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Fuji Xerox Phaser 5500, Service Manual

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Fuji Xerox Phaser 5500 Service Manual Download Page 8

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Phaser 5500 Printer Service Manual

Jam at H - F4-66 Compile Paper SNR Static  . . . . . . . . . . . . . .  3-121
Jam at F or G - F4-7n Top Tray Exit SNR ON . . . . . . . . . . . . . .  3-123
Jam at F or Stacker Upper Tray - F4-7nTop Tray SNR OFF  . . .  3-126
Jam at F or G - F4-7n Top Tray Exit SNR Static . . . . . . . . . . . .  3-129
Jam at F - F4-82 Gate SNR ON. . . . . . . . . . . . . . . . . . . . . . . . .  3-131
Jam at F or G - Gate SNR Static Jam (Upper Tray)  . . . . . . . . .  3-135
Jam at F or G - Gate SNR Static Jam (Lower Tray)  . . . . . . . . .  3-138
Tray n Failure - H1 -1/2/3/4 Tray n Fail. . . . . . . . . . . . . . . . . . .  3-141
Tray 6 Failure - H1-5 Tray 6 Fail. . . . . . . . . . . . . . . . . . . . . . . .  3-144
Duplex Unit Failure - H2-7 Duplex Comm Failure. . . . . . . . . . .  3-148
Incorrect Duplex Unit Installed - H2-8 Duplex Type Error  . . . .  3-149
Exit Unit Failure - H3-n Offset Error . . . . . . . . . . . . . . . . . . . . .  3-150
Exit Unit Failure - H3-7 Exit Board Comm Failure. . . . . . . . . . .  3-152
Tray 1/MPT Paper Guide Does Not Match Size Menu  . . . . . . .  3-154
Tray Paper Guide Does Not Match Size Menu -H4-1/2. . . . . . .  3-155
Tray Paper Guide Does Not Match Size Menu -H4-3/4. . . . . . .  3-157
Finisher Board Failure - H5-4, 7, 8 NVM/Comm/Type Error . . .  3-159
Stacker Lower Tray Failure - H5-11 Low Tray Fail . . . . . . . . . .  3-160
Stacker Lower Tray Failure - H5-12 Low Tray Upper Limit  . . .  3-162
Stacker Lower Tray Failure - H5-13 Low Tray Lower Limit  . . .  3-165
Stacker Lower Tray Failure - H5-2n Front Home SNR . . . . . . .  3-168
Stacker Lower Tray Failure - H5-2n Rear Home SNR. . . . . . . .  3-170
Punch Failure - H5-3n SNR . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-172
Punch Failure - H5-3n Home SNR . . . . . . . . . . . . . . . . . . . . . .  3-174
Stacker Lower Tray Failure - H5-8n Eject Clamp SNR . . . . . . .  3-176
Stacker Lower Tray Failure - H5-8n Set Clamp SNR  . . . . . . . .  3-178
Stacker Lower Tray Failure - H5-86 Side Regi SNR OFF  . . . . .  3-181
Stapler Failure - H5-91 Staple Fail . . . . . . . . . . . . . . . . . . . . . .  3-184
Stapler Failure - H5-9n Move SNR . . . . . . . . . . . . . . . . . . . . . .  3-185
Tray 6 Logic Board Failure - H6-4 NVM R/W Error  . . . . . . . . .  3-187
Tray 6 Logic Board Failure - H6-7 HCF Comm Failure . . . . . . .  3-188
Tray 4-5 Logic Board Failure - NVM. . . . . . . . . . . . . . . . . . . . .  3-189
Tray 4-5 Logic Board Failure - H7-7 Comm Failure  . . . . . . . . .  3-190
Incorrect Tray 4-5 Installed - H7-8 Type Error . . . . . . . . . . . . .  3-191
Tray N Failure - H8-1, 2 Tray Size Sensor Broken  . . . . . . . . . .  3-193
Tray N Failure - H8-3, 4 Tray Size Sensor Broken  . . . . . . . . . .  3-194
Toner Empty- J1-2 Toner Empty . . . . . . . . . . . . . . . . . . . . . . .  3-197
No Drum Cartridge - J3-1 Drum Not Installed . . . . . . . . . . . . .  3-199
Drum Cartridge Failure - J4-1 ATC SNR Defect . . . . . . . . . . . .  3-200
Replace Drum Cartridge - J6-1 DRUM End of Life . . . . . . . . . .  3-200
Drum Cartridge Failure - J7-n Comm/NVRAM/Type Error . . . .  3-201
Replace Incorrect Drum Cartridge - J7-3 DRUM Mismatch . . .  3-203
Toner Cartridge Failure - J8-n Toner Comm/Read/Write . . . . .  3-204
Replace Incorrect Toner Cartridge - J8-3 Toner Mismatch  . . .  3-205
Toner Is Low - Toner Low . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-206
Drum Cartridge Near End of Life - DRUM Life Near End  . . . . .  3-207

Summary of Contents for Phaser 5500

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Page 3: ...g 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 the operating instructions unless you are qualified to do so First Printing August 2004 071 0873 00 ...

Page 4: ...er LocalTalk Macintosh Mac OS TrueType Apple Chancery Chicago Geneva Monaco New York and QuickDraw are trademarks of Apple Computer Inc in the United States and or other countries PCL and HP GL are trademarks of Hewlett Packard Corporation in the United States and or other countries IBM is a trademark of International Business Machines Corporation in the United States and or other countries Window...

Page 5: ...View 1 4 Rear View 1 4 Front Panel 1 5 Printer Options 1 6 Hard Drive 1 6 Additional Memory 1 6 Exit 2 1 6 Networking 1 6 1000 Sheet Feeder 1 7 Duplex Unit 1 7 Stacker Finisher 1 8 2000 Sheet Feeder 1 9 Envelope Tray 1 9 Consumables and Routine Maintenance Items 1 10 Supply Life Counters 1 10 Printer Specifications 1 11 Physical Dimensions 1 11 Memory Specifications 1 11 Operational Clearances 1 1...

Page 6: ...nter Drive and Electrical 2 32 3 Error Messages Codes and Procedures Introduction 3 2 Servicing Instructions 3 2 System Startup 3 3 Power On Self Test POST 3 4 POST Soft Fault Messages 3 5 POST Hard Fault Messages 3 6 Service Usage Profile 3 7 Accessing Fault Histories 3 7 Interpreting Fault History Error Codes 3 7 Service Diagnostics 3 11 Using Service Diagnostics 3 12 Starting Service Diagnostic...

Page 7: ...Tray n Pre Feed 3 56 Jam at Tray n Registration 3 59 Jam at Tray n Feed Out 3 3 61 Jam at Tray n Feed Out 4 3 63 Jam at Tray 5 C4 0 Tray 5 3 65 Jam at Tray 6 C5 1 Tray 6 3 68 Jam at Tray 6 C5 2 Tray 6 3 71 Jam at B C5 3 Tray 6 3 73 Jam at B C8 2 F O3 SNR Static Jam 3 76 Jam at C C8 3 F O4 SNR Static Jam 3 77 Jam at C C8 4 F O5 SNR Static Jam 3 78 Jam at Tray 6 C8 5 HCF F O SNR Static Jam 3 79 Jam ...

Page 8: ...cker Lower Tray Failure H5 2n Front Home SNR 3 168 Stacker Lower Tray Failure H5 2n Rear Home SNR 3 170 Punch Failure H5 3n SNR 3 172 Punch Failure H5 3n Home SNR 3 174 Stacker Lower Tray Failure H5 8n Eject Clamp SNR 3 176 Stacker Lower Tray Failure H5 8n Set Clamp SNR 3 178 Stacker Lower Tray Failure H5 86 Side Regi SNR OFF 3 181 Stapler Failure H5 91 Staple Fail 3 184 Stapler Failure H5 9n Move...

Page 9: ...Punch Waste Box is Missing 3 232 Punch Waste Box is Full 3 233 Printer Front Door is Open Front Cover is Open 3 235 Slide In Tray 6 Feeder Tray 6 Undocked 3 236 Close Door A Door A is Open 3 237 Close Door B Door B is Open 3 238 Close Door C Door C is Open 3 239 Close Door D Door D is Open 3 240 Close Door E Door E is Open 3 242 Close Door F Door F is Open 3 243 Close Door G Door G is Open 3 245 C...

Page 10: ...Spots 5 5 Fusing 5 6 Resolution 5 7 Registration 5 8 Registration Side to Side 5 9 Skips Smears 5 10 Spots 5 11 Skew 5 12 Other Print Defects 5 13 Print Quality Troubleshooting 5 14 Light Undertoned Print 5 14 Blank Print No image 5 16 Black Prints 5 19 Vertical Deletions 5 21 Horizontal Deletions 5 23 Vertical Streaks 5 25 Horizontal Streaks 5 27 Spots 5 29 Unfused Image 5 30 Damaged Print 5 33 R...

Page 11: ...Values 6 11 Resetting Printer Controls Setup Values 6 11 Resetting File Security Setup Values 6 12 Resetting Printer Default Settings PostScript NVRAM 6 12 7 Cleaning and Maintenance Service Preventive Maintenance Procedure 7 2 Recommended Tools 7 2 Cleaning 7 2 8 FRU Disassembly Overview 8 2 Standard Orientation of the Printer 8 2 General Notes on Disassembly 8 3 Preparation 8 3 Notations in the ...

Page 12: ... 34 Pick Up Gear Spring 8 35 Tray 1 Pick Up Solenoid 8 36 Cam Gear Spring 8 36 Feed Roller Assembly 8 38 Retard Pad 8 39 Lower Transportation and Registration 8 40 Take Away Bracket 8 40 Door B Interlock Switch 8 41 Take Away Roller Assembly 8 41 Door B 8 43 Transfer Roller 8 44 Door A Interlock Switch 8 45 Door A 8 46 Registration Roller 8 46 Registration Transport Assembly 8 49 Registration Clut...

Page 13: ...ply 8 92 AC Accessory Panel 8 93 GFI Breaker 8 94 9 Parts Lists Serial Number Format 9 2 Using the Parts List 9 3 Print Engine Parts 9 4 Xerox Supplies and Accessories 9 44 10 Wiring Diagrams Print Engine Plug Jack Designators 10 2 Plug Jack Locator Diagrams 10 6 Drum and Toner Cartridge 10 6 Laser Assembly and Exit PWB 10 7 Fuser and Exit 1 10 8 Tray 1 MPT 10 9 Registration Transport Assembly 10 ...

Page 14: ...nt Engine Motors Fan Test Menu A 12 Duplex Unit Motor Tests Menu A 12 Exit 2 Motor Tests Menu A 13 Trays 4 5 Motor Tests Menu A 13 Tray 6 Motor Tests Menu A 13 Finisher Motor Tests Menu A 14 Print Engine Sensor Switch Tests Menu A 15 Duplex Unit Sensor Switch Tests Menu A 16 Exit 2 Sensor Switch Tests Menu A 17 Tray 4 5 Sensor Switch Tests Menu A 17 Tray 6 Sensor Switch Tests Menu A 18 Finisher Se...

Page 15: ... printer however it is NOT an option to the product Common Acronyms FRU Field Replaceable Unit PL Corresponds to the FRU Parts List CRU Customer Replaceable Unit ESD Electrostatic Discharge Note A note indicates an operating or maintenance procedure practice or condition that is necessary to efficiently accomplish a task A note can provide additional information related to a specific subject or ad...

Page 16: ...ee the sign Symbols Marked on the Product DANGER high voltage Protective ground earth symbol Hot surface on or in the printer Use caution to avoid personal injury The surface is hot while the printer is running After turning off the power wait 40 minutes Avoid pinching fingers in the printer Use caution to avoid personal injury Use caution or draws attention to a particular component Refer to the ...

Page 17: ...oduct loses its ground connection contact with conductive parts may cause an electrical shock Disconnecting Power Turning the power off using the On Off switch does not completely de energize the printer You must also disconnect the printer power cord from the AC outlet Position the power cord so that it is easily accessible during servicing so that you may power down the printer during an emergen...

Page 18: ...the wrist strap before applying power to the unit under test to avoid potential shock After removing a static sensitive assembly from its anti static bag place it on a grounded conductive surface If the anti static bag is conductive you may ground the bag and use it as a conductive surface Do not use freon propelled chemicals These can generate electrical charges sufficient to damage some devices ...

Page 19: ...tor and ground A protective ground connection by way of the grounding conductor in the power cord is essential for safe operation Warning Labels Read and obey all posted warning labels Throughout the printer warning labels are displayed on potentially dangerous components As you service the printer check to make certain that all warning labels remain in place Safety Interlocks Make sure all covers...

Page 20: ...rd so that it is easily accessible during servicing Warning Do not touch any electrical component unless you are instructed to do so by a service procedure Servicing Mechanical Components When servicing mechanical components within the printer manually rotate drive assemblies rollers and gears Warning Do not try to manually rotate or manually stop the drive assemblies while any printer motor is ru...

Page 21: ... immunity compliance and could void the user s authority to operate this product To ensure compliance use shielded interface cables A shielded parallel cable can be purchased directly from Xerox at www xerox com office 5500supplies Xerox has tested this product to internationally accepted electromagnetic emission and immunity standards These standards are designed to mitigate interference caused o...

Page 22: ... copy of the Declaration of Conformity for this product can be obtained from Xerox EN 60950 IEC 60950 Safety of Information Technology Equipment including Electrical Business Equipment EN 55022 1998 CISPR 22 Limits and Methods of measurement of radio interference characteristics of Information Technology Equipment Class B EN 61000 3 2 1995 A1 1998 A2 1998 IEC 61000 3 2 Part 3 Limits Section 2 Limi...

Page 23: ...s these sections Introductory Safety and Regulatory Information This section contains important safety information regulatory requirements and information about this manual Chapter 1 General Information This section contains an overview of the printer s operation configuration specifications and consumable Chapter 2 Theory of Operation This section contains detailed functional information on print...

Page 24: ...ns Book 2 includes information important for the repair or replacement of option components Use the troubleshooting procedures in Book 1 to diagnose and isolated the problem Book 2 contains these sections Introductory Safety and Regulatory Information This section contains important safety information regulatory requirements and information about this manual Chapter 1 General Information This sect...

Page 25: ...1 Chapter General Information In this chapter Printer Introduction and Overview Printer Configurations Parts of the Printer Consumables and Routine Maintenance Items Printer Specifications ...

Page 26: ...printer features a bi directional parallel interface and a USB port The Phaser 5500 printer provides a 100 sheet Tray 1 MPT from which specialty media card stock larger format paper and envelopes are fed Tray 1 also supports manual feeding Two additional trays Tray 2 and 3 each provide 500 sheets of capacity The Standard Output Tray holds 500 sheets face down Phaser 5500 printer options add memory...

Page 27: ... True 1200 dpi 600 or True 1200 dpi 600 or True 1200 dpi USB Parallel Yes Yes Yes Yes Yes Ethernet Capabilities Optional Standard Standard Standard Standard 1000 Sheet Feeder Optional Optional Optional Standard Standard Automatic 2 Sided Printing Requires Duplex Unit Optional Optional Standard Standard Standard Hard Drive Optional Optional Optional Optional Standard Job Collation Hard Drive Requir...

Page 28: ...00 Sheet Feeder Tray 4 5 8 Finisher 9 Stacker Lower Tray 10 Stacker Upper Tray 1 Parallel Connection 2 Ethernet Connection 3 USB Connection 4 Configuration Card 5 Mode Select Port 6 Serial Debug Port 7 Ground Fault Interrupt Reset 8 Printer Power Connection 9 Finisher Connection 10 1000 Sheet Feeder Connection 11 Duplex Unit Connector 2 1 4 5 6 9 3 8 7 10 5500 107 s5500 017 9 10 11 7 8 1 2 3 5 6 4...

Page 29: ...enu system 3 Toner Gauge 8 OK select button 4 Cancel button 9 Information button for additional explanation or help 5 Back button LED State Printer State Green Ready to Print Flashing Yellow Warning but can still print Flashing Green In Power Saver mode or busy receiving or processing data Flashing Red Error cannot print 5500 016 1 Information Walk Up Features Printer Setup Troubleshooting Shutdow...

Page 30: ...rovide additional RAM in 128 MB and 256 MB increments Also available is 16 MB of Flash Memory for fonts forms and macros Both RAM and NVRAM options install to the Image Processing board The Startup Page and Configuration Page list the amount of installed RAM See Memory Specifications on page 1 11 Exit 2 Exit 2 is required when either the Duplex Unit or Stacker Finisher is installed When used in co...

Page 31: ...eder is secured to the print engine with two screws located under the front edge of Tray 3 Duplex Unit The Duplex Unit adds two sided printing The Duplex Unit attaches to the left side above Tray 1 using two twist locks Installation of the Duplex Unit requires that the Exit 2 Module also be added to provide reverse drive Electrical connection to the printer is made by an interface cable s5500 012 ...

Page 32: ...lled the top surface of the Horizontal Transport serves as the top tray and paper output capacity remains at 500 sheets Depending on the level of Stacker Finisher options and job specifications as paper enters the Stacker Finisher it is punched stapled offset and stacked Control signals reach the Stacker Finisher through a single connector Power is supplied from the printer s AC Accessory Panel 1 ...

Page 33: ...side of printers equipped with the 1000 Sheet Feeder option just below Tray 1 MPT using the supplied docking bracket Electrical connection to the printer is made by an interface cable Envelope Tray The Envelope Tray replaces Tray 2 to handle up to 35 envelopes Caution To avoid damage to the Envelope Tray use the Tray 2 position only s5500 013 s5500 014 ...

Page 34: ... is provided on the Front Panel that approximates the Toner Cartridge counter value As counters near their minimums warning messages appear on the Front Panel Print life ratings are based on 5 coverage and an average job length of 6 pages 1 Fuser 3 Drum Cartridge 2 Transfer Roller 4 Toner Cartridge Consumables Print Life Number of Images Toner Cartridge 30 000 Routine Maintenance Items Fuser 300 0...

Page 35: ...2 142 mm 5 6 in 130 mm 5 1 in 460 mm 18 1 in 2 kg 4 4 lbs Envelope Tray 76 mm 3 0 in 538 mm 21 2 in 521 mm 20 5 in 3 2 kg 7 lbs 2000 Sheet Feeder 363 mm 14 3 in 385 5 mm 15 1 in 600 mm 23 6 in 50 kg 110 lbs Characteristic Specification Minimum RAM 128 MB Maximum RAM 512 MB Supported RAM SO DIMM 144 pin module of 128 or 256 MB All combinations are allowed for configurations of 128 256 384 and 512 M...

Page 36: ...er 5500 Printer Service Manual 118 cm 46 in 119 cm 47 in 20 cm 8 in 218 cm 86 in 65 cm 26 in 46 cm 18 in 100 cm 39 in 46 cm 18 in 46 cm 18 in 118 cm 46 in 120 cm 47 in 89 cm 35 in 20 cm 8 in 20 cm 8 in s5500 610 ...

Page 37: ...i Continuous Operating Printing Speed 50 pages per minute for plain Letter paper simplex or duplex 50 pages per minute for A4 paper simplex or duplex Warm Up Time Sleep Mode Stand By 45 sec 6 sec Characteristic Specification Primary Line Voltages 120 VAC nominal min 99 V max 135 V 220 240 VAC nominal min 198 V max 254 V Primary Line Voltage Frequency Range 50 60 Hz 3 Hz Input Current Operating Rus...

Page 38: ...acteristic Trays Specifications Printable Area All Within 4 mm of paper edge guaranteed Edge to edge printing supported Supported Envelopes Tray 1 or Tray 2 with Envelope Tray installed COM 10 4 1 x 9 5 in Monarch 3 8 x 7 5 in DL 110 x 220 mm C5 162 x 229 mm Supported Media Weights Tray 1 3 4 5 6 Tray 2 Duplex 60 216 g m2 16 lb bond to 133 lb card stock 60 105 g m2 16 to 28 lb bond 60 163 g m2 Tra...

Page 39: ...unch These custom widths are supported with stapling and hole punching 210 mm 8 27 in 257 mm 10 12 in 297 mm 11 70 in 8 50 in 216 mm 10 50 in 267 mm 11 00 in 279 mm Paper Size Letter 8 5 x 11 in A4 210 x 297 mm 2 3 4 Legal 8 5 x 14 in US Folio 8 5 x 13 in 2 Executive 7 25 x 10 5 in 2 3 4 A5 148 x 210 mm Statement 5 5 x 8 5 in Small US Postcard 3 5 x 5 5 in Large US Postcard 4 0 x 6 0 in A6 105 x 1...

Page 40: ...er Weight 60 105 g m2 16 28 lb Bond 105 120 g m2 28 32 lb Bond 120 176 g m2 32 47 lb Bond 176 215 g m2 47 57 lb Bond Paper Sizes and Weights Continued User Selected Size Auto Sensed Size Supported Supported only when Long Edge Feed Input Output Tray 1 MPT Tray 2 Tray 3 5 Tray 6 Envelope Tray 2 Sided Printing Standard Output Tray Stacker Upper Tray Stacker Lower Tray Holes Punched Staple Depending ...

Page 41: ...2 Chapter Theory of Operation In this chapter Phaser 5500 Operational Overview Paper Path Sensors Xerographics Major Assemblies ...

Page 42: ...gh capacity 2000 Sheet Feeder Tray 6 brings the maximum paper capacity to 4 100 sheets An Envelope Tray replacing Tray 2 holds up to 35 envelopes On the output side 3500 sheet stapler punch stacker is available This section focuses on the printer s operational characteristics providing detailed descriptions of the paper path sensors xerographics and major system assemblies Operational details of t...

Page 43: ... along with the paper stack against the Nudger Roller of the paper feeder assembly To pick paper the Nudger Roller advances the top sheet to the Feed Roller and Retard Roller The Retard Roller prevents multi picks The Feed Roller advances the paper to the Take Away Rollers which feed the paper to the Registration Rollers 6 Transfer The pressure of the Transfer Roller against the drum assists in dr...

Page 44: ...f the pattern of sensor state changes differs from the expected timing for a particular paper size and path an error is reported Main Motor The Main Motor through the gear and pulley drive the Take Away Roller Feed Roller Registration Roller Fuser and Exit 1 OCT Roller Drum Motor The rotating force of the Drum Motor is transmitted through the gears to components that need mechanical driving force ...

Page 45: ...rinter along the paper path shown below s5500 022 Retard Roller Retard Roller Exit Registration Roller Feed Roller Tray 1 MPT Drive Roller Nudger Roller Tray 2 Feed Roller OCT Roller Duplex A3L Roller Invert Roller OCT Roller Transfer Roller Nudger Roller Feeder Assy Feeder Assy Take Away Roller Tray 3 Feed Roller Option Exit2 OCT2 Exit1 Fuser CRU Option Duplex Drum Heat Roller Pressure Roller Exi...

Page 46: ...1 MPT Pick up Solenoid causing the Feed Roller to rotate When the Feed Roller contacts the paper a sheet is fed into the gap between the Feed Roller and the Pinch Rollers Heat Roller OCT Rollers Face Up Roller Exit 2 Duplex Unit Transfer Roller A3L Rollers Pinch Rollers Drum 1000 Sheet Feeder s5500 233 Tray 2 Tray 3 Tray 4 Tray 5 Exit Pinch Rollers Invert Roller Duplex Roller Feed Roller Pinch Rol...

Page 47: ...ler in the path The paper continues along the path until the sheet of paper arrives at the Registration Roller Output Paper Path The Phaser 5500 paper path for paper exiting the fuser are Direct through Exit 1 to the Output Tray on the Top Cover facedown Direct through Exit 1 the Horizontal Transport to the Stacker Trays Direct through Exit 2 to the Output Tray on the Horizontal Transport Cover In...

Page 48: ...t 2 when the Horizontal Transport is installed Horizontal Transport When either the Stacker Upper or Lower Trays are designated as the output location the Exit 1 Exit Gate opens and paper is fed from Exit 1 to the Horizontal Transport The Horizontal Transport motor is activated by Horizontal Transport PWB to drive the two feed belts running between the Left and Right Shaft assemblies The paper is ...

Page 49: ...Tray by the Lower Exit Rollers For Punch operations the paper is drawn across the Buffer or Transfer Rollers then reversed to back into the Punch guide After the sheet is punched it moves out of the Punch and depending on the job either moves upward to the Stacker Upper Tray or continues to the Stapler For compiled stapled or offset print jobs the Buffer Gate is raised by the Buffer Gate Solenoid ...

Page 50: ...ation Roller for printing on the opposite side The purpose of the Duplex Unit is to accept a printed sheet of paper from the Fuser exit area effectively flipping the sheet over wait a period of time for the second side to develop then reinsert the sheet back into the printer registration area to receive an image on the reverse side The Duplex Unit provides duplex printing for paper fed from all av...

Page 51: ...sensors have the light emitter and light receiver aligned on a single surface Output of the photo receptor is High 4 5 V when light is being reflected back and Low 3 V when it isn t Photo receptive sensors consist of a LED in one arm of a U shaped holder and a photo transistor in the other arm When the sensing area is vacant nothing is between the arms of the sensor light falls on the photo recept...

Page 52: ...Detects paper jams in the feeder Registration Photo receptive Detects paper at the registration rollers Feed Out Photo reflective Detects paper leaving the feeder Exit Photo receptive Detects paper as it leaves the Exit Stack Full Photo receptive Detects when the output tray is full Temperature Thermistor Monitor temperature of the Heat Roller Door Interlocks Microswitch Interrupts 24 V to the Mai...

Page 53: ...tion is based on paper transport timing through the sensing area Door Interlock Sensors The Interlock Sensors for Doors A through E and J as well as selected paper feed sensors appear in the following diagram Tray 6 Paper Size Sensors Tray 6 Pre Feed Sensor Door E Interlock Door A Interlock Door D Interlock Door C Interlock s5500 584 Door J Interlock Door B Interlock Tray 6 Docking Interlock Front...

Page 54: ...es are adjusted the levers on the bottom of the trays change the size sensor actuator locations Actuating different combinations of the paper size sensors produces different combinations of high and low signals These signals identify what size of paper has been loaded and what to display on the Front Panel Also any actuation of the paper size sensor signals the Engine Logic Board that the tray is ...

Page 55: ... of drum cycles per page and the prints available varies according to the customer s usage patterns The Drum Cartridge Life specification of 60 000 prints is based on an average job length of six single sided pages As an example of how job length effects the Drum Cartridge Life count a continuous print job having a job length of 500 to 1000 pages results in a drum cycle count of 3 2 cycles per pag...

Page 56: ...surface of the paper Thus the developed image is transferred from the surface of the drum to the surface of the paper The Detack Saw located adjacent to the Transfer Roller helps to separate the paper from the drum surface Magnetic Roller A thin layer of developer and toner adheres to the surface of this roller which transports the toner to the Drum surface Charging and Metering CM Blade The CM Bl...

Page 57: ... Assembly The Toner Dispense Assembly operates the Toner Cartridge dispense door and moves toner from the cartridge through a dispense tube to the Drum Cartridge Left s5500 607 Transfer Roller s5500 594 Toner Dispense Assembly Dispense Tube ...

Page 58: ...ans from one end of the drum surface to the other while being turned off and on forming a single line of a latent image The resolution of the dual beam laser is either 600 dpi or 1200 dpi and is determined by the customer setting Both beams are always on For 600 dpi both beams receive the same data For 1200 dpi the beams receive different data resulting in a smaller pixel size The Scanner Motor tu...

Page 59: ... board Laser Assembly Components Component Function Laser Diode Assembly Produces two laser beams that are turned on and off according to the print data signal Scanner Assembly Consists of a faceted polygonal mirror mounted on the shaft of the scanner motor that reflects the beams to the drum surface through lenses and mirrors to scan the beams across the drum Start of Scan Board When the laser be...

Page 60: ...Motor Operational Modes Operational Mode Laser Power On Off Standby mode Always Off Print mode Turns On upon receiving the signal from the controller and turns Off after a preset time has passed from the end of printing Also turns Off if a print command is not received within 30 seconds from the reception of the signal Sleep mode Always Off Laser Reference Value Laser Assembly Reference Value Desc...

Page 61: ...ser errors Fuser components are described below Fuser Components Component Function Heat Roller The Heat Roller is a metal tube with a coated surface and a Heater Assembly inside As paper passes between the Heat Roller and Pressure Roller the heat fuses the toner to the paper Pressure Roller The Pressure Roller is a metal shaft coated with sponge rubber It maintains pressure on the paper passing b...

Page 62: ...s in the Fuser One is located at the center of Heat Roller the other is located where the edge of a letter size sheet of paper comes through The third is located at the center of the Pressure Roller The sensors monitor the surface temperature of the Heat and Pressure Rollers Thermostat The Thermostat provides a second level of protection If the Heat Roll temperature exceeds the preset temperature ...

Page 63: ... Thermistor does not detect the idling stop temperature even after the specified time has passed During print the Control Thermistor does not detect the required temperature even when the specified time has passed During print the Control Thermistor does not detect the required temperature even when the specified time has passed Fuser Temperature Regulation Fuser temperature regulation is managed ...

Page 64: ...uous printing When an abnormally high temperature is detected When an abnormally high temperature is detected the printer stops the print job and enters the following cool down process which continues until the target Control Temperature is reached Front Panel Fuser Temperature Modes by Paper Type Paper Type Temperature Low Medium High Extra High Plain Letterhead Colored Special Plain Paper Mode 1...

Page 65: ...2 202 187 185 11 30 206 196 211 201 186 185 31 50 205 195 210 200 185 185 51 99 205 195 210 200 185 185 100 150 205 195 210 200 185 185 150 205 195 210 200 185 185 Fuser Control Temperatures for Thick Paper Modes Paper Type Thick Paper Mode 1 2 3 4 Letter COM10 Label Start Temp o C Max Cold Min Hot Max Cold Min Hot Max Cold Min Hot Max Cold Min Hot Number of Sheets in Print Run 1 3 218 210 223 215...

Page 66: ... MPT Drive Roller that feeds paper into the printer Pick up Solenoid that engages the Main Motor to the Feed Roller No Paper Sensor that detects whether paper is in Tray 1 MPT Paper Size Sensor detects the position of the Side Guides and reports the width of paper in Tray 1 Tray 1 MPT incorporates a single set of guides to establish paper width The time required for the paper to clear the No Paper...

Page 67: ...he switch states corresponding to the pre defined paper sizes The switches are denoted by SW1 SW2 SW3 SW4 and SW5 respectively when viewed from the left side Universal Tray Paper Size Switch Signal States Paper size Paper Size Switch Output SW1 SW2 SW3 SW4 SW5 No tray 0 0 0 0 0 5 5 x 8 5 A5 SEF 0 0 1 0 0 B5 SEF 0 0 1 1 1 8 5 x 13 SEF 0 1 0 1 0 8 5 x 14 SEF 0 1 0 1 1 A4 SEF 0 1 1 0 0 8 5 x 11 SEF 0...

Page 68: ...with the Nudger Roller The Feeder s Level Sensor uses an actuator to determine whether paper in the tray is lifted to the feeding position As the level of paper drops the flag of the actuator enters the Level Sensor s sensing area triggering the Feed Lift Motor to raise the Bottom Plate The Feeder s Feed Lift Motor raises the Bottom Plate by rotating the Lift up Shaft through the Gear 13T 60T and ...

Page 69: ...When the flag of the actuator leaves the sensing area the sensor detects that the paper has been lifted Pre Feed Sensor The Pre Feed Sensor detects a paper jam in the tray by the paper position and sensor transition time No Paper Sensor The No Paper Sensor uses an actuator to determine whether the tray is empty When the actuator lowers the No Paper Sensor signal goes High indicating an empty tray ...

Page 70: ...r This roller transports the printed paper sent out from the Fuser to the Standard Output Tray Exit Gate The Exit Gate switches the paper path When the Exit Gate is in its resting position paper is fed to the Standard Output Tray or Horizontal Transport When it is lowered by the Exit Gate Solenoid paper is fed to Exit 2 The Exit Gate is operated by the Exit Gate Solenoid located in the Exit 2 modu...

Page 71: ... Position Sensor detects the OCT Roller position Exit PWB The Exit PWB controls paper feeding and reports sensor switch information back to the Engine Logic Board The Exit PWB also controls the Exit 2 module when attached Paper Weight Controls paper exiting the Exit module Removed from printers equipped with a Horizontal Transport Full Stack Sensor This sensor detects that the Standard Output Tray...

Page 72: ... for paper transport and a second drives the Drum Cartridge The assembly gets 24 VDC power from the LVPS The motor enable and speed control signals come from the microprocessor on the Engine Logic Board Toner Dispense Motor This drives the Toner Cartridge and dispense tube auger to gradually release toner to the Drum Cartridge s5500 040 Main Motor Drum Motor Motor Assembly s5500 596 Toner Dispense...

