Xerox 1632 2240 3535 Color Carrera Manual
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6/02 4-67 DC1632/2240 REP 8.6 Repairs and Adjustments Prelaunch Training/Review REP 8.6 Registration Transport AssemblyParts List on PL 2.6 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 Left Cover Assembly (REP 8.1). 7. Remove Registration Transport Assembly (Figure 1). a. Observe position of harness for later reinstallation. b. Remove Screws (2). c. Pivot top of Registration Transport out and disconnect Harness. d. Lift to remove Registration Transport. Figure 1 Removing Registration Transport Assembly ReplacementNOTE: bearing is equipped with two Anti-rotation Tabs. If one breaks during removal, install bearing so other tab is employed. NOTE: Check that ground spring is pressing against Bronze bushing after installing it. Harness Screws (2)
6/02 4-68DC1632/2240 REP 8.7 Prelaunch Training/Review Repairs and Adjustments REP 8.7 Exit Transport AssemblyParts List on PL 2.10 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 Rear Cover (REP 14.2). 4. Remove Power Switch Cover (REP 14.5). 5. Remove Exit Transport (Figure 1). a. Disconnect P/Jís (2). b. Remove Screws (3) c. Rotate Exit Transport slightly to disengage Tab and then lift to remove Exit Trans- port. Figure 1 Removing Exit Transport P/Jís (2) Screws (3) Ta b
6/02 4-69 DC1632/2240 REP 9.1, REP 9.2Repairs and Adjustments Prelaunch Training/Review REP 9.1 Drum CartridgeParts List on PL 4.1 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. Remove Drum Cartridge. a. Open Left Cover Assembly. b. Open Front Cover. c. Actuate orange release and pull out Drum Cartridge. CAUTION Drum Cartridge photoreceptor damage is likely if Drum Cartridge is handled carelessly. This results in image quality defects. Use caution when Drum Cartridge is removed from machine. d. Place Drum Cartridge in a black bag. REP 9.2 ROS Shutter MotorParts 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. 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 MSI Tray (REP 7.1). 6. Remove Left Cover Assembly (REP 8.1). 7. Remove Registration Transport (REP 8.6). 8. Remove Shutter Actuator(Figure 1). Figure 1 Removing Shutter ActuatorReplacementEnsure solenoid arm engages 1Disconnect 2Remove Screw 3Pull out Shutter Actuator
6/02 4-70DC1632/2240 REP 9.3, REP 9.4 Prelaunch Training/Review Repairs and Adjustments REP 9.3 Waste Toner Cartridge CoverParts List on PL 4.1 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 Waste Cartridge Cover (Figure 1). a. Open Waste Cartridge Cover. b. Remove Screw. c. Remove Waste Toner Cartridge Cover. Figure 1 Removing Waste Toner Cartridge Cover REP 9.4 Waste Toner CartridgeParts List on PL 4.1 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 Waste Cartridge (Figure 1). a. Open Waste Cartridge Cover. b. Release Lever and move half way down. c. Pull out to remove Waste Cartridge. Figure 1 Removing Waste Cartridge Waste Cartridge Cover Screw Waste CartridgeWaste Cartridge Cover Lever
6/02 4-71 DC1632/2240 REP 9.5, REP 9.6Repairs and Adjustments Prelaunch Training/Review REP 9.5 Full Toner SensorParts List on PL 4.1 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 Waste Cartridge (REP 9.4). 3. Remove Waste Cartridge Cover (REP 9.3). 4. Access Waste Cartridge Full Sensor (Figure 1). a. Lift Left End slightly and pull left to disengage Mounting Tabs. b. Rotate Sensor Support and remove. Left End harness connection limits movement. Figure 1 Accessing Waste Cartridge Full Sensor 5. Remove Waste Cartridge Full Sensor (Figure 2). a. Push against Sensor Head while releasing Locking Tabs. b. Disconnect sensor from harness. Figure 2 Removing Waste Cartridge Full Sensor REP 9.6 Inner 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. Open Left Cover Assembly. 3. Remove Y, M, C, K, Drum. 4. Remove Fuser Front Cover (REP 14.8). 5. Release and move Xerographic Release Lever half way down. 6. Remove Dispenser Assembly Cover (Figure 1). a. Remove Screws (4). b. Remove Dispenser Assembly Cover. Figure 1 Removing Toner Transport Cover Left End Mounting Tabs Sensor Support Connected Harness Locking Tabs Waste Car- tridge Full Sensor Sensor Head Screws (4)
