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Xerox 2135DT Service Guide - Page 5

Service safety summary

UPC - 042215474696

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Symbols as marked on product: DANGER high voltage: Protective ground (earth) terminal: Use caution. Refer to the manual(s) for information: ! WARNING: If the product loses the ground connection, usage of knobs and controls (and other conductive parts) can cause an electrical shock. Electrical product may be hazardous if misused. Service safety summary For qualiﬁed service personnel only: Refer also to the preceding Users Safety Summary. Do not service alone: Do not perform internal service or adjustment of this product unless another person capable of rendering ﬁrst aid or resuscitation is present. Use care when servicing with power on: Dangerous voltages may exist at several points in this product. To avoid personal injury, do not touch exposed connections and components while power is on. Disconnect power before removing the power supply shield, soldering, or replacing components. Do not wear jewelry: Remove jewelry prior to servicing. Rings, necklaces, and other metallic objects could come into contact with dangerous voltages and currents. Power source: This product is intended to operate from a power source that will not apply more than 120 or 250 volts AC RMS (depending on printer model) between the supply conductors or between either supply conductor and ground. A protective ground connection by way of the grounding conductor in the power cord is essential for safe operation.

Section	Page
Cover Page	1
Contents.pdf	6
The Phaser 2135 Color Printer 2	6
Printer RAM and printer capabilities 4	6
CRC life counter behavior 4	6
Print engine assemblies 5	6
The image processor board 8	6
The control panel 9	6
On Line LED 9	6
! Fault 9	6
Rear panel 10	6
Accessing special operating modes 11	6
System controller board LEDs 11	6
Paper tray size sensing 12	6
Specifications 13	6
Regulatory specifications 16	6
Error Codes and Messages 17	6
Error messages 17	6
Troubleshooting 29	6
Fault History Log 29	6
Power on self-diagnostic test 30	6
Print engine troubleshooting 31	6
Testing the print engine controller board 31	6
Verifying printer operation byusing its selftest print 32	6
Verifying power supply operation 32	6
Measuring power supply voltages 32	6
Inspecting the low-voltage power supply fuse 34	6
Safety interlocks 34	6
Ensuring the +5 VDC loop is complete 35	6
Testing for a shortedmotor 36	6
Motor and fuser roller resistances 37	6
Media jams and the paper path 38	6
Media-based problems 38	6
Media problems 38	6
Multiple-sheet pick 38	6
The media skews passing through the paper path 39	6
The paper tray indicates it is empty when it is not 39	6
Jams 40	7
Wrong media 40	7
Paper jams at the paper tray 40	7
Manual bypass feeder feed jams 41	7
Paper jams at the registration rollers 41	7
Paper jams at the transfer belt 41	7
Fuser jams 42	7
Eject jams 42	7
Jams in the duplex unit 43	7
No imaging drum installed 43	7
Imaging drum up/down error 43	7
Fan error 44	7
Fuser unit error 44	7
Other problems 45	7
The printer continuously displays “Booting” or “Initializing.” 45	7
False “No toner cartridge installed” message 45	7
False “No fuser unit installed” message 45	7
Right-side door indicated being open when it is closed 46	7
High temperature error 46	7
Low temperature error 46	7
Invalid memory DIMM 46	7
Printing and print quality problems 47	7
Light or blurred images 47	7
Dark, stained background 48	7
Blank print 49	7
Black stripe in direction of paper travel 50	7
White stripe in direction of paper travel 51	7
Poor fusing, toner offsetting 52	7
Repeating defect or voids on print 53	7
Missing characters or voids in print 54	7
Color misalignments 55	7
Unexpected colors 56	7
Image is skewed on the paper 57	7
Image is not centered on the print 57	7
The print is wrinkled 57	7