Page 73: ...es the print data and directs the development of images on the Drum Cartridge Exit PWB Specialized operational control of both Exit 1 and 2 Printer parameters are held by non volatile memory located in both these boards s5500 041 Power Switch Door A Interlock Fuser Fan Front Door Interlock Drum Cartridge Detect Interlock Door B Interlock LVPS Image Processor Board HVPS GFI Breaker Engine Logic Boa...

Page 74: ... P Board is to provide print control Front Panel control configuration setup error reporting and job recovery Before the I P Board can receive and process data it must first pass the Power On Self Test POST This test process verifies proper operation of the Image Processor and prepares it for processing the host data by putting the Image Processor in a known state The Image Processor Board connect...

Page 75: ... I P Board and from sensors and switches located throughout the printer The Engine Logic Board performs seven main functions Communicates with the Image Processor Controls the print sequence Distributes low DC voltages to various printer components Monitors printer status Maintains a running print count Writes the NVRAM settings Controls printer options s5500 042 ...

Page 76: ...inter Service Manual Exit PWB The Exit PWB controls timing feed and motor operation for Exit 1 and the optional Exit 2 HVPS The HVPS provides high AC and DC voltages to Xerographic components Exit PWB s5500 044 s5500 043 ...

Page 77: ...ias Charge Roller Magnetic Roller Transfer Roller and Detack Saw LVPS The Low Voltage Power Supply LVPS generates low voltages 5 V and 3 3 V for logic circuits 5 V for Laser Diodes and 24 V for motors clutches from AC power It also contains the Fuser Relay to switch AC power to the Heater Rod of the Fuser s5500 045 LVPS ...

Page 78: ...38 Phaser 5500 Printer Service Manual AC Accessory Panel The AC Accessory Panel provides AC power for the Finisher and accepts the Printer Power Cord AC Accessory Panel GFI Breaker s5500 046 Reset Switch ...

Page 79: ...3 Chapter Error Messages Codes and Procedures In this chapter Introduction Power On Self Test POST Service Usage Profile Service Diagnostics Error Messages Codes and Procedures ...

Page 80: ... 1 Identify the Problem Verify the reported problem does exist Check for any error codes and write them down Print normal customer prints and service test prints Make note of any print quality problems in the test prints Make note of any mechanical or electrical abnormalities present Make note of any unusual noise or smell coming from the printer Print a Service Usage Profile if the printer is abl...

Page 81: ...ns have been pushed POST continues execution 7 The display is reset addressable area turns Gray 8 The Front Panel LED cycles Green Yellow Red and then off 9 The display backlight turns on high intensity with nominal contrast display 10 The display area is turned on dark Black for 1 second 11 The display is cleared 12 The display backlight turns on with nominal intensity 13 The POST Vn nn message a...

Page 82: ...lt Type Description SDRAM 1 Hard This test fails if the Boot Loader finds faulty or no RAM I O ASIC 3 Hard This test determines if the I O chip is functioning properly Memory 4 Hard This test checks 64 bit reads and writes to RAM memory EEPROM 10 Hard This test checks addressing of the NVRAM Ethernet 11 Hard This test checks the Ethernet core CPU Interrupts 12 Hard This test checks that each CPU i...

Page 83: ...the upper left corner of the box in the center of the Start Page and extending to the right margin similar to the one shown here These messages are substituted for device Real Time Clock RAM Memory Slot 1 Checksum RAM Memory Slot 2 Checksum RAM Memory Slot 1 Rejected RAM Memory Slot 2 Rejected IDE Disk For Real Time Clock errors replace the Image Processor Board For IDE Disk errors replace the Har...

Page 84: ...ED Blink Pattern Front Panel Message Action 1 RAM ERROR No RAM present or faulty RAM Alternate 1 2 second interval blink at Front Panel and health LEDs 1 1 1 3 I O ASIC Image Processor Board ASIC failure Go to Image Processor Isolation on page 4 13 1 1 1 1 4 MEMORY Checks installed memory walking ones address walking one and complement data Tests RAM memory above diagnostics code and data addresse...

Page 85: ...go to the Troubleshooting menu and select Service Tools b From the Service Tools menu select Engine Error or Jam History Or If the printer is operational and connected to a network view the fault history using a browser a Open a web browser b Enter the printer s IP address as the URL c Select the Troubleshoot link and the Fault History displays Interpreting Fault History Error Codes Fault historie...

Page 86: ...ror 0 No Error 15 Toner Cartridge Failure J8 1 J8 2 1 Duplex Unit Failure H2 7 16 Drum Cartridge Failure J4 1 J7 1 J7 2 2 Exit Unit Fail H3 1 H3 3 H3 7 17 Temperature Sensor Failure No error code 3 Stacker Lower Tray Failure H5 11 13 21 24 81 84 86 18 Humidity Sensor Failure No error code 4 Stapler Failure H5 91 95 96 19 Main Motor Failure U0 1 U1 1 5 Punch Failure H5 31 34 20 Drum Motor Failure U...

Page 87: ...code and Total Page counter at the time the error occurred Fault History Codes for Jams Last Jam Location Item 291 Last Jam Error Item 298 Jam History Log Paper Size Jam E1 1 PSE 1 18 Jam at Tray 1 C9 3 1 Jam at Tray 2 C1 2 C1 3 2 Jam at Tray 3 C2 1 C2 2 3 Jam at Tray 4 C3 0 C3 1 4 Jam at Tray 5 C4 0 C4 1 C4 4 5 Jam at Tray 6 C5 1 C5 2 C8 5 6 Jam at A E1 2 E1 6 E3 1 E3 2 E3 6 E4 1 E4 5 F4 12 F4 16...

Page 88: ...Message Summary table and the Jam Location Map to locate the jam point Jam Location Map The following illustrates the Door designators that key the jam location error codes and messages Refer to this diagram when questions arise regarding the area of the jam s5500 614 Door J Door B Door C Door D Door E Door A Door F Door G Door H ...

Page 89: ...Tests the Feed Lift and Take Away motors Finisher Motor Tests Tests the Horizontal Transport Finisher Stapler and Punch Engine Sensor Switch Test Tests print engine sensor status and operation Duplex Sensors Switch Tests the Wait sensor and Door D Interlock Switch Exit 2 Sensor Switch Tests Exit 2 sensors and the Door E Interlock Switch Tray 4 5 Sensor Switch Tests Tray 4 5 sensors and the Door C ...

Page 90: ...ooting procedure use Service Diagnostics to exercise select parts in the vicinity of the reported error Tests are controlled from the Front Panel and are described in detail in the Appendix See Service Diagnostics Menu Map on page A 4 Starting Service Diagnostics Access the Service Diagnostics menu one of two ways Entering without rebooting the printer 1 From the printer s main menu scroll to Trou...

Page 91: ...P Scrolls up one menu item within a menu list This control does not wrap Used to increment data in tests requiring user input DOWN Scrolls down one menu item within a menu list This control does not wrap the end of a menu list is designated by three asterisks Used to decrement data in tests requiring user input OK Enters the highlighted menu Executes the current test item Used to select a data val...

Page 92: ...g F O Feed Out Used as sensor designators F O1 or F O 2 T A Take Away Function designator for roller or motor H Xport Horizontal Transport Horizontal Transport section of the Finisher MCU Main Control Unit Engine Logic Board I P Board Image Processor Image Processor Board OCT Offset Catch Tray Offset Rollers at Exit HCF High Capacity Feeder Option Tray 6 or 2000 Sheet Feeder MSI or MPT Multi Sheet...

Page 93: ... Error Go to Page Main Motor Failure U0 1 Main Motor Stop 19 3 23 Main Motor Failure Drum Motor Failure U1 1 Main Motor Rotation U1 4 Drum Motor Rotation 19 20 3 23 3 24 Laser Unit Failure Laser Motor Failure U3 3 Laser Power U3 5 Polygon Motor Rotation 23 22 3 25 3 26 Fuser Failure Fuser Failure Fuser Failure Fuser Failure Fuser Failure Fuser Failure Fan Failure U4 1 On Time U4 2 Over Heat Temp U...

Page 94: ...1 Tray 6 C5 2 Tray 6 C5 3 Tray 6 6 6 8 3 68 3 71 3 73 Jam at D and A Jam at D and A C6 1 Duplex Area Jam C6 2 Duplex Area Jam 15 15 3 51 3 53 Jam at B Jam at C Jam at C Jam at Tray 6 Jam at D C8 2 F O2 SNR Static Jam C8 3 F O3 SNR Static Jam C8 4 F O4 SNR Static Jam C8 5 HCF F O SNR Static jam C8 6 Duplex 8 9 9 6 10 3 76 3 77 3 78 3 79 3 83 Jam at Tray 1 MPT C9 3 Tray 1 MPT 1 3 84 Jam at A Jam at ...

Page 95: ...m C 12 12 13 13 17 12 13 13 3 123 3 126 3 123 3 123 3 126 3 129 3 129 3 129 Jam at F Jam at F Jam at G Jam at G Jam at F Jam at G Jam at G F4 82 Gate Sensor ON F4 83 Gate Sensor Static Jam A F4 84 Gate Sensor Static Jam B F4 85 Gate Sensor Static Jam C F4 86 Gate Sensor Static Jam A F4 87 Gate Sensor Static Jam B F4 88 Gate Sensor Static Jam C 12 12 13 13 12 13 13 3 131 3 135 3 135 3 135 3 138 3 1...

Page 96: ... 3 3 3 3 3 3 5 5 5 5 3 3 3 3 3 4 4 4 3 159 3 159 3 159 3 160 3 162 3 165 3 168 3 170 3 168 3 170 3 172 3 172 3 174 3 174 3 176 3 176 3 178 3 178 3 181 3 184 3 185 3 185 Tray 6 Logic Board Failure Tray 6 Logic Board Failure H6 4 NVM R W Error H6 7 HCF Comm Failure 13 13 3 187 3 188 Tray 4 5 Logic Board Failure Tray 4 5 Logic Board Failure Tray 4 5 Logic Board Failure Incorrect Tray 4 5 Unit Install...

Page 97: ...219 3 219 Standard Output Tray is Full Face down Tray 1 full Face down Tray 2 full 3 220 3 220 Stacker Upper Tray is Full Finisher Tray Paper Full 3 222 Stacker Lower Tray is Full Finisher Mix Full Stack 3 223 Stapler is Empty Staple Pin Warning 3 225 Stapler Cartridge is Low Staple Pin Misfeed 3 226 Staple Failure Staple Failure 3 228 Finisher Stacker set over count Staple Set Over Count 3 229 Pu...

Page 98: ...or a Yes reply If your response to the question is No then follow the instructions for a No reply 7 Note that two types of photo sensors are used photo reflective and photo receptive Photo reflective sensors use light reflected back from an object to detect its presence or absence Photo receptive sensors use an actuator or the object itself to block the light path to detect an object or condition ...

Page 99: ...l Ground You can substitute any RTN pin or test point in the printer and you can use FG frame ground in place of any SG pin or test point To locate connectors or test points see Wiring Diagrams for more information 5 Before measuring voltages make sure the printer is switched On the Drum Cartridge and the paper trays are in place and the interlock switches are actuated unless instructed otherwise ...

Page 100: ...Menu select Troubleshooting and press OK 2 Select Print Quality Problems and press OK 3 Select Test Prints and press OK Does the printer display an error message or code while printing Go to the procedure for that error message or code Go to Step 5 5 Do the test prints print Go to Step 6 Go to Step 7 6 Evaluate the test prints Does the print quality meet the print quality specifications Go to Step...

Page 101: ...tions and Questions Yes No 1 Check the Motor Assembly installation Remove the Upper Rear Cover page 8 15 Is the Motor Assembly installed correctly Go to Step 2 Correct the installation 2 Test Motor Assembly operation Run the Service Diagnostics Main Motor test Does the motor run Go to Step 6 Go to Step 3 3 Check the Motor Assembly connection Are P J214 and P J408 connected Go to Step 4 Connect P J...

Page 102: ...r installed properly Go to Step 2 Correct the Fuser page 8 76 2 Check the Drum Cartridge installation Is the Drum Cartridge installed properly Go to Step 3 Correct the installation 3 Test the Drum Motor Run the Service Diagnostics Drum Motor test Does the motor run Go to Step 4 Verify motor installation Go to Step 5 4 Check the Motor Assembly installation Remove the Upper Rear Cover Is the Motor i...

Page 103: ...rical page 9 40 Laser Assembly Troubleshooting Procedure Step Actions and Questions Yes No 1 Check the Drum Cartridge installation Is the Drum Cartridge installed properly Go to Step 2 Correct the installation 2 Check the Laser Assembly installation Is the Laser Assembly installed properly Go to Step 3 Correct the Laser page 8 74 3 Check the Laser Assembly connection Are P J140 and P J406 connecte...

Page 104: ...ge 8 89 Scanner Motor Troubleshooting Reference Applicable Parts References Drum Cartridge Laser Assembly Engine Logic Board Print Engine P J Laser and Exit PWB page 10 7 Print Engine laser Assembly Wiring page 10 29 PL5 1 Laser CRU and Toner Dispense page 9 32 PL8 1 Print Engine Electrical page 9 40 Scanner Motor Troubleshooting Procedure Step Actions and Questions Yes No 1 Check the Drum Cartrid...

Page 105: ...t detect the idling stop temperature even after the specified time has passed During print the Control Thermistor does not detect the required temperature even when the specified time has passed 4 Check the Laser connections Are P J130 P J620 and P J406 connected Go to Step 5 Connect P J130 P J620 and P J406 5 Check continuity between the Laser and the Engine Logic Board Is there continuity on eac...

Page 106: ...ty on the pins Go to Step 4 Replace the Fuser page 8 76 4 Check Fuser resistance Is the resistance across P J600 1 and P J600 11 less than or equal to 100 ohms Go to Step 5 Replace the Fuser page 8 76 5 Check Fuser resistance Is the resistance across P J600 4 and P J600 11 less than or equal to 100 ohm Go to Step 6 Replace the Fuser page 8 76 6 Check Fuser resistance Is the resistance across P J60...

Page 107: ...n the Fuser and LVPS Is there continuity on each wire between P J600 P J6 Go to Step 12 Repair the wiring 12 Check for 5 V to the Fuser Is there 5 V between these pins P J6 1 P6 2 P J6 1 P6 3 P J6 1 P6 4 Replace the Fuser page 8 76 Replace the LVPS page 8 92 13 Check the LVPS and the Engine Logic Board connection Are P J401 and P J525 connected Replace the Engine Logic Board page 8 89 Connect P J4...

Page 108: ...esistance across P J131 1 and P J131 2 more than or equal to 3 k ohm Go to Step 3 Replace the Fuser page 8 76 3 For FS2 Thermistor Only Is the resistance between P J132 1 and P J132 2 greater than or equal to 3 k ohm Go to Step 4 Replace the Fuser page 8 76 4 For Pressure Roller Thermistor Only Is the resistance across P J133 1 and P J133 2 greater than or equal to 3 k ohm Go to Step 5 Replace the...

Page 109: ...tics Fuser Exit Sensor test Does sensor state change each time the Fuser is installed or removed Go to Step 5 Go to Step 4 4 Check the resistance of the Fuser Is there an open circuit in the Center Thermistor between J131 1 and J131 2 Is the resistance of the Rear STS across J131 1 and J131 2 equal or greater than 3 k ohm Go to Step 7 Replace the Fuser page 8 76 5 Check the Pressure Roller Thermis...

Page 110: ...user Fan installation 1 Remove the I P Board Cover 2 Remove the Upper Rear Cover Is the Fan installed properly label out Go to Step 2 Correct the installation 2 Check if the Fuser Fan rotates Does the Fan rotate Go to Step 7 Go to Step 3 3 Test the Fuser Fan Run the Service Diagnostic Fuser Fan test Does the Fuser Fan operate properly Go to Step 7 Go to Step 4 4 Check the Fuser Fan connection CN10...

Page 111: ... 2 2 Check Toner Dispense Assembly rotation Does the gear located at the lower part of the Toner Dispense Assembly rotate Go to Step 3 Restore proper operation 3 Check Toner Dispense Assembly clogging Is the pipe located at the lower part of the Toner Dispense Assembly clogged Go to Step 4 Clean the pipe 4 Test Dispense Motor operation Run the Service Diagnostics Dispense Motor test Does the motor...

Page 112: ... Fan installed properly label out Go to Step 2 Correct the installation 2 Check if the Drum Cartridge Fan rotates Does the Fan rotate Go to Step 7 Go to Step 3 3 Test the Drum Cartridge Fan Run the Service Diagnostic Drum Cartridge Fan test Does the Fan operate properly Go to Step 7 Go to Step 4 4 Check the Fan connection Is P J221 connected Go to Step 5 Connect the Fan 5 Check continuity between ...

Page 113: ... Registration Sensor located behind Door A within the specified time Applicable Error Code Paper Size Jam E1 1 Regi Area Jam Engine Logic Board Troubleshooting Reference Applicable Parts References Engine Logic Board Engine Logic Board P J Locator page 10 13 PL8 1 Print Engine Electrical page 9 40 Engine Logic Board Troubleshooting Procedure Step Actions and Questions Yes No 1 Does the error occur...

Page 114: ...Sensor 1 Open Door A 2 Run the Service Diagnostics Registration Sensor test Does the sensor change state Go to Step 7 Go to Step 4 4 Check the Registration Sensor connection Are P J104 and P J403B connected Go to Step 5 Connect the sensor 5 Check continuity between the Registration Sensor and Engine Logic Board Is there continuity on each wire between P J104 P J403 Go to Step 6 Repair the wiring 6...

Page 115: ...ting Reference Applicable Parts References Fuser Exit Sensor Registration Clutch Take Away Roller Exit PWB Engine Logic Board Print Engine P J Drum and Toner Cartridge page 10 6 Print Engine Exit 1 Wiring page 10 30 PL4 1 Transportation and Registration page 9 22 PL4 5 Registration page 9 30 PL6 1 Laser CRU and Toner Dispense page 9 32 PL8 1 Print Engine Electrical page 9 40 E1 2 Regi Area Jam Fus...

Page 116: ...8 77 Replace the Engine Logic Board page 8 89 7 Test the Registration Clutch operation Run the Service Diagnostics Registration Clutch test Does the clutch operate properly Replace the Engine Logic Board page 8 89 Go to Step 8 8 Check the Registration Clutch connection Are P J215 and P J403B connected Go to Step 9 Connect P J215 and P J403B 9 Check continuity between the Registration Clutch and En...

Page 117: ...shooting Procedure Step Actions and Questions Yes No 1 Check paper position at Door A Is paper touching the Registration Sensor Remove the paper Go to Step 2 2 Test the Registration Sensor 1 Open Door A 2 Run the Service Diagnostics Registration Sensor test Does the sensor change state Replace the Engine Logic Board page 8 89 Go to Step 3 3 Check the Registration Sensor connection Are P J104 and P...

Page 118: ...ser installation Open Door A Is the Fuser installed correctly Go to Step 4 Correct the installation 4 Check the Take Away Roller Open Door A Is the Take Away Roller worn or contaminated with paper dust Go to Step 5 Clean or replace Take Away Roller page 8 41 5 Test the Fuser Exit Sensor operation 1 Open Door A 2 Run the Service Diagnostic Fuser Exit Sensor test Does the sensor state change each ti...

Page 119: ...es No 1 Check paper position at Door A Is paper touching the Fuser Exit Sensor Remove the paper Go to Step 2 2 Test the Fuser Exit Sensor 1 Open Door A 2 Run the Service Diagnostics Fuser Exit Sensor test Does the sensor change state Replace the Engine Logic Board page 8 89 Go to Step 3 3 Check the Fuser Exit Sensor connection Are P J125 and P J410 connected Go to Step 4 Connect the sensor 4 Check...

Page 120: ... Step Actions and Questions Yes No 1 Check paper position at Door A Is paper touching the Fuser Exit Sensor Remove the paper Go to Step 2 2 Check paper position at Door E Is paper touching the Exit Sensor Remove the paper Go to Step 3 3 Check the OCT Roller Is the OCT Roller worn or contaminated with paper dust Clean or replace the OCT Roller Go to Step 4 4 Check the drive transmission Does the OC...

Page 121: ...c Board Are P J431 and P J421 connected Go to Step 14 Connect P J431 and P J421 14 Check continuity between the Exit PWB and the Engine Logic Board Is there continuity on each wire between P J431 P J421 Go to Step 15 Repair the wiring 15 Check the connection between the Exit PWB and the LVPS Are P J430 and P J526 connected Go to Step 16 Connect P J430 and P J526 16 Check continuity between the Exi...

Page 122: ...tween the Exit PWB and Engine Logic Board Are P J431 and P J421 connected Go to Step 23 Connect P J431 and P J421 23 Check continuity between the Exit PWB and Engine Logic Board Is there continuity on each wire between P J431 P J421 Go to Step 24 Repair the wiring 24 Check the connection between the Exit PWB and the LVPS Are P J430 and P J526 connected Go to Step 25 Connect P J430 and P J526 25 Ch...

Page 123: ...per Go to Step 2 2 Check the FU Roller Is the FU Roller worn or contaminated with paper dust Clean or replace the FU Roller Go to Step 3 3 Check the drive transmission Does the FU Roller and gears rotate smoothly Go to Step 4 Restore proper operation 4 Check the Inv Roller Is the INV Roller worn or contaminated with paper dust Clean or replace the INV Roller Go to Step 5 5 Check the drive transmis...

Page 124: ... J434 Go to Step 14 Repair the wiring 14 Check for 5 V at the Exit Sensor Is there 5 V across the sensor connector s P J112 3 ground Replace the Exit 2 Sensor page 3 102 Go to Step 15 15 Check the connection between the Exit PWB and Engine Logic Board Are P J431 and P J421 connected Go to Step 16 Connect P J431 and P J421 16 Check continuity between the Exit PWB and the Engine Logic Board Is there...

Page 125: ...Motor Is there 24 V across P208 5 ground Replace the Exit 2 Motor page 3 104 Go to Step 24 24 Check the connection between the Exit PWB and Engine Logic Board Are P J431 and P J421 connected Go to Step 25 Connect P J431 and P J421 25 Check continuity between the Exit PWB and Engine Logic Board Is there continuity on each wire between P J431 P J421 Go to Step 26 Repair the wiring 26 Check the conne...

Page 126: ...ce Diagnostics Exit Sensor test Does the sensor change state Replace the Engine Logic Board page 8 89 Go to Step 3 3 Check the Exit Sensor connection Are P J112 P J606B and P J434 connected Go to Step 4 Connect the sensor 4 Check continuity between the Exit Sensor and Exit PWB Is there continuity on each wire between P J112 P J434 Go to Step 5 Repair the wiring 5 Check for 5 V at the Exit Sensor I...

Page 127: ...gine Logic Board page 10 13 Print Engine Exit 1 Wiring page 10 30 PL8 1 Print Engine Electrical page 9 40 Phaser 5500 Printer Options Service Manual Exit 2 Plug Jack Locator page 5 15 Exit 2 General Wiring page 5 7 Duplex Unit Plug Jack Locator page 5 12 Duplex Unit Wiring page 5 13 PL23 1 Duplex Unit page 4 34 PL24 1 Exit 2 L H Upper Chute page 4 38 PL24 2 Exit 2 Tray Guide Assembly page 4 40 E8 ...

Page 128: ... Motor and Exit PWB Is there continuity on each wire between P J208 P J433 Go to Step 11 Repair the wiring 11 Check for 24 V to the Exit 2 Motor Is there 24 V across P208 5 ground Replace the Exit 2 Motor page 3 104 Go to Step 12 12 Check the connection between the Exit PWB and Engine Logic Board Are P J431 and P J421 connected Go to Step 13 Connect P J431 and P J421 13 Check continuity between th...

Page 129: ...een the Wait Sensor and Duplex PWB Is there continuity on each wire between P J123 P J541 Go to Step 20 Repair the wiring 20 Check for 5 V to the Wait Sensor Is there 5 V across P123 3 ground Replace the Wait Sensor page 3 78 Go to Step 21 21 Check the Duplex PWB connection Are P J540 and P J417 connected Go to Step 22 Connect P J540 and P J417 surely 22 Check continuity between the Duplex PWB and...

Page 130: ...ion Sensor Remove the paper Go to Step 2 2 Check Duplex Unit installation 1 Reinstall the Duplex Unit 2 Print a 2 sided Test Print Does the error reoccur Go to Step 3 Problem solved 3 Check the A3L Rollers Open Door D Are the A3L Rollers worn or contaminated with paper dust Clean or replace the defective roller Go to Step 4 4 Check the roller drive Do the A3L Rollers and gears rotate smoothly Go t...

Page 131: ... Replace the Engine Logic Board page 8 89 14 Test the Registration Sensor Run the Service Diagnostics Registration Sensor test Does the sensor status change Replace the Engine Logic Board page 8 89 Go to Step 15 15 Check the Registration Sensor connection Are P J104 and P J403B connected Go to Step 16 Connect P J104 and P J403B 16 Check continuity between the Registration Sensor and Engine Logic B...

Page 132: ...ocedure Step Actions and Questions Yes No 1 Check the paper position Open Door A Does the paper touch the Registration Sensor Remove the paper Go to Step 2 2 Check the paper position Open Door D Does the paper touch the Wait Sensor Remove the paper Go to Step 3 3 Check the Duplex Unit installation 1 Reinstall the Duplex Unit 2 Print a 2 sided Test Print Does the error reoccur Go to Step 4 Problem ...

Page 133: ...ngine Logic Board page 8 89 14 Test the Duplex Motor Run the Service Diagnostics Duplex Motor test Does the Duplex Motor operate properly Go to Step 21 Go to Step 15 15 Check the Duplex Motor for connection Are P J212 and P J542 connected Go to Step 16 Connect P J212 and P J542 16 Check the Duplex Motor for continuity Is there continuity on each wire between P J212 P J542 Go to Step 17 Repair the ...

Page 134: ...connected Go to Step 23 Connect P J104 and P J403B 23 Check continuity between the Registration Sensor and Engine Logic Board Is there continuity on each wire between P J104 P J403 Go to Step 24 Repair the wiring 24 Check for 5 V to the Registration Sensor Is there 5 V across P J104 1 ground Replace the Registration Sensor page 8 52 Go to Step 25 25 Check continuity between the Duplex PWB and Engi...

Page 135: ...place the paper Go to Step 2 2 Check the paper size settings Does the paper size in use match the setting for the tray Go to Step 3 Correct paper size settings 3 Remove the tray and check the rollers Is the Feed Retard or Nudger Roller worn or contaminated with paper dust Clean or replace the Rollers Go to Step 4 4 Check paper position at Door A B or C Does the paper touch the Feeder s Registratio...

Page 136: ...e Logic Board page 8 89 12 Test the Feed Lift Motor Run the Service Diagnostics Lift Feed motor test for the appropriate tray Does the motor operate Replace the Engine Logic Board page 8 89 Go to Step 13 13 Check the Feed Lift Motor connections Is the Feed Lift motor connected Go to Step 14 Connect the motor 14 Test the Feed Lift Motor 1 Exchange the Feed Lift motor with one from a different feede...

Page 137: ...vice Manual 1000 Sheet Feeder P J Locator page 5 5 1000 Sheet Tray 4 5 Wiring page 5 9 PL20 4 Tray 4 5 Feeders 2 2 page 4 10 PL20 6 Tray 4 5 Drive and Electrical page 4 16 Jam at Tray n Registration Sensor Troubleshooting Procedure Step Actions and Questions Yes No 1 Check paper condition Is the paper in the tray damaged Replace the paper Go to Step 2 2 Check paper size settings Does the paper siz...

Page 138: ...Replace the Engine Logic Board page 8 89 Go to Step 10 10 For Trays 2 and 3 Only Check the Pre Feed Sensor connection Is the sensor connected Go to Step 11 Connect the sensor 11 For Trays 2 and 3 Only Check continuity between the Pre Feed Sensor and the Engine Logic Board Is there continuity on each wire between the sensor and board Go to Step 12 Repair the wiring 12 For Trays 2 and 3 Only Check f...

Page 139: ... at the Feed Out Sensor Is there 5 V across the sensor connector s Pin 1 ground Replace the sensor Go to Step 17 17 For Trays 4 5 Only Check connections between the Tray 4 5 PWB and Engine Logic Board Are P J541 and P J413 connected Go to Step 18 Connect P J541 and P J413 18 For Trays 4 5 Only Check continuity between the Tray 4 5 PWB and the Engine Logic Board Is there continuity on each wire bet...

Page 140: ... paper size match the setting Go to Step 3 Correct paper size settings 3 Remove the tray and check the rollers Is the Feed Retard or Nudger Roller worn or contaminated with paper dust Clean or replace the Rollers Go to Step 4 4 Check the paper position at Door B or C Does the paper block the Feed Out Sensor Remove the paper If the error persists go to Step 5 for Tray 2 or 3 or Step 9 for Tray 4 or...

Page 141: ...t Sensor and the Tray 4 5 PWB Is there continuity on each wire between the sensor and board Go to Step 12 Repair the wiring 12 For Trays 4 and 5 Only Check for 5 V at the Feed Out Sensor Is there 5 V across the sensor connector s Pin 3 ground Replace the sensor Go to Step 13 13 For Trays 4 5 Only Check connections between the Tray 4 5 PWB and Engine Logic Board Are P J541 and P J413 connected Go t...

Page 142: ...Step 3 Correct paper size settings 3 Remove the tray and check the rollers Is the Feed Retard or Nudger Roller worn or contaminated with paper dust Clean or replace the Rollers Go to Step 4 4 Check paper position at Door C Does the paper touch the Feed Out Sensor Remove the paper Go to Step 5 5 Test Feed Out Sensor 4 1 Open Door C 2 Run the Service Diagnostics Tray 4 Feed Out Sensor test Does the ...

Page 143: ...P J842 and P J548 connected Go to Step 14 Connect the sensor 14 Check continuity between the Feed Out Sensor 5 and the Tray 4 5 PWB Is there continuity on each wire between P J825 P J548 Go to Step 15 Repair the wiring 15 Check for 5 V at the Feed Out Sensor 5 Is there 5 V across the sensor connector s Pin 3 ground Replace Feed Out Sensor 5 page 3 22 Go to Step 16 16 Check connections between the ...

Page 144: ...ize settings 3 Remove the tray and check the rollers Is the Feed Retard or Nudger Roller worn or contaminated with paper dust Clean or replace the Rollers Go to Step 4 4 Check paper position at Door C Does the paper touch the Tray 5 Pre Feed or Feed Out Sensor 5 Remove the paper Go to Step 5 5 Test the Tray 5 Pre Feed Sensor 1 Open Door C 2 Run the Service Diagnostics Tray 5 Pre Feed Sensor test D...

Page 145: ...4 Check continuity between the Feed Out Sensor 5 and the Tray 4 5 PWB Is there continuity on each wire between P J825 P J548 Go to Step 15 Repair the wiring 15 Check for 5 V at the Feed Out Sensor 5 Is there 5 V across the sensor connector s Pin 3 ground Replace the sensor page 3 22 Go to Step 16 16 Check connections between the Tray 4 5 PWB and Engine Logic Board Are P J541 and P J413 connected G...

Page 146: ... 24 2000 Sheet Tray 6 Drive Wiring page 5 25 PL22 4 Tray 6 Feeder 1 3 page 4 24 PL22 5 Tray 6 Feeder 2 3 page 4 26 PL22 6 Tray 6 Feeder 3 3 page 4 28 PL22 8 Tray 6 Electrical page 4 32 Jam at Tray 6 Feed Out Sensor 6 Troubleshooting Procedure Step Actions and Questions Yes No 1 Check the paper path 1 Open Door J 2 Open the Upper Feeder Assembly Are the Rollers installed correctly clean and turn fr...

Page 147: ...voltage across JF02 5 PF04 2 on the PWB change when white paper is placed over the sensing area Go to Step 27 Replace the Pre Feed Sensor page 3 51 10 Test the Feed Lift Motor Run the Service Diagnostics Tray 6 Motor Feed test Does the Feed Lift Motor rotate normally Go to Step 18 Go to Step 11 11 Check the Harness connections Are the connectors PF58 PF56 and JF06 on the PWB connected Go to Step 1...

Page 148: ...cs Tray 6 Nudger Solenoid Test at High Power Does the Nudger Solenoid activate Go to Step 27 Go to Step 19 19 Check the harness connections Are the connectors PF59 PF56A and P JF06 on the PWB connected Go to Step 21 Connect and go to Step 20 20 Print a Test Print Does the error still occur Go to Step 21 Problem solved 21 Check the Feeder Harness for continuity 1 Disconnect PF59 and JF56A 2 Check f...

