Xerox 2135N - Phaser Color Laser Printer User manual

Printed on recycled paper

PHASER

2135

COLOR PRINTER

Service Quick Reference Guide

071-0725-00

Warning

The following servicing instructions are for

use by qualified service personnel only. To

avoid personal injury, do not perform any

servicing other than that contained in

operating instructions unless you are qualified

to do so.

This printing: January 2001

071-0725-00

PHASER® 2135

COLOR PRINTER

Service Quick Reference Guide

the United States. Contents of this publication may not be reproduced in any form without

permission of Xerox Corporation.

Phaser

, PhaserShare

, ColorStix

, the TekColor

icon, Made For Each Other

, DocuPrint

WorkSet

, Ethernet

, the stylized X, and XEROX

are registered trademarks of Xerox

Corporation. PhaserLink™, PhaserPort™, PhaserPrint™, PhaserSym™, PhaserTools™,

InfoSMART™, and the TekColor™ name are trademarks of Xerox Corporation. TekColor

Care

and RealSUPPORT

are service marks of Xerox Corporation.

FTP

Software is a registered trademark of FTP Software, Incorporated.

PCL

and HP-GL

are registered trademarks of Hewlett-Packard Corporation.

Novell

and NetWare

are registered trademarks of Novell, Incorporated.

Sun

, Sun Microsystems

, and Sun Microsystems Computer Corporation

are registered

trademarks of Sun Microsystems, Incorporated.Other marks are trademarks or registered

trademarks of the companies with which they are associated.

All trademarks noted herein are either the property of Xerox Corporation, Pantone, Inc., or

their respective companies.

TE/sn

Users safety summary

Terms in

CAUTION Conditions that can result in damage to the product.

manual:

WARNING Conditions that can result in personal injury

or loss of life.

Power source:

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

between the supply conductors or between either supply conductor and ground.

Use only the speciﬁed power cord and connector. For 220 VAC printers, do not

apply more than 260 volts RMS between the supply conductors or between either

supply conductor and ground. Use only the speciﬁed power cord and connector.

Refer to a qualiﬁed service technician for changes to the cord or connector.

Operation of product:

Avoid electric shock by contacting a qualiﬁed service

technician to replace fuses inside the product. Do not operate without the covers

and panels properly installed. Do not operate in an atmosphere of explosive

gases.

Safety instructions:

Read all installation instructions carefully before you plug the

product into a power source.

Terms on

CAUTION A personal injury hazard exists that may not be

product:

apparent. For example, a panel may cover the hazardous area.

Also applies to a hazard to property including the product itself.

DANGER A personal injury hazard exists in the area where

you see the sign.

Care of product:

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

Disconnect the power plug if the power cord or plug is frayed or otherwise

damaged, if you spill anything into the case, if product is exposed to any excess

moisture, if product is dropped or damaged, if you suspect that the product needs

servicing or repair, and whenever you clean the product.

Ground the product:

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

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

properly grounded outlet.

Lifting the printer:

To avoid injury or damage to the printer, use three people to

lift the printer.

Symbols as marked on product:

DANGER high voltage:

Protective ground (earth) terminal:

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

WARNING:

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

controls (and other conductive parts) can cause an electrical shock. Electrical

product may be hazardous if misused.

Service safety summary

For qualiﬁed service personnel only:

Refer also to the preceding Users Safety

Summary.

Do not service alone:

Do not perform internal service or adjustment of this

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

present.

Use care when servicing with power on:

Dangerous voltages may exist at several

points in this product. To avoid personal injury, do not touch exposed

connections and components while power is on.

Disconnect power before removing the power supply shield, soldering, or

replacing components.

Do not wear jewelry:

Remove jewelry prior to servicing. Rings, necklaces, and

other metallic objects could come into contact with dangerous voltages and

currents.

Power source:

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

not apply more than 120 or 250 volts AC RMS (depending on printer model)

between the supply conductors or between either supply conductor and ground.

Aprotective ground connection by way of the grounding conductor in the power

cord is essential for safe operation.

