Xerox Phaser 2135 Service Quick Reference Guide

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Service Quick Reference Guide

PHASER® 2135 COLOR PRINTER

Service Quick Reference Guide

Warning The following servicing instructions are for use by qualified service personnel only. To avoid personal injury, do not perform any servicing other than that contained in operating instructions unless you are qualified to do so.

This printing: January 2001 071-0725-00

Copyright © Xerox Corporation. Unpublished rights reserved under the copyright laws of the United States. Contents of this publication may not be reproduced in any form without permission of Xerox Corporation. Phaser®, PhaserShare®, ColorStix®, the T ekColor® 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

and RealSUPPORTSM are service marks of Xerox Corporation.

Care

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. © Pantone, Inc., 1988.

TE/sn

Users safety summary

Terms in manual:

Power source:

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:

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:

product into a power source.

Terms on product:

Care of product:

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 pr oduct needs servicing or repair, and whenever you clean the product.

CAUTION Conditions that can result in damage to the product. WARNING Conditions that can result in personal injury

or loss of life.

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

Avoid electric shock by contacting a qualiﬁed service

Read all installation instructions carefully before you plug the

CAUTION A personal injury hazard exists that may not be

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.

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

Ground the product:

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

Lifting the printer:

lift the printer.

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

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

Symbols as marked on product:

DANGER high voltage:

Protective ground (earth) terminal:

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

WARNING:

controls (and other conductive parts) can cause an electrical shock. Electrical product may be hazardous if misused.

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

Service safety summary

For qualiﬁed service personnel only:

Summary.

Do not service alone:

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

Use care when servicing with power on:

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:

other metallic objects could come into contact with dangerous voltages and currents.

Power source:

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. A pr otective ground connection by way of the gr ounding conductor in the power cord is essential for safe operation.

Do not perform internal service or adjustment of this

Remove jewelry prior to servicing. Rings, necklaces, and

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

Refer also to the preceding Users Safety

Dangerous voltages may exist at several

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

Service Guide

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

Phaser 2135 Color Printer

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

Service Guide

vii

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

viii

Phaser 2135 Color Printer

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

Service Guide

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 Door safety interlock switches 35 Print problem caused by dirty LED lens 83 Removing the top cover 88 Removing the rear cover 89 Removing the front cover 90 Removing the left-side cover 91 Removing the face-up tray 92 Removing the right door. 93 Removing the electrical card cage cooling 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-line connector (HOPFF) 100 Removing the printer unit chassis 101 Removing the top shield plate 103 Removing the left plate assembly 104 Removing the system controller board 105 Removing the RAM DIMMs 106 Removing the hard drive 107 Removing the print engine controller 108 Removing the toner sensor board 110 Removing the entrance sensor board 111 Removing the high voltage power supply 113 Removing the low voltage power supply 114 Removing the control panel 115 Removing the feed rollers and nudger roller 116 Removing the feed roller and nudger roller 117 Removing the main feeder assembly 118 Removing the multi-sheet bypass feeder 120

Phaser 2135 Color Printer

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 Fuser latching handle (left) 133 Fuser latching handle (left) 134 Removing the fuser exit roller 136 Removing the exit sensor assembly 137 Removing the eject guide assembly 138 Removing the stack full sensor 140 Removing the main motor assembly 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 146 Removing an LED assembly 147 Removing the drum contact assembly 148 Removing the toner sensor actuators 150 Removing the duplex unit 151 Cabinet and top cover FRUs 155 Top cover FRUs 157 Printer chassis FRUs (1 of 2) 159 Printer chassis FRUs (2 of 2) 161 Paper tray and paper tray guides FRUs 163 Electrical components FRUs 164 Duplexer unit 165 Lower Tray Assembly FRUs 167 Wiring diagram 177 Wire routing at the engine controller board 178 Details of wiring passthru 179 Wiring under the top shield plate 180 Wiring harnesses route by the imaging drum motors 181 Wire routing by the fuser and transfer belt motor unit. 181 Ribbon cable routing under the toner sensor board 182

Service Guide

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 Switch scans and 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 Periodically replaced parts 82 FRU parts list of the printer cabinet and top cover 154 FRU part list of the top cover inner frame 156 FRU part list of the printer chassis (1 of 2) 158 FRU of the printer chassis (2 of 2) 160 FRU of the paper tray and paper tray guides 162 Electrical components FRUs 164 FRUs of the duplexer unit 165 FRUs of the Lower Tray Assembly 166 Hardware kit 168 Gear kit 168 Harness kit 169 Sensor flag kit 170 Customer supplies and accessories 170

xii

Phaser 2135 Color Printer

General Information

This service guide contains information useful for troubleshooting, repairing, adjusting, and maintaining the Xerox Phaser includes troubleshooting guides, 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

To ensure a complete understanding of the product, Xerox recommends participation in Phaser 2135 printer service training.

Color Printer Service & Support Resources CD-ROM

2135 Color Printer. This manual

0725-56

The Phaser 2135 Color Printer with lower tray assembly and lower tray deck

Service Guide

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. All printer versions support the color PCL5C printer language.

The printer is available in three conﬁgurations:

The

■

Phaser 2135N

Additional 64-, 128- and 256-Mbyte RAM DIMMs can be added with a maximum usable capacity is 512 Mbytes. The printer contains 136 standard, built-in fonts. The Phaser 2135N prints at a color resolutions of 600 x 600 dots-per-inch and 600 x 1200 dots-per-inch.

The

■

Phaser 2135DT

192 Mbytes of memory, an auto-duplexer, an internal hard drive and a lower feeder tray assembly. With the hard drive the 2135DT supports a print collation mode, a “First Page Preview” mode and a secure print job “password” mode.

The

■

Phaser 2135DX

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)

■

comes standard with 128 Mbytes of RAM.

is the same as the Phaser 2135N except it includes

has all the features and capabilities of the

600 x 1200 dpi (High-quality)

■

The printer also accepts 300 x 300 dpi ﬁles from PCL legacy drivers, PCL bit map fonts, PCL bit map images, although these are imaged at 600 x 600 dpi. The resolution supported is a function of the PDL used and the feature being selected, such as Fax Friendly Black and Draft Mode. Both PostScript and PCL allow full selection of all paper sources, paper sizes, paper types and output trays.

The auto-duplexer unit (optional on the Phaser 2135N) allows the printer to automatically create two-sided prints.

Print speeds depend on the chosen resolution and selected media. For r esolutions of 600 x 600 (standard), in color, the printer prints at 21 pages-per-minute (ppm) on paper. Monochrome printing is at 26 ppm on paper. Transparency ﬁlm printing is always 6.5 ppm. For 600 x 1200 dpi (enhanced) color printing, the printer prints color at the same speeds as standard mode.

The printer support printing on paper sizes such as A-, A4- , Legal-, B-, A3-size and 12 x 18 in. paper and transparency ﬁlm from an adjustable tray. The printer supports up to 5 trays. The printer also features a built-in multi-sheet bypass feeder from which specialty media, cardstock and envelopes can be fed.

Phaser 2135 Color Printer

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

■

After being idle for the selected amount of time the printer switches into its Energy Star mode where it consumes less than 45 watts of power. It “awakens” upon receiving data at any of its ports.

Proof Jobs.

A proof job is a speciﬁc case of a multiple-copy job. With a proof job, the customer assigns a password and copy account at the client workstation before printing. The ﬁrst set of prints are printed immediately. The original number of requested sets are printed after the customer enters the matching password on the printer’s control panel. The customer has the option of printing the original number of requested sets or deleting the job. Since more than one job may be associated with the same password, the customer can print all the jobs, delete all the jobs or select or delete individual jobs. A proof job that has not been printed is retained on hard disk thr ough power cycles. Pr oof jobs sent 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 control panel. The customer assigns the password at the client workstation before printing. The job is stor ed, and printing is delayed until the password is entered on the printer’s control panel. Since more than one job can have the same password, all secure jobs with the same password are printed. A secure job that has not been printed or released is retained on disk through power cycles. The internal hard drive is required for this function.

TIFF Direct Printing.

TIFF ﬁles consist of compressed binary images. The TIFF format itself has no capability to select printing options such as orientation, paper size, or duplexing. All TIFF ﬁles downloaded to the printer are processed using the default PostScript parameters stored in the printer. Auto sensing of TIFF ﬁles are included in the emulation sensing and switching logic when the TIFF option is enabled. TIFF direct printing requires the internal hard drive.

PDF Direct Printing

. The printer supports a native PDF image processing. Processing PDF ﬁles directly requir es a hard disk. PDF printing uses the printer’s currently deﬁned imaging settings. Auto sensing of PDF ﬁles are included in the emulation sensing and switching logic when the PDF option is installed. PDF direct printing requires the internal hard drive.

Service Guide

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.

If the DIMM does not meets the system controller board’s speciﬁcations, then the printer reports an “Invalid Memory DIMM Conﬁguration” message and stops the booting process.

If the power-up self-test diagnostics detect a DIMM with defective memory cells the printer declares “Diagnostics Failed - Press Enter to Continue.” After the enter key is pressed the boot process continues and the defective RAM DIMM is ignored. Note that a seriously defective RAM DIMMs (with grounded address lines, for example) can keep the system controller board from booting up at all.

With more memory the printer gains the capabilities of printing without having to use image compression (which trades 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 three slots each of which can contain a 64-, 128-, or 256-Mbytes SDRAM DIMM. Any slot may be used for any size DIMM. DRAM memory totalling beyond 512 Mbytes will be ignored.

512 Mbytes, 256-Mbyte DRAM DIMMs cannot be mixed with 128-Mbyte RAM DIMMs.

non-volatile memory (NVRAM), to store all for the necessary values that can be set on the printer.

The image-processing controller board also contains 16-kbytes of

For a capacity of

CRC life counter behavior

Internal counters track customer replaceable consumable (CRC) life usage and store the values in NVRAM. The controller monitors these counters in order to display the near end-of-use and end-of-use messages.

The toner states displayed are OK, Low, and Empty, where the engine senses and automatically reports the Low and Empty states. When the empty state is reached for toner, the printer terminates printing at the end of current page and displays the appropriate message on the control panel. No further jobs are accepted from any input port. All printer CRCs wait for the current print job to ﬁnish before declaring a Low or Empty state.

Phaser 2135 Color Printer

Print engine assemblies

Toner Sensor Board

Control Panel Board

Low Voltage Power Supply Board

System Controller Board

Engine Controller Board

High Voltage Power Supply Board

Print engine circuit boards

Paper Size Sensor Board

Entrance Sensor Board

Service Guide

0725-64

Face-up Tray Open Sensor

Stack Full Sensor

Exit Sensor

Color Registration Sensor Assembly

Temperature/ Humidity Sensor Board

Belt Entrance Sensor

Cyan Toner Cartridge Sensor

Magenta Toner Cartridge Sensor

Yellow Toner Cartridge Sensor

Black Toner Cartridge Sensor

MBF Home Position Sensor

MBFTransparency Sensor

MPT Empty Sensor

Top Door Open Switch

Right-side Door Open Switch

Tray 1 Low Paper Sensor

Tray 1 Paper Out Sensor

Entrance Sensor

Registration Sensor

Print engine sensor and switch locations

Phaser 2135 Color Printer

Waste Toner Sensor

0725-63

Duplex Solenoid

Fuser Motor

Exit Solenoid

Color Registration Shutter Solenoid

Tray Lift Motor

Cyan Imaging Drum Motor

Magenta Imaging Drum Motor

Yellow Imaging Drum Motor

Black Imaging Drum Motor

Transfer Belt Drive Motor

Registration Motor

Registration Clutch

Paper Feed Motor

0725-62

Print engine motors, clutches and solenoids

Service Guide

The image processor board

SDRAM

Fan cooled processor

Features of the controller board

ROM DIMM

Hard drive

0728-05

Phaser 2135 Color Printer

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

The control panel

Key 0 places the printer off-line or on-line. Key 4 is an Enter key. The pairs of keys 1 and 5 are used to scroll through 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 ready to process data. When transitioning from “On Line” to “Off Line”, the LED ﬂashes at a rate of two times per second. When data is being received and processed, the LED ﬂashes at a rate of once per second.

! Fault

Red in color, this LED illuminates whenever operator intervention is required, such as a paper jam in the printer.

Service Guide

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

The printer rear panel

off

The LED LNK is

blinks

while data is transmitted to the host.

The LED SPD is when the card is set for 16 MBPS.

Phaser 2135 Color Printer

when the printer is not installed on an Ethernet network, it

off

when the card is set for 4 megabits-per-second (MBPS), on

0728-03

Accessing special operating modes

The printer can be placed in diagnostics or other operation modes by simultaneously holding the

Menu Up (1)

the printer.

