Page 1 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 S e rvic e G u id e Warning The following servicing instructions are for use by qualified service personnel only.
Page 2: Users Safety Summary
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.
Page 3 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.
Page 4: Table Of Contents
Contents General Information The Phaser 1235 Color Printer Printer RAM and printer capabilities CRU life counter behavior Print engine assemblies The image processor board The control panel On Line LED ! Fault Rear panel Accessing special operating modes System controller board LEDs Paper tray type sensing Specifications Regulatory specifications...
Page 5 Jams Wrong media Paper jams at the paper tray Manual bypass feeder feed jams Paper jams at the registration rollers Paper jams at the transfer belt Fuser jams Eject jams Jams in the duplex unit No drum imaging unit installed Imaging drum unit up/down error Fan error Fuser unit error...
Page 6 Service Tests and Adjustments Diagnostics mode Switch scan test LED head test Motor and clutch tests Test printing Consumable count initialization Consumable counter display Consumable continuation counter display Adjusting color density and balance Printing a Test Page Interpreting the Color Balance test print What to look for Making adjustments Adjustment recovery...
Page 7 Left plate assembly Electronic boards System controller board Print engine controller board Toner sensor board Entrance sensor board High voltage power supply Low voltage power supply Control panel Paper feed components Tray 1 feed roller and nudger roller Retard pad Paper-size sensing board Paper-size sensing actuator Main feeder assembly...
Page 8 Drive assembly components Main motor assembly Main feeder drive motor Transfer belt motor assembly Xerographic components Shutter plate Color registration sensor assembly Color registration solenoid LED assembly Drum contact assembly Toner sensor actuators Duplex unit Optional paper feeder components Idler roller assembly Inner frame Feeder clutch Feeder motor...
Page 9 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...
Page 10 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...
Page 11 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...
Page 12 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...
Page 13 Phaser 1235 Network Color Printer...
Page 14: General Information
General Information This service guide contains information useful for troubleshooting, repairing, ® adjusting, and maintaining the Xerox 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 &...
Page 15: The Phaser 1235 Color Printer
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.
Page 16 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 runs 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.
Page 17: Printer Ram And Printer Capabilities
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.
Page 18: Print Engine Assemblies
Print engine assemblies Paper size Toner sensor board sensing board Control panel assembly Entrance sensor board Low voltage power supply Duplex control (in duplexer) High voltage 7098 power supply Print engine circuit boards Service Guide...
Page 19: Print Engine Circuit Boards (Cont'd)
System controller board Print engine controller board Feeder control Paper-size sensing board Optional feeder 7099 Print engine circuit boards (cont’d) Phaser 1235 Network Color Printer...
Page 20: Print Engine Sensor And Switch Locations
Stack full Toner cartridge sensors sensor Exit sensor Top cover interlock switch Color registration sensor assembly Front cover interlock switch Belt entrance sensor Temperature sensor Waste toner sensor Humidity sensor Registration Entrance entrance 7100 cassette sensor sensor Print engine sensor and switch locations Service Guide...
Page 21: Print Engine Sensor And Switch Locations (Cont'd)
Stack full sensor Multi-sheet bypass tray empty sensor OHP sensor Fuser exit Multi-sheet bypass sensor position sensor Belt entrance sensor 7101 Print engine sensor and switch locations (cont’d) Phaser 1235 Network Color Printer...
Page 22: Print Engine Motors, Clutches And Solenoids
Duplex Gate Transfer belt solenoid motor assembly Registration motor Registration clutch Main feeder drive motor Registration shutter solenoid Duplex drive assembly 7102 Print engine motors, clutches and solenoids Service Guide...
Page 23: Optional Feeder Motor And Clutch
Feeder motor Optional feeder Feeder clutch 7103 Optional feeder motor and clutch Phaser 1235 Network Color Printer...
Page 24: The Image Processor Board
The image processor board Token ring card SDRAM Hard drive Fan cooled processor 0728-05 Features of the controller board Service Guide...
Page 25: The Control Panel
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...
Page 26: Rear Panel
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.
Page 27: Accessing Special Operating Modes
Accessing special operating modes The printer can be placed in diagnostics or other operation modes by simultaneously holding the Menu Up (1) and the Enter (4) keys as you turn on the printer. Entering special operating modes Key Combination Mode On Line (0) and This enables the Reset Menu to become available at the control panel.
Page 28: Paper Tray Type Sensing
Paper tray type sensing The positions of four tab pieces are 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 combinations of the tab position indicate the size of the paper in the tray.
Page 29: Specifications
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:...
Page 30 (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 ﬁlm is supported. Multi-sheet Bypass Feeder - 16 lb. to 54 lb. (60g/m...
Page 31 Electrical speciﬁcations Characteristic Speciﬁcation Primary line voltages 103 to 140 VAC (115 VAC nominal) 198 to 264 VAC (220 VAC nominal) Primary voltage frequency 50 (48 to 52) or 60 (58 to 62) Hz range Power consumption 250 watts during standby state, 1300 watts during warm-up 450 watts average reference value 45 watts during Energy Star state...
Page 32: Regulatory Specifications
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.
Page 33 Phaser 1235 Network Color Printer...
Page 34: Error Codes And Messages
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...
Page 35 Printer fault messages Code Front panel message Service message Jam A11, Remove Output Open Cover A, See A11-Paper Feed Jam Labels 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.
Page 36 Printer fault messages Code Front panel message Service message 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.
Page 37 Printer fault messages Code Front panel message Service message 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”...
Page 38 Printer fault messages Code Front panel message Service message A hard disk error was detected that prevented H1-Disk Read Error data from being read from the disk. A hard disk error was detected that prevented H2-Disk Write Error data from being written to the disk. A hard disk full error occurred that prevented H3-Hard Disk Full data from being written to the disk...
Page 39 Printer fault messages Code Front panel message Service message Yellow Toner Empty Replace Yellow Toner J9-Yellow Toner Empty Magenta Toner Empty Replace Magenta Toner J10-Magenta Toner Empty Cyan Toner Empty Replace Cyan Toner J11-Cyan Toner Empty Black Toner Empty Replace Black Toner J12-Black Toner Empty 1.
