Xerox 1632 2240 3535 Color Carrera Manual

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ADJ 5.5
Repairs and Adjustments Prelaunch Training/Review
ADJ 5.5  DADF Top RegistrationPurposeAlign image scanned from document with top edge of paper. Check1. Make two DADF originals. 
a. Register Test Chart 82E8220 on Platen with lead edge metrics LE1 through LE3
against left registration guide.
b. Select the following:
ï 1 to 1 sided 
ï A4 or 8.5 x 11 Long Edge Feed 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 top edge registration of DADF Originals.
a. On copy 2 measure and record the distance between the top edge and the reference
line and write  A next to this measurement (Figure 1).
b. Check that A is 10.0 ±0.5 mm.  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 Top Edge Registration of DADF Originals3. Check DADF Top Edge Registration for Side 1.
a. Load both DADF Originals in DADF, 1 on top, with top edge metrics LE1 through
LE3 toward right.
b. Select the following:
ï 1 to 1-sided
ï A4 or 8.5 x 11 Long Edge Feed 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 top edge and the
reference line and write B next to this measurement (Figure 2).
Figure 2 Checking Top Edge Registration of DADF
e. Compare A to B .  B must be within 0 ±1.1 mm of A.
If the difference between A and B is greater than 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 top edge metrics toward
right.
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 right of DADF. 
ii. Select the following:
ï 2 to 1 sided and press Start.
ï A4 or 8.5 x 11 Long Edge Feed Paper Supply
ï 100% Reduce/Enlarge
Paper 
Feed 
Direction
Manually 
labeled 2Top Edge 
of Copy
10.0 ±0.5 mm
A
Paper 
Feed 
DirectionTop Edge 
of CopyB
10.0 ±1.1 mm 
						

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ADJ 5.5
Prelaunch Training/Review Repairs and Adjustmentsï1 Copy
iii. Press the Start button.
c. Check that top edge metrics are same distance from edge of paper for both copies.
If the difference is greater than 1 mm, go to step 2 of the adjustment.
Otherwise DADF Side Registration is good.
Adjustment1. Adjust Side 1 DADF Side Registration.
a. Enter NVM Rear/Write (DC131) [710-005].
NOTE: Increasing value moves lead edge metrics LE1 through LE3 toward edge.
b. If B is more than A, increase the NVM value (5  = approx. 1 mm).
If B is less than A, decrease the NVM value (5  = approx. 1 mm).
c. Check results of adjustment and adjust if required.
2. Adjust Side 2 DADF Side Registration.
a. Enter following NVM Rear/Write (DC131) 
[710-025] for B5 SEF or smaller
[710-026] for B5 LEF, A4 SEF/LEF, 8.5x11 SEF/LEF
[710-027] for 8.5 x 14, B4, A3, 11x17
NOTE: Decreasing value moves lead edge metrics LE1 through LE3 toward edge.
b. If copy 2 edge metric is farther away from edge than copy 1, decrease the NVM
value ( 5  = approx. 1 mm).
If copy 2 edge metric is closer to edge than copy 1, increase the NVM value (5 =
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 [710-02X].
[710-02X] 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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ADJ 5.6
Repairs and Adjustments Prelaunch Training/Review
ADJ 5.6  DADF Document DetectionPurposePreliminary-Enable document size sensing.CheckdC927 Size Detection Automatic Correction
Perform this adjustment when the following operation is conducted:  
ï Replacing of the DADF ASSY.  
ï When an error is detected after replacing Registration Roll, Feed Roll, and Retard Roll.
ï When an error is found on the size detection.
Scan three sheets of document continuously in the DADF. Comparing the Slow Scan length
detected in the DADF with the standard value, correct the NVM data automatically.  The NVM
data subject to the correction is Document Slow Scan size correction value in Non CVT Mode
(Chain Link No.710-003).
Documents for scanning differ depending on each market as below.
FX, XE/AP: A4LEF (Slow scan length accuracy (210.0mm ±0.7mm))
XC: 8.5x11LEF (Slow scan length accuracy (215.9mm ±0.7mm))Adjustment1. Enter dC 527.
2. Set three documents to be transported in the DADF.
*Document sizes to be transported differ depending on each market.
FX, XE/AP: A4LEF (Slow scan length accuracy (210.0mm ±0.7mm))
XC: 8.5x11LEF (Slow scan length accuracy (215.9mm ±0.7mm))
3. When the [Enter] button is pressed, DADF starts pulling in the document and calculate the
correction value.  At this point, the [Entering] message appears.
4. The corresponding NVM data is updated and PSW screen indicates that the process has
been completed
Or, if this process becomes NG, the NVM data is not updated and the message telling that
NG has occurred appears on the screen.
5.  Pressing the [Exit] button completes the servicing.
Specification on Result Confirmation
The following result can be checked in the NVM Read after the process completes.
ï Once this process has started, it cannot be stopped (interrupted) half-way until it com-
pletes irrespective of success or failure.
ï This process does not allow the fourth sheet onwards to be pulled in when documents of
four or more sheets are set in the DADF.
NOTE: If the result is NG after the adjustment, perform the process again.
Table 1 
Chain-Link Indicated Data Name Remarks
710-003 Document slow scan size 
correction value in Non 
CVT ModeSetup Range=144~256
(Equivalent to ±56 Step 
[±10mm] 
						

