Phaser 5500/5550 Service Documentation · How to Use this Documentation ... Laser Unit Failure - U3-3 Laser Power ... Exit Unit Failure - H3-n Offset Error

705P01216March 2008

Phaser 5500/5550 Service Documentation

https://service-repair-manual.com/pcf/pages/xerox/xerox-phaser-5500-book1-book2-service-manual.php


March 2008iPhaser® 5500/5550 Printer

IntroductionInitial Issue

IntroductionAbout this Manual ........................................................................................................... iiiOrganization.................................................................................................................... iiiHow to Use this Documentation...................................................................................... ivPower Safety Precautions............................................................................................... viService Safety Summary................................................................................................. viiElectrostatic Discharge Precautions ............................................................................... viiiService Terms ................................................................................................................. ixSymbology and Nomenclature ........................................................................................ xRegulatory Specifications................................................................................................ xiiiPhaser 5500/5550 Printer Overview ............................................................................... xivPhaser 5500/5550 Printer Configurations ....................................................................... xivParts of the Printer .......................................................................................................... xvPrinter Options ................................................................................................................ xviConsumables and Routine Maintenance Items .............................................................. xviiiPrinter Specifications ...................................................................................................... xixPhaser 5500/5550 Printer Menu Map ............................................................................. xxi



March 20081-1Phaser® 5500/5550 Printer

Service Call ProceduresInitial Issue

1 Service Call ProceduresService Call Procedures.................................................................................................. 1-3Servicing Instructions ...................................................................................................... 1-4




Status Indicator RAPsInitial Issue

2 Status Indicator RAPsOverview ......................................................................................................................... 2-3

Messages, Codes, and ProceduresEntry Level Fault Isolation Procedure ............................................................................. 2-9Main Motor Failure .......................................................................................................... 2-9Drum Motor Failure - U1-4 Drum Motor Failure .............................................................. 2-10Laser Unit Failure - U3-3 Laser Power............................................................................ 2-10Laser Motor Failure - U3-5 Polygon Motor Rotation ....................................................... 2-11Fuser Failure - U4-1 On Time ......................................................................................... 2-11Fuser Failure - U4-n Over Heat / Thermistor .................................................................. 2-12Fuser Failure - U4-7 Cold Sagging ................................................................................. 2-13Fan Failure - U4-9 Fan Defect ........................................................................................ 2-14Toner Motor Failure - U5-1 Motor Rotation ..................................................................... 2-14Fan Failure - U5-9 Fan Failure........................................................................................ 2-15Engine Control Board Failure - U6-2, 3, 4, 5, 6, 7........................................................... 2-15Paper Size Jam - E1-1 Regi Area Jam ........................................................................... 2-16Jam at A - E1-2 Regi Area Jam ...................................................................................... 2-17Jam at A - E1-6 Regi Area Jam ...................................................................................... 2-18Jam at A - Fuser Area Jam ............................................................................................. 2-18Jam at A - E3-6 Fuser Area Jam..................................................................................... 2-19Jam at A - E4-1 Exit 2 Area Jam..................................................................................... 2-20Jam at E - E4-3 Exit 2 Area Jam..................................................................................... 2-21Jam at E - E4-6 Exit 2 Area Jam..................................................................................... 2-23Jam at E - E8-2 Duplex Area Jam................................................................................... 2-24Jam at D and A - C6-1 Duplex Area Jam........................................................................ 2-25Jam at D and A - C6-2 Duplex Area Jam........................................................................ 2-26Jam at Tray n - Pre-Feed ................................................................................................ 2-28Jam at Tray n - Registration............................................................................................ 2-29Jam at Tray n - Feed Out #3 ........................................................................................... 2-30Jam at Tray n - Feed Out #4 ........................................................................................... 2-31Jam at Tray 5 - C4-0 Tray 5 ............................................................................................ 2-32Jam at Tray 6 - C5-1 Tray 6 ............................................................................................ 2-33Jam at Tray 6 - C5-2 Tray 6 ............................................................................................ 2-35Jam at B - C5-3 Tray 6.................................................................................................... 2-37Jam at B - C8-2 F/03 SNR Static Jam ............................................................................ 2-38Jam at C - C8-3 F/04 SNR Static Jam ............................................................................ 2-39Jam at C - C8-4 F/05 SNR Static Jam ............................................................................ 2-39Jam at Tray 6 - C8-5 HCF F/0 Sensor Static Jam .......................................................... 2-40Jam at D - C8-6 Duplex................................................................................................... 2-42Jam at Tray 1/MPT - C9-3 Tray 1/MPT........................................................................... 2-42Jam at A - F4-12 H-Transport Entrance Sensor ON ....................................................... 2-43Jam at A or F - F4-n H-Transport Entrance Sensor Static .............................................. 2-45Jam at A or F - F4-n H-Transport Exit Sensor ON .......................................................... 2-46Jam at F - F4-26 H-Transport Exit Sensor Static ............................................................ 2-47Jam at F - F4-32 Transport Entrance Sensor ON ........................................................... 2-48Jam at F - F4-36 Transport Entrance Sensor Static ....................................................... 2-50Jam at G - F4-4n Buffer Path Sensor ON ....................................................................... 2-51Jam at G - F4-4n Buffer Path Sensor Static.................................................................... 2-54