Entering special operating modes

Key Combination Mode

On Line (0) and Enter (4)

Menu Up (1) and Menu Down (5)

Menu Up (1) and Enter (4)

Enter (4) and Value Down (7)

This enables the The Reset Menu is not normally available to the customer, as it contains

the ability to format devices and perform a factory reset of all items. The control panel displays To exit, switch the printer power off, then on.

This forces the The Control Panel will display

Mode

on the second line. This indicates that the printer is ready to be

have its ﬂash ﬁrmware updated. To exit, switch the printer power off, then on.

Forces the printer into the controller.

The control panel displays that the printer is ready to enter diagnostics.

To exit, switch the printer power off, then on. This reinitiates the NVRAM to factory defaults for all values except copy

counts and consumable counts. The control panel displays

Reset Menu

Software Update Mode

and the

Ready

Engine Diagnostics Mode

Diag Mode 1?

Ready

Enter (4)

to become available at the control panel.

when completed.

Entering...

when complete.

keys as you turn on

on the parallel port.

on the ﬁrst line

in the ﬁrst line. This indicates

and Download

, bypassing the

System controller board LEDs

A power LED (PWR), when illuminated, indicates +5V is being supplied to the system controller board.

The LED HDD, illuminates to ﬂashes to indicate hard drive read/write activity. LED GIO2 ﬂashes to indicate proper CPU operation. LED GIO3; off indicates 10baseT connection, on indicates 100baseT.

Service Guide

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.

Paper size detection

State of Microswitch Paper Size SW1

(top)

0000No tray installed 0001B4 0010A4 (landscape) 0011A3-Nobi 0100Legal 13 in. 0101Legal 14 in. 0110A5 0111A6 1000B5 (landscape) 1001A3 1010A/Letter (landscape) 1011B/Tabloid 1100B5 (portrait) 1101Executive 1110A4 (portrait) 1111A/Letter (portrait)

SW2 SW3 SW4

(bottom)

Back of paper tray

Tray switch sensors and actuators

Phaser 2135 Color Printer

Paper tray sensor board

0725-67

Speciﬁcations

Physical dimensions

Dimensions Speciﬁcation

Height: 46.0 cm (18.1 in.)

Width: 66.6 cm (26.2 in.) Depth: 62.6.0 cm (24.6 in.) Weight: About 72 kgs (158 lbs.)

Printer clearances

Clearances Speciﬁcation

Top: 91.5 cm (36 in.) Left: 30.5 cm (12 in.) Right: 30.5 cm (12 in.) Front: Unlimited for removal of consumables Rear: 15.3 cm (6 in.) for connecting computer cable and power cord Mounting surface

ﬂatness:

Each additional lower tray adds 12.7 cm (5 ins.) The lower tray deck adds 48 cm (19 ins.)

Each additional lower tray adds 16.8 kgs (37 lbs.). The lower tray deck weights 57.7 kbs (127 lbs)

Maximum deviation of 50 mm (2 in.) from horizontal, side-to-side, with all four feet in contact with the table surface.

Service Guide

Functional speciﬁcations

Characteristic Speciﬁcation

Printing process Electro-photographic, four color (CMYK) tandem transfer printing Color medium Four toner cartridges each contain one of four colors: cyan, magenta,

Addressability Selectable 600 x 600 and 600 x 1200 dpi, text and graphics Printing speed

pages per minute (ppm)

yellow or black. The toner is a nonmagnetic, monocomponent contact medium.

Time from paper-load to paper-eject for continuous printing:

Single-sided

A-size A4 B-size A3

Four-color: 20 21 11 11 Monochrome: 25 26 14.5 14.8 OHP: 6.6 6.4 na na Cover/specialty: 10 10 6 5.8

Two-sided

Four-color: 10 10 5 5 Monochrome: 12 12 7 7 OHP: na na na na Cover/specialty: na na na na

Print times do not include image processing time, which can vary depending on image complexity.

Minimum printing margins

Usable paper Tray: A-size (Letter), Legal, Executive (7.25 x 10.5 in.),

All sides 5 mm (0.2 in.),

A4-size (metric letter), SRA3, 12 x 18 in. B4, 8 x 13 in, A5 Tabloid (11 x 17 in.), A6, JIS B5, US Folio. Use only premium bond laser printer or copier paper, transparency ﬁlm, card stock and glossy paper in Tray 1 Tray feed paper weight: 60 to 163 g/m2 (16 to 43 lb.) Minimum paper size: 148 mm x 210 mm (5.83 x 8.27 in.)

Multi-sheet bypass feeder: A-size (Letter), Legal, Executive (7.25 x 10.5 in.), 8 x 10 in., 12 x 18 in., A 4-size (metric letter), SRA3, B4, 8 x 13 in, Tabloid (11 x 17 in.), A6, JIS B5, US Folio, A5. SP Folio, , Statement, Multi-sheet Bypass Feeder paper weight: 16 lb. to 54 lb. (60g/m2 to 203 g/m2)

Only

Xerox-brand Phaser 35-series A- and A4-size transparency ﬁlm is supported. Automatic two-sided printing: 75 to 120 g/m2 (20 to 32 lb.) A6 paper, transparency ﬁlm, heavy card stock, and glossy paper are not supported by Trays 2 thru 5

A-size A4 B-size A3

Phaser 2135 Color Printer

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. Varying number of envelopes and other special stock. The Multi-sheet Bypass Feeder can use media in the 20 to 203 gm2 range.

Electrical speciﬁcations

Characteristic Speciﬁcation

Primary line voltages 99 to 140 VAC (115 VAC nominal)

Primary voltage frequency range

Power consumption 150 Watts during standby state, (1300 Watts max)

Primary voltage fusing 110 VAC conﬁguration – 20 Amp

Secondary DC voltages Low Voltage Power Supply High Voltage Power Supply

RF emissions Both 110 and 220 VAC-conﬁgured instruments pass these

198 to 264 VAC (220 VAC nominal) 50 (48 to 52) or 60 (58 to 62) Hz

1400 Watts during warm-up 550 Watts operation average reference value 42 Watts during Energy Star state

220 VA C conﬁguration – 15 Amp

+3.3 VDC (CH) -900 to -1.4 kV + 5 V (DB) -10 to 400/+300 V +12 V (SB) -100 to -700 V + 32 V (TB) +1k to +7 kV +3.8 V (FIX) 0 to 7 kV

standards: FCC Part 15 Class B VDE Class B EN60555-2 Class A VCCI (CISPR 22:1997) Class B

Environmental speciﬁcations

Characteristic Speciﬁcation

Temperature Operating Non-operating Storage

Humidity Operating Non-operating

10o to 32o C (50oto 90oF) 0o to 32o C (32o to 90o F)

-10o to 43o C (-14 to 109o F) (with supplies) Media should be acclimated 24 hours before using in the printer.

10 to 80% relative humidity, non-condensing 10 to 90% relative humidity, non-condensing Media should be acclimated 24 hours before using in the printer.

Service Guide

Environmental speciﬁcations

Characteristic Speciﬁcation

Altitude Operating Non-operating

Vibration/shock Operating

Non-Operating (vibration) Non-operating (shock)

Acoustic Noise (operating) Standby: 45 dBa, Running: 54 dBa, Impulse: 57 dBa

0 to 2500 m (8,000 ft.) at 25oC 0 to 6000 m (20,000 ft.)

May drop any side or corner 50 mm (2 in.) without impairment of subsequent operation. On ﬁve mutually perpendicular axes: 0.5 g, 25-minute sweep, 5 to 200 to 5 Hz, 100 to 200 sec./sweep cycle. No resonant frequencies below 50 Hz. 15 g, trapezoidal ﬂared pulse, 20 msec each axis.

Regulatory speciﬁcations

The printer is a recognized component in conformance with the following regulatory standards:

The packaged product meets ASTM D4169-93 and ASTM D4728-91

■

Transportation Standards. Listed UL 1950 Information Processing and Business Equipment.

■

Certiﬁed CSA C22.2 No. 950 Safety of Information Technology

■

Equipment, Including Electrical Business Equipment. GS licensed IEC 950 (1991) Second Edition; EN60950 Information

■

Processing and Business Equipment. EN50022 (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

Phaser 2135 Color Printer

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.

Printer fault messages

Code Front panel message Service message

A6 Jam Inside Top Cover, Open Cover, See

Labels

Ensure the correct weight and type of paper is loaded in the feeder. Also ensure the paper is loaded correctly in the feeder.

Clean the bypass feeder’s pick roller.

Test the main feed motor as described in “Motor and clutch tests” on page 69.

Replace the main feed motor.

Replace the engine controller board.

A7 Jam Inside Top Cover, Open Cover, See

Labels

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.

Clean the duplex unit’s rollers.

Test the duplex motor and clutch as described in “Motor and clutch tests” on page 69.

Replace the duplex unit.

Replace the engine controller board.

A10 Jam Inside Top Cover, Open Cover, See

Labels

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.

Clean the exit rollers.

Ensure the exit rolls rotate freely when the exit roller gear train is rotated.

At the rear of the printer, inspect the gate which directs the print to the face-up output bin or the face-down output bin.

Test the fuser motor (which drives the exit gear train) using the test described in “Motor and clutch tests” on page 69.

Replace the engine controller board.

A6-Bypass Feeder Jam

A7-Duplex Entry Jam

A10-Paper Output Jam

Service Guide

Printer fault messages

Code Front panel message Service message

A11 Jam Inside Top Cover, Open Cover, See

Labels

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.

Clean the pick and registration rollers.

Ensure there are no obstructions in the paper path.

Test the registration motor and clutch as described in “Motor and clutch tests” on page 69. Replace the motor or clutch if necessary.

Inspect the wiring for the registration clutch and registration motor.

Replace the engine controller board.

A22 Jam Inside Top cover, Open Cover, See

Labels

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.

Clean the pick and registration rollers.

Ensure there are no obstructions in the paper path.

Test the registration motor and clutch as described in “Motor and clutch tests” on page 69. Replace the motor or clutch if necessary.

Inspect the wiring for the registration clutch and registration motor.

Replace the engine controller board.

B8 Jam Inside Duplex Unit, Open Cover, See

Labels

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.

Clean the duplex unit’s rollers.

Test the duplex motor and clutch as described in “Motor and clutch tests” on page 69.

Replace the duplex unit.

Replace the engine controller board.

B13 Jam Inside Duplex Unit, Open Cover, See

Labels

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.

Inspect and clean the eject rollers behind the fuser unit.

Ensure the paper path leading to the duplex unit and the duplex unit’ s paper path are both clear of obstructions.

Inspect the operation of the solenoid activated separator gate the direct the print into the duplex unit. Test the exit solenoid with the “Motor and clutch tests” on page 69.

Replace the duplex unit.

Replace the engine controller board.

A11-Paper Feed Jam

A22-Feed Path Jam

B8-Duplex Jam

B13-Duplex Inverter Jam

Phaser 2135 Color Printer

Printer fault messages

Code Front panel message Service message

B21 Jam Inside Right Door A, Open Right Door A B21-Duplex Area Jam

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.

Clean the duplex unit’s rollers.

Test the duplex motor and clutch as described in “Motor and clutch tests” on page 69.

Replace the duplex unit.

Replace the engine controller board. C1 Close Tray 1, Tray 1 Not Detected C1-Check Tray 1 C2 Close Tray 2, Tray 2 Not Detected C2-Check Tray 2 C3 Close Tray 3, Tray 3 Not Detected C3-Check Tray 3 C4 Close Tray 4, Tray 4 Not Detected C3-Check Tray 4 C5 Close Tray 5, Tray 5 Not Detected C3-Check Tray 5

Ensure the tray is installed correctly.

Inspect and test the paper size sensors and the tray’s corresponding

sensor ﬂags.

Replace the paper tray sensor board

Replace the paper tray.

Replace the engine controller board. E1 Tray 1 Misfeed, Open Rt Door A and Tray 1 E1-Tray 1 Misfeed E2 Tray 2 Misfeed, Open Rt Door 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 E1-Tray 5 Misfeed

Ensure the correct weight and type of paper is loaded in the tray. Also

ensure the paper is loaded correctly in the tray.

Clean the pick rollers.

Test the main feed motor as described in “Motor and clutch tests” on

page 69.

Replace the main feed motor.

Replace the engine controller board. E9 Top Cover Open, Close Top Cover A E9-Top Cover A Open

Close the cover.

Inspect the switch and ensure the switch’s actuator is not broken.

Test the top cover open switch using the sensor test described in “Switch

scan test” on page 63.

Inspect the switch’s wiring harness.

Replace the engine controller board. E12 Top Output Tray Full Remove Output E12-Output Bin Full, Top

Ensure the output bin full sensor ﬂag operates freely.

T est the output bin full sensor using the test described in “Switch scan test”

on page 63.

Inspect the sensor and its wiring harness.

Replace the engine controller board.

