Xerox 1235DT Service Guide

Xerox 1235DT - Phaser Color Solid Ink Printer Manual

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  • Xerox 1235DT | Service Guide - Page 1
    PHASER® 1235 NETWORK COLOR PRINTER Service Guide 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:
  • Xerox 1235DT | Service Guide - Page 2
    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
  • Xerox 1235DT | Service Guide - Page 3
    earth) terminal: Use caution. Refer to the manual(s) for information: ! WARNING: If the product not wear jewelry: Remove jewelry prior to servicing. Rings, necklaces, and other metallic more than 120 or 250 volts rms (depending on printer model) between the supply conductors or between either supply
  • Xerox 1235DT | Service Guide - Page 4
    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 Media-based problems 39 Media problems 39
  • Xerox 1235DT | Service Guide - Page 5
    Manual problems 46 The printer continuously displays "Booting" or "Initializing." 46 False "No toner 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
  • Xerox 1235DT | Service Guide - Page 6
    Service Making adjustments 78 Adjustment recovery 79 Cleaning and Maintenance 81 Service preventive maintenance procedure 81 Recommended tools 82 Periodically replaced parts chassis (card cage) 94 Electrical chassis cooling fan 96 Printer unit chassis 97 Main cooling fan 99 Top cover inner frame 100
  • Xerox 1235DT | Service Guide - Page 7
    plate assembly 108 Electronic boards 109 System controller board 109 Print engine controller board 110 Toner sensor board 111 Entrance sensor board roller 142 Exit sensor assembly 144 Duplex guide assembly 146 Eject guide assembly 148 Stack full sensor 149 viii Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 8
    registration solenoid 158 LED assembly 159 Drum contact assembly 160 Toner sensor actuators 161 Duplex unit 163 Optional paper feeder components 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
  • Xerox 1235DT | Service Guide - Page 9
    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
  • Xerox 1235DT | Service Guide - Page 10
    Removing the exit sensor assembly 145 Removing the duplex guide assembly 147 Removing the eject guide assembly 148 Removing the LED Assembly power connector 149 160 Disconnecting the LED assembly power harness 161 Removing the toner sensor actuators 162 Removing the duplex unit 163 Removing the
  • Xerox 1235DT | Service Guide - Page 11
    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 wiring passthru 220 Wiring under the top shield plate 221 xii Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 12
    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
  • Xerox 1235DT | Service Guide - Page 13
    xiv Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 14
    Phaser® 1235 Color Printer. This manual 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 Color Printer Service & Support
  • Xerox 1235DT | Service Guide - Page 15
    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: s 600 x 600 dpi (Normal) s 600 x 1200 dpi (High-quality) The printer also accepts 300 x 300 dpi files from PCL legacy drivers, PCL
  • Xerox 1235DT | Service Guide - Page 16
    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 in hex, rather than interpreted. This includes TIFF, PDF, and PJL. Service Guide 3
  • Xerox 1235DT | Service Guide - Page 17
    printer in the printer. Upon power cations it the printer reports and the printer declares system controller board from booting up at all. With more memory the printer throughput). The printer features three the printer. messages. The toner states displayed for toner, the printer terminates
  • Xerox 1235DT | Service Guide - Page 18
    Print engine assemblies Paper size sensing board Toner sensor board Low voltage power supply Duplex control (in duplexer) High voltage power supply Print engine circuit boards Control panel assembly Entrance sensor board 7098 Service Guide 5
  • Xerox 1235DT | Service Guide - Page 19
    Print engine controller board System controller board Optional feeder Print engine circuit boards (cont'd) Feeder control Paper-size sensing board 7099 6 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 20
    assembly Toner cartridge sensors Top cover interlock switch Front cover interlock switch Belt entrance sensor Temperature Waste toner sensor sensor Humidity sensor Registration Entrance entrance cassette sensor 7100 sensor Print engine sensor and switch locations Service Guide 7
  • Xerox 1235DT | Service Guide - Page 21
    Stack full sensor Multi-sheet bypass tray empty sensor OHP 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
  • Xerox 1235DT | Service Guide - Page 22
    Duplex Gate solenoid Registration shutter solenoid Duplex drive assembly Print engine motors, clutches and solenoids Transfer belt motor assembly Registration motor Registration clutch Main feeder drive motor 7102 Service Guide 9
  • Xerox 1235DT | Service Guide - Page 23
    Optional feeder Optional feeder motor and clutch Feeder motor Feeder clutch 7103 10 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 24
    The image processor board Token ring card SDRAM Fan cooled processor Features of the controller board Hard drive 0728-05 Service Guide 11
  • Xerox 1235DT | Service Guide - Page 25
    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 LED illuminates whenever operator intervention is required, such as a paper jam in the printer. 12 Phaser 1235 Network Color
  • Xerox 1235DT | Service Guide - Page 26
    : s Bi-directional parallel IEEE 1284-B connector. s Twisted Pair 10/100baseT Ethernet connector. With the addition of the Token Ring card the printer can connect to Token Ring network via its Ethernet interface. The printer rear panel Ethernet port Parallel port 0728-03 Service Guide 13
  • Xerox 1235DT | Service Guide - Page 27
    printer is attempting to insert itself into the Token Ring, on when the printer is properly inserted in the ring. The LED SPD, located next to the LNK LED, is off when the card is set for 4 megabitsper-second (MBPS), on when the card is set for 16 MBPS. 14 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 28
    set according 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 switch sensors and actuators 0728-04 Tray switch sensors and actuators Service Guide 15
  • Xerox 1235DT | Service Guide - Page 29
    16.9 cm (43.0 in.) 43.0 cm (16.9 in.) 62.0 cm (24.4 in.) 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 side, with all four feet in contact with the table surface. 16 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 30
    toner cartridges each contain one of four colors: cyan, magenta, yellow or black. The toner and A6 use only premium bond laser printer or copier paper Tray feed paper weight: 60 tray capacity Only Xerox-brand Phaser 1235 A- and A4-size transparency film is supported. Multi-sheet Service Guide 17
  • Xerox 1235DT | Service Guide - Page 31
    humidity, non-condensing 10 to 95% relative humidity, non-condensing Media should be acclimated 24 hours before using in the printer. o 0 to 2500 m (8,000 ft.) at 25 C 0 to 15000 m (50,000 ft.) May drop axis. Standby: 35 dBa, Running: 55 dBa, Impulse: 57 dBa 18 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 32
    Regulatory specifications The printer is a recognized component in conformance with the following regulatory standards: s The packaged product meets ASTM D4169-93 and VCCI (CISPR 22) Class B s FCC Class B (for 115 VAC equipment) pursuant to Sub-part J of Part 15. ICES 03 Class B Service Guide 19
  • Xerox 1235DT | Service Guide - Page 33
    20 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 34
    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 is rotated. 4. At the rear of the printer, inspect the gate which directs the print
  • Xerox 1235DT | Service Guide - Page 35
    Printer fault messages Code Front panel message Service message A11 Jam A11, Remove Output Open Cover A, See A11-Paper Feed Jam Labels 1. Ensure the "Motor and clutch tests" on page 69. 5. Replace the duplex unit. 6. Replace the engine controller board. 22 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 36
    Printer fault messages Code Front panel message Service message B21 Jam B21 Open Cover B, See Labels B21-Duplex Area Jam 1. Ensure the correct weight and type "Switch scan test" on page 63. 3. Inspect the sensor and its wiring harness. 4. Replace the engine controller board. Service Guide 23
  • Xerox 1235DT | Service Guide - Page 37
