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Tektronix 1235N - Phaser Color Laser Printer, Service Manual

The Tektronix 1235N - Phaser Color Laser Printer is a high-quality printing solution. Unlock the full potential of this device with the comprehensive Service Manual, offering step-by-step instructions and troubleshooting guidance. Download the manual for free from manualshive.com, and optimize the performance of your printer effortlessly.

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Service Guide

 

xiii

 

Tables

 

Entering special operating modes   14
Paper size detection   15
Physical dimensions   16
Printer clearances   16
Functional specifications   17
Electrical specifications   18
Environmental specifications   18
Printer fault messages   21
POWER Connector pinout   35
Motor and fuser roller resistances   38
Engine maintenance mode menu   62
Switch scans and the sensor and switches test   64
Motor and clutch test constraints   69
Test Print menu   71
Table 1:  Initialization items - consumables   73
Table 2:  Initialization items - calibration points   74
Consumable counter menu items   75
Consumable life-cycle counts   76
Periodically replaced parts   82
FRU parts list of the printer cabinet   188
FRU part list of the top cover assembly   190
FRU part list of the printer chassis (1 of 2)   192
FRU of the printer chassis (2 of 2)   194
FRU of the paper tray   196
FRU of the paper tray guide   198
FRUS of the multi-sheet bypass feeder   200
Electrical components FRUs   202
FRUs of the duplexer unit   204
FRUs of the Lower Tray Assembly   206
Hardware kit   208
Gear kit   208
Sensor flag kit   209
Harness kit   209
Customer replaceable consumables   210

Summary of Contents for 1235N - Phaser Color Laser Printer

Page 1: ...ersonnel only To avoid personal injury do not perform any servicing other than that contained in operating instructions unless you are qualified to do so This printing December 2000 071 0728 00 P H A S E R 1 2 3 5 N E T W O R K C O L O R P R I N T E R Service Quick Reference Guide ...

Page 2: ...demarks of Xerox Corporation TekColor CareSM and RealSUPPORTSM are service marks of Xerox Corporation FTP Software is a registered trademark of FTP Software Incorporated PCL and HP GL are registered trademarks of Hewlett Packard Corporation Novell and NetWare are registered trademarks of Novell Incorporated Sun Sun Microsystems and Sun Microsystems Computer Corporation are registered trademarks of...

Page 3: ...rly installed Do not operate in an atmosphere of explosive gases Safety instructions Read all installation instructions carefully before you plug the product into a power source Terms on CAUTION A personal injury hazard exists that may not be product apparent For example a panel may cover the hazardous area Also applies to a hazard to property including the product itself DANGER A personal injury ...

Page 4: ...esent Use care when servicing with power on Dangerous voltages may exist at several points in this product To avoid personal injury do not touch exposed connections and components while power is on Disconnect power before removing the power supply shield soldering or replacing components Do not wear jewelry Remove jewelry prior to servicing Rings necklaces and other metallic objects could come int...

Page 5: ...s and Messages 21 Error messages 21 Troubleshooting 31 Power on self diagnostic test 32 Print engine troubleshooting 33 Testing the print engine 33 Verifying printer operation by using its self test print 34 Verifying power supply operation 34 Measuring power supply voltages 34 Inspecting the low voltage power supply fuse 36 Safety interlocks 36 Testing for a shorted motor 37 Motor and fuser rolle...

Page 6: ...ng open when it is closed 47 High temperature error 47 Low temperature error 47 Invalid memory DIMM 47 Printing and print quality problems 48 Light or blurred images 48 Dark stained background 49 Blank print 50 Black stripe in direction of paper travel 51 White stripe in direction of paper travel 52 Poor fusing toner offsetting 53 Repeating defect or voids on print 54 Missing characters or voids i...

Page 7: ...Cleaning and Maintenance 81 Service preventive maintenance procedure 81 Recommended tools 82 Periodically replaced parts 82 Cleaning 83 Cleaning the LED bar 83 Cleaning the pickup roller 83 Resetting NVRAM 85 FRU Disassembly 87 Cabinet panels 87 Top cover 87 Left side cover 88 Right side cover 89 Rear cover 90 Front cover 91 Face up tray 92 Frames components 93 Right shield plate 93 Electrical cha...

Page 8: ...er tray lift arm roller 126 Multi sheet bypass feeder components 127 Multi sheet bypass feeder 127 Multi sheet bypass feeder entrance sensor actuator 129 Paper transport components 130 Tray 1 entrance sensor actuator 130 Belt entrance sensor actuator 131 Transfer belt unit 132 Registration components 133 Registration clutch 133 Registration motor assembly 134 Registration roller assembly A and dri...

Page 9: ...ntact assembly 160 Toner sensor actuators 161 Duplex unit 163 Optional paper feeder components 164 Idler roller assembly 164 Inner frame 166 Feeder clutch 169 Feeder motor 171 Feeder control board 173 Paper transport roll guide 175 Feeder drive assembly 177 Paper size sensing actuator 179 Paper size sensing board 180 Lower connector 181 Upper connector 183 Tray 2 3 feed roller and nudger roller 18...

Page 10: ...over 90 Removing the front cover 91 Removing the face up tray 92 Removing the right shield plate 93 Removing the electrical chassis 95 Removing the electrical chassis cooling fan 96 Disconnecting the registration motor in line connector HOPFF 97 Removing the printer unit chassis 98 Removing the main cooling fan 99 Removing the top shield plate 100 Removing the harnesses from the electrical chassis...

Page 11: ...ion roller assembly A and drive gear 136 Removing the registration roller assembly B 138 Removing the fuser unit 139 Fuser latching handle left 140 Removing the fuser latching handle right 141 Removing the fuser exit roller 143 Removing the exit sensor assembly 145 Removing the duplex guide assembly 147 Removing the eject guide assembly 148 Removing the LED Assembly power connector 149 Removing th...

Page 12: ...emoving the paper size sensing board 180 Removing the feeder control board cover plate 181 Removing the lower connector 182 Removing the feeder control board cover plate 183 Removing the upper connector 184 Removing the tray 2 3 feed roller and nudger roller 185 Cabinet FRUs 189 Top cover FRUs 191 Printer chassis FRUs 1 of 2 193 Printer chassis FRUs 2 of 2 195 Paper tray FRUs 197 Paper tray guide ...

Page 13: ...1 Initialization items consumables 73 Table 2 Initialization items calibration points 74 Consumable counter menu items 75 Consumable life cycle counts 76 Periodically replaced parts 82 FRU parts list of the printer cabinet 188 FRU part list of the top cover assembly 190 FRU part list of the printer chassis 1 of 2 192 FRU of the printer chassis 2 of 2 194 FRU of the paper tray 196 FRU of the paper ...

Page 14: ...xiv Phaser 1235 Network Color Printer ...

Page 15: ...uides adjustment procedures and a field replaceable units FRU list Topics such as printer theory of operation configuration page details and verifying printer operation are located on the companion Color Printer Service Support Resources CD ROM To ensure a complete understanding of the product we recommend participation in Phaser 1235 printer service training The Phaser 1235 Color Printer with low...

Page 16: ...features and capabilities of the Phaser 1235DT printers but includes 256 MBytes of RAM two lower feeder tray assemblies and a printer station cart The printer supports the following resolutions 600 x 600 dpi Normal 600 x 1200 dpi High quality The printer also accepts 300 x 300 dpi files from PCL legacy drivers PCL bit map fonts PCL bit map images although these are imaged at 600 x 600 dpi The reso...

Page 17: ...the same password are printed A secure job that has not been printed or released is retained on disk through power cycles The internal hard drive is required for this function TIFF Direct Printing TIFF files consist of compressed binary images The TIFF format itself has no capability to select printing options such as orientation paper size or duplexing All TIFF files downloaded to the printer are...

Page 18: ...ep the system controller board from booting up at all With more memory the printer gains the capabilities of printing without having to use image compression which trades less installed RAM for longer image processing time and dual frame buffers for printing one image while processing a second image which gives greater printing throughput The printer features three slots each of which can contain ...

Page 19: ...nt engine assemblies Print engine circuit boards 7098 Paper size sensing board Toner sensor board Control panel assembly Entrance sensor board Low voltage power supply High voltage power supply Duplex control in duplexer ...

Page 20: ...6 Phaser 1235 Network Color Printer Print engine circuit boards cont d 7099 Optional feeder System controller board Print engine controller board Feeder control Paper size sensing board ...

Page 21: ... full sensor Exit sensor Waste toner sensor Entrance cassette sensor Registration entrance sensor Belt entrance sensor Top cover interlock switch Front cover interlock switch Toner cartridge sensors Color registration sensor assembly Humidity sensor Temperature sensor ...

Page 22: ... Network Color Printer Print engine sensor and switch locations cont d 7101 Multi sheet bypass tray empty sensor OHP sensor Multi sheet bypass position sensor Fuser exit sensor Stack full sensor Belt entrance sensor ...

Page 23: ... 9 Print engine motors clutches and solenoids 7102 Duplex Gate solenoid Registration motor Registration clutch Registration shutter solenoid Transfer belt motor assembly Main feeder drive motor Duplex drive assembly ...

Page 24: ...10 Phaser 1235 Network Color Printer Optional feeder motor and clutch 7103 Feeder motor Feeder clutch Optional feeder ...

Page 25: ...Service Guide 11 The image processor board Features of the controller board SDRAM Token ring card Fan cooled processor Hard drive 0728 05 ...

