Tektronix 1235N - Phaser Color Laser Printer, Phaser 1235 Service 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 Quick Reference Guide
Copyright © Xerox Corporation. Unpublished rights reserved under the copyright laws of the United States. Contents of this publication may not be reproduced in any form without permission of Xerox Corporation. Phaser
®
, PhaserShare
®
, ColorStix
®
, the TekColor
®
icon, Made For Each Other
®
,
DocuPrint
®
, WorkSet
®
, Ethernet
®
, the stylized X, and XEROX
®
are registered trademarks of Xerox Corporation. PhaserLink™, PhaserPort™, PhaserPrint™, PhaserSym™, PhaserTools™, InfoSMART™, and the TekColor™ name are trademarks of Xerox Corporation. TekColor Care
SM
and RealSUPPORT
SM
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
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, and Sun Microsystems Computer Corporation
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are registered trademarks of Sun Microsystems, Incorporated.Other marks are trademarks or registered trademarks of the companies with which they are associated.
All trademarks noted herein are either the property of Xerox Corporation, Pantone, Inc., or their respective companies. © Pantone, Inc., 1988.
TE/sn
Users safety summary
Terms in
CAUTION Conditions that can result in damage to the pr oduct.
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 cor d 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 dr opped or damaged, if you suspect that the pr oduct 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.
!
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
Service Guide
v
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
vi
Phaser 1235 Network Color Printer
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
Service Guide
vii
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
viii
Phaser 1235 Network Color Printer
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
Service Guide
ix
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
x
Phaser 1235 Network Color Printer
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
Service Guide
xi
Removing the feeder control board cover 167 Removing the optional feeder inner plate 168 Removing the feeder control board cover 169 Removing the feeder clutch 170 Removing the feeder control board cover 171 Removing the feeder motor 172 Removing the feeder control board cover 173 Removing the feeder control board 174 Removing the feeder control board cover plate 175 Removing the paper transport roll guide 176 Removing the feeder control board cover plate 177 Removing the feeder drive assembly 178 Removing the paper size sensing actuator 179 Removing 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 FRUs 199 Multi-sheet bypass feeder FRUs 201 Electrical components FRUs 203 Duplexer unit 205 Lower Tray Assembly FRUs 207 Wiring diagram (part 1 of 3) 215 Wiring diagram (part 2 of 3) 216 Wiring diagram (part 3 of 3) 217 Wire routing at the engine controller board 218 Wire routing at the top of the engine controller board 219 Detail of wiring passthru 220 Wiring under the top shield plate 221
xii
Phaser 1235 Network Color Printer
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
Service Guide
xiii
xiv
Phaser 1235 Network Color Printer
General Information
This service guide contains information useful for troubleshooting, repairing, adjusting, and maintaining the Xerox Phaser includes troubleshooting guides, 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
Resources CD-ROM
To ensure a complete understanding of the product, we recommend participation in Phaser 1235 printer service training.
.
®
1235 Color Printer. This manual
Color Printer Service & Support
The Phaser 1235 Color Printer with lower tray feeders
Service Guide
1
The Phaser 1235 Color Printer
The Phaser 1235 Color Printer combines a 4-color LED-based, tandem-design print engine with an EFI image processing controller board supporting Adobe’s PostScript Level 3 page description language. The controller features a bi-directional parallel interface and an Ethernet port for host communication. The Ethernet port supports EtherTalk 10/100baseT, Novell and TCP/IP. An optional network adapter card allow the printer to communicate with Token Ring networks. All printer versions support the color PCL5C printer language.
The printer is available in three configurations:
The
Phaser 1235N
supplemented with an additional 32-, 64- and 128-Mbyte RAM DIMM; maximum usable capacity is 512 Mbytes. The printer contains 136 standard, built-in fonts. The Phaser 1235N prints at a color resolutions of 600 x 600 dots-per-inch and 600 x 1200 dots-per-inch.
The
Phaser 1235DT
128 Mbytes of memory , an auto-duplexer, an internal hard drive and a lower feeder tray assembly. With the hard drive the 1235DT supports a print collation mode, a “First Page Preview” mode and a secure printjob “password” mode.
comes standard with 64 Mbytes of RAM which can be
is the same as the Phaser 1235N except it includes
The
Phaser 1235DX
has all the 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 ar e imaged at 600 x 600 dpi. The resolution supported is a function of the PDL used and the feature being selected, such as Fax Friendly Black and Draft Mode. Both PostScript and PCL allow full selection of all paper sources, paper sizes, paper types and output destinations.
The auto-duplexer unit (optional on the Phaser 1235N) allows the printer to automatically create two-sided prints.
Print speeds depend on the chosen resolution and selected media. For resolutions of 600 x 600 (standard), in color, the printer prints at 12 pages-per-minute (ppm) on paper. Monochrome printing is at 20 ppm on paper. Transparency film printing is always 5 ppm. For 600 x 1200 dpi (enhanced) color printing, the printer prints color at the same speeds as standard mode.
The printers support printing on A-, A4- and Legal-sized paper and transparency film from an adjustable tray. Optional lower tray feeders, up to two can be installed, are available. The printer features a built-in multi-sheet bypass feeder from which specialty media, cardstock and envelopes can be fed. The printer also supports manual feeding using the multi-sheet bypass feeder.
2
Phaser 1235 Network Color Printer
If the printer is equipped with multiple trays loaded with the same-size paper, the printer will switch to an alternate tray as a paper source when a tray r uns out of paper .
After being idle for the selected amount of time the printer switches into its Energy Star mode where it consumes less than 45 watts of power. It “awakens” upon receiving data at any of its ports.
Proof Jobs.
A proof job is a specific case of a multiple-copy job. With a proof job, the customer assigns a password and copy account at the client workstation before printing. The first set of prints are printed immediately. The original number of requested sets are printed after the customer enters the matching password on the printer’s control panel. The customer has the option of printing the original number of requested sets or deleting the job. Since more than one job may be associated with the same password, the customer can print all the jobs, delete all the jobs or select or delete individual jobs. A proof job that has not been printed is retained on hard disk through power cycles. Proof jobs sent to a printer without the har d disk option ar e not printed and are discarded.
Secure Jobs.
Secure printing allows the customer to defer printing of a job until a matching password is entered from the control panel. The customer assigns the password at the client workstation before printing. The job is stored, and printing is delayed until the password is entered on the printer’s control panel. Since more than one job can have the same password, all secure jobs with the same password are printed. A secure job that has not been printed or released is retained on disk thr ough 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 processed using the default PostScript parameters stored in the printer. Auto sensing of TIFF files are included in the emulation sensing and switching logic when the TIFF option is enabled. TIFF direct printing requires the internal hard drive.
PDF Direct Printing
. The printer supports a native PDF image processing. Processing PDF files directly requires a hard disk. PDF printing uses the printer’s currently defined imaging settings. Auto sensing of PDF files are included in the emulation sensing and switching logic when the PDF option is installed. PDF direct printing requires the internal hard drive.
Hex Mode.
The printer features a hex mode in which all prints are printed as hexadecimal codes as well as the ASCII equivalent. Hex mode pages are numbered and formatted to clearly indicate the order in which data was received. Hex mode is invoked from the control panel’s Print Menu, and remains active until it is explicitly disabled at the control panel or the printer is reset. SNMP data may be processed in Hex mode, since it is not print data. EtherTalk or TokenTalk is not operational in Hex mode, since these protocols require the PostScript interpreter to be running. PostScript and PCL interpreters are not available in Hex mode. When Hex mode is active, all PDL job streams are printed in hex, rather than interpreted. This includes TIFF, PDF, and PJL.
Service Guide
3
Printer RAM and printer capabilities
The printer features three DIMM connectors which accept 64-, 128-, and 256-Mbytes RAM DIMMs. The printer can use off-the-shelf RAM meeting these specifications:
168-pin DIMM
Synchronous DRAM
3.3 volt
9 nsec speed
Valid on-board Serial Presence Detect ROM.
The Startup page and the Configuration Page list the amount of RAM installed in the printer.
Upon power-up, the image processor interrogates the 256 byte Serial Presence Detect ROM which describes the DIMM with details such as data width, clock delay, number of address columns and row, refresh rate and more. If the DIMM does not meets the required specifications it the printer reports and “Invalid Memory DIMM Configuration” message and stops the booting process.
If the power-up self-test diagnostics detect a DIMM with defective memory cells the printer declares “Diagnostics Failed - Press Enter to Continue.” After the enter key is pressed the boot process continues and the defective RAM DIMM is ignored. Note that a seriously defective RAM DIMMs (with grounded address lines, for example) can keep the system controller board from booting up at all.
W ith 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 a 64-, 128-, or 256-Mbytes SDRAM DIMM. Any slot may be used for any size DIMM. However, 256 Mbyte RAM DIMMs cannot be mixed with smaller RAM DIMMs. DRAM memory totalling beyond 512 Mbytes will be ignored. The image-processing controller board also contains 16 Kbytes of non-volatile memory (NVRAM), to store all for the necessary values that can be set on the printer.
CRU life counter behavior
Internal counters track customer replaceable unit (CRU) life usage and store the values in NVRAM. The controller monitors these counters in or der to display the near end of use and end of use messages.
The toner states displayed are OK, Low, and Empty, where the engine senses and automatically reports the Low and Empty states. When the empty state is reached for toner, the printer terminates printing at the end of current page and displays the appropriate message on the control panel. No further jobs are accepted from any input port.