6/02 4-72DC1632/2240 REP 9.7 Prelaunch Training/Review Repairs and Adjustments REP 9.7 Toner DispenserParts List on PL 6.1 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. Release and move Xerographic Release Lever half way down. 4. Remove Dispenser Assembly Cover (REP 9.6). 5. Remove Drum Cartridges as required. CAUTION Y must be removed first, followed in order by M, C, then K. They must be reinstalled in reverse order of removal, which is install K, C, M, and then Y. 6. Prepare to remove Toner Transport (Figure 1). a. Carefully pull out Toner Outlet Door while holding Housing back to shut off toner out- let. Figure 1 Closing Toner Outlet 7. Remove Toner Transport (Figure 2). a. Remove Screw, CAUTION Connection Tube may separate from upper or lower housing. Agitator may disconnect if flex coupling is compressed enough so agitator hits inside bot- tom of lower housing b. Pull out Upper and Lower Housings together while ensuring flexible Connection Tube remains connected. Figure 2 Removing Toner Transport Toner Outlet DoorHousing Upper HousingLower HousingScrew Connection Tube
6/02 4-73 DC1632/2240 REP 9.8 Repairs and Adjustments Prelaunch Training/Review REP 9.8 Plate AssemblyParts List on PL 4.2 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). CAUTION Note position of harnesses. Correct harness routing is required for assembly. NOTE: In next step, do not remove sensor. 9. Remove housing for Waste Cartridge Full Sensor (REP 9.5). 10. Disconnect Developer Housing Plugs, 4 large and 4 small (small not shown). Position wires straight out from machine. Wires remain stationary while removing Plate Assembly (Figure 1). Figure 1 Disconnecting Developer Housing Plugs Developer Housing Plugs (4 Large)
6/02 4-74DC1632/2240 REP 9.8 Prelaunch Training/Review Repairs and Adjustments 11. Disconnect Developer Housing Harnesses (Figure 2). a. Open Harness Clip and remove harness from Clip. b. Disconnect Harness P/Jís (3). c. Remove Screw from Inner Left Harness Cover and remove cover. d. Remove Developer Housing Harnesses from additional harness clips (not shown, under Harness Cover). Figure 2 Disconnecting Developer Harnesses12. Remove Plate Assembly (Figure 3). a. Remove Screws (6). b. Pull Plate Assembly toward front to remove it. Ensure harnesses are cared for. Figure 3 Removing Plate Assembly Harness P/Jís (3)Harness Clip Screw Inner Left Harness Cover
6/02 4-75 DC1632/2240 REP 9.9 Repairs and Adjustments Prelaunch Training/Review REP 9.9 Developer HousingParts List on PL 6.2 Removal WA R N I N GTo 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. Move Xerographic Release Lever up to a mid position. 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). CAUTION IBT belt damage results when Developer Housing is removed carelessly. 11. Remove Developer Housing (Figure 1). Figure 1 Removing Developer Housing ReplacementNOTE: If installing a new Developer Housing, go to step 1. If reinstalling existing developer housing, go to 5. 1. Install new Developer (REP 9.10) as required. 2.Remove ATC Sensor Setup Data Tag from new Developer Housing. On tag, highlight K, C, M, or Y as required for color of developer housing. Tag will be installed during machine reassembly. CAUTION Image quality defects occur when ATC Sensor Data is mishandled in dC921. 3. During machine assembly, install ATC Sensor Setup Data Tag as shown (Figure 2). Figure 2 Installing ATC Sensor Setup Data Tag 4. Perform dC921 ATC Sensor Setup (ADJ 9.2). 5. While reinstalling Developer Housing ensure pin at rear of Developer Housing engages hole in rear frame of machine. 1Raise Xerographic Release Lever 2Position Tag in correct location Tag with K highlighted Tag with C highlightedTag with M highlightedTa g w i t h Y highlighted
6/02 4-76DC1632/2240 REP 9.10 Prelaunch Training/Review Repairs and Adjustments REP 9.10 DeveloperParts 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. Remove Developer. (Figure 1). a. Carefully observe position of wiring harness for later reinstallation. Figure 1 Observing position of Harness b. Remove Housing Cover (Figure 2). Figure 2 Removing Housing Cover c. Rotate Drive Gear to remove Developer (Figure 3). Figure 3 Removing Developer Replacement1. Rotate Drive Gear while installing new Developer (Figure 4). Position of Harness 1Place Drop Cloth 2Release tabs and remove Cover Drive Gear