Page 40 Printer fault messages Code Front panel message Service message Fuser Upper Error T1 Power Off/On T1-Fuser Upper Error 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”...
Page 41 Printer fault messages Code Front panel message Service message 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.
Page 42 Printer fault messages Code Front panel message Service message Yellow Toner Missing Reseat Toner U22-Yellow Toner Missing Magenta Toner Missing Reseat Toner U23-Magenta Toner Missing Cyan Toner Missing Reseat Toner U24-Cyan Toner Missing Black Toner Missing Reseat Toner U25-Black Toner Missing 1.
Page 43 Controller board diagnostic error codes Code Test Possible Cause 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 board 21152 PCI-ISA Bridge Bad controller board PCI-PCI Bridge Bad controller board...
Page 44: Troubleshooting
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.
Page 45: Power On Self-Diagnostic Test
Power on self-diagnostic test Initial test. The following checks are automatically performed when the printer is powered on: 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. Flash ROM check.
Page 46: Print Engine Troubleshooting
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 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”...
Page 47: Verifying Printer Operation By Using Its Self-Test Print
Verifying printer operation by using its self-test print 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.” Verify that the system controller board’s health LED is ﬂashing.
Page 48: Power Connector Pinout
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...
Page 49: Inspecting The Low-Voltage Power Supply Fuse
Inspecting the low-voltage power supply fuse The 115 VAC power supply features a 20 A fuse. The 220 VAC power supply fuse uses a 10 A fuse. Turn off the printer. Disconnect the power cord from the printer. Remove the left-side cover as described in “Left-side cover” on page 88. Remove the main cooling fan as described in “Main cooling fan”...
Page 50: Testing For A Shorted Motor
Top Cover Open Switch Front Cover Open Switch 0728-01 Door safety interlock switches Testing for a shorted motor Remove the top and rear covers. Disconnect the motor harnesses and verify motor resistances (see the following topic). Refer to the topic “Wiring Diagram” on page 215 for a diagram that locates each connector.
Page 51: Motor And Fuser Roller Resistances
Motor and fuser roller resistances Turn off the printer and disconnect the power cord. 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 Between motor Pins 1 and 2...
Page 52: Media Jams And The Paper Path
Inspect the paper for bent, torn or folded corners. Ensure that the correct media is loaded in the paper tray. Only Xerox-brand 35-Series transparency ﬁlm for this printer should only be used. Refer to the media speciﬁcations in the table “Functional speciﬁcations,” on page 17.
Page 53: The Media Skews Passing Through The Paper Path
The media skews passing through the paper path Make sure that the media is properly installed in the tray. Does the pick-up roller pick up evenly? Is it clean? Is the paper tray damaged or obstructed? Are the tray's side paper guides snugly adjusted against the stack of media? The guides should be neither too loose nor too tight.
Page 54: Jams
Jams Wrong media Ensure the correct media type and size is loaded in the correct tray. For the multi-sheet bypass feeder, ensure the loaded media matches the control panel settings. Inspect the paper tray for damage to the tray’s paper size sensor actuators. Test the printer’s paper size sensors using the service test “Switch scan test”...
Page 55: Manual Bypass Feeder Feed Jams
“Motor and clutch tests” on page 69. Does the registration roller electric clutch operate correctly? Operate it with the service test “Motor and clutch tests” on page 69. Transparency ﬁlm. Use only Xerox-brand transparency ﬁlm meant for this printer. Paper jams at the transfer belt Check for a paper scrap in the paper path.
Page 56: Fuser Jams
Fuser jams Is the paper in good condition and appropriate for a laser printer? Is the printer printing within its environmental speciﬁcations? Print the Diagnostic Summary Page to determine the printer’s environmental conditions. Test the fuser motor using the service test “Motor and clutch tests” on page 69.
Page 57: No Drum Imaging Unit Installed
No drum imaging unit installed Ensure that the drum imaging units are properly installed. Check the high-voltage terminal connectors for the imaging unit to ensure that they are not damaged. Replace the drum imaging unit. Imaging drum unit up/down error Cycle the printer power to see if the problem clears.
Page 58: Fuser Unit Error
Fuser unit error Does the error occur immediately after the printer is turned on? Replace the fuser. Check that AC voltage supplied to the printer is correct. Does the fuser get hot? If not, replace the fuser. If the fuser does warm up, verify that it is reaching the correct temperature by running the service test “Switch scan test”...
Page 59: Other Problems
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.
Page 60: Front Door Indicated Being Open When It Is Closed
Front door indicated being open when it is closed Inspect that the front door’s interlock for damage. Replace the interlock switch. Check its wiring harness. Replace the engine controller board. Replace the power supply. High temperature error Check the fans for proper operation. Replace the low-voltage power supply unit.
Page 61: Printing And Print Quality Problems
Printing and print quality problems Required tools #1 Phillips screwdriver Conductive grease Volt-ohm-meter (VOM) Ruler Light or blurred images Is the correct paper being used in the printer? Are the toner cartridges low? Are any of the imaging drum reaching their end-of-life? Replace them if they are.
Page 62: Dark, Stained Background
Dark, stained background Determine if any of the imaging drums were exposed to light for an extended amount of time. If so, replace an unit which was. Examine the fuser rollers for contamination. Replace the fuser if they are. Ensure the media type is correctly set.
Page 63: Blank Print
Blank print Do the imaging drum units make good connection to their power terminals? Are the LED heads wiring harnesses undamaged and properly seated? Is +3.8V (red wire) supplied to Pin 3 of each LED head assembly? If yes, replace the LED head assembly.
Page 64: Black Stripe In Direction Of Paper Travel
Black stripe in direction of paper travel Do the imaging drum units make good connection to their power terminals? Are the LED heads wiring harnesses undamaged and properly seated? Is +3.8V (red wire) supplied to Pin 3 of each LED head assembly? If yes, replace the LED head assembly.
Page 65: White Stripe In Direction Of Paper Travel
White stripe in direction of paper travel Look for dirt or contamination on the LED heads. Clean them with an alcohol wipe. Do the imaging drum units make good connection to their power terminals? Are the LED heads wiring harnesses undamaged and properly seated? Is +3.8V (red wire) supplied to Pin 3 of each LED head...
Page 66: Poor Fusing, Toner Offsetting