Page 26: ...5 are used to scroll through the main menu Keys 2 and 6 navigate the sub menus and Keys 3 and 7 scroll sub menu values On Line LED Green in color this LED indicates when the printer is On Line and ready to process data When transitioning from On Line to Off Line the LED flashes at a rate of two times per second When data is being received and processed the LED flashes at a rate of once per second ...

Page 27: ...erface connectors Bi directional parallel IEEE 1284 B connector Twisted Pair 10 100baseT Ethernet connector With the addition of the Token Ring card the printer can connect to Token Ring network via its Ethernet interface The printer rear panel Ethernet port Parallel port 0728 03 ...

Page 28: ...PD located next to the LNK LED is off when the card is set for 4 megabits per second MBPS on when the card is set for 16 MBPS Entering special operating modes Key Combination Mode On Line 0 and Enter 4 This enables the Reset Menu to become available at the control panel The Reset Menu is not normally available to the customer as it contains the ability to format devices and perform a factory reset...

Page 29: ... activate four switches The combinations of the tab position indicate the size of the paper in the tray Paper size detection State of Microswitch Paper Size SW1 top SW2 SW3 SW4 bottom 0 0 0 0 No tray installed 0 1 1 1 Letter 0 1 0 1 Executive 0 0 1 1 A4 1 1 1 0 Legal 14 1 0 1 1 Legal 13 1 1 0 1 B5 1 1 0 0 A5 1 0 0 1 A6 Tray switch sensors and actuators Tray switch sensors and actuators Rotating se...

Page 30: ...ight About 51 kgs 112 2 lbs Printer clearances Clearances Specification Top 91 5 cm 36 in Left 30 5 cm 12 in Right 30 5 cm 12 in Front Unlimited for removal of consumables Rear 61 cm 24 in for connecting computer cable and power cord Mounting surface flatness Maximum deviation of 50 mm from horizontal side to side with all four feet in contact with the table surface ...

Page 31: ...le paper Tray A size letter Legal Folio Executive 7 25 x 10 5 in A4 size metric letter A5 B5 and A6 use only premium bond laser printer or copier paper Tray feed paper weight 60 to 176 g m2 16 to 47 lb Minimum paper size 148 mm x 210 mm 5 83 x 8 27 in Multi sheet bypass feeder A size letter Legal Folio Executive 7 25 x 10 5 in A4 size Metric letter A5 B5 and A6 Minimum paper size is 76 x 127 mm 3 ...

Page 32: ...2 Class A VCCI CISPR 22 Class B Environmental specifications Characteristic Specification Temperature Operating Non operating Storage 10 o to 32 o C 50 o to 90 o F 0 o to 32 o C 32 o to 90 o F 0 o to 45 o C 32 to 113 o F with supplies Media should be acclimated 24 hours before using in the printer Humidity Operating Non operating 10 to 85 relative humidity non condensing 10 to 95 relative humidity...

Page 33: ... Listed UL 1950 Information Processing and Business Equipment Certified CSA C22 2 No 950 Safety of Information Technology Equipment Including Electrical Business Equipment GS licensed IEC 950 1991 Second Edition EN60950 Information Processing and Business Equipment EN50022 CISPR 22 Class B EN61000 3 2 EN61000 3 3 VCCI CISPR 22 Class B FCC Class B for 115 VAC equipment pursuant to Sub part J of Par...

Page 34: ...20 Phaser 1235 Network Color Printer ...

Page 35: ...over A See Labels A7 Duplex Entry Jam 1 Ensure the correct weight and type of paper is loaded in the currently used tray Also ensure the paper is loaded correctly in the tray 2 Clean the duplex unit s rollers 3 Test the duplex motor and clutch as described in Motor and clutch tests on page 69 4 Replace the duplex unit 5 Replace the engine controller board A10 Jam A10 Remove Output Open Cover A See...

Page 36: ...he motor or clutch if necessary 5 Inspect the wiring for the registration clutch and registration motor 6 Replace the engine controller board B8 Jam B8 Open Cover B See Labels B8 Duplex Jam 1 Ensure the correct weight and type of paper is loaded in the currently used tray Also ensure the paper is loaded correctly in the tray 2 Clean the duplex unit s rollers 3 Test the duplex motor and clutch as d...

Page 37: ...sfeed Open Tray 2 Cover B E2 Tray 2 Misfeed E3 Tray 3 Misfeed Open Tray 3 Cover B E3 Tray 3 Misfeed 1 Ensure the correct weight and type of paper is loaded in the tray Also ensure the paper is loaded correctly in the tray 2 Clean the pick rollers 3 Test the main feed motor as described in Motor and clutch tests on page 69 4 Replace the main feed motor 5 Replace the engine controller board E9 Top C...

Page 38: ...drum unit 2 Inspect the spring loaded drum contact assembly Ensure they are clean and move up and down freely Remove the assembly and reseat it if necessary 3 Replace the engine controller board 4 Replace the printer unit chassis EE Transfer Belt Missing Reseat Belt Power Off On EE Transfer Belt Unit Missing 1 Remove and re install the transfer belt unit 2 Clean the transfer belt unit s contact on...

Page 39: ... 73 3 Replace the engine controller board J4 Replace Transfer Belt J4 Replace Transfer Belt 1 Install a new transfer belt 2 If a new transfer belt has been installed but the print engine continues to ask for a new transfer belt reset the transfer belt life count using the topic Consumable count initialization on page 73 3 Replace the engine controller board J5 Replace Yellow Drum J5 Replace Yellow...

Page 40: ...ror T29 Power Off On T29 Temp Sensor Error T30 RH Sensor Error T30 Power Off On T30 RH Sensor Error 1 Test the temperature sensor or the relative humidity sensor using the sensor test described in Switch scan test on page 63 2 Inspect the wiring harness leading to the entrance sensor board 3 Replace the entrance sensor board 4 Replace the engine controller board T31 Roller Over Temp T31 Power Off ...

Page 41: ...the engine controller board U6 Power Supply Error U6 Power Off On U6 Power Supply Error 1 Inspect the main cooling fan Ensure it is running correctly and is not blocked 2 Turn the printer off and then on 3 Replace the low voltage power supply 4 Replace the engine controller board U7 Feeder Home Error U7 Power Off On U7 Feeder Home Error 1 Test the manual bypass feeder home sensor using the test de...

Page 42: ...r 4 Replace the duplex unit 5 Replace the engine controller board U13 Tray 3 I F Error U13 Power Off On U13 Tray 3 I F Error U14 Tray 2 I F Error U14 Power Off On U14 Tray 2 I F Error 1 Turn the printer off and then on 2 Inspect the interface connector connecting the tray unit to the print engine Inspect the printer s corresponding connector on the underside of the printer Inspect the wiring harne...

Page 43: ...ess 4 Replace the toner sensor board 5 Replace the engine control board U26 Yellow Drum Error U26 Power Off On U26 Yellow Drum Error U27 Magenta Drum Error U27 Power Off On U27 Magenta Drum Error U28 Cyan Drum Error U28 Power Off On U28 Cyan Drum Error U29 Black Drum Error U29 Power Off On U29 Black Drum Error 1 Remove and install the drum unit 2 Inspect the spring loaded drum unit contacts in a s...

Page 44: ...oller board 9 IX Bad controller board 10 Parameter Flash R W not implemented 11 Strata Flash R W not implemented 12 Strata Flash Boot Block Integrity Bad controller board 13 Strata Flash File System Integrity Bad controller board 14 STE100 Bad controller board 15 VX2b 0 Bad controller board 16 VX2b 1 Bad controller board 17 VX2b 2 Bad controller board 18 VX2b 3 Bad controller board 19 Disk Identif...

Page 45: ...ng is discussed with two approaches A step by step verification procedure that systematically confirms that particular components of the printer are properly functioning until a problem is found A symptom cause scheme that lists particular printer failures or error codes and their possible causes ...

Page 46: ... engine fans are turned on and also checked to ensure they run properly The fuser heaters are activated to heat up the heated rollers The print engine checks to see that the imaging drum units are installed The engine motors are rotated to ensure that their rotation sensors are detected A sensor check is made to determine if any paper is jammed in the printer The print engine checks the presence o...

Page 47: ...on on page 34 2 Observe that the Ready message is displayed on the front panel If it is not go to the later topic Verifying power supply operation on page 34 3 To ensure the print engine operates correctly print one of its internal test pages as explained in the topic Test printing on page 71 If the printer prints a test print then the printer s print engine is working correctly Proceed with the n...

Page 48: ... and system controller board are working correctly and the printer s problem resides with the network or host interface Verifying power supply operation Verifying the power supply involves four steps Measuring the input and output voltages Checking the power supply fuse Checking its safety interlocks Testing for a shorted motor which would shut down the power supply or damage the engine controller...

Page 49: ... replace the power supply If DC voltages are not being output by the power supply proceed to the next step Inspecting the low voltage power supply fuse on page 36 If the 5 and 32 VDC voltages measure correctly but the printer does not operate correctly then proceed to the topic Safety interlocks on page 36 POWER Connector pinout Pin Voltage Signal Level Pin Voltage Signal Level 1 12 VDC 16 3 3 VDC...

Page 50: ...replace the low voltage power supply Safety interlocks The printer features two safety interlock switches Top door opened switch Front door opened switch When the top cover switch is opened the 32 VDC supply to the motors is shut down as well as the high voltage power supply When the front cover door is opened the 32 VDC supply to the duplex unit and high voltage power supply is disabled 5 Turn of...