Page 149: ...27 Problem Solved 27 Replace the Tray 6 PWB Print a Test Print Does the error still occur Replace the Engine Logic Board page 8 89 Problem solved Jam at Tray 6 Feed Out Sensor 6 Troubleshooting Reference Applicable Parts References Feed Roller Nudge Roller Retard Roller Take Away Roller Door J Feed Out Sensor Feeder Harness Main Harness Tray 6 PWB Take Away Motor Engine Logic Board Print Engine P ...

Page 150: ...Problem solved 6 Check the Feeder Harness for continuity 1 Disconnect P JF67 and PF54 2 Check for continuity of the following P JF67 1 JF54 3 P JF67 2 JF54 2 P JF67 3 JF54 1 Are these three conductive Go to Step 7 Repair the Harness 7 Check the Main Harness for continuity 1 Disconnect PF54 and P JF01 2 Check for continuity at the following PF54 1 P JF01 3 PF54 2 P JF01 2 PF54 3 P JF01 1 Are these ...

Page 151: ...JF06 9 PF57 4 P JF06 10 PF57 3 P JF06 12 PF57 2 P JF06 7 Are these conductive Go to Step 14 Repair the Tray 6 Main harness 14 Check Take Away Motor resistance Is there some amount of resistance across F57 3 4 COM and JF57 1 2 5 6 Go to Step 15 Replace the Take Away Motor page 3 64 15 Check for 24 V at the Take Away Motor Is there 24 V across PF06 9 PF04 2 and PF06 10 PF04 2 on the Tray 6 PWB Go to...

Page 152: ...ing Procedure Step Actions and Questions Yes No 1 Check the paper path Open Door J Are all the rollers installed correctly clean and turn freely Go to Step 2 Clean or replace the Rollers 2 Check the printer paper path Open Door A Is the paper path clean Go to Step 3 Clean the paper path 3 Test the Registration Sensor 1 Open Door A 2 Run the Service Diagnostics Registration Sensor test Does the sen...

Page 153: ...2 Problem solved 12 Check the Main Harness continuity 1 Disconnect PF57 and JF06 2 Check for continuity at the following PF57 7 P JF06 11 PF57 6 P JF06 8 PF57 5 P JF06 9 PF57 4 P JF06 10 PF57 3 P JF06 12 PF57 2 P JF06 7 Are these conductive Go to Step 13 Repair Main Harness 13 Check the Take Away Motor resistance Are the resistances across JF57 3 4 COM and JF57 1 2 5 6 XXXX ohm Go to Step 14 Repla...

Page 154: ...oubleshooting Procedure Step Actions and Questions Yes No 1 Check the paper path Open Door B Does the paper touch the Tray 3 Feed Out Sensor Remove the paper Go to Step 2 2 Test the Feed Out Sensor 3 1 Open Door B 2 Run the Service Diagnostics Tray 3 Feed Out Sensor test Does the sensor change state Replace the Engine Logic Board 8 89 Go to Step 3 3 Check the sensor connection Are P J105 P J608 an...

Page 155: ...or 4 Troubleshooting Procedure Step Actions and Questions Yes No 1 Check the paper path Open Door C Does the paper touch Feed Out Sensor 4 Remove the paper Go to Step 2 2 Test Feed Out Sensor 4 Run the Service Diagnostics Tray 4 Feed Out Sensor test Does the sensor change state Replace the Engine Logic Board page 8 89 Go to Step 3 3 Check the Feed Out Sensor 4 connection Are P J821 P J841 and P J5...

Page 156: ... 5 Electrical page 5 6 1000 Sheet Tray 4 Wiring page 5 9 PL20 5 Tray 4 5 Transportation page 4 14 PL20 6 Tray 4 5 Drive and Electrical page 4 16 Jam at C Feed Out Sensor 5 Troubleshooting Procedure Step Actions and Questions Yes No 1 Check the paper path Open Door C Does the paper touch Feed Out Sensor 5 Remove the paper Go to Step 2 2 Test Feed Out Sensor 5 Run the Service Diagnostics Tray 5 Feed...

Page 157: ...e Logic Board page 8 89 Jam at Tray 6 Feed Out Sensor 6 Troubleshooting Reference Applicable Parts References Feed Roller Retard Roller Take Away Roller Door J Pre Feed Sensor Feed Out Sensor 6 Feeder Harness Main Harness Take Away Motor Feeder Motor Tray 6 PWB Engine Logic Board Print Engine P J Engine Logic Board page 10 13 PL8 1 Print Engine Electrical page 9 40 Phaser 5500 Printer Options Serv...

Page 158: ...ected Go to Step 6 Connect and go to Step 5 5 Print a Test Print Does the error still occur Go to Step 6 Problem solved 6 Check the Feeder Harness for continuity 1 Disconnect PF61 and PF56B 2 Check for continuity of the following PF61 1 JF56B 3 PF61 2 JF56B 2 PF61 3 JF56B 1 Are these three conductive Go to Step 7 Repair the Feeder Harness 7 Check the Main Harness for continuity 1 Disconnect PF56B ...

Page 159: ...F01 2 Check for continuity at the following JF54 1 JF01 3 JF54 2 JF01 2 JF54 3 JF01 1 Are these three conductive Go to Step 16 Repair the Main Harness 16 Check for 5 V to the Feed Out Sensor 6 Is there 5 V across PF01 3 PF04 2 on the Tray 6 PWB Go to Step 17 Replace the Tray 6 PWB page 3 67 17 Check the Feed Out Sensor 6 signal Does the voltage across JF01 2 PF04 2 on the Tray 6 PWB change when th...

Page 160: ...t of resistance across PF58 2 5 COM and PF58 1 3 4 6 Go to Step 24 Replace the Feed Lift Motor page 3 49 24 Check for 24 V at the Feed Lift Motor Is there 24 V across PF06 3 PF04 3 and PF06 4 PF04 3 on the Tray 6 PWB Go to Step 25 Replace the Tray 6 PWB page 3 67 25 Replace the Feed Lift Motor Print a Test Print Does the error still occur Go to Step 33 Problem solved 26 Test the Take Away Motor Ru...

Page 161: ... Take Away Motor Is there 24 V across PF06 9 PF04 3 and PF06 10 PF04 3 on the PWB Go to Step 32 Replace the Tray 6 PWB page 3 67 32 Replace the Take Away Motor Print a Test Print Does the error still occur Go to Step 33 Problem solved 33 Replace the Tray 6 PWB Print a Test Print Does the error still occur Replace the Engine Logic Board page 8 89 Problem solved Jam at D Wait Sensor Troubleshooting ...

Page 162: ...the Engine Logic Board page 8 89 Go to Step 3 3 Check the Wait Sensor connection Are P J123 and P J541 connected Go to Step 4 Connect the sensor 4 Check continuity between the Wait Sensor and Duplex Unit PWB Is there continuity on each wire between P J123 P J541 Go to Step 5 Repair the wiring 5 Check for 5 V to the Wait Sensor Is there 5 V across P J123 3 ground Replace the Wait Sensor page 3 78 G...

Page 163: ...setting 3 Check paper position Open Door A Does the paper touch the Registration Sensor Remove the paper Go to Step 4 4 Check the size guides Do the size guides operate smoothly Go to Step 5 Repair or replace the guides 5 Check the Tray 1 Feeder installation 1 Reinstall the Tray 1 Feeder 2 Print a Test Print from Tray 1 Does the error occur Go to Step 6 Problem solved 6 Check the Feed Roller Remov...

Page 164: ...ine Logic Board page 8 89 Go to Step 13 13 Check the Pick Up Solenoid connection Are P J205 P J605 and P J411 connected Go to Step 14 Connect P J205 P J605 and P J411 14 Check the Pick Up Solenoid continuity Is there continuity on each wire between P J205 P J411 Go to Step 15 Repair the wiring 15 Check the Pick Up Solenoid resistance Is the resistance across J205 1 and J205 2 approximately 90 ohm ...

Page 165: ...cator page 5 29 Horizontal Transport Wiring page 5 39 Finisher Main PWB P J Locator page 5 35 PL25 2 Horizontal Transport 1 2 page 4 46 PL25 3 Horizontal Transport 2 2 page 4 48 PL25 14 Finisher Electrical page 4 70 Jam at A H X port Entrance Sensor Troubleshooting Procedure Step Actions and Questions Yes No 1 Check the paper path Open Door F Are the Belts and Pinch Rollers clean operate freely an...

Page 166: ...7 Go to Step 9 9 Check the H Xport Motor connections Is the H Xport Motor correctly connected to the harness Go to Step 11 Connect and go to Step 10 10 Print a Test Print Does the error still occur Go to Step 11 Problem solved 11 Check the harness for continuity 1 Disconnect P J8379 of the H Xport Motor and P8372 on the H Xport PWB 2 Check for continuity at the following P8372 13 J8379 6 P8372 12 ...

Page 167: ...or Finisher H X port PWB Phaser 5500 Printer Options Service Manual Horizontal Transport P J Locator page 5 29 Horizontal Transport Wiring page 5 39 Finisher Main PWB P J Locator page 5 35 PL25 2 Horizontal Transport 1 2 page 4 46 PL25 3 Horizontal Transport 2 2 page 4 48 PL25 14 Finisher Electrical page 4 70 Jam at A or F H X port Entrance Sensor Troubleshooting Procedure Step Actions and Questio...

Page 168: ...st the H Xport Motor Run the Service Diagnostics H Xport Motor test Does the motor rotate normally Replace the H Xport PWB page 3 247 Go to Step 8 8 Check the H Xport Motor connections Is the H Xport Motor correctly connected to the harness Go to Step 10 Connect and go to Step 9 9 Print a Test Print Does the error still occur Go to Step 10 Problem solved 10 Check the harness for continuity 1 Disco...

Page 169: ...able Parts References H X port Belts H X port Pinch Rollers H X port Motor H X port Harness H X port Exit Sensor Finisher H X port PWB Finisher Main PWB Engine Logic Board Print Engine P J Engine Logic Board page 10 13 PL8 1 Print Engine Electrical page 9 40 Phaser 5500 Printer Options Service Manual Horizontal Transport P J Locator page 5 29 Horizontal Transport Wiring page 5 39 Finisher Main PWB...

Page 170: ...to Step 6 Repair the harness 6 Check for 5 V to the Exit Sensor Is there 5 V across J8372 6 J8372 4 on the H Xport PWB Go to Step 7 Replace the H Xport PWB page 3 247 7 Check the Exit Sensor signal Does the voltage across J8372 5 J8372 4 on the H Xport PWB change when the sensor actuator is operated Replace the H Xport PWB page 3 247 Replace the sensor page 3 118 8 Test the H Xport Motor Run the S...

Page 171: ...4 V to the H Xport Motor Is there 24 V across J8372 15 J8372 7 and J8372 14 J8372 7 on the H Xport PWB Go to Step 14 Replace the H Xport PWB page 3 247 14 Replace the H Xport Motor Print a Test Print Does the error still occur Go to Step 15 Problem solved 15 Replace the H Xport PWB Print a Test Print Does the error still occur Replace the Finisher Main PWB page 3 248 Problem solved Jam at F H X po...

Page 172: ...e following P8372 4 J8381 3 P8372 5 J8381 2 P8372 6 J8381 1 Are these conductive Go to Step 5 Repair the harness 5 Check for 5 V to the H Xport Exit Sensor Is there 5 V across J8372 6 J8372 4 on the H Xport PWB Go to Step 6 Replace the H Xport PWB page 3 247 6 Check the H Xport Exit Sensor signal Does the voltage across J8372 5 J8372 4 on the H Xport PWB change when the sensor actuator is operated...

Page 173: ...J8379 1 P8372 10 J8379 3 P8372 15 J8379 2 P8372 3 J8379 5 Are these conductive Go to Step 11 Repair the harness 11 Check the H Xport Motor resistance Is there some amount of resistance across P8379 2 5 COM and P8379 1 3 4 6 Go to Step 12 Replace the H Xport Motor page 3 113 12 Check for 24 V to the H Xport Motor Is there 24 V across J8372 15 J8372 7 and J8372 14 J8372 7 on the H Xport PWB Go to St...

Page 174: ... Procedure Step Actions and Questions Yes No 1 Check the paper path Open Door F Are the Belts and Pinch Rollers clean operate freely and correctly installed Go to Step 2 Clean or replace affected components 2 Test the H Xport Exit Sensor 1 Open Door F 2 Run the Service Diagnostic H Xport Exit Sensor test Does the sensor change state Go to Step 8 Go to Step 3 3 Check the H Xport Harness connections...

Page 175: ...6 P8372 12 J8379 4 P8372 11 J8379 1 P8372 10 J8379 3 P8372 15 J8379 2 P8372 3 J8379 5 Are these conductive Go to Step 12 Repair the harness 12 Check the H Xport Motor resistance Is there some amount of resistance across P8379 2 5 COM and P8379 1 3 4 6 Go to Step 13 Replace the H Xport Motor page 3 113 13 Check for 24 V to the H Xport Motor Is there 24 V across J8372 15 J8372 7 and J8372 14 J8372 7...

Page 176: ...B 3 Are these conductive Go to Step 20 Repair the X port Entrance Sensor Harness 20 Check Main Sensor Harness continuity Disconnect P J8303 on the Main Sensor Harness and P J8302A on the Finisher Main PWB Check for continuity at the following J8303A 3 J8302A 1 J8303A 2 J8302A 2 J8303A 1 J8302A 3 Are these conductive Go to Step 21 Repair the Main Sensor Harness 21 Check for 5 V to the X port Entran...

Page 177: ...test Does the sensor change state Go to Step 8 Go to Step 2 2 Check the Sensor Harness connections Is the harness connected to the sensor and Finisher correctly Go to Step 4 Connect and go to Step 3 3 Print a Test Print Does the error still occur Go to Step 4 Problem solved 4 Check Sensor Harness continuity 1 Disconnect P J8319 and P J8303B 2 Check for continuity at the following J8319 3 J8303B 1 ...

Page 178: ...rror still occur Go to Step 12 Problem solved 12 Check Main Drive Harness continuity 1 Disconnect P J8342 and P J8304 2 Check for continuity at the following J8342 1 J8304 23 J8342 2 J8304 16 J8342 3 J8304 25 J8342 4 J8304 27 J8342 5 J8304 18 J8342 6 J8304 29 Are these conductive Go to Step 13 Repair the Main Drive Harness 13 Check Transport Motor resistance Is there some amount of resistance acro...

Page 179: ...te Sensor Sensor Harness Buffer Gate Solenoid Registration Motor Buffer Sensor Harness Buffer Path Sensor Phaser 5500 Printer Options Service Manual Finisher Main PWB P J Locator page 5 35 Finisher Sensors 1 2 Wiring page 5 40 Finisher Motors Wiring page 5 42 Finisher Clutch and Solenoids page 5 43 PL25 12 Finisher Transport 1 2 page 4 66 PL25 13 Finisher Transport 2 2 page 4 68 PL25 14 Finisher E...

Page 180: ...t P J8319 and P J8303B on the X port Entrance Sensor Harness 2 Check for continuity at the following J8319 3 J8303B 1 J8319 2 J8303B 2 J8319 1 J8303B 3 Are these conductive Go to Step 7 Repair the X port Entrance Sensor Harness 7 Check Main Sensor Harness continuity Disconnect P J8303A on the Main Sensor Harness and P J8302A on the Finisher Main PWB Check for continuity at the following J8303A 3 J...

Page 181: ...J8342 4 J8304 27 J8342 5 J8304 18 J8342 6 J8304 29 Are these conductive Go to Step 16 Repair the Main Drive Harness 16 Check the Transport Motor resistance Is there some amount of resistance across P8342 2 5 COM and P8342 1 3 4 6 Go to Step 17 Replace the Transport Motor page 3 222 17 Check for 24 V to the Transport Motor Is there 24 V across J8304 16 ground and J8304 18 ground on the Finisher Mai...

Page 182: ... to Step 31 Go to Step 26 26 Check Main Drive Harness connections Are P J8394 and P J8304 connected Go to Step 28 Connect and go to Step 27 27 Print a Test Print Does the error still occur Go to Step 28 Problem solved 28 Check Main Drive Harness continuity 1 Disconnect P J8394 and P J8304 2 Check for continuity at the following J8394 1 J8304 35 J8394 2 J8304 34 J8394 3 J8304 36 Are these conductiv...

Page 183: ...ome amount of resistance across P8335 2 5 COM and P8335 1 3 4 6 Go to Step 38 Replace the Registration Motor page 3 245 38 Check for 24 V to the Registration Motor Is there 24 V across J8304 8 ground and J8304 10 ground on the Finisher Main PWB Go to Step 39 Replace the Finisher Main PWB page 3 248 39 Replace the Registration Motor Print a Test Print Does the error still occur Replace the Finisher...

Page 184: ... the Buffer Sensor Harness 46 Check Main Sensor Harness continuity 1 Disconnect P J8318A from the harness and P J8302A on the Finisher Main PWB 2 Check for continuity at the following J8318A 3 J8302A 13 J8318A 2 J8302A 14 J8318A 1 J8302A 15 Are these conductive Go to Step 47 Repair the Main Sensor Harness 47 Check for 5 V to the Buffer Path Sensor Is there 5 V across J8302A 15 J8302A 13 on the Fin...

Page 185: ...ensor state change Go to Step 10 Go to Step 2 2 Check the Buffer Path Sensor connection Are P J8392 and P J8318 connected Go to Step 4 Connect and go to Step 3 3 Print a Test Print Does the error still occur Go to Step 4 Problem solved 4 Check Main Sensor Harness connections Are P J8318A and P J8302 connected Go to Step 6 Connect and go to Step 5 5 Print a Test Print Does the error still occur Go ...

Page 186: ...in Drive harness connections Are P J8335 and P J8304 connected Go to Step 15 Connect and go to Step 14 14 Print a Test Print Does the error still occur Go to Step 15 Problem solved 15 Check Main Drive Harness continuity 1 Disconnect P J8335 and P J8304 2 Check for continuity at the following P J8335 1 P J8304 7 P J8335 2 P J8304 8 P J8335 3 P J8304 9 P J8335 4 P J8304 11 P J8335 5 P J8304 10 P J83...

Page 187: ...64 PL25 13 Finisher Transport 2 2 page 4 68 PL25 14 Finisher Electrical page 4 70 PL25 15 Finisher Harness page 4 72 Jam at F Compile Exit Sensor OFF Troubleshooting Procedure Step Actions and Questions Yes No 1 Check the paper path Open Door G Is the Lower Exit Roller clean installed correctly and roll freely Go to Step 2 Clean or replace the Lower Exit Roller 2 Test the Compile Exit Sensor Run t...

Page 188: ...mpile Exit Sensor signal Does the voltage across P8302A 5 P8302A 4 on the Finisher Main PWB change when the actuator is operated Replace the Finisher Main PWB page 3 248 Replace the Compile Exit Sensor page 3 189 11 Test the Exit Motor Run the Service Diagnostics Finisher Exit Motor Test Does the motor rotate normally Replace the Finisher Main PWB page 3 248 Go to Step 12 12 Test the Lower Exit Ro...

Page 189: ...k Exit Motor resistance Is there some amount of resistance across P8334 2 5 COM and P8334 1 3 4 6 Go to Step 18 Replace the Exit Motor page 3 243 18 Check for 24 V to the Exit Motor Is there 24 V across J8304 4 ground and J8304 6 ground on the Finisher Main PWB Go to Step 19 Replace the Finisher Main PWB page 3 248 19 Replace the Exit Motor Print a Test Print Does the error still occur Replace the...

Page 190: ...inisher Eject 3 3 page 4 64 PL25 12 Finisher Transport 1 2 page 4 66 PL25 13 Finisher Transport 2 2 page 4 68 PL25 14 Finisher Electrical page 4 70 PL25 15 Finisher Harness page 4 72 Jam at F or G Compile Exit Sensor ON Troubleshooting Procedure Step Actions and Questions Yes No 1 Check the paper path 1 Open Door G 2 Open the Upper Exit Chute 2A 3 Open the Bottom Buffer Chute 3 Are the Buffer and ...

Page 191: ...ce the Finisher Main PWB page 3 248 10 Check the Buffer Path Sensor signal Does the voltage across P8302A 14 P8302A 13 on the Finisher Main PWB change when the actuator is operated Replace the Finisher Main PWB page 3 248 Replace the Buffer Path Sensor page 3 207 11 Test the Registration Motor Run the Service Diagnostics Registration Motor CCW Test Does the motor rotate normally Go to Step 20 Go t...

Page 192: ...ill occur Replace the Finisher Main PWB page 3 248 Problem solved 20 Test the Compile Exit Sensor Run the Service Diagnostics Compile Exit Sensor test Does the sensor state change Replace the Finisher Main PWB page 3 248 Go to Step 21 21 Check the Compile Exit Sensor connection Are P J8320 and P J8391 connected Go to Step 23 Connect and go to Step 22 22 Print a Test Print Does the error still occu...

Page 193: ...pile Exit Sensor signal Does the voltage across P8302A 5 P8302A 4 on the Finisher Main PWB change when the actuator is operated Replace the Finisher Main PWB page 3 248 Replace the Compile Exit Sensor page 3 189 Static Jam at H Compile Exit Sensor Troubleshooting Reference Applicable Parts References Compile Exit Sensor Compiler Harness Main Sensor Harness Finisher Main PWB Main Drive Harness Exit...

Page 194: ... following P J8320A 3 J8391B 1 P J8320A 2 J8391B 2 P J8320A 1 J8391B 3 Are these conductive Go to Step 7 Repair the Compiler Harness 7 Check Main Sensor Harness continuity 1 Disconnect P J8391 from the harness and P J8302A on the Finisher Main PWB 2 Check for continuity at the following J8391A 3 P J8302A 4 J8391A 2 P J8302A 5 J8391A 1 P J8302A 6 Are these conductive Go to Step 8 Repair the Main Se...

Page 195: ...for continuity at the following P J8334 1 P J8304 2 P J8334 2 P J8304 4 P J8334 3 P J8304 1 P J8334 4 P J8304 3 P J8334 5 P J8304 6 P J8334 6 P J8304 5 Are these conductive Go to Step 16 Repair the Main Drive Harness 16 Check Exit Motor resistance Is there some amount of resistance across P8334 2 5 COM and P8334 1 3 4 6 Go to Step 17 Replace the Exit Motor page 3 243 17 Check for 24 V to the Exit ...

Page 196: ...age 4 64 PL25 14 Finisher Electrical page 4 70 PL25 15 Finisher Harness page 4 72 Jam at H Compile Tray No Paper Sensor Troubleshooting Procedure Step Actions and Questions Yes No 1 Check the paper path Is the Eject Roller clean rotate smoothly and installed correctly Go to Step 2 Clean or replace the Eject Roller 2 Test the Eject Clamp Motor Run the Service Diagnostics Eject Clamp Motor Up and Do...

Page 197: ...o to Step 12 Replace the Eject Bracket Assembly page 3 187 12 Check for 24 V to the Eject Motor Is there 24 V across P J8304 12 ground and P J8304 14 ground on the Finisher Main PWB Go to Step 13 Replace the Finisher Main PWB page 3 248 13 Replace the Eject Bracket Assembly Print a Test Print Does the error still occur Replace the Finisher Main PWB page 3 248 Problem solved 14 Test the Compile Exi...

Page 198: ...her Main PWB change when the actuator is operated Replace the Finisher Main PWB page 3 248 Replace the Compile Exit Sensor page 3 189 23 Test the Compile Tray No Paper Sensor Run the Service Diagnostics Compile Tray No Paper Sensor test Does the sensor s state change Replace the Finisher Main PWB page 3 248 Go to Step 24 24 Check the Compiler Harness connection Are P J8359 and P J8309 connected Go...

Page 199: ...s Service Manual Finisher Main PWB P J Locator page 5 35 Finisher Motors Wiring page 5 42 Finisher Clutch and Solenoids page 5 43 Finisher Compiler Tray Wiring page 5 44 PL25 9 Finisher Eject 1 3 page 4 60 PL25 10 Finisher Eject 2 3 page 4 62 PL25 14 Finisher Electrical page 4 70 PL25 15 Finisher Harness page 4 72 Static Jam at H No Paper Sensor Troubleshooting Procedure Step Actions and Questions...

Page 200: ...still occur Go to Step 9 Problem solved 9 Check Eject Motor Main Drive Harness continuity 1 Disconnect P J8336 and P J8304 2 Check for continuity at the following P J8336 1 P J8304 15 P J8336 2 P J8304 12 P J8336 3 P J8304 17 P J8336 4 P J8304 19 P J8336 5 P J8304 14 P J8336 6 P J8304 21 Are these conductive Go to Step 10 Repair the Main Drive Harness 10 Check Eject Motor resistance Is there some ...

Page 201: ...t Print Does the error still occur Go to Step 16 Problem solved 16 Check Compiler Harness continuity 1 Disconnect P J8359 and P J8309 2 Check for continuity at the following P J8359 3 P J8309 1 P J8359 2 P J8309 2 P J8359 1 P J8309 3 Are these conductive Go to Step 17 Repair the Compiler Harness 17 Check for 5 V to the Compile Tray No Paper Sensor Is there 5 V across J8309 3 J8309 1 on the Finishe...

Page 202: ...emove the Top Cover 3 Remove the Top L H Cover 4 Remove the Knob and open the Upper Entrance Chute Are the Rollers attached to the chute clean roll freely and correctly installed Go to Step 2 Clean or replace the appropriate roller 2 Check the paper path Open the Lower Top Exit Chute 2b Are the Pinch Rollers attached to the chute and the two Transport Rollers clean roll freely and correctly instal...

Page 203: ...ervice Diagnostics Finisher Transport Motor Test Does the error still occur Replace the Finisher Main PWB page 3 248 Problem solved 11 Test the Upper Tray Exit Sensor Run the Service Diagnostics Upper Tray Exit Sensor test Does the sensor state change Replace the Finisher Main PWB page 3 248 Go to Step 12 12 Check the Sensor Harness connections Are P J8321 and P J8312 on the sensor harness and P J...

Page 204: ...isher Main PWB page 3 248 17 Check the Upper Tray Exit Sensor signal Does the voltage across P8302A 8 P8302A 7 on the Finisher Main PWB change when sensor is actuated Replace the Finisher Main PWB page 3 248 Replace the Upper Tray Exit Sensor page 3 226 Jam at F or Upper Tray Exit Sensor OFF Troubleshooting Reference Applicable Parts References Transport Roller Pinch Roller Transport Motor Main Dr...

Page 205: ...nd P J8304 connected Go to Step 6 Connect and go to Step 5 5 Print a Test Print Does the error still occur Go to Step 6 Problem solved 6 Check Transport Motor Main Drive Harness continuity 1 Disconnect P J8342 and P J8304 2 Check for continuity at the following P J8342 1 P J8304 23 P J8342 2 P J8304 16 P J8342 3 P J8304 25 P J8342 4 P J8304 27 P J8342 5 P J8304 18 P J8342 6 P J8304 29 Are these co...

Page 206: ...Are these conductive Go to Step 14 Repair the Upper Tray Exit Sensor Harness 14 Check Main Exit Sensor Harness continuity 1 Disconnect P J8312 from the harness and P J8302A on the Finisher Main PWB 2 Check for continuity at the following J8312A 3 P J8302A 7 J8312A 2 P J8302A 8 J8312A 1 P J8302A 9 Are these conductive Go to Step 15 Repair the Main Sensor Harness 15 Check for 5 V to the Upper Tray E...

Page 207: ... 66 PL25 13 Finisher Transport 2 2 page 4 68 PL25 14 Finisher Electrical page 4 70 PL25 15 Finisher Harness page 4 72 Static Jam at F or G Stacker Upper Tray Exit Sensor Troubleshooting Procedure Step Actions and Questions Yes No 1 Test the Upper Tray Exit Sensor Run the Service Diagnostics Upper Tray Exit Sensor test Does the sensor state change Go to Step 8 Go to Step 2 2 Check the Upper Tray Ex...

Page 208: ...ort Motor Run the Service Diagnostics Finisher Transport Motor Test Does the motor rotate normally Go to Step 9 Go to Step 10 9 Test Entrance and Transport Roller drive Run the Service Diagnostics Finisher Transport Motor Test Do the Entrance and Transport Rollers rotate Replace the Finisher Main PWB page 3 248 Restore operation 10 Check the Finisher Transport Motor Main Drive Harness Are P J8342 ...

Page 209: ...Troubleshooting Reference Applicable Parts References H X port Belts H X port Pinch Rollers Entrance Rollers H X port Exit Sensor H X port Harness Finisher H X port PWB Finisher Entrance Sensor Main Sensor Harness Finisher Main PWB Transport Motor Main Drive Harness Transport Gate Sensor Gate Sensor Harness Phaser 5500 Printer Options Service Manual Horizontal Transport P J Locator page 5 29 Horiz...

Page 210: ... 4 Check the H X port Exit Sensor Harness connections Is the H X port Exit Sensor Harness connected to the Exit Sensor and H X port PWB Go to Step 6 Connect and go to Step 5 5 Print a Test Print Does the error still occur Go to Step 6 Problem solved 6 Check the H X port Exit Sensor Harness continuity 1 Disconnect J8381 on the Exit Sensor and P J8372 on the H X port PWB 2 Check for continuity at th...

Page 211: ... Main X port Entrance Sensor Harness continuity 1 Disconnect P J8303 on the harness and P J8302A on the Finisher Main PWB 2 Check for continuity at the following J8303A 3 P J8302A 1 J8303A 2 P J8302A 2 J8303A 1 P J8302A 3 Are these conductive Go to Step 14 Repair the Main Sensor Harness 14 Check for 5 V to X port Entrance Sensor Is there 5 V across J8302A 3 J8302A 1 on the Finisher Main PWB Go to ...

Page 212: ... 22 Repair the Main Drive Harness 22 Check the Transport Motor resistance Is there some amount of resistance across P8342 2 5 COM and P8342 1 3 4 6 Go to Step 23 Replace the Transport Motor page 3 222 23 Check for 24 V to the Transport Motor Is there 24 V across J8304 16 ground and J8304 18 ground on the Finisher Main PWB Go to Step 24 Replace the Finisher Main PWB page 3 248 24 Replace the Transp...

Page 213: ... Main PWB page 3 248 30 Check Gate Sensor signal Does the voltage across P8376 2 P8376 1 on the Finisher Main PWB change when the sensor is blocked Replace the Finisher Main PWB page 3 248 Replace the Gate Sensor page 3 236 Static Jam at F or G Gate Sensor Troubleshooting Reference Applicable Parts References Transport Motor Main Drive Harness Finisher Main PWB Top Exit Sensor Harness Gate Sensor ...

Page 214: ... for continuity at the following P J8342 1 P J8304 23 P J8342 2 P J8304 16 P J8342 3 P J8304 25 P J8342 4 P J8304 27 P J8342 5 P J8304 18 P J8342 6 P J8304 29 Are these conductive Go to Step 6 Repair the Transport Motor Main Drive Harness 6 Check the Transport Motor resistance Is there some amount of resistance across P8342 2 5 COM and P8342 1 3 4 6 Go to Step 7 Replace the Transport Motor page 3 ...

Page 215: ...noid tests Does the Buffer Gate open for Path in and close for Path out Replace the Finisher Main PWB page 3 248 Go to Step 16 16 Check Buffer Gate Solenoid Harness connections Are P J8394 and P J8304 connected Go to Step 18 Connect and go to Step 17 17 Print a Test Print Does the error still occur Go to Step 18 Problem solved 18 Check Buffer Gate Solenoid Harness continuity 1 Disconnect P J8394 a...

Page 216: ...ng page 5 42 Finisher Clutch and Solenoids page 5 43 PL25 12 Finisher Transport 1 2 page 4 66 PL25 13 Finisher Transport 2 2 page 4 68 PL25 14 Finisher Electrical page 4 70 PL25 15 Finisher Harness page 4 72 Static Jam at F or G Gate Sensor Troubleshooting Procedure Step Actions and Questions Yes No 1 Test the Finisher Transport Motor Run the Service Diagnostics Finisher Transport Motor Test Does ...

Page 217: ...otor Print a Test Print Does the error still occur Replace the Finisher Main PWB page 3 248 Problem solved 9 Test the Gate Sensor Run the Service Diagnostics Gate Sensor test Does the sensor state change when the sensor is blocked Go to Step 15 Go to Step 10 10 Check the Gate Sensor Harness Are P J8432 and P J8376 connected Go to Step 12 Connect and go to Step 11 11 Print a Test Print Does the err...