Jam at F or H - F4-5n Compile Exit Sensor OFF ............................................................ 2-56Jam at F or G - F4-5n Compile Exit Sensor ON.............................................................. 2-57Jam at H - F4-56 Compile Exit Sensor Static.................................................................. 2-59Jam at H - F4-61 Set Eject Jam ...................................................................................... 2-61Jam at H - F4-66 Compile Paper Sensor Static .............................................................. 2-62Jam at F or G - F4-7n Top Tray Exit Sensor ON............................................................. 2-64Jam at F or Stacker Upper Tray - F4-7n Top Tray Sensor OFF ..................................... 2-65Jam at F or G - F4-7n Top Tray Exit Sensor Static ......................................................... 2-67Jam at F - F4-82 Gate Sensor ON .................................................................................. 2-68Jam at F or G - Gate Sensor Static Jam (Upper Tray).................................................... 2-70Jam at F or G - Gate Sensor Static Jam (Lower Tray).................................................... 2-72Tray n Failure - H1 -1/2/3/4 Tray n Fail ........................................................................... 2-73Tray 6 Failure - H1-5 Tray 6 Fail ..................................................................................... 2-75Duplex Unit Failure - H2-7 Duplex Comm Failure ........................................................... 2-77Incorrect Duplex Unit Installed - H2-8 Duplex Type Error ............................................... 2-78Exit Unit Failure - H3-n Offset Error ................................................................................ 2-78Exit Unit Failure - H3-7 Exit Board Comm Failure........................................................... 2-80Tray 1/MPT Paper Guide Does Not Match Size Menu.................................................... 2-81Tray Paper Guide Does Not Match Size Menu -H4-1/2 .................................................. 2-81Tray Paper Guide Does Not Match Size Menu -H4-3/4 .................................................. 2-82Finisher Board Failure - H5-4, 7, 8 NVM/Comm/Type Error ........................................... 2-84Stacker Lower Tray Failure - H5-11 Low Tray Fail.......................................................... 2-85Stacker Lower Tray Failure - H5-12 Low Tray Upper Limit ............................................. 2-86Stacker Lower Tray Failure - H5-13 Lower Tray Limit..................................................... 2-87Stacker Lower Tray Failure - H5-2n Front Home Sensor................................................ 2-89Stacker Lower Tray Failure - H5-2n Rear Home Sensor ................................................ 2-91Punch Failure - H5-3n Sensor......................................................................................... 2-92Punch Failure - H5-3n Home Sensor .............................................................................. 2-93Stacker Lower Tray Failure - H5-8n Eject Clamp Sensor ............................................... 2-94Stacker Lower Tray Failure - H5-8n Set Clamp Sensor .................................................. 2-95Stacker Lower Tray Failure - H5-86 Side Regi Sensor OFF........................................... 2-97Stapler Failure - H5-91 Staple Fail .................................................................................. 2-99Stapler Failure - H5-9n Move Sensor.............................................................................. 2-100Tray 6 Control Board Failure - H6-4 NVM R/W Error ...................................................... 2-101Tray 6 Control Board Failure - H6-7 HFC Comm Failure ................................................ 2-101Tray 4-5 Control Board Failure - NVM............................................................................. 2-102Tray 4-5 Control Board Failure - H7-7 Comm Failure ..................................................... 2-103Incorrect Tray 4-5 Installed - H7-8 Type Error................................................................. 2-104Tray N Failure - H8-1, Tray 2-3 Size Sensor Broken ...................................................... 2-105Tray N Failure - H8-3, 4-5 Tray Size Sensor Broken ...................................................... 2-106Toner Empty - J1-2 Toner Empty ................................................................................... 2-107No Drum Cartridge - J3-1 Drum Not Installed ................................................................ 2-108Drum Cartridge Failure - J4-1 ATC Sensor Detect.......................................................... 2-109Replace Drum Cartridge - J6-1 Drum End of Life .......................................................... 2-109Drum Cartridge Failure - J7-n Comm/NVRAM/Type Error ............................................. 2-110Replace Incorrect Drum Cartridge - J7-3 DRUM Type Mismatch .................................. 2-110Toner Cartridge Failure - J8-n Toner Comm/Read/Write ............................................... 2-111Replace Incorrect Toner Cartridge - J8-3 Toner Cartridge Type Mismatch ................... 2-111