Service Guide

Printer fault messages

Code Front panel message Service message

E14 Close Duplex Unit, Duplex Unit Not Detected E14-Duplex Unit Not

Ensure the duplexer is installed correctly.

Inspect the connector at the rear end of the duplexer unit.

Inspect the wiring harness leading from the duplexer unit interface connector to the engine controller board.

Replace the duplexer unit.

Replace the engine controller board. E18 Right Door A Open, Close Right Door A E18-Right Door A Open E20 Right Door B Open, Close Right Door B E20-Right Door B Open E21 Right Door C Open, Close Right Door C E21-Right Door C Open E22 Right Door D Open, Close Right Door D E22-Right Door D Open E23 Right Door E Open, Close Right Door E E23-Right Door E Open

Ensure the cover’s sensor ﬂag operates

freely.

Test the output bin full sensor using the test

described in “Switch scan test” on page 63.

Inspect the sensor and its wiring harness.

Replace the engine controller board. EA Black Imaging Drum Missing, Reseat Drum EA-Black Imaging Drum

EB Cyan Imaging Drum Missing, Reseat Drum EA-Cyan Imaging Drum

EC Magenta Imaging Drum Missing, Reseat Drum EA-Magenta Imaging Drum

ED Yellow Imaging Drum Missing, Reseat Drum EA-Yellow Imaging Drum

Remove and install the drum unit.

Inspect the spring-loaded drum contact assembly. Ensure they are clean

and move up and down freely. Remove the assembly and reseat it, if

necessary.

Replace the engine controller board.

Replace the printer unit chassis

Detected

Missing

Phaser 2135 Color Printer

Printer fault messages

Code Front panel message Service message

EE Transfer Belt Missing, Reseat Belt EE-Transfer Belt Unit

Remove and re-install the transfer belt unit.

Clean the transfer belt unit’s contact on the front-left side of the engine chassis. Clean the corresponding contacts on the transfer belt unit.

Install a new transfer belt unit.

Replace the engine controller board.

Replace the printer unit chassis.

EF Fuser Missing, Reseat Fuser EF-Fuser Unit Missing

Remove and reinstall the fuser.

install a new fuser.

Replace the low-voltage power supply.

Replace the engine controller board.

H1 Disk Read Error, Press Enter to Clear

A hard disk error was detected that prevented data from being read from the disk.

H2 Disk Write Error, Press Enter to Clear

A hard disk error was detected that prevented data from being written to the disk.

H3 Disk Full Error, Press Enter to Clear

A hard disk full error occurred that prevented data from being written to the disk

Turn the printer off and on again. Ensure the hard drive is properly installed. Re initialize the hard drive. by scrolling to the Reset Menu and selecting the submenu item Disk Init . Replace the hard drive. Replace the system controller board.

J3 Replace Fuser J3-Replace Fuser

Install a new fuser. If a new fuser has been installed but the print engine continues to ask for a new fuser, reset the fuser life count using the topic “Consumable count initialization” on page 73. Replace the engine controller board.

J4 Replace Tr ansfer Belt J4-Replace T r ansfer Belt

Install a new transfer belt. If a new transfer belt has been installed but the print engine continues to ask for a new transf er belt, reset the tr ansf er belt life count using the topic “Consumable count initialization” on page 73. Replace the engine controller board.

Missing

H1-Disk Read Error

H2-Disk Write Error

H3-Hard Disk Full

Service Guide

Printer fault messages

Code Front panel message Service message

J5 Replace Yellow Imaging Drum J5-Replace Yellow Imaging

J6 Replace Magenta Imaging Drum J6-Replace Magenta

J7 Replace Cyan Imaging Drum J7-Replace Cyan Imaging

J8 Replace Black Imaging Drum J8-Replace Black Imaging

Install a new drum unit.

If a new drum unit has been installed but the print engine continues to ask

for a new drum unit, reset the drum unit life count using the topic

“Consumable count initialization” on page 73.

Inspect the spring-loaded drum unit contacts (in a set of three). Ensure

they are clean and move up and down freely. Remove and reseat them, if

necessary.

Replace the engine controller board. J9 Y ellow Toner Empty Replace Yellow Toner J9-Yellow T oner 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 Toner J12-Black Toner Empty

Install a new toner cartridge.

If a new cartridge has been installed but the print engine continues to ask

for a new cartridge, reset the toner cartridge life count using the topic

“Consumable count initialization” on page 73.

Replace the drum unit.

Replace the engine controller board. L0 Load Tray # 1 Size 2 Type 3 Load Tray #, Size Type

1. Load the requested size and type of paper in the tray.

2. Ensure the tray is installed correctly.

3. Inspect and test the paper size sensors and the tray’s corresponding

sensor ﬂags.

4. Replace the paper tray sensor board.

5. Replace the paper tray.

6. Replace the engine controller board.

Drum

Imaging Drum

Drum

Phaser 2135 Color Printer

Printer fault messages

Code Front panel message Service message

T1 Fuser Upper Error T1 Power Off/On T1-Fuser Upper Error T2 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” on page 63.

3. Replace the fuser.

4. Replace the low-voltage power supply.

5. Replace the engine controller board.

T29 Temp Sensor Error T29, Power Off/On T29-Temp Sensor Error T30 RH Sensor Error T30, Power Off/On T30-RH Sensor Error

1. Test the temperature sensor or the relative humidity sensor using the sensor test described in “Switch scan test” on page 63.

2. Inspect the wiring harness leading to the entrance sensor board.

3. Replace the 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 is not blocked.

2. Remove and install the fuser.

3. T est the thermistor inside the fuser using the test described in “Switch scan

test” on page 63.

4. Replace the fuser.

5. Replace the low-voltage power supply.

6. Replace the engine controller board.

T32 LED Over Temperature T32, Power Off/On T32-LED Over Temp Error

1. Ensure all the chassis cooling fan is operating and is not blocked.

2. Ensure the printer is operating in the correct temperature environment; the

printer’s Service Menu : Print Diag Summary test page lists the ambient temperature sensed by the printer.

3. Replace the LED heads.

4. Replace the engine controller board.

Service Guide 23

Printer fault messages

Code Front panel message Service message

U0 Engine ROM Error U0, Power Off/On U0-Engine ROM Error U1 Engine RAM Error U1, Power Off/On U1-Engine RAM Error U2 Engine EPROM Error U2, Power Off/On U2-Engine EPROM Error U3 Engine EPROM Missing U3, Power Off/On U3-Engine EPROM Missing U4 Engine SRAM Error U4, Power, Off/On U4-Engine SRAM Error U5 Engine Control Error U5, Power, Off/On U5-Engine Control 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.

U6 Power Supply Error U6, Power Off/On U6-Power Supply Error

1. Inspect the front and rear power supply fans. Ensure they is running correctly and are not blocked. The front fan blows into the chassis. The rear fan blows out from the chassis.

2. Turn the printer off and then on.

3. Replace the low-voltage power supply.

4. Replace the engine controller board.

U7 Feeder Home Error U7, Power Off/On U7-Feeder Home Error

1. Test the manual bypass feeder home sensor using the test described in “Switch scan test” on page 63.

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. Inspect the electrical chassis fan to see if it is running and not blocked.

2. Inspect the fan’s wiring harness.

3. Replace the fan.

4. Replace the engine controller board.

U9 Supply Fan Error U9, Power Off/On U9-Supply Fan Error

1. Inspect the main cooling fan to see if it is running and not blocked.

2. Inspect the fan’s wiring harness.

3. Replace the fan.

4. Replace the engine controller board.

U10 Roller Position Error U10, Power Off/On U10-Roller Position Error

1. Ensure the correct weight and type of paper is loaded in the currently used tray. Also ensure the paper is loaded correctly in the tray.

2. Clean the pick and registration rollers.

3. Ensure there are no obstructions in the paper path.

4. Test the registration motor and clutch as described in “Motor and clutch

tests” on page 69. Replace the motor or clutch if necessary.

5. Inspect the wiring for the registration clutch and registration motor.

6. Replace the engine controller board.

24 Phaser 2135 Color Printer

Printer fault messages

Code Front panel message Service message

U12 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). Inspect the printer’s corresponding connector on the printer chassis (covered by a ﬂexible metal plate).

3. Inspect the wiring harness leading from the engine control board to the duplex unit connector.

4. Replace the duplex unit.

5. Replace the engine controller board.

U13 Tray 3 I/F Error U13, Power Off/On U13-Tray 3 I/F Error U14 Tray 2 I/F Error U14, Power Off/On U14-Tray 2 I/F Error U16 Tray 4 I/F Error U13, Power Off/On U13-Tray 4 I/F Error U17 Tray 5 I/F Error U14, Power Off/On U14-Tray 5 I/F Error

1. Turn the printer off and then on.

2. Inspect the interface connector connecting the tray unit to the print engine.

Inspect the printer’s corresponding connector on the underside of the printer. Inspect the wiring harness leading from the connector to the engine control board.

3. Replace the engine controller board.

U15 Control Panel Error 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 Yellow LED Error U18, Power Off/On U18-Yellow LED Bar

U19 Magenta LED Error U19, Power Off/On U19-Magenta LED Bar

U20 Cyan LED Error U20, Power Off/On U20-Cyan LED Bar Missing U21 Black LED Error U21, Power Off/On U21-Black LED Bar Missing

1. Ensure the LED assembly is correctly installed.

2. Inspect the wiring harnesses leading to the LED assembly.

3. Replace the engine controller board.

U22 Yellow Toner Missing, Reseat Toner U22-Yellow Toner Missing U23 Magenta Toner Missing, Reseat Toner U23-Magenta Toner Missing U24 Cyan Toner Missing, Reseat Toner U24-Cyan Toner Missing U25 Black Toner Missing, Reseat Toner U25-Black Toner Missing

1. Inspect the toner cartridge sensor ﬂag. Ensure to moves properly and is not broken.

2. T est the sensor using the test described in “Switch scan test” on page 63.

3. Inspect he toner sensor boards wiring harness.

4. Replace the toner sensor board.

5. Replace the engine control board.

U26 Yellow Drum Error U26, Power Off/On U26-Yellow Drum Error

Missing

Service Guide 25

Printer fault messages

Code Front panel message Service message

U27 Magenta Drum Error U27, Power Off/On U27-Magenta Drum Error U28 Cyan Drum Error U28, Power Off/On U28-Cyan Drum Error U29 Black Drum Error U29 Power Off/On U29-Black Drum Error

1. Remove and install the drum unit.

2. Inspect the spring-loaded drum unit contacts (in a set of three). Ensure

they are clean and move up and down freely. Remove the assembly and reseat it, if necessary.

3. Test the drum unit contacts using the Drum contact switch test listed in “Switch scan test” on page 63.

4. Install a new drum unit.

5. Replace the engine 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 did not detect the CRC’s “new/used” fuse blow. An internal fuse of a new CRC ordinarily blows a few seconds after the CRC is installed. If the fuse cannot be blown, then the consumable’s counter can't be reset and the “consumable expired / replace” messages will not go away.

1. Remove the CRC.

2. Cycle the printer’s power.

3. Install the CRC again. If the error still

occurs, try a different CRC.

4. If error reoccurs with a different CRC, replace the engine controller board.

5. Replace the print unit chassis.

26 Phaser 2135 Color Printer

System controller board diagnostic error codes

Code Test Possible Cause

1 Memory Bad memory DIMMs 2 Memory Speed Bad DIMMs or system controller board 3 CPU Tick Bad system controller board 4 System Timer Bad system controller board 5 BX Host Bridge Bad system controller board 6 PIIX4 PCI-ISA Bridge Bad system controller board 7 21152 PCI-ISA Bridge Bad system controller board 8 PCI-PCI Bridge Bad system controller board 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

13 Strata Flash File System

Integrity 14 STE100 Bad system controller board 15 VX2b-0 Bad system controller board 16 VX2b-1 Bad system controller board 17 VX2b-2 Bad system controller board 18 VX2b-3 Bad system controller board 19 Disk Identify Bad hard disk drive 20 Disk Read/Write Bad hard disk drive 21 Disk Read Capability Bad hard disk drive 22 Disk Write Capability Bad hard disk drive 23 Disk Data Format Check Bad hard disk drive

Bad system controller board

Service Guide 27

These are error codes returned by the system controller board. In the event that one of these errors occurs:

1. Cycle printer power to see if the error reoccurs.

2. Reseat the system controller board.

3. 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

00 Unknown. Replace the hard drive before replacing the controller board. 04 Video T ask 08 Serial Task 10 System Display Task 14 System 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 Cleanup Task 3C Collation T ask 40 Parallel Port Hear Task 48 PostScript Task 1. Replace the hard drive before replacing the controller

board. 4C PostScript Task 2 50 PostScript_Wrapper Task 54 PCL Task. Replace the hard drive before replacing the controller board. 58 PJL T ask 78 Dequeue T ask 84 In-menu Print File Task 8C Alert Recovery Task 90 Sweeper T ask 94 SNMP Alert Task 98 SNMP Main Task 9C SNMP UDP Task A0 SNMP DDP Task A4 SNMP IPX Task A8 Notiﬁcation Manager B4 Image Handler C4 Job Manager D0 PowerSa ver Task D4 TIFF T ask

28 Phaser 2135 Color Printer

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.

