Xerox 2135DX - Phaser Color Laser Printer Service Manual Download Page 194

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Service Guide

181

Wiring harnesses route by the imaging drum motors

Wire routing by the fuser and transfer belt motor unit.

Route wiring harnesses under the imaging drum motors

EMI coils

Cable tie the wiring harnesses to the center restraint post

Route wiring harnesses between first and second
restraint posts

Summary of Contents for 2135DX - Phaser Color Laser Printer

Page 1: ...Printed on recycled paper P H A S E R 2 1 3 5 C O L O R P R I N T E R Service Reference Guide 071 0725 00...

Page 2: ...vice 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 P...

Page 3: ...emarks of Xerox Corporation TekColor CareSM and RealSUPPORTSM are service marks of Xerox Corporation FTP Software is a registered trademark of FTP Software Incorporated PCL and HP GL are registered tr...

Page 4: ...xplosive 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...

Page 5: ...nt 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 Disco...

Page 6: ...9 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 Verifyi...

Page 7: ...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...

Page 8: ...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...

Page 9: ...der 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 bypa...

Page 10: ...ansfer 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 Tone...

Page 11: ...g fan 94 Removing the front power supply fan 95 Removing the rear power supply fan 96 Removing the rear shield plate 97 Removing the electrical card cage 99 Disconnecting the registration motor in lin...

Page 12: ...y 142 Removing the fuser motor and transfer belt drive motor assembly 143 Removing the shutter plate 144 Removing the color registration sensor assembly 145 Removing the color registration solenoid 14...

Page 13: ...the sensor and switches test 64 Motor and clutch test constraints 70 Test Print menu 72 Table 1 Initialization items consumables 74 Consumable counter menu items 75 Consumable life cycle counts 76 Per...

Page 14: ...des adjustment procedures and a field replaceable units FRU list Topics such as printer theory of operation and required service tools are located on the companion Color Printer Service Support Resour...

Page 15: ...features and capabilities of the Phaser 2135DT printers but includes 256 MBytes of RAM and a three tray lower tray deck The printer supports the following resolutions 600 x 600 dpi Normal 600 x 1200...

Page 16: ...to a printer without the hard disk option are not printed and are discarded Secure Jobs Secure printing allows the customer to defer printing of a job until a matching password is entered from the co...

Page 17: ...rades less installed RAM for longer image processing time and dual frame buffers for printing one image while processing a second image which gives greater printing throughput The printer features thr...

Page 18: ...ies Print engine circuit boards 0725 64 System Controller Board Toner Sensor Board Engine Controller Board Control Panel Board Low Voltage Power Supply Board High Voltage Power Supply Board Entrance S...

Page 19: ...or Board Cyan Toner Cartridge Sensor Magenta Toner Cartridge Sensor Yellow Toner Cartridge Sensor Black Toner Cartridge Sensor MBF Home Position Sensor MBFTransparency Sensor Top Door Open Switch MPT...

Page 20: ...Feed Motor Cyan Imaging Drum Motor Magenta Imaging Drum Motor Yellow Imaging Drum Motor Black Imaging Drum Motor Registration Motor Registration Clutch Fuser Motor Exit Solenoid Duplex Solenoid Color...

Page 21: ...8 Phaser 2135 Color Printer The image processor board Features of the controller board SDRAM Fan cooled processor Hard drive 0728 05 ROM DIMM...

Page 22: ...ugh the main menu Keys 2 and 6 navigate the sub menus and Keys 3 and 7 scroll sub menu values Key 6 cancels print jobs On Line LED Green in color this LED indicates when the printer is On Line and rea...

Page 23: ...nnector Twisted Pair 10 100baseT Ethernet connector The LED LNK is off when the printer is not installed on an Ethernet network it blinks while data is transmitted to the host The LED SPD is off when...

Page 24: ...r as it contains the ability to format devices and perform a factory reset of all items The control panel displays Ready when completed To exit switch the printer power off then on Menu Up 1 and Menu...

Page 25: ...tions indicate the size of the paper in the tray Paper size detection State of Microswitch Paper Size SW1 top SW2 SW3 SW4 bottom 0 0 0 0 No tray installed 0 0 0 1 B4 0 0 1 0 A4 landscape 0 0 1 1 A3 No...

Page 26: ...158 lbs Each additional lower tray adds 16 8 kgs 37 lbs The lower tray deck weights 57 7 kbs 127 lbs Printer clearances Clearances Specification Top 91 5 cm 36 in Left 30 5 cm 12 in Right 30 5 cm 12...

Page 27: ...cessing time which can vary depending on image complexity Minimum printing margins All sides 5 mm 0 2 in Usable paper Tray A size Letter Legal Executive 7 25 x 10 5 in A4 size metric letter SRA3 12 x...

