Xerox 1235DT - Phaser Color Solid Ink Printer User manual

Warning

The following servicing instructions are for

use by qualified service 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

PHASER® 1235

NETWORK COLOR PRINTER

Service Guide

Users safety summary

Terms in

CAUTION Conditions that can result in damage to the product.

manual:

WARNING Conditions that can result in personal injury

or loss of life.

Power source:

For 110 VAC printers, Do not apply more than 140 volts RMS

between the supply conductors or between either supply conductor and ground.

Use only the speciﬁed power cord and connector. For 220 VAC printers, do not

apply more than 260 volts RMS between the supply conductors or between either

supply conductor and ground. Use only the speciﬁed power cord and connector.

Refer to a qualiﬁed service technician for changes to the cord or connector.

Operation of product:

Avoid electric shock by contacting a qualiﬁed service

technician to replace fuses inside the product. Do not operate without the covers

and panels properly 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 hazard exists in the area where

you see the sign.

Care of product:

Disconnect the power plug by pulling the plug, not the cord.

Disconnect the power plug if the power cord or plug is frayed or otherwise

damaged, if you spill anything into the case, if product is exposed to any excess

moisture, if product is dropped or damaged, if you suspect that the product needs

servicing or repair, and whenever you clean the product.

Ground the product:

Plug the three-wire power cord (with grounding prong) into

grounded AC outlets only. If necessary, contact a licensed electrician to install a

properly grounded outlet.

Symbols as marked on product:

DANGER high voltage:

Protective ground (earth) terminal:

Use caution. Refer to the manual(s) for information:

WARNING:

If the product loses the ground connection, usage of knobs and

controls (and other conductive parts) can cause an electrical shock. Electrical

product may be hazardous if misused.

Service safety summary

For qualiﬁed service personnel only:

Refer also to the preceding Users Safety

Summary.

Do not service alone:

Do not perform internal service or adjustment of this

product unless another person capable of rendering ﬁrst aid or resuscitation is

present.

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 into contact with dangerous voltages and

currents.

Power source:

This product is intended to operate from a power source that will

not apply more than 120 or 250 volts rms (depending on printer model) between

the supply conductors or between either supply conductor and ground. A

protective ground connection by way of the grounding conductor in the power

cord is essential for safe operation.

Service Guide

Contents

General Information 1

The Phaser 1235 Color Printer 2

Printer RAM and printer capabilities 4

CRU life counter behavior 4

Print engine assemblies 5

The image processor board 11

The control panel 12

On Line LED 12

! Fault 12

Rear panel 13

Accessing special operating modes 14

System controller board LEDs 14

Paper tray type sensing 15

Specifications 16

Regulatory specifications 19

Error Codes 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 roller resistances 38

Media jams and the paper path 39

Media-based problems 39

Media problems 39

Multiple-sheet pick 39

The media skews passing through the paper path 40

Paper tray indicates it is empty when it is not 40

Phaser 1235 Network Color Printer

Jams 41

Wrong media 41

Paper jams at the paper tray 41

Manual bypass feeder feed jams 42

Paper jams at the registration rollers 42

Paper jams at the transfer belt 42

Fuser jams 43

Eject jams 43

Jams in the duplex unit 43

No drum imaging unit installed 44

Imaging drum unit up/down error 44

Fan error 44

Fuser unit error 45

Other problems 46

The printer continuously displays “Booting” or “Initializing.” 46

False “No toner cartridge installed” message 46

False “No fuser unit installed” message 46

Front door indicated being 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 in print 55