Fault History Log

The printer maintains a log ﬁle of the last 50 errors that have occurred. The most recent error is displayed ﬁrst.

To view the log:

Turn on the printer.

Press the

Press the most recent error. Press the

Menu (5) Item(6) Value (7)

key to scroll to the

key to scroll to the menu item

key to scroll down the list of errors. The ﬁrst item is the

Value (3)

Support Menu.

Show Fault History

key to scroll back up the list.

Service Guide

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. Checks RAM by writing a preset data pattern in RAM, reading the contents of RAM, and comparing the data read from RAM by the data written in RAM.

EEPROM check. Checks ID numbers stored in the ﬁxed addresses of EEPROM. Checks the content of the menu area by control ﬁrmwar e and the engine area by engine ﬁrmware.

Flash ROM check. Checks Flash ROM by writing a present data pattern in Flash ROM, reading the contents of Flash ROM, and comparing the data read from Flash ROM by the data written in Flash ROM.

Mechanical check.

All 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 engine motors rotate to ensure that their rotation sensors are detected.

■

A sensor check is made to determine if any paper is jammed in the printer.

■

The print engine checks the presence of each toner cartridge.

■

Option unit check. Checks whether the optional units (such as the paper tray 2, paper tray 3, duplex unit) have been installed before entering the operation mode.

The print engine performs a color misalignment detection check by

■

laying down patches of toner on the transfer belt and reading their relative positions to each other with the color registration sensor assembly.

■

After the fuser reaches its idle temperature the printer is placed on line in its READY state.

The print engine is initialized. If the startup page feature has not been disabled and no error occurred with the printer, the printer prints a startup page.

Phaser 2135 Color Printer

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” on page 32.

Observe that the go to the later topic “Verifying power supply operation” on page 32.

To ensure the print engine operates correctly, print one of its internal test pages from its diagnostic menu as explained in the topic “Test printing” on page 71.

If the printer prints a test print, then the printer's print engine is working correctly. Proceed with the next topic, “Verifying printer operation by using its self-test print” on page 32.

If the printer does not make the test print, then a problem exists with the print engine. Proceed with the topic, “Verifying power supply operation” on page 32.

Ready

message is displayed on the front panel. If it is not,

Service Guide

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. The health LED is viewable through the rear panel. If the health LED is not ﬂashing, then the system controller board is not working.

When the

Ready

message is displayed, press the

Menu (1, 5)

buttons to

enter the menu.

Press the

Item (2, 6

Menu (1, 5)

buttons to navigate to the

Print Menu

item. Press the

) keys to scroll through the list of available test prints. Select any

test print.

Press

Enter

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 are working correctly and the printer's problem resides with the network or host interface.

Verifying power supply operation

Required tools

#1 Phillips screwdriver

■

Digital multimeter (DMM)

Verifying the power supply involves four steps:

Measuring the input and output voltages.

■

Checking the power supply fuse.

■

Checking the safety interlocks.

■

Ensuring the +5 VDC loop is complete.

■

Testing for a shorted motor which would shut down the power supply

■

or damage the engine controller board.

Measuring power supply voltages

Turn off the printer and unplug it from its power outlet.

AC Input:

being supplied to the printer. It should measure between 87 to 128 VAC (115 VAC nominal) or 174 to 250 VAC (220 VAC nominal).

With the DMM set to measure AC voltages, measure for power

Phaser 2135 Color Printer

Power supply fans

: With the power switch on, ar e the fr ont 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). If the voltage is not correct, replace the low-voltage power supply. Otherwise, replace the non-functioning power supply fan.

DC Output:

With the DMM set to measure DC voltages, measure the voltages at the POWER connector on the bottom of the print engine controller board for +3.3VDC, +5 VDC, +12 VDC and +32 VDC. (You must remove the rear cover and rear shield plate to access the engine controller board.)

If the voltages are not correct, inspect the wiring harness connecting the POWER connector of the engine controller board to the CN1 connector of the low-voltage power supply. If the harness is undamaged, replace the power supply.

POWER connector pinout

Pin Voltage/Signal Level Pin Voltage/Signal Level

1 +12 VDC 16 +3.3 VDC 2 No connection 17 +3.3 VDC 3 Ground 18 +3.3 VDC 4 Ground 19 No connection 5 Ground 20 Signal 6 Ground 21 Signal 7 +32 VDC 22 Signal 8 +32 VDC 23 Signal 9 +32 VDC 24 Signal 10 +32 VDC 25 Ground 11 +5 VDC 26 Ground 12 +5 VDC 27 Ground 13 +5 VDC 28 Ground 14 +5 VDC 29 Signal 15 +3.3 VDC 30 Signal

If DC voltages are not being output by the power supply, proceed to the next step, “Inspecting the low-voltage power supply fuse” on page 34.

If the +5 and +32 VDC voltages measure correctly, but the printer does not operate correctly, then proceed to the topic, “Safety interlocks” on page 34.

Service Guide

Inspecting the low-voltage power supply fuse

The 115 VAC power supply features a 20 A fuse. The 220 V AC 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” on page 95. The fuse is now accessible.

If the fuse is good, but the printer's power supply does not output DC voltages, replace the low-voltage power supply. Check the +% v loop circuit 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 top cover switch is opened, the +32 VDC supply to the motors is shut down, as well as the high-voltage power supply and an error message is displayed on the front panel. When the right cover door is opened, the +32 VDC supply to the duplex unit and high-voltage power supply is disabled.

Turn off the printer.

With a DMM set to measure resistance, test each switch when it is opened and closed.

Inspect each switch’s wiring harness for pinches, nicks or open connections.

If you ﬁnd a switch that is defective, replace it. If no motors appear to be at fault, replace the engine controller board.

Phaser 2135 Color Printer

Door safety interlock switches

Top Cover Open Switch

Front Cover Open Switch

0725-63

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. The +5V is then routed back out the toner sensor board through its power supply harness to the low-voltage power supply connector CN 2.

Upon power-up, if the low-voltage power supply does not detect 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:

Test surface-mount fuse F6 for continuity. It is located on the upper-right corner of the engine controller board next to the REG connector. If the fuse is opened, replace the engine controller board.

Inspect the two power wiring harnesses and the ribbon cable that carry the +5 VDC loop. Ensure they are properly connected. The wiring harness leading form the toner sensor board to the power supply features an interconnect next to the rear hinge. Ensure it is properly connected.

Service Guide

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.

Run a jumper wire from the +5V pins of the ﬁrst wiring harness (pins 11 14, red wire bundle) to the +5V pin (pin 9, dark-gray wire bundle) of the second power wiring harness. (With the jumper wire, you are bypassing the engine controller board, the OPTN ribbon cable 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 the engine controller board or the toner sensor board or their wiring. If the low-voltage power supply does not turn on, it is probably bad. (Ensure your jumper connection is correct.)

Testing for a shorted motor

Remove the top and rear covers.

Disconnect the motor harnesses and verify motor resistances (see the following topic).

Refer to the topic “Wiring Diagram” on page 215 for a diagram that locates each connector.

Turn on the printer again to see if it overloads now that the motors are disconnected from the engine driver board.

If the power supply still does not function, replace it.

Phaser 2135 Color Printer

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 Magenta drum unit motor Cyan drum unit motor Black drum unit motor

Between motor Pins 1 and 2 Between motor Pins 3 and 4

All the drum motors connect to connector ID at the top of the engine controller board Black Pins 1 thru 4 Yellow Pins 5 thru 8 magenta Pins 9 thru 12 Cyan Pins 13 thru 16

Transfer belt motor Registration motor 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 pins 1 thru 4

The main motor connects to

connector HOPFF pins 5 thru 8 Tray lift motor Between motor Pins 1 and 2 ~100 Fuser unit

Upper Roller

Between Pins A and B New fuser: The resistance between pins C and D of the lower roller will be O Ω, a fuse.

Used fuser: The fuse between pins C and D of the lower roller

Between Pins C and D

Between Pins E and F

Lower Roller

Between Pins A and B

Between Pins C and D

Between Pins E and F will be open. The fuse indicates a new fuser and is blown within seconds of being installed to indicate a fuser now in use.

B A

Ω

Open ~360 at 25

Ω

0 Ω or open (fuse) ~360 at 25

C D E F

Underside of fuser

Service Guide

Media jams and the paper path

Required tools

■ #1 Phillips screwdriver

■ DMM

Jams fall into the following four categories:

Media-based problems

■

Paper-picking errors

■

Printing jams

■

Paper-ejecting errors

■

Media-based problems

Media problems

Check that the correct type of media is being used. The customer should be using a quality laser printer paper. The printer may have trouble picking slick-ﬁnish paper.

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.

Refer to the media speciﬁcations in the table “Functional speciﬁcations,” on page 17.

Multiple-sheet pick

Is the paper in good condition and appropriate for a laser printer? Quality ofﬁce laser printer paper works best.

2. Is the printer printing within its environmental speciﬁcations? Print the

Diagnostic Summary Page to determine the printer’s condition.

3. Ensure the paper is correctly loaded in the tray.

4. Clean the pick rollers with a clean, dry, lint-free wipe if debris is visible.

5. Replace the paper pick rollers.

6. Check the tray’s retard roller for damage.

7. Replace the paper tray.

Phaser 2135 Color Printer

The media skews passing through the paper path

1. Make sure that the media is properly installed in the tray.

2. Does the pick-up roller pick up evenly? Is it clean? Clean it with a clean,

dry, lint-free cloth if debris is visible.

3. Is the paper tray damaged or obstructed?

4. Are the tray's side paper guides snugly adjusted against the stack of media?

The guides should be neither too loose nor too tight.

5. The problem occur when printing from a different tray?

6. Is there an obstacle blocking the paper path?

7. Is the media excessively curled?

8. Is the customer using an appropriate type of media – a type the printer can

handle?

9. Ensure the corners or the paper are under the tabs in the corners of the tray.

10. Replace the paper pick rollers.

The paper tray indicates it is empty when it is not

The procedure for troubleshooting 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 the left of the pick rollers.

2. Test the sensor using the service tests described in “Switch scan test” on

page 63.

3. Does the tray lift motor raise the loaded paper up to the sensor ﬂag when

the tray is installed? Remove most of the paper from the tray, reinsert the tray in the printer and then observe the tray paper level indicator on the front of the tray. The indicator should move from a level full indication (tray lift in lowest position) to a near-empty indication (tray lift in a higher position).

Ensure the tray lift mechanism in the tray moves freely. If you do not hear the tray lift motor operate, test the motor with the motor test in “Motor and clutch tests” on page 69. Replace the tray lift motor, if necessary. If the motor runs but the paper is not raised, replace the main feeder assembly.

4. Replace the engine controller board.

Service Guide 39

Jams

Wrong media

1. 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.

2. Inspect the paper tray for damage to the tray’s paper size sensor actuators.

3. Test the printer’s paper size sensors using the service test “Switch scan test”

on page 63. If the sensors test ok, then the engine controller board is probably bad.

4. Replace the paper size sensor board’s wiring harness.

Paper jams at the paper tray

1. Is the paper in good condition and appropriate 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 dirty? If so, clean them if debris is visible and try

printing again.

4. Remove the paper tray and inspect the paper tray lift levers on the

inner-sides of the paper tray cavity. Inspect the tray’s paper lift mechanism.

5. Does the paper feed motor run? Check the motor’s wiring harness and

connection (HOPFF) to the engine controller board.

6. Replace the main feeder assembly (it contains the paper feed motor).

7. Check the gear train for broken teeth and proper installation.

8. Replace the pick rollers.

9. Does the pick clutch work properly? If not, replace it.

10. Replace the engine controller board.

40 Phaser 2135 Color Printer

Manual bypass feeder feed jams

1. Is the paper in good condition and appropriate 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. Do not overload the manual bypass tray; otherwise jams will occur.

4. If debris is visible, clean the manual bypass feed pick roller. Replace the

roller, if necessary.

5. Test the manual bypass feeder sensors using the service test “Switch scan

test” on page 63.

6. Inspect the wiring harness from the manual bypass feeder to the engine

controller board.

7. Replace the manual bypass feeder assembly.

8. Replace the engine controller board.

Paper 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 obstructions that could block the

movement of a sheet of paper.

3. Clean the registration rollers with a clean, dry, lint-free wipe if debris is

visible.

4. Test, and if necessary, replace the registration motor. Test the motor using

the service test “Motor and clutch tests” on page 69.

5. Does the registration roller electric clutch operate correctly? Operate it with

the service test “Motor and clutch tests” on page 69.