Page 51: ...ing topic 3 Refer to the topic Wiring Diagram on page 215 for a diagram that locates each connector 4 Turn on the printer again to see if it overloads now that the motors are disconnected from the engine driver board If the power supply still does not function replace it Door safety interlock switches 0728 01 Top Cover Open Switch Front Cover Open Switch ...

Page 52: ...r belt motor Registration motor Fuser motor Main feed drive motor Between motor Pins 1 and 2 Between motor Pins 3 and 4 The transfer belt motor connects to connector BELTHET pins 5 thru 8 The feed motor connects to connector HOPFF pins 1 thru 4 The main motor connects to connector HOPFF pins 5 thru 8 10 8 Ω 10 8 Ω Fuser unit New fuser The resistance between pins C and D of the lower roller will be...

Page 53: ...x brand 35 Series transparency film for this printer should only be used 5 Refer to the media specifications in the table Functional specifications on page 17 Multiple sheet pick 1 Is the paper in good condition and appropriate for a laser printer Quality office laser printer paper works best 2 Is the printer printing within its environmental specifications Print the Diagnostic Summary Page to det...

Page 54: ...paper path 7 Is the media excessively curled 8 Is the customer using an appropriate type of media a type the printer can handle 9 Ensure the corners or the paper are under the tabs in the corners of the tray 10 Replace the paper pick rollers Paper tray indicates it is empty when it is not The procedure for troubleshooting this problem applies to the lower tray assembly as well 1 Does the paper emp...

Page 55: ... for a laser printer 2 Is the printer printing within its environmental specifications Print the Diagnostic Summary Page to determine the printer s environmental conditions 3 Are the pick rollers dirty If so clean them with an a dry lint free cloth if debris is visible and try printing again 4 Remove the paper tray and inspect the paper tray lift levers on the inner sides of the paper tray cavity ...

Page 56: ...oller board Paper jams at the registration rollers 1 Ensure that the pick up rollers are clean Clean them with an a dry lint free cloth if debris is visible 2 Check the paper path for burrs or foreign obstructions that could block the movement of a sheet of paper 3 Clean the registration rollers with an a dry lint free cloth if debris is visible 4 Test and if necessary replace the registration mot...

Page 57: ...ace down tray In such cases a lighter grade of paper should be used or face up mode to the rear output tray should be used 4 Is the paper excessively curved after passing through the fuser Try flipping the paper over in the paper tray 5 Clean all the eject rollers with an a dry lint free cloth if debris is visible 6 Does the exit sensor flag properly actuate its sensor Test the sensor using the se...

Page 58: ...ted with toner Remove an assembly from the printer to inspect if necessary 3 Open the top cover defeat the top cover open switch and observe if the color imaging drum unit are lifted up and down 4 Test the drum contact assemblies using service test Switch scan test on page 63 If a drum contact assembly is damaged replace it 5 Does each imaging drum motor rotate Test them using the service test Mot...

Page 59: ...AC voltage appear between Pins 1 and 2 of CN 4 1 and CN 4 2 of the fuser connector These pins connect to Pins A and B of the fuser illustrated below when the fuser is installed Remove the fuser to check If not replace the power supply Bear in mind that the correct AC voltage may be present at Pins 1 and 2 of CN 4 1 and CN 4 2 even though the drivers feeding these pins are damaged and cannot delive...

Page 60: ...izes If there was a problem with the system controller board it will now not affect the print engine controller board c If the print engine powers up correctly a traveling moves around the control panel display If not then your problem is most likely associated with the print engine controller board and you will need to replace it If however you see the traveling then the most likely cause is the ...

Page 61: ...ser is cold 4 Ensure the fuser unit is properly installed 5 Check the fuser unit s connection and wiring 6 Replace the fuser unit 7 Replace the low voltage power supply 8 Replace the engine controller board If the fuser is hot 1 Replace the fuser 2 Replace the engine controller board Invalid memory DIMM 1 Upon power up the system controller board checks each DIMM for information such as data width...

Page 62: ...o the POWER connector pins 1 2 3 4 5 6 7 and 8 on the junction board or at the 16 pin interconnect near the top cover hinge under the top shield plate Inspect the junction board s wiring connectors If the voltage is not OK replace the low voltage power supply 9 If 32 volts supplied to the POWER connector pins 7 8 9 and 10 on the engine controller board Inspect the wiring harnesses or replace the l...

Page 63: ... LED head assembly If yes replace the LED head assembly 8 Is 3 8 V supplied to the POWER connector pins 1 2 3 4 5 6 7 and 8 on the junction board or at the 16 pin interconnect near the top cover hinge under the top shield plate Inspect the junction board s wiring connectors If the voltage is not OK replace the low voltage power supply 9 If 32 volts supplied to the POWER connector pins 7 8 9 and 10...

Page 64: ... the top cover hinge under the top shield plate Inspect the junction board s wiring connectors If the voltage is not OK replace the low voltage power supply 5 If 32 volts supplied to the POWER connector pins 7 8 9 and 10 on the engine controller board Inspect the wiring harnesses or replace the low voltage power supply 6 Is 32V supplied to the HVOLT connector Pin 5 of the engine board If not repla...

Page 65: ... near the top cover hinge under the top shield plate Inspect the junction board s wiring connectors If the voltage is not OK replace the low voltage power supply 5 If 32 volts supplied to the POWER connector pins 7 8 9 and 10 on the engine controller board Inspect the wiring harnesses or replace the low voltage power supply 6 Is 32V supplied to the HVOLT connector Pin 5 of the engine board If not ...

Page 66: ... junction board or at the 16 pin interconnect near the top cover hinge under the top shield plate Inspect the junction board s wiring connectors If the voltage is not OK replace the low voltage power supply 6 If 32 volts supplied to the POWER connector pins 7 8 9 and 10 on the engine controller board Inspect the wiring harnesses or replace the low voltage power supply 7 Is 32V supplied to the HVOL...

Page 67: ...enance mode fuser test Test printing on page 71 and check the temperature displayed on the controller panel 9 Replace the engine controller board Transfer the old engine controller board s EEPROM lower right corner of board to the new engine controller board Offsetting and fuser temperature Offsetting occurs on specialty paper if the fuser s temperature does not match the paper loaded in the multi...

Page 68: ...ped something other than round If the spots are about 115 mm 4 in apart then the problem is a defect on a fuser roller Replace the fuser If the spots are 57 8 mm 2 27 in the problem is with the transfer roller of the transfer belt unit Replace the transfer belt unit 94 2 mm 3 7 in Imaging drum Replace the imaging drum unit 49 mm 1 9 in Developing roller Replace the imaging drum unit of the affecte...

Page 69: ... to the POWER connector pins 1 2 3 4 5 6 7 and 8 on the junction board or at the 16 pin interconnect near the top cover hinge under the top shield plate Inspect the junction board s wiring connectors If the voltage is not OK replace the low voltage power supply 8 If 32 volts supplied to the POWER connector pins 7 8 9 and 10 on the engine controller board Inspect the wiring harnesses or replace the...

Page 70: ...sure the spring loaded pins travel smoothly up and down 4 Replace any imaging drum units you suspect are defective 5 Are the LED heads ribbon cables undamaged and properly seated Replace any suspect LED head assembly if necessary 6 Inspect the wiring harnesses of the junction board for damage or improper seating 7 Inspect the wiring harnesses of the engine controller board for damage or improper s...

Page 71: ...6 Is 3 8 V supplied to the POWER connector pins 1 2 3 4 5 6 7 and 8 on the junction board or at the 16 pin interconnect near the top cover hinge under the top shield plate Inspect the junction board s wiring connectors If the voltage is not OK replace the low voltage power supply 7 If 32 volts supplied to the POWER connector pins 7 8 9 and 10 on the engine controller board Inspect the wiring harne...

Page 72: ... the paper feeder Image is not centered on the print 1 Is the paper in good condition and appropriate for a laser printer 2 Is the printer printing within its environmental specifications Print the Diagnostic Summary Page to determine the printer s conditions 3 Ensure that paper feed rollers are clean and undamaged Inspect its paper pick roller Look for obstructions in the paper path 4 Clean the f...

Page 73: ...rt Hotline for further assistance Please have the error page in hand 6 If available try printing to a black and white PostScript Level 2 printer such as an Apple LaserWriter If the file does not print on the black and white PostScript printer this may mean that the problem is application or network related Image is rotated 90 degrees 1 In the application s Page Setup make sure that the image is se...

Page 74: ...printer s Configuration Page 6 Verify that the printer is correctly cabled to the network and that the Ethernet cable functions properly 7 Locate and remove and Windows NT shared printers that have captured the AppleTalk queue for the printer 8 Verify the driver version for the built in Ethernet port on a Macintosh G3 9 Reset the printer s NVRAM settings 10 Disable QuickDraw GX Windows printing pr...

Page 75: ...enu 1 key to enter the maintenance mode menu 6 Press the Item 2 or 6 keys to scroll through the menu 7 Press the Enter 4 key to activate the displayed menu item Press the Enter 4 key again to discontinue a test in progress Use engine maintenance mode to test the printer sensors test the media transport system test the imaging LED banks and to reset NVRAM To exit engine maintenance mode while DIAGN...

Page 76: ...d motor or clutch is operated for 10 seconds TEST PRINT Items set for test print Select parameters of print such as paper source and print mode Test start stop Test the print engine s ability to print NV RAM INITIAL consumables count reset TABLE 1 TABLE 2 TABLE 3 Test start stop The selected table determines which items will be initialized The counter values are initialized after exchanging the dr...