Page 28: ...e Primary voltage fusing 110 VAC configuration 20 Amp 220 VAC configuration 15 Amp Secondary DC voltages Low Voltage Power Supply High Voltage Power Supply 3 3 VDC CH 900 to 1 4 kV 5 V DB 10 to 400 30...

Page 29: ...22 CISPR 22 Class B EN61000 3 2 EN61000 3 3 VCCI CISPR 22 Class B FCC Class B for 115 VAC equipment pursuant to Sub part J of Part 15 ICES 03 Class B Altitude Operating Non operating 0 to 2500 m 8 000...

Page 30: ...Inside Top Cover Open Cover See Labels A7 Duplex Entry 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 Cl...

Page 31: ...necessary 5 Inspect the wiring for the registration clutch and registration motor 6 Replace the engine controller board B8 Jam Inside Duplex Unit Open Cover See Labels B8 Duplex Jam 1 Ensure the corre...

Page 32: ...r B and Tray 2 E1 Tray 2 Misfeed E3 Tray 3 Misfeed Open Rt Door C and Tray 3 E1 Tray 3 Misfeed E4 Tray 4 Misfeed Open Rt Door D and Tray 4 E1 Tray 4 Misfeed E5 Tray 5 Misfeed Open Rt Door E and Tray 5...

Page 33: ...Right Door E E23 Right Door E Open 1 Ensure the cover s sensor flag operates freely 2 Test the output bin full sensor using the test described in Switch scan test on page 63 3 Inspect the sensor and...

Page 34: ...rror H3 Disk Full Error Press Enter to Clear A hard disk full error occurred that prevented data from being written to the disk H3 Hard Disk Full 1 Turn the printer off and on again 2 Ensure the hard...

Page 35: ...low Toner J9 Yellow Toner Empty J10 Magenta Toner Empty Replace Magenta Toner J10 Magenta Toner Empty J11 Cyan Toner Empty Replace Cyan Toner J11 Cyan Toner Empty J12 Black Toner Empty Replace Black T...

Page 36: ...temperature humidity sensor board 4 Replace the engine controller board T31 Roller Over Temp T31 Power Off On T31 Roller Over Error 1 Inspect the fuser cooling fan Ensure it is running correctly and...

Page 37: ...the test described in Switch scan test on page 63 2 Inspect the sensor and its wiring harness 3 Replace the engine controller board U8 Controller Fan Error U8 Power Off On U8 Controller Fan Error 1 I...

Page 38: ...rror U15 Power Off On U15 Control Panel Error 1 Turn the printer off and then on 2 Reset the printer NVRAM using the procedure Resetting NVRAM on page 85 3 Replace the engine controller board U18 Yell...

Page 39: ...e controller board 6 Replace the print unit chassis W16 Fuse Cut Error W16 Fuse Cut Error For the new Customer Replaceable Consumable imaging drums transfer belt or fuser just installed the printer di...

Page 40: ...9 IX Bad system controller board 10 Parameter Flash R W not implemented 11 Strata Flash R W not implemented 12 Strata Flash Boot Block Integrity Bad system controller board 13 Strata Flash File Syste...

Page 41: ...Status Task 18 Startup Key Press Processing Menus Task 1C Parallel Port Read Buffer Manager 20 Parallel Port Write Buffer Manager 24 NVEE Manager 28 Scheduler 2C Job Log 30 Print File Task 34 Video C...

Page 42: ...t lists particular printer failures or error codes and their possible causes Fault History Log The printer maintains a log file of the last 50 errors that have occurred The most recent error is displa...

Page 43: ...l the engine fans turned on and are checked to ensure they run properly The fuser heaters activate to heat up the heated rollers The print engine checks to see that the imaging drums are installed The...

Page 44: ...page 32 2 Observe that the Ready message is displayed on the front panel If it is not go to the later topic Verifying power supply operation on page 32 3 To ensure the print engine operates correctly...

Page 45: ...to print a test prints The printer should print a test page from the system controller board If the printer prints a test pattern then the print engine controller board and the system controller board...

Page 46: ...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 power supp...

Page 47: ...as described earlier in Ensuring the 5 VDC loop is complete on page 35 Safety interlocks The printer features two safety interlock switches Top door opened switch Right door opened switch When the to...

Page 48: ...t the return of the 5 VDC then the power supply will immediately shut down You may see the CPU fan bump or the engine board LED LED2 flash To troubleshoot the loop 1 Test surface mount fuse F6 for con...

Page 49: ...ble and the toner sensor board Turn the printer on If the jumper connection is correct the low voltage power supply will start and the power supply fans will run This indicates the problem lies with t...

