Xerox 1235DT - Phaser Color Solid Ink Printer, Service Manual

Page 1: ...rvice personnel 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...

Page 2: ...ly 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 pers...

Page 3: ...sent 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 Dis...

Page 4: ...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 pr...

Page 5: ...g 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...

Page 6: ...leaning 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 N...

Page 7: ...r 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...

Page 8: ...tact 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...

Page 9: ...ver 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 r...

Page 10: ...on 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...

Page 11: ...moving 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 connecto...

Page 12: ...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 o...

Page 13: ...xiv Phaser 1235 Network Color Printer...

Page 14: ...ides 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 Col...

Page 15: ...eatures 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 6...

Page 16: ...he 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...

Page 17: ...p 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...

Page 18: ...t 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...

Page 19: ...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 20: ...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 Co...

Page 21: ...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 e...

Page 22: ...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...

Page 23: ...10 Phaser 1235 Network Color Printer Optional feeder motor and clutch 7103 Feeder motor Feeder clutch Optional feeder...

Page 24: ...Service Guide 11 The image processor board Features of the controller board SDRAM Token ring card Fan cooled processor Hard drive 0728 05...

Page 25: ...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 read...

Page 26: ...rface 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 it...

Page 27: ...D 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...

Page 28: ...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 i...

Page 29: ...ght 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 connecti...

Page 30: ...e 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...

Page 31: ...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 4...

Page 32: ...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 Seco...

Page 33: ...20 Phaser 1235 Network Color Printer...

Page 34: ...ver 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...

Page 35: ...e 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 th...

Page 36: ...feed 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 c...

Page 37: ...rum 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 Repl...

Page 38: ...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 a...

Page 39: ...or 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 Swit...

Page 40: ...he 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...

Page 41: ...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 printe...

Page 42: ...ss 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 C...

Page 43: ...ller 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 In...

Page 44: ...g 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 symp...

Page 45: ...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 inst...

Page 46: ...n 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 corre...

Page 47: ...d 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...

Page 48: ...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 c...

Page 49: ...eplace 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...

Page 50: ...ng 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 engi...

Page 51: ...sfer 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...

Page 52: ...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...

Page 53: ...aper 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 th...

Page 54: ...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...

Page 55: ...ller 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...

Page 56: ...ce 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...

Page 57: ...ed 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...

Page 58: ...C 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 chec...

Page 59: ...zes 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 pane...

Page 60: ...er 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...

Page 61: ...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...

Page 62: ...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...

Page 63: ...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 connecto...

Page 64: ...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 con...

Page 65: ...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 s...

Page 66: ...nance 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...

Page 67: ...ed 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 transfe...

Page 68: ...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 I...

Page 69: ...ure 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 LE...

Page 70: ...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...

Page 71: ...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 Dia...

Page 72: ...t 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...

Page 73: ...rinter 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 cap...

Page 74: ...nu 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 discontin...

Page 75: ...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...

Page 76: ...N 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...

Page 77: ...64 Phaser 1235 Network Color Printer...

Page 78: ...ge 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 c...

Page 79: ...witch 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 Sca...

Page 80: ...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 Tr...

Page 81: ...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 Sw...

Page 82: ...art 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 cl...

Page 83: ...TOR 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 no...

Page 84: ...s 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...

Page 85: ...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 measureme...

Page 86: ...lized 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...

Page 87: ...lization 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 yell...

Page 88: ...splayed 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...

Page 89: ...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 Ente...

Page 90: ...r 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...

Page 91: ...ircle 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 densi...

Page 92: ...e 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 re...

Page 93: ......

Page 94: ...ng 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 h...

Page 95: ...rint 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 a...

Page 96: ...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 Colo...

Page 97: ......

Page 98: ...ur 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 Co...

Page 99: ......

Page 100: ...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 Remo...

Page 101: ...nt 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 s...

Page 102: ...r 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 cov...

Page 103: ...90 Phaser 1235 Network Color Printer...

Page 104: ...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 sitti...

Page 105: ...Network 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 Removin...

Page 106: ...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...

Page 107: ...e 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 th...

Page 108: ...l 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...

Page 109: ...m 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 pri...

Page 110: ...de 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 f...

Page 111: ...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 chas...

Page 112: ...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...

Page 113: ...g 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 114: ...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 scr...

Page 115: ...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 m...

Page 116: ...t 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 i...

Page 117: ...nit 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 low...

Page 118: ...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...

Page 119: ...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 righ...

Page 120: ...tailed 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 gu...

Page 121: ...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 assem...

Page 122: ...er 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...

Page 123: ...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 su...

Page 124: ...op 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 compone...

Page 125: ...e 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 wh...

Page 126: ...nter 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 t...

Page 127: ...assis 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...

Page 128: ...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 129: ...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...