Page 77: ...AN tests The table below list the SCAN test items and which sensors and switches and test by that menu item 4 Pressing the Value 3 key activates the currently displayed switch scan test The SWITCH SCAN number begins to blink and the corresponding logic state High or Low of the particular switches or sensors scanned by the test listed as 1 2 3 and 4 are displayed 5 With a test active you can manual...

Page 78: ...64 Phaser 1235 Network Color Printer ...

Page 79: ...dge Present Switch Scan 02 1 L Deactuated H Unit installed Open top cover and actuate sensor flag next to LED head Cyan Toner Cartridge Present Switch Scan 02 2 L Deactuated H Unit installed Open top cover and actuate sensor flag next to LED head Magenta Toner Cartridge Present Switch Scan 02 3 L Deactuated H Unit installed Open top cover and actuate sensor flag next to LED head Yellow Toner Cartr...

Page 80: ...Switch Scan 09 1 Encoded fuser roller temperature Temperature is encoded as a hexidecimal value The default is between 16 and A1 not used Switch Scan 09 2 not used Lower Fuser Thermistor 00F Switch Scan 09 3 Encoded fuser roller temperature Temperature is encoded as a hexidecimal value The default is between 16 and A1 not used Switch Scan 09 4 not used Humidity Sensor Switch Scan 10 1 Encoded envi...

Page 81: ... not used not used Switch Scan 14 2 not used Tray 2 Feed Sensor Switch Scan 14 3 L Actuated H Deactuated Open front door and toggle sensor flag behind feed rollers not used Switch Scan 14 4 not used Tray 3 Size 1 Switch Top Switch Scan 15 1 L Actuated H Deactuated Remove the tray and actuate the sensor flags on right side of tray cavity Tray 3 Size 2 Switch Switch Scan 15 2 L Actuated H Deactuated...

Page 82: ...h Scan 17 4 not used not used Switch Scan 18 not used not used Switch Scan 19 not used not used Switch Scan 20 not used not used Switch Scan 21 not used Switch scans and the sensor and switches test Switch or sensor Switch scan test Test result Details ...

Page 83: ...tart the displayed test The displayed test item blinks and the selected motor or clutch is driven for 10 seconds 6 Press the Value 7 key to stop the unit 7 Repeat the Steps 2 to 7 for other motor or clutch tests 8 Press Enter 4 ends the tests Motor and clutch test constraints Motor or clutch displayed on control panel Constraints displayed on control panel Details BLACK ID MOTOR REMOVE ID Run test...

Page 84: ...OTOR OPTION none Listen for the motor turning for about 5 seconds DUPLEX CLUTCH none none TRAY2 MOTOR OPTION EXIT TRAY2 CASSETTE Run the test with Tray 2 removed TRAY2 FEED ROLLER CLUTCH OPTION none none TRAY3 FEEDER MOTOR OPTION EXIT TRAY3 CASSETTE Run the test with Tray 3 removed TRAY3 FEED ROLLER CLUTCH OPTION none none MBF MOTOR Remove media form the multi sheet bypass feeder Open the multi sh...

Page 85: ...as which tray to print from and to print in blank and white or color Test Print menu Display Set Value Function PRINT EXECUTE Press Value 3 to start printing Press Value 7 to stop printing TEST PATTERN 1 Selection of Printing Patterns 1 LED Head Drive Pattern 2 Color Registration Adjust Pattern 3 Reserved 4 Gray pattern 5 Thin lines 6 Colored stripes 7 thru 14 Blank 2 3 4 5 6 7 14 CASSETTE TRAY1 L...

Page 86: ... showing at warm up and during printing P Number of sheets printed for test in units of sheets U Upper fuser heater temperature measurement in degrees Celsius L Lower fuser heater temperature measurement in degrees Celsius T Environmental temperature measurement in degrees Celsius H Environmental humidity measurement in units of The key Value 3 changes the display 7 Press Enter 4 to end the test ...

Page 87: ...alized Refer to the tables printed below 4 Press and hold Value 3 for 10 seconds to initialize the items of the selected table The front panel display NV RAM INITIAL blinks eight times 5 Press Enter 4 to exit the test mode Table 1 Initialization items consumables Initialization Item Detail Drum Counter Black Yellow Magenta Cyan Initializes the drum counter s count after the replacement of a drum B...

Page 88: ...alization of X axis Corrections for yellow magenta and cyan LED heads 0 1 1200 inch Registration Set Point y axis Left Yellow LED Magenta LED Cyan LED Initialization of Y axis Left Corrections for yellow magenta and cyan LED heads 0 1 1200 inch Registration Set Point y axis Right Yellow LED Magenta LED Cyan LED Initialization of X axis Right Corrections for yellow magenta and cyan LED heads 0 1 12...

Page 89: ...isplayed with the item The table below lists the menu items 4 Press Enter 4 to end the test Consumable counter menu items Upper Display Lower Display Detail FUSER UNIT IMAGES Shows the number of sheets fed since installation of a new fuser unit TR BELT UNIT IMAGES Shows the number of sheets fed since installation of a new transfer belt unit BLACK ID UNIT IMAGES Indicates the number of images proce...

Page 90: ...s on the upper display 3 Press the Item 2 6 keys to scroll through the list of supply items The life cycle consumption value is displayed with the item The table below lists the menu items 1 Press Enter 4 to end the test Consumable life cycle counts Upper Display Lower Display Unit Detail TOTAL SHEETS FED PRINTS Prints Indicates the total number of sheets fed including blank paper BLACK IMPRESSION...

Page 91: ... Balance The Black Density Images numbered 3K 0 3K show a lightness darkness range of 30 halftones using black only The Color Density Images numbered 3CMY 0 3CMY show a lightness darkness range of 30 gray halftones using three colors cyan magenta yellow The Color Balance Images numbered 0 10 11 21 show variations of three color gray Each of these circles contains gray with tints of other colors Co...

Page 92: ...circle to be the closest gray of any of the circles when compared to the gray background Making adjustments Use the following procedures to make adjustments to the color density and balance Black density adjustment 1 Press Item 2 6 keys until you see Color Adjust Menu Black Density 2 Press Value 3 7 keys until you see Black Density New Value Values are 3K 2K 1K 0 1K 2K 3K 3 Press Enter The Color A...

Page 93: ...re 0 1 2 3 4 5 6 7 8 9 10 11 12 13 4 Press Enter The Color Adjust Page prints and the front panel displays Color Adjust Menu Color Balance Repeat Steps 2 and 3 above until you are satisfied with the results Adjustment recovery While in the color adjustment routine you can choose to return the values to the factory default values by using the Color Adjust menu s Color Defaults item The printer will...

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Page 95: ...ing steps assures proper operation of the printer and reduces the probability of having to service the printer in the future The frequency of use and the type of paper a customer prints on determines how critical cleaning the machine is Users of ordinary laser Bond paper copier paper should have very few problems since this paper is smooth and relatively dust free You should thoroughly inspect and...

Page 96: ...print density No adjustment required after replacing toner cartridge Hi Capacity Toner Cartridge When the message is displayed When 10 000 pages are printed out 5 print density No adjustment required after replacing toner cartridge Drum Units When the message is displayed When 22 000 pages are printed out For 5 pages per job Letter size paper The printer s imaging drum unit counters are automatica...

Page 97: ...s such as a void or light printing running vertically down of the paper Clean the lens with an alcohol wipe to clean the LED bar An alcohol wipe always comes with the toner cartridge Print the 100 Color Stripe Pattern If a light or white stripe appears in any primary color or a secondary color has an irregular color streak clean the LED lens of the affected color Cleaning the pickup roller When mi...

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Page 99: ...our selection Network Defaults network settings Use the Item 2 6 keys to activate the Confirm Action Yes No menu Press Enter to confirm your selection Demo Mode Use the Item 2 6 keys to activate the Confirm Action Yes No menu Press Enter to confirm your selection CRU Reset consumable print counts Use the Item 2 6 keys to scroll through the list of consumable items Use the Value 2 6 keys to activat...

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Page 101: ...t settings and soft switch settings are covered in Service Tests and Adjustments on page 61 Cabinet panels Top cover Warning Switch off the power and disconnect the power cord 1 Open the top cover Remove the drum toner cartridge basket and store in a lightproof bag to protect the drum units from light 2 Remove the nine screws securing the top cover to the top cover inner unit 3 Remove the top cove...

Page 102: ...ont cover 3 Remove the drum toner cartridge basket Cover the basket in a lightproof black bag to protect the drum units from light and store in a safe place 4 Remove the four screws securing the left side cover 5 Pull the top of the cover out then up to remove To reinstall the left side cover reverse the removal order Removing the left side cover ...

Page 103: ...er cartridge basket Cover the basket in a lightproof black bag to protect the drum units from light and store in a safe place 2 Open the front cover 3 Remove the five screws securing the right side cover 4 Pull the right side cover up and out to remove Reverse these steps to install the right side cover Removing the right side cover ...

Page 104: ...topic Right side cover on page 89 5 Close the top cover 6 Remove the four screws securing the rear cover to the printer 7 Remove the rear cover To install the rear cover open the face up tray Note Ensure that the face up tray gate spring extends out the face up tray opening Reverse the removal steps to install the rear cover Install the rear cover with the face up tray in the open position to ensu...