    Printer fault messages Code Front panel message Service 3. Replace the engine controller board. 4. Replace the printer unit chassis EE Transfer Belt Missing Reseat Belt, Power 4. Replace the engine controller board. 5. Replace the printer unit chassis. EF Fuser Missing Reseat Fuser, Power Off
  • Xerox 1235DT | Service Guide - Page 38
    Printer fault messages Code Front panel message Service message H1 A hard 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. Replace the engine controller board. Service Guide 25
  • Xerox 1235DT | Service Guide - Page 39
    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. 26 Phaser 1235 Network Color
  • Xerox 1235DT | Service Guide - Page 40
    Printer fault messages Code Front panel message Service message T1 Fuser . 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 . 4. Replace the engine controller board. Service Guide 27
  • Xerox 1235DT | Service Guide - Page 41
    Printer fault messages Code Front panel message Service message U10 Roller Position Error U10 Power Off/On U10-Roller Position Error 1. Ensure installed. 2. Inspect the wiring harnesses leading to the LED assembly. 3. Replace the engine controller board. 28 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 42
    Printer fault messages Code Front panel message Service message 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
  • Xerox 1235DT | Service Guide - Page 43
    Memory Bad memory DIMMs Memory Speed Bad DIMMs or controller board CPU Tick Bad controller board System Timer Bad controller board BX Host Bridge Bad controller board PIIX4 PCI-ISA Bridge Bad controller Disk Data Format Check Bad hard disk drive 30 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 44
    two approaches: s A step-by-step verification procedure that systematically confirms that particular components of the printer are properly functioning until a problem is found. s A symptom/cause scheme that lists particular printer failures or error codes and their possible causes. Service Guide 31
  • Xerox 1235DT | Service Guide - Page 45
    performed when the printer is powered on: paper is jammed in the printer. s The print engine checks the presence of each toner cartridge. s Option unit by laying down patches of toner on the transfer belt and reading the fuser reaches its idle temperature the printer is placed on line in its READY
  • Xerox 1235DT | Service Guide - Page 46
    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. Service Guide 33
  • Xerox 1235DT | Service Guide - Page 47
    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 . Otherwise, replace the power supply fan. 34 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 48
    , proceed to the next step, "Inspecting the low-voltage power supply fuse" on page 36. If the +5 and +32 VDC voltages measure correctly, but the printer does not operate correctly, then proceed to the topic, "Safety interlocks" on page 36. Service Guide 35
  • Xerox 1235DT | Service Guide - Page 49
    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 to be at fault, replace the engine controller board. 36 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 50
    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. Service Guide 37
  • Xerox 1235DT | Service Guide - Page 51
    , test each motor's windings for correct resistance (disconnected from the printer). Motor and fuser roller resistances Motor Measure between ... Resistance Yellow 363 at 25oC 3 Ω 0 Ω or open (fuse) 363 at 25oC C D E F C D E F Underside of fuser 0728-0 38 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 52
    -picking errors s Printing jams s 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
  • Xerox 1235DT | Service Guide - Page 53
    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 service tests described in "Switch scan test" on page 63. 3. Replace the engine controller board 40 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 54
    the paper tray for damage to the tray's paper size sensor actuators. 3. Test the printer's paper size sensors using the service test "Switch scan test" on page 63. If the sensors test ok, then the clutch work properly? If not, replace it. 10. Replace the engine controller board. Service Guide 41
  • Xerox 1235DT | Service Guide - Page 55
    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. 42 Phaser 1235
  • Xerox 1235DT | Service Guide - Page 56
    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 service service test "Switch scan test" on page 63. 6. Test the duplex motor using the service
  • Xerox 1235DT | Service Guide - Page 57
    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 controller board. 44 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 58
    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 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
  • Xerox 1235DT | Service Guide - Page 59
    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 (
  • Xerox 1235DT | Service Guide - Page 60
    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, fications the printer displays an "Invalid memory DIMM" error message and then continues the bootup process. Service Guide 47
  • Xerox 1235DT | Service Guide - Page 61
    quality problems Required tools s #1 Phillips screwdriver s Volt-ohm-meter (VOM) s Conductive grease s Ruler Light or blurred images 1. Is the correct paper being used in the printer? 2. Are the toner harnesses. 12. Replace the high-voltage power supply. 48 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 62
    . 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 high-voltage wiring harnesses. 12. Replace the high voltage power supply. Service Guide 49
  • Xerox 1235DT | Service Guide - Page 63
    's EEPROM (lower-right corner of board) to the new engine controller board.) 7. Inspect the high-voltage wiring harnesses. 8. Replace the high voltage power supply. 50 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 64
    board's EEPROM (lower-right corner of board) to the new engine controller board.) 7. Inspect the high-voltage wiring harnesses. 8. Replace the high voltage power supply. Service Guide 51
  • Xerox 1235DT | Service Guide - Page 65
    's EEPROM (lower-right corner of board) to the new engine controller board. 8. Inspect the high-voltage wiring harnesses. 9. Replace the high voltage power supply. 52 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 66
    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 temperature used Cardstock Label/Envelope Glossy Letterhead/Light Cardstock Plain Paper/Transparency film Coolest fuser temperature used Service Guide 53
  • Xerox 1235DT | Service Guide - Page 67
    the repeating spots indicates the source of the problem. In some instances, the spots may be Toner supply roller. Replace the imaging drum unit of the affected color. s 44 mm (1.7 in.): Charging roller. Replace the imaging drum unit of the affected color. 54 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 68
    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' high-voltage wiring harnesses. 11. Replace the high voltage power supply. Service Guide 55
  • Xerox 1235DT | Service Guide - Page 69
    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 (lower-right corner of board) to the new engine controller board. 56 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 70
    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. new engine controller board. 9. Inspect the high-voltage wiring harnesses. 10. Replace the high voltage power supply. Service Guide 57
  • Xerox 1235DT | Service Guide - Page 71
    . 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). 58 Phaser 1235 Network Color
  • Xerox 1235DT | Service Guide - Page 72
    of your LaserWriter 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. Service Guide 59
  • Xerox 1235DT | Service Guide - Page 73
    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. 60 Phaser 1235
  • Xerox 1235DT | Service Guide - Page 74
    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 engine maintenance mode to test the printer sensors, test the media transport system, test the imaging LED banks,
  • Xerox 1235DT | Service Guide - Page 75
    all cleared to their initial values. The consumption status of each consumables is displayed in turn. Values show are of prints made and percentage of toner consumed. The life status of the selected consumable is displayed. 62 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 76
    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 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.