Macintosh printing problems 58	7
Image never prints 58	7
Image is rotated 90 degrees 58	7
Image prints in black-andwhite 58	7
Printer isn’t in the Chooser 59	7
Windows printing problems 59	7
Image never prints 59	7
Service Tests and Adjustments 61	8
Starting the diagnostics mode 61	8
Switch scan test 63	8
Motor and clutch tests 69	8
Test printing 72	8
Consumable count initialization 74	8
Consumable counter display 75	8
Consumable continuation counter display 76	8
Adjusting color density and balance 77	8
Printing a Test Page 77	8
Interpreting the Color Balance test print 77	8
What to look for 78	8
Making adjustments 78	8
Adjustment recovery 79	8
Cleaning and Maintenance 81	8
Service preventive maintenance procedure 81	8
Recommended tools 82	8
Periodically replaced parts 82	8
Cleaning 83	8
Cleaning the LED bar 83	8
Cleaning the pickup roller 83	8
Resetting NVRAM 85	8
FRU Disassembly 87	8
About screw colors 87	8
Cabinet panels 88	8
Top cover 88	8
Rear cover 89	8
Front cover 90	8
Left-side cover 91	8
Face-up tray 92	8
Right door 93	8
Frame components 94	8
Electrical card cage cooling fan 94	8
Front power supply fan 95	8
Rear power supply fan 96	8
Rear shield plate 97	8
Electrical card cage 98	8
Printer unit chassis 100	8
Top cover inner frame and front/rear top cover spring assembly 102	8
Front plate assembly 104	8
Electronic boards 105	9
System controller board 105	9
RAM DIMMs 106	9
Hard drive 107	9
Print engine controller board 108	9
Toner sensor board 109	9
Entrance sensor board 111	9
High voltage power supply 112	9
Low voltage power supply 114	9
Control panel 115	9
Paper feed components 116	9
Tray 1 feed roller and nudger roller 116	9
Paper-size sensing board 117	9
Main feeder assembly 118	9
Paper tray lift motor 118	9
Multi-sheet bypass feeder components 119	9
Multi-sheet bypass feeder 119	9
Drive gear 119	9
Multi-sheet bypass feeder sensors 119	9
Temperature/humidity sensor board 119	9
Paper transport components 121	9
Tray 1 entrance sensor actuator 121	9
Belt entrance and multi-sheet bypass feed sensor actuators 122	9
Duplex solenoid and exit solenoid 123	9
Transfer belt unit 124	9
Registration components 125	9
Registration clutch 125	9
Registration motor assembly 126	9
Registration roller assembly A and drive gear 127	9
Registration roller assembly B 129	9
Exit assembly and fuser components 130	9
Duplex guide assembly 130	9
Fuser latching handle (front) 132	9
Fuser latching handle (rear) 134	9
Fuser exit roller 135	9
Exit sensor assembly 137	9
Eject guide assembly 138	9
Stack full sensor 139	9
Drive assembly components 141	10
Main motor assembly 141	10
Imaging drum motor 142	10
Fuser motor and transfer belt drive motor assembly 143	10
Xerographic components 144	10
Shutter plate 144	10
Color registration sensor assembly 145	10
Color registration solenoid 146	10
LED assembly 147	10
Drum contact assembly 148	10
Toner sensor actuators 149	10
Duplex unit 151	10
FRUList 153	10
Using the parts list 153	10
Test Prints 173	10
Wiring Diagram 177	10
Figures	11
Tables	13
01_gen-info.pdf	14
The Phaser 2135 Color Printer	15
Printer RAM and printer capabilities	17
CRC life counter behavior	17
Print engine assemblies	18
The image processor board	21
The control panel	22
On Line LED	22
! Fault	22
Rear panel	23
Accessing special operating modes	24
System controller board LEDs	24
Paper tray size sensing	25
Specifications	26
Regulatory specifications	29
02_error-codes.pdf	30
Error messages	30
03_troubleshoot.pdf	42
Fault History Log	42
Power on self-diagnostic test	43
Print engine troubleshooting	44
Testing the print engine controller board	44
Verifying printer operation byusing its selftest print	45
Verifying power supply operation	45
Measuring power supply voltages	45
Inspecting the low-voltage power supply fuse	47
Safety interlocks	47
Ensuring the +5 VDC loop is complete	48
Testing for a shortedmotor	49
Motor and fuser roller resistances	50