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ADJ 5.7
Prelaunch Training/Review Repairs and Adjustments
ADJ 5.7  DADF Non-standard Document Custom 
RegistrationPurposePreliminary-Document sizes other than DADF detectable document size (non-standard size)
are registered and transported as standard document size.  Hence, special document sizes
specified by a user can be transported.CheckDocument size detection is performed based on custom-registered data and the DADF pro-
cess is performed by making the specified document sizes as scanning size.  Only one cus-
tom-registration is available.  If the registered data is valid, document size detection is
performed, placing priority over the existing detection table. 
Preparation:
1. Borrow the non-standard document to be custom- registered from the customer.
2. Check which direction (LEF or SEF) the customer wants to run in.
3. Check which paper size and direction the customer wants to make copies of.
4. Check the length of Fast Scan direction (X) and Slow Scan direction (Y) in Scale etc. of
the borrowed document accurately and write them down.Adjustment1. Enter the UI Diag and change the NVM Read/Write.
2. Set the following NVM Data to be custom-registered detection.
NOTE: Set Fast Scan direction max. value - Fast Scan direction min. value are 200 or
below.  (within 20mm)
NOTE: Set slow scan direction max. value - slow scan direction min. value are 200 or
below.  (within 20mm)
NOTE: The following sizes cannot be entered in order to prevent mis-detection of the size
sensor.
ï Fast Scan direction Max.:2190~2290
ï Fast Scan direction Min.:2810~2910
For the X and Y obtained at Preparation:
ï Set the 710-024 data to 1.  (Have the custom-registration valid.)
ï Store (X+10) x 10 in the 710-018 data.  (Set the Fast Scan direction Max. value)
ï Store (X-10) x 10 in the 710-019 data.  (Set the Fast Scan direction Min. value)
ï Store (Y+10) x 10 in the 710-020 data.  (Set the Slow scan direction Max. value)
ï Store (Y-10) x 10 in the 710-021 data.  (Set the Slow scan direction Min. value)
ï Enter the 710-022 data.  (Select the paper size that the customer specifies from the
table below, and enter it.)
ï Enter the 710-023 data.  (Select the paper direction that the customer specifies from
the table below, and enter it.)
Enter the 710-023 data.  (Select the paper direction that the customer specifies from
the table below, and enter it.)Enter the 710-023 data.  (Select the paper direction that the customer specifies from
the table below, and enter it.)
The following are information regarding the NVM entered above.
3. Check the settings of the NVM Data again.
4. Set the document that was custom-registered for the size detection table in the DADF and
feed it.  -> Check that the document size is detected as specified.
NOTE: Be careful with scan data image missing since the non-standard document size is
handled as standard document size.Table 1 
Chain-Link Indicated Data Name Remarks
710-018 Fast Scan direction Max. 
value  Note1)Setup Range=1297~3070  
Set by 0.1mm (initial 
value=2970)
710-019 Fast Scan direction Min. 
value  Note1)Setup Range=1297~3070  
Set by 0.1mm (initial 
value=2970)
710-020 Slow Scan direction Max. 
value  Note2)Setup Range=1297~4418  
Set by 0.1mm (initial 
value=2100)
710-021 Slow Scan direction Min. 
value  Note2)Setup Range=1297~4418  
Set by 0.1mm (initial 
value=2100)
710-022 Specified paper code for cus-
tom-registration03: 5.5 x 8.5
0.4: A5
05: B5
08: A4
09: 8x10
10: 8.5x11
11; 8.5x12.4
12: 8.5x13
13: 8.5x14
14: B4
15: A3
16: 11x17
17: 8K (267x388mm) 
20: ILLEGAL SIZE (Initial 
Value=08)
710-023 Feed direction of document 
size0: LEF, 1:SEF (Initial 
Va l u e = 0 ) 
						