  • Xerox 1235DT | Service Guide - Page 77
    64 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 78
    Manual Toner Switch Scan 03 Sensor 3= not used not used not used Manual Bypass Feeder Home Sensor Switch Scan 03 4= Switch Scan 04 Switch Scan 05 Switch Scan 06 1= Manual to the transfer unit. Manually rotate the registration roller unit caddy. Manually rotate the manual bypass feed roller
  • Xerox 1235DT | Service Guide - Page 79
    and switches test Switch or sensor not used Manual Bypass Feeder OHP Sensor Tray 1, Size Deactuated L - Actuated H - Deactuated Density Value ***H Manual feed a sheet of paper film thru the feeder. Close the cover. Reinsert the duplex unit in the printer. Pull out the duplex unit. Lift its cover.
  • Xerox 1235DT | Service Guide - Page 80
    . Place a sheet of paper inside on the sensor flag. Close the cover. Reinsert the duplex unit in the printer. Remove the tray and actuate the sensor flags on right side of tray cavity Pull Tray 2 out to test out to test sensor Remove tray 3 and toggle sensor flag behind feed rollers Service Guide 67
  • Xerox 1235DT | Service Guide - Page 81
    17 4= Switch Scan 18 Switch Scan 19 Switch Scan 20 Switch Scan 21 not used Details not used not used not used not used 68 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 82
    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 the drum unit caddy and observe the registration roller B turn Service Guide 69
  • Xerox 1235DT | Service Guide - Page 83
    Remove media form the multi-sheet bypass feeder Open the multi-sheet bypass feeder and observe the paper position plate cycle up and down 70 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 84
    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 or off. Lets you select between single-sided or double-sided printing. Service Guide 71
  • Xerox 1235DT | Service Guide - Page 85
    ) 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. 72 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 86
    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 after the replacement of a fuser unit. Initializes the toner use count after a toner cartridge is replaced Service Guide 73
  • Xerox 1235DT | Service Guide - Page 87
    , magenta, and cyan LED heads Initialization of X-axis 0 Right. Corrections for yellow, magenta, and cyan LED heads Unit 1/1200 inch 1/1200 inch 1/1200 inch 74 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 88
    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 it was installed. Shows the amount of toner remaining in each toner cartridge. Service Guide 75
  • Xerox 1235DT | Service Guide - Page 89
    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, imaging drum ******** IMAGES Image ******** IMAGES Image 76 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 90
    the desired effect. Note At any time, you can reset the printer to the factory defaults by selecting Color Defaults from the Color Adjust as needed. 16 21 10 15 Current 0 14 20 13 19 Xerox Corporation, 2000 ver 1.1 Gray Reference (30% Black Halfto abcdef abcdef Level: Service Guide 77
  • Xerox 1235DT | Service Guide - Page 91
    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. 78 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 92
    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 79
  • Xerox 1235DT | Service Guide - Page 93
  • Xerox 1235DT | Service Guide - Page 94
    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. Service Guide 81
  • Xerox 1235DT | Service Guide - Page 95
    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 transparencies or specialty papers and automatic two-sided printing. 82 Phaser 1235 Network Color
  • Xerox 1235DT | Service Guide - Page 96
    outside of the printer with a soft to clean the LED bar. (An alcohol wipe always comes with the toner cartridge.) Print the 100% Color Stripe Pattern. If a light or streak, clean the LED lens of the affected color. Print problem caused by dirty LED lens Cleaning the pickup roller When mispicks
  • Xerox 1235DT | Service Guide - Page 97
  • Xerox 1235DT | Service Guide - Page 98
    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 the NVRAM-stored parameters except the consumable counts. Refer to the service test procedure "Consumable count initialization" on page 73 to reset
  • Xerox 1235DT | Service Guide - Page 99
  • Xerox 1235DT | Service Guide - Page 100
    printer does not contain any mechanical field adjustable components. Default settings and soft switch settings are covered in "Service Tests and Adjustments" on page 61. Cabinet panels Top cover Warning Switch off the power and disconnect the power cord. 1. Open the top cover. Remove the drum/toner
  • Xerox 1235DT | Service Guide - Page 101
    and disconnect the power cord. 1. Open the top cover. 2. Open the front cover. 3. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag to protect the drum units from light and store in the left-side cover, reverse the removal order. 88 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 102
    Warning Switch off the power and disconnect the power cord. 1. Open the top cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag to protect the drum units from light and the right-side cover Reverse these steps to install the right-side cover. Service Guide 89
  • Xerox 1235DT | Service Guide - Page 103
    90 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 104
    top cover. Remove the drum/toner cartridge basket. Cover the basket printer up about 12 mm (1/2 in.) to remove the front cover and inner baffle. 6. Slide the front cover and inner baffle to the right and remove. Removing the front cover Reverse these steps to install the front cover. Service Guide
  • Xerox 1235DT | Service Guide - Page 105
    Face-up tray 1. Open the face-up tray. 2. Carefully pry the left stopper pin free of the rear cover. 3. Remove the face up tray. Removing the face-up t Reverse these steps to install the face-up tray. 92 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 106
    and disconnect the power cord. 1. Open the front cover. 2. Open the top cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag to protect the drum units from light and store shield plate Reverse these steps to install the right shield plate. Service Guide 93
  • Xerox 1235DT | Service Guide - Page 107
    power cord. 1. Open the top cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag to as explained in "Right-side cover" on page 89. 5. Remove the system controller board as shown on page 109. 6. Remove the right shield printer frame. 94 Phaser 1235 Network Color
  • Xerox 1235DT | Service Guide - Page 108
    16. Guide the bottom harnesses as you carefully remove the electrical chassis. Removing the electrical chassis Reverse these steps to install the electrical As you reinstall the chassis, ensure that the tab is not deformed and is positioned on the end of the paper feed shaft. Service Guide 95