Media jams and the paper path	51
Media-based problems	51
Media problems	51
Multiple-sheet pick	51
The media skews passing through the paper path	52
The paper tray indicates it is empty when it is not	52
Jams	53
Wrong media	53
Paper jams at the paper tray	53
Manual bypass feeder feed jams	54
Paper jams at the registration rollers	54
Paper jams at the transfer belt	54
Fuser jams	55
Eject jams	55
Jams in the duplex unit	56
No imaging drum installed	56
Imaging drum up/down error	56
Fan error	57
Fuser unit error	57
Other problems	58
The printer continuously displays “Booting” or “Initializing.”	58
False “No toner cartridge installed” message	58
False “No fuser unit installed” message	58
Right-side door indicated being open when it is closed	59
High temperature error	59
Low temperature error	59
Invalid memory DIMM	59
Printing and print quality problems	60
Light or blurred images	60
Dark, stained background	61
Blank print	62
Black stripe in direction of paper travel	63
White stripe in direction of paper travel	64
Poor fusing, toner offsetting	65
Repeating defect or voids on print	66
Missing characters or voids in print	67
Color misalignments	68
Unexpected colors	69
Image is skewed on the paper	70
Image is not centered on the print	70
The print is wrinkled	70
Macintosh printing problems	71
Image never prints	71
Image is rotated 90 degrees	71
Image prints in black-andwhite	71
Printer isn’t in the Chooser	72
Windows printing problems	72
Image never prints	72
04_adjust.pdf	74
Starting the diagnostics mode	74
Switch scan test	76
Motor and clutch tests	82
Test printing	85
Consumable count initialization	87
Consumable counter display	88
Consumable continuation counter display	89
Adjusting color density and balance	90
Printing a Test Page	90
Interpreting the Color Balance test print	90
What to look for	91
Making adjustments	91
Adjustment recovery	92
05_clean.pdf	94
Service preventive maintenance procedure	94
Recommended tools	95
Periodically replaced parts	95
Cleaning	96
Cleaning the LED bar	96
Cleaning the pickup roller	96
06_nvram.pdf	98
07_disass.pdf	100
About screw colors	100
Cabinet panels	101
Top cover	101
Rear cover	102
Front cover	103
Left-side cover	104
Right door	106
Frame components	107
Rear power supply fan	109
Rear shield plate	110
Electrical card cage	111
Printer unit chassis	113
Top cover inner frame and front/rear top cover spring assembly	115
Front plate assembly	117
Electronic boards	118
System controller board	118
RAM DIMMs	119
Hard drive	120
Print engine controller board	121
Toner sensor board	122
Entrance sensor board	124
High voltage power supply	125
Low voltage power supply	127
Control panel	128
Paper feed components	129
Tray 1 feed roller and nudger roller	129
Paper-size sensing board	130
Main feeder assembly	131
Paper tray lift motor	131
Multi-sheet bypass feeder components	132
Multi-sheet bypass feeder	132
Drive gear	132
Multi-sheet bypass feeder sensors	132
Temperature/humidity sensor board	132
Paper transport components	134
Tray 1 entrance sensor actuator	134
Belt entrance and multi-sheet bypass feed sensor actuators	135
Duplex solenoid and exit solenoid	136
Transfer belt unit	137
Registration components	138
Registration clutch	138
Registration motor assembly	139
Registration roller assembly A and drive gear	140
Registration roller assembly B	142
Exit assembly and fuser components	143
Fuser latching handle (front)	145
Fuser latching handle (rear)	147
Fuser exit roller	148
Exit sensor assembly	150
Eject guide assembly	151
Stack full sensor	152
Drive assembly components	154
Main motor assembly	154
Imaging drum motor	155
Fuser motor and transfer belt drive motor assembly	156
Xerographic components	157
Shutter plate	157
Color registration sensor assembly	158
Color registration solenoid	159
LED assembly	160
Drum contact assembly	161
Toner sensor actuators	162
Duplex unit	164
08_fru.pdf	166
Using the parts list	166
09_testprint.pdf	186