4
Phaser 1235 Network Color Printer
Print engine assemblies
Paper size sensing board
Low voltage power supply
Duplex control (in duplexer)
Toner sensor board
Control panel assembly
Entrance sensor board
High voltage power supply
Print engine circuit boards
7098
Service Guide
5
Print engine controller board
Optional feeder
System controller board
Feeder control
Paper-size sensing board
7099
Print engine circuit boards (cont’d)
6
Phaser 1235 Network Color Printer
Stack full sensor
Toner cartridge sensors
Exit sensor
Color registration sensor assembly
Waste toner sensor
Belt entrance sensor
Temperature sensor
Top cover interlock switch
Front cover interlock switch
Humidity sensor
Registration Entrance cassette
entrance
sensor sensor
Print engine sensor and switch locations
7100
Service Guide
7
Multi-sheet bypass tray empty sensor
OHP sensor
Stack full sensor
Multi-sheet bypass position sensor
Print engine sensor and switch locations (cont’d)
Fuser exit sensor
Belt entrance sensor
7101
8
Phaser 1235 Network Color Printer
Duplex Gate solenoid
Registration shutter solenoid
Transfer belt motor assembly
Registration motor
Registration clutch
Main feeder drive motor
Duplex drive assembly
Print engine motors, clutches and solenoids
7102
Service Guide
9
Feeder motor
Optional feeder
Optional feeder motor and clutch
Feeder clutch
7103
10
Phaser 1235 Network Color Printer
The image processor board
Token ring card
SDRAM
Hard drive
Fan cooled processor
Features of the controller board
0728-05
Service Guide
11
The control panel
The control panel consists of eight labeled keys. These keys navigate the menu system for printer operations. Two LEDs on the display indicate On Line and active faults. The LCD display is two lines by twenty-four characters wide.
Menu up/down
Item up/down
Value up/down
The control panel
Key 0 places the printer off-line or on-line. Key 4 is an Enter key. The pairs of keys 1 and 5 are used to scroll thr ough 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.
! Fault
Red in color, this LED illuminates whenever operator intervention is requir ed, such as a paper jam in the printer.
12
Phaser 1235 Network Color Printer
Rear panel
The rear panel of the printer features the host interface 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.
Ethernet port
The printer rear panel
Parallel port
0728-03
Service Guide
13
Accessing special operating modes
The printer can be placed in diagnostics or other operation modes by simultaneously holding the
Menu Up (1)
Entering special operating modes
Key Combination Mode
and the
Enter (4)
keys as you turn on the printer.
On Line (0) and Enter (4)
Menu Up (1) and Menu Down (5)
Menu Up (1) and Enter (4)
Enter (4) and Value Down (7)
This enables the The Reset Menu is not normally available to the customer, as it contains
the ability to format devices and perform a factory reset of all items. The control panel displays To exit, switch the printer power off, then on.
This forces the The Control Panel will display
Mode
on the second line. This indicates that the printer is ready to be
have its firmware flash updated. To exit, switch the printer power off, then on.
Forces the printer into the controller.
The control panel displays that the printer is ready to enter diagnostics.
To exit, switch the printer power off, then on. This reinitiates the NVRAM to factory defaults for all values except copy
counts. The control panel displays
Reset Menu
Software Update Mode
to become available at the control panel.
Ready
Engine Diagnostics Mode
Diag Mode 1?
Ready
when completed.
Entering...
when complete.
on the parallel port.
on the first line
in the first line. This indicates
and Download
, bypassing the
System controller board LEDs
A power LED (PWR), when illuminated, indicates +5V is being supplied to the system controller board.
The LED HDD, illuminates to flashes to indicate hard drive read/write activity. LED GIO2 flashes to indicate proper CPU operation. LED GIO3; off indicates 10baseT connection, on indicates 100baseT.
off
The LED LNK is
when the printer is not installed on an Ethernet network,
while data is transmitted to the host. When the optional Token Ring Card is installed, the LED LNK indicates the operation
of the Token Ring Card (Ethernet port operations are disabled). The LED Connection
off
when the printer is not inserted into the Token Ring,
is attempting to insert itself into the Token Ring,
on
when the printer is properly inserted
blinks
while the printer is
in the ring.
off
The LED SPD, located next to the LNK LED, is
on
per-second (MBPS),
when the card is set for 16 MBPS.
when the card is set for 4 megabits-
blinks
14
Phaser 1235 Network Color Printer
Paper tray type sensing
The positions of four tab pieces are set accor ding to the position of the paper guide. A cam interlocks the tabs with the paper guide of the paper tray.
Upon insertion of the tray in the printer, four actuator tabs 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)
0000No tray installed 0111Letter 0101Executive 0011A4 1110Legal 14 1011Legal 13 1101B5 1100A5 1001A6
SW2 SW3 SW4
(bottom)
Rotating sensor actuators (side of tray) Paper size sensors
Tray switch sensors and actuators
Tray switch sensors and actuators
0728-04
Service Guide
15
Specifications
Physical dimensions
Dimensions Specification
Height: 16.9 cm (43.0 in.) Width: 43.0 cm (16.9 in.) Depth: 62.0 cm (24.4 in.) Weight: 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
atness:
Maximum deviation of 50 mm from horizontal, side-to-side, with all four feet in contact with the table surface.
16
Phaser 1235 Network Color Printer
Functional specifications
Characteristic Specification
Printing process Electro-photographic, four color (CMYK) tandem transfer printing Color medium Four toner cartridges each contain one of four colors: cy an, magenta,
yellow or black. The toner is a nonmagnetic, monocomponent
contact medium. Addressability 600 x 1200 dpi text and graphics Printing speed
(A, A4)
Minimum printing margins
Usable paper Tray: A-size (letter), Legal, Folio, Executive (7.25 x 10.5 in.)
Time from paper-load to paper-eject for continuous A, A4 printing:
Four-color: 12 ppm
Monochrome: 20 ppm
Four-color transparency: 5 ppm
Monochrome transparencies: 12 ppm
Print times do not include image processing time, which can vary
depending on image complexity.
All sides 4.2 mm (0.167 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 x 5 in.)
Only
Xerox-brand Phaser 1235 A- and A4-size transparency lm is
supported.
Multi-sheet Bypass Feeder - 16 lb. to 54 lb. (60g/m2 to 203g/m2)
Paper tray capacity
Two-sided printing: 75 to 105 g/m2 (20 to 28 lb.)
Tray 1: 530 sheets of paper or 175 transparencies.
Tray 2 and Tray 3: 530 sheets of paper.
Multi-sheet Bypass Feeder: single sheet to 100 sheets of standard
paper. Varying number of env
Multi-sheet Bypass Feeder can use media in the 20 to 60 gm2 range.
elopes and other special stock. The
Service Guide
17
Electrical specifications
Characteristic Specification
Primary line voltages 103 to 140 VAC (115 VAC nominal)
198 to 264 VAC (220 VAC nominal)
Primary voltage frequency range
Power consumption 250 watts during standby state,
Primary voltage fusing 110 VAC conguration – 8 and 10 Amp
Secondary DC voltages Low Voltage Power Supply High voltage Power Supply
RF emissions Both 110 and 220 VAC-congured instruments pass these
50 (48 to 52) or 60 (58 to 62) Hz
1300 watts during warm-up 450 watts average reference value 45 watts during Energy Star state
220 V AC configuration – 4 and 5 Amp
+3.3 VDC (CH) -900 to 1.4 kV + 5 V (DB) -100 to 400/+300 V +12 V (SB) -200 to -700 V + 32 V (TB) +1k to +7 kV +3.8 V (FIX) 0 to 5 kV
standards: FCC Part 15 Class B VDE Class B EN60555-2 Class A VCCI (CISPR 22) Class B
Environmental specifications
Characteristic Specification
Temperature Operating Non-operating Storage
Humidity Operating Non-operating
Altitude Operating Non-operating
Vibration/shock Operating
Non-Operating (vibration) Non-operating (shock)
10o to 32o C (50oto 90oF) 0o to 32o C (32o to 90o F)
-0o to 45o C (32 to 113o F) (with supplies) Media should be acclimated 24 hours before using in the printer .
10 to 85% relative humidity, non-condensing 10 to 95% relative humidity, non-condensing Media should be acclimated 24 hours before using in the printer .
0 to 2500 m (8,000 ft.) at 25oC 0 to 15000 m (50,000 ft.)
May drop any side or corner 50 mm (2 in.) without impairment of subsequent operation. On ve mutually perpendicular axes: 0.5 g, 25-minute sweep, 5 to 200 to 5 Hz, 100 to 200 sec./sweep cycle. No resonant frequencies below 50 Hz. 15 g, trapezoidal ared pulse, 20 msec each axis.
Acoustic Noise (operating) Standby: 35 dBa, Running: 55 dBa, Impulse: 57 dBa
18
Phaser 1235 Network Color Printer
Regulatory specifications
The printer is a recognized component in conformance with the following regulatory standards:
The packaged product meets ASTM D4169-93 and ASTM D4728-91 Transportation Standards.
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 Part 15.
ICES 03 Class B
Service Guide
19
20 Phaser 1235 Network Color Printer
Service Guide
21
Error Codes and Messages
Error messages
The front panel displays error codes when it encounters certain system failures. These error codes are discussed in the next topic. When an error code first occurs, cycle power on the printer to see if the error re-occurs.
Printer fault messages
Code Front panel message Service message
A6 Jam A6, Remove Output Open Cover A, See
Labels
A6-Bypass Feeder Jam
1.
Ensure the correct weight and type of paper is loaded in the feeder. Also ensure the paper is loaded correctly in the feeder.
2.
Clean the bypass feeder’s pick roller.
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.
A7 Jam A7, Remove Output Open Cover 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
Labels
A10-Paper Output 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 exit rollers.
3.
Ensure the exit rolls rotate freely when the exit roller gear train is rotated.
4.
At the rear of the printer, inspect the gate which directs the print to the face-up output bin or the face-down output bin.
5.
Test the fuser motor (which drives the exit gear train) using the test described in “Motor and clutch tests” on page 69.
6.
Replace the engine controller board.
22
Phaser 1235 Network Color Printer
A11 Jam A11, Remove Output Open Cover A, See
Labels
A11-Paper Feed 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 pick and registration rollers.
3.
Ensure there are no obstructions in the paper path.
4.
Test the registration motor and clutch as described in “Motor and clutch tests” on page 69. Replace the motor or clutch if necessary.