Page 105: ... 3 Open the front cover 4 Open the front cover inner baffle 5 Carefully press the right side of the front cover to the left until the hinge pin disconnects from the printer Note If the printer is sitting on an optional lower tray assembly prop the front of the printer up about 12 mm 1 2 in to remove the front cover and inner baffle 6 Slide the front cover and inner baffle to the right and remove R...

Page 106: ...etwork Color Printer Face up tray 1 Open the face up tray 2 Carefully pry the left stopper pin free of the rear cover 3 Remove the face up tray Reverse these steps to install the face up tray Removing the face up tray ...

Page 107: ... toner cartridge basket Cover the basket in a lightproof black bag to protect the drum units from light and store in a safe place 3 Remove the right side cover as explained in Right side cover on page 89 4 Remove the screws securing the right shield plate 5 Remove the right shield plate Reverse these steps to install the right shield plate Removing the right shield plate ...

Page 108: ...te as explained on page 93 7 Remove the multi sheet bypass feeder as detailed on page 127 8 Remove the four screws securing the top shield plate to the electrical chassis Note To aid in reconnecting the harnesses label the harnesses as you disconnect them 9 Disconnect all the connectors from the print engine controller board 10 Pull out the disconnected harnesses routed through the top of the chas...

Page 109: ...al chassis Reverse these steps to install the electrical chassis Note Attached to the back of the electrical chassis is a grounding tab As you reinstall the chassis ensure that the tab is not deformed and is positioned on the end of the paper feed shaft Removing the electrical chassis ...

Page 110: ...om light and store in a safe place 2 Open the front cover 3 Remove the right side cover as shown on page 89 4 Remove the right shield plate as shown on page 93 5 Disconnect connector FAN 1 from the print engine controller board 6 Remove the two screws and spacers securing the fan to the electrical chassis 7 Remove the electrical chassis cooling fan Reverse these steps to install the electrical cha...

Page 111: ...ide cover as described in the topic Right side cover on page 89 7 Remove the right shield plate as described in the topic Right shield plate on page 93 8 Remove the rear shield plate it is secured by four screws 9 Remove the left shield plate it is secured by ten screws 10 Remove the rear cover as described in Rear cover on page 90 Remove the top cover as described in the topic Top cover on page 8...

Page 112: ... print engine controller board 18 Remove the ten screws securing the printer unit chassis to the frame 19 Lift the chassis about 7 5 cm 3 in while guiding the AC receptacle wiring through the rear chassis frame Also guide the printer unit chassis past the wiring at the front of the electrical chassis 20 Lift the printer unit chassis from the main chassis Rest the chassis upside down on a table Not...

Page 113: ... in the topic Left side cover on page 88 Also remove the left side shield plate 4 Remove the rear shield plate it is secured by four screws 5 Remove the left shield plate it is secured by ten screws 6 Remove the rear cover as described in Rear cover on page 90 7 Disconnect the main cooling fan s wiring harness from the low voltage power supply board 8 Slide the main cooling fan out of the printer ...

Page 114: ...ag and store in a safe place 2 Open the front cover 3 Remove the left side cover as detailed on page 88 4 Remove the right side cover as detailed on page 89 5 Remove the right shield plate as shown on page 93 6 Disconnect the nine LED connectors from the print engine controller board 7 Remove the four screws securing the top shield plate to the electrical chassis 8 Remove the shield plate Removing...

Page 115: ... and the metal washer from the center of the pivot arm 14 Remove the screw from the center of the right pivot arm 15 Remove the system controller board 16 From the top of the chassis remove the two screws holding the system controller board s upper guide rail 17 Through the access hole in the top of the electrical chassis loosen but do not remove the screw holding the strap to the right pivot arm ...

Page 116: ...e of the assembly is free of the printer 20 Carefully pull the right pivot arm out until the right side is free Caution Do not set the top cover inner frame face down as the LED assemblies or the LED mounting brackets can be damaged 21 Remove the top cover inner frame Reverse these steps to install the top cover inner frame Removing the top cover inner frame ...

Page 117: ...ct the power cord 1 Remove the top cover inner frame as described in the topic Top cover inner frame on page 100 2 Remove the four screws securing the top cover spring assembly Reverse these steps to install the left right top cover spring assembly Removing the left right top cover spring assembly ...

Page 118: ...unit if installed 3 Remove the electrical chassis as described on Electrical chassis card cage on page 94 4 Remove the printer unit chassis as shown on page 97 5 Remove the four screws securing the lower plate to the paper tray guide assemblies 6 Disconnect CN1 from the low voltage power supply 7 Lift the lower plate and power supplies from the tray guides Removing the lower plate assembly ...

Page 119: ...s detailed on page 123 9 Remove the three screws securing the left paper tray guide assembly to the bottom plate 10 Lift and remove the assembly Reverse these steps to install the left paper tray guide assembly Removing the left paper tray guide assembly ...

Page 120: ...e on page 94 2 Remove the printer unit chassis as shown on page 97 3 Remove the four screws securing the lower plate to the paper tray guide assemblies 4 Lift the lower metal shield plate from the right side of the metal plate and paper guide assembly 5 Disconnect CN1 from the low voltage power supply 6 Lift the lower plate and power supplies from the tray guides Removing the paper tray guide asse...

Page 121: ...etailed on page 123 8 Remove the five screws securing the right paper tray guide assembly to the bottom plate 9 Lift and remove the guide assembly Reverse these steps to install the right paper tray guide assembly Removing the right paper tray guide assembly ...

Page 122: ...r unit chassis as shown on page 97 2 Remove the two screws from the high voltage power supply fan Let the fan rest on the front of the lower plate 3 Remove the four screws securing the left plate assembly to the lower plate 4 Remove the assembly Reverse these steps to install the left plate assembly Removing the left plate assembly ...

Page 123: ...wer cord 1 Disconnect all cables connected to the rear of the system controller 2 Remove the two thumb screws securing the system controller to the printer 3 Slide the system controller out to the rear of the printer Reverse these steps to install the system controller board Removing the system controller board ...

Page 124: ... Remove the right shield plate as shown on page 93 5 Remove the system controller board as shown on page 109 6 Disconnect all connectors connected to the print engine controller board Remove the EMI suppessor coils and cable ties as necessary 7 Remove the five screws securing the print engine controller board 8 Remove the engine controller board Reverse these steps to install the print engine cont...

Page 125: ...top cover inner unit 4 Remove the four screws securing the metal shield over the toner sensor board 5 Remove the three screws securing the toner sensor board 6 Rotate the board up to expose the component side of the board Note Note for reassembly how the ribbon cables are routed under the sensor board in the next step 7 Disconnect the PANEL OPTN STUCK and POWER harnesses from the toner sensor boar...

Page 126: ...se steps to install the toner sensor board Ensure that all harnesses are in the cable channel Caution Ensure the ribbon cables are properly routed and dressed Do not crunch or fold the ribbon cables while installing the toner sensor board Removing the toner sensor board ...

Page 127: ...inter unit chassis as detailed on page 97 3 Remove registration roller assembly B as explained on page 137 4 Remove the spring loaded tray 1 entrance sensor actuator as explained on page 130 5 Remove the two screws securing the entrance sensor board 6 Remove the board and disconnect harness from FSNS Reverse these steps to install the entrance sensor board Removing the entrance sensor board ...

Page 128: ...hassis as detailed in the topic Printer unit chassis and low voltage power supply fan on page 97 2 Disconnect CN3 from the low voltage power supply 3 Disconnect CN1 from the high voltage power supply 4 Remove the three screws securing the high voltage power supply to the chassis 5 Lift the high voltage power supply and the contact assembly and remove ...

Page 129: ...Service Guide 115 6 Remove the contact assembly from the high voltage power supply Reverse these steps to install the high voltage power supply Removing the high voltage power supply ...

Page 130: ...n page 97 2 Disconnect CN3 CN1 CN2 from the low voltage power supply 3 Remove the six screws securing the low voltage power supply to the printer Disconnect the AC ground wire from the printer frame 4 Lift the power switch SW1 and the low voltage power supply to remove Reverse these steps to install the low voltage power supply Removing the low voltage power supply ...

Page 131: ... Remove the top cover as detailed in Top cover on page 87 2 Remove the screw securing the left side of the control panel 3 Lift the control panel and disconnect CN1 from the back of the panel 4 Remove the control panel Reverse these steps to install the control panel Removing the control panel ...

Page 132: ...ase the locking tab on the left end of the feed roller 3 Slide the feed roller to the left and remove 4 Release the locking tab on the left end of the nudger roller 5 Slide the nudger roller to the left and remove Reverse these steps to install the feed roller and nudger roller Removing the feed roller and nudger roller ...

Page 133: ...move the paper tray from the printer 2 Remove the two springs 3 Use a small screwdriver to carefully pry both arms free of the mounting pins 4 Remove the retard pad Reverse these steps to install the retard pad Removing the retard pad ...

Page 134: ... feeder as described in the topic Multi sheet bypass feeder on page 127 4 Remove the electrical chassis as described in the topic Electrical chassis card cage on page 94 5 Remove paper tray 1 6 Reaching in through the cavity left by paper tray 1 remove the screws securing the paper size sensing actuator Remove the actuator 7 Again reaching in through the cavity left by paper tray 1 remove the scre...

Page 135: ...Service Guide 121 Reverse these steps to install the paper size sensing board Removing the paper size sensing board ...