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ADJ 6.1
Repairs and Adjustments Prelaunch Training/Review  Scanner
ADJ 6.1 Full/Half Rate CarriagePurposeEstablish Full Rate and Half Rate Carriage position. 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.
NOTE: The Half Rate Carriage is checked, and adjusted if required by repositioning a pulley.
Then the Full Rate Carriage is checked, and adjusted if required by repositioning the carriage
on the cable.
1. Remove Platen Glass (REP 6.2).
2. Remove Alignment Tools (2)  from Storage (Figure 1).
Figure 1 Removing Tools3. Align Half Rate Carriage with Rail Hole (Figure 2).
a. Manually move Full Rate Carriage away from home position approximately 105 mm
while observing Rail Tool Hole to align with Carriage Tool Hole in Half Rate Carriage.
Figure 2 Aligning Half Rate Carriage with Rail Hole
Remove Screws
(2) and Tools (2)
Rail Hole for 
Alignment ToolCarriage Hole 
for Alignment 
Tool Front of Scanner 
						

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ADJ 6.1
Prelaunch Training/Review Repairs and Adjustments 4. Install Alignment Tool in front end of Half Rate Carriage (Figure 3).
Figure 3 Installing Alignment Tool in Front End of Half Rate Carriage5. Check that tool will install in other end of carriage.
If the tool installs, go to step 6. 
If tool does not install, loosen the Set Screw (2) and turn the pulley to align the tool holes
with each other (Figure 4). 
Figure 4 Loosening the Set Screw (2) 
						

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ADJ 6.1
Repairs and Adjustments Prelaunch Training/Review 6. Check that Alignment Tool can be installed through frame into alignment hole in Full Rate
Carriage (Figure 5).
If Alignment Tool fits through frame hole into Full Rate Carriage Alignment Hole, perform
the same check at the rear of the carriage.  
If the rear of the carriage is aligned, the check is good.  
If the rear of the carriage is not aligned, go to the adjustment.
If Alignment Tool does not fit through frame hole into Full Rate Carriage Alignment Hole,
go to the adjustment.
Figure 5 Checking Alignment Tool in Full Rate Carriage
AdjustmentNOTE: Front of Full Rate Carriage shown.  Adjustment steps are same for rear of Full Rate
Carriage.
1. Adjust Full Rate Carriage (Figure 6).
a. Loosen Screw.
b. Move carriage so that Alignment Tool will drop into Alignment Holes.
c. Tighten Screw.
Figure 6 Adjust Full Rate Carriage
Screw
Alignment 
Holes 
						

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ADJ 6.1
Prelaunch Training/Review Repairs and Adjustments 
						