  • Xerox 1235DT | Service Guide - Page 109
    Switch off the power and disconnect the power cord. 1. Open the top cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag to protect the drum units from light and these steps to install the electrical chassis cooling fan. 96 Phaser 1235 Network Color Printer
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    Printer unit chassis (and low-voltage power supply fan) Warning Switch off the power and disconnect the power cord. 1. Open the top cover. 2. Remove the drum/toner cartridge basket. Cover the basket in a lightproof . Disconnecting the registration motor in-line connector (HOPFF) Service Guide 97
  • Xerox 1235DT | Service Guide - Page 111
    -down on a table. Note The low-voltage power supply fan attaches to the underside of the printer unit chassis. Removing the printer unit chassis Reverse these steps to install the printer unit chassis. Ensure all wiring harnesses are not pinched during reassembly. 98 Phaser 1235 Network Color
  • Xerox 1235DT | Service Guide - Page 112
    and disconnect the power cord. 1. Open the top cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag and store in a main cooling fan out of the printer frame. Removing the main cooling fan Reverse these steps to install the main cooling fan. Service Guide 99
  • Xerox 1235DT | Service Guide - Page 113
    Switch off the power and disconnect the power cord. 1. Open the top cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag and store in a safe place. 2. Open chassis. 8. Remove the shield plate. Removing the top shield plate 100 Phaser 1235 Network Color Printer
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    the center of the right pivot arm. 15. Remove the system controller board. 16. From the top of the chassis, remove the two screws holding the system controller board's upper guide rail. 17. Through the access hole in the top of Hold it out of the way until the pivot arm is free. Service Guide 101
  • Xerox 1235DT | Service Guide - Page 115
    , carefully pull the left pivot arm out until the left side of the assembly is free of the printer. 20. Carefully pull the right pivot arm out until the right side is free. Caution Do not inner frame Reverse these steps to install the top cover inner frame. 102 Phaser 1235 Network Color Printer
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    the top cover spring assembly. Removing the left/right top cover spring assembly Reverse these steps to install the left/right top cover spring assembly. Service Guide 103
  • Xerox 1235DT | Service Guide - Page 117
    as shown on page 97. 5. Remove the four screws securing the lower plate to the paper tray guide assemblies 6. Disconnect CN1 from the low voltage power supply. 7. Lift the lower plate and power supplies from the tray guides. Removing the lower plate assembly 104 Phaser 1235 Network Color Printer
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    feeder assembly as detailed on page 123. 9. Remove the three screws securing the left paper tray guide assembly to the bottom plate. 10. Lift and remove the assembly. Removing the left paper tray guide assembly Reverse these steps to install the left paper tray guide assembly. Service Guide 105
  • Xerox 1235DT | Service Guide - Page 119
    Lift the lower metal shield plate from the right side of the metal plate and paper guide assembly. 5. Disconnect CN1 from the low voltage power supply. 6. Lift the lower plate and power supplies from the tray guides. Removing the paper tray guide assemblies 106 Phaser 1235 Network Color Printer
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    assembly as detailed on page 123. 8. Remove the five screws securing the right paper tray guide assembly to the bottom plate. 9. Lift and remove the guide assembly. Removing the right paper tray guide assembly Reverse these steps to install the right paper tray guide assembly. Service Guide 107
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    Left plate assembly Warning Switch off the power and disconnect the power cord. 1. Remove printer unit chassis as shown on page 97. 2. Remove the two screws from the high Removing the left plate assembly Reverse these steps to install the left plate assembly. 108 Phaser 1235 Network Color Printer
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    to the rear of the system controller. 2. Remove the two thumb screws securing the system controller to the printer. 3. Slide the system controller out to the rear of the printer. Removing the system controller board Reverse these steps to install the system controller board. Service Guide 109
  • Xerox 1235DT | Service Guide - Page 123
    the power cord. 1. Open the top cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag and the right shield plate as shown on page 93. 5. Remove the system controller board as shown on page 109. 6. Disconnect all connectors connected Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 124
    the toner sensor board. 6. Rotate the board up to expose the component side of the board. Note Note for reassembly how the ribbon cables are routed under the sensor board in the next step. 7. Disconnect the PANEL, OPTN, STUCK, and POWER harnesses from the toner sensor board. Service Guide 111
  • Xerox 1235DT | Service Guide - Page 125
    Reverse these steps to install the toner sensor board. Ensure that all harnesses are in the cable channel. Caution Ensure the ribbon cables are properly routed and dressed. Do not crunch or fold the ribbon cables while installing the toner sensor board. 112 Phaser 1235 Network Color Printer
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    . 1. Remove the multi-sheet bypass feeder as described in the topic on page 127. 2. Remove the printer unit chassis as detailed on page 97. 3. Remove registration roller assembly B as explained on page 137. sensor board Reverse these steps to install the entrance sensor board. Service Guide 113
  • Xerox 1235DT | Service Guide - Page 127
    supply Warning Switch off the power and disconnect the power cord. 1. Remove the printer unit chassis as detailed in the topic "Printer unit chassis (and low-voltage power supply fan)" on page 97. 2. voltage power supply and the contact assembly and remove. 114 Phaser 1235 Network Color Printer
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    6. Remove the contact assembly from the high voltage power supply. Removing the high voltage power supply Reverse these steps to install the high voltage power supply. Service Guide 115
  • Xerox 1235DT | Service Guide - Page 129
    CN3, CN1, & CN2 from the low voltage power supply. 3. Remove the six screws securing the low voltage power supply to the printer. Disconnect the AC ground wire from the printer frame. 4. Lift the power switch (SW1) and the low voltage power supply to remove. Removing the low voltage power supply
  • Xerox 1235DT | Service Guide - Page 130