Poor fusing, toner offsetting Is a supported paper type being used? Try printing on a different brand of paper. Is the fuser unit properly installed and making good electrical contact with the print engine? Inspect its connector. Inspect the fuser. Are its rollers contaminated or damaged? Ensure the media type is correctly set.
Page 67: Repeating Defect Or Voids On Print
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.
Page 68: Missing Characters Or Voids In Print
Missing characters or voids in print Look for dirt or contamination on the LED heads. Clean them with an alcohol wipe. Inspect and clean the imaging drum unit’s power terminals Ensure the spring-loaded pins travel smoothly up and down. Is a low-toner condition occurring? Replace any imaging drum units you suspect are defective.
Page 69: Color Misalignments
Color misalignments Test the registration sensor as described in the topic “Switch scan test” on page 63. Look for any broken gears in the printer. speciﬁcally, inspect the imaging drum gear assembly, the paper feeder assembly and the transfer belt assembly.
Page 70: Unexpected Colors
Unexpected colors The colors produced by the printer are dramatically different from the color you expected. Look for dirt or contamination on the LED heads. Clean them with an alcohol wipe. Inspect and clean the imaging drum unit’s power terminals Ensure the spring-loaded pins travel smoothly up and down.
Page 71: Image Is Skewed On The Paper
Image is skewed on the paper 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? Is the printer printing within its environmental speciﬁcations? Print the Diagnostic Summary Page to determine the printer’s conditions.
Page 72: Macintosh Printing Problems
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. Make sure that the correct printer icon was selected in the Chooser. Try printing the job again.
Page 73: Printer Isn't In The Chooser
Printer isn’t in the Chooser Ensure that the printer is turned on and the printer is in its READY mode. Check the Network or AppleTalk control panel to ensure the proper network or zone is selected. Power-cycle the printer. Check to see if the printer has not been renamed or placed in another zone.
Page 74: Service Tests And Adjustments
Service Tests and Adjustments Diagnostics mode To start the engine maintenance mode: Turn off the printer. Press and hold the Menu (1) and Enter (4) keys. Turn on the printer. When, is displayed on the control panel DIAGNOSTIC MODE xx.xx.xx (xx.xx.xx is the ROM version), release the control panel keys.
Page 75: Engine Maintenance Mode Menu
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 Items - scroll Settings - scroll...
Page 76: Switch Scan Test
Switch scan test Use this test to check the operation of the printer’s switches and sensors. Enter the diagnosis mode by pressing and holding the Menu (1) and Enter (4) keys as you turn on the printer. Press the Menu (1, 5) keys to scroll through the list of test until SWITCH appears on the upper display.
Page 77 Phaser 1235 Network Color Printer...
Page 78 Switch scans and the sensor and switches test Switch or Switch scan test Test result Details sensor Tray 1 No Paper Switch Scan 00 L - Paper present Pull main tray out to test sensor Sensor H - No paper Tray 1 Low Paper Switch Scan 00 L - Paper level OK...
Page 79: Switch Scans And The Sensor And Switches Test
Switch scans and the sensor and switches test Switch or Switch scan test Test result Details sensor not used Switch Scan 06 not used Manual Bypass Switch Scan 06 L - Transparency Manual feed a sheet of paper ﬁlm thru Feeder OHP H - Paper the feeder.
Page 80 Switch scans and the sensor and switches test Switch or Switch scan test Test result Details sensor not used Switch Scan 11 not used Duplex Front Switch Scan 11 L - Deactuated Pull out the duplex unit. Lift its cover. Sensor H - Actuated Place a sheet of paper inside on the...
Page 81: Led Head Test
Switch scans and the sensor and switches test Switch or Switch scan test Test result Details sensor not used Switch Scan 17 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...
Page 82: Motor And Clutch Tests
Motor and clutch tests Enter the diagnosis mode by pressing and holding the Menu (1) and Enter (4) keys as you turn on the printer. Press the Menu (1, 5) keys to scroll through the list of test until MOTOR appears on the upper display.
Page 83: Motor And Clutch Test Constraints
Motor and clutch test constraints Constraints Motor or clutch displayed displayed on on control panel control panel Details MAIN FEEDER MOTOR EXIT TRAY1 Run the test with Tray 1 removed CASSETTE REGISTRATION CLUTCH none Open the front cover and observe registration roller A turning REGISTRATION SHUTTER none...
Page 84: Test Printing
Test printing Enter the diagnosis mode by pressing and holding the Menu (1) and Enter (4) keys as you turn on the printer. Press the Menu (1, 5) keys to scroll through the list of test until TEST appears on the upper display. PRINT Press the Item (2, 6) keys to scroll through the list of test print items until the desired print option is displayed.
Page 85 Press the Item (2, 6) keys to scroll to the menu item PRINT EXECUTE Press Value (3) to starts printing. Press Value (7) to stop printing. The following messages are showing at warm-up and during printing. : Number of sheets printed for test (in units of sheets) : Upper fuser heater temperature measurement (in degrees Celsius) : Lower fuser heater temperature measurement (in degrees Celsius) : Environmental temperature measurement (in degrees Celsius)
Page 86: Consumable Count Initialization
Consumable count initialization This test menu item allows you to initialize the print engine’s consumable counts and registration set points. Enter the diagnosis mode by pressing and holding the Menu (1) and Enter (4) keys as you turn on the printer. Press the Menu (1, 5) keys to scroll through the list of test until NV-RAM appears on the upper display.
Page 87: Table 2: Initialization Items - Calibration Points
Table 2: Initialization items - calibration points Initialization Initialization Item Detail Value Unit Registration Set Yellow LED Initialization of X-axis 1/1200 inch Point x-axis Magenta LED Corrections for yellow, Cyan LED magenta, and cyan LED heads Registration Set Yellow LED Initialization of Y-axis 1/1200 inch Point y-axis...
Page 88: Consumable Counter Display
Consumable counter display This test indicate the status of each consumable supply. Enter the diagnosis mode by pressing and holding the Menu (1) and Enter (4) keys as you turn on the printer. Press the Menu (1, 5) keys to scroll through the list of test until appears on the upper display.
Page 89: Consumable Continuation Counter Display
Consumable continuation counter display The self-diagnosis is carried out to indicate the consumption status of each consumable supply. Enter the diagnosis mode by pressing and holding the Menu (1) and Enter (4) keys as you turn on the printer. Press the Menu (1, 5) keys to scroll through the list of test until appears on the upper display.
Page 90: Adjusting Color Density And Balance
Developer Bias Range: [251 - 550] Current Black Level: 0,10,11,...21, show variations of Current Cyan Level: Current Magenta Level: three-color gray. Each of these circles Current Yellow Level: Xerox Corporation, 2000 ver 1.1 contains gray with tints of other colors. Service Guide...