Page 130: ...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...

Page 131: ...se 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 lef...

Page 132: ...ove 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 r...

Page 133: ...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 Reachin...

Page 134: ...Service Guide 121 Reverse these steps to install the paper size sensing board Removing the paper size sensing board...

Page 135: ...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 pa...

Page 136: ...nit 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 t...

Page 137: ...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 138: ...hassis 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...

Page 139: ...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...

Page 140: ...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 HUM...

Page 141: ...128 Phaser 1235 Network Color Printer Reverse these steps to install the multi sheet bypass feeder Removing the multi sheet bypass feeder...

Page 142: ...e 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 she...

Page 143: ...nter 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 s...

Page 144: ...ay 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 bel...

Page 145: ...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 Usin...

Page 146: ...e 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...

Page 147: ...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 p...

Page 148: ...fer 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...

Page 149: ...er 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...

Page 150: ...n 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 rig...

Page 151: ...38 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 152: ...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...

Page 153: ...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...

Page 154: ...ed 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...

Page 155: ...age 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 securin...

Page 156: ...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 157: ...led 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 El...

Page 158: ...he 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 Removi...

Page 159: ...eft 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...

Page 160: ...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 161: ...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 th...

Page 162: ...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 s...

Page 163: ...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 164: ...sis 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 scre...

Page 165: ...5 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...

Page 166: ...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...

Page 167: ...mbly 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 rem...

Page 168: ...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 169: ...rough 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...

Page 170: ...s 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 li...

Page 171: ...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...

Page 172: ...hrough 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...

Page 173: ...wer 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 t...

Page 174: ...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 in...

Page 175: ...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...

Page 176: ...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 dupl...

Page 177: ...move 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 tw...

Page 178: ...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 179: ...r 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 bo...

Page 180: ...ard 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 t...

Page 181: ...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 feed...

Page 182: ...om 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 o...

Page 183: ...170 Phaser 1235 Network Color Printer 8 Remove the clutch Reverse these steps to install the optional feeder clutch Removing the feeder clutch...

Page 184: ...oard 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 Disconn...

Page 185: ...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 186: ...inter 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 Re...

Page 187: ...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 188: ...ve 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...

Page 189: ...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 190: ...e 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 o...

Page 191: ...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 a...

Page 192: ...tch 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...

Page 193: ...he 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 siz...

Page 194: ...arate 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 t...

Page 195: ...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 196: ...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 Disconnec...

Page 197: ...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 198: ...elease 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...

Page 199: ......

Page 200: ...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 indicate...

Page 201: ...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...

Page 202: ...Service Guide 189 Figure 1 Cabinet FRUs...

Page 203: ...er 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 038K1...

Page 204: ...Service Guide 191 Figure 2 Top cover FRUs...

Page 205: ...on 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 1...

Page 206: ...Service Guide 193 Figure 3 Printer chassis FRUs 1 of 2...

Page 207: ...ply 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 127K...

Page 208: ...Service Guide 195 Figure 4 Printer chassis FRUs 2 of 2...

Page 209: ...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 210: ...Service Guide 197 Figure 5 Paper tray FRUs...

Page 211: ...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 P...

Page 212: ...Service Guide 199 Figure 6 Paper tray guide FRUs...

Page 213: ...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 OH...

Page 214: ...Service Guide 201 Figure 7 Multi sheet bypass feeder FRUs...

Page 215: ...ooling 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...

Page 216: ...Service Guide 203 Figure 8 Electrical components FRUs...

Page 217: ...204 Phaser 1235 Network...

Page 218: ...Service Guide 205 Figure 9 Duplexer unit...

Page 219: ...62K00700 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 017E09...

Page 220: ...Service Guide 207 Figure 10 LowerTray Assembly FRUs...

Page 221: ...ler 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 SP...

Page 222: ...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 L...

Page 223: ...296 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 H...

Page 224: ...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 re...

Page 225: ...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 Adju...

Page 226: ...k 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...

Page 227: ...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 fro...

Page 228: ...Service Guide 215 Wiring Diagram Wiring diagram part 1 of 3...

Page 229: ...216 Phaser 1235 Network Color Printer Wiring diagram part 2 of 3...

Page 230: ...Service Guide 217 Wiring diagram part 3 of 3...

Page 231: ...218 Phaser 1235 Network Color Printer Wire routing at the engine controller board Tie wraps Bundle wires thru EMI coils...

Page 232: ...Service Guide 219 Wire routing at the top of the engine controller board Tie wrap...

Page 233: ...220 Phaser 1235 Network Color Printer Detail of wiring passthru...

Page 234: ...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 235: ...222 Phaser 1235 Network Color Printer...

Page 236: ...NOTES...

Page 237: ...NOTES...

Page 238: ...NOTES...

Page 239: ...NOTES...