    and disconnect CN1 from the back of the panel. 4. Remove the control panel. Removing the control panel Reverse these steps to install the control panel. Service Guide 117
  • Xerox 1235DT | Service Guide - Page 131
    roller to the left and remove. Removing the feed roller and nudger roller Reverse these steps to install the feed roller and nudger roller. 118 Phaser 1235 Network Color Printer
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    Retard pad 1. Remove the paper tray from the printer. 2. Remove the two springs. 3. Use a small screwdriver to carefully pry both arms free of the mounting pins. 4. Remove the retard pad. Removing the retard pad Reverse these steps to install the retard pad. Service Guide 119
  • Xerox 1235DT | Service Guide - Page 133
    power and disconnect the power cord. 1. Remove the system controller board as described in the topic "System controller board" on page 109. 2. Remove the print routing before removing harnesses. 8. Guide the harness through the frame as you remove the board. 120 Phaser 1235 Network Color Printer
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    Removing the paper size sensing board Reverse these steps to install the paper-size sensing board. Service Guide 121
  • Xerox 1235DT | Service Guide - Page 135
    the paper-size sensing actuator. 3. Remove the actuator. Removing the paper size sensing actuator Reverse these steps to install the paper-size sensing actuator. 122 Phaser 1235 Network Color Printer
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    power supply. 5. Lift the lower plate and power supplies from the tray guides. 6. Remove the four screws securing the main feeder assembly to the tray guides. 7. Disconnect harnesses from the optional feeder connector. 8. Pull harness and connectors through the printer frame. Service Guide 123
  • Xerox 1235DT | Service Guide - Page 137
    9. Lift and remove the main feeder assembly. Removing the main feeder assembly Reverse these steps to install the main feeder assembly. 124 Phaser 1235 Network Color Printer
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    chassis as detailed in "Electrical chassis (card cage)" on page 94. 2. Remove the printer chassis as described in the topic "Printer unit chassis (and low-voltage power supply fan)" on page 97. 3. Remove the plate assembly Reverse these steps to install the main feeder assembly. Service Guide 125
  • Xerox 1235DT | Service Guide - Page 139
    locking tabs and remove the roller. Removing the paper tray lift arm roller Reverse these steps to install the paper tray lift arm roller. 126 Phaser 1235 Network Color Printer
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    the power cord. 1. Open the top cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag and store three screws (two are black) securing the multi-sheet bypass feeder to the printer. 11. Lift and remove the multi-sheet bypass feeder. Note If replacing the
  • Xerox 1235DT | Service Guide - Page 141
    Removing the multi-sheet bypass feeder Reverse these steps to install the multi-sheet bypass feeder. 128 Phaser 1235 Network Color Printer
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    power cord. 1. Remove the multi-sheet bypass feeder as described in the topic on page 127. 2. Remove the printer unit chassis as described in the topic on page 97. 3. Remove the Tray 1 entrance sensor actuator as detailed in that the spring arm is in the notch in the frame. Service Guide 129
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    power and disconnect the power cord. 1. Remove the printer unit chassis as detailed in the topic on page 97. 2. From the bottom of the printer unit chassis, carefully squeeze the two locking tabs and these steps to install the tray 1 entrance sensor actuator. 130 Phaser 1235 Network Color Printer
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    actuator Warning Switch off the power and disconnect the power cord. 1. Remove the printer unit chassis described in the topic "Printer unit chassis (and low-voltage power supply fan)" on page 97. 2. Remove spring arm is properly located in the notch in the printer unit chassis. Service Guide 131
  • Xerox 1235DT | Service Guide - Page 145
    . 2. Remove the drum/toner cartridge basket and store in a lightproof bag to protect the drum units from light. 3. Push the transfer belt unit locking tabs toward the rear of the printer to release the unit. the transfer belt unit's locking tabs fully engage. 132 Phaser 1235 Network Color Printer
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    the power cord. 1. Open the top cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag and plate" on page 93. 5. Disconnect the RCL connector from the printer engine controller board. 6. Remove the screw securing the ground strap to clutch. Service Guide 133
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    Warning Switch off the power and disconnect the power cord. 1. Open top cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag and store in a safe place. 2. Reverse these steps to install the registration motor assembly. 134 Phaser 1235 Network Color Printer
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    Warning Switch off the power and disconnect the power cord. 1. Open the top cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag and store in a safe place. 2. Remove remove. Note If replacing the drive gear, continue with Steps 11 and 12. Service Guide 135
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    so that it drives the roller in the direction of paper travel. The blue plastic face should face the outside, next to the E-ring. 136 Phaser 1235 Network Color Printer
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    power and disconnect the power cord. 1. Remove tray 1. 2. Open the top cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag and store in a safe place. 3. Open . 9. Remove the four screws securing registration roller assembly B to the printer. Service Guide 137
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    10. Lower the assembly and slide to the left to remove. Removing the registration roller assembly B Reverse these steps to install the registration roller assembly B. 138 Phaser 1235 Network Color Printer
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    Exit assembly and fuser components Fuser unit Warning Switch off the power and disconnect the power cord. 1. Open the top cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag and store in a safe place. 2. Press the two latches to release the fuser unit. 3. Use
  • Xerox 1235DT | Service Guide - Page 153
    . 1. Open the top cover. 2. Open the front cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag and store in a spring. 6. Remove the screws securing the fuser latching handle to the printer frame. 7. Remove the left fuser latching handle. Fuser latching handle
  • Xerox 1235DT | Service Guide - Page 154