Page 50: ...r Fuser motor Main feed drive motor Between motor Pins 1 and 2 Between motor Pins 3 and 4 The transfer belt motor connects to connector BELTHET pins 5 thru 8 The feed motor connects to connector HOPFF...

Page 51: ...ansparency film for this printer should be used from Tray 1 or from the multi sheet bypass feeder 5 Refer to the media specifications in the table Functional specifications on page 17 Multiple sheet p...

Page 52: ...oting this problem applies to the lower tray assembly as well 1 Does the paper empty flag properly interrupt the paper empty sensor Remove the paper tray and actuate the paper empty flag located to th...

Page 53: ...te for a laser printer 2 Is the printer printing within its environmental specifications Print the Diagnostic Summary Page to determine the printer s environmental conditions 3 Are the pick rollers di...

Page 54: ...er jams at the registration rollers 1 Ensure that the pick up rollers are clean Clean them with a clean dry lint free cloth if debris is visible 2 Check the paper path for burrs or foreign obstruction...

Page 55: ...r board Eject jams 1 Is the paper in good condition and appropriate for a laser printer Is the paper curling 2 Is the printer printing within its environmental specifications Print the Diagnostic Summ...

Page 56: ...at they are not damaged 3 Replace the imaging drum Imaging drum up down error 1 Cycle the printer power to see if the problem clears 2 Ensure that each imaging drum unit is correctly installed and tha...

Page 57: ...e correct temperature by running the service test Switch scan test on page 63 5 If the fuser does not get warm Does AC voltage appear between Pins 1 and 2 of CN 4 1 and CN 4 2 of the fuser connector T...

Page 58: ...ectly a traveling moves around the control panel display If not then your problem is most likely associated with the print engine controller board and you will need to replace it If however you see th...

Page 59: ...er board Low temperature error If the fuser is cold 4 Ensure the fuser unit is properly installed 5 Check the fuser unit s connection and wiring 6 Replace the fuser unit 7 Replace the low voltage powe...

Page 60: ...WER connector pins 1 2 3 4 5 6 7 and 8 on the junction board or at the 16 pin interconnect near the top cover hinge under the top shield plate Inspect the junction board s wiring connectors If the vol...

Page 61: ...each LED head assembly If yes replace the LED head assembly 8 Is 3 8 V supplied to the POWER connector pins 1 2 3 4 5 6 7 and 8 on the junction board or at the 16 pin interconnect near the top cover...

Page 62: ...ver hinge under the top shield plate Inspect the junction board s wiring connectors If the voltage is not OK replace the low voltage power supply 5 If 32 volts supplied to the POWER connector pins 7 8...

Page 63: ...f each LED head assembly If yes replace the LED head assembly 4 Is 3 8 V supplied to the POWER connector pins 1 2 3 4 5 6 7 and 8 on the junction board or at the 16 pin interconnect near the top cover...

Page 64: ...d 4 Is 3 8V red wire supplied to Pin 3 of each LED head assembly If yes replace the LED head assembly 5 Is 3 8 V supplied to the POWER connector pins 1 2 3 4 5 6 7 and 8 on the junction board or at th...

Page 65: ...he maintenance mode fuser test Test printing on page 71 and check the temperature displayed on the controller panel 9 Replace the engine controller board Transfer the old engine controller board s EEP...

Page 66: ...art then the problem is a defect on a fusers heat roller Replace the fuser If the spots are about 113 mm 4 4 in apart then the problem is a defect on a fusers pressure roller Replace the fuser If the...

Page 67: ...s 3 8 V supplied to the POWER connector pins 1 2 3 4 5 6 7 and 8 on the junction board or at the 16 pin interconnect near the top cover hinge under the top shield plate Inspect the junction board s wi...

Page 68: ...assembly the paper feeder assembly and the transfer belt assembly 3 Inspect and clean the imaging drum unit s power terminals Ensure the spring loaded pins travel smoothly up and down 4 Replace any im...

Page 69: ...eated 6 Is 3 8V red wire supplied to Pin 3 of each LED head assembly If yes replace the LED head assembly 7 Is 3 8 V supplied to the POWER connector pins 1 2 3 4 5 6 7 and 8 on the junction board or a...

Page 70: ...laser printer 2 Is the printer printing within its environmental specifications Print the Diagnostic Summary Page to determine the printer s conditions 3 Ensure that paper feed rollers are clean and...

Page 71: ...upport Hotline for further assistance Please have the error page in hand 6 If available try printing to a black and white PostScript Level 2 printer such as an Apple LaserWriter If the file does not p...

Page 72: ...onfiguration Page 6 Verify that the printer is correctly cabled to the network and that the Ethernet cable functions properly 7 Locate and remove and Windows NT shared printers that have captured the...

Page 73: ......