6. Transparency ﬁlm. Use only Xerox 35-series transparency ﬁlm meant for

this printer.

Paper jams at the transfer belt

1. Check for a paper scrap in the paper path.

2. Is the transfer belt assembly correctly installed?

3. Test the transfer belt motor using the service test “Motor and clutch tests”

on page 69.

Service Guide 41

Fuser jams

1. Is the paper in good condition and appropriate for a laser printer?

2. Is Xerox Series-35 transparency ﬁlm being used.

3. Is the printer printing within its environmental speciﬁcations? Print the

Diagnostic Summary Page to determine the printer’s environmental conditions.

4. Test the fuser motor using the service test “Motor and clutch tests” on

page 69.

5. Does the exit sensor ﬂag properly actuate its sensor? Use the service test

“Switch scan test” on page 63 to test the senor.

6. Does the jam occur only during a two-sided print? Is so the duplex

solenoid may not be operating correctly and the print is jamming in the fuser.

7. Replace the fuser.

8. Replace the engine controller 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 Summary Page to determine the printer’s environmental conditions.

3. Is the jam caused by a heavy, stiff paper being printed to the face-down

tray? In such cases, a lighter grade of paper should be used or face-up mode to the side output tray should be used.

4. Is the paper excessively curved after passing through the fuser? Try

ﬂipping the paper over in the paper tray. Also, for A-, A4- and B5-sized paper , re-orient the paper in the tray so the short edge feeds into the printer.

5. Clean all the eject rollers with a clean, dry, lint-free wipe if debris is visible.

6. Does the exit sensor ﬂag properly actuate its sensor? Test the sensor using

the service test “Switch scan test” on page 63.

7. Replace the engine controller board.

42 Phaser 2135 Color Printer

Jams in the duplex unit

1. Is the duplex unit correctly installed?

2. Clean the rollers inside the duplex unit with a clean, dry, lint-free wipe if

debris is visible.

3. Inspect the duplex unit for foreign objects such as a scrap of paper.

4. Inspect the duplex unit’s electrical connector for damage.

5. Does the duplex unit’s sensors operate correctly? Test the sensors using the

service test “Switch scan test” on page 63.

6. Test the duplex motor using the service test “Motor and clutch tests” on

page 69.

7. Replace the duplex unit.

8. Replace the engine controller board.

No imaging drum installed

1. Ensure that the imaging drums are properly installed.

2. Check the high-voltage terminal connectors for the imaging drum to ensure

that 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 that each

unit’s drum contact assembly (a set of three spring-loaded pins) is not damaged. Ensure that each contact moves up and down freely and is not contaminated with toner. Remove an assembly from the printer to inspect, if necessary.

3. Open the top cover, defeat the top cover open switch, and observe if the

color imaging drum unit are lifted up and down.

4. Test the drum contact assemblies using service test “Switch scan test” on

page 63. If a drum contact assembly is damaged, replace it.

5. Does each imaging drum motor rotate. Test them using the service test

“Motor and clutch tests” on page 69. Replace the main motor assembly, if indicated.

6. Inspect the gear drive for each imaging drum unit for damage.

7. Replace the engine controller board.

Service Guide 43

Fan error

1. Is power supplied to pin 1 of the fan? If yes, replace the fan.

2. Inspect the fan’s wiring harness for damage.

3. Replace the low-voltage power supply

4. Replace the engine controller board.

Fuser unit error

1. Does the error occur immediately after the printer is turned on? Replace

the fuser.

2. Check that AC voltage supplied to the printer is correct.

3. Does the fuser get hot? If not, replace the fuser.

4. If the fuser does warm up, verify that it is reaching the correct temperature

by running the service 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. These pins connect to Pins A and B of the fuser (illustrated below) when the fuser is installed. Remove the fuser to check. If not, replace the power supply.

B A

C D E F

Underside of fuser

0728-02

Bear in mind that the correct AC voltage may be present at Pins 1 and 2 of CN 4-1 and CN 4-2 even though the drivers ICs feeding these pins are damaged and cannot deliver the current required by the fuser heaters.

6. Replace the engine controller board.

7. Replace the low-voltage power supply.

44 Phaser 2135 Color Printer

Printing and print quality problems

Required tools

■ #1 Phillips screwdriver ■ Conductive grease

■ Volt-ohm-meter (VOM) ■ Ruler

Light or blurred images

1. Is the correct paper being used

in the printer?

2. Are the toner cartridges low?

3. Are any of the imaging drum

reaching their end-of-life? Replace them if they are.

4. Do the imaging drum units

make good connection to their power terminals?

5. Are the LED heads dirty? Clean

each head with a clean, alcohol-soaked, lint-free cloth.

6. Are the LED heads wiring

harnesses undamaged and properly seated?

7. Is +3.8V (red wire) supplied to

Pin 3 of 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 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.

9. If +32 volts supplied to the POWER connector pins 7, 8, 9 and 10 on the

engine controller board? Inspect the wiring harnesses or replace the low-voltage power supply.

10. Is +32V supplied to the HVOLT connector Pin 5 of the engine board. If not

replace the engine board. (Transfer the old engine controller board’s EEPROM (lower-right corner of board) to the new engine contr oller boar d.)

11. Inspect the high-voltage wiring harnesses.

12. Replace the high-voltage power supply.

Service Guide 47

Dark, stained background

1. Determine if any of the imaging

drums were exposed to light for an extended amount of time. If so, replace any unit which was.

2. Examine the fuser rollers for

contamination. Replace the fuser if they are.

3. Ensure the media type is

correctly set.

4. Are the power supply fans both

running? A heat build-up under the imaging units can cause toner to stain the print’s background.

5. Do the imaging drum units

make good connection to their power terminals?

6. Are the LED heads wiring

harnesses undamaged and properly seated?

7. Is +3.8V (red wire) supplied to

Pin 3 of 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 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.

9. If +32 volts supplied to the POWER connector pins 7, 8, 9 and 10 on the

engine controller board? Inspect the wiring harnesses or replace the low-voltage power supply.

10. Is +32V supplied to the HVOLT connector Pin 5 of the engine board. If not,

replace the engine board. (Transfer the old engine controller board’s EEPROM (lower-right corner of board) to the new engine contr oller boar d.)

11. Inspect the high-voltage wiring harnesses.

12. Replace the high voltage power supply.

48 Phaser 2135 Color Printer

Blank print

1. Do the imaging drum units

make good connection to their power terminals?

2. Are the LED heads wiring

harnesses undamaged and properly seated?

3. Is +3.8V (red wire) supplied to

Pin 3 of each LED head assembly? If yes, replace the LED head assembly.

4. Is +3.8 V supplied to the

5. If +32 volts supplied to the

POWER connector pins 7, 8, 9 and 10 on the engine controller board? Inspect the wiring harnesses or replace the low-voltage power supply.

6. Is +32V supplied to the HVOLT connector Pin 5 of the engine board. If not,

replace the engine board. (Transfer the old engine controller board’s EEPROM (lower-right corner of board) to the new engine contr oller boar d.)

7. Inspect the high-voltage wiring harnesses.

8. Replace the high voltage power supply.

Service Guide 49

Black stripe in direction of paper travel

Note A-size prints are normally

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.

B-size prints are processed through the printer with the long edge of the print parallel to the paper path making artifacts parallel to the long axis of the print.

Leading Edge

1. Do the imaging drum units make

good connection to their power terminals?

2. Are the LED heads wiring

harnesses undamaged and properly seated?

3. Is +3.8V (red wire) supplied to

Pin 3 of 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

5. If +32 volts supplied to the POWER connector pins 7, 8, 9 and 10 on the

engine controller board? Inspect the wiring harnesses or replace the low-voltage power supply.

6. Is +32V supplied to the HVOLT connector Pin 5 of the engine board. If not

replace the engine board. (Transfer the old engine controller board’s EEPROM (lower-right corner of board) to the new engine contr oller boar d.)

7. Inspect the high-voltage wiring harnesses.

8. Replace the high voltage power supply.

50 Phaser 2135 Color Printer

White stripe in direction of paper travel

Note A-size prints are normally

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.

B-size prints are processed through the printer with the long edge of the print parallel to the paper path making artifacts parallel to the long axis of the print.

Leading Edge

1. Look for dirt or contamination

on the LED heads. Clean them with a clean, alcohol-soaked, lint-free wipe.

2. Do the imaging drum units make

good connection to their power terminals?

3. Are the LED heads wiring

harnesses undamaged and properly seated?

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 the 16-pin interconnect near the top cover 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.

6. If +32 volts supplied to the POWER connector pins 7, 8, 9 and 10 on the

engine controller board? Inspect the wiring harnesses or replace the low-voltage power supply.

7. Is +32V supplied to the HVOLT connector Pin 5 of the engine board. If not

replace the engine controller board. Transfer the old engine controller board’s EEPROM (lower-right corner of boar d) to the new engine contr oller board.

8. Inspect the high-voltage wiring harnesses.

9. Replace the high voltage power supply.

Service Guide 51

Poor fusing, toner offsetting

1. Is a supported paper type being

used? Try printing on a different brand of paper.

2. Is the fuser unit properly

installed and making good electrical contact with the print engine? Inspect its connector.

3. Inspect the fuser. Are its rollers

contaminated or damaged?

4. Ensure the media type is

correctly set.

5. Does AC voltage appear between

Pins 1 and 2 of CN 4-1 and CN 4-2 of the fuser connector. These pins connect to Pins A and B on the fuser’s underside when the fuser is installed; remove the fuser to check. If not, replace the power supply.

6. Is the resistance of the fuser’s

upper roller thermistor (at room temperature) between 190 to 980 Ω? If not replace the fuser.

7. Is the resistance of the fuser’s lower roller thermistor (at room temperature)

between 190 to 980 Ω? If not replace the fuser.

8. Is the fuser temperature correct during printing? Run the 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 EEPROM (lower-right corner of boar d) to the new engine contr oller board.

Offsetting and fuser temperature. Offsetting occurs on specialty paper if the fuser’s temperature does not match the paper loaded in the multi-sheet bypass feeder . For cold-of fsetting, characterized by toner ﬂ aking of f the completed print, you want to raise the fuser’s temperature. For hot-offsetting, characterized by toner pulled off print as it is fused, you want to lower the fuser’s temperature. The chart below lists the specialty paper types and relative fuser temperatures used. To correct offsetting, select the next paper type above or below the current paper type you are using. Removing and reloading paper in the multi-sheet bypass feeder, prompts you for the paper type at the control panel.

Hottest fuser temperature used

Thick Cardstock Glossy Thin Cardstock Heavy Paper Plain Paper Light Paper Coolest fuser temperature used

52 Phaser 2135 Color Printer

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. They may also be shaped something other than round.

■ If the spots are about 143 mm

(5.6 in.) apart, 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 spots are 58 mm

(2.3 in.) the problem is with the transfer roller of the transfer belt unit. Replace the transfer belt unit.

■ 94 mm (3.7 in.): Imaging drum. Replace the imaging drum unit.

■ 50 mm (2.0 in.): Developing roller. Replace the imaging drum unit of

the affected color.

■ 44 mm (1.7 in.): Charging roller. Replace the imaging drum unit of the

affected color.

■ 68 mm (2.7 in.): Toner supply roller. Replace the imaging drum unit of

the affected color.

Service Guide 53

Missing characters or voids in print

1. Look for dirt or contamination

on the LED heads. Clean them with a clean, alcohol-soaked, lint-free wipe.

2. Inspect and clean the imaging

drum unit’s power terminals Ensure the spring-loaded pins travel smoothly up and down.

3. Is a low-toner condition

occurring?

4. Replace any imaging drum

units you suspect are defective.

5. Are the LED heads’ ribbon

cables undamaged and properly seated?

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

8. If +32 volts supplied to the POWER connector pins 7, 8, 9 and 10 on the

engine controller board? Inspect the wiring harnesses or replace the low-voltage power supply.

9. Is +32V supplied to the HVOLT connector Pin 5 of the engine board. If not

replace the engine controller board. Transfer the old engine controller board’s EEPROM (lower-right corner of boar d) to the new engine contr oller board.

10. Inspect the high-voltage wiring harnesses.

11. Replace the high voltage power supply.

54 Phaser 2135 Color Printer

Color misalignments

1. 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, allowing no toner to fall on the senors.

2. Look for any broken gears in

the printer. speciﬁcally, inspect the imaging drum gear assembly, the paper feeder assembly and the transfer belt assembly.

3. Inspect and clean the imaging

drum unit’s power terminals Ensure the spring-loaded pins travel smoothly up and down.

4. Replace any imaging drum units you suspect are defective.

5. Are the LED heads’ ribbon cables undamaged and properly seated?

Replace any suspect LED head assembly, if necessary

6. Inspect the wiring harnesses of the junction board for damage or improper

seating.