Page 218: ...nect and go to Step 17 17 Print a Test Print Does the error still occur Go to Step 18 Problem solved 18 Check Buffer Gate Solenoid Harness continuity 1 Disconnect P J8394 and P J8304 2 Check for continuity at the following P J8394 1 P J8304 35 P J8394 2 P J8304 34 P J8394 3 P J8304 36 Are these conductive Go to Step 19 Repair the Main Drive Harness 19 Check for 24 V to the Buffer Gate Solenoid Is ...

Page 219: ...L8 1 Print Engine Electrical page 9 40 Phaser 5500 Printer Options Service Manual 1000 Sheet Feeder P J Locator page 5 5 1000 Sheet Feeder Tray 4 5 Wiring page 5 9 PL20 2 Tray 4 5 Tray 1 2 Feeder 1 2 page 4 6 PL20 3 Tray 4 5 Tray 2 2 page 4 8 PL20 4 Tray 4 5 Feeder 2 2 page 4 10 PL20 6 Tray 4 5 Drive and Electrical page 4 16 Universal Tray Failure Troubleshooting Procedure Step Actions and Questio...

Page 220: ... across the motor connector s Pin 4 ground Replace the motor Replace the Engine Logic Board page 8 89 If the error persists replace Tray 4 5 PWB page 3 29 9 Test the affected Level Sensor Run the Service Diagnostics Level Sensor test for the affected tray Does the sensor state change Go to Step 13 Go to Step 10 10 Check the Level Sensor connection Is the sensor connected to the harness Go to Step ...

Page 221: ...ness Go to Step 15 Connect the switch If problem persists go to Step 15 15 Check continuity between the Paper Size Switch and the Engine Logic Board Tray 2 3 or Tray 4 5 PWB Tray 4 5 Is there continuity on each wire between the switch P J412 Tray 2 3 or P J548 Tray 4 5 Go to Step 16 Repair the wiring 16 Check for 3 3 V to the Paper Size Switch Is there 5 V across P J412 1 ground for Tray 2 3 or 3 ...

Page 222: ...Wiring page 5 24 2000 Sheet Tray 6 Drive Wiring page 5 25 PL22 1 Tray 6 Covers page 4 18 PL23 3 Tray 2 2 page 4 20 PL22 4 Tray 6 Feeder 1 3 page 4 24 PL22 5 Tray 6 Feeder 2 3 page 4 26 PL22 8 Tray 6 Electrical page 4 32 Tray 6 Failure Troubleshooting Procedure Step Actions and Questions Yes No 1 Check Tray In Sensor alignment Pull the Tray out Does the actuator enter the sensing area of the Tray S...

Page 223: ... cables Remove the Tray from the HCF Are the two cables installed correctly Go to Step 11 Correct and go to Step 11 11 Test the Level Sensor Run the Service Diagnostics Tray 6 Level Sensor test Does the sensor state change Go to Step 19 Go to Step 12 12 Check the Level Sensor Harness connections Are PF62 and PF56B connected Go to Step 13 Connect and go to Step 13 13 Check the Level Sensor Harness ...

Page 224: ...ep 28 Go to Step 20 20 Check Nudger Solenoid harness connections Are PF59 and PF56 on the Feeder and Main Harnesses and JF06 on the Tray 6 PWB connected Go to Step 22 Connect and go to Step 21 21 Check the repair Does the error still occur Go to Step 22 Problem solved 22 Check Nudger Solenoid Harness continuity 1 Disconnect PF59 and JF56A 2 Check for continuity at the following PF59 2 JF56A 1 PF59...

Page 225: ...o to Step 36 Go to Step 29 29 Check the harness connections Are PF58 and PF56 on the Feeder and Main Harness and JF06 on the Tray 6 PWB connected Go to Step 31 Connect and go to Step 30 30 Check the repair Does the error still occur Go to Step 31 Problem solved 31 Check Feeder Harness continuity 1 Disconnect PF58 and JF56 2 Check for continuity at the following PF58 1 JF56 1 PF58 2 JF56 2 PF58 3 J...

Page 226: ... Problem solved 36 Replace the Tray 6 PWB Does the error still occur Replace the Engine Logic Board page 8 89 Problem solved Duplex Comm Failure Troubleshooting Reference Applicable Parts References Duplex Unit PWB Engine Logic Board Print Engine P J Engine Logic Board page 10 13 PL8 1 Print Engine Electrical page 9 40 Phaser 5500 Printer Options Service Manual Duplex Unit Plug Jack Locator page 5...

Page 227: ...o the Duplex PWB Is there 24 V across P J540 2 ground Replace the Duplex PWB page 3 77 Replace the Engine Logic Board page 8 89 Incorrect Duplex Unit Installed Troubleshooting Reference Applicable Parts References Duplex Unit PWB Engine Logic Board Print Engine P J Engine Logic Board page 10 13 PL8 1 Print Engine Electrical page 9 40 Phaser 5500 Printer Options Service Manual Duplex Unit Plug Jack...

Page 228: ...ine Exit 1 Wiring page 10 30 PL8 1 Print Engine Electrical page 9 40 Phaser 5500 Printer Options Service Manual Exit 2 Plug Jack Locator page 5 15 Exit 2 General Wiring page 5 7 PL24 2 Exit 2 Tray Guide Assembly page 4 40 Exit Offset Error OCT Position Sensor Troubleshooting Procedure Step Actions and Questions Yes No 1 Test the affected OCT Position Sensor Run the Service Diagnostics Exit 1 or 2 ...

Page 229: ...connected Go to Step 8 Connect P J430 and P J526 If problem persists go to Step 8 8 Check continuity between the Exit PWB and the LVPS 1 Disconnect P J430 and P J526 2 Check for continuity at the following P J430 3 P J526 6 P J430 4 P J526 5 P J430 1 P J526 8 P J430 2 P J526 7 Are these conductive Go to Step 9 Repair the wiring 9 Check for 24 V to the Exit PWB Is there 24 V across P J430 1 ground ...

Page 230: ...lowing P J433 1 J207 1 P J433 2 J207 2 P J433 3 J207 3 P J433 4 J207 4 P J433 5 J207 5 Is there continuity on each wire Go to Step 13 Repair the wiring 13 Check for 24 V to the affected Offset Motor Is there 24 V across Exit 2 P J433 1 or Exit 1 P J432 7 ground Replace the Offset Motor Replace the Exit PWB page 8 88 Exit Comm Failure Troubleshooting Reference Applicable Parts References Exit PWB L...

Page 231: ...1 5 P J431 5 P J421 4 P J431 6 P J421 3 P J431 7 P J421 2 P J431 8 P J421 1 Are these conductive Go to Step 3 Repair the wiring 3 Check the connection between the Exit PWB and the LVPS Are P J430 and P J526 connected Go to Step 4 Connect P J430 and P J526 4 Check continuity between the Exit PWB and the LVPS 1 Disconnect P J430 and P J526 2 Check for continuity at the following P J430 3 P J526 6 P ...

Page 232: ...aded in the tray properly Go to Step 2 Reload the paper 2 Check the paper guides Are the paper guides set correctly Go to Step 3 Reset the guides 3 Test the Paper Size Sensor for Tray 1 MPT Run the Service Diagnostics Tray 1 Size Sensor test Does the size displayed change as the size guides are moved in and out Replace the Engine Logic Board page 8 89 Go to Step 4 4 Check the Paper Size Switch con...

Page 233: ...e Switch Troubleshooting Procedure Step Actions and Questions Yes No 1 Check the paper in the affected tray Is paper loaded in the tray properly Go to Step 2 Reload the paper 2 Check the tray paper guides Are the paper guides set correctly Go to Step 3 Reset the guides 3 Check the Paper Size Switch for the affected tray Is the switch installed correctly Go to Step 4 Correct the installation 4 Test...

Page 234: ...110 and P J412 2 Check for continuity at the following P J110 1 P J412 9 P J110 2 P J412 8 P J110 3 P J412 7 P J110 4 P J412 6 Are these conductive Go to Step 7 Repair the wiring 7 Check for 5 V to the Paper Size Switch For Tray 2 Is there 5 V across J109 1 ground For Tray 3 Is there 5 V across J110 1 ground Replace the paper Size Switch for the affected tray Replace the Engine Logic Board page 8 ...

Page 235: ...PL20 6 Tray 4 5 Drive and Electrical page 4 16 Paper Size Failure Tray 4 5 Paper Size Switch Troubleshooting Procedure Step Actions and Questions Yes No 1 Check the Paper in the affected tray Is paper loaded in the tray properly Go to Step 2 Reload the paper 2 Check the tray paper guides Are the paper guides set correctly Go to Step 3 Set the guides properly 3 Check the Paper Size Switch for the a...

Page 236: ...d For Tray 5 Is there 3 3 V across P J824 1 ground Replace the Paper Size Switch for the affected tray Replace the Engine Logic Board page 8 89 8 Check the Tray 4 5 PWB connection Are P J413 and P J541 connected Go to Step 9 Connect P J413 and P 541 9 Check continuity between the Tray 4 5 PWB and the Engine Logic Board 1 Disconnect P J541 and P J413 2 Check for continuity at the following P J541 1...

Page 237: ...d Print Engine P J Engine Logic Board page 10 13 PL8 1 Print Engine Electrical page 9 40 Phaser 5500 Printer Options Service Manual Finisher Main PWB P J Locator page 5 35 PL25 14 Finisher Electrical page 4 70 Finisher Board Error NVRAM R W Error Troubleshooting Procedure Step Actions and Questions Yes No 1 Check the Finisher installation Are the interface cables connected correctly Go to Step 2 R...

Page 238: ... to Step 4 Repair the wiring 5 Check for 24 V to the Finisher Main PWB Is there 24 V across J416 6 ground Replace the Finisher Main PWB page 3 248 Replace the Engine Logic Board page 8 89 Stacker Lower Tray Failure Stack Height Sensors Troubleshooting Reference Applicable Parts References Lower Tray No Paper Sensor Upper Limit Actuator Finisher Main PWB Main Sensor Harness Elevator Motor Engine Lo...

Page 239: ...the Lower Tray No Paper Sensor Harness continuity 1 Disconnect P J8326 on the Lower Tray No Paper Sensor Harness and P J8302B on the Finisher Main PWB 2 Check for continuity at the following P J8326 3 P J8302B 15 P J8326 2 P J8302B 16 P J8326 1 P J8302B 17 Are these conductive Go to Step 7 Repair the Lower Tray No Paper Sensor Harness If problem persists go to Step 7 7 Check for 5 V to the Lower T...

Page 240: ...Upper Limit Sensor Upper Limit Actuator Finisher Main PWB Main Sensor Harness Elevator Motor Engine Logic Board Print Engine P J Engine Logic Board page 10 13 PL8 1 Print Engine Electrical page 9 40 Phaser 5500 Printer Options Service Manual Finisher Main PWB P J Locator page 5 35 Finisher Sensors 2 2 Wiring page 5 41 Finisher Clutch and Solenoids page 5 43 PL25 6 Finisher Stack page 4 54 PL25 14 ...

Page 241: ...8302B 17 Are these conductive Go to Step 7 Repair the Main Sensor Harness 7 Check for 5 V to the Lower Tray No Paper Sensor Is there 5 V across J8302B 17 J8302B 15 on the Finisher Main PWB Go to Step 8 Replace the Finisher Main PWB page 3 248 8 Check the Lower Tray No Paper Sensor Does the voltage across P8302B 16 P8302B 15 on the Finisher Main PWB change when the sensor is blocked Replace the Fin...

Page 242: ...ain PWB change when the sensor is blocked Replace the Finisher Main PWB page 3 248 Replace the Lower Tray Upper Limit Sensor page 3 143 15 Test the Elevator Motor Run the Service Diagnostics Stacker Motor Up and Down tests alternately Does the Elevator Motor operate Replace the Finisher Main PWB page 3 248 Go to Step 16 16 Check the Elevator Motor connection Is P J8305 connected to the Finisher Ma...

Page 243: ...6 Finisher Stack page 4 54 PL25 14 Finisher Electrical page 4 70 PL25 15 Finisher Harness page 4 72 Stacker Lower Trail Failure Stacker Encoder Sensor Troubleshooting Procedure Step Actions and Questions Yes No 1 Check the Stacker Lower Tray vertical transport and belts for obstacles and deformation Are there obstacles or belt wear in the vertical transport mechanism Remove any obstacles Go to Ste...

Page 244: ...e Stack Height Sensor 1 page 3 140 8 Test the Stack Height Sensor 2 bottom Run the Service Diagnostics Stack Height Sensor 2 test NOTE Sensor requires a 10 second timeout between sensing events Does the sensor state change when the sensor is blocked Go to Step 14 Go to Step 9 9 Check Stack Height Sensor 2 Sensor Harness connections Are P J8330 and P J8302A connected Go to Step 11 Connect and go to...

Page 245: ...rness continuity 1 Disconnect P J8328 on the harness and P J8302B on the Finisher Main PWB 2 Check for continuity at the following P J8328 3 P J8302B 12 P J8328 2 P J8302B 13 P J8328 1 P J8302B 14 Are these conductive Go to Step 18 Repair the Stacker Encoder Sensor Harness 18 Check for 5 V to Stacker Encoder Sensor Is the voltage across J8302B 14 J8302B 12 on the Finisher Main PWB Go to Step 19 Re...

Page 246: ...ace the Elevator Motor Print a Test Print Does the error still occur Replace the Finisher Main PWB page 3 248 Problem solved Tamper Front Tamper Home Sensor Troubleshooting Reference Applicable Parts References Front Tamper Home Sensor Compiler Tray Assembly Compiler Harness Finisher Main PWB Front Tamper Motor Phaser 5500 Printer Options Service Manual Finisher Main PWB P J Locator page 5 35 Fini...

Page 247: ... Front Tamper Home Sensor Is there 5 V across J8309 6 J8309 4 on the Finisher Main PWB Go to Step 7 Replace the Finisher Main PWB page 3 248 7 Check Front Tamper Home Sensor signal Does the voltage across P8309 5 P8309 4 on the Finisher Main PWB change when the sensor is blocked Replace the Finisher Main PWB page 3 248 Replace the Front Tamper Home Sensor page 3 180 8 Test the Front Tamper Motor R...

Page 248: ...P J8363B 4 P J8309 12 P J8363B 3 P J8309 13 P J8363B 2 No connection P J8363B 1 P J8309 14 Are these conductive Go to Step 12 Repair the Compiler Front Tamper Motor Harness 12 Check for 24 V to the Front Tamper Motor Is there 24 V across J8309 11 ground on the Finisher Main PWB Go to Step 13 Replace the Finisher Main PWB page 3 248 13 Replace the Front Tamper Motor Print a Test Print Does the erro...

Page 249: ...inuity at the following P J8361 3 P J8309 7 P J8361 2 P J8309 8 P J8361 1 P J8309 9 Are these conductive Go to Step 6 Repair the Compiler Rear Tamper Harness 6 Check for 5 V to the Rear Tamper Home Sensor Is there 5 V across J8309 9 J8309 7 on the Finisher Main PWB Go to Step 7 Replace the Finisher Main PWB page 3 248 7 Check Rear Tamper Home Sensor signal Does the voltage across P8309 8 P8309 7 o...

Page 250: ...Motor Is there 24 V across J8309 16 ground on the Finisher Main PWB Go to Step 13 Replace the Finisher Main PWB page 3 248 13 Replace the Front Tamper Motor Print a Test Print Does the error still occur Replace the Finisher Main PWB page 3 248 Problem solved Punch Failure Punch Home Sensor Troubleshooting Reference Applicable Parts References Punch Home Sensor Punch Harness Punch Sensor Harness Fi...

Page 251: ...nuity at the following P J8348 3 P J8333 7 P J8348 2 P J8333 8 P J8348 1 P J8333 9 Are these conductive Go to Step 6 Repair the Punch Home Sensor Harness 6 Check Punch Home Sensor Harness continuity 1 Disconnect P J8333 and P J8307 2 Check for continuity at the following P J8333 7 P J8307 B6 P J8333 8 P J8307 B5 P J8333 9 P J8307 B4 Are these conductive Go to Step 7 Repair the Punch Home Sensor Ha...

Page 252: ...nt a Test Print Does the error still occur Go to Step 12 Problem solved 12 Check Punch Motor Harness continuity 1 Disconnect P J8345 and P J8332 2 Check for continuity at the following P J8345 2 P J8332 2 P J8345 1 P J8332 1 Are these conductive Go to Step 13 Repair the Punch Harness 13 Check Punch Motor Drive Harness continuity 1 Disconnect P J8332 and P J8306 2 Check for continuity at the follow...

Page 253: ...Diagnostics Punch Unit Move Home Sensor test Does the sensor state when the sensor is blocked Go to Step 8 Go to Step 3 3 Check Punch Unit Move Home Sensor Harness connection Are P J8352 and P J8307 connected Go to Step 5 Connect and go to Step 4 4 Print a Test Print Does the error still occur Go to Step 5 Problem solved 5 Check Punch Unit Move Home Sensor Harness continuity 1 Disconnect P J8352 a...

Page 254: ...ctions Are P J8344 and P J8306 connected Go to Step 11 Connect and go to Step 10 10 Print a Test Print Does the error still occur Go to Step 11 Problem solved 11 Check Punch Motor Harness continuity 1 Disconnect P J8344 and P J8306 2 Check for continuity at the following P J8344 1 P J8306 7 P J8344 2 P J8306 3 P J8344 3 P J8306 6 P J8344 4 P J8306 5 P J8344 5 P J8306 2 P J8344 6 P J8306 1 Are thes...

Page 255: ...stallation 2 Test the Eject Clamp Home Sensor Run the Service Diagnostics Eject Clamp Home Sensor test Does the sensor change state Go to Step 8 Go to Step 3 3 Check Eject Clamp Sensor Harness connection Are P J8324 and P J8302B connected Go to Step 5 Connect and go to Step 4 4 Print a Test Print Does the error still occur Go to Step 5 Problem solved 5 Check Eject Clamp Sensor Harness continuity 1...

Page 256: ...ctions Are P J8339 and P J8304 connected Go to Step 11 Connect and go to Step 10 10 Print a Test Print Does the error still occur Go to Step 11 Problem solved 11 Check Eject Clamp Motor Harness continuity 1 Disconnect P J8339 and P J8304 2 Check for continuity at the following P J8339 1 P J8304 33 P J8339 2 P J8304 31 Are these conductive Go to Step 12 Repair the Eject Clamp Motor Harness 12 Check...

Page 257: ...es the Eject Clamp move smoothly Go to Step 2 Correct the installation 2 Test the Set Clamp Home Sensor Run the Service Diagnostics Set Clamp Home Sensor test Does the sensor change state Go to Step 8 Go to Step 3 3 Check the Set Clamp Home Sensor Harness connection Are P J8325 and P J8302B connected Go to Step 5 Connect and go to Step 4 4 Print a Test Print Does the error still occur Go to Step 5...

Page 258: ...304 14 P J8336 6 P J8304 21 Are these conductive Go to Step 12 Repair the Eject Motor Harness 12 Check Eject Motor resistance Is there resistance across P8336 2 5 COM and P8336 1 3 4 6 Go to Step 13 Replace the Eject Bracket Assembly page 3 187 13 Check for 24 V to the Eject Motor Is there 24 V across J8304 12 ground and J8304 14 ground on the Finisher Main PWB Go to Step 14 Replace the Finisher M...

Page 259: ...the Finisher Main PWB Go to Step 20 Replace the Finisher Main PWB page 3 248 20 Replace the Set Clamp Clutch Print a Test Print Does the error still occur Replace the Finisher Main PWB page 3 248 Problem solved Punch Failure Side Registration Sensors Troubleshooting Reference Applicable Parts References Punch Move Motor Punch Drive Harness Finisher Main PWB Engine Logic Board Side Registration Sen...

Page 260: ...ity 1 Disconnect P J8344 and P J8306 2 Check for continuity at the following P J8344 1 P J8306 7 P J8344 2 P J8306 3 P J8344 3 P J8306 6 P J8344 4 P J8306 5 P J8344 5 P J8306 2 P J8344 6 P J8306 1 Are these conductive Go to Step 6 Repair the Punch Move Motor Harness 6 Replace the Bracket Assy Motor Punch Print a Test Print Does the error still occur Go to Step 7 Problem solved 7 Replace the Finish...

Page 261: ...3 P8333 14 P J8350 2 P8333 15 P J8350 1 P8333 16 P J8351 3 P8333 17 P J8351 2 P8333 18 P J8351 1 Are these conductive Go to Step 14 Repair the Punch Unit Harness 14 Check for 5 V at Side Regi Sensor 1 Is there 5 V between P J8307 A10 P J8307 A12 Go to Step 16 Go to Step 18 15 Check for 5 V at Side Regi Sensor 2 Is there 5 V between P J8307 A7 P J8307 A9 Go to Step 17 Go to Step 18 16 Replace the S...

Page 262: ... page 4 58 PL25 14 Finisher Electrical page 4 70 Stapler Failure Stapler Home Sensor Troubleshooting Procedure Step Actions and Questions Yes No 1 Test the Stapler Assembly Run the Service Diagnostics Staple Motor Forward and Reverse tests Does the Stapler Motor rotate normally Go to Step 5 Go to Step 2 2 Check the Staple Motor Harness connections Are P J8357 and P J8308 connected Go to Step 4 Con...

Page 263: ...tinuity at the following P J8356 1 P J8308 15 P J8356 2 P J8308 14 P J8356 3 P J8308 13 P J8356 4 P J8308 12 P J8356 5 P J8308 11 Are these conductive Go to Step 9 Repair the Staple Harness 9 Replace the Stapler Assembly Staple a Test Print Does the error still occur Go to Step 10 Problem solved 10 Replace the Finisher Main PWB Does the error still occur Replace the Engine Logic Board page 8 89 Pr...

Page 264: ...ved 5 Check Staple Move Motor Harness continuity 1 Disconnect P J8358 and P J8308 2 Check for continuity at the following P J8358 1 P J8308 3 P J8358 2 P J8308 6 P J8358 3 P J8308 5 P J8358 4 P J8308 1 P J8358 5 P J8308 4 P J8358 6 P J8308 2 Are these conductive Go to Step 6 Repair the Staple Move Motor Harness 6 Replace the Stapler Lower Carriage Staple a Test Print Does the error still occur Rep...

Page 265: ...p 12 Replace the Finisher Main PWB page 3 248 12 Check the Stapler Move Home Position Sensor signal Does the voltage across J8308 17 J8308 16 on the Finisher Main PWB change when the sensor is blocked by moving the Stapler Head Replace the Finisher Main PWB page 3 248 Replace the Staple Move Position Sensor page 3 162 Tray 6 NVRAM Error Troubleshooting Reference Applicable Parts References Tray 6 ...

Page 266: ...shooting Reference Applicable Parts References Tray 6 PWB Engine Logic Board Print Engine P J Engine Logic Board page 10 13 PL8 1 Print Engine Electrical page 9 40 Phaser 5500 Printer Options Service Manual 2000 Sheet Tray 6 Drive P J Locator page 5 21 2000 Sheet Tray 6 Drive Wiring page 5 25 PL22 8 Tray 6 Electrical page 4 32 Tray 6 NVRAM Error Troubleshooting Procedure Step Actions and Questions...

Page 267: ...ccur Replace the Tray 6 PWB page 3 67 Replace the Engine Logic Board page 8 89 Tray 4 5 NVRAM Error Troubleshooting Reference Applicable Parts References Tray 4 5 PWB Engine Logic Board Print Engine P J Engine Logic Board page 10 13 PL8 1 Print Engine Electrical page 9 40 Phaser 5500 Printer Options Service Manual 1000 Sheet Electrical P J Locator page 5 6 1000 Sheet Drive Wiring page 5 8 PL20 6 T...

Page 268: ...413 B3 P J541 9 P J413 B4 P J541 10 P J413 B5 P J541 11 P J413 B6 P J541 12 Are these conductive Go to Step 4 Repair the wiring 4 Check for 5 V to the Tray 4 5 PWB Is there 5 V across P J413 A5 ground Replace the Tray 4 5 PWB page 3 29 Replace the Engine Logic Board page 8 89 Tray 4 5 Comm Failure Troubleshooting Reference Applicable Parts References Tray 4 5 PWB Engine Logic Board Print Engine P ...

Page 269: ... Step 2 2 Check the Tray 4 5 PWB connection Is P J541 connected Go to Step 3 Connect P J413 3 Check continuity between the Tray 4 5 PWB and the Engine Logic Board 1 DisconnectP J413 and P J541 2 Check for continuity at the following P J413 A1 P J541 1 P J413 A2 P J541 2 P J413 A3 P J541 3 P J413 A4 P J541 4 P J413 A5 P J541 5 P J413 A6 P J541 6 P J413 B1 P J541 7 P J413 B2 P J541 8 P J413 B3 P J54...

Page 270: ... 4 5 PWB SW1 1 is in the Left position SW1 2 is in the Right position SW1 3 is in the Right position SW1 4 is in the Left position Are the switches set correctly Go to Step 3 Correct the Switch settings If problem persists go to Step 3 3 Check Tray 4 5 PWB connections Is P J541 connected Go to Step 4 Connect P J541 4 Check continuity between the Tray 4 5 PWB and the Engine Logic Board 1 Disconnect...

Page 271: ... Tray Failure Tray 2 3 Paper Size Switch Troubleshooting Procedure Step Actions and Questions Yes No 1 Check the Paper in the affected tray Is paper loaded in the tray properly Go to Step 2 Reload the paper 2 Check the Paper Size Switch for the affected tray Is the switch installed correctly Go to Step 3 Correct the installation 3 Test the Paper Size Switch for the affected tray Run the Service Di...

Page 272: ... P J109 1 P J412 4 P J109 2 P J412 3 P J109 3 P J412 2 P J109 4 P J412 1 For Tray 3 1 Disconnect P J110 and P J412 2 Check for continuity at the following P J110 1 P J412 9 P J110 2 P J412 8 P J110 3 P J412 7 P J110 4 P J412 6 Are these conductive Go to Step 6 Repair the wiring 6 Check for 5 V to the Paper Size Switch For Tray 2 Is there 5 V across J109 1 ground For Tray 3 Is there 5 V across J110...

Page 273: ...4 5 Paper Size Switch Troubleshooting Procedure Step Actions and Questions Yes No 1 Check the Paper in the affected tray Is paper loaded in the tray properly Go to Step 2 Reload the paper 2 Check the Paper Size Switch for the affected tray Is the switch installed correctly Go to Step 3 Correct the installation 3 Test the Paper Size Switch for the affected tray Run the Service Diagnostics Size Sens...

Page 274: ...For Tray 5 Is there 3 3 V across P J824 1 ground Replace the Paper Size Switch for the affected tray Replace the Engine Logic Board page 8 89 7 Check the Tray 4 5 PWB connection Are P J413 and P J541 connected Go to Step 9 Connect P J413 and P 541 8 Check continuity between the Tray 4 5 PWB and the Engine Logic Board 1 Disconnect P J541 and P J413 2 Check for continuity at the following P J541 1 P...

Page 275: ...int Engine P J Drum and Toner page 10 6 Print Engine P J Engine Logic Board page 10 13 Print Engine Xerographics Wiring page 10 24 Print Engine Drive CRUM Wiring page 10 25 PL5 1 Laser CRU and Toner Dispense page 9 32 PL8 1 Print Engine Electrical page 9 40 Toner Empty Troubleshooting Procedure Step Actions and Questions Yes No 1 Check remaining toner Does the Toner Cartridge contain sufficient to...

Page 276: ...ir the wiring 8 Check for 5 V to the Toner CRUM PWB Is there 5 V across P127 6 ground Go to Step 9 Replace the Engine Logic Board page 8 89 9 Test the Toner Dispense Motor Run the Service Diagnostics Toner Dispense Motor test Does the motor rotate Replace the Engine Logic Board page 8 89 Go to Step 10 10 Check Toner Dispense Motor connections Are P J216 and P J420 connected Go to Step 11 Connect P...

Page 277: ...ng Procedure Step Actions and Questions Yes No 1 Check the Drum Cartridge installation Was the Drum Cartridge replaced Go to Step 2 Replace the Drum Cartridge If the error persists go to Step 2 2 Test the Drum Cartridge Detect Switch Run the Service Diagnostics Detect DRUM Cartridge Switch test Does the switch status change when the Drum Cartridge is moved in and out Replace the Engine Logic Board...

Page 278: ...int Engine Electrical page 9 40 Drum Cartridge Failure ATC Sensor Troubleshooting Procedure Step Actions and Questions Yes No 1 Replace the Drum Cartridge Does the error reoccur Go to Step 2 Problem solved 2 Test the Front Harness A Run the Service Diagnostics DRUM Cartridge Detect Switch test Does the switch status change when the Drum Cartridge is moved in and out Replace the Engine Logic Board ...

Page 279: ...stions Yes No 1 Check the Drum Cartridge installation Was the Drum Cartridge replaced Go to Step 2 Replace the Drum Cartridge If the error persists go to Step 2 2 Check the Drum Cartridge CRUM PWB installation Is the Drum Cartridge CRUM PWB installed correctly Go to Step 3 Correct the installation 3 Check the Drum Cartridge CRUM PWB connection Are P126 and P J419 connected Go to Step 4 Connect P 1...

Page 280: ...um Cartridge installation Was the Drum Cartridge replaced Go to Step 2 Replace the Drum Cartridge If the error persists go to Step 2 2 Check the Drum Cartridge CRUM PWB Is the Drum Cartridge CRUM PWB installed correctly Go to Step 3 Correct the installation 3 Check the Drum Cartridge CRUM PWB connection Are P126 and P J419 connected Go to Step 4 Connect P 126 and P J419 4 Check continuity between ...

Page 281: ... Step Actions and Questions Yes No 1 Check the Drum Cartridge installation Was the Drum Cartridge replaced Go to Step 2 Replace the Drum Cartridge If the error persists go to Step 2 2 Check the Drum Cartridge CRUM PWB Is the Drum Cartridge CRUM PWB installed correctly Go to Step 3 Correct the installation 3 Check the Drum Cartridge CRUM PWB connection Are P126 and P J419 connected Go to Step 4 Con...

Page 282: ...ubleshooting Procedure Step Actions and Questions Yes No 1 Check the Toner Cartridge installation Was the Toner Cartridge replaced Go to Step 2 Replace the Toner Cartridge If the error persists go to Step 2 2 Check the Toner Cartridge CRUM PWB Is the Toner Cartridge CRUM PWB installed correctly Go to Step 3 Correct the installation 3 Check the Toner Cartridge CRUM PWB connection Are P127 and P J41...

Page 283: ... Non Xerox Toner Cartridge Troubleshooting Procedure Step Actions and Questions Yes No 1 Check the Toner Cartridge installation Was a Xerox Toner Cartridge replaced Go to Step 2 Replace with a Xerox Toner Cartridge If the error persists go to Step 2 2 Check the Toner Cartridge CRUM PWB installation Is the Toner Cartridge CRUM PWB installed correctly Go to Step 3 Correct the installation 3 Check th...

Page 284: ...oubleshooting Procedure Step Actions and Questions Yes No 1 Check the Toner Cartridge installation Was the Toner Cartridge replaced Go to Step 2 Replace the Toner Cartridge If the error persists go to Step 2 2 Check the Toner Cartridge installation Remove the Toner Cartridge and reinstall Does it operate properly Problem solved Go to Step 3 3 Check the gear of the Toner Dispense Assembly Does the ...

Page 285: ...ubleshooting Reference Applicable Parts References Drum Cartridge Drum Cartridge CRUM PWB Engine Logic Board Print Engine P J Drum and Toner page 10 6 Print Engine P J Engine Logic Board page 10 13 Print Engine Drive CRUM Wiring page 10 25 PL5 1 Laser CRU and Toner Dispense page 9 32 PL8 1 Print Engine Electrical page 9 40 Drum End of Life Drum CRUM Troubleshooting Procedure Step Actions and Quest...

Page 286: ...o Paper in Tray 2 or 3 No Paper Sensor Troubleshooting Reference Applicable Parts References No Paper Sensor Engine Logic Board Print Engine P J Engine Logic Board page 10 13 Print Engine Tray 2 3 Wiring page 10 26 PL2 3 Feeder 2 2 page 9 12 PL8 1 Print Engine Electrical page 9 40 No Paper in Tray 2 or 3 No Paper Sensor Troubleshooting Procedure Step Actions and Questions Yes No 1 Check for paper ...

Page 287: ...ese conductive Go to Step 5 Repair the wiring 5 Check for 5 V to the No Paper Sensor For Tray 2 Is there 5 V across P J101 3 ground For Tray 3 Is there 5 V across P J103 3 ground Replace the No Paper Sensor page 8 24 Replace the Engine Logic Board page 8 89 No Paper in Tray 4 or 5 No Paper Sensor Troubleshooting Reference Applicable Parts References No Paper Sensor Tray 4 5 PWB Engine Logic Board ...