Page 74: ...ess the Menu 1 key to enter the maintenance mode menu 6 Press the Item 2 or 6 keys to scroll through the menu 7 Press the Value 3 key to activate the displayed menu item Press the Value 7 key to disco...

Page 75: ...cted motor or clutch is operated for 10 seconds TEST PRINT Items set for test print Select parameters of print such as paper source and print mode Test start stop Test the print engine s ability to pr...

Page 76: ...N tests The table below list the SCAN test items and which sensors and switches and test by that menu item 4 Pressing the Value 3 key activates the currently displayed switch scan test The SWITCH SCAN...

Page 77: ...nt Toggle sensor flag behind the fuser Remove the fuser if necessary Stack Full Sensor Switch Scan 01 3 L Stack full H No paper Toggle the sensor flag at the exit bin not used Switch Scan 01 4 not use...

Page 78: ...h Scan 06 3 not used Manual Bypass Feeder OHP Sensor Switch Scan 06 4 L Transparency H Paper Manually feed a sheet of paper thru the feeder by rotating the registration roller Transparency film causes...

Page 79: ...printer not used Switch Scan 11 3 not used Duplex Front Sensor Switch Scan 11 4 L Deactuated H Paper present Pull out the duplex unit Lift its cover Place a sheet of paper inside on the sensor flag Cl...

Page 80: ...below the feed rollers not used Switch Scan 17 4 not used Tray 4 Size 1 Switch Top Switch Scan 18 1 L Actuated H Deactuated Remove the tray and actuate the sensor flags at the rear of the tray cavity...

Page 81: ...sensor not used Switch Scan 23 2 not used not used Switch Scan 23 3 not used not used Switch Scan 23 4 not used Black LED Head temperature Switch Scan 24 1 Encoded head temperature Temperature is enco...

Page 82: ...s refer to table below The front panel also reminds you to remove the necessary item before starting the test 3 Press the Item 2 6 keys to scroll through the list of motors and clutches until the desi...

Page 83: ...egistration roller B rotate REGISTRATION CLUTCH none Open the front cover and observe registration roller A turning FRONT MOTOR REGISTRATION MOTOR Remove media from the multi sheet bypass feeder Open...

Page 84: ...UTCH OPTIONAL none Remove Tray 3 and listen for the clutch FEED ROLLER 4 CLUTCH OPTIONAL none Remove Tray 4 and listen for the clutch FEED ROLLER 5 CLUTCH OPTIONAL none Remove Tray 5 and listen for th...

Page 85: ...ss the Item 2 6 keys to scroll to the menu item PRINT EXECUTE Press Value 3 to starts printing 6 Press Value 7 to stop printing Test Print menu Display Set Value Function PRINT EXECUTE Press Value 3 t...

Page 86: ...units of sheets U Upper fuser heater temperature measurement in degrees Celsius L Lower fuser heater temperature measurement in degrees Celsius T Environmental temperature measurement in degrees Cels...

Page 87: ...ed Refer to the table printed below 4 Press and hold Value 3 for 10 seconds to initialize the items of the selected table The front panel display NV RAM INITIAL blinks eight times 5 Press Enter 4 to e...

Page 88: ...ed with the item The table below lists the menu items 4 Press Enter 4 to end the test Consumable counter menu items Upper Display Lower Display Detail FUSER UNIT IMAGES Shows the number of sheets prin...

Page 89: ...the upper display 3 Press the Item 2 6 keys to scroll through the list of supply items The life cycle consumption value is displayed with the item The table below lists the menu items 1 Press Enter 4...

Page 90: ...actory defaults by selecting Color Defaults from the Color Adjust Menu Printing aTest Page 1 Press the Menu 1 5 keys until you see Color Adjust 2 Press Item 2 6 keys and the printer prints the Color B...

Page 91: ...ents Use the following procedures to make adjustments to the color density and balance Black density adjustment 1 Press Item 2 6 keys until you see Color Adjust Menu Black Density 2 Press Value 3 7 ke...

Page 92: ...e 0 1 2 3 4 5 6 7 8 9 10 11 12 13 4 Press Enter The Color Adjust Page prints and the front panel displays Color Adjust Menu Color Balance Repeat Steps 2 and 3 above until you are satisfied with the re...

Page 93: ......

Page 94: ...ng steps assures proper operation of the printer and reduces the probability of having to service the printer in the future The frequency of use and the type of paper a customer prints on determines h...

Page 95: ...after replacing toner cartridge Drum Units When the message is displayed When 35 000 pages are printed out for 3 Page Job printing of Letter paper The printer s imaging drum unit counters are automati...

Page 96: ...uch as a void or light printing running vertically down of the paper Clean the lens with an alcohol wipe to clean the LED bar An alcohol wipe always comes with the toner cartridge Print the 100 Color...

Page 97: ......