7. Inspect the wiring harnesses of the engine controller board for damage or

improper seating.

8. Replace the engine controller board. Transfer the old engine controller

board’s EEPROM (lower-right corner of boar d) to the new engine contr oller board.

Service Guide 55

Unexpected colors

The colors produced by the printer are dramatically different from the color you expected.

1. Look for dirt or contamination

on the LED heads. Clean them with a clean, alcohol-soaked, lint-free wipe.

2. If it appears that a single

primary color is missing, check that imaging drum’s toner cartridge to see if it is empty; the toner sensor board may not be detecting the empty sensor.

3. Inspect and clean the imaging

drum unit’s power terminals Ensure the spring-loaded pins travel smoothly up and down.

4. Replace any imaging drum

units you suspect are defective.

5. Are the LED heads wiring

harnesses undamaged and properly seated?

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

8. If +32 volts supplied to the POWER connector pins 7, 8, 9 and 10 on the

engine controller board? Inspect the wiring harnesses or replace the low-voltage power supply.

9. Is +32V supplied to the HVOLT connector Pin 5 of the engine board. If not

replace the engine controller board. Transfer the old engine controller board’s EEPROM (lower-right corner of boar d) to the new engine contr oller board.

10. Inspect the high-voltage wiring harnesses.

11. Replace the high voltage power supply.

56 Phaser 2135 Color Printer

Image is skewed on the paper

1. 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?

2. Is the printer printing within its environmental speciﬁcations? Print the

Diagnostic Summary Page to determine the printer’s conditions.

3. Ensure the tray is properly loaded with the tray’s paper guides correctly

snugged against the stack of paper.

4. Swap the tray from which the skewed print originates.

5. Ensure that paper feed rollers are clean and undamaged. Clean them with

a clean, dry, lint-free cloth if debris is visible. Inspect the paper pick roller.

6. Replace the paper pick rollers.

7. Look for obstructions in the paper path.

8. Clean the intermediate and aligning rollers. Clean them with a clean, dry,

lint-free cloth if debris is visible.

9. Replace the paper feeder.

Image is not centered on the print

1. Is the paper in good condition and appropriate for a 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 undamaged. Clean them with a

clean, dry, lint-free cloth if debris is visible. Inspect its paper pick roller. Look for obstructions in the paper path.

4. Clean the feed rollers and the registration rollers with a clean, lint-free wipe.

5. Use the margin adjust function found in the front panel Support Menu /

Margin Adjust.

6. Replace the engine controller board.

The print is wrinkled

1. Check for an obstruction in the paper path, particularly with the feed rollers

and the fuser.

2. Is the paper in good condition and appropriate size, weight, grain and

grade for a laser printer? Print the Diagnostic Summary Page to determine the printer’s conditions.

3. Is the printer printing within its environmental speciﬁcations?

4. If possible, you should feed long-grain paper into the printer. Long-grained

paper's grain is parallel to the paper path (the direction the paper travels while it is fed through the printer). Rotate A-, A4- and B5-size paper for short-edge feed to see if it makes a difference.

Service Guide 57

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.

1. Make sure that the correct printer icon was selected in the Chooser. Try

printing the job again. Try printing a different ﬁle or from a different application.

2. In the Chooser, switch background printing off. Try printing the job

again. With newer LaserWriter printer drivers, select Foreground Printing in the Print dialog box.

3. Download the Echo showpage snippet which produces a blank sheet of

paper, to determine if the printer is receiving and processing ﬁles.

4. Make sure you are printing with the correct PPD ﬁle.

5. Activate Error Handler using the front panel Advanced Printer

Settings menu. Alternately, download the Error Handler utility and try printing the job again. If an error page is printed after printing the job again, call the Customer Support 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 print on the black-and-white PostScript printer, this may mean that the problem is application- or network-related.

Image is rotated 90 degrees

1. In the application's Page Setup, make sure that the image is selected to

print in Portrait or Landscape orientation, as you expect.

Image prints in black-and-white

1. In the Chooser, ensure a color printer icon is displayed next to the

Phaser 2135 in the list of available printers. This indicates the printer’s PPD has been selected and properly conﬁgured.

2. In the Print dialog box, make sure that the Color/Grayscale option has

been selected.

3. Make sure that the Phaser 2135 printer icon was selected in the

Chooser. Try printing the job again.

4. Check the version of your LaserWriter driver to ensur e that it is version

8.0.x or higher. Earlier versions of the driver do not support color PostScript.

5. The application may require special instructions to print, such as those

contained in a PPD ﬁle; check in the Phaser 12135 Printer CD-ROM.

58 Phaser 2135 Color Printer

Printer isn’t in the Chooser

1. Ensure that the printer is turned on and the printer is in its READY

mode.

2. Check the Network or AppleTalk control panel to ensure the proper

network or zone is selected.

3. Power-cycle the printer.

4. Check to see if the printer has not been renamed or placed in another

zone. You can print a Conﬁguration Page, which lists this EtherTalk information as well as other information about the printer.

5. Verify the EtherTalk settings on the printer’s Conﬁguration 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 AppleTalk queue for the printer.

8. Verify the driver version for the built-in Ethernet port on a Macintosh

G3.

9. Reset the printer’s NVRAM settings.

10. Disable QuickDraw GX

Windows printing problems

Image never prints

The printer’s front panel Receiving data message is displayed as if receiving data, but nothing comes out of printer or the printer goes back to Ready to Print mode without printing an image.

1. From the printer driver, under the printer's set up options, set

TRANSMISSION RETRY = 850.

Service Guide 59

Service Tests and Adjustments

Starting the diagnostics mode

To start the engine maintenance mode:

Turn off the printer.

Press and hold the

Turn on the printer.

Menu (1)

and

Enter (4)

keys.

Use engine maintenance mode to test the printer sensors, test the media transport system, test the imaging LED banks, and to reset NVRAM.

To exit engine maintenance mode, while press then turn power back on.

DIAGNOSTIC MODE xx.xx.xx

When,

xx.xx.xx

( Press the Press the Press the

Press the

Online (0)

is the ROM version), release the control panel keys.

Menu (1) Item (2) or (6) Value (3)

Value (7)

key to enter the maintenance mode menu.

key to activate the displayed menu item. key to discontinue a test in progress.

. Alternately, you can turn the power off, wait a few seconds, and

is displayed on the control panel

keys to scroll through the menu.

DIAGNOSTIC MODE xx.xx

is displayed,

Service Guide

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 using Menu(1) or Menu(5)

SWITCH SCAN SCAN00 thru

MOTOR & CLUTCH TEST

TEST PRINT Items set for test

NV-RAM INITIAL (consumables count reset)

CONSUMABLE STATUS

PRINTER STATUS

Items -

scroll using Item(2) or Item(6)

SCAN19 Lists each motor

and clutch

TABLE 1 TABLE 2 TABLE 3

Displays each consumable item

Lists print count and impressions made by each imaging unit

Settings -

using Value(3] or Value(7)

Test start/stop Select and test printer

Test start/stop Alternation of setting or T est start/stop

Select parameters of print such as paper source and print mode. Test start/stop

Test start/stop Table 1 determines the

no settings

scroll

Description

switches and sensors Test the printer motors and

clutches. A selected motor or clutch is operated for 10 seconds

Test the print engine’s ability to print

counter values initialized after exchanging the drum belt unit, fuser unit or toner cartridge. The adjusted values for mechanical controls are all cleared to their initial values.

use Table 2 or Table 3.

The consumption status of each consumables is displayed in turn. Values show are of prints made and percentage of toner consumed.

The life status of the selected consumable is displayed.

Do not

Phaser 2135 Color Printer

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

Enter (4)

Press the

SCAN

Press the SWITCH SCAN tests. The table below list the SCAN test items and which sensors and switches and test by that menu item.

Pressing the test. The SWITCH SCAN number begins to blink, and the corresponding logic state (High or Low) of the particular switches or sensors scanned by the test (listed as 1=, 2=, 3=, and 4=) are displayed.

With a test active, you can manually actuate the sensors being scanned and look for a change at the control panel.

Press

Repeat steps 2 through 5 as required.

To exit the switch scan test mode, press

keys as you turn on the printer.

Menu (1, 5)

appears on the upper display.

Item (2,6)

Value (3)

Value (7)

keys to scroll through the list of test until

keys to scroll through the list of sensor tests, called

key activates the currently displayed switch scan

to stop the current test.

Enter (4)

Menu (1)

SWITCH

and

Service Guide

Face-down paper eject sensor

Face-down sensor

Paper eject sensor

Heat roller

Driving roller

Paper eject roller

Stacker full sensor

C drum

K drumY drumM drum

Entrance belt sensor

MT feed roller

Pinch roller 2

Backup roller

Duplex-in sensor

Duplex roller

Duplex rear sensor

Carrier belt

Duplex front sensor

Duplex feed roller

Driving roller

Belt cleaning blade

Switch scans and the sensor and switches test

Switch or sensor Switch scan test Test result Details

Tray 1 No Paper Sensor

Tray 1 Low Paper Sensor

Cassette Entrance

Manual Bypass Feeder Entrance sensor

Belt Entrance Switch Scan 011=L - Paper present

Exit Sensor Switch Scan 012=L - No paper

Stack Full Sensor Switch Scan 013=L - Stack full

not used

Black Toner Cartridge Present

Cyan Toner Cartridge Present

Magenta T oner Cartridge Present

Switch Scan 001=L - Paper present

H - No paper

Switch Scan 002=L - Paper level OK

H - Low paper

Switch Scan 003=L - Paper present

H - No paper

Switch Scan 004=L - Paper present

H - No paper

H - Paper present

H - No paper

Switch Scan 01 4=

Switch Scan 021=L - Deactuated

H - Unit installed

Switch Scan 022=L - Deactuated

H - Unit installed

Switch Scan 023=L - Deactuated

H - Unit installed

Pull main tray out to test sensor

Open right-side door and toggle sensor ﬂag below the feed rollers

Open right-side door and push sheet of paper into paper path leading to the transfer unit

Open right-side door and push sheet of paper into paper path leading to the transfer unit. Open the top cover and manually rotate the registration roller (use the green thumbwheel on the left end of the roller) to feed the paper to the transfer belt.

Toggle sensor ﬂag behind the fuser. Remove the fuser, if necessary

Toggle the sensor ﬂag at the exit bin

not used

Open top cover and pull down the sensor ﬂag next to rear of the LED head.

Registration roller B

Entrance MT sensor

1st feed roller

2nd feed roller

Registration roller A

Entrance cassette sensor

Auxiliary roller

Carrier sensor

Pinch roller 1

0725-75

Phaser 2135 Color Printer

Switch scans and the sensor and switches test

Switch or sensor Switch scan test Test result Details

Yellow Toner Cartridge Present

Top Cover Switch Switch Scan 031=L - Top closed

Right Cover Switch (Door A)

Waste Toner Sensor

not used

not used not used

Manual Bypass Feeder Home Sensor

Manual Bypass Feeder Paper Empty Switch

not used

Manual Bypass Feeder OHP Sensor

Tray 1, Size 1 Switch - (Top)

Tray 1, Size 2 Switch

Tray 1, Size 3 Switch

Tray 1, Size 4 Switch - (Bottom)

Color Registration (Front) - 006

Color Registration (Rear) - 00A

not used

Upper Fuser Thermistor - 00D

not used

Switch Scan 024=L - Deactuated

H - Unit installed

H - Top opened

Switch Scan 032=L - Cover closed

H - Cover opened

Switch Scan 033=L - Not full

H - Full

Switch Scan 03 4=

Switch Scan 04 Switch Scan 05 Switch Scan 061=L - Roller at home

H - Roller not home

Switch Scan 062=L - Paper loaded

H - No Paper

Switch Scan 06 3=

Switch Scan 064=L - Transparency

H - Paper

Switch Scan 071=L - Actuated

H - Deactuated

Switch Scan 072=L - Actuated

H - Deactuated

Switch Scan 073=L - Actuated

H - Deactuated

Switch Scan 074=L - Actuated

H - Deactuated

Switch Scan 081=Density Value

***H

Switch Scan 082=Density Value

***H

Switch Scan 08 3=

Switch Scan 08 4=

Switch Scan 091=Encoded fuser

roller temperature

Switch Scan 09 2=

Open top cover and pull down the sensor ﬂag next to rear of the LED head.

Open top cover

Open right-side door

Remove the drum units and the transfer belt. Locate the optical sensor in a hole below the registration rollers. Interrupt the sensor by inserting a scrap of paper

not used

not used not used

Open the top cover and remove the drum units. Manually rotate the manual bypass feed roller by turning the white gear on the right end of the registration roller.