Page 91: What To Look For
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.
Page 92: Adjustment Recovery
Color balance adjustment Press Menu (1, 5) keys until you see Color Adjust Menu Press Item (2, 6) keys until you see Color Adjust Menu: Color Balance. Press Value (3, 7) keys until you see Color Density = New Value Values are: 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13.
Page 94: Cleaning And Maintenance
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.
Page 95: Recommended Tools
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 Periodically replaced parts Part name Display or Recommended Adjustment after Warning condition for replacement Condition replacement...
Page 96: Cleaning
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.
Page 98: Resetting Nvram
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.
Page 100: Fru Disassembly
FRU Disassembly This topic illustrates how to remove and replace printer Field Replaceable Units (FRUs). Refer to the later topic “FRU List” on page 187 for a list of the printer’s FRUs. The printer does not contain any mechanical ﬁeld adjustable components. Default settings and soft switch settings are covered in “Service Tests and Adjustments”...
Page 101: Left-Side Cover
Left-side cover Warning Switch off the power and disconnect the power cord. Open the top cover. Open the front cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag to protect the drum units from light and store in a safe place.
Page 102: Right-Side Cover
Right-side cover Warning Switch off the power and disconnect the power cord. 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 in a safe place. Open the front cover.
Page 103: Rear Cover
Phaser 1235 Network Color Printer...
Page 104: Front Cover
Front cover Warning Switch off the power and disconnect the power cord. Remove Tray 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 store in a safe place. Open the front cover.
Page 105: Face-Up Tray
Face-up tray Open the face-up tray. Carefully pry the left stopper pin free of the rear cover. Remove the face up tray. Removing the face-up t Reverse these steps to install the face-up tray. Phaser 1235 Network Color Printer...
Page 106: Frames Components
Frames components Right shield plate Warning Switch off the power and disconnect the power cord. Open the front cover. 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 in a safe place.
Page 107: Electrical Chassis (Card Cage)
Electrical chassis (card cage) Warning Switch off the power and disconnect the power cord. 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 in a safe place. Open the front cover.
Page 108: Removing The Electrical Chassis
Guide the bottom harnesses as you carefully remove the electrical chassis. Removing the electrical chassis Reverse these steps to install the electrical chassis. Note Attached to the back of the electrical chassis is a grounding tab. As you reinstall the chassis, ensure that the tab is not deformed and is positioned on the end of the paper feed shaft.
Page 109: Electrical Chassis Cooling Fan
Electrical chassis cooling fan Warning Switch off the power and disconnect the power cord. 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 in a safe place. Open the front cover.
Page 110: Printer Unit Chassis
Printer unit chassis (and low-voltage power supply fan) Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag and store in a safe place. Open the front cover and inner bafﬂe.
Page 111: Removing The Printer Unit Chassis
Disconnect the harness from the registration motor. Disconnect the main cooling fan wiring harness from the low voltage power supply. Disconnect and remove the chassis cooling fan, it is held in place by two screws. Remove the two screws securing the AC inlet. Remove the screw securing the ground wire near the power switch.
Page 112: Main Cooling Fan
Main cooling fan Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag and store in a safe place. Open the front cover. Remove the left-side cover as detailed in the topic “Left-side cover”...
Page 113: Top Cover Inner Frame
Top cover inner frame Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag and store in a safe place. Open the front cover. Remove the left-side cover as detailed on page 88.
Page 114: Removing The Harnesses From The Electrical Chassis
Remove the three screws securing the cable shield to the top chassis. Remove the harnesses from the electrical chassis. Disconnect the POWER inline connector from the top cover inner frame. Removing the harnesses from the electrical chassis Remove the rear cover as detailed in “Rear cover” on page 90. Remove the screws from the metal strap attached to the left pivot arm.
Page 115: Removing The Top Cover Inner Frame
With the top cover inner frame open to the vertical position, carefully pull the left pivot arm out until the left side of the assembly is free of the printer. Carefully pull the right pivot arm out until the right side is free. Caution Do not set the top cover inner frame face down as the LED assemblies or the LED mounting brackets can be damaged.
Page 116: Left/Right Top Cover Spring Assembly
Left/right top cover spring assembly Warning Switch off the power and disconnect the power cord. Remove the top cover inner frame as described in the topic “Top cover inner frame” on page 100. Remove the four screws securing 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.
Page 117: Left Paper Tray Guide Assembly
Left paper tray guide assembly Note Switch off the power and disconnect the power cord. Remove the paper tray 1 from the printer. Remove the duplexer unit if installed. Remove the electrical chassis as described on “Electrical chassis (card cage)” on page 94 Remove the printer unit chassis as shown on page 97.
Page 118: Removing The Left Paper Tray Guide Assembly
Remove the main feeder assembly as detailed on page 123. Remove the three screws securing the left paper tray guide assembly to the bottom plate. 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...
Page 119: Right Paper Tray Guide Assembly
Right paper tray guide assembly Warning Switch off the power and disconnect the power cord. Remove the electrical chassis as described in “Electrical chassis (card cage)” on page 94. Remove the printer unit chassis as shown on page 97. Remove the four screws securing the lower plate to the paper tray guide assemblies.
Page 120: Removing The Right Paper Tray Guide Assembly
Remove the main feeder assembly as detailed on page 123. Remove the ﬁve screws securing the right paper tray guide assembly to the bottom plate. 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...
Page 121: Left Plate Assembly
Left plate assembly Warning Switch off the power and disconnect the power cord. Remove printer unit chassis as shown on page 97. Remove the two screws from the high-voltage power supply fan. Let the fan rest on the front of the lower plate. Remove the four screws securing the left plate assembly to the lower plate.
Page 122: Electronic Boards
Electronic boards System controller board Warning Switch off the power and disconnect the power cord. Disconnect all cables connected to the rear of the system controller. Remove the two thumb screws securing the system controller to the printer. 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.
