Page 1 P H A S E R 2 1 3 5 ® C O L O R P R I N T E R Se rvic e R ef erenc e Guide Printed on recycled paper 07 1-0725-00...
Page 2 P H A S E R ® 2 1 3 5 C O L O R P R I N T E R Se rvic e Qu ic k Re f e re n c e Gu id e Warning The following servicing instructions are for use by qualified service personnel only.
Page 3 Sun Microsystems, Incorporated.Other marks are trademarks or registered trademarks of the companies with which they are associated. All trademarks noted herein are either the property of Xerox Corporation, Pantone, Inc., or their respective companies. © Pantone, Inc., 1988.
Page 4: 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 5 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 6: Table Of Contents
Contents General Information The Phaser 2135 Color Printer Printer RAM and printer capabilities CRC 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 size sensing Specifications Regulatory specifications...
Page 7 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 imaging drum installed Imaging drum up/down error Fan error Fuser unit error Other problems...
Page 8 Service Tests and Adjustments Starting the diagnostics mode Switch scan 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 9 Electronic boards System controller board RAM DIMMs Hard drive 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 Paper-size sensing board Main feeder assembly Paper tray lift motor Multi-sheet bypass feeder components...
Page 10 Drive assembly components Main motor assembly Imaging drum motor Fuser motor and transfer belt drive motor assembly Xerographic components Shutter plate Color registration sensor assembly Color registration solenoid LED assembly Drum contact assembly Toner sensor actuators Duplex unit FRU List Using the parts list Test Prints Wiring Diagram...
Page 11 Figures The Phaser 2135 Color Printer with lower tray assembly and lower tray deck 1 Print engine circuit boards 5 Print engine sensor and switch locations 6 Print engine motors, clutches and solenoids 7 Features of the controller board 8 The control panel 9 The printer rear panel 10 Tray switch sensors and actuators 12...
Page 12 Removing the tray 1 entrance sensor actuator 121 Removing the belt entrance sensor actuator 122 Removing the duplex solenoid and the exit solenoid 123 Removing the transfer belt unit 124 Removing the registration clutch 125 Removing the registration motor assembly 126 Removing the registration roller assembly A and drive gear 128 Removing the registration roller assembly B 129 Removing the duplex guide assembly 131...
Page 13 Tables Entering special operating modes 11 Paper size detection 12 Physical dimensions 13 Printer clearances 13 Functional specifications 14 Electrical specifications 15 Environmental specifications 15 Printer fault messages 17 System controller board diagnostic error codes 27 System controller board fatal error codes 28 POWER connector pinout 33 Motor and fuser roller resistances 37 Engine maintenance mode menu 62...
Page 14: General Information
Topics such as printer theory of operation and required service tools are located on the companion Color Printer Service & Support Resources CD-ROM. To ensure a complete understanding of the product, Xerox recommends participation in Phaser 2135 printer service training.
Page 15: The Phaser 2135 Color Printer
The Phaser 2135 Color Printer The Phaser 2135 Color Printer combines a 4-color, LED-based, tandem-design Tabloid 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. The printer support these tray combination: One lower tray assembly Two lower tray assemblies One three-tray lower tray-desk One lower tray assembly and a three-tray lower tray deck...
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 Toner Sensor Board System Controller Board Control Panel Board Engine Controller Board Low Voltage Power Supply Board Paper Size Sensor Board High Voltage Power Supply Board Entrance Sensor Board 0725-64 Print engine circuit boards Service Guide...
Page 19: Print Engine Sensor And Switch Locations
Cyan Toner Cartridge Sensor Magenta Toner Cartridge Sensor Face-up Tray Open Sensor Yellow Toner Cartridge Sensor Black Toner Cartridge Sensor Stack Full Sensor MBF Home Position Exit Sensor Sensor MBFTransparency Color Registration Sensor Sensor Assembly MPT Empty Sensor Temperature/ Humidity Sensor Board Top Door Open Switch...
Page 20: Print Engine Motors, Clutches And Solenoids
Transfer Belt Drive Motor Duplex Solenoid Fuser Motor Registration Motor Exit Solenoid Registration Clutch Color Registration Shutter Solenoid Paper Feed Motor Tray Lift Motor Cyan Imaging Drum Motor Magenta Imaging Drum Motor Yellow Imaging Drum Motor 0725-62 Black Imaging Drum Motor Print engine motors, clutches and solenoids Service Guide...
Page 21: The Image Processor Board
The image processor board ROM DIMM SDRAM Hard drive Fan cooled processor 0728-05 Features of the controller board Phaser 2135 Color Printer...
Page 22: 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 23: 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. LEDs Ethernet port Parallel port 0728-03 The printer rear panel The LED LNK is off when the printer is not installed on an Ethernet network, it blinks while data is transmitted to the host.
Page 24: 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 25: Paper Tray Size Sensing
Paper tray size sensing The position of a multi-slotted plate, at the rear of the paper tray, is set according to the position of the tray’s paper guides. Upon insertion of the tray in the printer, the plate’s four rows of slots activate four switches. The combinations of the slot positions indicate the size of the paper in the tray.
Page 26: Specifications