March 20082-2

Initial IssueStatus Indicator RAPs

Toner Is Low - Toner Low ............................................................................................... 2-112Drum Cartridge Near End of Life - DRUM Life Near End................................................ 2-113Tray Empty - No Paper in Tray 2 or 3 ............................................................................. 2-114Tray Empty - No Paper in Tray 4 or 5 ............................................................................. 2-115Tray Empty - No Paper in Tray 6 .................................................................................... 2-116Paper Size Jam - Paper Size in Tray 2 or 3 .................................................................... 2-117Paper Size Jam - Paper Size in Tray 4 or 5 .................................................................... 2-118Paper Size Jam - Paper Size in Tray 6 ........................................................................... 2-120Drum Cartridge Failure - Drum ATC Value Out of Range............................................... 2-121Temp/Humidity Sensor Failure - Value Out of Range..................................................... 2-121Face Down Tray Paper Full - Face Down Tray Full ........................................................ 2-122Stacker Upper Tray Full - Finisher Tray Paper Full......................................................... 2-123Stacker Lower Tray Full - Finisher Mix Full Stack........................................................... 2-124Stapler is Empty - Staple Pin Warning ............................................................................ 2-125Staple Cartridge is Low or Missing - Staple Pin Misfeed ................................................ 2-126Stapler Failure - Staple Failure ....................................................................................... 2-127Staple Set Over Count .................................................................................................... 2-128Stacker Lower Tray Failure ............................................................................................. 2-128Punch Waste Box is Missing........................................................................................... 2-129Punch Waste Box is Full ................................................................................................. 2-130Printer Front Door is Open - Front Cover is Open .......................................................... 2-131Slide In Tray 6 Feeder - Tray 6 Undocked ...................................................................... 2-132Close Door A - Door A is Open ....................................................................................... 2-133Close Door B - Door B is Open ....................................................................................... 2-133Close Door C - Door C is Open....................................................................................... 2-134Close Door D - Door D is Open....................................................................................... 2-135Close Door E - Door E is Open ....................................................................................... 2-136Close Door F - Door F is Open ....................................................................................... 2-136Close Door G - Door G is Open ...................................................................................... 2-137Close Door H - Door H is Open....................................................................................... 2-138Close Door J - Door J is Open ........................................................................................ 2-139Replace Maintenance Kit ................................................................................................ 2-140Invalid or Missing Configuration Card ............................................................................. 2-141Duplicate IP Address Detected ....................................................................................... 2-141




Image QualityInitial Issue

3 Image QualityPrint-Quality Problems Overview .................................................................................... 3-3Analyzing Test Prints ...................................................................................................... 3-3

Image Quality RAPsIQ1 Deletions (Line, Band, Spots)................................................................................... 3-5IQ2 Unfused Image ......................................................................................................... 3-6IQ3 Resolution ................................................................................................................ 3-8IQ4 Registration .............................................................................................................. 3-9IQ5 Registration (Side to Side) ....................................................................................... 3-10IQ6 Skips and Smears .................................................................................................... 3-12IQ7 Spots ........................................................................................................................ 3-13IQ8 Skewed Image.......................................................................................................... 3-15IQ9 Light (Undertoned) Print ........................................................................................... 3-16IQ10 Blank Print (No Image) ........................................................................................... 3-17IQ11 Black Prints ............................................................................................................ 3-19IQ12 Process Deletions .................................................................................................. 3-20IQ13 Scan Deletions ....................................................................................................... 3-21IQ14 Process Streaks ..................................................................................................... 3-22IQ15 Scan Streaks .......................................................................................................... 3-23IQ16 Damaged Print ....................................................................................................... 3-24IQ17 Spot Deletions ........................................................................................................ 3-25IQ18 Repeating Defects.................................................................................................. 3-26IQ19 Residual Image ...................................................................................................... 3-27IQ20 Background ............................................................................................................ 3-28IQ21 Uneven Density ...................................................................................................... 3-29