Page 123: Print Engine Controller Board
Print engine controller board Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag and store in a safe place. Open the front cover. Remove the right-side cover as shown on page 89.
Page 124: Toner Sensor Board
Toner sensor board Warning Switch off the power and disconnect the power cord. Remove the top cover as detailed on “Top cover” on page 87. Disconnect the four LED power harnesses from the toner sensor board. Disconnecting the LED power harnesses Close the top cover inner unit.
Page 125: Removing The Toner Sensor Board
Remove the board. Removing the toner sensor board 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.
Page 126: Entrance Sensor Board
Entrance sensor board Warning Switch off the power and disconnect the power cord. Remove the multi-sheet bypass feeder as described in the topic on page 127. Remove the printer unit chassis as detailed on page 97. Remove registration roller assembly B as explained on page 137. Remove the spring-loaded tray 1 entrance sensor actuator as explained on page 130.
Page 127: High Voltage Power Supply
High voltage power supply Warning Switch off the power and disconnect the power cord. Remove the printer unit chassis as detailed in the topic “Printer unit chassis (and low-voltage power supply fan)” on page 97. Disconnect CN3 from the low voltage power supply. Disconnect CN1 from the high voltage power supply.
Page 128: Removing The High Voltage Power Supply
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...
Page 129: Low Voltage Power Supply
Low voltage power supply Warning Switch off the power and disconnect the power cord. Remove the printer unit chassis as shown on page 97. Disconnect CN3, CN1, & CN2 from the low voltage power supply. Remove the six screws securing the low voltage power supply to the printer.
Page 130: Control Panel
Control panel Warning Switch off the power and disconnect the power cord. Remove the top cover as detailed in “Top cover” on page 87. Remove the screw securing the left side of the control panel. Lift the control panel and disconnect CN1 from the back of the panel. Remove the control panel.
Page 131: Paper Feed Components
Paper feed components Tray 1 feed roller and nudger roller Remove tray 1. Release the locking tab on the left end of the feed roller. Slide the feed roller to the left and remove. Release the locking tab on the left end of the nudger roller. Slide the nudger roller to the left and remove.
Page 132: Retard Pad
Retard pad Remove the paper tray from the printer. Remove the two springs. Use a small screwdriver to carefully pry both arms free of the mounting pins. Remove the retard pad. Removing the retard pad Reverse these steps to install the retard pad. Service Guide...
Page 133: Paper-Size Sensing Board
Paper-size sensing board Warning Switch off the power and disconnect the power cord. Remove the system controller board as described in the topic “System controller board” on page 109. Remove the print engine controller board as described in the topic “Print engine controller board”...
Page 134: Removing The Paper Size Sensing Board
Removing the paper size sensing board Reverse these steps to install the paper-size sensing board. Service Guide...
Page 135: Paper-Size Sensing Actuator
Paper-size sensing actuator Warning Switch off the power and disconnect the power cord. Remove paper tray 1. Remove the screw securing the paper-size sensing actuator. Remove the actuator. Removing the paper size sensing actuator Reverse these steps to install the paper-size sensing actuator. Phaser 1235 Network Color Printer...
Page 136: Main Feeder Assembly
Main feeder assembly Note Switch off the power and disconnect the power cord. Remove the electrical chassis as detailed in “Electrical chassis (card cage)” on page 94. Remove the printer chassis as described in the topic “Printer unit chassis (and low-voltage power supply fan)” on page 97. Remove the four screws securing the lower plate to the paper tray guide assemblies.
Page 137: Removing The Main Feeder Assembly
Lift and remove the main feeder assembly. Removing the main feeder assembly Reverse these steps to install the main feeder assembly. Phaser 1235 Network Color Printer...
Page 138: Tray 1 No-Paper/Low-Paper Sensors
Tray 1 no-paper/low-paper sensors Warning Switch off the power and disconnect the power cord. Remove the electrical chassis as detailed in “Electrical chassis (card cage)” on page 94. Remove the printer chassis as described in the topic “Printer unit chassis (and low-voltage power supply fan)” on page 97. Remove the main feeder assembly as described in the previous procedure “Main feeder assembly”...
Page 139: Paper Tray Lift Arm Roller
Paper tray lift arm roller Warning Switch off the power and disconnect the power cord. Remove paper tray 1. Caution Take care not to break the locking tabs in the next step. Release the two locking tabs and remove the roller. Removing the paper tray lift arm roller Reverse these steps to install the paper tray lift arm roller.
Page 140: Multi-Sheet Bypass Feeder Components
Multi-sheet bypass feeder components Multi-sheet bypass feeder Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag and store in a safe place. Open the front cover.
Page 141: Removing The Multi-Sheet Bypass Feeder
Removing the multi-sheet bypass feeder Reverse these steps to install the multi-sheet bypass feeder. Phaser 1235 Network Color Printer...
Page 142: Multi-Sheet Bypass Feeder Entrance Sensor Actuator
Multi-sheet bypass feeder entrance sensor actuator Warning Switch off the power and disconnect the power cord. Remove the multi-sheet bypass feeder as described in the topic on page 127. Remove the printer unit chassis as described in the topic on page 97. Remove the Tray 1 entrance sensor actuator as detailed in the topic on page 130.
Page 143: Paper Transport Components
Paper transport components Tray 1 entrance sensor actuator Warning Switch off the power and disconnect the power cord. Remove the printer unit chassis as detailed in the topic on page 97. From the bottom of the printer unit chassis, carefully squeeze the two locking tabs and remove the sensor.
Page 144: Belt Entrance Sensor Actuator
Belt entrance sensor actuator Warning Switch off the power and disconnect the power cord. Remove the printer unit chassis described in the topic “Printer unit chassis (and low-voltage power supply fan)” on page 97. Remove the Tray 1 entrance sensor actuator as described in the topic “Tray 1 entrance sensor actuator”...
Page 145: Transfer Belt Unit
Transfer belt unit Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridge basket and store in a lightproof bag to protect the drum units from light. Push the transfer belt unit locking tabs toward the rear of the printer to release the unit.
Page 146: Registration Components
Registration components Registration clutch Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag and store in a safe place. Open the front cover. Remove the right-side cover as described in the topic “Right-side cover”...
Page 147: Registration Motor Assembly
Registration motor assembly Warning Switch off the power and disconnect the power cord. Open top cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag and store in a safe place. Open the front cover. Remove the right-side cover as described in the topic “Right-side cover”...