Toggle the switch located at the inner-base of the Manual Bypass Feeder tray next to the pick pad

not used

Manually feed a sheet of paper thru the feeder by rotating the registration roller. Transparency ﬁlm causes no change

Remove the tra y and actuate the sensor ﬂags at the rear of the tray cavity

Color value in hexidecimal format. The default is between 000 to 060 when the sensors are exposed to light. Manually open the registration shutter to expose the sensors to light. If the sensor reading is too high, clean any toner dust off the sensor lens and test again.

not used

Temperature is encoded as a hexidecimal value. The default is between 001 and 0D4.

not used

Service Guide

Switch scans and the sensor and switches test

Switch or sensor Switch scan test Test result Details

Lower Fuser Thermistor - 00F

not used

Humidity Sensor Switch Scan 101=Encoded

Temperature Sensor

not used

Duplex In Sensor Switch Scan 111=L - Deactuated

Duplex Rear Sensor

not used

Switch Scan 093=Encoded fuser

roller temperature

Switch Scan 09 4=

environmental humidity

Switch Scan 102=Encoded

environmental temperature

Switch Scan 10 3=

Switch Scan 10 4=

H - Paper present

Switch Scan 112=L - Deactuated

H - Paper present

Switch Scan 113=not used

Temperature is encoded as a hexidecimal value. The default is between 001 and0 D4.

not used

Ambient environmental humidity is encoded as a hexidecimal value. The default is between 158 and 2A7.

Ambient environmental temperature is encoded as a hexidecimal value. The default is between 0E7 and 27C.

not used

Pull out the duplex unit. Lift its cover. Place a sheet of paper inside on the sensor ﬂag. Close the cover. Reinsert the duplex unit in the printer.

Duplex Front Sensor

Tray 2, Size 1 Switch - (Top)

Tray 2, Size 2 Switch

Tray 2, Size 3 Switch

Tray 2, Size 4 Switch - (Bottom)

Tray 2 No Paper Sensor

Tray 2 Low Paper Sensor

not used

Right Door Tray 2 Switch Scan 141=L - Opened

not used

Tray 2 Feed Sensor

not used

Switch Scan 114=L - Deactuated

H - Paper present

Switch Scan 121=L - Actuated

H - Deactuated

Switch Scan 122=L - Actuated

H - Deactuated

Switch Scan 123=L - Actuated

H - Deactuated

Switch Scan 124=L - Actuated

H - Deactuated

Switch Scan 131=L - Paper present

H - No paper

Switch Scan 132=L - Paper level OK

H - Low paper

Switch Scan 133=not used

Switch Scan 134=not used

H - Closed

Switch Scan 142=not used

Switch Scan 143=L - Actuated

H - Deactuated

Switch Scan 144=not used

Pull out the duplex unit. Lift its cover. Place a sheet of paper inside on the sensor ﬂag. Close the cover. Reinsert the duplex unit in the printer.

Remove the tra y and actuate the sensor ﬂags at the rear of the tray cavity

Pull tray out to test sensor

Open door to test sensor

Open the Tray 2 right-side door and toggle sensor ﬂag below the feed rollers

Phaser 2135 Color Printer

Switch scans and the sensor and switches test

Switch or sensor Switch scan test Test result Details

Tray 3, Size 1 Switch - (Top)

Tray 3, Size 2 Switch

Tray 3, Size 3 Switch

Tray 3, Size 4 Switch - (Bottom)

Tray 3 No Paper Sensor

Tray 3 Low Paper Sensor

not used

Switch Scan 151=L - Actuated

H - Deactuated

Switch Scan 152=L - Actuated

H - Deactuated

Switch Scan 153=L - Actuated

H - Deactuated

Switch Scan 154=L - Actuated

H - Deactuated

Switch Scan 161=L - Paper present

H - No paper

Switch Scan 162=L - Paper level OK

H - Low paper

Switch Scan 163=not used

Remove the tra y and actuate the sensor ﬂags at the rear of the tray cavity

Pull tray out to test sensor

not used

Right Door Tray 3 Switch Scan 17

not used

Tray 3 Feed Sensor

not used

Tray 4, Size 1 Switch - (Top)

Tray 4, Size 2 Switch

Tray 4, Size 3 Switch

Tray 4, Size 4 Switch - (Bottom)

Tray 4 No Paper Sensor

Tray 4 Low Paper Sensor

not used

Right Door Tray 4 Switch Scan 201=L - Opened

not used

Switch Scan 164=not used

1= Switch Scan 172=not used

Switch Scan 173=L - Actuated

Switch Scan 174=not used

Switch Scan 181=L - Actuated

Switch Scan 182=L - Actuated

Switch Scan 183=L - Actuated

Switch Scan 184=L - Actuated

Switch Scan 191=L - Paper present

Switch Scan 192=L - Paper level OK

Switch Scan 193=not used

Switch Scan 194=not used

Switch Scan 202=not used

L - Opened H - Closed

H - Deactuated

H - No paper

H - Low paper

H - Closed

Open door to test sensor

Open the Tray 3 right-side door and toggle sensor ﬂag below the feed rollers

Remove the tra y and actuate the sensor ﬂags at the rear of the tray cavity

Pull tray out to test sensor

Open door to test sensor

Tray 4 Feed Sensor

not used

Switch Scan 203=L - Actuated

H - Deactuated

Switch Scan 204=not used

Open the Tray 4 right-side door and toggle sensor ﬂag below the feed rollers

Service Guide

Switch scans and the sensor and switches test

Switch or sensor Switch scan test Test result Details

Tray 5, Size 1 Switch - (Top)

Tray 5, Size 2 Switch

Tray 5, Size 3 Switch

Tray 5, Size 4 Switch - (Bottom)

Tray 5 No Paper Sensor

Tray 5 Low Paper Sensor

not used

Switch Scan 211=L - Actuated

H - Deactuated

Switch Scan 212=L - Actuated

H - Deactuated

Switch Scan 213=L - Actuated

H - Deactuated

Switch Scan 214=L - Actuated

H - Deactuated

Switch Scan 221=L - Paper present

H - No paper

Switch Scan 222=L - Paper level OK

H - Low paper

Switch Scan 223=not used

Remove the tra y and actuate the sensor ﬂags at the rear of the tray cavity

Pull tray out to test sensor

not used

Right Door Tray 5 Switch Scan 23

not used

Black LED Head temperature

Yellow LED Head temperature

Magenta LED Head temperature

Cyan LED Head temperature

Black Imaging Drum Contact

Cyan Imaging Drum Contact

Magenta Imaging Drum Contact

Yellow Imaging Drum Contact

Switch Scan 224=not used

1= Switch Scan 232=not used

Switch Scan 233=not used

Switch Scan 234=not used

Switch Scan 241=Encoded head

Switch Scan 242=Encoded head

Switch Scan 243=Encoded head

Switch Scan 244=Encoded head

Switch Scan 251=L - Installed

Switch Scan 252=L - Installed

Switch Scan 253=L - Installed

Switch Scan 254=L - Installed

L - Opened H - Closed

temperature

H - Missing

Open door to test sensor

Temperature is encoded as a hexidecimal value. The default is between 083 and 316.

T ests the imaging drum up/down sensor . Remove drum unit to test.

Phaser 2135 Color Printer

Motor and clutch tests

Enter the diagnosis mode by pressing and holding the

Enter (4)

keys as you turn on the printer.

Menu (1)

and

Press the

& CLUTCH TEST

Caution

Press the clutches until the desired item is displayed.

If indicated, remove the consumable items constraining the test.

Press the item blinks, and the selected motor or clutch is driven for 10 seconds.

Press the

Menu (1, 5)

Before running some motor and clutch tests you must remove certain printer consumable items; refer to table below. The front panel also reminds you to remove the necessary item before starting the test.

Item (2, 6)

Value (3)

Value (7) key to stop the unit.

keys to scroll through the list of test until

appears on the upper display.

keys to scroll through the list of motors and

key to start the displayed test. The displayed test

7. Repeat the Steps 2 to 7 for other motor or clutch tests.

8. Press Enter (4) ends the tests.

MOTOR

Service Guide

Motor and clutch test constraints

Constraints Motor or clutch displayed on control panel

BLACK-ID MOTOR REMOVE ID Run test with the drum units removed.

YELLOW-ID MOTOR REMOVE ID Run test with the drum units removed.

MAGENTA-ID MOTOR REMOVE ID Run test with the drum units removed.

CYAN-ID MOTOR REMOVE ID Run test with the drum units removed.

TRANSFER BELT MOTOR REMOVE ID Run test with the drum units removed. FUSER MOTOR none Remove the fuser and observe the fuser

REGISTRATION MOTOR Remove media

REGISTRATION CLUTCH none Open the front cover and observe

FRONT MOTOR (REGISTRATION MOTOR)

REGISTRATION SHUTTER none Remove the imaging drums and the

EXIT SOLENOID none Open the top cover and observe the exit

FACEDOWN SOLENOID none Open the face-up tray and observe the

DUPLEX MOTOR none Listen for the motor turning for about 5

DUPLEX REAR CLUTCH none Listen for the clutch activating DUPLEX FRONT CLUTCH none Listen for the clutch activating TRAY 1 MOTOR

(FEED MOTOR)

TRAY 2 MOTOR (FEED MOTOR)

displayed on

control panel Details

Observe the imaging drum drive gear rotate

drive gears turn.

Remove the imaging drums and observe from the multi-sheet bypass feeder

Remove media from the multi-sheet bypass feeder

EXIT TRA Y1 CASSETTE

EXIT TRA Y2 CASSETTE

the registration roller B rotate

registration roller A turning

Open the multi-sheet bypass feeder and

observe the paper position plate cycle up

and down

transfer belt to watch the shutter open

and close smoothly and completely.

gate move up and down

facedown gate move up and down

seconds

Run the test with Tray 1 removed.

Observe the pick roller rotate as the

motor runs

Run the test with Tray 2 removed.

Observe the pick roller rotate as the

motor runs

70 Phaser 2135 Color Printer

Motor and clutch test constraints

Constraints Motor or clutch displayed on control panel

TRAY 3 MOTOR (FEED MOTOR)

TRAY 4 MOTOR (FEED MOTOR)

TRAY 5 MOTOR (FEED MOTOR)

TRAY 1 HOPPING CLUTCH none Remove Tray 1 and listen for the clutch TRAY 2 HOPPING CLUTCH

(OPTIONAL) TRAY 3 HOPPING CLUTCH

(OPTIONAL) TRAY 4 HOPPING CLUTCH

(OPTIONAL) TRAY 5 HOPPING CLUTCH

(OPTIONAL) FEED ROLLER 1 CLUTCH none Remove Tray 1 and listen for the clutch FEED ROLLER 2 CLUTCH

(OPTIONAL) - FEED ROLLER 3 CLUTCH

(OPTIONAL) FEED ROLLER 4 CLUTCH

(OPTIONAL) FEED ROLLER 5 CLUTCH

(OPTIONAL) ID UP/DOWN Raises and lowers the imaging drum units FAN1 TEST Chassis fan, runs for 10 seconds FAN2 TEST Fuser fan, runs for 10 seconds

TRAY 1 LIFT MOTOR EXIT TRAY1

TRAY 2 LIFT MOTOR (OPTIONAL)

TRAY 3 LIFT MOTOR (OPTIONAL)

TRAY 4 LIFT MOTOR (OPTIONAL)

displayed on

control panel Details

EXIT TRA Y3

CASSETTE

EXIT TRA Y4

CASSETTE

EXIT TRA Y5

CASSETTE

none Remove Tray 2 and listen for the clutch

none Remove Tray 3 and listen for the clutch

none Remove Tray 4 and listen for the clutch

none Remove Tray 5 and listen for the clutch

none Remove Tray 2 and listen for the clutch

none Remove Tray 3 and listen for the clutch

none Remove Tray 4 and listen for the clutch

none Remove Tray 5 and listen for the clutch

CASSETTE

EXIT TRA Y2

CASSETTE

EXIT TRA Y3

CASSETTE

EXIT TRA Y4

CASSETTE

Run the test with Tray 3 removed. Observe the pick roller rotate as the motor runs

Run the test with Tray 4 removed. Observe the pick roller rotate as the motor runs

Run the test with Tray 5 removed. Observe the pick roller rotate

Run the test with Tray 1 removed. This test activates the tray 1’ s lift motor. Watch it raise the l paper lift plate

Run the test with Tray 2 removed. This test activates the tray 2’ s lift motor. Watch it raise the l paper lift plate

Run the test with Tray 3 removed. This test activates the tray 3’ s lift motor. Watch it raise the l paper lift plate

Run the test with Tray 4 removed. This test activates the tray 4’ s lift motor. Watch it raise the l paper lift plate

Service Guide 71

Test printing

1. Enter the diagnosis mode by pressing and holding the Menu (1) and

Enter (4) keys as you turn on the printer.

2. Press the Menu (1, 5) keys to scroll through the list of test until TEST

appears on the upper display.