Repairs and AdjustmentsInitial Issue

4 Repairs and Adjustments Disassembly OverviewOverview ......................................................................................................................... 4-5General Notes on Disassembly....................................................................................... 4-5

CoversREP 1.1 Front Left Cover................................................................................................ 4-6REP 1.2 Top Rear Cover ................................................................................................ 4-6REP 1.3 Top Cover ......................................................................................................... 4-7REP 1.4 Front Door......................................................................................................... 4-7REP 1.5 Inner Main Cover .............................................................................................. 4-8REP 1.6 Front Door Interlock Switch .............................................................................. 4-8REP 1.7 Upper Right Cover ............................................................................................ 4-9REP 1.8 Rear Panel Cover ............................................................................................. 4-9REP 1.9 Lower Right Cover ............................................................................................ 4-10REP 1.10 I/P Board Cover .............................................................................................. 4-10REP 1.11 Upper Rear Cover........................................................................................... 4-11REP 1.12 Tray 1/MPT Rear Cover.................................................................................. 4-11REP 1.13 Lower Rear Cover........................................................................................... 4-12REP 1.14 Option Interface Cover.................................................................................... 4-12REP 1.15 Exit 1 Top Cover ............................................................................................. 4-13REP 1.16 Control Panel .................................................................................................. 4-13

Upper Transportation and RegistrationREP 2.1 Paper Size Switches......................................................................................... 4-14REP 2.2 Tray 2 Feeder ................................................................................................... 4-14REP 2.3 Tray 3 Feeder ................................................................................................... 4-15REP 2.4 Feed/Lift Motor.................................................................................................. 4-16REP 2.5 Tray 2 and 3 No Paper Sensor ......................................................................... 4-16REP 2.6 Tray 2 and 3 Level Sensor Actuator ................................................................. 4-17REP 2.7 Tray 2 and 3 Level Sensor................................................................................ 4-17REP 2.8 Tray 2 and 3 Pre-Feed Sensor ......................................................................... 4-18REP 2.9 Feed Roller ....................................................................................................... 4-18REP 2.10 Retard Roller................................................................................................... 4-19REP 2.11 Nudger Roller.................................................................................................. 4-19

Tray 1 DisassemblyREP 3.1 Tray 1 Feeder ................................................................................................... 4-21REP 3.2 Tray 1/MPT No Paper Sensor Actuator ............................................................ 4-21REP 3.3 Tray 1/MPT No Paper Sensor .......................................................................... 4-22REP 3.4 Pick Up Gear .................................................................................................... 4-22REP 3.5 Pick Up Solenoid .............................................................................................. 4-23REP 3.6 Cam Gear Spring.............................................................................................. 4-23REP 3.7 Feed Roller Assembly....................................................................................... 4-24REP 3.8 Retard Pad........................................................................................................ 4-24

Lower Transportation and RegistrationREP 4.1 Take Away Bracket........................................................................................... 4-25REP 4.2 Door B Interlock Switch .................................................................................... 4-25

REP 4.3 Take Away Roller Assembly ............................................................................. 4-26REP 4.4 Door B............................................................................................................... 4-26REP 4.5 Transfer Roller .................................................................................................. 4-27REP 4.6 Door A Interlock Switch..................................................................................... 4-27REP 4.7 Door A............................................................................................................... 4-28REP 4.8 Registration Roller ............................................................................................ 4-28REP 4.9 Registration Transport Assembly...................................................................... 4-29REP 4.10 Registration Clutch.......................................................................................... 4-30REP 4.11 Registration Sensor ........................................................................................ 4-31REP 4.12 Take Away Clutch ........................................................................................... 4-31REP 4.13 Feed Out Sensor 3.......................................................................................... 4-32

XerographicsREP 5.1 Drum Cartridge Fan Intake Duct ....................................................................... 4-33REP 5.2 Drum Cartridge Fan .......................................................................................... 4-34REP 5.3 Fuser Fan.......................................................................................................... 4-34REP 5.4 Drum Cartridge Detect Switch .......................................................................... 4-35REP 5.5 Environmental Sensor PWB ............................................................................. 4-37REP 5.6 Drum Cartridge CRUM PWB ............................................................................ 4-40REP 5.7 Toner Cartridge CRUM PWB............................................................................ 4-40REP 5.8 Toner Dispense Assembly ................................................................................ 4-41REP 5.9 Toner Dispense Motor ...................................................................................... 4-42REP 5.10 Laser Assembly .............................................................................................. 4-42