Page 98: ...rm Action Yes No menu Press Enter to confirm your selection Network Defaults network settings Use the Item 2 6 keys to activate the Confirm Action Yes No menu Press Enter to confirm your selection Dem...

Page 99: ......

Page 100: ...l field adjustable components Default settings and soft switch settings are covered in Service Tests and Adjustments on page 61 About screw colors Black screws are coarse thread screws used to join pl...

Page 101: ...them in a lightproof black bag to protect the drum units from light and store in a safe place 2 Remove the rear cover as explained in Rear cover on page 89 3 Remove the 10 screws securing the top cov...

Page 102: ...age 105 2 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 3 Remove the seven screws securing the...

Page 103: ...the drum units from light and store in a safe place 3 Remove the duplex unit paper tray 4 Remove the seven screws securing the cover to the printer frame Remove the cover by lifting it straight up Rev...

Page 104: ...place 3 Remove the front cover as described in Front cover on page 90 4 Remove the rear cover as described in Rear cover on page 89 5 Lift the face up tray to access and remove the two screws underne...

Page 105: ...he sides of the face up tray 3 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: ...the door s link strap to the printer frame 3 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 Reverse these step...

Page 107: ...the rear cover as shown on Rear cover on page 89 3 Remove the rear shield plate as described on page 97 4 Disconnect connector FAN 1 from the print engine controller board 5 Remove the two screws and...

Page 108: ...e the front shield plate Pull out the duplex unit tray 1 to access the shield plates s lower screws 4 Disconnect the front power supply fan s wiring harness from the low voltage power supply board 5 R...

Page 109: ...98 3 Remove the left side cover as described in Left side cover on page 91 4 Remove the left shield plate 5 Disconnect the rear power supply fan s wiring harness from the engine controller board 6 Rem...

Page 110: ...a lightproof black bag to protect the drum units from light and store in a safe place 2 Remove the rear cover as explained in Rear cover on page 89 3 Remove the screws securing the rear shield plate 4...

Page 111: ...tors from the print engine controller board Label the ribbon cables leading to the top cover inner frame to ease re connection 6 Pull out the disconnected cable harnesses routed through the top of the...

Page 112: ...Attached to the back of the electrical card cage 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 Removing the e...

Page 113: ...1 7 Remove the left side shield plate 8 Remove the electrical card cage as described in the topic Electrical card cage on page 98 9 Remove the top cover as described in the topic Top cover on page 88...

Page 114: ...it chassis and lay it aside 18 Disconnect the front power supply fan the chassis fan and the duplex solenoid connectors from the front of the low voltage power supply 19 Remove the 12 screws securing...

Page 115: ...ses from the print engine controller board 9 Remove the four screws securing the cable shield to the top of the electrical card cage Free the flat wiring harnesses from the card cage 10 Disconnect the...

Page 116: ...he LED mounting brackets can be damaged Reverse these steps to install the top cover inner frame Removing the top shield plate Remove Screws Remove Screws Top Cover Inner Frame Rear Top Cover Hinge Sp...

Page 117: ...supply fan Let the fan rest on the front of the lower plate 3 Disconnect the chassis fan from the front of the low voltage power supply 4 Remove the four screws securing the left plate assembly to th...

Page 118: ...rear of the system controller board 2 Remove the two screws securing the system controller board to the printer 3 Slide the system controller board out to the rear of the printer Reverse these steps t...

Page 119: ...roller board as described in the procedure System controller board on page 105 2 Spread apart the latches securing each end of the RAM DIMM connector 3 Lift the DIMM out of the connector Reverse these...

Page 120: ...e system controller board as described in the procedure System controller board on page 105 2 Remove the four screws securing the hard drive to the board 3 Slide the slightly to disconnect the hard dr...

Page 121: ...Remove the system controller board as shown on page 105 5 Disconnect all connectors connected to the print engine controller board Remove the EMI suppessor coils and cable ties as necessary 6 Remove...

Page 122: ...inner frame disconnect the four LED power harnesses from the toner sensor board 3 Close the top cover inner unit 4 Remove the three screws securing the toner sensor board 5 Rotate the board up to exp...

Page 123: ...ard 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: ...side down remove registration roller assembly B as shown on page 129 4 Remove the spring loaded tray 1 entrance sensor actuator as explained on page 121 Note the orientation of the actuator s spring f...

Page 125: ...nter unit chassis as detailed in the topic Printer unit chassis on page 100 2 Disconnect CN1 from the high voltage power supply 3 Disconnect CN3 from the low voltage power supply 4 Remove the three sc...

Page 126: ...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 Removing the high voltage powe...

Page 127: ...CN2 CN3 CN5 and CN9 from the low voltage power supply 3 Disconnect the AC power switch wiring harness interconnect 4 Remove the eight screws securing the low voltage power supply to the printer 5 Remo...