Page 288: ...A and P J549 connected Go to Step 4 Connect the sensor 4 Check continuity between the No Paper Sensor and Engine Logic Board For Tray 4 1 Disconnect P J101 and P J409 2 Check for continuity at the following P J102B 3 P J549 B10 P J102B 2 P J549 B11 P J102B 1 P J549 B12 For Tray 5 1 Disconnect P J103 and P J409 2 Check for continuity at the following P J102A 3 P J549 A10 P J102A 2 P J549 A11 P J102...

Page 289: ...PWB Is there 5 V across P J541 5 ground Replace the Tray 4 5 PWB page 3 29 Replace the Engine Logic Board page 8 89 No Paper in Tray 6 No Paper Sensor Troubleshooting Reference Applicable Parts References No Paper Sensor Tray 6 PWB Engine Logic Board Phaser 5500 Printer Options Service Manual 2000 Sheet Tray 6 Feeder P J Locator page 5 20 2000 Sheet Tray 6 Drive Wiring page 5 25 PL22 5 Tray 6 Feed...

Page 290: ...F02 9 P JF02 7 Go to Step 5 Replace the Tray 6 PWB page 3 67 5 Check the Tray 6 No Paper Sensor signal Does the voltage across P JF02 8 P JF02 7 change when the sensor is blocked Replace the Tray 6 PWB page 3 67 Replace the No Paper Sensor page 3 54 Paper Size Mismatch in Tray 2 or 3 Troubleshooting Reference Applicable Parts References Paper Size Switch Front Size Guide Rear Side Guide End Size G...

Page 291: ...110 and P J412 connected Go to Step 6 Connect the switch 6 Check continuity between the Paper Size Switch and Engine Logic Board For Tray 2 1 Disconnect P J109 and P J412 2 Check for continuity at the following P J109 1 P J412 4 P J109 2 P J412 3 P J109 3 P J412 2 P J109 4 P J412 1 For Tray 3 1 Disconnect P J110 and P J412 2 Check for continuity at the following P J110 1 P J412 9 P J110 2 P J412 8...

Page 292: ...r Options Service Manual 1000 Sheet P J Tray 4 5 Electrical page 5 6 PL20 6 Tray 4 5 Drive and Electrical page 4 16 Paper Size Mismatch in Tray 4 or 5 Troubleshooting Procedure Step Actions and Questions Yes No 1 Check for paper Is paper loaded in the selected tray Go to Step 2 Load paper 2 Check the tray s paper size guides Are the paper size guides set correctly Go to Step 3 Set the guides prope...

Page 293: ...e Paper Size Switch page 3 10 Go to Step 8 8 Check the Tray 4 5 PWB connections Are P J413 and P J541 connected Go to Step 9 Connect P J413 and P 541 9 Check continuity between the Tray 4 5 PWB and Engine Logic Board 1 Disconnect P J541 and P J413 2 Check for continuity at the following P J541 1 P J413 A1 P J541 2 P J413 A2 P J541 3 P J413 A3 P J541 4 P J413 A4 P J541 5 P J413 A5 P J541 6 P J413 A...

Page 294: ... 16 16 Check the Registration Sensor connection Are J104 and J403B connected Go to Step 17 Connect J104 and J403 17 Check continuity between the Registration Sensor and Engine Logic Board Is there continuity on each wire between J104 J403 Go to Step 18 Repair the wiring 18 Check for 5 V to the Registration Sensor Is there 5 V across J403 B13 ground Replace the Registration Sensor page 8 52 Replace...

Page 295: ...sors Wiring page 5 24 PL22 1 Tray 6 Covers page 4 18 PL22 8 Tray 6 Electrical page 4 32 Paper Size Jam in Tray 6 Paper Size Sensors Troubleshooting Procedure Step Actions and Questions Yes No 1 Check the installation of Tray 6 Paper Size Sensors Remove the Rear and Top Covers Are the Paper Size Sensors installed correctly Go to Step 2 Correct the installation If the error persists go to Step 2 2 T...

Page 296: ...or Paper Size Sensor B Is there 5 V across PF53 1 ground Replace the Paper Size Sensors page 3 42 Replace the Tray 6 PWB page 3 67 Temperature Sensor Failure ATC Sensor Troubleshooting Reference Applicable Parts References Drum Cartridge Front Harness A Drum Cartridge Detect Engine Logic Board Print Engine P J Drum and Toner page 10 6 Print Engine P J Engine Logic Board page 10 13 Print Engine LVP...

Page 297: ...Detect Switch Is there 5 V across P J404 3 ground Replace the Drum Cartridge Detect Switch page 8 60 Replace the Engine Logic Board page 8 89 Temp Humidity Sensor Failure Environmental PWB Troubleshooting Reference Applicable Parts References Environmental Sensor PWB Engine Logic Board Print Engine P J Registration Transport page 10 10 Print Engine P J Engine Logic Board page 10 13 Print Engine Xe...

Page 298: ...rd Output Tray Full Exit Full Stack Sensor Troubleshooting Reference Applicable Parts References Exit PWB Engine Logic Board Full Stack Actuator Link Full Stack Actuator Full Stack Sensor Print Engine P J Laser and Exit PWB page 10 7 Print Engine P J Engine Logic Board page 10 13 Print Engine Exit 1 Wiring page 10 30 PL6 2 Exit 1 page 9 36 PL8 1 Print Engine Electrical 1 2 Phaser 5500 Printer Opti...

Page 299: ... the wiring 5 Check for 5 V to the Stack Full Sensor For Exit 1 Is there 5 V across P J118 3 ground For Exit 2 Is there 5 V across P J113 3 ground Replace the Full Stack Sensor Go to Step 6 6 Check the Exit PWB connections Are P J421 and P J431 connected Go to Step 7 Connect P J421 and P J431 7 Check continuity between the Exit PWB and Engine Logic Board 1 Disconnect P J431 and P J421 2 Check for ...

Page 300: ...or Run the Service Diagnostics Upper Tray Full Sensor test Does the sensor state change when the sensor area is covered Replace the Finisher Main PWB page 3 248 Go to Step 2 2 Check the Top Tray Sensor and Main Sensor Harness connections Are P J8322 P J8393 and P J8302A of the Top Tray Sensor Harness connected Go to Step 4 Connect and go to Step 3 3 Print a Test Print Does the error still occur Go...

Page 301: ...ervice Manual Finisher Main PWB P J Locator page 5 35 Finisher Sensors 2 2 Wiring page 5 41 Finisher Clutch and Solenoids Wiring page 5 43 PL25 6 Finisher Stack page 4 54 PL25 14 Finisher Electrical page 4 70 PL25 15 Finisher Harness page 4 72 Lower Tray Full Stack Encoder Sensor Troubleshooting Procedure Step Actions and Questions Yes No 1 Check the Stacker Lower Tray for obstructions Are there a...

Page 302: ... Main PWB page 3 248 8 Check Stacker Encode Sensor signal Does the voltage across P8302B 13 and P8302B 12 on the Finisher Main PWB change when the sensing area is blocked or opened Replace the Finisher Main PWB page 3 248 Replace Stacker Encode Sensor page 3 142 9 Check the Elevator Motor Run the Service Diagnostics Stacker Motor Up and Down tests alternately Does the Elevator Motor operate Replac...

Page 303: ...aple Sensor test Does the sensor state change when the Staple Cartridge is removed or replaced Go to Step 9 Go to Step 2 2 Check the Staple Cartridge for faulty parts and foreign particles Are there damaged parts or foreign particles Replace faulty parts or clean as needed Go to Step 3 3 Check the Staple Harness connections Are P J8356 and P J8308 connected Go to Step 5 Connect and go to Step 4 4 ...

Page 304: ... Main PWB Staple Harness Stapler Assembly Engine Logic Board Phaser 5500 Printer Options Service Manual Finisher Main PWB P J Locator page 5 35 Finisher Staple P J Locator page 5 30 Finisher Stapler Wiring page 5 45 PL25 8 Finisher Staple page 4 58 PL25 14 Finisher Electrical page 4 70 Staple Cartridge Low or Missing Self Priming Senor Troubleshooting Procedure Step Actions and Questions Yes No 1 ...

Page 305: ... J8308 12 P J8356 5 P J8308 11 Are these conductive Go to Step 8 Repair the Staple Harness 8 Check for 5 V to the Self Priming Sensor Is there 5 V across J8308 11 J8308 15 on the Finisher Main PWB Go to Step 9 Replace the Finisher Main PWB page 3 248 9 Check the Self Priming Sensor signal Does the voltage across P8308 14 P8308 15 on the Finisher Main PWB change when the Staple Cartridge is removed...

Page 306: ...tep Actions and Questions Yes No 1 Check the Compiler Tray for obstructions Are there any obstructions in the Compiler Tray Remove the obstacles Go to Step 2 2 Test the Staple Motor in the Staple Head Run the Service Diagnostics Staple Motor Forward and Reverse tests alternately Does the Staple Motor operate Go to Step 6 Go to Step 3 3 Check the Staple Motor Harness connections Are P J8357 and P J...

Page 307: ...8 11 J8308 15 on the Finisher Main PWB Go to Step 11 Replace the Finisher Main PWB page 3 248 11 Replace the Stapler Assembly Does the error still occur Go to Step 12 Problem solved 12 Replace the Finisher Main PWB Does the error still occur Replace the Engine Logic Board page 8 89 Problem solved Staple Set Over Count Troubleshooting Reference Applicable Parts References Finisher Main PWB Engine L...

Page 308: ...0 Printer Options Service Manual Finisher Main PWB P J Locator page 5 35 Finisher Sensors 2 2 Wiring page 5 41 Finisher Clutch and Solenoids page 5 43 PL25 6 Finisher Stack page 4 54 PL25 14 Finisher Electrical page 4 70 PL25 15 Finisher Harness page 4 72 Lower Tray Failure No Paper Sensor Troubleshooting Procedure Step Actions and Questions Yes No 1 Check the lower part of the Stacker for obstacl...

Page 309: ...Stacker No Paper Sensor signal Does the voltage across P8302B 16 P8302B 15 on the Finisher Main PWB change when the sensor is blocked Replace the Finisher Main PWB page 3 248 Replace the sensor page 3 143 9 Test the Elevator Motor Run the Service Diagnostics Stacker Motor Up and Down tests alternately Does the Elevator Motor operate Go to Step 13 Go to Step 10 10 Check the Elevator Motor connectio...

Page 310: ...er Harness page 4 72 Punch Box Missing Punch Box Set Sensor Troubleshooting Procedure Step Actions and Questions Yes No 1 Test the Punch Box Set Sensor 1 Open Door G 2 Remove the Punch Box 3 Run the Service Diagnostics Punch Box Set Sensor test Does the sensor state change when the Punch Box is removed and replaced Go to Step 8 Go to Step 2 2 Check the harness connections Are P J8353 and P J8355 o...

Page 311: ...change when the Punch Box is removed or replaced Go to Step 8 Replace the Punch Box Set Sensor page 3 154 8 Replace the Finisher Main PWB Does the error still occur Replace the Engine Logic Board page 8 89 Problem solved Punch Box Full Punch Box Counter Troubleshooting Reference Applicable Parts References Punch Box Set Sensor Punch Box Sensor Harness Punch Sensor Harness Finisher Main PWB Engine ...

Page 312: ...the Punch Box Sensor Harness and P J8355 and P J8307 of the Punch Sensor Harness connected Go to Step 5 Connect and go to Step 4 4 Cycle the printer power Does the error still occur Go to Step 5 Problem solved 5 Check Punch Box Sensor Harness continuity 1 Disconnect P J8353 and P J8355 2 Check for continuity at the following J8353 3 P8355 3 J8353 2 P8355 2 J8353 1 P8355 1 Are these conductive Go t...

Page 313: ... P J Locator LVPS page 10 16 Print Engine LVPS Wiring page 10 21 PL1 1 Covers 2 2 page 9 6 PL8 1 Print Engine Electrical page 9 40 Front Door Open Front Door Interlock Troubleshooting Procedure Step Actions and Questions Yes No 1 Check Front Door operation Does the Front Door open and close normally Go to Step 2 Correct the installation 2 Test the Front Door Interlock Switch Run the Service Diagno...

Page 314: ...on page 4 30 PL22 8 Tray 6 Electrical page 4 32 Tray 6 Undocked Docking Interlock Switch Troubleshooting Procedure Step Actions and Questions Yes No 1 Check the Tray 6 installation Is Tray 6 installed correctly Go to Step 2 Correct and go to Step 2 2 Check the Docking Switch condition Is the Docking Switch damaged Replace the Docking Switch page 3 66 Go to Step 3 3 Test the Docking Switch 1 Pull T...

Page 315: ...r still occur Replace the Engine Logic Board page 8 89 Problem solved Door A Open Door A Interlock Switch Troubleshooting Reference Applicable Parts References Door A Interlock Switch Engine Logic Board Print Engine P J Locator Electrical page 10 12 Print Engine P J Engine Logic Board page 10 13 Print Engine LVPS Wiring page 10 21 PL4 2 L H Upper Assembly page 9 24 PL8 1 Print Engine Electrical pa...

Page 316: ... P J Engine Logic Board page 10 13 Print Engine Registration Transport Wiring page 10 23 PL4 1 L H Upper Assembly page 9 22 PL8 1 Print Engine Electrical page 9 40 Door B Open Door B Interlock Switch Troubleshooting Procedure Step Actions and Questions Yes No 1 Check Door B operation Does Door B open and close normally Go to Step 2 Correct the installation 2 Test the Door B Interlock Switch Run th...

Page 317: ...ock Switch Troubleshooting Procedure Step Actions and Questions Yes No 1 Check Door C operation Does Door C open and close normally Go to Step 2 Correct the installation 2 Test the Door C Interlock Switch Run the Service Diagnostics Door C Interlock Switch test Does the sensor state change each time the switch is pressed Replace the Engine Logic Board page 8 89 Go to Step 3 3 Check the switch conn...

Page 318: ... Go to Step 8 Repair the wiring 8 Check for 24 V to the Tray 4 5 PWB Is there 24 V across P J541 7 ground Replace the Tray 4 5 PWB page 3 29 Replace the Engine Logic Board page 8 89 Door D Open Door D Interlock Switch Troubleshooting Reference Applicable Parts References Door D Interlock SW Duplex PWB Engine Logic Board Print Engine P J Engine Logic Board page 10 13 PL8 1 Print Engine Electrical p...

Page 319: ... ground Replace the switch page 3 74 Go to Step 6 6 Check the Duplex PWB connection Are P J540 and P J417 connected Go to Step 7 Connect P J540 and P J417 7 Check continuity between the Duplex PWB and the Engine Logic Board 1 Disconnect P J540 and P J417 2 Check for continuity at the following P J540 1 P J417 A1 P J540 2 P J417 B1 P J540 3 P J417 A2 P J540 4 P J417 B2 P J540 5 P J417 A3 P J540 6 P...

Page 320: ...erlock Switch Troubleshooting Procedure Step Actions and Questions Yes No 1 Check Door E operation Does Door E open and close normally Go to Step 2 Correct the installation 2 Test the Door E Interlock Switch Run the Service Diagnostics Door E Interlock Switch test Does the sensor state change each time the switch is pressed Reconnect the Engine Logic Board connector Go to Step 3 3 Check the switch...

Page 321: ... 4 48 PL25 14 Finisher Electrical 1 2 page 4 70 Door F Open Door F Interlock Sensor Troubleshooting Procedure Step Actions and Questions Yes No 1 Check Door F operation Does Door F open and close smoothly Go to Step 2 Correct the installation 2 Check the Door F Interlock Sensor Actuator Is the actuator damaged Replace the Top Cover page 3 108 Go to Step 3 3 Check the Door F Interlock Sensor instal...

Page 322: ...WB Go to Step 9 Replace the Finisher Main PWB page 3 248 9 Check the Door F Interlock Sensor signal Does the voltage across P J8372 3 P J8372 1 on the H X port PWB change when the sensor is blocked Go to Step 10 Replace the Door F Interlock Sensor page 3 116 10 Replace the Door F Interlock Sensor Cycle the printer power Does the error still occur Go to Step 11 Problem solved 11 Replace the Finishe...

Page 323: ...ect 1 3 page 4 60 PL25 14 Finisher Electrical 1 2 page 4 70 PL25 15 Finisher Electrical 2 2 page 4 72 Door G Open Door G Interlock Switch Troubleshooting Procedure Step Actions and Questions Yes No 1 Check Door G operation Does Door G open and close smoothly Go to Step 2 Correct the installation 2 Check the Door G Interlock Switch installation Is the sensor installed correctly Go to Step 3 Correct...

Page 324: ...Does the voltage across J8314 2 J8314 3 on the Finisher Main PWB change when the switch is pressed Replace the Finisher Main PWB page 3 248 Replace the Switch page 3 127 9 Check the Eject Cover Switch Does the voltage across J8365 1B ground on the Door G Interlock Harness change when the Eject Cover Switch is actuated Go to Step 10 Replace the Door H Interlock Switch page 3 176 10 Check the Door G...

Page 325: ...Finisher Electrical 2 2 page 4 72 Door H Open Door H Interlock Switch Troubleshooting Procedure Step Actions and Questions Yes No 1 Check Door G operation Does Door G open nd close correctly Go to Step 2 Correct the installation 2 Check the Door H Interlock Sensor installation Is the sensor installed correctly Go to Step 3 Correct the installation 3 Check the Door H Interlock Harness connections A...

Page 326: ...e 3 176 9 Check the Door G Interlock signal Does the voltage across J8388 2 ground on the Finisher Main PWB change when the Eject Cover SW and Door G Interlock Switch are actuated simultaneously Go to Step 10 Replace the Door G Interlock Switch page 3 127 10 Replace the Finisher Main PWB Cycle printer power Does the error still occur Replace the Engine Logic Board page 8 89 Problem solved Door J O...

Page 327: ...still occur Go to Step 5 Problem solved 5 Check Door J Interlock Harness continuity 1 Disconnect FS001 FS002 and P JF05 2 Check for continuity at the following FS002 P JF05 2 FS001 P JF05 1 Are these conductive Go to Step 6 Repair the Door J Interlock Harness 6 Check for 24 V to the Door J Interlock Switch Is there 24 V across PF05 2 PF04 3 on the Tray 6 PWB Go to Step 7 Replace the Tray 6 PWB pag...

Page 328: ...ng Procedure Step Actions and Questions Yes No 1 Warning Allow the Fuser to cool 1 Install a new Maintenance Kit 2 Reset the Fuser Life counter page 6 9 Does the error still occur Replace the Engine Logic Board page 8 89 Problem solved Invalid or Missing Configuration Card Troubleshooting Reference Applicable Parts References Configuration Card I P Board PL8 1 Print Engine Electrical page 9 40 Upg...

Page 329: ...ooting Reference Applicable Parts References I P Board Resetting Connection Setup Values 6 10 PL8 1 Print Engine Electrical page 9 40 Duplicate IP Address Detected Troubleshooting Procedure Step Actions and Questions Yes No 1 Check the TCP IP Address stored in the printer s NVRAM Is the address correct for the printer Advise the customer of the address conflict Enter the correct IP address ...

Page 330: ...3 252 Phaser 5500 Printer Service Manual ...

Page 331: ...shooting In this chapter Introduction Network Problems Operating System and Application Problems Front Panel Troubleshooting Low Voltage Power Supply Troubleshooting AC Power Supply Troubleshooting Print Engine Troubleshooting ...

Page 332: ...e is a Connection Setup Page Configuration Page and a network reset available for troubleshooting Network problems To Print an Event Log or Runtime Log 1 From the main menu select the Troubleshooting Menu then select Network Log Pages 2 Highlight the appropriate menu item from the list and select the OK button 3 The page should now print Operating System and Application Problems More troubleshooti...

Page 333: ...riginal document may be causing the problem Image Rotated 90 Degrees In the application s Page Setup make sure that the image is selected to print in portrait or landscape orientation to match the document Also ensure the selected paper size is correct Windows Printing Problems Image Never Prints 1 Try printing a test page from the printer driver s properties dialog box 2 Try printing from another...

Page 334: ...edure Step Actions and Questions Yes No 1 Check the Front Panel input DC voltages On the Image Processor Board measure the voltages at the following test points J150 5 Ground 5 V J150 6 Ground 3 8V J150 7 Ground 5 V J150 8 Ground 3 8V J150 9 Ground 3 8 V J150 10 Ground 5 V Are the voltages within specification Go to Step 2 Replace the Image Processor Board page 8 91 2 Check Continuity between the ...

Page 335: ...nter power On 3 Measure AC voltage at the following test points on the LVPS P J1 1 P J1 4 Is the voltage across pins 1 and 4 equal to 120V or 220V line voltage Go to Step 2 Verify correct power from the AC outlet Verify the power cord is in good condition and plugged into the Printer and AC outlet Verify that the GFI Breaker is not tripped Verify correct operation of the printer power switch and A...

Page 336: ...LVPS if problem continues verify the wire harness to the Exit PWB If the wiring checks out replace the Exit PWB page 8 88 Finisher LVPS Troubleshooting Reference Applicable Parts References LVPS Power Cord Printer AC Accessory Panel Phaser 5500 Printer Options Service Manual Finisher LVPS Plug Jack Locator page 5 35 Finisher Power Wiring Diagram page 5 38 PL25 14 Finisher Electrical page 4 70 Fini...

Page 337: ...ps the cause must be corrected Caution the customer NOT to connect the machine to the wall outlet Advise the customer that a licensed electrician must correct the wiring Do not attempt to correct the wiring yourself 2 Check DC voltages on the LVPS harness Measure the voltage at these points P J505 3 ground 2 8V P J505 4 ground 2 8V Are the voltage levels correct Go to Step 3 Replace the Finisher L...

Page 338: ...between Line and Ground should range from 99 to 135 VAC and the voltage between Neutral and Ground should be less than 3 VAC Is the AC voltage within specification Go to Step 2 Inform customer of insufficient voltage or improper wiring For 220V 1 Disconnect the AC power cord from the wall outlet 2 Measure the AC voltage between Line and Neutral between AC Line and Earth Ground and between Neutral ...

Page 339: ...he voltage between Neutral and Ground should be less than 3 VAC Is the AC line voltage within specification Go to Step 2 Inform customer of insufficient voltage or improper wiring 2 1 Check the continuity through all connections of the power cord 2 The measurement should be less than 10 ohms for each connection Does continuity test per specification Test the Print Engine LVPS page 4 5 Replace the ...

Page 340: ...eaker AC Accessory Panel Wall Outlet Print Engine Electrical Specifications page 1 13 AC Accessory Panel Plug Jack Locator page 10 15 PL8 1 Print Engine Electrical page 9 40 Inoperative Printer Troubleshooting Procedure Step Actions and Questions Yes No 1 Check the AC Power Cord Is the AC Power Cord plugged into the printer and the AC outlet Is the GFI breaker operational Go to Step 2 Plug in the ...

Page 341: ...rify the Power Cord is in good condition and is the correct cord If necessary replace the cord Verify the GFI breaker is not tripped and is operational If problem persists repair the AC inlet connector wiring If necessary replace the GFI Breaker page 8 94 6 Check the AC Voltage from the LVPS to the Power Switch Measure AC voltage at the following test points on the LVPS P J 1 3 P J 1 6 120V or 220...

Page 342: ...ord is in good condition and plugged into the Printer and AC outlet Verify that the GFI breaker is not tripped Verify correct operation of the printer power switch and AC harness Verify correct power from the AC outlet 2 Check DC supply voltage to the Engine Logic Board 1 Remove the I P Board Cover Upper and Lower Rear Covers 2 Turn the printer power On 3 Measure the voltage at these points P J400...

Page 343: ...nected to the Rear Panel 3 Remove all on board options Hard Drive etc from the Image Processor Board 4 Switch the printer power On Does the printer boot correctly and is Ready displayed on the Front Panel Go to Step 3 Go to Step 2 2 1 Switch the printer power Off 2 Remove then re install the cable between P J590 on the Image Processor Board and P J402 on the Engine Logic Board 3 Switch the printer...

Page 344: ... Image Processor Board Troubleshooting Procedure Step Actions and Questions Yes No 1 Check the DC power suppled from the LVPS 1 Disconnect P J120 on the Image Processor Board 2 Measure voltages across these points P120 1 ground 3 3 V P120 4 ground 5 V P120 6 ground 3 3 V P120 12 ground 3 3 V Are the voltages correct Replace the I P Board page 8 91 Go to Print Engine LVPS page 4 5 and verify LVPS o...

Page 345: ... Power On Self Test Error RAM ERROR Initial Actions Check that the RAM devices aremaking positive contact with their connectors 1 Power off the printer 2 Remove and re install the RAM memory after verifying it meets the Xerox specifications See Memory Specifications on page 1 11 If the problem persists use the following procedure to correct it POST RAM Memory Failure Troubleshooting Reference Appl...

Page 346: ... a memory fault message displayed Go to Step 8 Go to Step 7 7 1 Power off the printer and remove the first DIMM 2 Install the second DIMM and power on the printer Is a memory fault message displayed Go to Step 8 Go to Step 9 8 1 Power off the printer and move the suspected defective DIMM to the other memory socket 2 Power on the printer Does the DIMM fail in the new location Replace the DIMM and g...

Page 347: ...5 Chapter Print Quality Troubleshooting In this chapter Print Quality Problems Overview Analyzing Test Prints Print Quality Troubleshooting ...

Page 348: ...r When analyzing a print quality defect first determine if the defect is repeating or random Continuous defects in the process direction such as voids and lines are the most difficult to diagnose The visible surfaces of all rollers should be inspected for obvious defects Analyzing Test Prints The Test Print analysis procedures explain each of the areas and the print quality parameters Further assi...

Page 349: ...the page page 5 11 Unfused Image Part of or all of the image is unfused Refer to the specification page 5 30 Damaged Prints Creases wrinkles excessive curl cuts folds or embossed marks page 5 33 Resolution At 600 dpi the two pixel lines and halftone patches cannot be reproduced clearly on the print page 5 7 Spot Deletions Solid areas are marked with irregular white areas page 5 35 Repeating Defect...

Page 350: ...5 4 Phaser 5500 Printer Service Manual Print Quality Test Print s5500 619 Test Print Test Print Phaser5500 040302 2 L Phaser5500 040302 2 L 8 5x11 LEF Only 8 5x11 LEF Only LEAD EDGE ...

Page 351: ...s Yes No 1 Inspect the test print for the presence of deletions missing image There should be no deletions with a diameter larger than 0 5 mm visible on test prints Are there deletions on the test prints Go to Step 2 Go to Fusing on page 5 6 2 Are there vertical in process direction Line Band deletions present Go to Vertical Deletions on page 5 21 Go to Step 3 3 Are there Horizontal in direction o...

Page 352: ...ts Fusing Errors Troubleshooting Procedure Actions and Questions Yes No Rub the image three times at the marked check points with a soft cloth or tissue The image should not lift off of the surface Does the fusing quality of the image appear acceptable Go to Resolution on page 5 7 Go to Unfused Image on page 5 30 s5500 049 Test Print Test Print Phaser5500 040302 2 L Phaser5500 040302 2 L 8 5x11 LE...

Page 353: ...us The diagonal lines might appear to be narrower than the others Arrow 2 The text paragraphs should be roughly equal in density Arrow 3 The half tone patches adjacent to the solid blocks in the corners should be uniform in appearance Are the check points arrows 1 2 and 3 within specification The printed test patterns meet the Resolution Specification Go to page 5 8 Go to Resolution on page 5 34 s...

Page 354: ...e test prints Fold the paper in half leading edge to trailing edge Observe the fold line of the paper with reference to the cross hairs of the target Is the fold within 2 5 mm of the target cross hairs each line on the target is 1 mm The test prints meet the Leading Edge to Trailing Edge Registration Specification Go to Registration Side to Side on page 5 9 Go to Registration on page 5 45 s5500 05...

Page 355: ... two consecutive test prints 1 Fold the paper in half side to side 2 Observe the fold line of the paper with reference to the cross hairs of the target Is the fold within 2 0 mm of the target cross hairs each line on the target is 1 mm The printed test patterns meet the Side to Side Registration Specification Go to Skewed Image on page 5 44 Go to Registration on page 5 45 s5500 052 ...

Page 356: ...Questions Yes No Inspect the ladder chart test pattern as shown in the figure Is the pattern free from skips and smears Go to Spots on page 5 11 Go to Skips and Smears on page 5 47 s5500 053 Test Print Test Print Phaser5500 040302 2 L Phaser5500 040302 2 L 8 5x11 LEF Only 8 5x11 LEF Only LEAD EDGE Smear Skip ...

Page 357: ...thin a 289 X 95 mm square There should be no spots larger than or equal to 0 5 mm visible on the prints There should be no more than 1 spot measuring between 0 4 mm and 0 5 mm visible on the print There should be no more than 16 spots measuring between 0 25 mm and 0 4 mm visible on the print Any spot measuring less than 0 25 mm is acceptable Are the prints free of spots or the spots that are visib...

Page 358: ... 3 Select Test Prints then press the OK 4 Measure the dimensions A and B on two consecutive test patterns Is the difference between A and B 1 25 mm or less The printed test patterns meet the Skew specifications Go to Skips and Smears on page 5 47 Go to Skewed Image on page 5 44 s5500 055 Lead Edge of Paper Test Print Test Print Phaser5500 040302 2 L Phaser5500 040302 2 L 8 5x11 LEF Only 8 5x11 LEF...

Page 359: ...s free of defects Return to Analyzing Test Prints on page 5 2 Go to Step 2 2 Are there dark streaks present on the test prints Go to Vertical Streaks on page 5 25 or Horizontal Streaks on page 5 27 Go to Step 3 3 Is there a residual image ghost on the test print Go to Residual Image on page 5 38 Go to Step 4 4 Is the paper damage wrinkles creases tears etc Go to Damaged Print on page 5 33 Problem ...

Page 360: ...ct points are clean Ensure that there are no obstructions in the Laser path Ensure that draft mode is turned off Light Print Troubleshooting Reference Applicable Parts Example Print Durm Cartridge Toner Cartridge Transfer Roller High Voltage Power Supply Image Processor Board Engine Logic Board Light Print Troubleshooting Procedure Step Actions and Questions Yes No 1 Checking paper condition Load ...

Page 361: ...ormed Correct and clean Earth Plate or replace the Drum Cartridge Go to Step 6 6 Check image development 1 Print a Test Print 2 Turn off the power while printing 3 Carefully remove the Drum Cartridge and check the image formed on the drum right before the Transfer Roller Is the image completely formed on the drum Is it clear black and easy to read Go to Step 7 Go to Step 9 7 Check image transfer C...

Page 362: ... Reference Applicable Parts Example Print Laser Assembly Drum Cartridge Transfer Roller High Voltage Power Supply Image Processor Board Engine Logic Board Blank Print Troubleshooting Procedure Step Actions and Questions Yes No 1 Check the Print Engine Print a Test Print Is the Test Print Normal Print a Configuration Page Go to Step 2 Go to Step 4 2 Check Confirguration Page Print the Configuration...

Page 363: ...n the Earth Plate or replace the Drum Cartridge Go to Step 5 8 Check laser beam path 1 Check that there are no obstacles between the Laser Assembly and Drum 2 Check the Laser Assembly window for contamination Is there any obstacle in the laser beam path or in the window Remove obstacles or clean the Laser Assembly window Go to Step 9 9 Check Laser Assembly installation Is the Laser Assembly instal...

Page 364: ... 13 Check image transfer Check the image formed on the drum right after the Transfer Roller Is the image completely transferred on the paper Go to Step 14 Go to Step 15 14 Check the HVPS 1 Replace the HVPS page 8 86 2 Print a Test Print Is the Test Print normal Problem solved Go to Step 15 15 Check the Engine Logic Board 1 Replace the Engine Logic Board page 8 89 2 Print a Test Print Is the Test P...

Page 365: ...place and no outside light enters the printer Black Print Troubleshooting Reference Applicable Parts Example Print Drum Cartridge High Voltage Power Supply Image Processor Board Engine Logic Board Black Print Troubleshooting Procedures Step Actions and Questions Yes No 1 Check the Print Engine Print a Test Print Is the Test Print Normal Print a Configuration Page Go to Step 2 Go to Step 4 2 Check ...

Page 366: ...tall a new Drum Cartridge 2 Run a Test Print Is the image density normal Problem solved Go to Step 5 5 Check the HVPS 1 Replace the HVPS page 8 86 2 Print a Test Print Is the Test Print normal Problem solved Go to Step 6 6 Check the Engine Logic Board 1 Replace the Engine Logic Board page 8 89 2 Print a Test Print Is the Test Print normal Problem solved Replace the I P Board page 8 91 Black Print ...