Page 136: ... Warning Switch off the power and disconnect the power cord 1 Remove paper tray 1 2 Remove the screw securing the paper size sensing actuator 3 Remove the actuator Reverse these steps to install the paper size sensing actuator Removing the paper size sensing actuator ...

Page 137: ...unit chassis and low voltage power supply fan on page 97 3 Remove the four screws securing the lower plate to the paper tray guide assemblies 4 Disconnect CN1 from the low voltage power supply 5 Lift the lower plate and power supplies from the tray guides 6 Remove the four screws securing the main feeder assembly to the tray guides 7 Disconnect harnesses from the optional feeder connector 8 Pull h...

Page 138: ...124 Phaser 1235 Network Color Printer 9 Lift and remove the main feeder assembly Reverse these steps to install the main feeder assembly Removing the main feeder assembly ...

Page 139: ...chassis as described in the topic Printer unit chassis and low voltage power supply fan on page 97 3 Remove the main feeder assembly as described in the previous procedure Main feeder assembly on page 123 4 The no paper and low paper sensors are not spared separately If either sensor is defective replace the main feeder assembly Reverse these steps to install the main feeder assembly Removing the ...

Page 140: ...f the power and disconnect the power cord 1 Remove paper tray 1 Caution Take care not to break the locking tabs in the next step 2 Release the two locking tabs and remove the roller Reverse these steps to install the paper tray lift arm roller Removing the paper tray lift arm roller ...

Page 141: ... and lower EMI suppressors on the print engine controller harnesses Use a small screwdriver to release the latch on each suppressor Cut cable ties as necessary 7 Disconnect the wiring harnesses REG HUMTMP and COVOPN from the print engine controller board 8 Remove the three screws securing the multi sheet bypass feeder top cover Remove the cover 9 Open the multi sheet bypass feeder tray 10 Remove t...

Page 142: ...128 Phaser 1235 Network Color Printer Reverse these steps to install the multi sheet bypass feeder Removing the multi sheet bypass feeder ...

Page 143: ...ve the Tray 1 entrance sensor actuator as detailed in the topic on page 130 4 Remove the entrance sensor board as shown on page 113 5 From the bottom squeeze the two locking tabs securing the multi sheet bypass feeder entrance sensor actuator 6 Remove the actuator from the top Reverse these steps to install the multi sheet bypass feeder entrance sensor actuator Ensure that the spring arm is in the...

Page 144: ...inter unit chassis as detailed in the topic on page 97 2 From the bottom of the printer unit chassis carefully squeeze the two locking tabs and remove the sensor For reassembly reinstall the entrance sensor actuator Ensure the spring arm is on the plastic post Reverse these steps to install the tray 1 entrance sensor actuator Removing the tray 1 entrance sensor actuator ...

Page 145: ...ray 1 entrance sensor actuator on page 130 3 Remove the entrance sensor board as described in the topic Entrance sensor board on page 113 4 From the bottom squeeze the two locking tabs securing the belt entrance sensor actuator 5 Remove the actuator from the top Reverse these steps to install the belt entrance actuator For reassembly install the entrance sensor actuator and ensure the spring arm i...

Page 146: ...t the drum units from light 3 Push the transfer belt unit locking tabs toward the rear of the printer to release the unit 4 Using the transfer belt unit handle lift the unit about 1 2 inch 12 mm 5 Using the handle and the front frame of the transfer belt unit remove the unit Reverse these steps to install the transfer belt unit Ensure the transfer belt unit s locking tabs fully engage Removing the...

Page 147: ...he right side cover as described in the topic Right side cover on page 89 4 Remove the right shield plate as described in the topic Right shield plate on page 93 5 Disconnect the RCL connector from the printer engine controller board 6 Remove the screw securing the ground strap to the motor bracket 7 Remove the E Ring securing the clutch to registration shaft B 8 Remove the registration clutch Rev...

Page 148: ... side cover as described in the topic Right side cover on page 89 4 Remove the registration clutch as detailed in Registration clutch on page 133 5 Remove the screws securing the motor bracket to the printer 6 Remove the registration motor assembly 7 Disconnect the harness from the registration motor 8 If replacing the motor remove the two screws securing the motor to the motor bracket Reverse the...

Page 149: ...sfer belt unit 4 Open the front cover 5 Remove the left side cover as described in the topic Left side cover on page 88 6 Remove the right side cover as described in the topic Right side cover on page 89 7 Remove the right shield plate as described in the topic Right shield plate on page 93 8 Remove the multi sheet bypass feeder as described in the topic Multi sheet bypass feeder on page 127 9 Rem...

Page 150: ...ler shaft 12 Remove the drive gears Reverse these steps to install the registration roller assembly A and drive gear Install the drive gear so that it drives the roller in the direction of paper travel The blue plastic face should face the outside next to the E ring Removing the registration roller assembly A and drive gear ...

Page 151: ...in a safe place 3 Open front cover 4 Open front cover inner baffle 5 Remove duplex unit if installed 6 Remove the right side cover as described in the topic Right side cover on page 89 7 Remove the right shield plate as described in the topic Right shield plate on page 93 8 Remove registration clutch as detailed in the topic Registration clutch on page 133 9 Remove the four screws securing registr...

Page 152: ...138 Phaser 1235 Network Color Printer 10 Lower the assembly and slide to the left to remove Reverse these steps to install the registration roller assembly B Removing the registration roller assembly B ...

Page 153: ...e power cord 1 Open the top cover Remove the drum toner cartridge basket Cover the basket in a lightproof black bag and store in a safe place 2 Press the two latches to release the fuser unit 3 Use the handle to lift and remove the fuser unit Reverse these steps to install the fuser unit Removing the fuser unit ...

Page 154: ... bag and store in a safe place 3 Remove the left side cover as described in the topic Left side cover on page 88 Remove the left side metal shield 4 Remove the fuser assembly as detailed on page 139 5 Release the fuser latching handle spring 6 Remove the screws securing the fuser latching handle to the printer frame 7 Remove the left fuser latching handle Reverse these steps to install the fuser l...

Page 155: ...led in Electrical chassis card cage on page 94 2 Remove the printer unit chassis as detailed on page 97 3 Release the fuser latching handle spring 4 Remove the E ring securing the fuser latching handle 5 Remove the fuser latching handle right Reverse these steps to install the fuser latching handle right Removing the fuser latching handle right ...

Page 156: ...page 89 5 Remove the right shield plate as shown in Right shield plate on page 93 6 Remove the card cage as detailed in the topic Electrical chassis card cage on page 94 7 Remove the two screws securing the duplex gate solenoid 8 Remove the screw securing the fuser exit roller ground contact 9 Release the locking tab and remove the fuser drive gear 10 Remove the bearing located behind the fuser dr...

Page 157: ...Service Guide 143 14 Lift the left end of the shaft and remove Reverse these steps to install the fuser exit roller Removing the fuser exit roller ...

Page 158: ...iled in the topic Left side cover on page 88 4 Remove the right side cover as described on page 89 5 Remove the right shield plate as shown on page 93 6 Remove the card cage as detailed in the topic Electrical chassis card cage on page 94 7 Remove the multi sheet bypass feeder as shown on page 127 8 Remove the fuser exit roller as detailed on page 142 9 Disconnect the in line connector to the exit...

Page 159: ...the harness through the chassis as you remove the assembly Reverse these steps to install the exit sensor assembly Ensure that the tab on the clutch is positioned on the pin on the paper handler Removing the exit sensor assembly ...

Page 160: ...Left side cover on page 88 4 Remove the right side cover as described in the topic Right side cover on page 89 5 Remove the right shield plate as described in the topic Right shield plate on page 93 6 Remove the rear cover Rear cover on page 90 7 Remove the top cover inner frame as described in the topic Top cover inner frame on page 100 8 Carefully pry the left side of the duplex guide assembly t...

Page 161: ...Service Guide 147 10 Lift the duplex guide assembly and remove Reverse these steps to install the duplex guide assembly Removing the duplex guide assembly ...

Page 162: ...r cover 2 Open the top cover Remove the drum toner cartridge basket Cover the basket in a lightproof black bag and store in a safe place 3 Remove the five screws securing the eject guide assembly to the top cover 4 Remove the eject guide assembly Reverse these steps to install the eject guide assembly Removing the eject guide assembly ...

Page 163: ...r unit 4 Remove the four screws securing the metal shield over the toner cartridge sensor board 5 Remove the three screws securing the toner sensor board 6 Rotate the board up to expose the component side of the board 7 Disconnect the STUCK connector from the toner sensor board 8 Free the disconnected cable from all cable retainers 9 Release the four locking tabs securing the stack full sensor Rem...

Page 164: ...150 Phaser 1235 Network Color Printer 10 Remove the stack full sensor Reverse these steps to install the stack full sensor Removing the stack full sensor ...

Page 165: ...ssis as detailed on page 97 3 Free the harnesses from the channel along the right side of the main motor assembly 4 Disconnect the ribbon cable from the high voltage power supply 5 Remove the four screws securing the main motor assembly to the frame 6 Lift the front of the main motor assembly about 2 cm 3 4 in 7 Carefully thread the high voltage power supply fan harness through the harness guide a...

Page 166: ...35 Network Color Printer 8 Carefully guide the ribbon cable through the assembly as you lift the main motor assembly and remove Reverse these steps to install the main motor assembly Removing the main motor assembly ...

