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Xerox 1632 2240 3535 Color Carrera Manual

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    							6/02
4-77 DC1632/2240
REP 9.10, REP 9.11
Repairs and Adjustments Prelaunch Training/ReviewFigure 4 Installing Developer
2. Install Developer Housing.
a. Ensure pin at rear of Developer Housing engages hole in rear frame of machine.
b. Reassemble machine.
c. Adjust ATC Sensor (ADJ).
REP 9.11 Toner Dispenser Base AssemblyParts 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 Drum Cartridges.
3. Remove Fuser Front Cover (REP 14.8). 
4. Release and move Xerographic Release Lever half way down.
5. Remove Dispenser Assembly Cover (REP 9.6).
6. Remove all Dispenser Assemblies (REP 9.7). 
7. Remove Top Cover (REP 14.1). 
8. Remove Right Cover (REP 14.3). 
9. Remove Toner Dispense Module (Figure 1).
a. Remove Screws (2).
b. Carefully observe position of wiring harness for later reinstallation
c. Disconnect motor connectors (4).
d. Lift to remove Toner Dispense Module.
Figure 1 Removing Toner Dispense Module
Harness
Screws (2)
Motor P/Jís
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    							6/02
4-78DC1632/2240
REP 9.12, REP 9.13
Prelaunch Training/Review Repairs and Adjustments
REP 9.12 IBT Steering Drive AssemblyParts List on PL 1.3
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 Steering Drive Motor (Figure 1). 
a. Disconnect Motor P/J.
b. Remove Screws (3).
c. Pull out to remove using care to avoid damage to steering gear.
Figure 1 Removing Steering Drive Motor
REP 9.13 Agitator Motor AssemblyParts 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 Fuser Front Cover (REP 14.8). 
4. Release and move Xerographic Release Lever half way down.
5. Remove Dispenser Assembly Cover (REP 9.6).
6. Remove Waste Toner Agitator (Figure 1).
a. Disconnect P/J.
b. Remove Screws (2) and remove Waste Toner Agitator.
Figure 1 Removing Waste Toner Agitator
Motor P/JScrews (3)
ScrewP/JScrew
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    							6/02
4-79 DC1632/2240
REP 9.14, REP 9.15
Repairs and Adjustments Prelaunch Training/Review
REP 9.14 MOB Sensor AssemblyParts List on  PL 1.3 
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 Fuser Front Cover (REP 14.8). 
4. Release and move Xerographic Release Lever half way down.
5. Remove Dispenser Assembly Cover (REP 9.6).
6. Remove Waste Toner Agitator (REP 9.13).
7. Remove MOB Sensor Assembly (Figure 1).
a. Open Harness Clip and remove harness from Clip.
b. Remove Screw and remove Inner Left Harness Cover.
c. Disconnect Harness P/Jís (3)
d. Remove MOB Sensor Assembly Harnesses (violet) from additional harness clips
(not shown).
e. Remove MOB Sensor Assembly Screw and pull out to remove MOB Sensor Assem-
bly.  Xerographic Release Lever must be down as shown.
Figure 1 Removing MOB Sensor Assembly
REP 9.15 IBT Belt AssemblyParts List on PL 5.2
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. Release and move Xerographic Release Lever down.
3. Open Right Side Door. 
4. Remove IBT Belt Assembly (Figure 1). 
a. Lift to release Slide Lock.
b. Pull out IBT Unit to remove it.  Use Handle to transport IBT Unit.
c. Protect IBT Belt Assembly from direct light.
Figure 1 Removing IBT Belt Assembly
Harness Clip
Inner Left 
Harness 
CoverHarness 
P/Jís (3)Belt Mark 
Sensor 
Screw
Xerographic 
Release 
Lever
Screw
Slide 
Lock
Handle
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    							6/02
4-80DC1632/2240
REP 9.16, REP 9.17
Prelaunch Training/Review Repairs and Adjustments
REP 9.16 IBT Cleaner AssemblyParts List on PL 5.3
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. Remove Right Cover (REP 14.3). 
4. Remove IBT Belt Assembly just enough to access Belt Cleaner (REP 9.15). 
CAUTION
In next step, toner may spill out of Belt Cleaner if cleaner is handled carelessly.