5.
Inspect the wiring for the registration clutch and registration motor.
6.
Replace the engine controller board.
A22 Jam A22, Remove Output Open Cover A, See
Labels
A22-Feed Path 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 pick and registration rollers.
3.
Ensure there are no obstructions in the paper path.
4.
Test the registration motor and clutch as described in “Motor and clutch tests” on page 69. Replace the 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 described in “Motor and clutch tests” on page 69.
4.
Replace the duplex unit.
5.
Replace the engine controller board.
B13 Jam B13 Open Area B, See Labels B13-Duplex Inverter 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.
Inspect and clean the eject rollers behind the fuser unit.
3.
Ensure the paper path leading to the duplex unit and the duple x unit’s paper path are both clear of obstructions.
4.
Inspect the operation of the solenoid activated separator gate the direct the print into the duplex unit. Test the exit solenoid with the “Motor and clutch tests” on page 69.
5.
Replace the duplex unit.
6.
Replace the engine controller board.
Printer fault messages
Code Front panel message Service message
Service Guide
23
B21 Jam B21 Open Cover B, See Labels B21-Duplex Area 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. C1 Check Tray 1 No Tray Present C1-Check Tray 1 C2 Check Tray 2 No Tray Present C2-Check Tray 2 C3 Check Tray 3 No Tray Present C3-Check Tray 3
1.
Ensure the tray is installed correctly.
2.
Inspect and test the paper size sensors and the tray’s corresponding
sensor flags.
3.
Replace the paper tray sensor board or its metal finger-lik e actuators if they
are damaged.
4.
Replace the engine controller board. E1 Tray 1 Misfeed Open Tray 1, Cover B E1-Tray 1 Misfeed E2 Tray 2 Misfeed 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 Cover A Open Close Top Cover A E9-Top Cover A Open
1.
Close the cover.
2.
Inspect the switch and ensure the switch’s actuator is not broken.
3.
Test the top cover open switch using the sensor test described in “Switch
scan test” on page 63.
4.
Inspect the switch’s wiring harness.
5.
Replace the engine controller board. E12 Top Output Bin Full Remove Output E12-Output Bin Full, Top
1.
Ensure the output bin full sensor flag operates freely.
2.
Test the output bin full sensor using the test described in “Switch scan test”
on page 63.
3.
Inspect the sensor and its wiring harness.
4.
Replace the engine controller board.
Printer fault messages
Code Front panel message Service message
24
Phaser 1235 Network Color Printer
E14 Front Cover B Open Close Front Cover B E14-Front Cover B Open
1.
Close the cover.
2.
Inspect the switch and ensure the switch’s actuator is not broken.
3.
Test the front cover open switch using the sensor test described in “Switch scan test” on page 63.
4.
Inspect the switch’s wiring harness.
5.
Replace the engine controller board.
EA Black Drum Missing Reseat Drum, Power
Off/On
EA-Black Drum Missing
EB Cyan Drum Missing Reseat Drum, Power
Off/On
EB-Cyan Drum Missing
EC Magenta Drum Missing Reseat Drum, Power
Off/On
EC-Magenta Drum Missing
ED Yellow Drum Missing Reseat Drum, Power
Off/On
ED-Yellow Drum Missing
1.
Remove and install the 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 the front-left side of the engine chassis. Clean the corresponding contacts on the transfer belt unit.
3.
Install a new transfer belt unit.
4.
Replace the engine controller board.
5.
Replace the printer unit chassis.
EF Fuser Missing Reseat Fuser, Power Off/On EF-Fuser Unit Missing
1.
Remove and reinstall the fuser.
2.
install a new fuser.
3.
Replace the low-voltage power supply.
4.
Replace the engine controller board.
Printer fault messages
Code Front panel message Service message
Service Guide
25
H1 A hard disk error was detected that prevented
data from being read from the disk.
H1-Disk Read Error
H2 A hard disk error was detected that prevented
data from being written to the disk.
H2-Disk Write Error
H3 A hard disk full error occurred that prevented
data from being written to the disk
H3-Hard Disk Full
1.
Turn the printer off and on again.
2.
Ensure the hard drive is properly installed.
3.
Reinitialize the hard drive. by scrolling to the
Reset Menu
and selecting the
submenu item
Disk Init
.
4.
Replace the hard drive.
5.
Replace the system controller board. J3 Replace Fuser J3-Replace Fuser
1.
Install a new fuser.
2.
If a new fuser has been installed but the print engine continues to ask f or a
new fuser, reset the fuser life count using the topic “Consumable count
initialization” on page 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 tr ansf er belt, reset the tr ansf er belt life count using the topic
“Consumable count initialization” on page 73.
3.
Replace the engine controller board. J5 Replace Y ellow Drum J5-Replace Y ello w Drum J6 Replace Magenta Drum J6-Replace Magenta Drum J7 Replace Cyan Drum J7-Replace Cyan Drum J8 Replace Black Drum J8-Replace Black Drum
1.
Install a new drum unit.
2.
If a new drum unit has been installed but the print engine continues to ask
for a new drum unit, reset the drum unit life count using the topic
“Consumable count initialization” on page 73.
3.
Inspect the spring-loaded drum unit contacts (in a set of three). Ensure
they are clean and move up and down freely. Remove and reseat them, if
necessary.
4.
Replace the engine controller board.
Printer fault messages
Code Front panel message Service message
26
Phaser 1235 Network Color Printer
J9 Yellow Toner Empty Replace Yellow Toner J9-Yellow Toner Empty J10 Magenta Toner Empty Replace Magenta Toner J10-Magenta Toner Empty J11 Cyan Toner Empty Replace Cyan Toner J11-Cyan Toner Empty J12 Black Toner Empty Replace Black Toner J12-Black Toner Empty
1.
Install a new toner cartridge.
2.
If a new cartridge has been installed but the print engine continues to ask for a new cartridge, reset the toner cartridge life count using the topic “Consumable count initialization” on page 73.
3.
Replace the drum unit.
4.
Replace the engine controller board.
L0 Load Tray # 1 Size 2 Type 3 Load Tray #, Size Type
1.
Load the requested size and type of paper in the tray.
1.
Ensure the tray is installed correctly.
2.
Inspect and test the paper size sensors and the tray’s corresponding sensor flags.
3.
Replace the paper tray sensor board or its metal finger-lik e actuators if they are damaged.
4.
Replace the engine controller board. T29 Temp Sensor Error 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/On T31-Roller Over Error
1. Inspect the main cooling fan. Ensure it is running correctly and is not blocked.
2. Remove and install the fuser.
3. T est the thermistor inside the fuser using the test described in “Switch scan
test” on page 63.
4. Replace the fuser.
5. Replace the low-voltage power supply.
6. Replace the engine controller board.
T32 LED Over Temperature T32 Power Off/On T32-LED Over Temp Error
1. Ensure all the main cooling fan is operating and is not blocked.
2. Ensure the printer is operating in the correct temperature environment; the
printer’s Service Menu : Print Diag Summary test page lists the ambient temperate sensed by the printer.
3. Replace the LED heads.
4. Replace the engine controller board.
Printer fault messages
Code Front panel message Service message
Service Guide 27
T1 Fuser Upper Error T1 Power Off/On T1-Fuser Upper Error T2 Fuser Lower Error T2 Power Off/On T2-Fuser Lower error
1. Remove and install the fuser.
2. Test the thermistors inside the fuser using the test described in “Switch
scan test” on page 63.
3. Replace the fuser.
4. Replace the low-voltage power supply.
5. Replace the engine controller board.
U0 Engine ROM Error U0 Power Off/On U0-Engine ROM Error U1 Engine RAM Error U1 Power Off/On U1-Engine RAM Error U2 Engine EPROM Error U2 Power Off/On U2-Engine EPROM Error U3 Engine EPROM Missing U3 Power Off/On U3-Engine EPROM Missing U4 Engine SRAM Error U4 Power Off/On U4-Engine SRAM Error U5 Engine Control Error U5 Power Off/On U5-Engine Control Error
1. Turn the printer off and then on
2. Reset the printer NVRAM using the procedure “Resetting NVRAM” on
page 85.
3. Replace 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 described in “Switch scan test” on page 63.
2. Inspect the sensor and its wiring harness.
3. Replace the engine controller board.
U8 Controller Fan Error U8 Power Off/On U8-Controller Fan Error
1. Inspect the electrical chassis fan to see if it is running and not blocked.
2. Inspect the fan’s wiring harness.
3. Replace the fan.
4. Replace the engine controller board.
U9 Supply Fan Error U9 Power Off/On U9-Supply Fan Error
1. Inspect the main cooling fan to see if it is running and not blocked.
2. Inspect the fan’s wiring harness.
3. Replace the fan.
4. Replace the engine controller board.
Printer fault messages
Code Front panel message Service message
28 Phaser 1235 Network Color Printer
U10 Roller Position Error U10 Power Off/On U10-Roller Position Error
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 pick and registration rollers.
3. Ensure there are no obstructions in the paper path.
4. Test the registration motor and clutch as described in “Motor and clutch
tests” on page 69. Replace the motor or clutch if necessary.
5. Inspect the wiring for the registration clutch and registration motor.
6. Replace the engine controller board.
U12 Duplex I/F Error U12 Power Off/On U12-Duplex I/F Error
1. Turn the printer off and on.
2. Pull out the duplex er and inspect its connector at the right front corner (the
connector faces rearward). Inspect the printer’s corresponding connector on the printer chassis (covered by a flexible metal plate).
3. Inspect the wiring harness leading from the engine control board to the duplex unit connector.
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 tra y unit to the print engine.
Inspect the printer’s corresponding connector on the underside of the printer. Inspect the wiring harness leading from the connector to the engine control board.
3. Replace the engine controller board.
U15 Control Panel Error U15 Power Off/On U15-Control Panel Error
1. Turn the printer off and then on.
2. Reset the printer NVRAM using the procedure “Resetting NVRAM” on
page 85.