Page 167: ... detailed in Printer unit chassis and low voltage power supply fan on page 97 2 Disconnect the inline connector from the HOPFF connector 3 Remove the two screws securing the main feeder drive motor to the mounting bracket 4 Remove the motor Reverse these steps to install the main feeder drive motor Removing the main feeder drive motor ...

Page 168: ...embly 3 Tilt the transfer belt motor assembly over and lift about 2 5 cm 1 in Note If the cable harness does not have enough slack to allow disconnecting and reconnecting the two incline connectors remove the electrical chassis and free the harness from the run along the right side of the main motor assembly Mark the two inline connectors attached to the motor assembly to ensure proper reinstallat...

Page 169: ...Service Guide 155 5 Remove the transfer belt motor assembly Reverse these steps to install the transfer belt motor assembly Removing the transfer belt motor assembly ...

Page 170: ...hrough the opening in the shutter plate carefully remove the Shutter Spring 5 Open the shutter plate to the full open position 6 Carefully lift the tabs on the front edge of the shutter plate over the stopper and continue to move it toward the front 7 Remove the shutter plate Reverse these steps to install the shutter plate ensure all guide pins on the shutter plate are properly aligned when reins...

Page 171: ...as detailed on page 132 4 Remove the shutter plate as described in the previous procedure Shutter plate on page 156 5 Remove the three screws securing the color registration sensor assembly 6 As you lift the assembly carefully disconnect the two harnesses RSNS LSNS GGU connected to the assembly 7 Remove the color registration sensor assembly Reverse these steps to install the color registration se...

Page 172: ... shown on page 97 2 Remove the shutter plate as explained on page 156 3 Disconnect the shutter solenoid in line connector 4 Release the shutter solenoid harness from all cable clamps 5 Remove the screw securing the shutter solenoid to the printer unit chassis Reverse these steps to install the color registration solenoid Removing the color registration solenoid ...

Page 173: ...through the hole in the end of the LED assembly and lifting up on the connector Free the harness from the LED assembly 3 Disconnect the power harness from the toner sensor board 4 Note the two springs on the back of the LED assembly Ensure they remain with the top cover inner frame 5 Rotate the LED assembly down until the locking tabs align with the slots in the frame 6 Carefully spread the mounti...

Page 174: ...ower cord 1 Open the top cover 2 Remove the four imaging cartridges and basket Cover the cartridges and store in a safe place 3 Use a small screwdriver to carefully pry the drum contact assembly from the printer chassis Reverse these steps to install the drum contact assembly Removing the drum contact assembly ...

Page 175: ...e toner sensor board 3 Close the top cover inner unit 4 Remove the four screws securing the metal shield over the toner sensor board 5 Remove the three screws securing the toner sensor board and the insulator 6 Rotate the board up to expose the component side of the board 7 Open the top cover inner unit 8 From the underside of the top cover inner unit use a small screwdriver to carefully push up t...

Page 176: ...k Color Printer 9 Remove the sensor actuator Reverse these steps to install the toner sensor actuators When replacing the toner sensor board insure all harnesses are in the cable channels Removing the toner sensor actuators ...

Page 177: ... left and right rails Accessing the rails may be easiest at the rear of the printer by reaching through the cavity left by the removed paper tray 5 Remove the duplex unit Alternately to remove the duplex unit 1 Pull the duplex unit out until it stops 2 While holding the right rail pull out the left rail with a moderate amount of force to free it 3 Free the right rail by moving the unit to the left...

Page 178: ...emove the four screws securing the feeder control board cover plate Remove the plate 3 Carefully disconnect harness SNS0 from the feeder control board connector SNS0 is a six pin connector with only two wires it may be necessary to remove the feeder control board to disconnect the harness 4 Remove the two screws securing the idler roller assembly to the feeder frame Removing the feeder control boa...

Page 179: ...Service Guide 165 5 Guide the sensor wires through the frame as you remove the idler roller assembly Reverse these steps to install the idler roller assembly Removing the idler roller assembly ...

Page 180: ...er from the optional paper feeder 2 Remove the paper tray from the optional paper feeder 3 Turn the optional paper feeder on to its left or right side 4 Remove the four brass colored screws from the bottom of the paper feeder 5 Turn the feeder to its right side up position Removing the optional feeder inner frame bottom screws ...

Page 181: ...oard cover plate Remove the plate 7 Remove the idler roller assembly as explained on page 164 8 Disconnect the PSZ and MAIN2 harnesses from the feeder control board 9 Remove the eight screws securing the inner frame to the base frame Removing the feeder control board cover ...

Page 182: ...5 Network Color Printer 10 Guide the disconnected MAIN2 harness through the frame as you remove the inner frame Reverse these steps to install the optional feeder inner frame Removing the optional feeder inner plate ...

Page 183: ...rom the feeder 3 Remove the four screws securing the feeder control board cover plate Remove the plate 4 Remove the idler roller assembly as explained on page 164 5 Remove the inner frame as detailed on page 166 6 Disconnect the CL1 harness from the feeder control board 7 Remove the E ring securing the feeder clutch to the shaft Removing the feeder control board cover ...

Page 184: ...170 Phaser 1235 Network Color Printer 8 Remove the clutch Reverse these steps to install the optional feeder clutch Removing the feeder clutch ...

Page 185: ...board cover plate Remove the plate 4 Remove the idler roller assembly as explained on page 164 5 Remove the inner frame as detailed on page 166 6 Remove the feeder clutch as shown on page 169 7 Disconnect the MOTOR harness from the feeder control board 8 Remove the screw securing the feed motor bracket to the inner frame 9 Remove the two screws securing the feed motor to the feed motor bracket Rem...

Page 186: ...172 Phaser 1235 Network Color Printer 10 Remove the feed motor Reverse these steps to install the optional feeder motor Removing the feeder motor ...

Page 187: ...rinter from the optional paper feeder 2 Remove the four screws securing the feeder control board cover plate Remove the plate 3 Disconnect the seven harnesses connected to the feeder control board 4 Remove the two screws securing the feeder control board to the inner frame Removing the feeder control board cover ...

Page 188: ...174 Phaser 1235 Network Color Printer 5 Remove the feeder control board Reverse these steps to install the optional feeder control board Removing the feeder control board ...

Page 189: ...ove the four screws securing the feeder control board cover plate Remove the plate 4 Remove the idler roller assembly as shown on page 164 5 Remove the inner frame as shown on page 166 6 Remove the two screws securing the paper transport roll guide to the inner frame 7 Carefully pull down and out on the center of the guide to release the two locking tabs Removing the feeder control board cover pla...

Page 190: ...176 Phaser 1235 Network Color Printer 8 Remove the guide Reverse these steps to install the paper transport roll guide Removing the paper transport roll guide ...

Page 191: ...ge 164 5 Remove the inner frame as detailed on page 166 6 Remove the feeder clutch as shown on page 169 7 Remove the feeder motor as shown on page 171 8 Remove the paper transport roll guide as shown on page 175 9 Disconnect harness SNS2 from the feeder control board 10 Release the two locking tabs securing the feed roll drive gear to the feed shaft and move the shaft to the left Remove the gear 1...

Page 192: ...o the left and right of the nudger roll there is a 1 2 in 12mm cutout in the edge of the feeder drive assembly At the cutouts insert a small screwdriver between the metal frame and the drive assembly and release the two locking tabs Remove the feeder drive assembly Reverse these steps to install the feeder drive assembly Removing the feeder drive assembly ...

Page 193: ...itch off the power and disconnect the power cord 1 Remove paper tray 2 3 2 Remove the screw securing the paper size sensing actuator 3 Remove the actuator Reverse these steps to install the paper size sensing actuator Removing the paper size sensing actuator ...

Page 194: ...the paper tray from the feeder 3 Remove the four screws securing the feeder control board cover plate Remove the plate 4 Disconnect flat harness PSZ from the feeder control board 5 Remove the paper size actuator as detailed in the topic Paper size sensing actuator on page 179 6 Remove the screw securing the paper size sensing board to the feeder frame Remove the board Reverse these steps to instal...

Page 195: ...parate feeder 2 from feeder 3 4 Remove the four screws securing the feeder control board cover plate Remove the plate 5 Disconnect harness MAIN2 from the feeder control board 6 Set the feeder so that the front extends over the edge of the work surface by 6 in 152mm 7 Remove the two screws securing the lower connector to the bottom of the feeder Removing the feeder control board cover plate ...

Page 196: ...182 Phaser 1235 Network Color Printer 8 Guide the harness through the feeder as you remove the lower connector Reverse these steps to install the lower connector Removing the lower connector ...

Page 197: ...e upper connector from feeder 3 remove feeder 2 from feeder 3 2 Remove the paper tray from the feeder 3 Remove the four screws securing the feeder control board cover plate Remove the plate 4 Disconnect harness MAIN1 from the feeder control board 5 Remove the two screws securing the upper connector to the feeder frame Removing the feeder control board cover plate ...

Page 198: ...184 Phaser 1235 Network Color Printer 6 Guide the harness through the feeder as you remove the upper connector Reverse these steps to install the upper connector Removing the upper connector ...

Page 199: ...Release the locking tab on the left end of the feed roller 3 Slide the feed roller to the left and remove 4 Release the locking tab on the left end of the nudger roller 5 Slide the nudger roller to the left and remove Reverse these steps to install the tray 2 3 feed roller and nudger roller Removing the tray 2 3 feed roller and nudger roller ...

Page 200: ......