5. Remove Screws and remove Belt Cleaner (Figure 2).
Figure 1 Removing IBT Cleaner AssemblyReplacementEnsure both rear locating pins engage holes in IBT Belt Assembly frame during installation of
IBT Cleaner Assembly.
REP 9.17 Auger AssemblyParts List on PL 5.2
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 Waste Cartridge (REP 9.4).
3. Release and move Xerographic Release Lever down.
4. Remove Right Cover (REP 14.3). 
5. Remove Belt Module (REP 9.15). 
6. Move Xerographic Release Lever to up position.
7. Remove Waste Toner Agitator (Figure 1).
a. Remove Screws (2).
b. Move Waste Auger toward Bearing to disengage Cutout from Bearing.
c. Remove Waste Auger.
Figure 1 Removing Waste Toner AgitatorReplacementMove Xerographic Release Lever to down position before reinstalling Belt Module.
Screws 
(2)
Screws (2)
Cutout Bearing
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    							6/02
4-81 DC1632/2240
REP 9.18, REP 9.19
Repairs and Adjustments Prelaunch Training/Review
REP 9.18 LeverParts List on PL 5.1
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 (REP 9.4). 
4. Remove Waste Cartridge Cover (REP 9.3).
5. Remove Inner Left Harness Cover (REP 14.10).
6. Release and move Xerographic Release Lever down.
7. Remove Drum Cartridges.
8. Remove Right Cover (REP 14.3). 
9. Remove Belt Module (REP 9.15). 
10. Remove Xerographic Release Lever (Figure 1).
a. Remove Screw, Washer, and Hinge Pin.
b. Remove E-Ring and Hinge Pin.
c. Remove Xerographic Release Lever.
Figure 1 Removing Xerographic Release LeverReplacementMove Xerographic Release Lever to down position before reinstalling Belt Module.
REP 9.19 Left Hinge/Right HingeParts List on PL 5.1
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 (REP 9.4). 
4. Remove Waste Cartridge Cover (REP 9.3).
5. Remove Inner Left Harness Cover (REP 14.10).
6. Release and move Xerographic Release Lever down.
7. Remove Drum Cartridges.
8. Remove Right Cover (REP 14.3). 
9. Remove Belt Module (REP 9.15). 
10. Remove Xerographic Release Lever (REP 9.18).
11. Remove Xerographic Release Lever Brackets (Figure 1). 
a. Remove Screws (2) and remove Bracket.
b. Remove Screws (2) and remove Bracket.
Figure 1 Removing Xerographic Release LeverReplacementMove Xerographic Release Lever to down position before reinstalling Belt Module.
Screw, Washer, 
Hinge Pin 
E-Ring, 
Hinge Pin
Screws 
(2)
Screws 
(2)
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    							6/02
4-82DC1632/2240
REP 9.20
Prelaunch Training/Review Repairs and Adjustments
REP 9.20 Right Lift AssemblyParts List on PL 5.1
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 (REP 9.4). 
4. Remove Waste Cartridge Cover (REP 9.3).
5. Remove Inner Left Harness Cover (REP 14.10).
6. Release and move Xerographic Release Lever down.
7. Remove Drum Cartridges.
8. Remove Right Cover (REP 14.3). 
9. Remove Belt Module (REP 9.15). 
10. Remove Xerographic Release Lever (REP 9.18).
11. Remove Lift Bracket (Figure 1). 
a. Remove E-Rings (2) and Washers (2).
b. Remove Screws (4) and remove Lift Bracket.
c. Remove Bearings (2) and Washers (2).
Figure 1 Removing Lift Bracket
12. Remove Right Xerographic Lift (Figure 2).
a. Remove Auger Mounting Screws (2).
b. Remove Lift Position Screw.
c. Remove Secondary Position Screw.d. Remove Lower Screws (2).
e. Remove Right Xerographic Lift.
Figure 2 Removing Right Xerographic Lift
ReplacementMove Xerographic Release Lever to down position before reinstalling Belt Module.
Washers (2)
E-Rings (2)
Screws (4)
Bearing Washe r
WasherBearing
Lift Posi-
tion 
ScrewLift Secondary 
Position Screw
Auger 
Mounting 
Screws (2)
Lower Screws (2)
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    							6/02
4-83 DC1632/2240
REP 9.21
Repairs and Adjustments Prelaunch Training/Review
REP 9.21 Left Lift AssemblyParts List on PL 5.1
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 (REP 9.4). 