Speciﬁcations Physical dimensions Dimensions Speciﬁcation Height: 46.0 cm (18.1 in.) Each additional lower tray adds 12.7 cm (5 ins.) The lower tray deck adds 48 cm (19 ins.) Width: 66.6 cm (26.2 in.) Depth: 62.6.0 cm (24.6 in.) Weight: About 72 kgs (158 lbs.) Each additional lower tray adds 16.8 kgs (37 lbs.).
Page 27: Functional Specifications
, Statement, Multi-sheet Bypass Feeder paper weight: 16 lb. to 54 lb. (60g/m to 203 g/m Only Xerox-brand Phaser 35-series A- and A4-size transparency ﬁlm is supported. Automatic two-sided printing: 75 to 120 g/m (20 to 32 lb.) A6 paper, transparency ﬁlm, heavy card stock, and glossy paper are...
Page 28 Functional speciﬁcations Characteristic Speciﬁcation Paper tray capacity Tray 1: 550 sheets of 20 lb. paper, 250 standard transparencies, 200 premium transparencies. Tray 2 and Tray 5: 550 sheets of paper. Multi-sheet Bypass Feeder: single sheet to 100 sheets of standard paper.
Page 29: Regulatory Specifications
Environmental speciﬁcations Characteristic Speciﬁcation Altitude Operating 0 to 2500 m (8,000 ft.) at 25 Non-operating 0 to 6000 m (20,000 ft.) Vibration/shock Operating May drop any side or corner 50 mm (2 in.) without impairment of subsequent operation. Non-Operating (vibration) On ﬁve mutually perpendicular axes: 0.5 g, 25-minute sweep, 5 to 200 to 5 Hz, 100 to 200 sec./sweep cycle.
Page 30: 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. Except for media jams and other such errors, when an error code ﬁrst occurs, cycle power on the printer to see if the error re-occurs.
Page 31 Printer fault messages Code Front panel message Service message Jam Inside Top Cover, Open Cover, 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 32 Printer fault messages Code Front panel message Service message Jam Inside Right Door A, Open Right Door A 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 33 Printer fault messages Code Front panel message Service message Close Duplex Unit, Duplex Unit Not Detected E14-Duplex Unit Not Detected 1. Ensure the duplexer is installed correctly. 2. Inspect the connector at the rear end of the duplexer unit. 3. Inspect the wiring harness leading from the duplexer unit interface connector to the engine controller board.
Page 34 Printer fault messages Code Front panel message Service message Transfer Belt Missing, Reseat Belt EE-Transfer Belt Unit Missing 1. Remove and re-install the transfer belt unit. 2. Clean the transfer belt unit’s contact on the front-left side of the engine chassis.
Page 35 Printer fault messages Code Front panel message Service message Replace Yellow Imaging Drum J5-Replace Yellow Imaging Drum Replace Magenta Imaging Drum J6-Replace Magenta Imaging Drum Replace Cyan Imaging Drum J7-Replace Cyan Imaging Drum Replace Black Imaging Drum J8-Replace Black Imaging Drum 1.
Page 36 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 37 Printer fault messages Code Front panel message Service message Engine ROM Error U0, Power Off/On U0-Engine ROM Error Engine RAM Error U1, Power Off/On U1-Engine RAM Error Engine EPROM Error U2, Power Off/On U2-Engine EPROM Error Engine EPROM Missing U3, Power Off/On U3-Engine EPROM Missing Engine SRAM Error U4, Power, Off/On U4-Engine SRAM Error...
Page 38 Printer fault messages Code Front panel message Service message Duplex I/F Error U12, Power Off/On U12-Duplex I/F Error 1. Turn the printer off and on. 2. Pull out the duplexer and inspect its connector at the right front corner (the connector faces rearward).
Page 39 Printer fault messages Code Front panel message Service message Magenta Drum Error U27, Power Off/On U27-Magenta Drum Error Cyan Drum Error U28, Power Off/On U28-Cyan Drum Error Black Drum Error U29 Power Off/On U29-Black Drum Error 1. Remove and install the drum unit. 2.
Page 40: System Controller Board Diagnostic Error Codes
System controller board diagnostic error codes Code Test Possible Cause Memory Bad memory DIMMs Memory Speed Bad DIMMs or system controller board CPU Tick Bad system controller board System Timer Bad system controller board BX Host Bridge Bad system controller board PIIX4 PCI-ISA Bridge Bad system controller board 21152 PCI-ISA Bridge...
Page 41: System Controller Board Fatal Error Codes
These are error codes returned by the system controller board. In the event that one of these errors occurs: Cycle printer power to see if the error reoccurs. Reseat the system controller board. Replace the system controller board. These errors can also be caused by the board’s hard drive or the RAM DIMMs. System controller board fatal error codes Code Description Unknown.
Page 42: 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 43: 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. RAM check.
Page 44: 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 controller board 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 45: 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 46: Power Connector Pinout
Power supply fans: With the power switch on, are the front and rear power supply fans running? (Access the fans by removing the front and rear covers.) If not, check the fans’ wiring harnesses (CN2 and CN5) to the low-voltage power supply board; each fan’s voltage should measure 32 to 38VDC (the voltage drops to zero when you disconnect a fan).
Page 47: 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 15 A fuse. Turn off the printer. Disconnect the power cord from the printer. Remove the front cover as described in “Front cover” on page 90. Remove the AC power switch (1 screw) and the front power supply fan as described in “Front power supply fan”...
Page 48: Ensuring The +5 Vdc Loop Is Complete