    the electrical chassis as detailed in "Electrical chassis (card cage)" on page 94. 2. Remove the printer unit chassis as detailed on page 97. 3. Release the fuser latching handle spring. 4. Remove the (right) Reverse these steps to install the fuser latching handle (right). Service Guide 141
  • Xerox 1235DT | Service Guide - Page 155
    Warning Switch off the power and disconnect the power cord. 1. Open the top cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag and store in a safe place. 2. Open to the right until the left end of the staff is free. 142 Phaser 1235 Network Color Printer
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    14. Lift the left end of the shaft and remove. Removing the fuser exit roller Reverse these steps to install the fuser exit roller. Service Guide 143
  • Xerox 1235DT | Service Guide - Page 157
    Switch off the power and disconnect the power cord. 1. Open the top cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag and store in a safe place. 2. Open exit gate. 11. Remove the screw securing the exit sensor assembly. 144 Phaser 1235 Network Color Printer
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    12. Guide the harness through the chassis as you remove the assembly. Removing the exit sensor assembly Reverse these steps to install the exit sensor assembly. Ensure that the tab on the clutch is positioned on the pin on the paper handler. Service Guide 145
  • Xerox 1235DT | Service Guide - Page 159
    guide assembly Warning Switch off the power and disconnect the power cord. 1. Remove the top cover. Remove the drum/toner cartridge guide assembly to free the duplex guide assembly from the printer frame. 9. Carefully pry the right locking tabs to free the right side of the guide. 146 Phaser 1235
  • Xerox 1235DT | Service Guide - Page 160
    10. Lift the duplex guide assembly and remove. Removing the duplex guide assembly Reverse these steps to install the duplex guide assembly. Service Guide 147
  • Xerox 1235DT | Service Guide - Page 161
    in a lightproof black bag and store in a safe place. 3. Remove the five screws securing the eject guide assembly to the top cover. 4. Remove the eject guide assembly. Removing the eject guide assembly Reverse these steps to install the eject guide assembly. 148 Phaser 1235 Network Color Printer
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    the toner toner sensor board. 6. Rotate the board up to expose the component side of the board. 7. Disconnect the STUCK connector from the toner sensor board. 8. Free the disconnected cable from all cable retainers. 9. Release the four locking tabs securing the stack full sensor. Service Guide
  • Xerox 1235DT | Service Guide - Page 163
    10. Remove the stack full sensor. Removing the stack full sensor Reverse these steps to install the stack full sensor. 150 Phaser 1235 Network Color Printer
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    chassis as detailed in "Electrical chassis (card cage)" on page 94. 2. Remove the printer unit chassis as detailed on page 97. 3. Free the harnesses from the channel along the high-voltage power supply fan harness through the harness guide and main motor assembly before lifting. Service Guide 151
  • Xerox 1235DT | Service Guide - Page 165
    8. Carefully guide the ribbon cable through the assembly as you lift the main motor assembly and remove. Removing the main motor assembly Reverse these steps to install the main motor assembly. 152 Phaser 1235 Network Color Printer
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    Switch off the power and disconnect the power cord. 1. Remove the print unit chassis as detailed in "Printer unit chassis (and low-voltage power supply fan)" on page 97. 2. Disconnect the inline connector from drive motor Reverse these steps to install the main feeder drive motor. Service Guide 153
  • Xerox 1235DT | Service Guide - Page 167
    assembly Warning Turn the power off and disconnect the power cord. 1. Remove the printer unit chassis as detailed on page 97. 2. Remove the two screws securing the transfer assembly to ensure proper reinstallation. 4. Disconnect the two inline connectors. 154 Phaser 1235 Network Color Printer
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    5. Remove the transfer belt motor assembly. Removing the transfer belt motor assembly Reverse these steps to install the transfer belt motor assembly. Service Guide 155
  • Xerox 1235DT | Service Guide - Page 169
    disconnect the power cord. 1. Open the top cover. 2. Remove the drum/toner cartridge basket. Place them in a lightproof bag and store in a safe shutter plate Reverse these steps to install the shutter plate; ensure all guide pins on the shutter plate are properly aligned when reinstalling. Move the
  • Xerox 1235DT | Service Guide - Page 170
    to the assembly. 7. Remove the color registration sensor assembly. Removing the color registration sensor assembly Reverse these steps to install the color registration sensor assembly. Service Guide 157
  • Xerox 1235DT | Service Guide - Page 171
    Switch off the power and disconnect the power cord. 1. Remove the printer unit chassis as shown on page 97. 2. Remove the shutter plate cable clamps. 5. Remove the screw securing the shutter solenoid to the printer unit chassis. Removing the color registration solenoid Reverse these steps to
  • Xerox 1235DT | Service Guide - Page 172
    lifting up on the connector. Free the harness from the LED assembly. 3. Disconnect the power harness from the toner sensor board. 4. Note the two springs on the back of the LED assembly. Ensure they remain with the an LED assembly Reverse these steps to install the LED assembly. Service Guide 159
  • Xerox 1235DT | Service Guide - Page 173
    four imaging cartridges and basket. Cover the cartridges and store in a safe place. 3. Use a small screwdriver to carefully pry the drum contact assembly from the printer chassis. Removing the drum contact assembly Reverse these steps to install the drum contact assembly. 160
  • Xerox 1235DT | Service Guide - Page 174
    bag and store in a safe place. 2. Disconnect the four LED power harnesses from the bottom of the toner sensor board. Disconnecting the LED assembly power harness 3. Close the top cover inner unit. 4. Remove the four push up the arms of the sensor actuator until they are free. Service Guide 161
  • Xerox 1235DT | Service Guide - Page 175
    9. Remove the sensor actuator. Removing the toner sensor actuators Reverse these steps to install the toner sensor actuators. When replacing the toner sensor board, insure all harnesses are in the cable channels. 162 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 176
    the latches on the left and right rails. Accessing the rails may be easiest at the rear of the printer by reaching through the cavity left by the removed paper tray. 5. Remove the duplex unit. Removing the duplex 3. Free the right rail by moving the unit to the left and out. Service Guide 163