Service Guide

General Information 1

The Phaser 2135 Color Printer 2

Printer RAM and printer capabilities 4

CRC life counter behavior 4

Print engine assemblies 5

The image processor board 8

The control panel 9

On Line LED 9

! Fault 9

Rear panel 10

Accessing special operating modes 11

System controller board LEDs 11

Paper tray size sensing 12

Specifications 13

Regulatory specifications 16

Error Codes and Messages 17

Error messages 17

Troubleshooting 29

Fault History Log 29

Power on self-diagnostic test 30

Print engine troubleshooting 31

Testing the print engine controller board 31

Verifying printer operation by using its self-test print 32

Verifying power supply operation 32

Measuring power supply voltages 32

Inspecting the low-voltage power supply fuse 34

Safety interlocks 34

Ensuring the +5 VDC loop is complete 35

Testing for a shorted motor 36

Motor and fuser roller resistances 37

Media jams and the paper path 38

Media-based problems 38

Media problems 38

Multiple-sheet pick 38

The media skews passing through the paper path 39

The paper tray indicates it is empty when it is not 39

Contents

Phaser 2135 Color Printer

Jams 40

Wrong media 40

Paper jams at the paper tray 40

Manual bypass feeder feed jams 41

Paper jams at the registration rollers 41

Paper jams at the transfer belt 41

Fuser jams 42

Eject jams 42

Jams in the duplex unit 43

No imaging drum installed 43

Imaging drum up/down error 43

Fan error 44

Fuser unit error 44

Other problems 45

The printer continuously displays “Booting” or “Initializing.” 45

False “No toner cartridge installed” message 45

False “No fuser unit installed” message 45

Right-side door indicated being open when it is closed 46

High temperature error 46

Low temperature error 46

Invalid memory DIMM 46

Printing and print quality problems 47

Light or blurred images 47

Dark, stained background 48

Blank print 49

Black stripe in direction of paper travel 50

White stripe in direction of paper travel 51

Poor fusing, toner offsetting 52

Repeating defect or voids on print 53

Missing characters or voids in print 54

Color misalignments 55

Unexpected colors 56

Image is skewed on the paper 57

Image is not centered on the print 57

The print is wrinkled 57

Macintosh printing problems 58

Image never prints 58

Image is rotated 90 degrees 58

Image prints in black-and-white 58

Printer isn’t in the Chooser 59

Windows printing problems 59

Image never prints 59

Service Guide

vii

Service Tests and Adjustments 61

Starting the diagnostics mode 61

Switch scan test 63

Motor and clutch tests 69

Test printing 72

Consumable count initialization 74

Consumable counter display 75

Consumable continuation counter display 76

Adjusting color density and balance 77

Printing a Test Page 77

Interpreting the Color Balance test print 77

What to look for 78

Making adjustments 78

Adjustment recovery 79

Cleaning and Maintenance 81

Service preventive maintenance procedure 81

Recommended tools 82

Periodically replaced parts 82

Cleaning 83

Cleaning the LED bar 83

Cleaning the pickup roller 83

Resetting NVRAM 85

FRU Disassembly 87

About screw colors 87

Cabinet panels 88

Top cover 88

Rear cover 89

Front cover 90

Left-side cover 91

Face-up tray 92

Right door 93

Frame components 94

Electrical card cage cooling fan 94

Front power supply fan 95

Rear power supply fan 96

Rear shield plate 97

Electrical card cage 98

Printer unit chassis 100

Top cover inner frame and front/rear top cover spring assembly 102

Front plate assembly 104

viii

Phaser 2135 Color Printer

Electronic boards 105

System controller board 105

RAM DIMMs 106

Hard drive 107

Print engine controller board 108

Toner sensor board 109

Entrance sensor board 111

High voltage power supply 112

Low voltage power supply 114

Control panel 115

Paper feed components 116

Tray 1 feed roller and nudger roller 116

Paper-size sensing board 117

Main feeder assembly 118

Paper tray lift motor 118

Multi-sheet bypass feeder components 119

Multi-sheet bypass feeder 119

Drive gear 119

Multi-sheet bypass feeder sensors 119

Temperature/humidity sensor board 119

Paper transport components 121

Tray 1 entrance sensor actuator 121

Belt entrance and multi-sheet bypass feed sensor actuators 122

Duplex solenoid and exit solenoid 123

Transfer belt unit 124

Registration components 125

Registration clutch 125

Registration motor assembly 126

Registration roller assembly A and drive gear 127

Registration roller assembly B 129

Exit assembly and fuser components 130

Duplex guide assembly 130

Fuser latching handle (front) 132

Fuser latching handle (rear) 134

Fuser exit roller 135

Exit sensor assembly 137

Eject guide assembly 138

Stack full sensor 139

Service Guide

Drive assembly components 141

Main motor assembly 141

Imaging drum motor 142

Fuser motor and transfer belt drive motor assembly 143

Xerographic components 144

Shutter plate 144

Color registration sensor assembly 145

Color registration solenoid 146

LED assembly 147

Drum contact assembly 148

Toner sensor actuators 149

Duplex unit 151

FRU List 153

Using the parts list 153

Test Prints 173

Wiring Diagram 177

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