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ADJ 9.1, ADJ 9.2Repairs and Adjustments Prelaunch Training/Review
ADJ 9.1 Max Setup PurposeTo conduct a check of the machine and set it up so that excellent copy quality can be consis-
tently obtained by stabilizing the development potential and copy density.AdjustmentMax Setup consists of 5 separate adjustments that should be performed in the following
sequence:
1.ADJ 9.7, IIT Calibration (dC945)     
NOTE: Perform ADJ 9.2 only when replacing the ATC Sensor or Developer Housing.
2.ADJ 9.2, ATC Sensor Setup (dC921)
3.ADJ 9.3, TRC Control/Toner Density Setup (dC922)
4.ADJ 9.4, ADC Output (dC934)
NOTE: Perform ADJ 9.5 only when the customer requests.
5.ADJ 9.5, Manual TRC Adjust (dC924)
ADJ 9.2 ATC Sensor Setup (dC921)PurposeNOTE: This procedure should only be performed when the ATC Sensor or Developer Housing
has been replaced, or when there is reason to believe that the calibration values in NVM are
incorrect.
To set the calibration values [ATC Correction Coefficient], [ATC Correction Offset] in NVM  to
calibrate the new ATC Sensor.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 TC/ATC Sensor Setup tab.
4. Locate the ATC Sensor calibration code on the ATC Sensor. This is the 3-digit number in
the 3rd line of text on the label (it will always start with a zero).
5. Enter the last 2 digits of this code into the appropriate column of the first row.
6. Select the Read button.
7.  Proceed to ADJ 9.3, TRC Control/Toner Density Setup (dC922) 
						

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ADJ 9.3, ADJ 9.4
Prelaunch Training/Review Repairs and Adjustments
ADJ 9.3   TRC Control/Toner Density Setup (dC922)PurposeTo check the output of ATC Sensor and to determine if TC Control performed normally.  
Allows manual adjustment of TC if control is not functioning. Check1. 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 Control tab.
4. Load letter size paper (8.5 x 11 or A4) into Tray 1.
5. Select the Start button. The machine will read the output of the ATC Sensor and display
the results in the row labeled ATC Mean Detected Value. If the routine is unable to read
the ATC Sensor correctly, this fact will be displayed in the row labeled ATC Sensor Fail
Determination.
6. If the row labeled ATC Sensor Fail Determination displays OK for all colors, continue
with the check. If any color is not OK, go to the appropriate RAP (9-380 for yellow, 9-381
for magenta,09-382  for cyan, or 9-383 for black) to fix the problem before continuing with
this procedure.
7. Compare the data in the row labeled ATC Mean Detected Value with the data in the row
labeled ATC Control Environment Correction Standard. If the measured value for any
color is more than  50 bits higher or lower than the target (correction standard) value, per-
form the Adjustment.
8. If the Check is OK, proceed to ADJ 9.4, ADC Output Check.AdjustmentThe Tone Judge window in the upper right portion of the screen shows the result of the ATC
Sensor read. Perform the following steps to adjust the toner density.
1. Select Run. The control logic will automatically tone up or tone down each color per the
display.
2. When the tone up/down cycle is complete, select Start to re-run the check.
NOTE: It is not necessary to repeat the tone up/down procedure until the match is exact.
3. Repeat steps 2 and 3 until the ATC Mean Detected Value is within 50 bits of the AT C
Control Environment Correction Standard for all colors. 
4. Proceed to ADJ 9.4, ADC Output Check.
ADJ 9.4  ADC Output Check (dC934)Purposeï To check the following functions
ï ADC (2 gradation) patch for Potential Control on the IBT 
ï ADC Sensor output 
ï Laser Diode light outputCheck1. 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 ADC AGC Setup tab.
4. Select the Start button. The machine will read the output of the ADC Sensor, The Laser
Diode, and Developer bias, and display the results on the screen.
5. Check for unsatisfactory results:
ï If a fault code is declared, go to the RAP for that code. Resolve the problem, then
repeat the Check.
ïIf ADC Shutter Fail is NG go to the 9-654 RAP and troubleshoot the shutter sole-
noid circuits
ïIf ADC Sensor Fail is NG go to the 9-654 RAP and troubleshoot the sensor circuits.