Page 148: Registration Roller Assembly A And Drive Gear
Registration roller assembly A and drive gear Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag and store in a safe place. Remove the four imaging cartridges and basket.
Page 149: Removing The Registration Roller Assembly A And Drive Gear
Remove the E-Ring securing the drive gear to the right end of the registration roller shaft. Remove the drive gears. Removing the registration roller assembly A and drive gear Reverse these steps to install the registration roller assembly A and drive gear. Install the drive gear so that it drives the roller in the direction of paper travel.
Page 150: Registration Roller Assembly B
Registration roller assembly B Warning Switch off the power and disconnect the power cord. Remove tray 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. Open front cover.
Page 151: Removing The Registration Roller Assembly B
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. Phaser 1235 Network Color Printer...
Page 152: Exit Assembly And Fuser Components
Exit assembly and fuser components Fuser unit Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag and store in a safe place. Press the two latches to release the fuser unit.
Page 153: Fuser Latching Handle (Left)
Fuser latching handle (left) Warning Switch off the power and disconnect the power cord. Open the top cover. Open the front cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag and store in a safe place. Remove the left-side cover as described in the topic “Left-side cover”...
Page 154: Fuser Latching Handle (Right)
Fuser latching handle (right) Warning Switch off the power and disconnect the power cord. Remove the electrical chassis as detailed in “Electrical chassis (card cage)” on page 94. Remove the printer unit chassis as detailed on page 97. Release the fuser latching handle spring. Remove the E-ring securing the fuser latching handle.
Page 155: Fuser Exit Roller
Fuser exit roller Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag and store in a safe place. Open the front cover. Remove the left-side cover as detailed in the topic “Left-side cover”...
Page 156: Removing The Fuser Exit Roller
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...
Page 157: Exit Sensor Assembly
Exit sensor assembly Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag and store in a safe place. Open the front cover. Remove the left-side cover as detailed in the topic “Left-side cover”...
Page 158: Removing The Exit Sensor Assembly
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...
Page 159: Duplex Guide Assembly
Duplex guide assembly Warning Switch off the power and disconnect the power cord. Remove the top cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag and store in a safe place. Open the front cover. Remove the left-side cover as described in the topic “Left-side cover”...
Page 160: Removing The Duplex Guide Assembly
Lift the duplex guide assembly and remove. Removing the duplex guide assembly Reverse these steps to install the duplex guide assembly. Service Guide...
Page 161: Eject Guide Assembly
Eject guide assembly Warning Switch off the power and disconnect the power cord. Remove the rear cover. Open the top cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag and store in a safe place. Remove the ﬁve screws securing the eject guide assembly to the top cover.
Page 162: Stack Full Sensor
Stack full sensor Warning Switch off the power and disconnect the power cord. Remove the top cover. Disconnect the four LED assembly power harnesses from the bottom of the toner sensor board. Removing the LED Assembly power connector Close the top cover inner unit. Remove the four screws securing the metal shield over the toner cartridge sensor board.
Page 163: Removing The Stack Full Sensor
Remove the stack full sensor. Removing the stack full sensor Reverse these steps to install the stack full sensor. Phaser 1235 Network Color Printer...
Page 164: Drive Assembly Components
Drive assembly components Main motor assembly Note Switch off the power and disconnect the power cord. Remove the electrical chassis as detailed in “Electrical chassis (card cage)” on page 94. Remove the printer unit chassis as detailed on page 97. Free the harnesses from the channel along the right side of the main motor assembly.
Page 165: Removing The Main Motor Assembly
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. Phaser 1235 Network Color Printer...
Page 166: Main Feeder Drive Motor
Main feeder drive motor Warning Switch off the power and disconnect the power cord. Remove the print unit chassis as detailed in “Printer unit chassis (and low-voltage power supply fan)” on page 97. Disconnect the inline connector from the HOPFF connector. Remove the two screws securing the main feeder drive motor to the mounting bracket.
Page 167: Transfer Belt Motor Assembly
Transfer belt motor assembly Warning Turn the power off and disconnect the power cord. Remove the printer unit chassis as detailed on page 97. Remove the two screws securing the transfer belt motor assembly. Tilt the transfer belt motor assembly over and lift about 2.5 cm (1 in.). Note If the cable harness does not have enough slack to allow disconnecting and reconnecting the two incline connectors,...
Page 168: Removing The Transfer Belt Motor Assembly
Remove the transfer belt motor assembly. Removing the transfer belt motor assembly Reverse these steps to install the transfer belt motor assembly. Service Guide...
Page 169: Xerographic Components
Xerographic components Shutter plate Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridge basket. Place them in a lightproof bag and store in a safe place. Remove the transfer belt unit as explained on page 132. Through the opening in the shutter plate, carefully remove the Shutter Spring.
Page 170: Color Registration Sensor Assembly
Color registration sensor assembly Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the four imaging cartridges and basket. Cover the cartridges and store in a safe place. Remove the transfer belt unit as detailed on page 132. Remove the shutter plate as described in the previous procedure “Shutter plate”...
Page 171: Color Registration Solenoid
Color registration solenoid Warning Switch off the power and disconnect the power cord. Remove the printer unit chassis as shown on page 97. Remove the shutter plate as explained on page 156. Disconnect the shutter solenoid in-line connector. Release the shutter solenoid harness from all cable clamps. Remove the screw securing the shutter solenoid to the printer unit chassis.
Page 172: Led Assembly
LED assembly Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag and store in a safe place. Carefully disconnect the ﬂat harness connector from the LED assembly by inserting a small, ﬂat-blade screwdriver through the hole in the end of the LED assembly and lifting up on the connector.
Page 173: Drum Contact Assembly
Drum contact assembly Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the four imaging cartridges and basket. Cover the cartridges and store in a safe place. Use a small screwdriver to carefully pry the drum contact assembly from the printer chassis.
Page 174: Toner Sensor Actuators