Top Cover Open Switch Front Cover Open Switch 0725-63 Door safety interlock switches Ensuring the +5 VDC loop is complete The +5 voltage from low-voltage power supply is routed out of the power supply connector CN1, via a wiring harness, to the POWER connector the engine controller board, through surface-mount fuse F6, out the engine controller board via the ribbon cable OPTN to the toner sensor board.
Page 49: Testing For A Shorted Motor
Disconnect the POWER wiring harness (red wire bundle) from the engine controller board. Also, disconnect the power wiring harness interconnect connecting the toner sensor board’s white wire harness to the low-voltage power supply board’s dark-gray wire harness. The interconnect is located by the rear hinge.
Page 50: 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 51: 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 be used from Tray 1 or from the multi-sheet bypass feeder.
Page 52: 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? Clean it with a clean, dry, lint-free cloth if debris is visible. 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 53: 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 54: 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 35-series transparency ﬁlm meant for this printer. Paper jams at the transfer belt Check for a paper scrap in the paper path.
Page 55: Fuser Jams
Fuser jams Is the paper in good condition and appropriate for a laser printer? Is Xerox Series-35 transparency ﬁlm being used. Is the printer printing within its environmental speciﬁcations? Print the Diagnostic Summary Page to determine the printer’s environmental conditions.
Page 56: Jams In The Duplex Unit
Jams in the duplex unit Is the duplex unit correctly installed? Clean the rollers inside the duplex unit with a clean, dry, lint-free wipe if debris is visible. Inspect the duplex unit for foreign objects such as a scrap of paper. Inspect the duplex unit’s electrical connector for damage.
Page 57: Fan Error
Fan error Is power supplied to pin 1 of the fan? If yes, replace the fan. Inspect the fan’s wiring harness for damage. Replace the low-voltage power supply Replace the engine controller board. Fuser unit error Does the error occur immediately after the printer is turned on? Replace the fuser.
Page 58: 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 59: Right-Side Door Indicated Being Open When It Is Closed
Right-side door indicated being open when it is closed Inspect that the front door’s interlock for damage. Check the interlock switch for +32 V. Replace the switch if necessary. Check its wiring harness. Replace the engine controller board. Replace the power supply if +32 volts is not present. High temperature error Check the fans for proper operation.
Page 60: 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 61: 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 any unit which was. Examine the fuser rollers for contamination. Replace the fuser if they are. Ensure the media type is correctly set.
Page 62: 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 63: Black Stripe In Direction Of Paper Travel
Black stripe in direction of paper travel Note A-size prints are normally Leading Edge processed through the printer with the short edge of the print parallel to the direction of the paper path making print artifacts parallel to the short edge of the print.
Page 64: White Stripe In Direction Of Paper Travel
White stripe in direction of paper travel Note A-size prints are normally Leading Edge processed through the printer with the short edge of the print parallel to the direction of the paper path making print artifacts parallel to the short edge of the print.
Page 65: 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 66: 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 67: Missing Characters Or Voids In Print
Missing characters or voids in print Look for dirt or contamination on the LED heads. Clean them with a clean, alcohol-soaked, lint-free 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...
Page 68: Color Misalignments
Color misalignments Test the registration sensor as described in the topic “Switch scan test” on page 63. Ensure the registration sensors are clean without toner dust on them. Also test the registration solenoid, as described in the topic “Motor and clutch tests” on page 69, to ensure the registration shutter operates smoothly and closes complely,...
Page 69: 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 a clean, alcohol-soaked, lint-free wipe. If it appears that a single primary color is missing, check that imaging drum’s toner cartridge to see if it is empty;...
Page 70: 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 71: 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 72: 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 Starting the 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: Consumable Status
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 Face-down paper eject sensor Paper eject roller Face-down sensor Stacker full sensor Entrance belt sensor C drum M drum Y drum K drum Heat roller MT feed roller Pinch roller 2 Paper eject sensor Driving roller Pinch roller 1 Driving roller Carrier belt Registration roller A Backup roller...
Page 78 Switch scans and the sensor and switches test Switch or sensor Switch scan test Test result Details Yellow Toner Switch Scan 02 L - Deactuated Open top cover and pull down the Cartridge Present H - Unit installed sensor ﬂag next to rear of the LED head. Top Cover Switch Switch Scan 03 L - Top closed...
Page 79: Switch Scans And The Sensor And Switches Test
Switch scans and the sensor and switches test Switch or sensor Switch scan test Test result Details Lower Fuser Switch Scan 09 Encoded fuser Temperature is encoded as a Thermistor - 00F roller temperature hexidecimal value. The default is between 001 and0 D4. not used Switch Scan 09 not used...