Page 367: ...ontacts are clean Ensure there are no obstructions in the laser path Check that rollers and other paper path components are clean and unobstructed Vertical Deletions Troubleshooting Reference Applicable Parts Example Print Drum Cartridge Transfer Roller Laser Assembly Fuser Image Processor Board Engine Logic Board Vertical Deletions Troubleshooting Procedure Step Actions and Questions Yes No 1 Che...

Page 368: ...cking the Transfer Roller 1 Remove the Transfer Roller 2 Check for contamination or wear Is there any contamination or wear on the Transfer Roller Replace the Transfer Roller page 8 44 Go to Step 8 8 Check the Heat and Pressure Rollers WARNING Allow the Fuser to cool before removing it Remove the Fuser Is there contamination or defects on the Heat or Pressure Roller Replace the Fuser page 8 76 Go ...

Page 369: ...acts are clean Check the Transfer Roller for contamination or wear Check that rollers and other paper path components are clean and unobstructed Horizontal Deletions Troubleshooting Reference Applicable Parts Example Print Drum Cartridge Transfer Roller Laser Assembly Fuser Image Processor Board Engine Logic Board Horizontal Deletions Troubleshooting Procedure Step Actions and Questions Yes No 1 C...

Page 370: ...age development 1 Print a Test Print 2 Turn off the power while printing 3 Carefully remove the Drum Cartridge and check the image formed on the drum right before the Transfer Roller Is the image completely formed on the drum Is it clear black and easy to read Go to Step 7 Go to Step 8 7 Check image transfer Check the image formed on the drum right after the Transfer Roller Is the image completely...

Page 371: ...tacts are clean Inspect the paper path for contamination or obstructions Vertical Streaks Troubleshooting Reference Applicable Parts Example Print Drum Cartridge Transfer Roller Laser Assembly Fuser Image Processor Board Engine Logic Board Vertical Streaks Troubleshooting Procedure Step Actions and Questions Yes No 1 Check paper condition 1 Load new dry paper 2 Print a Test Print Does the problem ...

Page 372: ...d the Drum Cartridge Is the Earth Plate contaminated or deformed Correct and clean Earth Plate or replace the Drum Cartridge Go to Step 7 7 Check laser beam path 1 Check that there are no obstacles between the Laser Assembly and Drum 2 Check the Laser Assembly window for contamination Is there obstacles in the laser beam path or window Remove obstacles or clean the Laser Assembly window Go to Step...

Page 373: ...contacts are clean Horizontal Streaks Troubleshooting Reference Applicable Parts Example Print Drum Cartridge Transfer Roller Laser Assembly Fuser Image Processor Board Engine Logic Board Horizontal Streaks Troubleshooting Procedure Step Actions and Questions Yes No 1 Check paper condition 1 Load new dry paper 2 Print a Test Print Does the problem still occur Go to Step 2 Problem solved 2 Check th...

Page 374: ...mage completely formed on the drum Is it clear black and easy to read Go to Step 7 Go to Step 8 7 Check image transfer Check the image formed on the drum right after the Transfer Roller Is the image completely transferred on the paper Go to Step 9 Go to Step 8 8 Check the HVPS 1 Replace the HVPS page 8 86 2 Print a Test Print Is the Test Print normal Problem solved Go to Step 9 9 Check the Engine ...

Page 375: ...for spots or contamination Check the Fuser for wear or contamination Check that the Drum Cartridge ground contacts are clean Spots Troubleshooting Reference Applicable Parts Example Print Drum Cartridge Transfer Roller Fuser Image Processor Board Engine Logic Board Spots Troubleshooting Procedure Step Actions and Questions Yes No 1 Check paper condition 1 Load new dry paper 2 Print a Test Print Do...

Page 376: ... Check the Drum Cartridge 1 Install a new Drum Cartridge 2 Print a Test Print Is the image density normal Problem solved Go to Step 4 4 Check the Transfer Roller 1 Remove the Transfer Roller 2 Check for contamination or wear Is there contamination or wear Go to Step 5 Replace the Transfer Roller page 8 44 5 Check the Heat and Pressure Roller WARNING Allow the Fuser to cool before removing it Remov...

Page 377: ...h Envelope High Special Medium Unfused Image Troubleshooting Reference Applicable Parts Example Print Fuser High Voltage Power Supply Image Processor Board Engine Logic Board Unfused Image Troubleshooting Procedure Step Actions and Questions Yes No 1 1 Replace the paper with new dry paper from an unopened ream 2 Print a Test Print Is the Test Print Normal Problem solved Go to Step 2 s5500 064 ...

Page 378: ...image formed on the drum right before the Transfer Roller Is the image completely formed on the drum Is it clear black and easy to read Go to Step 5 Go to Step 7 5 Check image transfer Check the image formed on the drum right after the Transfer Roller Is the image completely transferred on the paper Go to Step 6 Go to Step 7 6 Check the HVPS 1 Replace the HVPS page 8 86 2 Print a Test Print Is the...

Page 379: ...the paper supply is dry and meets specifications Inspect the paper path for items such as staples paper clips and paper scraps Check that rollers and other paper path components are clean and unobstructed Damaged Print Troubleshooting Reference Applicable Parts Example Print Fuser Feed Rollers Tray Damaged Print Troubleshooting Procedure Step Actions and Questions Yes No 1 Check the installation l...

Page 380: ...emove obstacles or contamination 5 Check rollers in the paper path 1 Check Feed and paper path rollers for contamination wear or damage 2 Check whether pinch rollers rotate freely and spring pressure is applied evenly Is there any contamination wear or damage to the rollers Replace defective rollers Go to Step 6 6 Check the Heat and Pressure Roller WARNING Allow the Fuser to cool before removing i...

Page 381: ...m Cartridge ground contacts are clean Resolution Troubleshooting Procedure Step Actions and Questions Yes No 1 1 Install a new Drum Cartridge 2 Print a Test Print Is the test print output resolution good Problem solved Go to Step 2 2 Replace the following in order until the defective component is found Laser Assembly page 8 74 Engine Logic Board page 8 89 Spot Deletions Troubleshooting Reference A...

Page 382: ...ive image Is the image density normal Problem solved Go to Step 4 4 Checking the Transfer Roller 1 Remove the Transfer Roller 2 Check the Transfer Roller for contamination and wear Is there any contamination or wear on the Transfer Roller Replace the Transfer Roller page 8 44 Go to Step 5 5 Check the Heat and Pressure Roller WARNING Allow the Fuser to cool before removing it Remove the Fuser Is th...

Page 383: ...problem Repeating Defects Troubleshooting Procedure Step Actions and Questions Yes No 1 1 Replace paper with new paper 2 Print a test print Do the repeating defects still appear Go to Step 2 Problem solved 2 Do the defects occur every 44 mm 1 7 in 56 5 mm 2 2 in 94 2 mm 3 7 in Install a new Drum Cartridge Go to Step 3 3 Do the defects occur every 58 7 mm 2 3 in Replace the Transfer Roller page 8 4...

Page 384: ...the Paper Tips Page Residual Image Troubleshooting Reference Applicable Parts Example Print Fuser Engine Logic Board Image Processor Board HVPS Residual Image Troubleshooting Procedure Step Actions and Questions Yes No 1 Check image quality Is the customer printing the same image in large quantity Go to Step 2 Go to Step 3 2 Print 30 Test Prints Does the residual image appear Go to Step 3 Print 30...

Page 385: ... new Drum Cartridge 2 Print 30 Test Prints Does the residual image appear Go to Step 7 Problem solved 7 Check the Heat and Pressure Roller WARNING Allow the Fuser to cool before attempting to remove it Remove the Fuser Is there any contamination or defects on Heat or Pressure Roller Replace the Fuser page 8 76 Go to Step 8 8 Check that the HVPS is installed correctly Is the HVPS installed correctl...

Page 386: ...the paper path for items such as staples paper clips and paper scraps Check the installation of the Drum Cartridge Check that the Drum Cartridge ground contacts are clean Ensure the covers are in place and no outside light enters the printer Background Troubleshooting Reference Applicable Parts Example Print Drum Cartridge Transfer Roller High Voltage Power Supply Engine Logic Board Image Processo...

Page 387: ...er while printing 3 Carefully remove the Drum Cartridge and check the image formed on the drum right before the Transfer Roller Is the image completely formed on the drum Is it clear black and easy to read Go to Step 6 Go to Step 7 6 Check image transfer Check the image formed on the drum right after the Transfer Roller Is the image completely transferred on the paper Go to Step 8 Go to Step 7 7 C...

Page 388: ...ably level Check to make sure the Laser path is clean and unobstructed Remove the Drum Cartridge and check for wear contamination or obstructions Uneven Density Troubleshooting Reference Applicable Parts Example Print Drum Cartridge Transfer Roller Fuser Uneven Density Troubleshooting Procedure Step Actions and Questions Yes No 1 1 Install a new Drum Cartridge 2 Print a test print Does the test pr...

Page 389: ... Go to Step 3 Repair or replace the Transfer Roller page 8 44 3 Check image transfer Check the image formed on the drum right after the Transfer Roller Is the image completely transferred on the paper Go to Step 4 Repair or replace the Transfer Roller page 8 44 4 Look at the print on the paper before the Fuser Does the print on the paper have even density Replace the Fuser Assembly page 8 76 Repla...

Page 390: ...ting Reference Applicable Parts Example Print Drum Cartridge Engine Logic Board Image Processor Board Tray Skewed Image Troubleshooting Procedure Step Actions and Questions Yes No 1 Check the installation site Is the printer insalled on a level surface Go to Step 2 Correct the installation If problem persists go to Step 2 2 Check the paper 1 Reload new dry paper in the source tray 2 Print a Test P...

Page 391: ...otate freely and spring pressure is applied evenly Is there any contamination wear or damage to the rollers Replace defective rollers Go to Step 5 Registration Troubleshooting Reference Applicable Parts Example Print If Duplex only replace Duplex Unit From all trays in the process direction replace the Registration Transport Assembly From a specific tray in the process direction replace in sequenc...

Page 392: ...n specifications Go to Step 3 Go to Step 2 2 Perform the registration adjustment procedure Is the image registration correct after the adjustment Problem solved Replace the Engine Logic Board page 8 89 If the problem persists replace the I P Board page 8 91 3 Have the customer run a print job Are the customer s prints correctly registered Problem solved Problem may be application related Have the ...

Page 393: ...oller Fuser Skips Smears Troubleshooting Procedure Step Actions and Questions Yes No 1 Replace the Drum Cartridge Does the printed image still have skips smears Go to Step 2 Problem solved 2 Replace the Transfer Roller Does the printed image still have skips smears Go to Step 3 Problem solved 3 Replace the Fuser Does the printed image still have skip smears Go to Step 4 Problem solved 4 Replace in...

Page 394: ...5 48 Phaser 5500 Printer Service Manual ...

Page 395: ...6 Chapter Adjustments and Calibrations In this chapter Service Test Prints Adjustments Resetting the Printer to Default Values ...

Page 396: ...he OK button The printer automatically doubles the image quality selected As an example if one page is selected the printer prints two images Note The printer prints the test print using the job defaults established in the Printer Setup menu Insure that Edge to Edge Printing located under the PCL Setup menu is set to Off before printing the test print otherwise the image is shifted left If the def...

Page 397: ...ou press the OK button to toggle the setting between On and Off 5 When you have finished setting all the parameters select Exit and press the OK button to return the printer to the Ready state Print Quality Test Print s5500 619 Test Print Test Print Phaser5500 040302 2 L Phaser5500 040302 2 L 8 5x11 LEF Only 8 5x11 LEF Only LEAD EDGE ...

Page 398: ...the current settings in NVRAM are at the factory defaults of 50 for the scan direction and 33 for the process direction Once set to factory defaults perform registration testing on all input trays in both simplex and duplex modes Use the job defaults to change the supply tray and mode to generate Print Quality test prints from each source 1 From the Main menu select Troubleshooting then press the ...

Page 399: ...n below 6 Check the point where the fold line intersects the target Maximum deflection from the centerline is 2 5 mm in either direction The target lines are graduated in 1 mm increments If the fold line falls more than 2 5 mm from the target use the following procedure to realign the image on the paper s5500 051 ...

Page 400: ... image position For the process direction the factory default is 33 The maximum is 66 and the minimum is zero 0 Changes to the current value for process direction variables by one 1 moves the leading edge of the image 363mm closer or further from the edge of the paper 1 Enter Service Diagnostics 2 Select Printer NVRAM Adjustments then press the OK button 3 Select either the process adjustment Tray...

Page 401: ...llowing procedure to make the necessary duplex registration adjustments 1 Enter Service Diagnostics 2 Select Printer NVRAM Adjustments then press the OK button 3 Select either the duplex process adjustment Duplex Proc Dir or scan adjustment Duplex Scan Dir then press the OK button 4 Use the Up Arrow and Down Arrow buttons to set the new value based on measurements taken from the target area 5 Pres...

Page 402: ...n 5 Select a temperature setting from the four available then press the OK button to place a check mark by that setting Note You must scroll up to see the Extra High setting 6 Select Exit then press the OK button Front Panel Fuser Temperature Modes by Paper Type Paper Type Temperature Low Medium High Extra High Plain Letterhead Colored Special Plain Paper Mode 1 Plain Paper Mode 1 Default Thick Pa...

Page 403: ...lect Reset Fuser Life NOW then press the OK button to reset the fuser life Resetting the Printer to Default Values You can reset printer values on the following menus to the factory default settings Connection Setup Paper Handling Setup PostScript Setup PCL Setup General Setup Front Panel Setup Printer Controls File Security available if the printer has a hard drive You can reset all of the Image ...

Page 404: ...up Values Resetting the paper handling setup values resets the default paper source 2 sided printing tray setup default paper type size load paper timeout tray sequence tray prompt custom size paper units default paper destination job offset output tray switch fuser temperature configuration and reprint jammed pages settings 1 From the Main menu select Printer Setup then press the OK button 2 Sele...

Page 405: ...3 Select Reset General Setup then press the OK button 4 Select Reset General Setup NOW then press the OK button Resetting Front Panel Setup Values Resetting the Front Panel values resets the Front Panel Language Front Panel Brightness Front Panel Contrast and Accessible Front Panel settings 1 From the Main menu select Printer Setup then press the OK button 2 Select Front Panel Setup then press the...

Page 406: ...pt NVRAM restores all printer values stored in the Image Processor Board including network printer setup job defaults and margin to their factory default values The print counts and the Adobe firmware serial number are not affected by this reset Caution Before resetting the printer default settings to factory default values make note of the current network settings or print a Configuration Page to...

Page 407: ...highlighted press the OK button 4 When Resetting NVRAM Are you sure is displayed highlight Yes and press the OK button The printer then exits Service Diagnostics and reboots While booting NVRAM is reset Using the Front Panel Shortcut 1 At power on press the Back OK buttons together 2 When Password appears press and hold the Up Arrow Down Arrow buttons together within 2 seconds ...

Page 408: ...6 14 Phaser 5500 Printer Service Manual ...

Page 409: ...7 Chapter Cleaning and Maintenance In this chapter Service Preventive Maintenance Procedure Recommended Tools Cleaning ...

Page 410: ... it in a light protective bag Note Never use a damp cloth to clean up toner 1 Record number of sheets printed 2 Print several sheets of paper to check for problems or defects Print to all output trays and staple or punch if Finisher is installed 3 Turn off the printer and disconnect the Power Cord 4 Remove the I P Board and Upper Rear covers and clean the Fuser Fan with a brush or dry cloth to rem...

Page 411: ...8 Chapter FRU Disassembly In this chapter Overview General Notes on Disassembly Print Engine FRU Removal Procedures ...

Page 412: ...t process is not a simple reversal of the removal a replacement procedure is included Replacement Notes provide tips and suggestions that can aid in reassembling the part Standard Orientation of the Printer Locations given in the repairs such as left right front or rear assume you are facing the printer Front Panel When needed the orientation of the printer is called out in the procedure for locat...

Page 413: ...t 2 Remove the Drum Cartridge and protect it from exposure to light by covering it with a light proof bag or by placing it in a light tight container Disconnect all computer interface cables from the printer 3 Wear an electrostatic discharge wrist strap to help prevent damage to the sensitive electronics of the printer circuit boards 4 Remove the Fuser Assembly or wait at least 5 minutes after you...

Page 414: ...esult Warning Unplug the AC power cord from the wall outlet before removing any printer part Notations in the Disassembly Text The notation PLX X X at the top of each Figure references the FRU parts list containing this part or assembly Page number references are given in line for procedural steps previously described Bold arrows in an illustration show direction of movement when removing or repla...

Page 415: ...FRU Disassembly 8 5 Print Engine Covers Front Left Cover 1 Open the Front Door PL1 1 2 2 Remove the one screw securing the Front Left Cover 3 Remove the Front Left Cover Front Left Cover s5500 076 ...

Page 416: ...over PL1 1 3 1 Remove the Rear Panel Cover page 8 12 2 Remove the Upper Rear Cover page 8 15 3 Remove the screw securing the Top Rear Cover 4 Remove the Top Rear Cover by sliding it left then lifting as shown Top Rear Cover s5500 077 Upper Rear Cover ...

Page 417: ...8 5 PL1 1 8 3 Remove the two screws securing the Top Cover 4 Remove the Top Rear Cover by first lifting the right edge while sliding the cover to the right then pulling the cover forward and left 5 Disconnect the Front Panel connector from the Top Cover Replacement Note Make sure the spur and tab on the rear side of the cover engage the frame Top Cover Connector s5500 078 ...

Page 418: ... 4 Lower the Front Door perpendicular to the printer and slide the Front Door to the right to release the lower right holder from the boss on the right of the printer 5 With the lower right holder released hold the cover at a slight angle to the printer and slide it to the left to release the lower left holder from the boss Front Cover s5500 079 A B ...

Page 419: ...Door A 5 Remove the Drum Cartridge 6 Remove the three screws securing the Inner Main Cover to the frame 7 Remove the Inner Main Cover by tilting the cover outwards and lifting to release the hooks Replacement Note When installing put the four lower hooks on the Inner Main Cover inside the rolled edge of the printer frame Inner Main Cover s5500 081 Hook Hook ...

Page 420: ...age 8 8 3 Remove the Front Left Cover page 8 5 4 Remove the Inner Main Cover page 8 9 PL1 1 5 5 Remove the screw securing the Interlock Switch Bracket 6 Remove the switch together with the bracket 7 Disconnect the connector from the switch 8 Release the switch by pressing the hooks 9 Remove the switch s5500 082 Bracket Switch ...

Page 421: ...uring the Upper Right Cover 2 Lower the Upper Right Cover to release the upper rib 3 Remove the Upper Right Cover Replacement Note Be sure to secure the lower rib on the Upper Right Cover to the upper part of the Lower Right Cover s5500 083 Upper Right Cover Lower Right Cover ...

Page 422: ...Service Manual Rear Panel Cover PL1 2 4 1 Open the Rear Panel Cover 2 Remove the lower boss securing the Rear Panel Cover to the printer It is easier to remove by pushing down the retainer of the boss Rear Panel Cover s5500 084 ...

Page 423: ...3 Lower Right Cover 1 Remove the Upper Right Cover page 8 11 2 Pull out Trays 2 and 3 at least partially PL1 2 2 3 Remove the Lower Right Cover by lifting upwards to release the hooks then outward s5500 Lower Right Cover ...

Page 424: ...500 Printer Service Manual I P Board Cover PL8 1 20 1 Loosen the two captive thumbscrews securing the I P Board Cover 2 Remove the I P Board Cover by moving it in the direction of the arrow s5500 087 I P Board Cover ...

Page 425: ... Rear Cover 1 Remove the I P Board Cover page 8 14 PL1 2 5 2 Remove the two screws securing the Upper Rear Cover to the printer 3 Remove the Upper Rear Cover by moving it in the direction of the arrow s5500 088 Upper Rear Cover ...

Page 426: ...Rear Cover PL3 1 14 1 Remove the one screw securing the Tray 1 MPT Rear Cover to the frame Lower Rear Cover 1 Remove the I P Board Cover page 8 14 2 Remove the Upper Rear Cover page 8 15 PL1 2 6 s5500 089 Tray 1 MPT Cover Lower Rear Cover Rear s5500 627 ...

Page 427: ...twards slightly then lifting the cover up and out Replacement Note Attach the four lower hooks on the Lower Rear Cover to the bracket on the printer Option Interface Cover PL1 2 7 1 Remove the Option Interface Cover from the Lower Rear Cover by moving the Option Interface Cover in the direction of the arrow Option Interface Cover s5500 090 ...

Page 428: ...8 18 Phaser 5500 Printer Service Manual Exit 1 Top Cover PL6 2 22 1 Remove the Exit 1 Top Cover by moving it in the direction of the arrow Exit 1 Top Cover s5500 091 ...

Page 429: ...e Tray 2 or Tray 3 Paper Size switches Note To remove the Tray 2 switch remove the Engine Logic Board page 8 89 and loosen the Engine Logic Board Bracket 1 Remove the I P Board Cover page 8 14 2 Remove the Upper Rear Cover page 8 15 3 Remove the Lower Rear Cover page 8 16 PL2 1 4 4 Remove the three screws securing the AC Accessory Panel AC Accessory Panel Paper Size Switch Switch Bracket s5500 092...

Page 430: ...er page 8 16 2 Remove the Tray 1 MPT Feeder page 8 32 3 Remove Door A page 8 46 4 Remove the Take Away Bracket page 8 40 5 Remove Tray 2 6 Release the harness from the two clamps on the frame 7 Disconnect the connector 8 Remove the two screws securing the Feeder to the frame 9 Remove the Feeder by moving it in the direction of the arrow Replacement Note When installing the Feeder fit the two bosse...

Page 431: ...e both ends on the Feed Out Chute securing it to the frame Release the right side first and remove the chute 8 Remove the two screws securing the Take Away Chute to the frame Caution The Take Away Chute is easily damaged if the latches located on the backside of the chute are not released before attempting to remove the chute from the frame Release these latches before attempting to remove the Tak...

Page 432: ... 5500 Printer Service Manual 9 Reach in and release the latch at the center of the Take Away Chute from behind and remove the chute Bearing Sleeve Bearing Take Away Roller Gear 18T E Ring Take Away Chute s5500 096 ...

Page 433: ... in the direction of the arrow Replacement Note When installing the Feeder fit the two bosses on the frame into the holes on the Feeder When installing the Take Away Chute fit the bosses on the Take Away Chute into the holes on the frame Feed Lift Motor 1 Remove the Tray 1 MPT Rear Cover page 8 16 2 Remove the Tray 1 MPT Feeder page 8 32 3 Remove Door A page 8 46 4 Remove the Take Away Bracket pag...

Page 434: ... Lift Motor 7 Remove the two Phillips screws securing the Feed Lift Motor to the Feeder 8 Remove the Feed Lift Motor Tray 2 and 3 No Paper Sensor 1 Remove the Tray 1 MPT Rear Cover page 8 16 2 Remove the Tray 1 MPT Feeder page 8 32 3 Remove Door A page 8 46 4 Remove the Take Away Bracket page 8 40 Feeder Assembly Feed Lift Up Motor Connector s5500 104 ...

Page 435: ...e as shown in the figure 7 Disconnect the connector from the No Paper Sensor 8 Remove the No Paper Sensor Tray 2 and 3 Level Sensor Actuator 1 Remove the Tray 1 MPT Rear Cover page 8 16 2 Remove the Tray 1 MPT Feeder page 8 32 3 Remove Door A page 8 46 4 Remove the Take Away Bracket page 8 40 No Paper Sensor Upper Frame Harness Feeder s5500 109 Hooks ...

Page 436: ...er page 8 21 PL2 3 13 6 Release the two bosses on the Actuator securing the Actuator to the Upper Frame 7 Remove the Actuator Note As an alternate procedure remove Trays 2 and 3 then reach in and release the actuator bosses from the feeder assembly Feeder Actuator Bosses s5500 108 Upper Frame ...

Page 437: ...the Take Away Bracket page 8 40 5 Remove the Tray 2 Feeder page 8 20 or Tray 3 Feeder page 8 21 6 Remove the Level Sensor Actuator page 8 25 PL2 3 14 7 Release the hooks securing the Level Sensor to the Upper Frame as shown in the figure 8 Disconnect the connector from the Level Sensor and remove the sensor Level Sensor Harness Hook s5500 110 Feeder Upper Frame Hooks ...

Page 438: ...e Tray 1 MPT Feeder page 8 32 3 Remove Door A page 8 46 4 Remove the Take Away Bracket page 8 40 5 Remove the Tray 2 Feeder page 8 20 or Tray 3 Feeder page 8 21 PL2 3 15 6 Remove the Pre Feed Sensor from the Front Chute as shown in the figure 7 Disconnect the connector from the Pre Feed Sensor Feeder Pre Feed Sensor s5500 111 ...

Page 439: ...r 1 Remove the tray PL2 3 20 2 Move the Front Chute in the direction of the arrow 3 Release the hook securing the Feed Roller to the Shaft and remove the Feed Roller s5500 114 Front Chute Feed Roll Shaft Oneway Clutch Oneway Gear 22T ...

Page 440: ...nter Service Manual Retard Roller 1 Remove the tray PL2 3 28 2 Release the hook securing the Retard Roller to the Shaft as shown in the figure 3 Remove the Retard Roller Retard Roller s5500 117 Support Assembly Front Chute ...

Page 441: ...Remove the tray PL2 3 32 2 Move the Front Chute in the direction of the arrow 3 Release the hook securing the Nudger Roller to the Shaft as shown in the figure 4 Remove the Nudger Roller Nudger Roller Support Assembly Front Chute s5500 120 ...

Page 442: ...connect the connector from the printer 3 Release the harness from the clamp 4 Remove the two screws securing the Tray 1 MPT Feeder to the frame 5 Remove the Tray 1 Feeder Replacement Note Place the harness along the slot on the left of the Feeder to avoid pinching the harness between the Feeder and the Frame Tray 1 Feeder s5500 124 ...

Page 443: ... upper frame to the printer 4 Remove the upper frame by moving it in the direction of the arrow 5 Pull the right side of the Actuator toward you then pull it out of the hole in the upper frame Replacement Note When installing the actuator into the Upper Frame press on both sides of the actuator pivot point to avoid breaking the part Actuator s5500 125 Upper Frame Hook Upper Frame Slot ...

Page 444: ...e 8 32 PL3 1 4 3 Release the two hooks securing the Upper Frame to the Tray 1 Feeder and move the Upper Frame in the direction of the arrow to remove 4 Disconnect the connector from the sensor 5 Release the hooks securing the sensor to the Tray 1 upper frame 6 Remove the sensor Upper Frame Connector Hook Upper Frame Slot No Paper Sensor s5500 126 ...

Page 445: ...ge 8 16 2 Remove the Tray 1 MPT Feeder page 8 32 PL3 2 6 3 Remove the Spring from the Gear Bracket and Pick Up Gear Replacement Note Slide the Pick Up Gear until it locks on the Stopper Lever Gear Bracket s5500 129 Pick Up Gear Pick Up Gear Spring Pick Up Shaft Hook Tray 1 Feeder ...

Page 446: ...olenoid to the Gear Bracket 7 Disconnect the connector from the Pick Up Solenoid 8 Lower the Gear Lever in the direction of the arrow and remove the Pick Up Solenoid Cam Gear Spring 1 Remove the Tray 1 MPT Rear Cover page 8 16 2 Remove the Tray 1 MPT Feeder page 8 32 3 Remove the Feed Roller page 8 38 4 Remove the Spring from the Gear Bracket Leave the other end of the Spring connected to the Pick...

Page 447: ...e the Pick Up Gear together with the Spring Cam Gear and Stopper Lever 7 Remove the Cam Gear Spring securing the Pick Up Gear to the Cam Gear PL3 2 16 Cam Gear Cam Gear Bearing 8 Bearing 8 Pick Up Shaft Pick Up Cam E Ring Stopper Lever Gear Bracket s5500 132 Pick Up Gear Hook Spring E Ring Lower Frame ...

Page 448: ...e Note the orientation of the roller and remove the Pinch Chute 4 While releasing the two hooks of the Roller Core left and right securing the Feed Roller to the Pick Up Shaft as shown in the figure and slide the Feed Roller outward 5 Remove the Feed Roller from the Pick Up Shaft by moving it in the direction of the arrow to the front Pinch Chute Feed Roller Roller Core Roller Core Pick Up Shaft s...

Page 449: ...ion The Retard pad springs are easily lost Grip each spring firmly when removing them The Retard Pad is held down by the force of the Feed Roller 4 Remove two Pad Springs under the Retard Pad 5 Remove the Retard Pad and the Retard Shaft by moving it in the direction of the arrow from the backside Retard Shaft Retard Shaft Retard Pad Pad Spring Lower Frame s5500 134 ...

Page 450: ...ay 1 MPT Feeder page 8 32 3 Remove Door A page 8 46 4 Open Door B PL4 1 1 5 Remove the two screws securing the Take Away Bracket to the printer 6 Disconnect the harness and release the harness from the clamp on the Take Away Bracket 7 Disconnect the Door B Interlock Switch from the harness and remove the Take Away Bracket Take Away Bracket s5500 139 Door B ...

Page 451: ...tch to the Take Away Bracket 3 Disconnect the connector from the switch 4 Remove the Door B Interlock Switch Take Away Roller Assembly 1 Remove the Tray 1 MPT Rear Cover page 8 16 2 Remove the Tray 1 MPT Feeder page 8 32 3 Remove Door A page 8 46 s5500 140 Door B Take Away Bracket Door B Interlock Switch ...

Page 452: ...o screws securing the Take Away Chute to the frame 6 Reach in and release the latch at the center of the Take Away Chute from behind and remove the chute 7 Remove the K clip on the right side securing the Take Away Roller to the frame Caution The Take Away Bearing and Gear 18T are not captive on the shaft Use care to capture these parts as you remove the shaft 8 Remove the Take Away Roller by movi...

Page 453: ...FRU Disassembly 8 43 Door B 1 Open Door B PL4 1 10 2 Remove the two screws securing the Lower Chute to the frame 3 Remove Door B together with the Lower Chute Door B Lower Chute s5500 141 ...

Page 454: ...5500 Printer Service Manual Transfer Roller 1 Open Door A PL4 2 1 2 Pinch the hooks at each end of the Transfer Roller and lift to remove the Transfer Roller from the chute Hook Hook Left s5500 598 Transfer Roller ...

Page 455: ...per Rear Cover page 8 15 3 Remove the single screw securing the Door A Interlock Switch to the frame 4 Disconnect the switch from the harness and remove the switch and bracket from the Printer 5 Remove the switch from the bracket by compressing the hooks Bracket Door A Interlock Switch Rear s5500 623 ...

Page 456: ...er Service Manual Door A 1 Open Door A PL4 2 8 2 Remove the screw securing the Stopper to the Door 3 Remove Door A by moving it in the direction of the arrow Registration Roller 1 Remove the Door A page 8 46 Door A s5500 144 ...

Page 457: ...FRU Disassembly 8 47 2 Release the two hooks one on each side securing the chute to Door A as shown 3 Remove the Transfer Roller page 8 44 Hooks s5500 145 L H Chute Door A ...

Page 458: ...inch Out Bearings on the left and right securing the Registration Rollers to the Chute as shown in the figure PL4 3 3 5 Move the Registration Rollers in the direction of the arrow to remove Registration Pinch Roller Bearing Hooks s5500 146 Transfer Roller L H Chute Door A ...

Page 459: ...er page 8 32 3 Remove Door A page 8 46 PL4 5 1 4 Release the bosses on each end of the Feed Out Chute starting with the right end and remove the Feed Out Chute Feed Out Chute Boss Pinch Roller Boss Registration Transport Assembly Chute R Connector Connector Clamp s5500 147 Left View Pinch Roller Registration Transport Assembly ...

Page 460: ...om the notch in the frame while pushing the Registration Transport Assembly to the left and lifting the center upward to release the retaining tab from the frame Extract the Registration Transport Assembly from the frame by moving it in the direction of the arrow Use care to avoid damage to the wiring connected on the back Note It could require significant force to flex the Registration Transport ...

Page 461: ...move the Registration Transport Assembly page 8 49 PL4 5 2 5 Remove the E ring securing the Registration Clutch to the Registration Roller 6 Remove the Registration Clutch together with the harness Replacement Note Route the harness through the hole as shown Avoid pinching the harness Registration Clutch Registration Transport Assembly s5500 148 E Ring Boss ...

Page 462: ...ve the Tray 1 MPT Feeder page 8 32 3 Remove Door A page 8 46 4 Remove the Registration Transport Assembly page 8 49 PL4 5 7 5 Release the three hooks securing the sensor to the Registration Transport Assembly and remove Registration Transport Assembly Registration Sensor Registration Sensor Hook Hooks s5500 150 ...