3. Replace the engine controller board.
U18 Yellow LED Error U18 Power Off/On U18-Yellow LED Bar
Missing
U19 Magenta LED Error U19 Power Off/On U19-Magenta LED Bar
Missing U20 Cyan LED Error U20 Power Off/On U20-Cyan LED Bar Missing U21 Black LED Error U21 Power Off/On U21-Black LED Bar Missing
1. Ensure the LED assembly is correctly installed.
2. Inspect the wiring harnesses leading to the LED assembly.
3. Replace the engine controller board.
Printer fault messages
Code Front panel message Service message
Service Guide 29
U22 Yellow Toner Missing Reseat Toner U22-Yellow Toner Missing U23 Magenta Toner Missing Reseat Toner U23-Magenta Toner Missing U24 Cyan Toner Missing Reseat Toner U24-Cyan Toner Missing U25 Black Toner Missing Reseat Toner U25-Black Toner Missing
1. Inspect the toner cartridge sensor flag. Ensure to moves properly and is not broken.
2. Test the sensor using the test described in “Switch scan test” on page 63.
3. Inspect he toner sensor boards wiring harness.
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 set of three). Ensure
they are clean and move up and down freely. Remove the assembly and reseat it, if necessary.
3. Install a new drum unit.
4. Replace the engine controller board.
5. Replace the print unit chassis.
Printer fault messages
Code Front panel message Service message
30 Phaser 1235 Network Color Printer
Controller board diagnostic error codes
Code Test Possible Cause
1 Memory Bad memory DIMMs 2 Memory Speed Bad DIMMs or controller board 3 CPU Tick Bad controller board 4 System Timer Bad controller board 5 BX Host Bridge Bad controller board 6 PIIX4 PCI-ISA Bridge Bad controller board 7 21152 PCI-ISA Bridge Bad controller board 8 PCI-PCI Bridge Bad controller 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 Identify Bad hard disk drive 20 Disk Read/Write Bad hard disk drive 21 Disk Read Capability Bad hard disk drive 22 Disk Write Capability Bad hard disk drive 23 Disk Data Format
Check
Bad hard disk drive
Service Guide
31
Troubleshooting
This topic discusses troubleshooting the printer. Troubleshooting 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.
32
Phaser 1235 Network Color Printer
Power on self-diagnostic test
Initial test. The following checks are automatically performed when the printer is powered on:
1.
ROM check (loader). Checks ROM by comparing the sum of bits in the received data unit by the number of bits in the transferred data unit.
2.
Flash ROM check. Checks Flash ROM by writing a present data pattern in Flash ROM, reading the contents of Flash ROM, and comparing the data read from Flash ROM by the data written in Flash ROM.
3.
RAM check. Checks RAM by writing a preset data pattern in RAM, r eading the contents of RAM, and comparing the data read from RAM by the data written in RAM.
4.
EEPROM check. Checks ID numbers stored in the fixed addresses of EEPROM. Checks the content of the menu area by contr ol firmware and the engine area by engine firmware.
5.
Mechanical check.
All the 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 of each toner cartridge.
Option unit check. Checks whether the optional units (such as the paper tray 2, paper tray 3, duplex unit) have been installed before entering the operation mode.
The print engine performs a color misalignment detection check by laying down patches of toner on the transfer belt and reading their relative positions to each other with the color registration sensor assembly.
After the fuser reaches its idle temperatur e the printer is placed on line in its READY state.
The print engine is initialized. If the startup page feature has not been disabled and no error occurred with the printer, the printer prints a startup page.
Service Guide
33
Print engine troubleshooting
This topic is a step-by-step procedure for systematically verifying particular aspects of the printer's operation. Following this procedure should lead to the cause of a printer's failure.
Testing the print engine
1.
If the printer does not power up, or does not initialize, or the printer initializes but the motors do not run properly, go to the later topic, “Verifying power supply operation” 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 next topic, “Verifying printer operation by using its self-test print” on page 34.
If the printer does not make the test print, then a problem exists with the print engine. Proceed with the topic, “Verifying power supply operation” on page 34.
34
Phaser 1235 Network Color Printer
Verifying printer operation by using its self-test print
1.
If not already on, turn on the printer. If the printer does not power up, or does not initialize, or the printer initializes but the motors do not run properly, go to the next topic “Verifying power supply operation.”
2.
Verify that the system controller board’s health LED is flashing. The health LED is viewable through the rear panel. If the health LED is not flashing, then the system controller board is not working.
3.
When the Ready message is displayed, press the Menu (1, 5) buttons to enter the menu.
4.
Press the Menu (1, 5) buttons to navigate to the
Print Menu
item. Press the
Item (2, 6 ) keys to scroll through the list of available test prints. Select any
test print.
5.
Press Enter to print a test prints. The printer should print a test page from the system controller board.
If the printer prints a test pattern, then the print engine controller board 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 board.
Measuring power supply voltages
1.
Turn off the printer and unplug it from its power outlet.
2.
AC Input: With the DMM set to measure AC voltages, measure for power
being supplied to the printer. It should measure between 87 to 128 VAC (115 VAC nominal) or 174 to 250 VAC (220 VAC nominal).
3.
Power supply fan : With the power switch on, is the main fan running?
(Access the fan by removing the left side cover.) If not, check the fan’s wiring harness (CN5) to the low-voltage power supply board; it should measure 32 to 38VDC (the voltage drops to zero when the fan is disconnected). If the voltage is not correct, replace the low-voltage power supply. Otherwise, replace the power supply fan.
Required tools
#1 Phillips screwdriver
Digital multimeter (DMM)
Service Guide
35
DC Output: With the DMM set to measure DC voltages, measure the voltages at
the POWER connector on the bottom of the print engine controller board for +3.3VDC, +5 VDC, +12 VDC and +32 VDC. (You must remove the right side cover and right shield plate to access the engine controller board.)
If the voltages are not correct, inspect the wiring harness connecting the POWER connector of the engine controller board to the CN1 connector of the low-voltage power supply. If the harness is undamaged, 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 corr ectly, 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 2 No connection 17 +3.3 VDC 3 Ground 18 +3.3 VDC 4 Ground 19 32 V 5 Ground 20 Ground 6 Ground 21 No connection 7 +32 VDC 22 No connection 8 +32 VDC 23 Ground 9 +32 VDC 24 Ground 10 +32 VDC 25 Ground 11 +5 VDC 26 Ground 12 +5 VDC 27 Ground 13 +5 VDC 28 Ground 14 +5 VDC 29 No connection 15 +3.3 VDC 30 24 VDC
36
Phaser 1235 Network Color Printer
Inspecting the low-voltage power supply fuse
The 1 15 VAC power supply features a 20 A fuse. The 220 VAC power supply fuse uses a 10 A fuse.
1.
Turn off the printer.
2.
Disconnect the power cord from the printer.
3.
Remove the left-side cover as described in “Left-side cover” on page 88.
4.
Remove the main cooling fan as described in “Main cooling fan” on page 99. The fuse is now accessible.
If the fuse is good, but the printer's power supply does not output DC voltages, 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 off the printer.
6.
With a DMM set to measure resistance, test each switch when it is opened and closed.
7.
Inspect each switch’s wiring harness for pinches, nicks or open connections.
If you find a switch that is defective, replace it. If no motors appear to be at fault, replace the engine controller board.
Service Guide
37
Testing for a shorted motor
1.
Remove the top and rear covers.
2.
Disconnect the motor harnesses and verify motor resistances (see the following 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
38
Phaser 1235 Network Color Printer
Motor and fuser roller resistances
1.
Turn off the printer and disconnect the power cord.
2.
With a DMM set for measuring resistance, test each motor's windings for correct resistance (disconnected from the printer).
Motor and fuser roller resistances
Motor Measure between ... Resistance
Yellow drum unit motor Magenta drum unit motor Cyan drum unit motor Black drum unit motor
Between motor Pins 1 and 2 Between motor Pins 3 and 4
All the drum motors connect to connector ID at the top of the engine controller board Black Pins 1 thru 4 Yellow Pins 5 thru 8 magenta Pins 9 thru 12 Cyan Pins 13 thru 16
4 Ω
4 Ω
Transfer 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
Fuser unit New fuser: The resistance
between pins C and D of the lower roller will be O , a fuse.
Used fuser: The between pins C and D of the lower roller will be open. The fuse indicates a new fuser and is blown within seconds of being installed to indicate a fuser now in use.
Upper Roller Between Pins A and B Between Pins C and D Between Pins E and F Lower Roller Between Pins A and B Between Pins C and D Between Pins E and F
2 Ω Open 363 at 25
o
C
3
0
or open (fuse)
363 at 25
o
C
B A
C D E F
C D E F
B A
Underside of fuser
-
Service Guide
39
Media jams and the paper path
Jams fall into the following four categories:
Media-based problems
Paper-picking errors
Printing jams
Paper-ejecting errors
Media-based problems
Media problems
1.
Check that the correct type of media is being used. The customer should be using a quality laser printer paper. The printer may have trouble picking slick-finish paper.
2.
Inspect the paper for bent, torn or folded corners.
3.
Ensure that the correct media is loaded in the paper tray.
4.
Only Xerox-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 determine the printer’s condition.
3.
Ensure the paper is correctly loaded in the tray.
4.
Clean the pick rollers with an a dry, lint-free cloth if debris is visible.
5.
Replace the paper pick rollers.
6.
Check the tray’s retard pad for damage.
7.
Replace the paper tray.
Required tools
#1 Phillips screwdriver
DMM
40
Phaser 1235 Network Color Printer
The media skews passing through the paper path
1.
Make sure that the media is properly installed in the tray.
2.
Does the pick-up roller pick up evenly? Is it clean?
3.
Is the paper tray damaged or obstructed?
4. Are the tray's side paper guides snugly adjusted against the stack of media?
The guides should be neither too loose nor too tight.
5. The problem occur when printing from a different tray?
6. Is there an obstacle blocking the 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 empty flag properly interrupt the paper empty sensor?