Page 80 Switch scans and the sensor and switches test Switch or sensor Switch scan test Test result Details Tray 3, Size 1 Switch Scan 15 L - Actuated Remove the tray and actuate the sensor Switch - (Top) H - Deactuated ﬂags at the rear of the tray cavity Tray 3, Size 2 Switch Scan 15...
Page 81 Switch scans and the sensor and switches test Switch or sensor Switch scan test Test result Details Tray 5, Size 1 Switch Scan 21 L - Actuated Remove the tray and actuate the sensor Switch - (Top) H - Deactuated ﬂags at the rear of the tray cavity Tray 5, Size 2 Switch Scan 21...
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 BLACK-ID MOTOR REMOVE ID Run test with the drum units removed. Observe the imaging drum drive gear rotate YELLOW-ID MOTOR REMOVE ID Run test with the drum units removed.
Page 84 Motor and clutch test constraints Constraints Motor or clutch displayed displayed on on control panel control panel Details TRAY 3 MOTOR EXIT TRAY3 Run the test with Tray 3 removed. (FEED MOTOR) CASSETTE Observe the pick roller rotate as the motor runs TRAY 4 MOTOR EXIT TRAY4...
Page 85: 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 86 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) : Environmental humidity measurement (in units of%).
Page 87: 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 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
Adjusting color density and balance Over the life of the printer, colors may change. For example, reds may begin to take on a purple cast, or blues may take on a green cast. This happens during the normal use of a color printer and can be easily remedied by using the color adjustment procedure described in this section This front panel procedure involves printing a test page and adjusting the densities and colors based on the appearance of the test page.
Page 91: What To Look For
What to look for There are three things to look for in examining the test print. The correct Black Density is determined by selecting the image in which the foreground and background grays most closely match. The correct Color Balance is determined by matching the “Current” disk in the center with the gray background.
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 Warning Recommended Adjustment after Condition condition for replacement replacement Toner Cartridge...
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: Cabinet Panels
Cabinet panels Top cover Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridges. Place them in a lightproof black bag to protect the drum units from light and store in a safe place.
Page 102: Rear Cover
Rear cover Warning Switch off the power and disconnect the power cord. Remove the system controller board as explained in “System controller board” on page 105. Open the top cover. Remove the drum/toner cartridges. Place them in a lightproof black bag to protect the drum units from light and store in a safe place.
Page 103: Front Cover
Front cover Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridges. Place them in a lightproof black bag to protect the drum units from light and store in a safe place. Remove the duplex unit/paper tray.
Page 104: Left-Side Cover
Left-side cover Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridges. Place them in a lightproof black bag to protect the drum units from light and store in a safe place. Remove the front cover as described in “Front cover”...
Page 105: Face-Up Tray
Face-up tray Open the face-up tray out 25 mm (1 in.). Free the end of the tray links from the sides of the face-up tray. To free the trays links from the printer cabinet, rotate them up so they are parallel with the cabinet face. Remove the keyed ends of the links from the left cabinet cover.
Page 106: Right Door
Right door Open the right door. Remove the screw securing the door’s link strap to the printer frame. Carefully push the door rearward so the door’s front pivot point clears it pin. Once the pin is cleared, remove the door from the printer. Link Right Cover 0725-76...
Page 107: Frame Components
Frame components Electrical card cage cooling fan Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridges. Place them in a lightproof black bag to protect the drum units from light and store in a safe place.
Page 108: Front Power Supply Fan
Front power supply fan Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridges. Place them in a lightproof black bag to protect the drum units from light and store in a safe place.
Page 109: Rear Power Supply Fan
Rear power supply fan Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridges. Place them in a lightproof black bag to protect the drum units from light and store in a safe place.
Page 110: Rear Shield Plate
Rear shield plate Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridges. Place them in a lightproof black bag to protect the drum units from light and store in a safe place. Remove the rear cover as explained in “Rear cover”...
Page 111: Electrical Card Cage
Electrical card cage Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridges. Place them in a lightproof black bag to protect the drum units from light and store in a safe place. Remove the system controller board as shown on page 105.
Page 112: Removing The Electrical Card Cage
Guide the bottom harnesses as you carefully remove the electrical card cage. Remove Screws Top Shield Plate Electrical Card Cage Electrical Chassis Cooling Fan air direction Rear Shield Plate 0725-15 Removing the electrical card cage Reverse these steps to install the electrical card cage. Note Attached to the back of the electrical card cage is a grounding tab.