Color misalignments 56

Unexpected colors 57

Image is skewed on the paper 58

Image is not centered on the print 58

The print is wrinkled 58

Macintosh printing problems 59

Image never prints 59

Image is rotated 90 degrees 59

Image prints in black-and-white 59

Printer isn’t in the Chooser 60

Windows printing problems 60

Image never prints 60

Service Guide

vii

Service Tests and Adjustments 61

Diagnostics mode 61

Switch scan test 63

LED head test 68

Motor and clutch tests 69

Test printing 71

Consumable count initialization 73

Consumable counter display 75

Consumable continuation counter display 76

Adjusting color density and balance 77

Printing a Test Page 77

Interpreting the Color Balance test print 77

What to look for 78

Making adjustments 78

Adjustment recovery 79

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 chassis (card cage) 94

Electrical chassis cooling fan 96

Printer unit chassis 97

Main cooling fan 99

Top cover inner frame 100

Left/right top cover spring assembly 103

Left paper tray guide assembly 104

Right paper tray guide assembly 106

viii

Phaser 1235 Network Color Printer

Left plate assembly 108

Electronic boards 109

System controller board 109

Print engine controller board 110

Toner sensor board 111

Entrance sensor board 113

High voltage power supply 114

Low voltage power supply 116

Control panel 117

Paper feed components 118

Tray 1 feed roller and nudger roller 118

Retard pad 119

Paper-size sensing board 120

Paper-size sensing actuator 122

Main feeder assembly 123

Tray 1 no-paper/low-paper sensors 125

Paper 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 drive gear 135

Registration roller assembly B 137

Exit assembly and fuser components 139

Fuser unit 139

Fuser latching handle (left) 140

Fuser latching handle (right) 141

Fuser exit roller 142

Exit sensor assembly 144

Duplex guide assembly 146

Eject guide assembly 148

Stack full sensor 149

Service Guide

Drive assembly components 151

Main motor assembly 151

Main feeder drive motor 153

Transfer belt motor assembly 154

Xerographic components 156

Shutter plate 156

Color registration sensor assembly 157

Color registration solenoid 158

LED assembly 159

Drum contact 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 185

FRU List 187

Using the parts list 187

Test Prints 211

Wiring Diagram 215

Phaser 1235 Network Color Printer

Figures

The Phaser 1235 Color Printer with lower tray feeders 1

Print engine circuit boards 5

Print engine circuit boards (cont’d) 6

Print engine sensor and switch locations 7

Print engine sensor and switch locations (cont’d) 8

Print engine motors, clutches and solenoids 9

Optional feeder motor and clutch 10

Features of the controller board 11

The control panel 12

The printer rear panel 13

Tray switch sensors and actuators 15

Door safety interlock switches 37

LED Head Test Pattern 68

Print problem caused by dirty LED lens 83

Removing the top cover 87

Removing the left-side cover 88

Removing the right-side cover 89

Removing the rear cover 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 101

Removing the top cover inner frame 102

Removing the left/right top cover spring assembly 103

Removing the lower plate assembly 104

Removing the left paper tray guide assembly 105

Removing the paper tray guide assemblies 106

Removing the right paper tray guide assembly 107

Removing the left plate assembly 108

Removing the system controller board 109

Removing the print engine controller 110

Disconnecting the LED power harnesses 111

Removing the toner sensor board 112

Service Guide

Removing the entrance sensor board 113

Removing the high voltage power supply 115

Removing the low voltage power supply 116

Removing the control panel 117

Removing the feed roller and nudger roller 118

Removing the retard pad 119

Removing the paper size sensing board 121

Removing the paper size sensing actuator 122

Removing the main feeder assembly 124

Removing the lower plate assembly 125

Removing the paper tray lift arm roller 126

Removing the multi-sheet bypass feeder 128

Removing the multi-sheet bypass feeder entrance sensor actuator 129

Removing the tray 1 entrance sensor actuator 130

Removing the belt entrance sensor actuator 131

Removing the transfer belt unit 132

Removing the registration clutch 133

Removing the registration motor assembly 134

Removing the registration 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 the stack full sensor 150

Removing the main motor assembly 152

Removing the main feeder drive motor 153

Removing the transfer belt motor assembly 155

Removing the shutter plate 156

Removing the color registration sensor assembly 157

Removing the color registration solenoid 158

Removing an LED assembly 159

Removing the drum contact assembly 160

Disconnecting the LED assembly power harness 161

Removing the toner sensor actuators 162

Removing the duplex unit 163

Removing the feeder control board cover 164

Removing the idler roller assembly 165

Removing the optional feeder inner frame bottom screws 166

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