Page 463: ...ake Away Clutch Bracket to the frame and Motor Assembly and remove the bracket 4 Disconnect the Take Away Clutch connector from the harness 5 Remove the E clip securing the Take Away Clutch and remove the Clutch Replacement Note Make sure the notch in the clutch fits over the protrusion Take Away Bracket Take Away Clutch E Ring Protrusion Notch Rear s5500 599 ...

Page 464: ... Open Door B PL4 5 18 Caution The Take Away Chute is easily damaged if the latches located on the backside of the chute are not released before attempting to remove the chute from the frame Release these latches before attempting to remove the Take Away Chute Take Away Chute Take Away Chute Feed Out Sensor 3 Hook s5500 152 ...

Page 465: ...ase the latch at the center of the Take Away Chute from behind and remove the chute 7 Disconnect the connector from the Feed Out Sensor 8 Release the hook securing the sensor to the Take Away Chute and remove Replacement Note When installing fit the bosses on the Take Away Chute into the holes on the frame ...

Page 466: ...erographics Drum Cartridge Fan Intake Duct 1 Remove the Top Cover page 8 7 2 Disconnect the harness from the junction connector on the Intake Duct PL5 1 117 Front Intake Duct Hooks Holes Junction Connector Connector Connector s5500 624 Clamps ...

Page 467: ...olding the Intke Duct to the Toner Dispense Assembly 4 Move the Intake Duct in the direction of the arrow while lifting the left side Front Toner Dispense Assembly s5500 625 Intake Duct Hook Hook Front View Toner Dispense Assembly Intake Duct ...

Page 468: ... 7 2 Remove the Drum Cartridge Fan Intake Duct page 8 56 3 Disconnect the Drum Cartridge Fan from the junction connector PL5 1 18 4 Release the two hooks holding the fan to the Intake Duct and remove the fan Drum Cartridge Fan s5500 626 Hooks Junction Connector Intake Duct Front Connector ...

Page 469: ...connect the Fan connector from the Motor Assembly 4 Release the hooks left and right securing the Fan to the duct as shown and remove the Fan Replacement Note Install the Fan with the label facing outward Also route the Fan harness in the slot as shown in the figure CN102 CN102 Label Hooks Fuser Fan Motor Assembly s5500 163 ...

Page 470: ...e the Top Cover page 8 7 3 Remove the Drum Cartridge 4 Remove the Toner Cartridge 5 Remove the Front Door page 8 8 6 Remove the Inner Main Cover page 8 9 7 Remove the HVPS page 8 86 8 Remove the Drum Cartridge Fan Intake Duct page 8 56 9 Remove the Toner Dispense Assembly page 8 71 10 Remove the Lower Rear Cover page 8 16 PL5 1 4 11 Disconnect the two connectors P403 and P404 from the Engine Logic...

Page 471: ... Remove the Registration Transport Assembly page 8 49 13 Remove the two screws securing the Laser C to the frame 14 Release the harness from the clamp on the Laser C Laser C Clamps Connector Toner Dispense Assembly s5500 154 ...

Page 472: ... Disconnect the connector from the Laser C 16 Remove the Laser C by moving it in the direction of the arrow 17 Remove the four screws securing the SUB Guide Assembly to the frame Screws Sub Guide Assembly Connector Junction Connector s5500 155 ...

Page 473: ...ssing the Drum Motor gear located on the rear side of the Motor Assembly lift the left side of the SUB Guide Assembly upward 21 Release the harness from the clamp on the rear side of the SUB Guide Assembly 22 While pressing the Drum Motor gear located on the rear side of Motor Assembly lower the left side left of the SUB Guide Assembly Hook Hook Contact Cover Sub Guide Assembly Drum Motor Gear s55...

Page 474: ... with the Switch Plate Environmental Sensor PWB 1 Remove the Front Left Cover page 8 5 2 Remove the Top Cover page 8 7 3 Remove the Drum Cartridge 4 Remove the Toner Cartridge 5 Remove the Front Door page 8 8 6 Remove the Inner Main Cover page 8 9 7 Remove the HVPS page 8 86 8 Remove the Drum Cartridge Fan Intake Duct page 8 56 9 Remove the Toner Dispense Assembly page 8 71 Drum Cartridge Detect S...

Page 475: ...emove the Lower Rear Cover page 8 16 PL5 1 5 11 Disconnect the two connectors P403 and P404 from the Engine Logic Board 12 Release the harness from the clamp on the printer 13 Open Door A Engine Logic Board s5500 153 P403 P404 ...

Page 476: ... Phaser 5500 Printer Service Manual 14 Remove the Registration Trans Assembly page 8 49 15 Remove the two screws securing the Laser C to the frame Laser C Clamps Connector Toner Dispense Assembly s5500 154 ...

Page 477: ...harness from the clamp on the Laser C 17 Remove the Laser C by moving it in the direction of the arrow 18 Remove the four screws securing the SUB Guide Assembly to the frame Screws Sub Guide Assembly Connector Junction Connector s5500 155 ...

Page 478: ... 19 Slide the SUB Guide Assembly toward the left side and disconnect the connector from the Front Harness A 20 Remove the two hooks securing the Contact Cover to the frame Hook Hook Contact Cover Sub Guide Assembly Drum Motor Gear s5500 156 ...

Page 479: ...lift the left side of the SUB Guide Assembly upward 22 Disconnect the connector from the Environmental Sensor PWB 23 Remove the screw securing the Environmental Sensor PWB to the SUB Guide Assembly 24 Remove the Environmental Sensor PWB Humidity And Temperature Sensor Sub Guide Assembly Connector s5500 159 ...

Page 480: ...idge CRUM PWB 1 Remove the Top Cover page 8 7 PL5 1 8 2 Disconnect the connector from the Drum Cartridge CRUM PWB 3 Remove the Drum Cartridge CRUM PWB by moving it in the direction of the arrow Drum Cartridge CRUM PWB Toner Dispense Assembly s5500 158 ...

Page 481: ... PWB in the direction of the arrow to remove Toner Dispense Assembly 1 Remove the Front Left Cover page 8 5 2 Remove the Top Cover page 8 7 3 Remove the Drum Cartridge 4 Remove the Toner Cartridge 5 Remove the Drum Cartridge Fan Intake Duct page 8 56 6 Remove the Front Door page 8 8 7 Remove the Duplex Unit if present 8 Remove Door A page 8 46 s5500 589 Toner Cartridge CRUM PWB ...

Page 482: ...from the clamps on the left side of the Toner Dispense Assembly 11 Disconnect the harness Toner Cartridge CRUM PWB on the right side 12 Remove the two screws securing the Toner Dispense Assembly to the frame s5500 161 Toner Dispense Assembly Toner Dispense Motor Shaft Screw Toner Dispense Assembly Harness Clamps ...

Page 483: ...Dispense Assembly to the Toner Dispense Motor Also fit the shaft into the hole on the Toner Dispense Motor Toner Dispense Motor 1 Remove the Front Left Cover page 8 5 2 Remove the Top Cover page 8 7 3 Remove the Drum Cartridge 4 Remove the Toner Cartridge 5 Remove the Front Door page 8 8 6 Remove the Inner Main Cover page 8 9 7 Remove the Drum Cartridge Fan Intake Duct s5500 594 Toner Dispense Ass...

Page 484: ...m the Toner Dispense Motor 10 Remove the four screws securing the Toner Dispense Motor to the frame and remove Laser Assembly 1 Remove the Top Cover page 8 7 2 Remove the Front Door page 8 8 3 Remove the Drum Cartridge 4 Remove the Toner Cartridge 5 Remove the Inner Main Cover page 8 9 Connector s5500 162 Toner Dispense Motor ...

Page 485: ...ge 8 71 PL5 1 14 7 Disconnect the three connectors from the Laser Assembly 8 Disconnect the connector from the junction connector 9 Remove the four screws securing the Laser Assembly to the frame 10 Lift the Laser Assembly from the frame Laser Assembly s5500 164 ...

Page 486: ...0 Printer Service Manual Fuser and Exit 1 Fuser Assembly 1 Open Door A PL6 1 7 2 Loosen the two knobs securing the Fuser to the frame 3 Pull the Fuser toward you by holding the two handles Fuser Handle Knob s5500 165 ...

Page 487: ...Door A 2 Remove the Fuser page 8 76 PL6 1 4 3 Remove the screw securing the bracket to the frame 4 Disconnect the connector from the sensor 5 Release the three hooks securing the sensor to the bracket Fuser Exit Sensor Hook Sensor Bracket s5500 166 ...

Page 488: ...page 8 6 3 Open Door A 4 Remove the Exit 1 Top Cover page 8 18 5 Open the Front Door 6 Remove the Front Left Cover page 8 5 PL6 2 1 7 Remove the two screws securing the Exit Bracket to the frame 8 Remove the Exit bracket Replacement Note Make sure the Stack Full Actuator rotates freely s5500 167 Exit Bracket Door A Upper Rear Cover ...

Page 489: ... the connector from the Offset Motor 11 Disconnect the two connectors from the two sensors 12 Remove the two screws securing the Exit Transport Assembly to the frame 13 Remove the Exit Transport Assembly by lifting upward s5500 168 Exit Transport Assembly Harness Connectors ...

Page 490: ...4 Remove the Exit 1 Top Cover page 8 18 5 Open the Front Door 6 Remove the Front Left Cover page 8 5 7 Remove the Exit Transport Assembly page 8 78 PL6 2 3 8 Disconnect the connector from the Offset Motor 9 Remove the two standard Phillips head screws securing the Offset Motor to the Exit Connector Offset Motor Clamps Exit Transport Assembly s5500 169 ...

Page 491: ...Front Left Cover page 8 5 7 Remove the Exit Transport Assembly page 8 78 PL6 2 5 8 Remove the Exit 1 Offset Motor 9 Remove the two screws securing the sensor bracket to the Exit Transport Assembly 10 Release the three hooks securing the Offset Home Position Sensor to the sensor bracket 11 Remove the Offset Home Position Sensor Offset Home Position Sensor Hooks Hook Sensor Bracket Exit Transport As...

Page 492: ... 8 18 5 Open the Front Door 6 Remove the Front Left Cover page 8 5 7 Remove the two screws securing the Exit Bracket to the frame 8 Remove the Exit Bracket PL6 2 5 9 Remove the two screws securing the bracket to the Exit Transport Assembly 10 Release the three hooks securing the sensor to the bracket 11 Remove the sensor Full Stack Sensor Exit Transport Assembly Hook Hooks s5500 171 ...

Page 493: ... P Board Cover page 8 14 2 Remove the Upper Rear Cover page 8 15 3 Remove the Exit 1 Top Cover page 8 18 PL7 1 5 4 Release the hook on the Exit Flange securing the belt to the Motor Assembly to remove the Exit Flange Rear s5500 176 Main Drive Belt Exit Flange ...

Page 494: ... Belt if the Motor is rotated slowly by hand Fit the flange to the D shaped shaft and install the flange until the hook locks Motor Assembly 1 Remove the I P Board Cover page 8 14 2 Remove the Upper Rear Cover page 8 15 3 Remove the Exit 1 Top Cover page 8 18 4 Open the Front Door 5 Pull out the Drum Cartridge Main Drive Belt s5500 177 ...

Page 495: ...ke Away Clutch bracket to the frame and to the Motor Assembly to remove the bracket 9 Remove the four screws securing the Motor Assembly to the frame Replacement Note Install the Motor Assembly by pushing the Gear on the upper part of the Motor in the direction of the arrow Motor Assembly Main Drive Belt Take Away Clutch Bracket CN101 CN102 Exit Flange s5500 178 ...

Page 496: ...age 8 8 5 Remove the Inner Main Cover page 8 9 PL8 1 1 6 Disconnect the connector from the HVPS 7 Release the harness from the clamps 8 Remove the two screws securing the HVPS to the frame 9 Carefully remove the HVPS by moving it in the direction of the arrow Replacement Note Insert the board into the guides on both sides Power Switch 1 Remove the Top Cover page 8 7 2 Open the Front Door HVPS Clam...

Page 497: ...move the bracket and switch to the left to remove from the frame 6 Disconnect the four connectors from the Power Switch 7 Release the hooks securing the Power Switch to the bracket as shown Replacement Note Fit the notch on the Power Switch to the boss on the frame Connector Hook Switch Bracket Power Switch Notch s5500 180 Hook ...

Page 498: ...ws securing the Lower Bracket to the frame 4 Release the locks of the supports holding the Exit PWB to the frame as shown in the figure 5 Remove the Exit PWB together with Lower Bracket from the frame 6 Remove the two screws securing the Exit PWB to the Lower Bracket 7 Remove the Exit PWB Replacement Note Fit the tips of the supports into the holes on the Exit PWB Exit PWB Connectors Lower Bracket...

Page 499: ...ve the Lower Rear Cover page 8 16 PL8 1 5 4 Mark and disconnect all connectors from the Engine Logic Board Connectors P J400 P J401 and TTM 2TM have a hook Disconnect by pushing the hook 5 Remove the six screws securing the Engine Logic Board to the frame 6 Remove the Engine Logic Board Engine Logic Board Connectors s5500 184 ...

Page 500: ... 7 PL1 1 6 2 Place the Top Cover up side down and remove the Front Panel Cover by releasing the four hooks securing the Cover to the Top Cover 3 Move the Front Panel Cover in the arrow direction right side to remove Front Panel Top Cover Bottom View s5500 185 Hooks Hooks Hooks Hooks ...

Page 501: ...5mm hex head screws securing the I P Board to the frame 5 Remove the I P Board and its carrier using the knob provided on the rear panel Replacement Note Tighten the back panel screw before tightening the board mounting screws If installing a new I P Board be sure to transfer NVRAM Configuration Card and if installed the Flash Memory and Hard Drive to the new board s5500 613 Image Processor Board ...

Page 502: ... P1 P2 P6 P521 and P526 have a hook Disconnect by pushing the hook 3 Remove the nine screws securing the LVPS to the frame 4 Remove the LVPS Replacement Note Fit the holes on the board to the two bosses on the frame P7 is unused Caution J11 Black wire J12 White wire are interchangeable Use the designators printed on the board to identify the proper connection s5500 186 LVPS ...

Page 503: ...emove the I P Board Cover page 8 14 2 Remove the Upper Rear Cover page 8 15 3 Remove the Lower Rear Cover page 8 16 4 Remove the Top Cover page 8 7 5 Remove the Upper Right Cover page 8 11 PL8 1 10 RIGHT VIEW s5500 187 Connectors Harness Clamps ...

Page 504: ...printer 9 Release the harness from the clamp 10 Remove the AC Accessory Panel GFI Breaker 1 Remove the I P Board Cover page 8 14 2 Remove the Upper Rear Cover page 8 15 3 Remove the Lower Rear Cover page 8 16 PL8 1 13 4 Remove the three screws securing the AC Accessory Panel to the frame 5 Disconnect the two connectors from the GFI Breaker 6 Remove the two screws securing the GFI Breaker to the AC...

Page 505: ...9 Chapter Parts Lists In this chapter Serial Number Format Using the Parts List Print Engine Parts Xerox Supplies and Accessories ...

Page 506: ...ound on a label located on the rear frame of the printer just inside Door A Open Door A to see it The nine digit serial number has the following format PPP SSSSSS PPP product code as shown in the following table SSSSSS Numeric serial number For example a printer having RET219638 as its Serial Number Is a 110 V Phaser 5500 Printer Has a 219638 serial number Product Code Product Configuration RET 55...

Page 507: ...llowed by a parenthetical statement in an illustrated parts list means the item is a parent assembly made up of the individual parts called out in parentheses The notation with X Y following a part name indicates an assembly that is made up of components X through Y For example 1 with 2 4 means part 1 consists of part 2 part 3 and part 4 An asterisk following a part name indicates the page contain...

Page 508: ...9 4 Phaser 5500 Printer Service Manual Print Engine Parts Parts List 1 1 Covers 1 2 Left Front s5500 190 2 1 14 14 12 10 4 5 8 11 6 7 3 15 13 S S S S S S S S 9 with 10 12 ...

Page 509: ...Cover 802E55361 4 BRACKET ILSW 5 SWITCH Front Door Interlock Switch 110E94770 6 CONSOLE PANEL Front Panel 802E64160 7 HARN ASSY CONPANEL 962K24041 8 COVER ASSY TOP PR Top Cover 802K74170 9 COVER ASSY FRONT with 10 12 Front Door 802K74080 10 MAGNET CATCH 11 COVER FRONT 12 STRIP Stopper 802E55351 13 COVER ASSY INNER MAIN Inner Main Cover 802K58180 14 FOOT FRONT 15 PLATE SER ...

Page 510: ...9 6 Phaser 5500 Printer Service Manual Parts List 1 2 Covers 2 2 Right Rear s5500 191 1 8 9 5 4 7 6 2 3 S S S S S ...

Page 511: ...GHT LOW Lower Right Cover 802E55241 3 COVER ESS RH 802E55260 4 COVER CAP ESS PR Rear Panel Cover 802E55381 5 COVER REAR UPR Upper Rear Cover 802E55271 6 COVER REAR LOW PR Lower Rear Cover 110V 802K74120 COVER REAR LOW PR Lower Rear Cover 220V 802K74130 7 COVER CAP MCU Option Interface Cover 802E55292 8 FOOT FRONT 9 FOOT REAR LEFT ...

Page 512: ...9 8 Phaser 5500 Printer Service Manual Parts List 2 1 Tray 1 2 and Feeder 1 2 s5500 192 Left Front 5 4 2 12 1 2 7 6 10 11 3 7 13 14 15 14 S S S S S 99 with 3 12 PL20 2 2 PL20 2 3 9 with 13 14 15 ...

Page 513: ... Size Switch 110K11680 5 BRACKET SW 6 CHUTE ASSY FEEDER 054K24091 7 FEEDER ASSY PL2 3 2 1 059K26934 9 CHUTE FEED OUT with 13 14 054K27550 10 LABEL TRAY NO1 included with 97 11 LABEL TRAY NO2 included with 97 12 LABEL INST M N 13 CHUTE FEED OUT 14 PAD ASSY LH LOW 15 COVER SENSOR 97 KIT LABEL with 10 11 PL20 2 2 PL20 2 3 604K23370 98 TRAY ENVELOPE as option not shown 604K24320 99 500 TRAY 109R00733 ...

Page 514: ...9 10 Phaser 5500 Printer Service Manual Parts List 2 2 Tray 2 2 A B D D B A C C 2 10 6 5 8 4 9 8 12 13 14 15 15 16 17 18 19 20 21 22 23 24 25 25 26 s5500 193 Front Left 11 1 with 2 26 E E S S S S S S ...

Page 515: ...BEL MAX 5 BOTTOM PAD 6 FRONT SIDE GUIDE 7 8 TRAY PAD 9 REAR SIDE GUIDE 10 BOTTOM PLATE 11 TRAY 12 SIDE GUIDE ACTUATOR 13 GUIDE ACTUATOR 14 SPRING 15 PINION GEAR 16 END GUIDE 17 SPRING 18 END GUIDE ACTUATOR 19 LINK 20 COUPLING GEAR 13T 21 GEAR 13T 60T 22 SECTOR GEAR 60T 23 BRACKET 24 LIFT UP SHAFT 25 STOPPER 26 SEAL 99 KIT LABEL ...

Page 516: ... B A C C 2 44 45 45 14 14 3 7 8 9 10 11 16 13 12 46 17 39 39 18 19 21 22 23 24 25 27 47 26 29 30 33 35 36 37 50 49 31 48 38 20 20 20 34 40 42 43 15 Pre Feed Sensor Level Sensor No Paper Sensor 5 6 4 s5500 194 Right Front 1 with 2 50 99 with 20x3Pcs E E S S S S S S S S S ...

Page 517: ...GEAR 13T 10 BEARING 11 SHAFT 12 FRONT CHUTE 13 ACTUATOR No Paper Sensor Actuator 120E22481 14 SENSOR No Paper or Level Sensor 930W00113 15 SENSOR Pre Feed Sensor 930W00211 16 WIRE HARNESS 17 GEAR 28T 21T 18 GEAR 29T 19 SPRING 809E51070 20 ROLLER ASSY Periodic replacement part per 300k prints included with 99 Feed Roller 21 ONEWAY CLUTCH 22 ONEWAY GEAR 22T 23 SHAFT 24 CHUTE 25 SPRING 26 FRICTION CL...

Page 518: ...ARING 39 WASHER 40 UPPER FRAME 41 42 HOLDER HARNESS CTR 43 HOLDER HARNESS REAR 44 HOLDER HARNESS UPPER 45 HOLDER HARNESS PS1 ALT CLAMP MINI SADDLE ALT 46 RAIL 47 SUPPORT RETARD 48 SUPPORT NUDGER 49 HOLDER 50 SPRING 99 KIT ROLLS with 20 x 3 pcs Periodic replacement per 300k print 604K20530 Parts List 2 3 Feeder 2 2 No Name Description Part Number ...

Page 519: ...Parts Lists 9 15 This page intentionally left blank ...

Page 520: ...haser 5500 Printer Service Manual Parts List 3 1 Tray 1 MPT Assembly s5500 195 Left Front 14 20 20 2 3 4 5 6 7 8 18 17 19 9 9 18 17 16 13 10 12 PL3 3 1 11 PL3 2 1 S S S S S 1 with 2 12 15 19 15 with 8 9 16 19 ...

Page 521: ...ENSOR PHOTO IN No Paper Sensor 930W00113 5 HARNESS ASSY MSI 6 SPRING MSI Pick Up Gear Spring 809E38160 7 BRKT ASSY GEAR 8 CHUTE PINCH 9 ROLL ASSY PINCH 10 CHUTE LOW 11 FRAME ASSY LOWER PL3 2 12 TRAY ASSY MSI PL3 3 13 COVER MSI FR Tray 1 MPT Front Cover 802K74140 14 COVER MSI RR Tray 1 MPT Rear Cover 802E55211 15 CHUTE ASSY PINCH 16 GUIDE PINCH 17 SPRING PINCH 18 SPACER SPRING PINCH 19 SHAFT PINCH ...

Page 522: ...haser 5500 Printer Service Manual Parts List 3 2 Tray 1 MPT Lower Frame Assembly s5500 196 Left Front 6 22 7 4 21 14 20 16 19 18 13 3 9 26 15 8 23 12 5 24 24 21 28 9 27 2 25 25 10 11 17 19 1 with 2 28 E E E S ...

Page 523: ...1 11 PLATE BOTTOM 12 PAD ASSY RETARD 019K07085 13 GUIDE PAPER MSI 14 ROLL ASSY DRIVE 15 SOLENOID PICK UP 121E92780 16 SHAFT ASSY PICK UP 17 CAM PICK UP 2 008E93831 18 CAM PICK UP FRONT 008E94270 19 ROLL CORE 20 ROLLER ASSY FEED Feed Roller with installation instructions 604K23380 21 BEARING SLEEVE 22 GEAR CAM 23 SPRING LEVER GE 24 SPRING PAD Retard Pad Spring 809E27650 25 SPRING N F 26 SPRING GEAR...

Page 524: ...9 20 Phaser 5500 Printer Service Manual Parts List 3 3 Tray 1 MPT Assembly s5500 197 Left Front 7 13 5 10 2 3 12 4 6 8 11 9 S S 1 with 2 13 ...

Page 525: ... Description Part Number 1 TRAY ASSY MSI with 2 13 050K49741 2 GEAR PINION 3 RACK FRONT 4 RACK REAR 5 LINK SENSOR 6 GUIDE SIDE FRONT 7 GUIDE SIDE REAR 8 TRAY MSI 9 TRAY EXT 10 SENSOR ASSY MSI Paper Size Sensor 11 COVER TRAY 12 SPRING SENSOR 13 HARNESS ASSY SIZE ...

Page 526: ...ter Service Manual Parts List 4 1 Transportation and Registration L H Lower Left Front s5500 198 2 3 4 6 7 5 8 12 17 9 19 21 22 18 20 21 11 19 13 15 14 1 with 2 3 E S S 10 with 11 22 Door B Interlock Switch 16 with 17 22 S ...

Page 527: ... 110E11580 4 RIVET 029E31600 5 CHUTE LOWER 6 BEARING TA 013E26990 7 GEAR 18T 007E79270 8 ROLLER ASSY TA Take Away Roller 059K26840 9 BEARING SLEEVE 413W77559 10 COVER ASSY LH LOW C with 11 22 Door B 802K58280 11 CHUTE LH LOW C 12 HANDLE LH LOW 13 SPRING COMP LH LOW 14 COVER LH LOW C 15 PLATE EARTH 16 BRKT ASSY LH LOW C with 17 22 17 BRKT LH LOW 18 ROLLER TA PINCH 19 BEARING OUT 20 BEARING IN 21 SP...

Page 528: ...9 24 Phaser 5500 Printer Service Manual Parts List 4 2 L H Upper Assembly s5500 199 Left Front 3 5 6 1 8 PL4 4 1 7 PL4 3 1 Door A Interlock Switch 2 4 E S S ...

Page 529: ...t Number 1 HSG ASSY BTR Periodic replacement part per 300k prints Transfer Roller 802K56094 2 COVER ASSY CONTACT 802K49240 3 LINK ASSY SHUTTER 012K94341 4 SWITCH Door A Interlock Switch 110E94770 5 BRACKET ILSW 6 STUD 826E08440 7 CHUTE ASSY LH PL4 3 1 8 COVER ASSY LH PL4 4 1 ...

Page 530: ...9 26 Phaser 5500 Printer Service Manual Parts List 4 3 L H Chute Assembly 2 2 4 3 5 5 5 5 6 6 6 6 8 s5500 200 7 7 7 Left Front 9 S 1 with 2 9 ...

Page 531: ...ts List 4 3 L H Chute Assembly No Name Description Part Number 1 CHUTE ASSY LH with 2 9 054K24051 2 BEARING PINCH OUT 3 ROLLER ASSY REGI P 4 CHUTE ASSY 5 SPRING COMP FL 6 GUIDE 7 SPRING COMP PINCH 8 PLATE TIE 9 PLATE EARTH ...

Page 532: ...9 28 Phaser 5500 Printer Service Manual Parts List 4 4 L H Cover Assembly 2 3 4 6 7 8 9 s5500 201 Left Front 10 S S S 1 with 2 10 ...

Page 533: ...Description Part Number 1 COVER ASSY L H with 2 10 Door A 802K58260 2 HANDLE L H 003E59832 3 ROD CRU SHUTTER 024E03250 4 CHUTE LHCOV 5 6 CHUTE ASSY DUP 054K24060 7 FRAME ASSY LH 8 COVER LH 9 SPRING COMP LH 809E42460 10 SUPPORT LH COVER Door A Stopper 849E13981 ...

Page 534: ...9 30 Phaser 5500 Printer Service Manual Parts List 4 5 Registration Left Front 16 20 15 14 13 11 12 2 3 6 5 4 7 8 7 6 9 18 19 10 s5500 202 E E E E E S S S S 1 with 2 8 17 with 9 18 19 ...

Page 535: ...EGI 4 ROLLER REGI IDLER 5 ROLLER ASSY REGI 6 BEARING REGI E 7 SNR ASSY REGI Registration Sensor 130K64270 8 PLATE EARTH F G 9 CHUTE TA 054E23910 10 CHUTE ASSY R 054K23940 11 BEARING 013E26090 12 SHAFT TA 13 GEAR 19T 007E79320 14 CLUTCH ASSY TA Take Away Clutch 121K31640 15 BRACKET TA 16 BEARING 013E26060 17 CHUTE TA with 9 18 19 Take Away Chute 18 SENSOR Feed Out Sensor 3 930W00211 19 HARNESS 20 P...

Page 536: ...9 32 Phaser 5500 Printer Service Manual Parts List 5 1 Laser CRU and Toner Dispense Right Front 9 8 10 15 16 17 18 7 11 8 13 12 14 6 1 98 3 4 5 2 s5500 203 S S S S S S S ...

Page 537: ...E ASSY SUB 032K96910 7 HSG ASSY LASER C 802K73190 8 PWBA CRUM CP1 Drum Cartridge Toner Cartridge CRUM 160K95830 9 HARN ASSY FRONT A 10 GUIDE ASSY CTG30 SUB Toner Dispense Assembly 032K96951 11 MOTOR ASSY DISP 30K Toner Dispense Motor 127K38040 12 DUCT FUSER 13 FAN FUSER 127K37880 14 ROS ASSY 12 Laser Assembly 062K13614 15 CRU DRUM CARTRIDGE 113R00670 16 TONER CARTRIDGE 113R00668 17 DUCT INTAKE 18 ...

Page 538: ...9 34 Phaser 5500 Printer Service Manual Parts List 6 1 Fuser and Exit 1 Unit s5500 204 1 8 PL6 2 3 4 99 6 5 7 Left Front E E S S ...

Page 539: ...SOR PHOTO Fuser Exit Sensor included with 99 5 SPRING ACTUATOR included with 99 6 BRKT SENSOR EXIT included with 99 7 FUSER ASSY 120V Periodic replacement part per 300k prints 126K18300 7 FUSER ASSY 220V Periodic replacement part per 300k prints 126K18310 8 TRANS ASSY EXIT PL6 2 99 KIT EXIT SENSOR with 3 6 Fuser Exit Sensor Kit 015K60900 ...

Page 540: ...6 Phaser 5500 Printer Service Manual Parts List 6 2 Exit 1 Right Front 22 25 26 27 28 3 33 2 4 18 17 16 5 5 15 19 24 23 29 32 34 35 31 7 6 8 9 14 20 21 13 10 11 12 10 s5500 205 1 with 2 21 34 35 E E S S 30 ...

Page 541: ...19T 8 CAP 9 GEAR EXIT 10 BEARING ROLL 11 CHUTE OCT1 12 SPRING PINCH EXIT 13 RLR PINCH EXIT 14 ROLL ASSTY OCT 15 CHUTE LOW 16 BRACKET SENSOR 17 GEAR OFFSET 18 SPRING GATE 809E42370 19 GATE EXIT 1 Exit Gate 050E19802 20 BEARING 21 PLATE EARTH 22 COVER TOP EXIT 1 802E55151 23 BRKT EXIT 2 24 ELIMINATOR EXIT 25 GUIDE TRAY EXIT 1 26 ACTUATOR FULLSTACK 120E22171 27 ACTUATOR 120E24670 28 WEIGHT ASSY PAPER...

Page 542: ...9 38 Phaser 5500 Printer Service Manual Parts List 7 1 Drive s5500 206 PL6 2 9 1 2 3 4 7 9 8 5 Right Rear 6 with 7 8 99 with 1 4 S ...

Page 543: ...umber 1 COLLAR 2 GEAR 21 21T MSI 3 GEAR 18T MSI 4 GEAR 28T TA 5 BELT SYNCHRONOUS BAN Main Drive Belt 423W13155 6 DRIVE ASSY 242 with 7 8number Motor Assembly 007K88596 7 MOTOR ASSY 242 8 PULLEY 25T 020E36600 9 FLANGE EXIT 005E17860 99 KIT GEAR with 1 2 3 4 604K23270 ...

Page 544: ...0 Phaser 5500 Printer Service Manual Parts List 8 1 Electrical Right Rear 1 2 3 6 24 4 9 8 11 14 13 15 12 16 7 5 20 21 27 28 s5500 207 10 with 11 16 S S S S S S S S S S S 22 23 S 25 32 33 30 31 34 26 35 29 ...

Page 545: ...ory Panel 11 SCREW 12 BRACKET CONN AC 13 BREAKER GFI INL GFI Breaker 908W01201 14 HARNESS ASSY F G E 15 HARN ASSY AC US EU 16 OUTLET MN 17 18 19 20 COVER ASSY ESS I P Board Cover 802K73070 21 PANEL ASSY CONN HCF 22 BRKT GUIDE PRX 23 CHASSIS ASSY ESS PRX 24 BRKT EXIT LOW 25 IMAGE PROCESSOR BOARD with NVRAM 650 4341 00 26 PLATE ASSY LVPS 27 PKG POWER CORD 110V 673K44480 28 PKG POWER CORD 220V 673K55...

Page 546: ...9 42 Phaser 5500 Printer Service Manual Parts List 8 2 Harness Right Rear 1 2 3 4 5 6 7 8 9 10 s5500 2 11 12 13 ...

Page 547: ... 1 HARN ASSY FEEDER C 2 HARN ASSY MSI A 3 HARN ASSY SIZE A 4 HARN ASSY ESS C 5 HARN ASSY ROS C 6 HARN ASSY EXIT C 7 HARN ASSY PH C 8 HARN ASSY FUSER AC C 962K18991 9 HARN ASSY LV PWR C 10 HARN ASSY INTLK A 11 HARN ASSY MAIN SW C 12 HARN ASSY DRIVE A 13 WIRE HARNESS CRUM B ...