Toner sensor actuators Warning Switch off the power and disconnect the power cord. Remove the top cover. Remove the drum/toner cartridge basket. Cover the basket in a lightproof black bag and store in a safe place. Disconnect the four LED power harnesses from the bottom of the toner sensor board.
Page 175: Removing The Toner Sensor Actuators
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. Phaser 1235 Network Color Printer...
Page 176: Duplex Unit
Duplex unit Warning Switch off the power and disconnect the power cord. Remove tray 1. Open the front cover and the front cover inner bafﬂe. Pull the duplex unit out until it stops. Release 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.
Page 177: Optional Paper Feeder Components
Optional paper feeder components Idler roller assembly Warning Switch off the power and disconnect the power cord. Remove the printer from the optional paper feeder. Remove the four screws securing the feeder control board cover plate. Remove the plate. Removing the feeder control board cover Carefully disconnect harness SNS0 from the feeder control board (connector SNS0 is a six pin connector with only two wires - it may be necessary to remove the feeder control board to disconnect the harness).
Page 178: Removing The Idler Roller Assembly
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...
Page 179: Inner Frame
Inner frame Warning Switch off the power and disconnect the power cord. Remove the printer from the optional paper feeder. Remove the paper tray from the optional paper feeder. Turn the optional paper feeder on to its left or right side. Remove the four brass colored screws from the bottom of the paper feeder.
Page 180: Removing The Feeder Control Board Cover
Remove the four screws securing the feeder control board cover plate. Remove the plate. Removing the feeder control board cover Remove the idler roller assembly as explained on page 164. Disconnect the PSZ and MAIN2 harnesses from the feeder control board.
Page 181: Removing The Optional Feeder Inner Plate
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. Phaser 1235 Network Color Printer...
Page 182: Feeder Clutch
Feeder clutch Warning Switch off the power and disconnect the power cord. Remove the printer from the optional paper feeder. Remove the paper tray from the feeder. Remove the four screws securing the feeder control board cover plate. Remove the plate. Removing the feeder control board cover Remove the idler roller assembly as explained on page 164.
Page 183: Removing The Feeder Clutch
Remove the clutch. Removing the feeder clutch Reverse these steps to install the optional feeder clutch. Phaser 1235 Network Color Printer...
Page 184: Feeder Motor
Feeder motor Warning Switch off the power and disconnect the power cord. Remove the printer from the optional paper feeder. Remove the paper tray from the feeder. Remove the four screws securing the feeder control board cover plate. Remove the plate. Removing the feeder control board cover Remove the idler roller assembly as explained on page 164.
Page 185: Removing The Feeder Motor
Remove the feed motor. Removing the feeder motor Reverse these steps to install the optional feeder motor. Phaser 1235 Network Color Printer...
Page 186: Feeder Control Board
Feeder control board Warning Switch off the power and disconnect the power cord. Remove the printer from the optional paper feeder. Remove the four screws securing the feeder control board cover plate. Remove the plate. Removing the feeder control board cover Disconnect the seven harnesses connected to the feeder control board.
Page 187: Removing The Feeder Control Board
Remove the feeder control board. Removing the feeder control board Reverse these steps to install the optional feeder control board. Phaser 1235 Network Color Printer...
Page 188: Paper Transport Roll Guide
Paper transport roll guide Warning Switch off the power and disconnect the power cord. Remove the printer from the optional paper feeder. Remove the paper tray from the feeder. Remove the four screws securing the feeder control board cover plate. Remove the plate.
Page 189: Removing The Paper Transport Roll Guide
Remove the guide. Removing the paper transport roll guide Reverse these steps to install the paper transport roll guide. Phaser 1235 Network Color Printer...
Page 190: Feeder Drive Assembly
Feeder drive assembly Warning Switch off the power and disconnect the power cord. Remove the printer from the optional paper feeder. Remove the paper tray from the feeder. Remove the four screws securing the feeder control board cover plate. Remove the plate. Removing the feeder control board cover plate Remove the idler roller assembly as explained on page 164.
Page 191: Removing The Feeder Drive Assembly
Remove the two screws securing the feeder drive assembly to the metal frame. Turn the inner frame up side down. To the left and right of the nudger roll, there is a 1/2 in. (12mm) cutout in the edge of the feeder drive assembly.
Page 192: Paper Size Sensing Actuator
Paper size sensing actuator Warning Switch off the power and disconnect the power cord. Remove paper tray 2/3. Remove the screw securing the paper size sensing actuator. Remove the actuator. Removing the paper size sensing actuator Reverse these steps to install the paper size sensing actuator. Service Guide...
Page 193: Paper Size Sensing Board
Paper size sensing board Warning Switch off the power and disconnect the power cord. Remove the printer from the optional paper feeder. Note If removing the size sensing board from feeder 3, remove feeder 2 from feeder 3. Remove the paper tray from the feeder. Remove the four screws securing the feeder control board cover plate.
Page 194: Lower Connector
Lower connector Warning Switch off the power and disconnect the power cord. Remove the printer from the optional paper feeder. Remove the paper tray 2 from the feeder. Separate feeder 2 from feeder 3 Remove the four screws securing the feeder control board cover plate. Remove the plate.
Page 195: Removing The Lower Connector
Guide the harness through the feeder as you remove the lower connector. Removing the lower connector Reverse these steps to install the lower connector. Phaser 1235 Network Color Printer...
Page 196: Upper Connector
Upper connector Warning Switch off the power and disconnect the power cord. Remove the printer from the optional paper feeder. Note If removing the upper connector from feeder 3, remove feeder 2 from feeder 3. Remove the paper tray from the feeder. Remove the four screws securing the feeder control board cover plate.
Page 197: Removing The Upper Connector
Guide the harness through the feeder as you remove the upper connector. Removing the upper connector Reverse these steps to install the upper connector. Phaser 1235 Network Color Printer...
Page 198: Tray 2/3 Feed Roller And Nudger Roller
Tray 2/3 feed roller and nudger roller Warning Switch off the power and disconnect the power cord. Remove paper tray 2/3. Release the locking tab on the left end of the feed roller. Slide the feed roller to the left and remove. Release the locking tab on the left end of the nudger roller.
Page 200: Fru List
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 important when ordering parts to include the following information: Component's part number.
