 RAP.
Moire
Patterns in the image areas of the print that have the 
appearance of a screen or grid overlaying the 
image. The pattern may be uniform or nonuniform in 
area or shape.ï Switch between photo modes to determine which mode minimizes the defect.
ï Decrease the Sharpness level.
ï Reduce or enlarge the copy slightly.
ï Rotate the original on the platen by 90 degrees.
Newton Rings
Repetitive, irregular-shaped marks that occur when 
making copies of glossy photographs. These marks 
are most noticeable in large low-density or highlight 
areas.Clean the Document Glass
Place a transparency between the document and the glass 
						

							6/02
3-5 DC1632/2240
IQ3, IQ4Image Quality Prelaunch Training/Review
IQ3 Low Image Density RAPThis RAP troubleshoots the causes of output images showing image density lower than speci-
ficationInitial Actionsï Clean the ROS windows
ï Replace the paper in use with fresh, dry paper of the correct specification
ï Determine if the Drum Cartridge or any of the Toner Cartridges are approaching end-of-
life. Replace if necessary.
ï Perform the Automatic Gradation procedure (refer to the User Guide). If this does not
resolve the problem, continue with this RAP.ProcedureGo to dC612. Print Test pattern??????. The defect involves a single color.
YN
Go to dC612. Print Test pattern??????. Open the Front Door in the middle of the print  job
(approximately 7 seconds after selecting Start.). There is a good toner image on the
Transfer Belt.
YN
Go to the IQ21 RAP to check the Developer Bias. If this does not resolve the prob-
lem, go to the IQ20 RAP to check the 1st BTR bias. 
If the problem continues, check the ROS for contamination of the windows or mis-
alignment.
Check the 2nd BTR for damage or incorrect installation. Go to the IQ22 RAP to check the 
Backup Roll bias. If the problem continues, replace 2nd BTR Assembly (PL 7.1). If this
does not resolve the problem, replace the Transfer Belt (PL 5.3). 
Swap the affected Drum Cartridge with an adjacent unit. Print Test Pattern???.   The defect
moved to the new color.
YN
Go to the IQ21 RAP to check the Developer Bias. If this does not resolve the problem, go
to the IQ20 RAP to check the 1st BTR bias. If the problem continues, replace the Devel-
oper for the affected color (PL 6.2). If this does not resolve the problem, replace the ATC
Sensor for the affected color (PL 6.2).
Replace the Drum Cartridge (see Machine Consumables in Section 6).
IQ4 Wrinkled Image RAPInitial Actions
ProcedureTBD 
						

							6/02
3-6DC1632/2240
IQ5
Prelaunch Training/Review Image Quality
IQ5 Residual Image (Ghosting) RAPInitial Actionsï Check the end-of-life counter for the Drum Cartridge. If the unit is at or near end-of-life,
replace the Drum Cartridge (see Machine Consumables in Section 6).
NOTE: Some ghosting on transparencies is unavoidable.
ï If the problem occurs only with certain types of media, ensure that the media in use is
within specification, and that the customer is aware of correct operation of print driver.
ï If the distance between the intended image and the residual image has a fixed rate of rep-
etition, go to the IQ14 RAP. Return to this procedure if the problem persists.ProcedureThe problem is with a single primary color
YN
Remove the Fuser. Examine the Heat Roll and Pressure Roll for evidence of toner offset-
ting. There is Toner adhering to the Heat Roll. 
YN
Check for a residual image on the Transfer Belt. Repair or replace the IBT Cleaner
(PL 5.3) as required.
Check the 2nd BTR for contamination. Clean/replace as required
Clean the Heat Roll. If the problem persists, replace the Fuser (PL 7.1). 
Check the Erase Lamp for the affected color:
ï Enter dC330 [009-045] (C, Y, or M), or [009-042] (K), as appropriate.
ï Remove the Drum cartridge for the affected color.
ï check for light along the mounting rail left side
The Erase lamp is lit.
YN
Go to Flag 1 (C), Flag 2 (Y), Flag 3 (M), or Flag 4 (K). Check for an open circuit. If the
wires are OK, replace the Erase Lamp (PL 4.2) for the affected color. If the problem per-
sists, Replace the MCU PWB (PL 13.1).
Go to the IQ21 RAP. Check for a short circuit in the Developer bias circuit of the affected color. 
						

							6/02
3-7 DC1632/2240
IQ5
Image Quality Prelaunch Training/ReviewFigure 1 IQ5 RAP Circuit Diagram 
						