Page 113: Printer Unit Chassis
Printer unit chassis Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridges. Place them in a lightproof black bag to protect the drum units from light and store in a safe place. Remove the front cover as described in “Front cover”...
Page 114: Removing The Printer Unit Chassis
Remove the rear shield plate and the front shield plate. Remove the duplex unit/tray 1 to access the front shield plates lower screws. Free the wiring harnesses attached to the rear power supply fan duct. Then remove the rear fan and duct as described“Rear power supply fan”...
Page 115: Top Cover Inner Frame And Front/Rear Top Cover Spring Assembly
Top cover inner frame and front/rear top cover spring assembly Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridges. Place them in a lightproof black bag to protect the drum units from light and store in a safe place.
Page 116: Removing The Top Shield Plate
Caution Do not set the top cover inner frame face down as the LED assemblies or the LED mounting brackets can be damaged. Top Cover Inner Frame Rear Top Cover Remove Hinge Springs Screws Inner Shaft Front Top Cover Hinge Springs Rear Top Cover Damper Remove...
Page 117: Front Plate Assembly
Front plate assembly Warning Switch off the power and disconnect the power cord. Remove printer unit chassis as shown on page 100. Remove the two screws from the front power supply fan. Let the fan rest on the front of the lower plate. Disconnect the chassis fan from the front of the low-voltage power supply.
Page 118: 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 board. Remove the two screws securing the system controller board to the printer. Slide the system controller board out to the rear of the printer. 0725-23 Removing the system controller board Reverse these steps to install the system controller board.
Page 119: Ram Dimms
RAM DIMMs Warning Switch off the power and disconnect the power cord. Remove the system controller board as described in the procedure “System controller board” on page 105. Spread apart the latches securing each end of the RAM DIMM connector. Lift the DIMM out of the connector.
Page 120: Hard Drive
Hard drive Warning Switch off the power and disconnect the power cord. Remove the system controller board as described in the procedure “System controller board” on page 105. Remove the four screws securing the hard drive to the board. Slide the slightly to disconnect the hard drive from its connector and free it from the system controller board.
Page 121: 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 cartridges. Place them in a lightproof black bag to protect the drum units from light and store in a safe place.
Page 122: 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 88. From the underside of the top cover inner frame, disconnect the four LED power harnesses from the toner sensor board. Close the top cover inner unit.
Page 123: Removing The Toner Sensor Board
Remove the board. Remove Screws Disconnect Wiring Harness Toner Sensor Board 0725-25 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 124: 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 119. Remove the printer unit chassis as detailed on page 100. Turning the printer unit chassis upside-down, remove registration roller assembly B as shown on page 129.
Page 125: 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” on page 100. Disconnect CN1 from the high voltage power supply. Disconnect CN3 from the low voltage power supply. Remove the three screws securing the high voltage power supply to the chassis.
Page 126: Removing The High Voltage Power Supply
Remove the contact assembly from the high voltage power supply. Remove Screws High Voltage Power Supply 0725-27 Removing the high voltage power supply Reverse these steps to install the high voltage power supply. Ensure the plastic insulator plate is positioned correctly under the power supply. Service Guide...
Page 127: 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 100. Disconnect CN1, CN2, CN3, CN5 and CN9 from the low voltage power supply. Disconnect the AC power switch wiring harness interconnect. Remove the eight screws securing the low voltage power supply to the printer.
Page 128: 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 88. 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 129: 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 rollers. Slide the feed rollers to the left and remove. Note the clutch on the shaft behind the upper roller.
Page 130: Paper-Size Sensing Board
Paper-size sensing board Warning Switch off the power and disconnect the power cord. Remove paper tray 1. Reaching in through the cavity left by paper tray 1, disconnect the ribbon cable attached to the paper size sensing board. Again reaching in through the cavity left by paper tray 1, remove the four screws securing the paper-size sensing board.
Page 131: Main Feeder Assembly
Main feeder assembly Warning Switch off the power and disconnect the power cord. Remove the front cover as described on page 90. Also remove the right-front cover. Remove the rear cover as described on page 89. Remove the rear shield plate as described on page 97. Disconnect the seven wiring harnesses leading to the main feeder assembly.
Page 132: 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 cartridges. Place them in a lightproof black bag to protect the drum units from light and store in a safe place.
Page 133: Removing The Multi-Sheet Bypass Feeder
Remove Screws Multi-sheet Bypass Feeder Top Cover Multi-sheet Bypass Feeder MBF Feed Sensor Link Link Transparency Sensor Drive Gear MBF Empty Sensor Spread Locking Tabs to Free Gear Link Joint Multi-sheet Bypass Feeder Tray Joint 0725-32 Removing the multi-sheet bypass feeder Reverse these steps to install the multi-sheet bypass feeder.