Remove the paper tray and actuate the paper-empty flag located to the left of the pick rollers.
2. Test the sensor using the service tests described in “Switch scan test” on
page 63.
3. Replace the engine controller board.
Service Guide 41
Jams
Wrong media
1. Ensure the correct media type and size is loaded in the corr ect tray. For the
multi-sheet bypass feeder, ensure the loaded media matches the control panel settings.
2. Inspect the paper tray for damage to the tray’s paper size sensor actuators.
3. T est the printer’s paper size sensors using the service test “Switch scan test”
on page 63. If the sensors test ok, then the engine controller board is probably bad.
4. Replace the paper size sensor board’s wiring harness.
Paper jams at the paper tray
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 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. Inspect the tray’s paper lift mechanism.
5. Does the paper feed motor run? Check the motor’s wiring harness and
connection (HOPFF) to the engine controller board.
6. Replace the paper feed motor.
7. Check the gear train for broken teeth and proper installation.
8. Replace the pick rollers.
9. Does the pick clutch work properly? If not, replace it.
10. Replace the engine controller board.
42 Phaser 1235 Network Color Printer
Manual bypass feeder feed jams
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 environmental conditions.
3. Do not overload the manual bypass tray; otherwise jams will occur.
4. Clean with an a dry, lint-free cloth if debris is visible or replace the manual
bypass feed pick roller.
5. Test the manual bypass feeder sensors using the service test “Switch scan
test” on page 63.
6. Inspect the wiring harness from the manual bypass feeder to the engine
controller board.
7. Replace the manual bypass feeder.
8. Replace the engine controller 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 motor. Test the motor using
the service test “Motor and clutch tests” on page 69.
5. Does the registration roller electric clutch operate correctly? Operate it with
the service test “Motor and clutch tests” on page 69.
6. Transparency film. Use only Xerox-brand transparency film meant for this
printer.
Paper jams at the transfer belt
1. Check for a paper scrap in the paper path.
2. Is the transfer belt assembly correctly installed?
3. Test the transfer belt motor using the service test “Motor and clutch tests”
on page 69.
Service Guide 43
Fuser jams
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 environmental conditions.
3. Test the fuser motor using the service test “Motor and clutch tests” on
page 69.
4. Does the exit sensor flag properly actuate its sensor? Use the service test
“Switch scan test” on page 63 to test the senor.
5. Replace the fuser.
6. Replace the engine controller board.
Eject jams
1. Is the paper in good condition and appropriate for a laser printer? Is the
paper curling?
2. Is the printer printing within its environmental specifications? Print the
Diagnostic Summary Page to determine the printer’s environmental conditions.
3. Is the jam caused by a heavy, stiff paper being printed to the face-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 service test “Switch scan test” on page 63.
7. Replace the engine controller board.
Jams in the duplex unit
1. Is the duplex unit correctly installed?
2. Clean the rollers inside the duplex unit with an a dry, lint-free cloth if debris
is visible.
3. Inspect the duplex unit for foreign objects such as a scrap of paper.
4. Inspect the duplex unit’s electrical connector for damage.
5. Does the duplex unit’s sensors operate correctly? Test the sensors using the
service test “Switch scan test” on page 63.
6. Test the duplex motor using the service test “Motor and clutch tests” on
page 69.
7. Replace the duplex unit.
8. Replace the engine controller board.
44 Phaser 1235 Network Color Printer
No drum imaging unit installed
1. Ensure that the drum imaging units are properly installed.
2. Check the high-voltage terminal connectors for the imaging unit to ensure
that they are not damaged.
3. Replace the drum imaging unit.
Imaging drum unit up/down error
1. Cycle the printer power to see if the problem clears.
2. Ensure that each imaging drum unit is correctly installed and that each
unit’s drum contact assembly (a set of three spring-loaded pins) is not damaged. Ensure that each contact moves up and down freely and is not contaminated 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
“Motor and clutch tests” on page 69. Replace the main motor assembly, if indicated.
6. Inspect the gear drive for each imaging drum unit for damage.
7. Replace the engine controller board.
Fan error
1. Is power supplied to pin 1 of the fan? If yes, replace the fan.
2. Inspect the fan’s wiring harness for damage.
3. Replace the low-voltage power supply
4. Replace the engine controller board.
Service Guide 45
Fuser unit error
1. Does the error occur immediately after the printer is turned on? Replace the
fuser.
2. Check that AC voltage supplied to the printer is correct.
3. Does the fuser get hot? If not, replace the fuser.
4. If the fuser does warm up, verify that it is reaching the correct temperature
by running the service test “Switch scan test” on page 63.
5. Does 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 deliver the current required by the fuser heaters.
6. Replace the engine controller board.
7. Replace the low-voltage power supply.
B A
C D E F
C D E F
B A
Underside of fuser
0728-02
46 Phaser 1235 Network Color Printer
Other problems
These problems may be indicated as errors on the front panel.
The printer continuously displays “Booting” or “Initializing.”
The most likely cause is that the system controller board has not successfully loaded its EEPROM contents (instructions) into RAM. The health indicator LED (heart beat) usually indicates such an error state by being on or off but not flashing. All print engine operation halts, and will only become ready when the system controller board successfully boots.
1. Re-powering the printer, or perform a NVRAM reset can may fix this
problem.
2. To verify if the system controller board has failed: a. Power down the printer, and remove the system controller board
board.
b. Power-up the printer. W ait at least 5 minutes while the print engine
initializes. If there was a problem with the system contr oller boar d, 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 system controller board.
False “No toner cartridge installed” message
1. Ensure that the toner cartridge is correctly installed.
2. Replace the toner cartridge.
3. Test the toner cartridge sensor board using the service test “Switch scan
test” on page 63.
4. Replace the engine controller board.
False “No fuser unit installed” message
1. Ensure that the fuser unit is correctly installed.
2. Check the condition of fuser units’s connector and their corresponding
receptacles on the print engine (under the fuser unit).
3. Replace the fuser unit.
4. Replace the engine controller board.
5. Replace the low-voltage power supply.
Service Guide 47
Front door indicated being open when it is closed
1. Inspect that the front door’s interlock for damage.
2. Replace the interlock switch.
3. Check its wiring harness.
4. Replace the engine controller board.
5. Replace the power supply.
High temperature error
1. Check the fans for proper operation.
2. Replace the low-voltage power supply unit.
3. Replace the engine controller board.
Low temperature error
If the fuser 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, clock delay, number of address columns and row, refresh rate and more. If the DIMM does not meets the required specifications the printer displays an “Invalid memory DIMM” error message and then continues the bootup process.
48 Phaser 1235 Network Color Printer
Printing and print quality problems
Light or blurred images
1. Is the correct paper being used
in the printer?
2. Are the toner cartridges low?
3. Are any of the imaging drum
reaching their end-of-life? Replace them if they are.
4. Do the imaging drum units
make good connection to their power terminals?
5. Are the LED heads dirty?
Clean each head with an alcohol-soaked, lint-free cloth.
6. Are the LED heads wiring
harnesses undamaged and properly seated?
7. Is +3.8V (red wire) supplied to
Pin 3 of each 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 on the
engine controller board? Inspect the wiring harnesses or replace the low-voltage power supply.
10. Is +32V supplied to the HVOLT connector Pin 5 of the engine board. If not
replace the engine board. (Transfer the old engine controller board’s EEPROM (lower-right corner of board) to the new engine contr oller boar d.)
11. Inspect the high-voltage wiring harnesses.
12. Replace the high-voltage power supply.
Required tools
#1 Phillips screwdriver Conductive grease
Volt-ohm-meter (VOM) ■ Ruler
Service Guide 49
Dark, stained background
1. Determine if any of the imaging
drums were exposed to light for an extended amount of time. If so, replace an unit which was.
2. Examine the fuser rollers for
contamination. Replace the fuser if they are.
3. Ensure the media type is
correctly set.
4. Are the power supply fans both
running? A heat build-up under the imaging units can cause toner to stain the print’s background.
5. Do the imaging drum units
make good connection to their power terminals?
6. Are the LED heads wiring
harnesses undamaged and properly seated?
7. Is +3.8V (red wire) supplied to
Pin 3 of each 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 on the
engine controller board? Inspect the wiring harnesses or replace the low-voltage power supply.
10. Is +32V supplied to the HVOLT connector Pin 5 of the engine board. If not
replace the engine board. (Transfer the old engine controller board’s EEPROM (lower-right corner of board) to the new engine contr oller boar d.)
11. Inspect the high-voltage wiring harnesses.
12. Replace the high voltage power supply.
50 Phaser 1235 Network Color Printer
Blank print
1. Do the imaging drum units
make good connection to their power terminals?
2. Are the LED heads wiring
harnesses undamaged and properly seated?
3. Is +3.8V (red wire) supplied to
Pin 3 of each LED head assembly? If yes, replace the LED head assembly.
4. 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.
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
replace the engine board. (Transfer the old engine controller board’s EEPROM (lower-right corner of board) to the new engine contr oller boar d.)
7. Inspect the high-voltage wiring harnesses.
8. Replace the high voltage power supply.
Service Guide 51
Black stripe in direction of paper travel
1. Do the imaging drum units
make good connection to their power terminals?
2. Are the LED heads wiring
harnesses undamaged and properly seated?
3. Is +3.8V (red wire) supplied to
Pin 3 of each LED head assembly? If yes, replace the LED head assembly.
4. 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.
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
replace the engine board. (Transfer the old engine controller board’s EEPROM (lower-right corner of board) to the new engine contr oller boar d.)
7. Inspect the high-voltage wiring harnesses.
8. Replace the high voltage power supply.
52 Phaser 1235 Network Color Printer
White stripe in direction of paper travel
1. Look for dirt or contamination
on the LED heads. Clean them with an alcohol wipe.
2. Do the imaging drum units
make good connection to their power terminals?
3. Are the LED heads wiring
harnesses undamaged and properly seated?
