Tektronix PHASER 1235 Service Quick Reference Manual - User Manual

Full Text Searchable PDF User Manual

Warning
The following servicing instructions are for
use by qualified service personnel only. To
avoid personal injury, do not perform any
servicing other than that contained in
operating instructions unless you are qualified
to do so.

This printing: December 2000
071-0728-00

P H A S E R ® 1 2 3 5
N E T W O R K C O L O R P R I N T E R

Servic e Quic k Referenc e 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 Unpublished rights reserved under the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

and RealSUPPORT

are

service marks of Xerox Corporation.

FTP

Software is a registered trademark of FTP Software, Incorporated.

PCL

and HP-GL

are registered trademarks of Hewlett-Packard Corporation.

Novell

and NetWare

are registered trademarks of Novell, Incorporated.

Sun

, Sun Microsystems

, and Sun Microsystems Computer Corporation

are

registered trademarks of 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 product.

manual:

WARNING

Conditions that can result in personal injury
or loss of life.

Power source:

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

between the supply conductors or between either supply conductor and ground.
Use only the specified power cord and connector. For 220 VAC printers, do not
apply more than 260 volts RMS between the supply conductors or between either
supply conductor and ground. Use only the specified power cord and connector.
Refer to a qualified service technician for changes to the cord or connector.

Operation of product:

Avoid electric shock by contacting a qualified service

technician to replace fuses inside the product. Do not operate without the covers
and panels properly installed. Do not operate in an atmosphere of explosive
gases.

Safety instructions:

Read all installation instructions carefully before you plug the

product into a power source.

Terms on

CAUTION

A personal injury hazard exists that may not be

product:

apparent. For example, a panel may cover the hazardous area.
Also applies to a hazard to property including the product itself.

DANGER

A personal injury hazard exists in the area where
you see the sign.

Care of product:

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

Disconnect the power plug if the power cord or plug is frayed or otherwise
damaged, if you spill anything into the case, if product is exposed to any excess
moisture, if product is dropped or damaged, if you suspect that the product needs
servicing or repair, and whenever you clean the product.

Ground the product:

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

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

Symbols as marked on product:

DANGER high voltage:

Protective ground (earth) terminal:

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

WARNING:

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

controls (and other conductive parts) can cause an electrical shock. Electrical
product may be hazardous if misused.

Service safety summary

For qualified service personnel only:

Refer also to the preceding Users Safety

Summary.

Do not service alone:

Do not perform internal service or adjustment of this

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

Use care when servicing with power on:

Dangerous voltages may exist at several

points in this product. To avoid personal injury, do not touch exposed
connections and components while power is on.

Disconnect power before removing the power supply shield, soldering, or
replacing components.

Do not wear jewelry:

Remove jewelry prior to servicing. Rings, necklaces, and

other metallic objects could come into contact with dangerous voltages and
currents.

Power source:

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

not apply more than 120 or 250 volts rms (depending on printer model) between
the supply conductors or between either supply conductor and ground. A
protective ground connection by way of the grounding conductor in the power
cord is essential for safe operation.

Service Guide

Contents

General Information

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

Error messages 21

Troubleshooting

Power on self-diagnostic test 32
Print engine troubleshooting 33

Testing the print engine  33
Verifying printer operation by using its self-test print  34
Verifying power supply operation  34

Measuring power supply voltages  34
Inspecting the low-voltage power supply fuse  36
Safety interlocks  36
Testing for a shorted motor  37

Motor and fuser roller resistances  38
Media jams and the paper path  39
Media-based problems  39

Media problems  39
Multiple-sheet pick  39
The media skews passing through the paper path  40
Paper tray indicates it is empty when it is not  40

Phaser 1235 Network Color Printer

Jams 41

Wrong media  41
Paper jams at the paper tray  41
Manual bypass feeder feed jams  42
Paper jams at the registration rollers  42
Paper jams at the transfer belt  42
Fuser jams  43
Eject jams  43
Jams in the duplex unit  43
No drum imaging unit installed  44
Imaging drum unit up/down error  44
Fan error  44
Fuser unit error  45

Other problems 46

The printer continuously displays “Booting” or “Initializing.”  46
False “No toner cartridge installed” message  46
False “No fuser unit installed” message  46
Front door indicated being open when it is closed  47
High temperature error  47
Low temperature error  47
Invalid memory DIMM  47

Printing and print quality problems 48

Light or blurred images  48
Dark, stained background  49
Blank print  50
Black stripe in direction of paper travel  51
White stripe in direction of paper travel  52
Poor fusing, toner offsetting  53
Repeating defect or voids on print  54
Missing characters or voids in print  55
Color misalignments  56
Unexpected colors  57
Image is skewed on the paper  58
Image is not centered on the print  58
The print is wrinkled  58

Macintosh printing problems 59

Image never prints  59
Image is rotated 90 degrees  59
Image prints in black-and-white  59
Printer isn’t in the Chooser  60

Windows printing problems 60

Image never prints 60

Service Guide

vii

Service Tests and Adjustments

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

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

FRU Disassembly

Cabinet panels 87

Top cover  87
Left-side cover  88
Right-side cover  89
Rear cover  90
Front cover  91
Face-up tray  92