Page 134: 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 100. Turn the printer unit chassis upside-down and then carefully squeeze the actuator’s two locking tabs and remove the sensor.
Page 135: Belt Entrance And Multi-Sheet Bypass Feed Sensor Actuators
Belt entrance and multi-sheet bypass feed sensor actuators Warning Switch off the power and disconnect the power cord. Remove the printer unit chassis described in the topic “Printer unit chassis” on page 100. Remove the Tray 1 entrance sensor actuator as described in the topic “Tray 1 entrance sensor actuator”...
Page 136: Duplex Solenoid And Exit Solenoid
Duplex solenoid and exit solenoid Warning Switch off the power and disconnect the power cord. Remove the front cover as described in “Front cover” on page 90. Remove the front shield plate. Free the front power supply fan. Disconnect the wiring harness of the solenoid you wish to remove. Remove the two screws securing the solenoid you wish to remove.
Page 137: Transfer Belt Unit
Transfer belt unit Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum unit caddy. Cover the drum units and store in a safe place. Push the transfer belt unit locking tabs toward the left side of the printer to release the unit.
Page 138: Registration Components
Registration components Registration clutch Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridges. Place them in a lightproof black bag to protect the drum units from light and store in a safe place.
Page 139: Registration Motor Assembly
Registration motor assembly Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridges. Place them in a lightproof black bag to protect the drum units from light and store in a safe place. Open the front cover.
Page 140: 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 cartridges. Place them in a lightproof black bag to protect the drum units from light and store in a safe place.
Page 141: 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. Remove E-Ring Remove Screws Registration Roller Assembly A Drive Gear 0725-38 Removing the registration roller assembly A and drive gear Reverse these steps to install the registration roller assembly A and drive gear.
Page 142: Registration Roller Assembly B
Registration roller assembly B Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridges. Place them in a lightproof black bag to protect the drum units from light and store in a safe place.
Page 143: Exit Assembly And Fuser Components
Exit assembly and fuser components 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.
Page 144: Removing The Duplex Guide Assembly
Carefully lift the duplex guide assembly to free it from the printer. Duplex Guide Assembly Spring Spring Printer Unit 0725-40 Removing the duplex guide assembly Service Guide...
Page 145: Fuser Latching Handle (Front)
Fuser latching handle (front) Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridges. Place them in a lightproof black bag to protect the drum units from light and store in a safe place.
Page 146: Fuser Latching Handle (Left)
Remove the left fuser latching handle. Fuser Latching Handle Fuser Latching Handle Spring Remove Screw 0725-41 Fuser latching handle (left) Reverse these steps to install the fuser latching handle (left). Service Guide...
Page 147: Fuser Latching Handle (Rear)
Fuser latching handle (rear) Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridges. Place them in a lightproof black bag to protect the drum units from light and store in a safe place.
Page 148: Fuser Exit Roller
Fuser exit roller Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridges. Place them in a lightproof black bag to protect the drum units from light and store in a safe place. Remove the front cover as detailed in the topic “Front cover”...
Page 149: Removing The Fuser Exit Roller
Slide the fuser exit roller to the rear until the front end of the staff is free. Fuser Eject Roller Bearing Fuser Eject Roller Fuser Drive Gear Assembly Fuser Drive Gear 0725-43 Roller Contact Removing the fuser exit roller Reverse these steps to install the fuser exit roller. Phaser 2135 Color Printer...
Page 150: Exit Sensor Assembly
Exit sensor assembly Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridges. Place them in a lightproof black bag to protect the drum units from light and store in a safe place. Remove the fuser exit roller as detailed on page 135.
Page 151: Eject Guide Assembly
Eject guide assembly Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridges. Place them in a lightproof black bag to protect the drum units from light and store in a safe place. Remove the top cover inner frame as detailed in “Top cover inner frame and front/rear top cover spring assembly”...
Page 152: Stack Full Sensor
Stack full sensor Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridges. Place them in a lightproof black bag to protect the drum units from light and store in a safe place. Remove the top cover.
Page 153: Removing The Stack Full Sensor
Remove the stack full sensor. Stack Full Sensor Stack Full Sensor Assembly 0725-46 Removing the stack full sensor Reverse these steps to install the stack full sensor. Phaser 2135 Color Printer...
Page 154: Drive Assembly Components
Drive assembly components Main motor assembly Note Switch off the power and disconnect the power cord. Remove the electrical card cage as detailed in “Electrical card cage” on page 98. Remove the printer unit chassis as detailed on page 100. Disconnect each wiring harnesses from the four imaging drum motors.
Page 155: Imaging Drum Motor