3. Press the Item (2, 6) keys to scroll through the list of test print items

until the desired print option is displayed.

4. With a test print menu item displayed, press the Value (3, 7) keys to

scroll through the printing options of that item, such as which tray to print from and to print in blank-and-white or color.

Test Print menu

Display Set Value Function

PRINT EXECUTE

TEST PATTERN

CASSETTE TRAY1 Lets you select the source of paper for the test print.

PAGE XXXX Set number of print you wish the printer to print, 0000 mean

COLOR ON Lets you select between color or monochrome printing

DUPLEX ON Lets you select between single-sided or double-sided printing.

- Press Value (3) to start printing. Press Value (7) to stop printing.

1 Selection of Printing Patterns 2 3 4 5 6 7 - 14

TRAY2 TRAY3 FF NONE

OFF

1: LED Head Drive Pattern 2: Color Registration Adjust Pattern 3: Reserved 4: Gray pattern 5: Thin lines 6: Colored stripes 7 thru 14: Do not use

continuous printing.

5. Press 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.

72 Phaser 2135 Color Printer

The following messages are showing at warm-up and during printing.

P: Number of sheets printed for test (in 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 Celsius) H: Environmental humidity measurement (in units of%). The key

Value (3) changes the display.

7. Press Enter (4) to end the test.

Service Guide 73

Consumable count initialization

This test menu item allows you to initialize the print engine’s consumable counts and registration set points.

1. Enter the diagnosis mode by pressing and holding the Menu (1) and

Enter (4) keys as you turn on the printer.

2. Press the Menu (1, 5) keys to scroll through the list of test until NV-RAM

appears on the upper display.

INITIAL

3. Press the Item (2, 6) keys to select Table 1. The table indicates which

NVRAM items will be initialized. 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 times.

5. Press Enter (4) to exit the test mode.

Table 1: Initialization items - consumables

Initialization Item Detail

NV-RAM INITIAL blinks eight

Drum Counter Black Yellow Magenta Cyan

Belt Unit Counter

Fuser Unit Counter

Toner Counter Black Yellow Magenta Cyan

Initializes the drum counter’s count after the replacement of a drum.

Initializes the print count after the replacement of a transfer belt unit.

Initializes the fuser’s print count after the replacement of a fuser unit.

Initializes the toner use count after a toner cartridge is replaced

74 Phaser 2135 Color Printer

Consumable counter display

This test indicate the status of each consumable supply.

1. Enter the diagnosis mode by pressing and holding the Menu (1) and

Enter (4) keys as you turn on the printer.

2. Press the Menu (1, 5) keys to scroll through the list of test until

CONSUMABLE STATUS appears on the upper display.

3. Press the Item (2, 6) keys to scroll through the list of consumable supply

items. The consumption value is displayed 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 printed since

installation of a new fuser unit.

TR BELT UNIT ********IMAGES Shows the number of images printed since

installation of a new transfer belt unit. BLACK ID UNIT ********IMAGES Indicates the number of images processed by YELLOW ID UNIT ********IMAGES MAGENTA ID UNIT ********IMAGES CYAN ID UNIT ********IMAGES BLACK TONER ***% Shows the amount of toner consumed from each YELLOW TONER ***% MAGENTA TONER ***% CY AN T ONER ***%

each imaging drum unit since it was installed.

toner cartridge.

Service Guide 75

Consumable continuation counter display

The self-diagnosis is carried out to indicate the consumption status of each consumable supply.

1. Enter the diagnosis mode by pressing and holding the Menu (1) and

Enter (4) keys as you turn on the printer.

2. Press the Menu (1, 5) keys to scroll through the list of test until

PRINTER STATUS appears on 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) to end the test.

Consumable life-cycle counts

Upper Display Lower Display Unit Detail

TOTAL SHEETS FED

BLACK IMPRESSIONS

YELLOW IMPRESSIONS

MAGENTA IMPRESSIONS

CYAN IMPRESSIONS

******** PRINTS Prints Indicates the total number of sheets fed

including blank paper

******** IMAGES Image Displays the number of images printed

by each imaging drum

******** IMAGES Image

76 Phaser 2135 Color Printer

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. You may need to repeat this procedure and test your adjustments until you achieve the desired effect.

Note At any time, you can reset the printer to the factory defaults by

selecting Color Defaults from the Color Adjust Menu.

Printing a Test 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 Balance test print.

Interpreting the Color Balance test print

The Color Balance test print contains numbered images and disks that indicate possible adjustments that can be made. You can choose to make an adjustment to the Black Density, the Color Balance, or the Color Density.

■ The Black Density Images, numbered

-3K...0,...+3K, show a lightness/darkness range using black only.

■ The Color Balance Images, numbered

0,1,2,...12, show variations of three-color gray. Each of these circles contains gray with tints of other colors.

■ The Color Density Images, numbered

-3CMY...0,...+3CMY, show a lightness/darkness range using three colors (cyan, magenta, yellow).

Service Guide 77

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. The background is produced using black only and the circles are produced using a combination of cyan, magenta, and yellow.

■ The correct Color Density is determined by selecting the image in

which the foreground and background gray patterns most closely match.

Making adjustments

Use the following procedures to make adjustments to the color density and balance:

Black density adjustment

Press Item (2, 6) keys until you see Color Adjust Menu: Black Density.

2. Press Value (3, 7) keys until you see Black Density = New V alue .

Values are: -3K, -2K, -1K, 0, +1K, +2K, +3K.

3. Press Enter. The Color Adjust Page prints and the front panel displays

Color Adjust Menu: Black Density.

Repeat Steps 2 and 3 above until you are satisﬁed with the results.

Color density adjustment

1. Press Item (2, 6) keys until you see Color Adjust Menu: Color Density.

2. Press Value (3, 7) keys until you see Color Density = New V alue.

Values are: -3CMY, -2CMY, -1CMY, 0, +1CMY, +2CMY, +3CMY.

3. Press Enter. The Color Adjust Page prints and the front panel displays

Color Adjust Menu: Color Density.

Repeat Steps 2 and 3 above until you are satisﬁed with the results.

78 Phaser 2135 Color Printer

Color balance adjustment

1. Press Menu (1, 5) keys until you see Color Adjust Menu.

2. Press Item (2, 6) keys until you see Color Adjust Menu: Color Balance.

3. Press Value (3, 7) keys until you see Color Density = New V alue.

Values are: 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 results.

Adjustment recovery

While in the color adjustment routine you can choose to return the values to the factory default values by using the Color Adjust menu’s Color Defaults item.

The printer will be restored to the default values.

Service Guide 79

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.

The frequency of use and the type of paper a customer prints on determines how critical cleaning the machine is. Users of ordinary laser Bond paper (copier paper) should have very few problems since this paper is smooth and relatively dust-free. You should thoroughly inspect and clean these printers.

Service Guide

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

Part name Display or Warning

Toner Cartridge When the message is

Drum Units When the message is

Fuser Unit When the message is

Transfer Belt Unit

Condition

displayed

When the message is displayed

Recommended condition for replacement

When 15,000 (hi-cap cartridge) or 7,500 (standard cartridge) pages are printed (5% print density).

When 35,000 pages are printed out (for 3 Page/Job printing of Letter paper).

When 80,000 pages are printed out.

Adjustment after replacement

No adjustment required after replacing toner cartridge

The printer’s imaging drum unit counters are automatically reset due to a fuse being blown in the unit a few seconds after a unit is installed

The printer’s fuser unit counter is automatically reset due to a fuse being blown in the unit a few seconds after it is installed

The printer’s transfer belt unit counter is automatically reset due to a fuse being blown in the unit a few seconds after it is installed

Phaser 2135 Color Printer

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.

Cleaning the LED bar

The LED lens array must be cleaned when the printed paper has white lines or irregular colors (such 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 Stripe Pattern. If a light or white stripe appears in any primary color or a secondary color has an irregular color streak, clean the LED lens of the affected color.

Print problem caused by dirty LED lens

Cleaning the pickup roller

When mispicks occur, clean the pickup roller.

Note

The roller should be cleaned with a clean, dry, lint-free cloth if debris is visible so the surface is not scratched.

Service Guide

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.

Turn off the printer.

Press and hold-down the

Turn on the printer . When the message

Menu (1, 4)

the

Reset Menu

item Use the

■

Factory Defaults

Use the Press

keys to scroll through the list of menu items to the menu

. Press

Menu (1, 4)

Item (2, 6)

Enter

to conﬁrm your selection.

On Line (0)

Enter (4)

keys to scroll through the list of reset options:

. (print engine settings)

keys to activate the

key and the

Ready

Enter (4)

will be displayed use the

Conﬁrm Action Yes/No

keys.

menu.

Network Defaults

■

Use the Press

■

Demo Mode

Use the Press

■

CRU Reset

Use the Use the the consumable item displayed. Press

Alternately, refer to the service test procedure “Consumable count initialization” on page 73 to reset the print engine’s NVRAM-stored consumable counts or the registration set points parameters.

A customer-accessible NVRAM reset is available through the front panel menu

Support Menu

item but does not clear copy counts nor consumable counts.

Item (2, 6)

Enter

to conﬁrm your selection.

Item (2, 6)

Enter

to conﬁrm your selection. . (consumable print counts)

Item (2, 6)

Value (2, 6)

. (network settings)

keys to activate the

keys to scroll through the list of consumable items.

keys to activate the

. This reset returns the printer to its factory-default settings

Conﬁrm Action Yes/No

Conﬁrm Action Y es/No

Enter

to conﬁrm your selection.

menu.

menu for

Service Guide

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” on page 61.

About screw colors

Black screws

illustrations the black screws are marked with a

Gold-colored screws

mount plastic to metal. In the illustrations the gold-colored screws are marked with a

are coarse-thread screws used to join plastic to plastic. In the

are ﬁne-thread screws used to join metal to metal or to

Service Guide

Cabinet panels

Top cover

Warning

Open the top cover . Remove the dr um/toner cartridges. Place them in a lightproof black bag to protect the drum units fr om light and stor e in a safe place.

Remove the rear cover as explained in “Rear cover” on page 89

Remove the 10 screws securing the top cover to the top cover inner unit.

Remove the top cover.

Switch off the power and disconnect the power cord.

Top Cover

0725-09

Inner Unit

Remove Screws

Removing the top cover

To reinstall the top cover, reverse the removal order.

Phaser 2135 Color Printer

Rear cover

Warning

Remove the system controller board as explained in “System controller board” on page 105.

Open the top cover . Remove the dr um/toner cartridges. Place them in a lightproof black bag to protect the drum units fr om light and stor e in a safe place.

Remove the seven screws securing the rear cover to the printer. Remove the rear cover.

Switch off the power and disconnect the power cord.

Remove Screws

Removing the rear cover

Reverse the removal steps to install the rear cover.

0725-11

Rear Cover

Service Guide

Front cover

Warning

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.

Remove the seven screws securing the cover to the printer frame. Remove the cover by lifting it straight up.

Switch off the power and disconnect the power cord.

Remove Screws

Front Cover

0725-10

Removing the front cover

Reverse these steps to install the front cover. Lower the front cover into the gap created by the chassis and the fully-open top cover.

Phaser 2135 Color Printer

Left-side cover

Warning

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” on page 90.

Remove the rear cover as described in “Rear cover” on page 89.

Lift the face-up tray to access and remove the two screws underneath.

Remove the four screws securing the left side cover.

Pull the top of the cover out then up to remove.

Switch off the power and disconnect the power cord.

Left-side Cover

0725-13

Removing the left-side cover

To reinstall the left-side cover, reverse the removal order.

Remove Screws

Service Guide

Xerox Phaser 2135 Service Quick Reference Guide

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Figures

Tables

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

Error Codes and Messages

Error messages

Troubleshooting

Fault History Log

Power on self-diagnostic test

Print engine troubleshooting

Testing the print engine controller board

Verifying power supply operation

Measuring power supply voltages

Inspecting the low-voltage power supply fuse

Safety interlocks

Ensuring the +5 VDC loop is complete

Motor and fuser roller resistances

Media jams and the paper path

Media-based problems

Media problems

Multiple-sheet pick

The media skews passing through the paper path

The paper tray indicates it is empty when it is not

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

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

False “No toner cartridge installed” message

False “No fuser unit installed” message

Right-side door indicated being open when it is closed

High temperature error

Low temperature error

Invalid memory DIMM

Printing and print quality problems

Light or blurred images

Dark, stained background

Blank print

Black stripe in direction of paper travel

White stripe in direction of paper travel

Poor fusing, toner offsetting

Repeating defect or voids on print

Missing characters or voids in print

Color misalignments

Unexpected colors

Image is skewed on the paper

Image is not centered on the print

The print is wrinkled

Macintosh printing problems

Image never prints

Image is rotated 90 degrees

Printer isn’t in the Chooser

Windows printing problems

Image never prints