Frames components 93

Right shield plate  93
Electrical chassis (card cage)  94
Electrical chassis cooling fan  96
Printer unit chassis  97
Main cooling fan  99
Top cover inner frame  100
Left/right top cover spring assembly  103
Left paper tray guide assembly  104
Right paper tray guide assembly  106

viii

Phaser 1235 Network Color Printer

Left plate assembly 108

Electronic boards 109

System controller board  109
Print engine controller board  110
Toner sensor board  111
Entrance sensor board  113
High voltage power supply  114
Low voltage power supply  116
Control panel  117

Paper feed components 118

Tray 1 feed roller and nudger roller  118
Retard pad  119
Paper-size sensing board  120
Paper-size sensing actuator  122
Main feeder assembly  123
Tray 1 no-paper/low-paper sensors  125
Paper tray lift arm roller  126

Multi-sheet bypass feeder components 127

Multi-sheet bypass feeder 127
Multi-sheet bypass feeder entrance sensor actuator 129

Paper transport components 130

Tray 1 entrance sensor actuator  130
Belt entrance sensor actuator  131
Transfer belt unit  132

Registration components 133

Registration clutch  133
Registration motor assembly  134
Registration roller assembly A and drive gear  135
Registration roller assembly B  137

Exit assembly and fuser components 139

Fuser unit  139
Fuser latching handle (left)  140
Fuser latching handle (right)  141
Fuser exit roller  142
Exit sensor assembly  144
Duplex guide assembly  146
Eject guide assembly  148
Stack full sensor  149

Service Guide

Drive assembly components 151

Main motor assembly  151
Main feeder drive motor  153
Transfer belt motor assembly  154
Xerographic components  156
Shutter plate  156
Color registration sensor assembly  157
Color registration solenoid  158
LED assembly  159
Drum contact assembly  160
Toner sensor actuators  161

Duplex unit 163
Optional paper feeder components 164

Idler roller assembly  164
Inner frame  166
Feeder clutch  169
Feeder motor  171
Feeder control board  173
Paper transport roll guide  175
Feeder drive assembly  177
Paper size sensing actuator  179
Paper size sensing board  180
Lower connector  181
Upper connector  183
Tray 2/3 feed roller and nudger roller  185

FRU List

187

Using the parts list 187

Test Prints

211

Wiring Diagram

215

Phaser 1235 Network Color Printer

Figures

The Phaser 1235 Color Printer with lower tray feeders 1
Print engine circuit boards 5
Print engine circuit boards (cont’d) 6
Print engine sensor and switch locations 7
Print engine sensor and switch locations (cont’d) 8
Print engine motors, clutches and solenoids 9
Optional feeder motor and clutch 10
Features of the controller board 11
The control panel 12
The printer rear panel 13
Tray switch sensors and actuators 15
Door safety interlock switches 37
LED Head Test Pattern 68
Print problem caused by dirty LED lens 83
Removing the top cover 87
Removing the left-side cover 88
Removing the right-side cover 89
Removing the rear cover 90
Removing the front cover 91
Removing the face-up tray 92
Removing the right shield plate 93
Removing the electrical chassis 95
Removing the electrical chassis cooling fan 96
Disconnecting the registration motor in-line connector (HOPFF) 97
Removing the printer unit chassis 98
Removing the main cooling fan 99
Removing the top shield plate 100
Removing the harnesses from the electrical chassis 101
Removing the top cover inner frame 102
Removing the left/right top cover spring assembly 103
Removing the lower plate assembly 104
Removing the left paper tray guide assembly 105
Removing the paper tray guide assemblies 106
Removing the right paper tray guide assembly 107
Removing the left plate assembly 108
Removing the system controller board 109
Removing the print engine controller 110
Disconnecting the LED power harnesses 111
Removing the toner sensor board 112

Service Guide

Removing the entrance sensor board 113
Removing the high voltage power supply 115
Removing the low voltage power supply 116
Removing the control panel 117
Removing the feed roller and nudger roller 118
Removing the retard pad 119
Removing the paper size sensing board 121
Removing the paper size sensing actuator 122
Removing the main feeder assembly 124
Removing the lower plate assembly 125
Removing the paper tray lift arm roller 126
Removing the multi-sheet bypass feeder 128
Removing the multi-sheet bypass feeder entrance sensor actuator 129
Removing the tray 1 entrance sensor actuator 130
Removing the belt entrance sensor actuator 131
Removing the transfer belt unit 132
Removing the registration clutch 133
Removing the registration motor assembly 134
Removing the registration roller assembly A and drive gear 136
Removing the registration roller assembly B 138
Removing the fuser unit 139
Fuser latching handle (left) 140
Removing the fuser latching handle (right) 141
Removing the fuser exit roller 143
Removing the exit sensor assembly 145
Removing the duplex guide assembly 147
Removing the eject guide assembly 148
Removing the LED Assembly power connector 149
Removing the stack full sensor 150
Removing the main motor assembly 152
Removing the main feeder drive motor 153
Removing the transfer belt motor assembly 155
Removing the shutter plate 156
Removing the color registration sensor assembly 157
Removing the color registration solenoid 158
Removing an LED assembly 159
Removing the drum contact assembly 160
Disconnecting the LED assembly power harness 161
Removing the toner sensor actuators 162
Removing the duplex unit 163
Removing the feeder control board cover 164
Removing the idler roller assembly 165
Removing the optional feeder inner frame bottom screws 166

xii

Phaser 1235 Network Color Printer

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

Service Guide

xiii

Tables

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

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