  • Xerox 1235DT | Service Guide - Page 177
    roller assembly Warning Switch off the power and disconnect the power cord. 1. Remove the printer from the optional paper feeder. 2. Remove the four screws securing the feeder control board cover screws securing the idler roller assembly to the feeder frame. 164 Phaser 1235 Network Color Printer
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    5. Guide the sensor wires through the frame as you remove the idler roller assembly. Removing the idler roller assembly Reverse these steps to install the idler roller assembly. Service Guide 165
  • Xerox 1235DT | Service Guide - Page 179
    Inner frame Warning Switch off the power and disconnect the power cord. 1. Remove the printer from the optional paper feeder. 2. Remove the paper tray from the optional paper feeder. inner frame bottom screws 5. Turn the feeder to its right side up position. 166 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 180
    page 164. 8. Disconnect the PSZ and MAIN2 harnesses from the feeder control board. 9. Remove the eight screws securing the inner frame to the base frame. Service Guide 167
  • Xerox 1235DT | Service Guide - Page 181
    10. Guide the disconnected MAIN2 harness through the frame as you remove the inner frame. Removing the optional feeder inner plate Reverse these steps to install the optional feeder inner frame. 168 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 182
    Feeder clutch Warning Switch off the power and disconnect the power cord. 1. Remove the printer from the optional paper feeder. 2. Remove the paper tray from the feeder. 3. Remove the from the feeder control board. 7. Remove the E-ring securing the feeder clutch to the shaft. Service Guide 169
  • Xerox 1235DT | Service Guide - Page 183
    8. Remove the clutch. Removing the feeder clutch Reverse these steps to install the optional feeder clutch. 170 Phaser 1235 Network Color Printer
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    Feeder motor Warning Switch off the power and disconnect the power cord. 1. Remove the printer from the optional paper feeder. 2. Remove the paper tray from the feeder. 3. Remove the four the inner frame. 9. Remove the two screws securing the feed motor to the feed motor bracket. Service Guide 171
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    10. Remove the feed motor. Removing the feeder motor Reverse these steps to install the optional feeder motor. 172 Phaser 1235 Network Color Printer
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    Feeder control board Warning Switch off the power and disconnect the power cord. 1. Remove the printer from the optional paper feeder. 2. Remove the four screws securing the feeder control board board. 4. Remove the two screws securing the feeder control board to the inner frame. Service Guide 173
  • Xerox 1235DT | Service Guide - Page 187
    5. Remove the feeder control board. Removing the feeder control board Reverse these steps to install the optional feeder control board. 174 Phaser 1235 Network Color Printer
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    Paper transport roll guide Warning Switch off the power and disconnect the power cord. 1. Remove the printer from the optional paper feeder. 2. Remove the paper tray Remove the two screws securing the paper transport roll guide to the inner frame. 7. Carefully pull down and out on the center of the
  • Xerox 1235DT | Service Guide - Page 189
    8. Remove the guide. Removing the paper transport roll guide Reverse these steps to install the paper transport roll guide. 176 Phaser 1235 Network Color Printer
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    Feeder drive assembly Warning Switch off the power and disconnect the power cord. 1. Remove the printer from the optional paper feeder. 2. Remove the paper tray from the feeder. 3. Remove the . Release the nudger roll spring attached to the right end of the feeder drive assembly. Service Guide 177
  • Xerox 1235DT | Service Guide - Page 191
    release the two locking tabs. Remove the feeder drive assembly Removing the feeder drive assembly Reverse these steps to install the feeder drive assembly. 178 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 192
    securing the paper size sensing actuator. 3. Remove the actuator. Removing the paper size sensing actuator Reverse these steps to install the paper size sensing actuator. Service Guide 179
  • Xerox 1235DT | Service Guide - Page 193
    size sensing board Warning Switch off the power and disconnect the power cord. 1. Remove the printer from the optional paper feeder. Note If removing the size sensing board from feeder 3, remove Reverse these steps to install the paper size sensing board. 180 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 194
    Lower connector Warning Switch off the power and disconnect the power cord. 1. Remove the printer from the optional paper feeder. 2. Remove the paper tray 2 from the feeder. 3. Separate feeder 2 ). 7. Remove the two screws securing the lower connector to the bottom of the feeder. Service Guide 181
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    8. Guide the harness through the feeder as you remove the lower connector. Removing the lower connector Reverse these steps to install the lower connector. 182 Phaser 1235 Network Color Printer
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    Upper connector Warning Switch off the power and disconnect the power cord. 1. Remove the printer from the optional paper feeder. Note If removing the upper connector from feeder 3, remove feeder 2 . 5. Remove the two screws securing the upper connector to the feeder frame. Service Guide 183
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    6. Guide the harness through the feeder as you remove the upper connector. Removing the upper connector Reverse these steps to install the upper connector. 184 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 198
    to the left and remove. Removing the tray 2/3 feed roller and nudger roller Reverse these steps to install the tray 2/3 feed roller and nudger roller. Service Guide 185
  • Xerox 1235DT | Service Guide - Page 199
  • Xerox 1235DT | Service Guide - Page 200
    FRU List This topic provides a list of field replaceable units for the printer. Changes to Xerox instruments are made to accommodate improved components as they become available. It is of item 1.1)" indicates that the part is included with item 1.2.1 (PL1.2, line item 1). Service Guide 187
  • Xerox 1235DT | Service Guide - Page 201
    Table 1 FRU parts list of the printer cabinet Fig 1 Part parts number Name and description 1 802E33490 Top Cover 2 802K24020 Right Side Up Tray 10 - - - - - Label (part of Rear Cover) S - - - - - Screw (part of item Hardware Kit p.n. 600K89010) 188 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 202
    Figure 1 Cabinet FRUs Service Guide 189
  • Xerox 1235DT | Service Guide - Page 203