Page 548: ...acking Instructions 075 0918 00 Envelope Tray instructions 075 0913 00 User Guide English only 001 1581 00 User Documentation CD ROM 063 3455 00 B to N Upgrade Instructions 075 0917 00 Tray 1 MPT Feed Roller Replacement 075 0908 00 Printer Installer and Utilities CD ROM 063 3456 00 Adding Memory Instructions 075 0915 00 Flash Memory DIMM Instructions 075 0916 00 Hard Drive Instructions 075 9914 00...

Page 549: ...er Trays 4 5 097S03218 2000 Sheet Feeder Tray 6 097S03219 Duplex Unit 097S03220 3 500 Sheet Stacker 097S03221 3 500 Sheet Finisher w 2 or 4 hole punch 097S03281 3 500 Sheet Finisher w 3 hole punch 097S03282 Envelope Tray replaces Tray 2 097S03286 Routine Maintenance Items Description Part Number Maintenance Kit 110 V 109R00731 Maintenance Kit 220 V 109R00732 Drum Cartridge 60K 113R00670 500 Sheet ...

Page 550: ...9 46 Phaser 5500 Printer Service Manual ...

Page 551: ...10 Chapter Wiring Diagrams In this chapter Print Engine Plug Jack Designators Print Engine Plug Jack Locator Diagrams Notations Used in Wiring Diagrams Print Engine Wiring Diagrams ...

Page 552: ...ts the LVPS and GFI Breaker 20 J 141 Connects the Fuser Main Lamp Heat Rod and Fuser Harness 21 J 141 Connects the Fuser Sub Lamp 1 and Fuser Harness 22 J 141 Connects the Fuser Sub Lamp 2 and Fuser Harness 50 F 229 Connects the GFI Breaker and LVPS 56 B 238 Connects the Power Switch and Power Switch Harness 57 B 239 Connects the Power Switch and Power Switch Harness 68 B 239 Connects the Power Sw...

Page 553: ... C 244 Connects the Front Door Interlock Switch and INTLK Harness 125 C 106 Connects the Fuser Exit Sensor and PH Harness 126 D 122 Connects the Drum Cartridge and CRUM Harness 127 F 108 Connects the Toner Cartridge and CRUM Harness 130 E 124 Connects the Laser Scanner and Laser Harness 131 B 139 Connects the Center STS and Fuser Outlet 132 B 139 Connects the 2nd STS and Fuser Outlet 133 B 139 Con...

Page 554: ... Logic Board and Registration Harness 404 E 212 Connects the Engine Logic Board and Xerographics Harness 405 G 212 Connects the Engine Logic Board and Interlink Harness 406 D 212 Connects the Engine Logic Board and Laser Harness 407 C 212 Connects the Engine Logic Board and Laser Harness 408 G 211 Connects the Engine Logic Board and Drive Harness 409 G 213 Connects the Engine Logic Board and Feede...

Page 555: ... J 123 Connects the I P Board and Engine Logic Board 600 A 139 Connects the Fuser and Fuser AC Harness 600 H 196 Connects the Fuser and Fuser Harness 601 C 183 Connects the Tray 2 Feeder Harness and Feeder Harness 602 C 184 Connects the Tray 3 Feeder Harness and Feeder Harness 605 I 199 Connects the Tray 1 MPT and Tray 1 MPT Harness 606 G 195 Connects the EXIT 2 Harness and EXIT Harness 607 G 199 ...

Page 556: ...location of primary connections within the printer Use these illustrations to locate connections called out in the troubleshooting procedures presented in Chapters 3 4 and 5 Drum and Toner Cartridge A 102 103 104 105 106 107 108 109 110 111 112 113 114 115 101 B C D E F G H I J K L s5500 209 127 221 125 500 610 216 ...

Page 557: ...Wiring Diagrams 10 7 Laser Assembly and Exit PWB A 117 118 119 120 121 122 123 124 125 126 127 128 129 130 116 B C D E F G H I J K L s5500 210 170 140 160 620 126 430 432 434 433 431 130 Exit PWB ...

Page 558: ... 8 Phaser 5500 Printer Service Manual Fuser and Exit 1 A 132 133 134 135 136 137 138 139 140 141 142 143 144 145 131 B C D E F G H I J K L s5500 211 600 131 132 133 117 118 20 21 22 Exit 1 Fuser Assembly ...

Page 559: ...Wiring Diagrams 10 9 Tray 1 MPT A 147 148 149 150 151 152 153 154 155 156 157 158 159 160 146 B C D E F G H I J K L s5500 212 108 609 107 205 ...

Page 560: ...10 10 Phaser 5500 Printer Service Manual Registration Transport Assembly A 162 163 164 165 166 167 168 169 170 171 172 173 174 175 161 B C D E F G H I J K L s5500 213 215 104 150 ...

Page 561: ...ay 2 3 Feeder Assemblies A 177 178 179 180 181 182 183 184 185 186 187 188 189 190 176 B C D E F G H I J K L s5500 214 Tray 2 100 Tray 3 102 Tray 2 101 Tray 3 103 Tray 2 133 Tray 3 134 Tray 2 201 601 106 602 608 105 Tray 3 202 ...

Page 562: ... 12 Phaser 5500 Printer Service Manual Print Engine Electrical A 192 193 194 195 196 197 198 199 200 201 202 203 204 205 191 B C D E F G H I J K L s5500 215 206 613 120 600 204 800 605 110 109 606 214 607 ...

Page 563: ...iagrams 10 13 Engine Logic Board A 207 208 209 210 211 212 213 214 215 216 217 218 219 220 206 B C D E F G H I J K L s5500 216 407 420 421 412 401 400 416 413 417 414 415 411 409 410 405 406 402 404 403 408 419 ...

Page 564: ...10 14 Phaser 5500 Printer Service Manual Image Processor Board A 117 118 119 120 121 122 123 124 125 126 127 128 129 130 116 B C D E F G H I J K L s5500 620 120 150 590 890 831 830 540 490 ...

Page 565: ...Wiring Diagrams 10 15 AC Accessory Panel A 222 223 224 225 226 227 228 229 230 231 232 233 234 235 221 B C D E F G H I J K L s5500 217 50 72 75 74 73 ...

Page 566: ...10 16 Phaser 5500 Printer Service Manual LVPS A 237 238 239 240 241 242 243 244 245 246 247 248 249 250 236 B C D E F G H I J K L s5500 218 69 311 525 68 12 11 1 121 2 56 7 3 521 57 526 Power Switch 6 ...

Page 567: ... using a conductive member such as a plate spring and indicates its signal name contents The arrow or on the line represents the direction of signal flow Represents a function and a logical value High H or Low L of a signal when the function is activated The voltage indicates a value when the signal is High The arrow indicates the direction of signal flow Represents a function and a logical value ...

Page 568: ...connection terminal with a plate spring on the printed circuit board The connector No is indicated inside the box Represents a connector directly connected to the printed circuit board The connector No is indicated inside the box Represents a part PL X Y Z indicates the item Z of the plate PL X Y described in Chapter 5 Parts List Represents a functional part within a part and indicates the name of...

Page 569: ...18 Offset Motor P J206 P J526 P J430 P J1 P J400 Drum Cartridge Detect Sw Power Switch P J2 Outlet MN P J5 Choke Coil P J404 P J405 P J120 Door A Interlock Switch P J121 P J410 P J607 P J600 P J6 P J401 P J525 Fuser Exit Sensor P J125 Tray 1 Paper Size P J107 Solenoid Pick Up P J205 Tray 1 No Paper Sensor P J108 P J406 SOS Sensor ROS Motor P J140 P J130 P J302 P J160 P J170 P J406 P J411 P J605 P ...

Page 570: ...eed Lift Up Motor P J201 P J601 P J409 Tray 2 Level Sensor P J100 Tray 2 No Paper Sensor P J101 Tray 2 Pre Feed Sensor P J133 Tray 2 Size Sensor P J109 Drum Cartridge CRUM P J126 Toner Cartridge CRUM P J127 Tray 3 Feed Lift Up Motor P J202 P J602 Tray 3 Level Sensor P J102 Tray 3 No Paper Sensor P J103 Tray 3 Pre Feed Sensor P J134 Tray 3 Size Sensor P J110 P J412 P J409 P J412 P J408 P J419 Main ...

Page 571: ... P J405 4 P J121 B1 A1 3 I L 24VDC P J404 1 3 LD 5VDC 3 3VDC Supply 1 2 6 7 3 8 P J521 5 1 2 6 7 4 9 P J300 12 Main Power On 3 3VDC 3 3VDC SG SG SG 5VDC 1 3 4 P J526 2 5 7 8 P J526 6 4 2 1 P J430 3 SG 5VDC 24VDC RTN 4 2 1 P J400 3 24VDC RTN SG 5VDC ON OFF 5VDC Supply 24VDC Supply 6 3 4 P J1 1 1 4 3 2 HOT NUT 5 P J2 1 2 P J5 1 Breaker GFI INL P J50 1 2 T11 1 T12 1 HOT NUT Interlock 24VDC From XERO ...

Page 572: ...C Sub Lamp2 On H 5VDC Relay On L 24VDC Zero Cross P J600 1 4 7 11 Heater Control P J410 7 6 P607 1 J607 6 2 5 P J600 2 3 Center STS Signal SG Center STS P131 2 1 5 3 4 5 2ND STS Signal P132 1 4 4 3 6 SG 2 3 5 2 8 Rear STS Signal P133 1 2 6 1 9 SG 2 2nd STS Rear STS P J125 3 2 1 P J410 8 9 10 5VDC Fuser Exit Paper Sensed L 5VDC SG 5VDC Fuser Exit Sensor s5500 221 ...

Page 573: ...utch J104 1 2 3 Registration Sensor Paper Sensed L 5VDC SG 5VDC P J410 16 24VDC 17 Takeaway Clutch ON L 24VDC P204 2 1 1 2 Take Away Clutch P J410 12 11 J106 1 2 SG Door B Open H 5VDC Door B Interlock Switch J410 15 14 15 J105 1 2 3 F O 3 Sensor Sensed L 5VDC SG 5VDC P608 1 J608 3 2 2 3 1 24VDC 5VDC 5VDC 24VDC s5500 222 Registration Sensor Feed out 3 Sensor ...

Page 574: ... BCR AC ON BCR DC Remote DEVE BIAS DC Remote DEVE BIAS DC ON Drum Cartridge Chute Assembly BTR Transfer Roller Drum BCR Mag Roll DTS ATC Sensor P J403 B5 B11 B12 B2 B1 P610 6 5 J610 2 3 4 4 3 5 1 7 ATC Sensor Signal 5VDC 5VDC SG LD 5VDC Interlock 24VDC P J403 B15 B7 B4 B6 Environmental Sensor P J150 1 2 3 4 5VDC Humidity Signal SG Temperature Signal 5VDC 5VDC P J420 1 2 P J216 2 1 Dispense Motor O...

Page 575: ...M C Clock Main Motor Ref Clock Main Motor On L 5VDC Drum Motor Fail H 5VDC Drum Motor Ref Clock Drum Motor On L 5VDC Drum Motor CW CCW M Main Motor M Drum Motor CN102 2 3 1 P J419 1 2 3 4 Fuser Fan J221 P221 P J417 2 3 1 Drum Cartridge Fan 5 Drum Cartridge CRUM PWB P126 6 5 1 2 4 3 3 4 2 5 1 6 Interlock 24VDC 5VDC 5VDC SG TX DATA MUTE CDET P J419 6 7 8 9 10 Toner Cartridge CRUM PWB P127 6 5 1 2 4 ...

Page 576: ... 3 2 1 P601 9 J601 7 8 8 7 9 P J409 A7 A8 A9 5VDC Tray 2 Level Up H 5VDC SG 5VDC Tray 2 No Paper Sensor P J101 3 2 1 P601 6 J601 10 5 11 4 12 P J409 A10 A11 A12 5VDC Tray 2 Paper Sensed L 5VDC SG 5VDC P J133 3 2 1 P601 3 J601 13 2 14 1 15 P J409 A13 A14 A15 5VDC Tray 2 Pre Feed Sensed L 5VDC SG 5VDC Tray 2 Pre Feed Sensor P J412 4 3 2 5VDC 1 P J109 1 2 3 Tray 2 Size Sensor 4 5VDC SG Tray 2 Size Sw...

Page 577: ...02 9 J602 7 8 8 7 9 P J409 B7 B8 B9 5VDC Tray 3 Level Up H 5VDC SG 5VDC Tray 3 No Paper Sensor P J103 3 2 1 P602 6 J602 10 5 11 4 12 P J409 B10 B11 B12 5VDC Tray 3 Paper Sensed L 5VDC SG 5VDC P J134 3 2 1 P602 3 J602 13 2 14 1 15 P J409 A13 A14 A15 5VDC Tray 3 Pre Feed Sensed L 5VDC SG 5VDC Tray 3 Pre Feed Sensor P J412 9 8 7 5VDC 6 P J110 1 2 3 Tray 3 Size Sensor 4 5VDC SG Tray 3 Size Switch Sign...

Page 578: ...205 2 1 1 2 Pick Up Solenoid J411 1 2 3 J107 1 2 3 Tray 1 MPT Paper Size Sensor Tray 1 MPT Size Sensor Signal SG 5VDC P605 8 J605 1 7 2 6 3 5VDC 24VDC P609 3 J609 1 2 2 1 3 P605 5 J605 4 4 5 P J108 3 2 1 P605 3 J605 6 2 7 1 8 P J411 6 7 8 5VDC Tray 1 MPT Paper Sensed L 5VDC SG 5VDC s5500 227 Tray 1 MPT No Paper Sensor ...

Page 579: ...S Signal ROS VREF Out Signal ROS Monitor Power Control2 On L 5VDC LD Enable On L 5VDC LD PWB Laser Assembly P J406 1 3 2 SOS Sensor I P Board P J890 2 1 4 3 P J160 2 1 P J170 2 1 VD01 VD01 VD02 VD02 P J406 10 11 12 13 P620 4 J620 1 3 2 P J130 5 4 3 1 2 3 1 4 M Scanner Motor 24VDC RTN Scanner Motor On L 5VDC Scanner Motor Clock 24VDC s5500 228 From Power ...

Page 580: ...SG 5VDC Full Stack Sensor P J118 3 2 1 P613 3 J613 4 2 5 1 6 P J432 4 5 6 5VDC Full Stack Sensed L 5VDC SG 5VDC P J432 7 8 9 P206 5 J206 1 4 2 3 3 2 4 1 5 10 11 Offset Motor B Offset Motor A Offset Motor B P J431 1 2 3 4 5 6 7 8 P J421 8 7 6 5 4 3 2 1 SG Engine To Exit Exit To Engine SG Fuser Exit Paper Sensed H 5VDC Full Stack Sensed L 5VDC Registration Clutch On L 5VDC Exit Gate Solenoid On H 5V...

Page 581: ... Board Engine Logic Board P J402 1 2 3 4 5 6 7 8 P J301 18 17 16 15 14 13 12 11 SG Command I P To Engine Status Engine To I P SG Command Ready 9 10 11 12 13 14 15 16 17 18 9 8 7 6 5 4 3 2 1 10 SG Status Ready SClock FWE TOP BD Start PRED Engine Ready I P Ready Ready s5500 230 ...

Page 582: ... J120 P J521 1 2 3 4 5 6 7 8 9 10 11 12 LVPS 3 3 V GND No Connection 5 V No Connection 3 3 V GND GND GND GND No Connection 3 3 V P J150 1 2 3 4 5 Front Panel GND TXD GND RXD GND Mode Select Port 6 7 8 9 10 THRTL 1 2 3 4 5 GND SW1 SW2 SW3 Reset 6 GND GND RST VCC VCC s5500 621 J601 ...

Page 583: ...8 9 10 11 12 Engine Logic Board RDY CPRDY PPRDY PRFD START BD TOP No Connection No Connection No Connection CCLK CBSY 13 14 15 16 17 18 SBSY STA CMD GND GND GND VX_RXD N C 3 3V VX_TXD GND P J890 P J890 P J160 P J170 J700 1 2 3 4 Laser Assembly Serial Debug Port VDO1 VDO1 VDO2 VDO2 s5500 622 ...

Page 584: ...10 34 Phaser 5500 Printer Service Manual ...

Page 585: ...A Appendix Reference Contents Phaser 5500 Laser Printer Menu Map Service Diagnostics Menu Map Service Diagnostics Tests and Utilities Mode Select Port ...

Page 586: ...Finisher Office Demonstration 2 Sided Demonstration Model Printer Name Print Server IP Address Serial Activation Date Serial Total Impressions Black Impressions Large Black Impressions Supplies Usage Page Toner Cartridge Life Drum Cartridge Life Staple Cartridge Life Fuser Life Reset Fuser Life Total Print Count TCP IP DHCP BOOTP AutoIP TCP IP Address TCP IP Network Mask TCP IP Gateway Port 9100 L...

Page 587: ...fo Image Smoothing Edge to Edge Printing Reset PostScript Setup Font Number Pitch Point Size Symbol Set Orientation Form Length Line Termination Edge to Edge Printing Reset PCL Setup Startup Page Power Saver Timeout Date and Time Metric Defaults Power Saver Reset Printer Controls Front Panel Language Front Panel Brightness Front Panel Contrast Accessible Front Panel Reset Front Panel Setup Paper S...

Page 588: ... Version Finisher Version Tray 6 Feeder Version Total Print Count Transfer Roller Count Drum Cartridge Count Drum Cartridge Cycles Tray 1 MPT Feed Count Tray 2 Feed Count Tray 3 Feed Fount Tray 4 Feed Count Tray 5 Feed Count Tray 6 Feed Count Test Print Starts the Test Print Print Pattern Print Quantity Input Tray Output Tray Duplex Staple Selection Pages Per Set Punch Selection Select Pattern Pri...

Page 589: ...x Assembly Motor Test Duplex Motor Exit 2 Assembly Motor Tests Offset Output Motor 2 Front Offset Output Motor 2 Rear Exit Output Motor 2 Forward Exit Output Motor 2 Reverse Exit 2 Fan Trays 4 5 Motor Tests Tray 4 Lift Motor Tray 4 Feed Motor Tray 5 Lift Motor Tray 5 Feed Motor Take Away Drive Motor Tray 6 Motor Tests Tray 6 Lift Motor Tray 6 Feed Motor Tray 6 Take Away Motor Slow Tray 6 Take Away...

Page 590: ... High Speed Forward Motor Low Speed Reverse Motor High Speed Reverse Stacker Motor Up Stacker Motor Down Printer Sensor Switch Tests Print Engine Sensor Switch Tests Tests the function of sensors switches by manually toggling each sensor switch Door A Interlock Switch Door B Interlock Switch Front Cover Interlock Switch Tray 1 MPT Size Sensor displays paper size for tray Tray 2 Size Sensor display...

Page 591: ...Feed Sensor Tray 6 Feed Out Sensor Tray 6 Interlock Switch Tray 6 Size Sensor A Tray 6 Size Sensor B Tray 6 Tray In Sensor Finisher Sensor Switch Tests Test the sensors and switches for the Finisher Stacker punch and stapler Door F Interlock Sensor Door G Interlock Switch Door H Interlock Switch Horizontal Transport Entrance Sensor Horizontal Transport Exit Sensor Transport Entrance Sensor Gate Se...

Page 592: ...noid Tray 4 5 Clutch Test Take Away Clutch Tray 6 Solenoid Tests Tray 6 Nudger Solenoid High Power Tray 6 Nudger Solenoid Low Power Finisher Solenoid Clutch Tests Buffer Gate Solenoid Path Out Buffer Gate Solenoid Path In Transport Gate Solenoid Upper Tray Transport Gate Solenoid Lower Tray Sub Paddle Solenoid Set Clamp Clutch IP NVRAM Access This menu lets you reset NVRAM locations PostScript NVR...

Page 593: ...Version Displays code version and release data stored in the Exit 2 Module Tray 4 5 Feeder Version Displays code version and release data for the 1000 Sheet Feeder Finisher Version Displays code version and release data stored in the Finisher Tray 6 Feeder Version Displays code version and release data for the 2000 Sheet Feeder Total Print Count Displays the number of prints made since the printer...

Page 594: ... these utilities to adjust image registration For convenience similar registration adjustment utilities have been grouped together in the following table However all 19 adjustments appear on the Service Diagnostics Menu Map on page A 4 Test Print Utilities Utility Action Requirement Print Pattern Print one of the stored Engine test pages Grid Chart Dark Dusting or Blank Start or Stop printing test...

Page 595: ...r instructions on using the Print Quality test print to evaluate image registration performance Printer NVRAM Registration Adjustment Utilities Utility Action Requirement Scan Direction All Trays Sets scan direction image registration on all trays for both simplex and duplex prints Scan Direction Tray 1 6 Sets scan direction image registration on the tray selected for both simplex and duplex print...

Page 596: ... at high speed Laser Scan Motor Runs the laser scan motor Press the Back button to halt the test Tray 2 Lift Motor Runs the Feed Lift motor in a clockwise direction Press the Back button to halt the test Tray 3 Lift Motor Runs the Feed Lift motor in a clockwise direction Press the Back button to halt the test Tray 2 Feed Motor Runs the Feed Lift motor in a counter clockwise direction for about 2 s...

Page 597: ...or in the forward direction for two seconds Exit Output Motor 2 Reverse Runs the Exit 2 Output Motor in reverse for two seconds Exit 2 Fan Runs the Exit 2 fan Tray 4 5 Motor Tests Test Action Requirement Tray 4 Lift Motor Runs the Feed Lift motor in the Lift direction for two seconds Tray 4 Feed Motor Runs the Feed Lift motor in the Feed direction for two seconds Tray 5 Lift Motor Runs the Feed Li...

Page 598: ...otor Slow CW Runs the Registration motor clockwise at slow speed Registration Motor CCW Runs the Registration motor counter clockwise Exit Motor Fast CW Runs the Exit motor at high speed in the clockwise direction Exit Motor Slow CW Runs the Exit motor at slow speed in the clockwise direction Exit Motor CCW Runs the Exit motor in the counter clockwise direction Punch Unit Motor Front Moves the Pun...

Page 599: ...in the forward direction Stapler Motor Reverse Runs the Staple Motor in reverse opening the clamp If the clamp is already open no movement occurs To close the clamp rotate the black gear on the Staple Head until the clamp is closed down position The clamp returns to the open position following the test To repeat the test re close the clamp Eject Clamp Motor Up Opens the Eject Clamp Eject Clamp Mot...

Page 600: ...removing all but three or four sheets of paper from the tray and reinserting it Tray 3 Level Sensor Reports Not Low in the resting position and Low when lifted Test the sensor by removing all but three or four sheets of paper from the tray and reinserting it Tray 2 Pre Feed Sensor Displays the status With or Without Paper Tray 3 Pre Feed Sensor Displays the status With or Without Paper Tray 3 Feed...

Page 601: ...r C Interlock Displays the status Open or Closed of the Door C Interlock Switch Tray 4 Size Sensor Displays the size indicated by the guide position Tray 5 Size Sensor Displays the size indicated by the guide position Tray 4 No Paper Sensor Reports Without Paper in the resting position and With Paper when lifted Test the sensor by removing all paper from the tray and reinserting it Another method ...

Page 602: ... With or Without Paper when actuated Tray 6 Sensor Switch Tests Test Action Requirement Door J Interlock Switch Displays Open or Closed when actuated Tray 6 Paper Size Sensor Displays the paper size indicated by the guide position Tray 6 No Paper Sensor Reports Without Paper in the resting position and With Paper when lifted Tray 6 Level Sensor Reports Up in the resting position and Down when lift...

Page 603: ...status With Paper or Without Paper when toggled Upper Tray Exit Sensor Displays the status With Paper or Without Paper Upper Tray Full Sensor Displays the sensor status Empty or Full Compiler Exit Sensor Displays the sensor status as With Paper or Without Paper Compiler Tray No Paper Sensor Displays the sensor state as With Paper or Without Paper Side Registration Sensor 1 Displays the sensor stat...

Page 604: ... Staple Sensor Displays the sensor state as Low or Not Low Staple Head Self Prime Sensor Displays the sensor state as ready or Not Ready Staple Head Home Sensor Displays the sensor status Home or Not Home when toggled Lower Tray No Paper Sensor Displays the sensor output as Blocked or Unblocked Lower Tray Upper Limit Sensor Display the sensor output as At upper limit or Not at upper limit Stacker ...

Page 605: ...on Exit 2 Solenoid Test Test Action Requirement Exit Gate Solenoid Energize the Exit Gate Solenoid This test runs with Door E open Tray 4 5 Clutch Test Test Action Requirement Take Away Clutch Energize the Take Away Clutch on the optional tray module Tray 6 Solenoid Clutch Tests Test Action Requirement Nudger High Power Energize the Nudger Solenoid at high power Nudger Low Power Energize the Nudge...

Page 606: ... Solenoid Activate the Sub Paddle Solenoid Set Clamp Clutch Energize the Finisher Set Clamp Clutch Controller NVRAM Utilities Utility Action Requirement Reset PostScript NVM Resets the PS NVRAM You are prompted to confirm your decision to perform a reset operation Factory Reset NVRAM Reset NVRAM to factory defaults This utility is password protected The password to access the reset functions is 43...

Page 607: ...e Engine Logic Board Replacement menu and press OK Data is transferred from the reserved location on the Image Processor to the replaced Engine Logic board During the process the front panel will display Restoring NVRAM once the routine is completed the front panel will display Restore Complete 3 Exit diagnostics Finisher Board Setup Menu This menu allows you to reset the Punch configuration of th...

Page 608: ... PostScript back channel information Service Mode inhibits printing of the Startup page and causes POST to treat all errors as Hard Faults See Power On Self Test POST on page 3 4 Service mode also switches the Serial Debug Port from PostScript back channel information to the printer s operating system console Disaster Recovery mode instructs the printer to load only its operating system bypassing ...

Page 609: ...n 3 248 Feed Out Sensor 6 2 14 motor tests A 13 Nudger Solenoid testing A 21 option part number 9 45 sensor locations 2 13 sensor tests A 18 tray empty 3 211 A abbreviations 3 14 AC Accessory Panel GFI Breaker part number 9 41 removal 8 94 operational description 2 38 plug jack locator 10 15 removal 8 93 AC power supply troubleshooting 4 7 AC power tests 4 8 adjustment adjustment utilities A 10 du...

Page 610: ...ber 9 33 removal 8 70 Toner Cartridge CRUM connector 10 3 part number 9 33 removal 8 71 customer debug mode A 24 customer mode A 24 D damaged prints 5 33 DC power supply testing 4 5 default character set 6 11 Detack Saw 2 16 Diagnostics See Service Diagnostics disaster recovery mode A 24 display 1 5 brightness 6 11 contrast 6 11 language 6 11 testing 4 4 Door A Interlock close Door A 3 237 locatio...

Page 611: ...Diode 2 21 Duplex Unit 1 7 Door D open 3 240 Duplex PWB failure 3 148 interconnect location 1 4 motor tests A 12 Duplex Unit cont operational description 2 10 option part number 9 45 paper path 2 10 registration adjustment 6 7 roller location 2 6 sensor tests A 16 set duplex printing default 6 10 type error 3 149 Wait Sensor 2 10 duplicate IP address 3 251 E EEPROM error 3 6 engine command error 3...

Page 612: ...ram 10 30 Exit 2 1 6 Door E open 3 242 Exit Gate Solenoid 2 10 testing A 21 Exit Motor 2 10 fan testing A 13 location 2 7 motor tests A 13 operational description 2 10 Exit 2 cont roller location 2 6 sensor tests A 17 Exit PWB 2 31 failure 3 152 location 2 33 operational description 2 36 part number 9 41 plug jack locator 10 7 power supply wiring 10 21 removal 8 88 Exit Sensor 2 12 wiring 10 22 F ...

Page 613: ...y 2 9 Transfer Gate 2 9 Transfer Gate Solenoid 2 9 Transport Motor 2 9 Finisher LVPS testing 4 6 firmware version information A 9 Front Door Interlock location 2 13 part number 9 5 printer front door is open 3 235 removal 8 10 wiring 10 21 Front Panel brightness 6 11 buttons 1 5 contrast 6 11 error messages 3 15 harness part number 9 5 language 6 11 LED indications 1 5 lockout 6 11 part number 9 5...

Page 614: ...2 36 part number 9 41 removal 8 86 wiring diagram 10 24 I I O ASIC error 3 6 IDE disk error 3 5 image adjustment adjustment utilities A 11 factory defaults A 11 process direction 6 6 registration 6 6 scan direction 6 6 image data wiring 10 29 image defects background contamination 5 40 black prints 5 19 blank prints 5 14 horizontal deletions 5 23 horizontal streaks 5 27 light prints 5 14 registrat...

Page 615: ... offset setup 6 10 K Keypad See Front Panel L Laser Assembly 2 3 components 2 19 failure 3 25 Laser Diode 2 21 laser diode assembly 2 19 operational description 2 18 Laser Assembly cont part number 9 33 plug jack locator 10 7 removal 8 74 Scanner Motor 2 20 wiring diagram 10 29 Laser Diode 2 21 LED blink patterns 3 6 color definitions 1 5 Front Panel start up 3 3 Health LED 3 3 Level Sensor 2 12 p...

Page 616: ...elect Port location 1 4 operational description A 24 wiring diagram 10 32 Motor Assembly Belt part number 9 39 removal 8 83 description 2 32 Drum Motor 2 4 gear kit 9 39 Motor Assembly cont Main Motor 2 4 part number 9 39 plug jack locator 10 12 removal 8 84 wiring diagram 10 25 N NetWare setup 6 10 network ethernet speed setting 6 10 IP setup 6 10 logging 4 2 option part number 9 41 reset 4 2 tro...

Page 617: ...ory error correction 4 15 soft faults 3 5 corrective actions 3 5 Start Page format 3 5 types 3 5 test descriptions 3 4 power saver setup 6 11 timeout 6 11 Power Switch location 2 33 part number 9 41 plug jack locator 10 16 removal 8 86 wiring diagram 10 21 Pre Feed Sensor 2 12 locations 2 14 part number 9 13 removal 8 28 Pressure Roller 2 21 print defects 5 3 damaged print 5 33 fusing 5 6 lead edg...

Page 618: ...23 image streaking 5 27 measurement 6 5 registration verification 5 8 proof print setup 6 12 Punch 2 9 configuration settings A 23 location 2 7 sensor tests A 19 testing A 14 waste box full 3 233 waste box missing 3 232 R RAM DIMM fault isolation 4 15 real time clock errors 3 5 registration adjustment parameters A 11 adjustment utilities A 10 duplex adjustment 6 7 factory defaults A 11 simplex adj...

Page 619: ... Feed Out 2 7 functions 2 12 interlocks 2 13 level sensing 2 15 Sensor cont microswitch 2 11 operational description 2 11 paper detection 2 15 paper size detection 2 14 photo receptive 2 11 photo reflective 2 11 testing A 15 thermistor 2 12 Tray 1 MPT sensors 2 26 types 2 11 Serial Debug Port location 1 4 operational description A 24 wiring diagram 10 33 serial number interpretation 9 2 location 9...

Page 620: ...5 supply voltage testing 4 8 T Take Away Chute part number 9 31 precautions 8 21 removal 8 55 Take Away Clutch part number 9 31 removal 8 53 testing A 20 wiring 10 23 Take Away Roller 2 7 part number 9 23 Temperature Sensor 2 12 removal 8 64 test prints 6 2 analyzing 5 2 print job setup A 10 Thermistor 2 12 timeout loading paper 6 10 power saver 6 11 Toner Cartridge 2 3 CRUM 3 14 connector 10 3 fa...

Page 621: ... 2 26 Drive Roller 2 26 Feed Roller 2 6 part number 9 19 removal 8 38 Feeder 2 26 part number 9 17 No Paper Sensor connector designator 10 3 location 2 26 part number 9 17 removal 8 34 testing A 15 Tray 1 MPT cont operation description 2 26 Paper Size Sensor 2 26 testing A 15 parts 9 16 Pick Up Gear Spring part number 9 17 removal 8 35 Pick up Solenoid 2 6 location 2 26 part number 9 19 removal 8 ...

Page 622: ...or 3 6 location 1 4 V version status A 9 voltage requirements 1 13 voltage tolerances 3 21 W Wait Sensor 2 10 testing A 16 wall outlet testing 4 8 warm up time 1 13 Windows printing problems 4 3 wiring diagram conventions 10 17 X xerographics component dimensions 5 37 Drum Cartridge 2 15 part number 9 33 wiring 10 24 Fuser 2 21 part number 9 35 removal 8 76 Laser Assembly 2 18 image data wiring 10...

Page 623: ...071 0873 00 A ...

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