Page 128: ...8 2 Remove the screw securing the left side of the control panel 3 Lift the control panel and disconnect CN1 from the back of the panel 4 Remove the control panel Reverse these steps to install the co...

Page 129: ...haft behind the upper roller Note the torque limiter on the shaft behind the lower feed roller 4 Release the locking tab on the left end of the nudger roller 5 Slide the nudger roller to the left and...

Page 130: ...eft by paper tray 1 disconnect the ribbon cable attached to the paper size sensing board 3 Again reaching in through the cavity left by paper tray 1 remove the four screws securing the paper size sens...

Page 131: ...nnect the seven wiring harnesses leading to the main feeder assembly 5 Remove the main feeder cross brace it is held in place with five screws 6 Remove the six screws securing the main feeder assembly...

Page 132: ...7 Remove the four black screws securing the multi sheet bypass feeder top cover Remove the cover 8 Open the multi sheet bypass feeder tray 9 Remove the two black screws securing the multi sheet bypass...

Page 133: ...feeder Removing the multi sheet bypass feeder Joint Joint Drive Gear Spread Locking Tabs to Free Gear Link Multi sheet Bypass Feeder Multi sheet Bypass Feeder Tray Link Link MBF Feed Sensor Transparen...

Page 134: ...he printer unit chassis upside down and then carefully squeeze the actuator s two locking tabs and remove the sensor For reassembly reinstall the entrance sensor actuator Ensure the spring arm is on t...

Page 135: ...tuator on page 121 3 Remove the entrance sensor board as described in the topic Entrance sensor board on page 111 4 From the bottom squeeze the two locking tabs securing the belt entrance sensor actua...

Page 136: ...e 90 2 Remove the front shield plate 3 Free the front power supply fan 4 Disconnect the wiring harness of the solenoid you wish to remove 5 Remove the two screws securing the solenoid you wish to remo...

Page 137: ...t unit locking tabs toward the left side of the printer to release the unit 4 Using the transfer belt unit handle lift the unit about 1 2 inch 12 mm 5 Using the handle and the front frame of the trans...

Page 138: ...safe place 2 Remove the rear shield plate as described in the topic Rear shield plate on page 97 3 Disconnect the RCL connector from the printer engine controller board 4 Remove the screw securing th...

Page 139: ...scribed in the topic Rear shield plate on page 97 4 Remove the registration clutch as detailed in Registration clutch on page 125 5 Remove the screws securing the motor bracket to the printer 6 Remove...

Page 140: ...units from light and store in a safe place 2 Remove the transfer belt unit 3 Remove the rear shield plate as described in the topic Rear shield plate on page 97 4 Remove the multi sheet bypass feeder...

Page 141: ...hese 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 The blue plastic face should face the outsi...

Page 142: ...store in a safe place 2 Remove the printer unit chassis as described in Printer unit chassis on page 100 3 Turn the printer unit chassis upside down 4 Remove the four screws securing registration roll...

Page 143: ...fe place 2 Open the front cover 3 Remove the left side cover as described in the topic Left side cover on page 91 4 Remove the right side cover as described in the topic Rear shield plate on page 97 5...

Page 144: ...Service Guide 131 8 Carefully lift the duplex guide assembly to free it from the printer Removing the duplex guide assembly Printer Unit Duplex Guide Assembly Spring Spring 0725 40...

Page 145: ...rtridges Place them in a lightproof black bag to protect the drum units from light and store in a safe place 2 Remove the front cover as described in the topic Front cover on page 90 Remove the left s...

Page 146: ...uide 133 6 Remove the left fuser latching handle Reverse these steps to install the fuser latching handle left Fuser latching handle left 0725 41 Fuser Latching Handle Fuser Latching Handle Spring Rem...

Page 147: ...ce 2 Remove the printer unit chassis as described the topic Printer unit chassis on page 100 3 Release the fuser latching handle spring 4 Remove the E ring securing the rear fuser latching handle to i...

Page 148: ...y fan on page 96 5 Remove the front power supply fan as described in Front power supply fan on page 95 6 Remove the rear shield plate as shown in Rear shield plate on page 97 7 Remove the card cage as...

Page 149: ...ller to the rear until the front end of the staff is free 14 Reverse these steps to install the fuser exit roller Removing the fuser exit roller Fuser Drive Gear Assembly Fuser Drive Gear Roller Conta...

Page 150: ...Remove the fuser exit roller as detailed on page 135 3 At the engine controller board disconnect the connector to the exit sensor assembly PARTTEMP 4 Lift and remove the duplex exit gate 5 Remove the...

Page 151: ...nits from light and store in a safe place 2 Remove the top cover inner frame as detailed in Top cover inner frame and front rear top cover spring assembly on page 102 3 Remove the five screws securing...