    802E33490 Top Cover 2 140E45610 Toner Sensor Board 3 - - - - - Toner Sensor Actuator (part of Flag Eject Roller 12 130K65650 Stack Full Sensor w/actuator 13 038K13450 Eject Guide Assembly 14 - - - - - LED Harness C (part Kit, p.n. 600K88980) 190 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 204
    Figure 2 Top cover FRUs Service Guide 191
  • Xerox 1235DT | Service Guide - Page 205
    printer chassis (1 of 2) Fig 3 parts 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 S Part number Name and description 038K13460 Duplex Guide Toner Sensor Actuator (part of Flag Kit, p.n. 600K88990) 101K42820 Printer Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 206
    Figure 3 Printer chassis FRUs (1 of 2) Service Guide 193
  • Xerox 1235DT | Service Guide - Page 207
    Table 4 FRU of the printer chassis (2 of 2) Fig 4 parts 1 Part number 127K35180 Name and description Main Motor Assembly 2 115K02020 - Lower Plate 12 116-1058-00 High-Voltage Power Supply Fan S - - - - - Screw (part of Hardware Kit, p.n. 600K89010) 194 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 208
    Figure 4 Printer chassis FRUs (2 of 2) Service Guide 195
  • Xerox 1235DT | Service Guide - Page 209
    Table 5 FRU of the paper tray Fig 5 parts 1 Part number 050K50630 Name and description Paper Tray Cassette 2 600K89020 Retard Pad and Springs Kit 196 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 210
    Figure 5 Paper tray FRUs Service Guide 197
  • Xerox 1235DT | Service Guide - Page 211
    ) 18 032K03320 Paper Tray 1 Left Guide Assembly (includes items 2, 4, 5, 8-10, 17, 19) 19 - - - - - Paper Tray Lift Arm (Left) (part of item 18) 20 - - - - - Duplex Connector (part of item 1) S - - - - - Screw (part of Hardware Kit, p.n. 600K89010) 198 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 212
    Figure 6 Paper tray guide FRUs Service Guide 199
  • Xerox 1235DT | Service Guide - Page 213
    Assembly 5 - - - - - Multi-sheet Bypass OHP Sensor (part of item 1) 6 - - - - - Multi-sheet Bypass Tray Empty Sensor (part of item 1) S - - - - - Screw (part of Hardware Kit, p.n. 600K890 200 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 214
    Figure 7 Multi-sheet bypass feeder FRUs Service Guide 201
  • Xerox 1235DT | Service Guide - Page 215
    )) 4 127K35220 Electrical Chassis Cooling Fan 5 140E45640 Print Engine Controller Board 6 672-1595-00 System Controller Board (Image Processor Board) 7 121K25530 Internal Hard Drive 8 - - - - - - - - - - Screw (part of Hardware Kit, p.n. 600K89010) 202 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 216
    Figure 8 Electrical components FRUs Service Guide 203
  • Xerox 1235DT | Service Guide - Page 217
    204 Phaser 1235 Network
  • Xerox 1235DT | Service Guide - Page 218
    Figure 9 Duplexer unit Service Guide 205
  • Xerox 1235DT | Service Guide - Page 219
    Assembly 8 017E09930 Foot (4) 9 120E20420 Paper Size Actuator 10 140E45620 Paper Size Sensing Board w/Harness 050K50630 Paper Tray Cassette 022K79600 Lower Tray Assembly (with tray) 206 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 220
    Figure 10 Lower Tray Assembly FRUs Service Guide 207
  • Xerox 1235DT | Service Guide - Page 221
    number Name and description 600K89000 Gear Kit - - - - - Main Feeder Drive Gear - - - - - Gear H1 - - - - - Gear H2 - - - - - Fuser Drive Gear (A) - - - - - Fuser Drive Gear (B) - - - - - Fuser Drive Gear (C) 208 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 222
    - - - A Reg Exit Sensor Actuator - - - - - Toner Sensor Actuator Table 14 Harness kit Part number Name and description 600K88980 Harness Kit Harness - - - - - HV Tape Harness - - - - - 26 pin LED connector - - - - - Numerous other harnesses (cables) to be added soon. Service Guide 209
  • Xerox 1235DT | Service Guide - Page 223
    013R90133 Imaging Drum (Cyan) (1235) 013R90134 Imaging Drum (Magenta) (1235) 013R90135 Imaging Drum (Yellow) (1235) 016-1934-00 Cyan/Magenta/Yellow Imaging Drum Rainbow Pack (1235) 001R00559 Transfer Belt Unit (1235) 801K01300 Drum/Toner Cartridge Basket 210 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 224
    Prints This topic illustrates the test prints produced by the printer. The topic "Printing and print quality problems" on page 48 discusses solutions to problems revealed in the test prints. Interpreting the 100% Color neighbor. Each bar is separated by a thin black line. 0728-16 Service Guide 211
  • Xerox 1235DT | Service Guide - Page 225
    Use this pattern to identify defects such as deletions, banding, color misregistration, side-to-side density problems, and text problems. Look for: 1. Solid fills in the color blocks. 2. Ensure the small text is "Adjusting color density and balance" on page 77. 212 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 226
    full-page, fill made up of a 35% gray tint. It is useful for isolating black imaging and LED head problems. Look for uniform fill with no banding or lines. 0728-19 Interpreting the Blank Print (with crosshatch) Each print areas of a print as well as residual offsetting. 0728-20 Service Guide 213
  • Xerox 1235DT | Service Guide - Page 227
    % fill of a primary color bar and progressing in 10% steps to a 0% (white) fill bar. Use these pages to isolate primary color imaging or LED head problems. Look for uniform transitions from dark to light. 0728-21 214 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 228
    Wiring Diagram Wiring diagram (part 1 of 3) Service Guide 215
  • Xerox 1235DT | Service Guide - Page 229
    Wiring diagram (part 2 of 3) 216 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 230
    Wiring diagram (part 3 of 3) Service Guide 217
  • Xerox 1235DT | Service Guide - Page 231
    Bundle wires thru EMI coils Wire routing at the engine controller board 218 Phaser 1235 Network Color Printer Tie wraps
  • Xerox 1235DT | Service Guide - Page 232
    Tie wrap Wire routing at the top of the engine controller board Service Guide 219
  • Xerox 1235DT | Service Guide - Page 233
    Detail of wiring passthru 220 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 234
    Ensure wiring harness is routed inside the wiring shield Wiring under the top shield plate Make sure wiring is not pinched by top shield plate when it is installed Service Guide 221
  • Xerox 1235DT | Service Guide - Page 235
    222 Phaser 1235 Network Color Printer
  • Xerox 1235DT | Service Guide - Page 236
    NOTES
  • Xerox 1235DT | Service Guide - Page 237
    NOTES
  • Xerox 1235DT | Service Guide - Page 238
    NOTES
  • Xerox 1235DT | Service Guide - Page 239
    NOTES
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Warning
The following servicing instructions are for
use by qualified service personnel only.
To
avoid personal injury, do not perform any
servicing other than that contained in
operating instructions unless you are qualified
to do so.
This printing:
December 2000
071-0728-00
PHASER® 1235
NETWORK COLOR PRINTER
Service Guide