							6/02
3-8DC1632/2240
IQ6, IQ7
Prelaunch Training/Review Image Quality
IQ6 IOT Background RAPInitial ActionsNOTE: Some background is unavoidable on certain media, such as heavyweight paper and
transparencies. Ensure that the customer selects the correct settings on the UI and print driver.
Perform Max Setup (ADJ 9.1). If this does not resolve the problem, continue with this RAP.ProcedureThe problem is Single Color Background.
YN
Examine the face of the ADC Sensor. The ADC Sensor is clean.
YN
Go to the 9-684 RAP to troubleshoot the ADC Sensor Solenoid.
Examine the Transfer Belt for excessive dirt, damage, or uncleaned toner. The Belt is
clean.
YN
Check the Belt Cleaner for damage or wear. Clean or replace as required.
WARNING
HIGH VOLTAGE!
Exercise care when making the voltage check in the following steps.
Enter dC140 [09-026]. Measure the voltage from P/J 580, pins 1, 3, 5, and 7. The volt-
age is approximately -540 VDC on all pins.
YN
Go to the IQ21 RAP to troubleshoot the Developer bias circuit.
Replace the Transfer Belt (PL 5.3). If this does not resolve the problem, replace the 2nd
BTR (PL 2.8). If the problem persists, replace the MCU PWB (PL 13.1). 
The background is very high and even density, and covers the entire sheet (no edge
erase.
YN
Check the following:
ï Check the end-of-life counter for the Toner Cartridge and Drum Cartridge for the
affected color. Replace if at or near end-of-life (see Machine Consumables in Sec-
tion 6).
ï If the problem continues, examine the Developer Housing for the affected color.
Check for toner bridging, uneven brush, or loose High Voltage terminals. Clean,
repair, or replace as required (PL 6.2).
Go to the IQ23 RAP.
IQ7 Deletions RAPInitial ActionsReload the machine with fresh, dry paper of the correct specifications. If the problem occurs
when using heavyweight paper, ensure that the correct selections are being made on the print
driver. If the problem is not resolved, continue with this RAP.
NOTE:  Small white deletions with a sharp edge are usually caused by Fuser offsetting. Go to
the IQ16 Spots RAP.ProcedureThe problem is debris-centered deletions (small-area deletions surrounding a dark
speck).
YN
Enter dC612. Print a copy of the 20% coverage pattern for each color.  The defect is
present for all colors.
YN
Make several prints of the Test Page (?????). The defect is present in approxi-
mately the same location on all letter-size prints.
YN
Remove the Drum cartridge for the affected color. Check  for  light  from  the
Erase Lamp along the mounting rail left side The Erase lamp is lit.
YN
Examine the surface of the Drum Cartridge. Check for dents, scratches, or
contamination such as fingerprints, etc. The drum is free from damage.
YN
Clean or replace the Drum Cartridge as required (see Machine Con-
sumables in Section 6).
Switch the affected Drum Cartridge with an adjacent unit. The problem
moves with  the cartridge.
YN
Go to the IQ20 RAP and check Flags 1 through 3 for a loose, cor-
roded, or damaged connection.
Replace the Developer (PL 6.2) for the affected color. 
Replace the Drum Cartridge (see Machine Consumables in Section 6).
Go to Flag 1 (C), Flag 2 (Y), Flag 3 (M), or Flag 4 (K). Check for a short circuit.
If the wires are OK, replace the Erase Lamp for the affected color. If the prob-
lem persists, Replace the MCU PWB (PL 13.1). 
Remove the ROS. Examine the ROS windows for dirt or damage. Clean or replace
as required PL 3.1). 
Check the Transfer Belt (PL 5.3) for dirt, damage, or contamination. Clean/replace as
required.
Check the 2nd BTR (PL 2.8) for damage or wear. Clean or replace if required.
Examine the spot in the center of the DCD. Replace the Developer (PL 6.2) and Toner Car-
tridge for the affected color. If the problem persists, replace the Developer Housing for the
affected color (PL 6.2). 
						

							6/02
3-9 DC1632/2240
IQ7
Image Quality Prelaunch Training/ReviewFigure 1 IQ7 RAP Circuit Diagram 
						

							6/02
3-10DC1632/2240
IQ8, IQ9
Prelaunch Training/Review Image Quality
IQ8 Color-to-Color Misregistration RAPInitial ActionsAdjust the color registration (ADJ 9.6). If the problem remains, continue with this procedure ProcedureThe problem involves a single color.
YN
Check that the ROS is securely mounted and that the ROS window is not dirty or dam-
aged. If the problem persists, replace the ROS (PL 3.1).
Check the mounting of the Developer Housing for the affected color. Ensure that it is installed
correctly and that it is free from damage. Repair or replace as required (PL 6.2). 
IQ9 Skew/Misregistration RAPThis RAP is used when Skew, System Registration, or Magnification are out of specification.
For Color-to-Color-Misregistration, go to the IQ8 RAP.Initial ActionsLoad some new, dry 24 lb. 11X17/A3 Xerox COLOR Xpressions (NASG), or 90 GSM Colortech
+ (ESG) into each paper tray (use 8.5X11/A4 in Tray 1). Make 3 full color copies from each
paper tray. Mark the appropriate paper tray on these copies. ProcedureThe problem is still present when using the proper paper.
YN
Explain to the customer that new, dry, 24 lb. Xerox COLOR Xpressions (NASG), or 90
GSM Colortech + (ESG) paper is the specified paper for use in the DocuColor 1632/2240. 
The problem occurs only in the Printer Mode
YN
The defect occurs when the document is manually registered on the platen glass. 
YN
Ensure that the Document Transport Belt is clean. Check the Document Handler
Adjustments (ADJ 5.1 through ADJ 5.7). If the problem continues, check the DADF
drive rolls and pinch rolls for wear or glossing. 
The problem is Skew
YN
The problem is Misregistration
YN
Adjust the IIT Vertical/Horizontal Magnification (ADJ 9.12) and the IOT Lead
Edge/Side Edge Registration (ADJ 9.9). 
Enter dC612. Select Pattern????.  Misregistration is present on the copy
YN
Adjust the IOT Lead Edge/Side Edge Registration (ADJ 9.9), then the IIT Lead
Edge and Side Edge Registration (ADJ 9.10 and ADJ 9.11).
The defect occurred on copies from all five paper trays. 
YN
Check the IOT Lead Edge/Side Edge Registration (ADJ 9.9) for that tray. 
 Check the feeder for the affected tray  for wear, slipping, damage, or contami-
nation.  
ï Tray 1 Feeder (PL 2.4)
ï Tray 2 Feeder (PL 16.7)
ï Tray 3 Feeder (PL 16.9) 
ï Tray 4 Feeder (PL 16.11)
ï Tray 5 Feed Assembly (PL 2.14)
Registration varies from copy to copy.
YN
Go to ADJ 9.9, Lead/Side Edge Adjustment.A
B
C