4. Is +3.8V (red wire) supplied to
Pin 3 of each LED head assembly? If yes, replace the LED head assembly.
5. 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.
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 HVOLT connector Pin 5 of the engine board. If not
replace the engine controller board. Transfer the old engine controller board’s EEPROM (lower-right corner of boar d) to the new engine contr oller board.
8. Inspect the high-voltage wiring harnesses.
9. Replace the high voltage power supply.
Service Guide 53
Poor fusing, toner offsetting
1. Is a supported paper type being
used? Try printing on a different brand of paper.
2. Is the fuser unit properly
installed and making good electrical contact with the print engine? Inspect its connector.
3. Inspect the fuser . Are its rollers
contaminated or damaged?
4. Ensure the media type is
correctly set.
5. Does 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 on the fuser’s underside when the fuser is installed; remove the fuser to check. If not, replace the power supply.
6. Is the resistance of the fuser’s
upper roller thermistor (at room temperature) between 190 to 980 ohms? If not replace the fuser.
7. Is the resistance of the fuser’s lower roller thermistor (at room temperatur e)
between 190 to 980 ohms? If not replace the fuser.
8. Is the fuser temperature correct during printing? Run the maintenance
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 boar d) 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-sheet bypass feeder. For cold-offsetting, characterized by toner flaking off the completed print, you want to raise the fuser’s temperature. For hot-offsetting, characterized by toner pulled off print as it is fused, you want to lower the fuser’s temperature. The chart below lists the specialty paper types and relative fuser temperatures used. To correct offsetting, select the next paper type above or below the current paper type you are using. Removing and reloading paper in the multi-sheet bypass feeder, prompts you for the paper type at the control panel.
Hottest fuser temperature used
Cardstock Label/Envelope Glossy Letterhead/Light Cardstock Plain Paper/Transparency film Coolest fuser temperature used
54 Phaser 1235 Network Color Printer
Repeating defect or voids on print
This can usually be traced to a dent-like defect in the developer roller of the imaging drum unit in question. Measure the spacing between the spots. The distance between the repeating spots indicates the source of the problem.
In some instances, the spots may be dark instead of white. They may also be shaped something other than round.
If the spots are about 1 15 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 affected color.
57.8 mm (2.27 in.): Toner supply roller. Replace the imaging drum unit
of the affected color.
44 mm (1.7 in.): Charging roller. Replace the imaging drum unit of the
affected color.
Service Guide 55
Missing characters or voids in print
1. Look for dirt or contamination
on the LED heads. Clean them with an alcohol wipe.
2. Inspect and clean the imaging
drum unit’s power terminals Ensure the spring-loaded pins travel smoothly up and down.
3. Is a low-toner condition
occurring?
4. Replace any imaging drum
units you suspect are defective.
5. Are the LED heads’ ribbon
cables undamaged and properly seated?
6. Is +3.8V (red wire) supplied to
Pin 3 of each LED head assembly? If yes, replace the LED head assembly.
7. 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.
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 low-voltage power supply.
9. Is +32V supplied to the HVOLT connector Pin 5 of the engine board. If not
replace the engine controller board. Transfer the old engine controller board’s EEPROM (lower-right corner of boar d) to the new engine controller board.
10. Inspect the high-voltage wiring harnesses.
11. Replace the high voltage power supply.
56 Phaser 1235 Network Color Printer
Color misalignments
1. Test the registration sensor as
described in the topic “Switch scan test” on page 63.
2. Look for any broken gears in
the printer. specifically, inspect the imaging drum gear assembly, the paper feeder assembly and the transfer belt assembly.
3. Inspect and clean the imaging
drum unit’s power terminals Ensure 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 seating.
8. Replace the engine controller board. Transfer the old engine controller
board’s EEPROM (lower-right corner of boar d) to the new engine contr oller board.
Service Guide 57
Unexpected colors
The colors produced by the printer are dramatically different from the color you expected.
1. Look for dirt or contamination
on the LED heads. Clean them with an alcohol wipe.
2. Inspect and clean the imaging
drum unit’s power terminals Ensure the spring-loaded pins travel smoothly up and down.
3. Replace any imaging drum
units you suspect are defective.
4. Are the LED heads wiring
harnesses undamaged and properly seated?
5. Is +3.8V (red wire) supplied to
Pin 3 of each LED head assembly? If yes, replace the LED head assembly.
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 harnesses or replace the low-voltage power supply.
8. Is +32V supplied to the HVOLT connector Pin 5 of the engine board. If not
replace the engine controller board. Transfer the old engine controller board’s EEPROM (lower-right corner of boar d) to the new engine controller board.
9. Inspect the high-voltage wiring harnesses.
10. Replace the high voltage power supply.
58 Phaser 1235 Network Color Printer
Image is skewed on the paper
1. Is the paper in good condition and the recommended type and weight for a
laser printer? Does the paper in the multi-sheet bypass feeder match the front panel settings?
2. Is the printer printing within its environmental specifications? Print the
Diagnostic Summary Page to determine the printer’s conditions.
3. Ensure the tray is properly loaded with the tray’s paper guides correctly
snugged against the stack of paper.
4. Swap the tray from which the skewed print originates.
5. Ensure that paper feed rollers are clean and undamaged. Inspect its paper
pick roller. Clean them with an a dry, lint-free cloth if debris is visible.
6. Replace the paper pick rollers.
7. Look for obstructions in the paper path.
8. Clean the intermediate and aligning rollers with an a dry, lint-free cloth if
debris is visible.
9. Replace 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 feed rollers and the registration rollers with an a dry, lint-free
cloth if debris is visible.
5. Replace the engine controller board.
The print is wrinkled
1. Check for an obstruction in the paper path, particularly with the feed rollers
and the fuser.
2. Is the paper in good condition and appropriate size, weight, grain and
grade for a laser printer? Print the Diagnostic Summary Page to determine the printer’s conditions.
3. Is the printer printing within its environmental specifications?
4. If possible, you should feed long-grain paper into the printer . Long-grained
paper's grain is parallel to the paper path (the direction the paper travels while it is fed through the printer).
Service Guide 59
Macintosh printing problems
Image never prints
The printer indicates it is receiving data, but no print comes out of printer or the printer goes back to Ready to Print mode without printing an image.
1. Make sure that the correct printer icon was selected in the Chooser. Try
printing the job again. Try printing a different file or from a different application.
2. In the Chooser, switch background printing off. Try printing the job
again. With newer LaserWriter printer drivers, select Foreground Printing in the Print dialog box.
3. Download the Echo showpage snippet which produces a blank sheet of
paper, to determine if the printer is receiving and processing files.
4. Make sure you are printing with the correct PPD file.
5. Activate Error Handler using the front panel Advanced Printer
Settings menu. Alternately, download the Error Handler utility and try printing the job again. If an error page is printed after printing the job again, call the Customer Support 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 selected to
print in Portrait or Landscape orientation, as you expect.
Image prints in black-and-white
1. In the Chooser, ensure a color printer icon is displayed next to the
Phaser 1235 in the list of available printers. This indicates the printer’s PPD has been selected and properly configured.
2. In the Print dialog box, make sure that the Color/Grayscale option has
been selected.
3. Make sure that the Phaser 1235 printer icon was selected in the Chooser.
Try printing the job again.
4. Check the version of your LaserW riter driver to ensure that it is version
8.0.x or higher. Earlier versions of the driver do not support color PostScript.
5. The application may require special instructions to print, such as those
contained in a PPD file; check in the Phaser 1235 Printer CD-ROM.
60 Phaser 1235 Network Color Printer
Printer isn’t in the Chooser
1. Ensure that the printer is turned on and the printer is in its READY
mode.
2. Check the Network or AppleTalk control panel to ensure the proper
network or zone is selected.
3. Power-cycle the printer.
4. Check to see if the printer has not been renamed or placed in another
zone. You can print a Configuration Page, which lists this EtherTalk information as well as other information about the printer.
5. Verify the EtherTalk settings on the 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 problems
Image never prints
The printer’s front panel Receiving data message is displayed as if receiving data, but nothing comes out of printer or the printer goes back to Ready to Print mode without printing an image.
1. From the printer driver, under the printer's set up options, set
TRANSMISSION RETRY = 850.
Service Guide
61
Service Tests and Adjustments
Diagnostics mode
To start the engine maintenance mode:
1.
Turn off the printer.
2.
Press and hold the
Menu (1)
and
Enter (4)
keys.
3.
Turn on the printer.
4.
When,
DIAGNOSTIC MODE xx.xx.xx
is displayed on the control panel
(
xx.xx.xx
is the ROM version), release the control panel keys.
5.
Press the
Menu (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
DIAGNOSTIC MODE xx.xx
is displayed,
press
Online (0)
. Alternately, you can turn the power off, wait a few seconds, and
then turn power back on.
62
Phaser 1235 Network Color Printer
These are the items of the engine maintenance mode menu.
Switch Scan Test
Motor & Clutch Tests
Test Print
Consumables count reset
Consumable Status
Printer Status
This table details the menu items, their sub-menus, and settings.
Engine maintenance mode menu
Menu - scroll
using Menu(1) or Menu(5)
Items - scroll
using Item(2) or Item(6)
Settings - scroll
using Value(3] or Value(7) Description
SWITCH SCAN SCAN00 thru
SCAN19
Test start/stop Select and test printer
switches and sensors
MOTOR & CLUTCH TEST
Lists each motor and clutch
Test start/stop Alternation of setting or Test start/stop
Test the printer motors and clutches. A selected 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 drum belt unit, fuser unit or toner cartridge. The adjusted values for mechanical controls are all cleared to their initial values.
CONSUMABLE STATUS
Displays each consumable item
no settings
The consumption status of each consumables is displayed in turn. Values show are of prints made and percentage of toner consumed.
PRINTER STATUS
Lists print count and impressions made by each imaging unit
no settings
The life status of the selected consumable is displayed.