4. Remove Waste Cartridge Cover (REP 9.3).
5. Remove Inner Left Harness Cover (REP 14.10).
6. Release and move Xerographic Release Lever down.
7. Remove Drum Cartridges.
8. Remove Right Cover (REP 14.3). 
9. Remove Belt Module (REP 9.15). 
10. Remove Xerographic Release Lever (REP 9.18).
11. Remove Rear Cover (REP 14.2). 
12. Remove Power Switch Cover (REP 14.6).
13. Remove Upper Rear Left Cover (REP 14.4). 
14. Close Left Cover Assembly.
15. Remove MSI Tray (REP 7.1).
16. Remove Left Cover Assembly (REP 8.1). 
17. Optional for improved visibility: Remove Fuser Module (REP 10.1). 
18. Remove Registration Transport (REP 8.6). 
19. Remove Dispenser Assembly Cover (REP 9.6). 
20. Remove Waste Toner Agitator (REP 9.13).
21. Remove Belt Mark Sensor (REP 9.14). 
22. Remove Left Xerographic Release Lever Bracket (REP 9.19). 
23. Remove Front Cover (REP 14.7).
24. Remove K and C Toner Cartridges.
25. Remove  K and C Dispenser Assembly (REP 9.7).
NOTE: In next step, do not remove sensor from housing
26. 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.
27. Remove Plate Assembly (REP 9.8). 
28. Remove K and C Developer Housing (REP 9.9).
29. Remove Left Xerographic Lift (Figure 1). 
NOTE: In next step, use a magnet to capture E-Ring and Washer while removing them.
a. From inside Developer Housing cavity, remove E-Ring and Washer from each end of
Left Xerographic Lift.b. Remove Screws (4).
c. Remove Left Xerographic Lift and maintain orientation to ensure Bearings (2) and
Washers (2) do not fall off posts.
Figure 1 Removing Left Xerographic Lift
Replacement1. Install Lift.
a. Position Lift in frame.
b. Raise or lower xerographic frame as required and push in or pull out Lift actuator as
required to engage lift bearings with slots in xerographic frame.
c. Install front top screw, then front bottom screw, then rear screws (2).
d. Install washers (2) and e-rings (2).
2. Assemble remaining machine components.
E-RingE-Ring Washer
Washer
Screws (2)Screws (2)
Bearing
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    							6/02
4-84DC1632/2240
REP 9.22
Prelaunch Training/Review Repairs and Adjustments
REP 9.22  Transfer BeltParts List on PL 5.3
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.
CAUTION
Cover Transfer Belt in a black bag.
NOTE: Keep your hand off Transfer Belt.
1. Remove IBT Belt Assembly (REP 9.15).
2. Remove IBT Cleaner Assembly (REP 9.16).
3. Remove Stand Plate (Figure 1). 
a. Remove Screw (2).
b. Remove Stand Plate in direction of arrow.
Figure 1 Removing Stand Plate 4. Remove Handle (Figure 2). 
Figure 2 Removing Handle
5. Remove screws on both sides (Figure 3).
Figure 3 Removing Screws (both sides)
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4-85 DC1632/2240
REP 9.22
Repairs and Adjustments Prelaunch Training/Review 6. Position Latch (Figure 4) 
a. Remove Screw.
b. Remove Latch.
c. Fix Latch.
Figure 4 Positioning Latch7. Install Stand Plate (Figure 5)
a. Install Plate.
Figure 5 Installing Stand Plate
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4-86DC1632/2240
REP 9.22
Prelaunch Training/Review Repairs and Adjustments 8. Place Stand Plate below and stand IBT Belt Assembly.
9. Relax tension of Belt on both sides (Figure 6)
a. Push up Bracket.
b. Push up Lever and hang Pin on Hole.
Figure 6 Relaxing Belt Tension10. Remove Bracket (Figure 7)
a. Remove Screw (2).
b. Remove Bracket.
c. Remove Screw (3).
d. Remove Bracket.
Figure 7 Removing Bracket
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