Remove Screws Disconnect Main Motor Assembly wiring harnesses at motors 0725-47 Removing the main motor assembly Imaging drum motor Remove the two screws securing the motor to the main motor assembly. Reverse these steps to install the main motor assembly. Phaser 2135 Color Printer...
Page 156: Fuser Motor And Transfer Belt Drive Motor Assembly
Fuser motor and transfer belt drive motor assembly Warning Switch off the power and disconnect the power cord. Remove the print unit chassis as detailed in “Printer unit chassis” on page 100. Remove the rear fuser latching handle as described in “Fuser latching handle (rear)”...
Page 157: Xerographic Components
Xerographic components Shutter plate Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridges. Place them in a lightproof black bag to protect the drum units from light and store in a safe place.
Page 158: Color Registration Sensor Assembly
Color registration sensor assembly Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridges. Place them in a lightproof black bag to protect the drum units from light and store in a safe place.
Page 159: 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 100. Remove the shutter plate as explained on page 144. 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 160: Led Assembly
LED assembly Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridges. Place them in a lightproof black bag to protect the drum units from light and store in a safe place. Carefully disconnect the ﬂat data harnesses 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 161: Drum Contact Assembly
Drum contact assembly Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridges. Place them in a lightproof black bag to protect the drum units from light and store in a safe place. Use a small screwdriver to carefully pry the drum contact assembly from the printer chassis.
Page 162: Toner Sensor Actuators
Toner sensor actuators Warning Switch off the power and disconnect the power cord. Open the top cover. Remove the drum/toner cartridges. Place them in a lightproof black bag to protect the drum units from light and store in a safe place. Disconnect the four LED power harnesses from the bottom of the toner sensor board.
Page 163: Removing The Toner Sensor Actuators
Remove the sensor actuator. Remove Screws Disconnect Wiring Harness Toner Sensor Actuators 0725-54 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 2135 Color Printer...
Page 164: Duplex Unit
Duplex unit Warning Switch off the power and disconnect the power cord. Note The duplex unit and Tray 1 are interlocked. The duplex unit cannot be removed without the paper tray. Open the duplex unit release cover. Pull the duplex unit release handle and pull out the duplex tray and Tray 1 together until they stop.
Page 166: 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 167 Table 1 FRU parts list of the printer cabinet and top cover Fig 1 Part Name and description parts number 116-0998-00 Top Cover/Face Down Stack Bin 116-1083-00 Side Output Tray/Face Up Stack Tray 116-1061-00 Side Output Tray Link 116-1052-00 Top Cover Hinge Spring - Rear 116-1053-00 Top Cover Hinge Shaft 116-1051-00 Top Cover Hinge Spring - Front 116-1006-00 Left Side Cover...
Page 168: Cabinet And Top Cover Frus
0725-01 Figure 1 Cabinet and top cover FRUs Service Guide...
Page 169: Fru Part List Of The Top Cover Inner Frame
Table 2 FRU part list of the top cover inner frame Fig 2 Part Name and description parts number Exit/Stack Full Sensor Actuator (part of 116-1036-00 Flag Kit) 116-1000-00 Exit/Stack Full Sensor 116-1054-00 Top Output (Face-down) Eject Sensor Assembly 116-1082-00 Control Panel Bezel 116-1003-00 Control Panel Assembly Control Panel Tape Harness (part of 116-1035-00 Harness Kit) Idler Rollers/Face Up Side Tray (part of 116-1038-00 Hardware Kit)
Page 170: Top Cover Frus
0725-02 Figure 2 Top cover FRUs Service Guide...
Page 171: 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 116-1022-00 Fuser Exit Roller 116-1019-00 Duplex Guide Assembly Fuser Latch Handle Spring (part of 116-1038-00 Hardware Kit) 003E55690 Fuser Latching Handle (Front) 130K65670 Fuser Exit Sensor Assembly 116-1021-00 Top/Side Output Solenoid Assembly...
Page 172: Printer Chassis Frus (1 Of 2)
0725-03 Figure 3 Printer chassis FRUs (1 of 2) Service Guide...
Page 173 Table 4 FRU of the printer chassis (2 of 2) Fig 4 Part Name and description parts number 003E55700 Fuser Latching Handle (Rear) 116-1011-00 Transfer Belt Motor Assembly 116-1026-00 Low Voltage Power Supply (115 VAC) 116-1027-00 Low Voltage Power Supply (220 VAC) 116-1029-00 Front Plate Assembly 116-1034-00 Low Voltage Power Supply Insulator 116-1067-00 Duplex Exit Paper Guide...
Page 174: Printer Chassis Frus (2 Of 2)
0725-04 Figure 4 Printer chassis FRUs (2 of 2) Service Guide...
Page 175 Table 5 FRU of the paper tray and paper tray guides Fig 5 Part Name and description parts number 116-1009-00 Universal Paper Tray 116-1085-00 Connector with Harness 116-1065-00 Right Cover Interlock Switch 116-1086-00 Main Feeder Assembly 116-1062-00 Paper Feed Roller 116-1010-00 Media Plate Lift Motor 116-1007-00 Paper Size Sensing Board (includes Ribbon Harness) 41402901...
Page 176: Paper Tray And Paper Tray Guides Frus
0725-05 Figure 5 Paper tray and paper tray guides FRUs Service Guide...
Page 177: Electrical Components Frus
Table 6 Electrical components FRUs Fig 8 Part Name and description parts number 116-1050-00 Electrical Card Cage 116-1023-00 Electrical Chassis Cooling Fan 537E61970 CRU EEPROM 816A2323M000 116-1031-00 Engine Controller Board 671-5269-00 System Controller Board (EFI Controller), Image Processor 156-4811-10 64-Mbyte RAM DIMM 156-4780-10 128-Mbyte RAM DIMM 156-4839-00...
Page 178: Duplexer Unit