Service Guide
63
Switch scan test
Use this test to check the operation of the printer’s switches and sensors.
1.
Enter the diagnosis mode by pressing and holding the Menu (1) and
Enter (4) keys as you turn on the printer.
2.
Press the Menu (1, 5) keys to scroll through the list of test until
SWITCH
SCAN
appears on the upper display.
3.
Press the Item (2,6) keys to scroll through the list of sensor tests, called SWITCH SCAN 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 manually actuate the sensors being scanned and look for a change at the control panel.
6.
Press Value (7) to stop the current test.
7.
Repeat steps 2 through 5 as required.
8.
To exit the switch scan test mode, press Enter (4) .
64
Phaser 1235 Network Color Printer
Service Guide
65
Switch scans and the sensor and switches test
Switch or sensor
Switch scan test Test result Details
Tray 1 No Paper Sensor
Switch Scan 00 1=
L - Paper present H - No paper
Pull main tray out to test sensor
Tray 1 Low Paper Sensor
Switch Scan 00 2=
L - Paper level OK H - Low paper
Pull main tray out to test sensor
Cassette Entrance
Switch Scan 00 3=
L - No paper H - Paper present
Open front door and toggle sensor flag
behind feed rollers
Manual Bypass Feeder Entrance/ Registration sensor
Switch Scan 00 4=
L - No paper H - Paper present
Open front door and push sheet of paper
into paper path leading to the transfer
unit
Belt Entrance Switch Scan 01
1=
L - Paper present H - No paper
Open front door and push sheet of paper
into paper path leading to the transfer
unit. Manually rotate the registration
roller (use the thumbwheel on the left
end of the roller) to feed the paper to the
transfer belt.
Exit Sensor Switch Scan 01
2=
L - No paper H - Paper present
Toggle sensor flag behind the fuser.
Remove the fuser if necessary
Stack Full Sensor Switch Scan 01
3=
L - No paper H - Stack full
Toggle the sensor flag at the exit bin
not used
Switch Scan 01 4=
not used
Black Toner Cartridge 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 T oner Cartridge Present
Switch Scan 02 3=
L - Deactuated H - Unit installed
Open top cover and actuate sensor flag
next to LED head.
Yellow T oner Cartridge Present
Switch Scan 02 4=
L - Deactuated H - Unit installed
Open top cover and actuate sensor flag
next to LED head.
Top Cover Switch Switch Scan 03
1=
L - Top closed H - Top opened
Open top cover
Front Cover Switch
Switch Scan 03 2=
L - Cover closed H - Cover opened
Open front cover
Waste Toner Sensor
Switch Scan 03 3=
L - Not full H - Full
Remove the drum unit caddy and the
transfer belt. Locate the sensor below
the registration rollers. Interrupt the
sensor with a scrap of paper
not used
Switch Scan 03 4=
not used
not used
Switch Scan 04
not used
not used
Switch Scan 05
not used
Manual Bypass Feeder Home Sensor
Switch Scan 06 1=
L - Roller at home H - Roller not home
Open the top cover and remove the
drum unit caddy. Manually rotate the
manual bypass f eed roller by turning the
white gear on the right end of the roller.
Manual Bypass Feeder Paper Empty Switch
Switch Scan 06 2=
L - Paper loaded H - No Paper
Toggle the switch located at the
inner-base of the Manual Bypass F eeder
tray
66
Phaser 1235 Network Color Printer
not used
Switch Scan 06 3=
not used
Manual Bypass Feeder OHP Sensor
Switch Scan 06 4=
L - Transparency H - Paper
Manual feed a sheet of paper film thru the feeder. Transparency film causes no change
Tray 1, Size 1 Switch - (Top)
Switch Scan 07 1=
L - Actuated H - Deactuated
Remove the tray and actuate the sensor flags on right side of tray cavity
Tray 1, Size 2 Switch
Switch Scan 07 2=
L - Actuated H - Deactuated
Tray 1, Size 3 Switch
Switch Scan 07 3=
L - Actuated H - Deactuated
Tray 1, Size 4 Switch - (Bottom)
Switch Scan 07 4=
L - Actuated H - Deactuated
Color Registration (Left) - 006
Switch Scan 08 1=
Density V alue ***H
Color value in hexidecimal format. The default is 094
Color Registration (Right) - 00A
Switch Scan 08 2=
Density V alue ***H
Color value in hexidecimal format. The default is 073
not used
Switch Scan 08 3=
not used
not used
Switch Scan 08 4=
not used
Upper Fuser Thermistor - 00D
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 environmental humidity
Default - 036
Temperature Sensor
Switch Scan 10 2=
Encoded environmental temperature
Default - 21E
not used
Switch Scan 10 3=
not used
not used
Switch Scan 10 4=
not used
Duplex In Sensor Switch Scan 11
1=
L - Deactuated H - Actuated
Pull out the duplex unit. Lift its cover. Place a sheet of paper inside on the sensor flag. Close the cover. Reinsert the duplex unit in the printer.
Duplex Rear Sensor
Switch Scan 11 2=
L - Deactuated H - Actuated
Pull out the duplex unit. Lift its cover. Place a sheet of paper inside on the sensor flag. Close the cover. Reinsert the duplex unit in the printer.
Switch scans and the sensor and switches test
Switch or sensor
Switch scan test Test result Details
Service Guide
67
not used
Switch Scan 11 3=
not used
Duplex Front Sensor
Switch Scan 11 4=
L - Deactuated H - Actuated
Pull out the duplex unit. Lift its cover.
Place a sheet of paper inside on the
sensor flag. Close the cover. Reinsert
the duplex unit in the printer.
Tray 2, Size 1 Switch - (Top)
Switch Scan 12 1=
L - Actuated H - Deactuated
Remove the tray and actuate the sensor
flags on right side of tray cavity
Tray 2, Size 2 Switch
Switch Scan 12 2=
L - Actuated H - Deactuated
Tray 2, Size 3 Switch
Switch Scan 12 3=
L - Actuated H - Deactuated
Tray 2, Size 4 Switch - (Bottom)
Switch Scan 12 4=
L - Actuated H - Deactuated
Tray 2 No Paper Sensor
Switch Scan 13 1=
L - Actuated H - Deactuated
Pull Tray 2 out to test sensor
Tray 2 Low Paper Sensor
Switch Scan 13 2=
L - Actuated H - Deactuated
Pull Tray 2 out to test sensor
not used
Switch Scan 13 3=
not used
not used
Switch Scan 13 4=
not used
not used
Switch Scan 14 1=
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
Tray 3, Size 3 Switch
Switch Scan 15 3=
L - Actuated H - Deactuated
Tray 3, Size 4 Switch - (Bottom)
Switch Scan 15 4=
L - Actuated H - Deactuated
Tray 3 No Paper Sensor
Switch Scan 16 1=
L - Actuated H - Deactuated
Pull Tray 3 out to test sensor
Tray 3 Low Paper Sensor
Switch Scan 16 2=
L - Actuated H - Deactuated
Pull Tray 3 out to test sensor
not used
Switch Scan 16 3=
not used
not used
Switch Scan 16 4=
not used
not used
Switch Scan 17 1=
not used
not used
Switch Scan 17 2=
not used
Tray 3 Feed Sensor
Switch Scan 17 3=
L - Actuated H - Deactuated
Remove tray 3 and toggle sensor flag
behind feed rollers
Switch scans and the sensor and switches test
Switch or sensor
Switch scan test Test result Details
68
Phaser 1235 Network Color Printer
not used
Switch 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
Service Guide
69
Motor and clutch tests
1.
Enter the diagnosis mode by pressing and holding the Menu (1) and
Enter (4) keys as you turn on the printer.
2.
Press the Menu (1, 5) keys to scroll through the list of test until
MOTOR
& CLUTCH TEST
appears on the upper display.
Caution
Before running some motor and clutch tests you must remove certain printer consumable items; refer to table below. The front panel also reminds you to remove the necessary item before starting the test.
3.
Press the Item (2, 6) keys to scroll through the list of motors and clutches until the desired item is displayed.
4.
If indicated, remove the consumable items constraining the test.
5.
Press the Value (3) key to start 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 with the drum unit caddy
removed.
YELLOW-ID MOTOR REMOVE ID Run test with the drum unit caddy
removed.
MAGENTA-ID MOTOR REMOVE ID Run test with the drum unit caddy
removed.
CYAN-ID MOTOR REMOVE ID Run test with the drum unit caddy
removed.
TRANSFER BELT MOTOR REMOVE ID Run test with the drum unit caddy
removed.
FUSER MOTOR
none
Remove the fuser and observe the fuser drive gears turn.
REGISTRATION MOTOR
none
Remove the drum unit caddy and observe the registration roller B turn
70
Phaser 1235 Network Color Printer
MAIN FEEDER MOTOR EXIT TRAY1
CASSETTE
Run the test with Tray 1 removed
REGISTRATION CLUTCH none Open the front cover and observe
registration roller A turning
REGISTRATION SHUTTER none Remove the imaging drums and the
transfer belt to watch the shutter open and close.
EXIT SOLENOID none Open the top cover and observe the exit
gate move up and down
DUPLEX MOTOR (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 TRA Y3 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-sheet bypass feeder and
observe the paper position plate cycle up
and down
Motor and clutch test constraints
Motor or clutch displayed on control panel
Constraints displayed on control panel Details
Service Guide 71
Test printing
1. Enter the diagnosis mode by pressing and holding the Menu (1) and
Enter (4) keys as you turn on the printer.
2. Press the Menu (1, 5) keys to scroll through the list of test until TEST
PRINT
appears on the upper display.
3. Press the Item (2, 6) keys to scroll through the list of test print items
until the desired print option is displayed.
4. With a test print menu item displayed, press the Value (3, 7) keys to
scroll through the printing options of that item, such as which tray to print from and to print in blank-and-white or color.
Test Print menu
Display Set V alue 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 Lets you select the source of paper for the test print.