Page 201: ... in an illustration stand for C ring E ring and Screw respectively A shaded triangle t in an illustration indicates the item is part of an assembly The notation with X Y following an part name indicates an assembly that is made up of components X through Y For example 1 with 2 4 means part 1 consists of part 2 part 3 and part 4 An asterisk following a part name indicates the page contains a note a...

Page 202: ... 802K24020 Right Side Cover 3 802E34550 Multi sheet Bypass Feeder Assembly Top Cover 4 802K24030 Multi sheet Bypass Feeder Assembly 5 055K30000 Front Cover Inner Baffle 6 802K24010 Front Cover Assembly 7 802E33510 Left Side Cover 8 802E33500 Rear Cover 9 055K50620 Face Up Tray 10 Label part of Rear Cover S Screw part of item Hardware Kit p n 600K89010 ...

Page 203: ...Service Guide 189 Figure 1 Cabinet FRUs ...

Page 204: ...ver Latch part of item 10 9 Top Cover Handle part of item 10 10 600K88450 Top Cover Inner Frame Kit includes items 7 9 20 21 11 022E24900 Eject Roller 12 130K65650 Stack Full Sensor w actuator 13 038K13450 Eject Guide Assembly 14 LED Harness C part of Harness Kit p n 600K88980 15 LED Harness M part of Harness Kit p n 600K88980 16 LED Harness Y part of Harness Kit p n 600K88980 17 LED Harness K par...

Page 205: ...Service Guide 191 Figure 2 Top cover FRUs ...

Page 206: ...ion Clutch 16 A Registration Exit Sensor Actuator part of Flag Kit p n 600K88990 17 A Registration Entrance Sensor Actuator part of Flag Kit p n 600K88990 18 600K88480 Entrance Sensor Board w harness 19 022K78620 Registration Roller Assembly B 20 B Registration Entrance Sensor Actuator part of Flag Kit p n 600K88990 21 Waste Toner Sensor Actuator part of Flag Kit p n 600K88990 22 101K42820 Printer...

Page 207: ...Service Guide 193 Figure 3 Printer chassis FRUs 1 of 2 ...

Page 208: ...pply Insulation 4 015K55950 Left Plate Assembly 5 127K35190 Transfer Belt Motor Assembly 6 Fuser Latching Handle Spring part of Hardware Kit p n 600K89010 7 003E55700 Fuser Latching Handle Right 8 127K35170 Main Feeder Drive Motor 9 Gear H1 part of Gear Kit p n 600K89000 10 Gear H2 part of Gear Kit p n 600K89000 11 Lower Plate 12 116 1058 00 High Voltage Power Supply Fan S Screw part of Hardware K...

Page 209: ...Service Guide 195 Figure 4 Printer chassis FRUs 2 of 2 ...

Page 210: ...196 Phaser 1235 Network Color Printer Table 5 FRU of the paper tray Fig 5 parts Part number Name and description 1 050K50630 Paper Tray Cassette 2 600K89020 Retard Pad and Springs Kit ...

Page 211: ...Service Guide 197 Figure 5 Paper tray FRUs ...

Page 212: ... Paper Tray Lock part of item 1 part of item 18 9 Paper Tray Lock Spring part of item 1 part of item 18 10 Plastic Slide part of item 1 and 18 11 022K78600 Main Feeder Assembly 12 Feed Roller part of Paper Feed Kit p n 600K89320 13 Nudger Roller part of Paper Feed Kit p n 600K89320 14 Main Feeder Drive Gear part of Gear Kit p n 600K89000 15 Right Duplex Ground Contact part of item 1 16 Bottom Plat...

Page 213: ...Service Guide 199 Figure 6 Paper tray guide FRUs ...

Page 214: ...escription 1 022K78630 Multi sheet Bypass Feeder Assembly 2 012E12690 Link 3 007K11740 Multi sheet Bypass Feeder Drive Gear 4 802K24030 Multi sheet Bypass Feeder Cover Assembly 5 Multi sheet Bypass OHP Sensor part of item 1 6 Multi sheet Bypass Tray Empty Sensor part of item 1 S Screw part of Hardware Kit p n 600K89010 ...

Page 215: ...Service Guide 201 Figure 7 Multi sheet bypass feeder FRUs ...

Page 216: ...Cooling Fan 5 140E45640 Print Engine Controller Board 6 672 1595 00 System Controller Board Image Processor Board 7 121K25530 Internal Hard Drive 8 Shield Plate 9 Right Shield Plate 10 110K13470 Front Cover B Interlock Switch 11 12 110K13450 Top Cover A Interlock Switch 13 162K68220 Paper Tray 2 Connector with Harness 14 098S04423 Token Ring Card 15 537E61970 Print Engine Controller EEPROM 16 156 ...

Page 217: ...Service Guide 203 Figure 8 Electrical components FRUs ...

Page 218: ...204 Phaser 1235 Network Color Printer Table 9 FRUs of the duplexer unit Fig 9 parts Part number Name and description 1 022K78640 Duplexer Transport Assembly ...

Page 219: ...Service Guide 205 Figure 9 Duplexer unit ...

Page 220: ...962K00700 Upper Connector w harness 3 962K00690 Lower Connector w harness 4 022K79500 Idler Roller Assembly 5 127K40870 Feeder Motor 6 121K26030 Feeder Clutch 7 022K79510 Feeder Drive Assembly 8 017E09930 Foot 4 9 120E20420 Paper Size Actuator 10 140E45620 Paper Size Sensing Board w Harness 050K50630 Paper Tray Cassette 022K79600 Lower Tray Assembly with tray ...

Page 221: ...Service Guide 207 Figure 10 LowerTray Assembly FRUs ...

Page 222: ...ller Bushing L 1 Fuser Exit Roller Bushing R 1 Shutter Spring 1 Fuser Latch Handle Springs 2 Screw T3x8 10 Screw T3x10 10 Screw T4x10 10 Screw M2x8 10 Screw M3x6 10 Screw M3x8 10 Screw M4x8 10 Screw SP3x10 10 Table 12 Gear kit Part number Name and description 600K89000 Gear Kit Main Feeder Drive Gear Gear H1 Gear H2 Fuser Drive Gear A Fuser Drive Gear B Fuser Drive Gear C ...

Page 223: ...r A Reg Entrance Sensor Actuator A Reg Exit Sensor Actuator Toner Sensor Actuator Table 14 Harness kit Part number Name and description 600K88980 Harness Kit LED Harness M LED Harness C LED Harness Y LED Harness K Control Panel Tape Harness HV Tape Harness 26 pin LED connector Numerous other harnesses cables to be added soon ...

Page 224: ...0296 Standard Toner Cartridge Yellow 1235 006R90303 Hi Capacity Toner Cartridge Black 1235 006R90304 Hi Capacity Toner Cartridge Cyan 1235 006R90305 Hi Capacity Toner Cartridge Magenta 1235 006R90306 Hi Capacity Toner Cartridge Yellow 1235 013R90132 Imaging Drum Black 1235 013R90133 Imaging Drum Cyan 1235 013R90134 Imaging Drum Magenta 1235 013R90135 Imaging Drum Yellow 1235 016 1934 00 Cyan Magen...

Page 225: ... Color Stripe Pattern consist of two set of bars Each set of bars is made of of a seven bars each bar is a 100 solid fill of the primary colors cyan magenta yellow and black and the secondary colors red green and blue Look for 1 Consistent fills in each primary color Each color should be consistent across the width of the page with no voids 2 No separation or misconvergence where each bar meets it...

Page 226: ... combination of cyan magenta and yellow The adjustment objective is for the CURRENT circle to be the closest gray of any of the circles when compared to the gray background Refer to the adjustment Adjusting color density and balance on page 77 c gogo c gogo Test Pattern A 600 x 600 c gogo c gogo c gogo c gogo c gogo c gogo c gogo c gogo c gogo c gogo c gogo c gogo c gogo c gogo Abc Defg Hijk Abc D...

Page 227: ...ck imaging and LED head problems Look for uniform fill with no banding or lines Interpreting the Blank Print with crosshatch Each print consists of a blank page with a single primary colored crosshatch printed near the top of the page Use these pages to identify color on non printed areas of a print as well as residual offsetting 0728 19 Gray 35 Halftone Test Pattern 0728 20 ...

Page 228: ...s starting with a100 fill of a primary color bar and progressing in 10 steps to a 0 white fill bar Use these pages to isolate primary color imaging or LED head problems Look for uniform transitions from dark to light 0728 21 Cyan Step Test Pattern Magenta Step Test Pattern Yellow Step Test Pattern Black Step Test Pattern ...

Page 229: ...Service Guide 215 Wiring Diagram Wiring diagram part 1 of 3 ...

Page 230: ...216 Phaser 1235 Network Color Printer Wiring diagram part 2 of 3 ...

Page 231: ...Service Guide 217 Wiring diagram part 3 of 3 ...

Page 232: ...218 Phaser 1235 Network Color Printer Wire routing at the engine controller board Tie wraps Bundle wires thru EMI coils ...

Page 233: ...Service Guide 219 Wire routing at the top of the engine controller board Tie wrap ...

Page 234: ...220 Phaser 1235 Network Color Printer Detail of wiring passthru ...

Page 235: ...Service Guide 221 Wiring under the top shield plate Ensure wiring harness is routed inside the wiring shield Make sure wiring is not pinched by top shield plate when it is installed ...

Page 236: ...222 Phaser 1235 Network Color Printer ...

Page 237: ...NOTES ...

Page 238: ...NOTES ...

Page 239: ...NOTES ...

Page 240: ...NOTES ...

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