Table 7 FRUs of the duplexer unit Fig 9 Part Name and description parts number 116-1088-00 Duplex Transport Assembly 0725-06 Figure 7 Duplexer unit Service Guide...
Page 179 Table 8 FRUs of the Lower Tray Assembly Fig 10 Part Name and description parts number 119-6376-00 Lower Tray Assembly (with tray) 119-6377-00 Lower Tray Deck (with trays) 116-1045-00 Lower Tray Assembly Left Cover 116-1043-00 Lower Tray Assembly Front Right Cover 116-1009-00 Lower Tray Assembly Universal Tray 116-1013-00 Castor Wheel 116-1046-00 Lower Tray Assembly Right Side Cover (Door)
Page 180: Lower Tray Assembly Frus
0725-07 Figure 8 Lower Tray Assembly FRUs Service Guide...
Page 181: Hardware Kit
Table 9 Hardware kit Part Name and description number 116-1038-00 Hardware Kit LED Assembly Spring Kit Fuser Exit Roller Bushing (Front) Fuser Exit Roller Bushing (Back) Registration Shutter Spring Fuser Latch Handle Springs Screw (T3x8) Screw (T3x10) Screw (T4x10) Screw (M2x8) Screw (M3x6) Screw (M3x8) Screw (M4x8)
Page 182: Harness Kit
Table 11 Harness kit Part Name and description number 116-1035-00 Harness Kit LED Harness M LED Harness C LED Harness Y LED Harness K 26 pin LED connector Control Panel Tape Harness High Voltage Tape Harness For Heat Motor, Belt Motor For MBF paper End sensor, Near End sensor, OHP sensor For 1stPaperEnd sensor, Near end sensor, 2nd Interface, Temp/Humidity sensor...
Page 183 Table 12 Sensor ﬂag kit Part Name and description number 116-1036-00 Flag Kit Stack Full Flag Toner Sensor Actuator (qty of 4) Intermediate Exit Flag B Reg Entrance Sensor Flag A Reg Entrance Sensor Flag A Reg Exit Sensor Flag Tray 1 Media Low Flag Tray 1 Media Out Flag Table 13 Customer supplies and accessories...
Page 184 Table 13 Customer supplies and accessories Part Name and description number 003-1633-00 PLCC IC removal tool 161-0310-00 Power cord, US, shielded 161-0066-09 Power cord, 220V Euro 161-0066-10 Power cord, U.K. 161-0066-11 Power cord, Australian 161-0154-00 Power cord, Swiss 161-0240-00 Power cord, Danish 006-7998-00 Conductive grease, silicon 065-0598-00 Shipping box, replacement kit 004-5127-00 Shipping Carton...
Page 186: 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 187 Interpreting the Print Diagnostic Print Quality prints The print produces ﬁve pages, one page of each primary color and one page with 4 primary color ﬁlls. Look for: Consistent ﬁlls in each primary color. Each color should be consistent across the width of the page with no voids.
Page 188 Interpreting the Color Balance and Density Adjustment Page. You use this print to assess and adjust color balance, color density and black density. Use the 30% halftones to judge the current level and decide on a preference. Look for: The Color Density and Black Density should be at approximately the same level.
Page 189 Interpreting the Blank Print (with crosshatch) Each print consists of a blank page with a single primary-colored crosshatch printed near the top of the page. Use these pages to identify color on non-printed areas of a print as well as residual offsetting. 0728-20 Interpreting the Step Test Patterns The Step Test Patterns consist of 11 color...
Page 190: Wiring Diagram
Wiring Diagram connected to trays of up to 5th, Flex cable Large-Capacity Tray including 2nd tray Sensor/Microswitch Paper Width Paper Empty Sensing Board Yellow LTD/LTA Paper Near Empty Carrier Sensor Connector Y2 Blue New NC2135 Connector FDWPAP Retard Sensor Face-down Stack Full Sensor Blue Board A73 JOBOFFS...
Page 191: Wire Routing At The Engine Controller Board
The wiring receptacles are color-coded with their plugs for correct placement Bundle wires thru EMI coils Tie wraps Wire routing at the engine controller board Phaser 2135 Color Printer...
Page 192: Details Of Wiring Passthru
Route wiring harnesses thru cable clamp Bundle wires thru EMI coils Route wiring harnesses thru cable clamp Details of wiring passthru Service Guide...
Page 193: Wiring Under The Top Shield Plate
Ensure the wiring harnesses are routed inside the wiring shield except the power wiring harness which is routed under the wiring shield Ensure the power harness inter-connect is dressed behind the flat ribbon cables to ensure it does not disconnect when the top cover is closed Make sure wiring is not pinched by the top shield plate when it is installed Wiring under the top shield plate...
Page 194: Wiring Harnesses Route By The Imaging Drum Motors
Route wiring harnesses under the imaging drum motors EMI coils Wiring harnesses route by the imaging drum motors Route wiring harnesses between first and second restraint posts Cable tie the wiring harnesses to the center restraint post Wire routing by the fuser and transfer belt motor unit. Service Guide...
Page 195: Ribbon Cable Routing Under The Toner Sensor Board
Harnesses route through channel around post Note how harness route through slot Ribbon cable routing under the toner sensor board Phaser 2135 Color Printer...
Page 196 NOTES Hexidecimal conversions To convert hexadecimal to decimal use the following information: Hex value Decimal equivalent For example: The hexadecimal value 13FA breaks down into: 1 is 1 3 is 3 F is 15 A is 10 For the For the For the For the 4th column 3rd column...
Page 197 NOTES...
Page 198 NOTES...
Page 199 NOTES...

This manual is also suitable for:

2135dt - phaser color laser printer Tektronix phaser 2135

Xerox 2135DX - Phaser Color Laser Printer Service Manual

General Information

Error Codes and Messages

Troubleshooting

Service Tests and Adjustments

Cleaning and Maintenance

Resetting NVRAM

FRU Disassembly

FRU List

Test Prints

Wiring Diagram

Quick Links

Troubleshooting

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Summary of Contents for Xerox 2135DX - Phaser Color Laser Printer