TRAY2 TRAY3 FF NONE
COLOR ON* Lets you select between color or monochrome printing
OFF
FUSER ON* Lets you select between the fuser heater being on or off.
OFF
DUPLEX ON* Lets you select between single-sided or double-sided printing.
OFF
72 Phaser 1235 Network Color Printer
5. Press the Item (2, 6) keys to scroll to the menu item PRINT EXECUTE.
Press Value (3) to starts printing.
6. Press Value (7) to stop printing.
The following messages are 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.
Service Guide 73
Consumable count initialization
This test menu item allows you to initialize the print engine’s consumable counts and registration set points.
1. Enter the diagnosis mode by pressing and holding the Menu (1) and
Enter (4) keys as you turn on the printer.
2. Press the Menu (1, 5) keys to scroll through the list of test until NV-RAM
INITIAL
appears on the upper display.
3. Press the Item (2, 6) keys to select either Table 1 or Table 2. The tables
determine which NVRAM items will be initialized. 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.
Belt Unit Counter
Initializes the print count after the replacement of a transfer belt unit.
Fuser Unit Counter
Initializes the fuser’s print count after the replacement of a fuser unit.
Toner Counter Black Yellow Magenta Cyan
Initializes the toner use count after a toner cartridge is replaced
74 Phaser 1235 Network Color Printer
Table 2: Initialization items - calibration points
Initialization Item Detail
Initialization Value Unit
Registration Set Point x-axis
Yellow LED Magenta LED Cyan LED
Initialization 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 Left­Corrections 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 1/1200 inch
Service Guide 75
Consumable counter display
This test indicate the status of each consumable supply.
1. Enter the diagnosis mode by pressing and holding the Menu (1) and
Enter (4) keys as you turn on the printer.
2. Press the Menu (1, 5) keys to scroll through the list of test until
CONSUMABLE STATUS appears on the upper display.
3. Press the Item (2, 6) keys to scroll through the list of consumable supply
items. The consumption value is displayed 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 f ed since installation
of a new fuser unit.
TR BEL T 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 processed by
each imaging drum unit since it was installed.
YELLOW ID UNIT ********IMAGES MAGENTA ID UNIT ********IMAGES CYAN ID UNIT ********IMAGES BLACK TONER ***% Shows the amount of toner remaining in each
toner cartridge.
YELLOW T ONER ***% MAGENTA TONER ***% CY AN T ONER ***%
76 Phaser 1235 Network Color Printer
Consumable continuation counter display
The self-diagnosis is carried out to indicate the consumption status of each consumable supply.
1. Enter the diagnosis mode by pressing and holding the Menu (1) and
Enter (4) keys as you turn on the printer.
2. Press the Menu (1, 5) keys to scroll through the list of test until
PRINTER STATUS appears 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 f ed
including blank paper
BLACK IMPRESSIONS
******** IMAGES Image Displays the number of images printed
by each imaging drum
YELLOW IMPRESSIONS
******** IMAGES Image
MAGENTA IMPRESSIONS
******** IMAGES Image
CYAN IMPRESSIONS
******** IMAGES Image
Service Guide 77
Adjusting color density and balance
Over the life of the printer, colors may change. For example, reds may begin to take on a purple cast, or blues may take on a green cast. This happens during the normal use of a color printer and can be easily remedied by using the color adjustment procedure described in this section
This front panel procedure involves printing a test page and adjusting the densities and colors based on the appearance of the test page. You may need to repeat this procedure and test your adjustments until you achieve the desired effect.
Note At any time, you can reset the printer to the factory defaults by
selecting Color Defaults from the Color Adjust Menu.
Printing a Test Page
1. Press the Menu (1, 5) keys until you see Color Adjust.
2. Press Item (2, 6) keys and the printer prints the Color Balance test print.
Interpreting the Color Balance test print
The Color Balance test print contains numbered images that indicate possible adjustments that can be made. You can choose to make an adjustment to the Color Density, the Black Density, or the Color 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.
Color Balance and Density Adjustment Test
Xerox Corporation, 2000 ver 1.1
18
17
12
11
19
13
10
16
14
15
20
21
Current
0
abcdef abcdef abcdef abcdef
abcdef
abcdef abcdef abcdef
Step 1. Adjust Black Density until ìCurrentì = 30% Black Halftone. Repeat as needed.
BLACK / GRAYSCALE
-3K -2K -1K +1K +2K +3K
Current
0
Decrease Increase
Developer Bias Range: [251 - 550] Current Black Level: Current Cyan Level: Current Magenta Level: Current Yellow Level:
Density Rate Set Points Range: [80 - 100] Current Black Level: Current Cyan Level: Current Magenta Level: Current Yellow Level:
Gray Reference
(30% Black Halfto
Step 3. Adjust Color Balance to match ìCurrent Circleì with Gray Reference. Repeat as needed.
Step 2. Adjust Color Density to match Black Density Squares from Step 1. Repeat as needed.
CYAN + MAGENTA + YELLOW
-3CMY +2CMY +1CMY -1CMY -2CMY +3CM
Current
0
Decrease Increase
Step 4. Iterate between Step 2 and Step 3 as needed.
78 Phaser 1235 Network Color Printer
What to look for
There are three things to look for in examining the test print.
The Color Density and the Black Density are a matter of taste. The 30%
halftones can be used to judge the current level and decide on a preference.
The Color Density and Black Density should be at approximately the
same level. This is important in order to make the Color Balance adjustment.
The correct Color Balance is determined by comparing the circle in the
center of the Color Balance object marked “CURRENT” with the gray background. The background is produced using black only and the circles are pr oduced using a 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.
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 V alue.
Values are: -3K, -2K, -1K, 0, +1K, +2K, +3K.
3. Press Enter. The Color Adjust Page prints and the front panel displays
Color Adjust Menu: Black Density.
Repeat Steps 2 and 3 above until you are satisfied with the results.
Color density adjustment
1. Press Item (2, 6) keys until you see Color Adjust Menu: Color Density.
2. Press Value (3, 7) keys until you see Color Density = New V alue.
Values are: -3CMY, -2CMY, -1CMY, 0, +1CMY, +2CMY, +3CMY.
3. Press Enter. The Color Adjust Page prints and the front panel displays
Color Adjust Menu: Color Density.
Repeat Steps 2 and 3 above until you are satisfied with the results.
Service Guide 79
Color balance adjustment
1. Press Menu (1, 5) keys until you see Color Adjust Menu.
2. Press Item (2, 6) keys until you see Color Adjust Menu: Color Balance.
3. Press Value (3, 7) keys until you see Color Density = New V alue.
Values are: 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 be restored to the default values.
Service Guide
81
Cleaning and Maintenance
Service preventive maintenance procedure
Whenever you check, service, or repair a printer, you should perform the following procedures. Cleaning the printer, as outlined in the following 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 clean these printers.
82
Phaser 1235 Network Color Printer
Recommended tools
Toner vacuum cleaner
Suction bulb (air blower)
Cleaning water
Lint-free wipes
Cotton swabs
Imaging unit cover
Isopropyl alcohol (greater than 90% pure)
Periodically replaced parts
The following usage patterns may significatly reduce the lives of toner cartridges, imaging drums and transfer belts: Printing less than 5 pages per job, opening and closing the top cover, turning the printer off and on, printing on transpar encies or specialty papers and automatic two-sided printing.
Periodically replaced parts
Part name Display or
Warning Condition
Recommended condition for replacement
Adjustment after replacement
Standard Toner Cartridge
When the message is displayed
When 5,000 pages are printed out (5% 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 automatically reset due to a fuse being blown in the unit a few seconds after a unit is installed
Fuser Unit When the message
is displayed
When 60,000 pages are printed out.
The printer’s fuser unit counter is automatically reset due to a fuse being blown in the unit a few seconds after it is installed
Transfer Belt Unit
When the message is displayed
When 66,000 pages are printed out. (For 5 pages-per-job, Letter-size paper)
The printer’s transfer belt unit counter is automatically reset due to a fuse being blown in the unit a few seconds after it is installed
Service Guide
83
Cleaning
Periodically clean the inside and outside of the printer with a soft cloth and small vacuum cleaner when necessary.
Caution
Do not touch the terminals of the image drums, the LED bar, and the LED head connector block. Clean with alcohol wipe, if necessary.
Cleaning the LED bar
The LED lens array must be cleaned when the printed paper has white lines or irregular colors (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 mispicks occur, clean the pickup roller.
Note
The roller should be cleaned with an a dry, lint-free cloth if debris is visible so the surface is not scratched.
Print problem caused by dirty LED lens
Service Guide
85
Resetting NVRAM
Resetting NVRAM returns all the image processor's NVRAM-stored parameters, including the network card, to their factory defaults except the print counts and the Adobe firmware serial number. This procedure reset all values, including language and color balance, to the factory default values. Event logs cannot cleared.
1.
Turn off the printer.
2.
Press and hold-down the
On Line (0)
key and the
Enter (4)
keys.
3.
Turn on the printer. When the message
Ready
will be displayed use the
the
Menu (1, 4)
keys to scroll through the list of menu items to the menu
item
Reset Menu
. Press
Enter (4)
.
4.
Use the
Menu (1, 4)
keys to scroll through the list of reset options:
Factory Defaults
. (print engine settings)
Use the
Item (2, 6)
keys to activate the
Confirm Action Yes/No
menu.
Press
Enter
to confirm your 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 activate the
Confirm Action Y es/No
menu for
the consumable item displayed. Press
Enter
to confirm your selection.
Delete Jobs. Deletes all Secure Print and Proof Print jobs from the hard disk.
Disk Init. Initializes the hard drive.
Disk format - Formats the hard drive.
Alternately, pressing and holding-down the
Enter (4) key and the Value Down (7)
keys upon power up will reset all the NVRAM-stored parameters except the consumable counts.
Refer to the service test procedure “Consumable count initialization” on page 73 to reset the print engine’s NVRAM-stored consumable counts or the registration set points parameters.
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