Page 201: Fru Parts List Of The Printer Cabinet
Table 1 FRU parts list of the printer cabinet Fig 1 Part Name and description parts number 802E33490 Top Cover 802K24020 Right Side Cover 802E34550 Multi-sheet Bypass Feeder Assembly Top Cover 802K24030 Multi-sheet Bypass Feeder Assembly 055K30000 Front Cover Inner Bafﬂe 802K24010 Front Cover Assembly 802E33510...
Page 202: Cabinet Frus
Figure 1 Cabinet FRUs Service Guide...
Page 203: Fru Part List Of The Top Cover Assembly
Table 2 FRU part list of the top cover assembly Fig 2 Part Name and description parts number 802E33490 Top Cover 140E45610 Toner Sensor Board - - - - - Toner Sensor Actuator (part of Flag Kit, p.n. 600K88990)) 056E04120 Control Panel Bezel (English) 056E04660 Control Panel Bezel (Icon)
Page 204: Top Cover Frus
Figure 2 Top cover FRUs Service Guide...
Page 205: Fru Part List Of The Printer Chassis (1 Of 2)
Table 3 FRU part list of the printer chassis (1 of 2) Fig 3 Part Name and description parts number 038K13460 Duplex Guide Assembly 022E24940 Fuser Exit Roller 009K01960 Right Top Cover Spring Assembly - - - - - Fuser Drive Gear A (part of Gear Kit, p.n. 600K89000) - - - - - Fuser Drive Gear B (part of Gear Kit, p.n.
Page 206: Printer Chassis Frus (1 Of 2)
Figure 3 Printer chassis FRUs (1 of 2) Service Guide...
Page 207 Table 4 FRU of the printer chassis (2 of 2) Fig 4 Part Name and description parts number 127K35180 Main Motor Assembly 115K02020 Transfer Contact Assembly 118E16970 Power Supply Insulation 015K55950 Left Plate Assembly 127K35190 Transfer Belt Motor Assembly - - - - - Fuser Latching Handle Spring (part of Hardware Kit, p.n.
Page 208: Printer Chassis Frus (2 Of 2)
Figure 4 Printer chassis FRUs (2 of 2) Service Guide...
Page 209: Fru Of The Paper Tray
Table 5 FRU of the paper tray Fig 5 Part Name and description parts number 050K50630 Paper Tray Cassette 600K89020 Retard Pad and Springs Kit Phaser 1235 Network Color Printer...
Page 210: Paper Tray Frus
Figure 5 Paper tray FRUs Service Guide...
Page 211: Fru Of The Paper Tray Guide
Table 6 FRU of the paper tray guide Fig 6 Part Name and description parts number 032K03330 Paper Tray 1 Right Guide Assembly (includes items 2-10, 15, 20) 017E09930 Foot - - - - - Paper Tray Lift Arm (Right) (part of item 1 and 18) - - - - - Plastic Roller (part of Hardware Kit, p.n.
Page 212: Paper Tray Guide Frus
Figure 6 Paper tray guide FRUs Service Guide...
Page 213: Frus Of The Multi-Sheet Bypass Feeder
Table 7 FRUS of the multi-sheet bypass feeder Fig 7 Part Name and description parts number 022K78630 Multi-sheet Bypass Feeder Assembly 012E12690 Link 007K11740 Multi-sheet Bypass Feeder Drive Gear 802K24030 Multi-sheet Bypass Feeder Cover Assembly - - - - - Multi-sheet Bypass OHP Sensor (part of item 1) - - - - - Multi-sheet Bypass Tray Empty Sensor (part of item 1)
Page 214: Multi-Sheet Bypass Feeder Frus
Figure 7 Multi-sheet bypass feeder FRUs Service Guide...
Page 215: Electrical Components Frus
Table 8 Electrical components FRUs Fig 8 Part Name and description parts number 105K25110 Low Voltage Power Supply (115V) 105K25130 Low Voltage Power Supply (230V) 105K25120 High Voltage Power Supply - - - - - High Voltage Tape Harness (part Harness Kit, p.n. 600K88980)) 127K35220 Electrical Chassis Cooling Fan 140E45640...
Page 216: Electrical Components Frus
Figure 8 Electrical components FRUs Service Guide...
Page 217 Phaser 1235 Network...
Page 218: Duplexer Unit
Figure 9 Duplexer unit Service Guide...
Page 219: Frus Of The Lower Tray Assembly
Table 10 FRUs of the Lower Tray Assembly Fig 10 Part Name and description parts number 140E46240 Feeder Control Board 962K00700 Upper Connector w/harness 962K00690 Lower Connector w/harness 022K79500 Idler Roller Assembly 127K40870 Feeder Motor 121K26030 Feeder Clutch 022K79510 Feeder Drive Assembly 017E09930 Foot (4) 120E20420...
Page 220: Lower Tray Assembly Frus
Figure 10 Lower Tray Assembly FRUs Service Guide...
Page 221: Hardware Kit
Table 11 Hardware kit Part Name and description number 600K89010 Hardware Kit - - - - - LED Assembly Spring Kit (2) - - - - - Plastic Roller (2) - - - - - Fuser Exit Roller Bushing (L) (1) - - - - - Fuser Exit Roller Bushing (R) (1) - - - - -...
Page 222: Harness Kit
Table 13 Sensor ﬂag kit Part Name and description number 600K88990 Flag Kit - - - - - B Reg Entrance Sensor Actuator - - - - - A Reg Entrance Sensor Actuator - - - - - A Reg Exit Sensor Actuator - - - - - Toner Sensor Actuator Table 14 Harness kit...
Page 223: Customer Replaceable Consumables
Table 15 Customer replaceable consumables Part Name and description number 008R12685 Fuser (1235) (110 V) 008R12686 Fuser (1235) (220 V) 006R90293 Standard Toner Cartridge (Black) (1235) 006R90294 Standard Toner Cartridge (Cyan) (1235) 006R90295 Standard Toner Cartridge (Magenta) (1235) 006R90296 Standard Toner Cartridge (Yellow) (1235) 006R90303 Hi Capacity Toner Cartridge (Black) (1235) 006R90304...
Page 224: Test Prints
Test 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 Stripe Pattern The 100% Color Stripe Pattern consist of two set of bars.
Page 225 Interpreting Test Pattern A This pattern consists of color blocks and c gogo c gogo c gogo c gogo bars. Use this pattern to identify defects c gogo c gogo c gogo c gogo such as deletions, banding, color c gogo c gogo c gogo c gogo c gogo c gogo c gogo c gogo...
Page 226 Interpreting the Gray 35% Halftone Test Pattern Gray 35% Halftone Test Pattern The Gray 35% Halftone Test Pattern is a 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.
Page 227 Interpreting the Step Test Patterns The Step Test Patterns consist of 11 color Cyan Step Test Pattern bars, starting with a100% ﬁll of a primary color bar and progressing in 10% steps to a 0% (white) ﬁll bar. Use these pages to Magenta Step Test Pattern isolate primary color imaging or LED head problems.
Page 228: Wiring Diagram
Wiring Diagram Wiring diagram (part 1 of 3) Service Guide...
Page 229: Phaser 1235 Network Color Printer
Wiring diagram (part 2 of 3) Phaser 1235 Network Color Printer...
Page 230: Service Guide
Wiring diagram (part 3 of 3) Service Guide...
Page 231: Wire Routing At The Engine Controller Board
Tie wraps Bundle wires thru EMI coils Wire routing at the engine controller board Phaser 1235 Network Color Printer...
Page 232: Wire Routing At The Top Of The Engine Controller Board
Tie wrap Wire routing at the top of the engine controller board Service Guide...
Page 233: Detail Of Wiring Passthru
Detail of wiring passthru Phaser 1235 Network Color Printer...
Page 234: Wiring Under The Top Shield Plate
Ensure wiring harness is routed inside the wiring shield Make sure wiring is not pinched by top shield plate when it is installed Wiring under the top shield plate Service Guide...
Page 235 Phaser 1235 Network Color Printer...
Page 236 NOTES...
Page 237 NOTES...
Page 238 NOTES...
Page 239 NOTES...

This manual is also suitable for:

Phaser 1235 Phaser 1235n Phaser 1235dx

Xerox 1235DT - Phaser Color Solid Ink Printer Service Manual

General Information

Error Codes and Messages

Troubleshooting

Service Tests and Adjustments

Cleaning and Maintenance

Resetting NVRAM

FRU Disassembly

FRU List

Quick Links

Troubleshooting

Need help?

Questions and answers

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Summary of Contents for Xerox 1235DT - Phaser Color Solid Ink Printer