Page 152: ...ower harnesses from the underside of the toner sensor board 3 Close the top cover inner unit 4 Remove the four screws securing the metal shield over the toner cartridge sensor board 5 Remove the three...

Page 153: ...140 Phaser 2135 Color Printer 10 Remove the stack full sensor Reverse these steps to install the stack full sensor Removing the stack full sensor 0725 46 Stack Full Sensor Stack Full Sensor Assembly...

Page 154: ...rd cage on page 98 2 Remove the printer unit chassis as detailed on page 100 3 Disconnect each wiring harnesses from the four imaging drum motors 4 Remove the five screws securing the main motor assem...

Page 155: ...motor 1 Remove the two screws securing the motor to the main motor assembly Reverse these steps to install the main motor assembly Removing the main motor assembly Remove Screws Main Motor Assembly 07...

Page 156: ...motor and belt drive motor assembly 4 Remove the two screws securing the fuser motor and belt drive motor assembly to the printer frame 5 Remove the motor assembly Reverse these steps to install the...

Page 157: ...rough the opening in the shutter plate carefully remove the shutter spring 4 Open the shutter plate to the full open position 5 Carefully lift the tabs on the front edge of the shutter plate over the...

Page 158: ...tailed on page 124 3 Remove the shutter plate as described in the previous procedure Shutter plate on page 144 4 Remove the two screws securing the color registration sensor assembly 5 As you lift the...

Page 159: ...te as explained on page 144 3 Disconnect the shutter solenoid in line connector 4 Release the shutter solenoid harness from all cable clamps 5 Remove the screw securing the shutter solenoid to the pri...

Page 160: ...LED assembly and lifting up on the connector Free the harnesses from the LED assembly 3 Disconnect the LED assembly s power harness from the toner sensor board 4 Push the LED assembly against its spr...

Page 161: ...dges Place them in a lightproof black bag to protect the drum units from light and store in a safe place 2 Use a small screwdriver to carefully pry the drum contact assembly from the printer chassis R...

Page 162: ...afe place 2 Disconnect the four LED power harnesses from the bottom of the toner sensor board 3 Close the top cover inner unit 4 Remove the three screws securing the toner sensor board and the insulat...

Page 163: ...ator Reverse these steps to install the toner sensor actuators When replacing the toner sensor board insure all harnesses are in the cable channels Removing the toner sensor actuators 0725 54 Remove S...

Page 164: ...tray 1 and pull the right side out slightly to free them from the printer 4 Slide the release lever to raise the two spring loaded guide pins that align the duplex unit to tray 1 The release lever is...

Page 165: ......

Page 166: ...in an illustration stand for C ring E ring and Screw respectively A shaded triangle t in an illustration indicates the item is part of an assembly The notation with X Y following an part name indicate...

Page 167: ...Left Side Cover 8 116 1004 00 Front Cover 9 116 1039 00 Duplex Slot Cover 10 116 1055 00 Top Cover Damper Front 12 116 1008 00 Foot 13 116 1084 00 Right Side Door 14 012E12690 Multi Sheet Bypass Links...

Page 168: ...Service Guide 155 Figure 1 Cabinet and top cover FRUs 18 12 14 14 8 13 23 10 19 20 6 5 4 7 2 9 15 22 21 3 3 1 0725 01 24 17...

Page 169: ...116 1038 00 Hardware Kit 8 116 1057 00 Top Cover Stack Bin Inner Cover 9 116 1002 00 Eject Guide Assembly 10 116 0999 00 LED Bar Assembly 11 LED Assembly Spring part of 116 1038 00 Hardware Kit 12 26...

Page 170: ...Service Guide 157 Figure 2 Top cover FRUs 15 12 12 13 14 16 11 11 11 11 9 6 5 7 3 8 4 1 20 19 18 17 2 10 0725 02...

Page 171: ...te Shutter 12 Registration Shutter Spring part of 116 1038 00 Hardware Kit 13 121K26000 Color Registration Shutter Solenoid 14 116 1087 00 Printer Chassis 15 B Registration Entrance Sensor Flag part o...

Page 172: ...Service Guide 159 Figure 3 Printer chassis FRUs 1 of 2 1 25 24 24 23 27 22 21 26 3 5 4 17 16 15 14 12 13 20 19 18 11 10 8 6 7 0725 03 2 9...

Page 173: ...Low Voltage Power Supply 220 VAC 4 116 1029 00 Front Plate Assembly 5 116 1034 00 Low Voltage Power Supply Insulator 6 116 1067 00 Duplex Exit Paper Guide 7 115K01960 Rear Contact Assembly 8 116 1033...

Page 174: ...Service Guide 161 Figure 4 Printer chassis FRUs 2 of 2 3 4 1 2 9 7 10 6 11 8 5 12 0725 04 13...

Page 175: ...niversal Paper Tray 2 116 1085 00 Connector with Harness 3 116 1065 00 Right Cover Interlock Switch 4 116 1086 00 Main Feeder Assembly 5 116 1062 00 Paper Feed Roller 6 116 1010 00 Media Plate Lift Mo...

Page 176: ...Service Guide 163 Figure 5 Paper tray and paper tray guides FRUs 7 4 2 1 0725 05 5 6 3 8 9...

Page 177: ...CRU EEPROM 816A2323M000 4 116 1031 00 Engine Controller Board 5 671 5269 00 System Controller Board EFI Controller Image Processor 6 156 4811 10 156 4780 10 156 4839 00 64 Mbyte RAM DIMM 128 Mbyte RAM...

Page 178: ...Service Guide 165 Table 7 FRUs of the duplexer unit Fig 9 parts Part number Name and description 1 116 1088 00 Duplex Transport Assembly Figure 7 Duplexer unit 1 0725 06...

Page 179: ...Lower Tray Assembly Left Cover 2 116 1043 00 Lower Tray Assembly Front Right Cover 3 116 1009 00 Lower Tray Assembly Universal Tray 4 116 1013 00 Castor Wheel 5 116 1046 00 Lower Tray Assembly Right S...

Page 180: ...Service Guide 167 Figure 8 LowerTray Assembly FRUs 1 2 5 6 7 8 9 3 4 4 4 0725 07...

Page 181: ...ter Spring Fuser Latch Handle Springs Screw T3x8 Screw T3x10 Screw T4x10 Screw M2x8 Screw M3x6 Screw M3x8 Screw M4x8 Screw SP3x10 Screw T4X6 Screw T4X8 Plastic Eject Rollers Table 10 Gear kit Part num...

Page 182: ...Interface Temp Humidity sensor For Geared Motor For Feed sensor For Color Registration sensor For Board N71 For Board R71 For Board A73 For Duplexer For Power For Right side Cover Open Stacker Cover...

Page 183: ...nual Pack Italian 061 4291 00 Phaser 2135 Manual Pack German 061 4292 00 Phaser 2135 Manual Pack Spanish 061 4293 00 Phaser 2135 Manual Pack Brazilian Portuguese 061 4294 00 Phaser 2135 Manual Pack Si...

Page 184: ...0V 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 replaceme...

Page 185: ......

Page 186: ...Color Stripe Pattern consist of two set of bars Each set of bars is made of of a seven bars each bar is a 100 solid fill of the primary colors cyan magenta yellow and black and the secondary colors re...

Page 187: ...y or damaged imaging drum 5 Look for complete fusing Cold or hot offset fusing could indicate the incorrect paper weight has been selected Interpreting Test Pattern A This pattern consists of color bl...

Page 188: ...he Color Balance object marked CURRENT with the gray background The background is produced using black only and the circles are produced using a combination of cyan magenta and yellow The adjustment o...

Page 189: ...int as well as residual offsetting Interpreting the Step Test Patterns The Step Test Patterns consist of 11 color bars starting with a100 fill of a primary color bar and progressing in 10 steps to a 0...

Page 190: ...Sensor Board A73 T2 White T10 Red T1 Blue T1 White T7 White T11 T11 does not exist in the lowest DUP In Sensor DUP Middle Sensor DUP Front Sensor DUP DUP Front Clutch DUP Rear Clutch D3 Blue V73 Board...

Page 191: ...178 Phaser 2135 Color Printer Wire routing at the engine controller board Bundle wires thru EMI coils Tie wraps The wiring receptacles are color coded with their plugs for correct placement...

Page 192: ...Service Guide 179 Details of wiring passthru Bundle wires thru EMI coils Route wiring harnesses thru cable clamp Route wiring harnesses thru cable clamp...

Page 193: ...ield plate when it is installed 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 c...

Page 194: ...drum motors Wire routing by the fuser and transfer belt motor unit Route wiring harnesses under the imaging drum motors EMI coils Cable tie the wiring harnesses to the center restraint post Route wir...

Page 195: ...182 Phaser 2135 Color Printer Ribbon cable routing under the toner sensor board Harnesses route through channel around post Note how harness route through slot...

Page 196: ...ple The hexadecimal value 13FA breaks down into 1 3 F A 1 is 1 3 is 3 F is 15 A is 10 For the For the For the For the 4th column 3rd column 3rd column 3rd column multiply multiply multiply multiply 1...

Page 197: ...NOTES...

Page 198: ...NOTES...

Page 199: ...NOTES...

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Xerox 2135DX - Phaser Color Laser Printer, Service Manual

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