Fuser and Exit 1REP 6.1 Fuser Assembly ................................................................................................ 4-43REP 6.2 Fuser Exit Sensor ............................................................................................. 4-43REP 6.3 Exit Transport Assembly ................................................................................... 4-44REP 6.4 Exit 1 Offset Motor ............................................................................................ 4-45REP 6.5 Offset Home Position Sensor............................................................................ 4-45REP 6.6 Full Stack Sensor.............................................................................................. 4-46REP 7.1 Main Drive Belt.................................................................................................. 4-46REP 7.2 Motor Assembly ................................................................................................ 4-47REP 8.1 High Voltage Power Supply .............................................................................. 4-48REP 8.2 Power Switch .................................................................................................... 4-48REP 8.3 Exit PWB........................................................................................................... 4-49REP 8.4 Engine Control Board........................................................................................ 4-49REP 8.5 Image Processor Board .................................................................................... 4-50REP 8.6 Low Voltage Power Supply ............................................................................... 4-50REP 8.7 AC Accessory Panel ......................................................................................... 4-51REP 8.8 GFI Breaker ...................................................................................................... 4-52

1000-Sheet Feeder Assembly1000-Sheet Feeder Assembly......................................................................................... 4-53REP 20.1 Top Cover ....................................................................................................... 4-53REP 20.2 Right Cover ..................................................................................................... 4-54REP 20.3 Foot Cover ...................................................................................................... 4-54REP 20.4 Left Cover ....................................................................................................... 4-55



March 2008Phaser® 5500/5550 Printer

Parts ListInitial Issue

5 Parts ListParts List Overview ......................................................................................................... 5-3Using the Parts List ......................................................................................................... 5-3Serial Number Format..................................................................................................... 5-4

Parts List

CoversPL 1.1 Covers (1/2) ......................................................................................................... 5-5PL 1.2 Covers (2/2) ......................................................................................................... 5-6

TraysPL 2.1 Tray (1/2) and Feeder (1/2) ................................................................................. 5-7PL 2.2 Tray (2/2) ............................................................................................................. 5-8

FeederPL 2.3 Feeder (2/2) ......................................................................................................... 5-9PL 2.3 Feeder (2/2) (Continued) ..................................................................................... 5-10

Tray 1/MPTPL 3.1 Tray 1/MPT Assembly ......................................................................................... 5-11PL 3.2 Tray 1/MPT Lower Frame Assembly ................................................................... 5-12PL 3.3 Tray 1/MPT Assembly ......................................................................................... 5-13

DevelopmentPL 4.1 Transportation and Registration L/H Lower ......................................................... 5-14PL 4.2 L/H Upper Assembly............................................................................................ 5-15PL 4.3 L/H Chute Assembly ............................................................................................ 5-16PL 4.4 L/H Cover Assembly ............................................................................................ 5-17PL 4.5 Registration.......................................................................................................... 5-18

XerographicsPL 5.1 Laser, CRU and Toner Dispense......................................................................... 5-19

Fuser and ExitPL 6.1 Fuser and Exit 1................................................................................................... 5-20

Exit 1PL 6.2 Exit 1.................................................................................................................... 5-21

DrivePL 7.1 Drive .................................................................................................................... 5-22

ElectricalPL 8.1 Electrical .............................................................................................................. 5-23PL 8.2 Harness ............................................................................................................... 5-24

1000-Sheet FeederPL 20.1 1000-Sheet Feeder (Tray 4 & 5)........................................................................ 5-25PL 20.2 Tray (1/2) and Feeder (1/2) (Trays 4 and 5) ...................................................... 5-26PL 20.3 Tray (2/2) ........................................................................................................... 5-27PL 20.4 Feeder (2/2) ....................................................................................................... 5-28

PL 20.4 Feeder (2/2) (Continued) ................................................................................... 5-29PL 20.5 Transportation (Trays 4 & 5) .............................................................................. 5-30PL 20.6 Drive and Electrical (Trays 4 & 5) ...................................................................... 5-31

2000-Sheet Feeder (Tray 6)PL 22.1 Tray 6 (HCF) Covers.......................................................................................... 5-32PL 22.2 Tray (1/2) ........................................................................................................... 5-33PL 22.3 Tray (2/2) ........................................................................................................... 5-34PL 22.4 Tray 6 Feeder (1/3) ............................................................................................ 5-35PL 22.5 Tray 6 Feeder (2/3) ............................................................................................ 5-36PL 22.6 Tray 6 Feeder (3/3) ............................................................................................ 5-37PL 22.7 Tray 6 Drive and Transportation ........................................................................ 5-38PL 22.8 Tray 6 Electrical ................................................................................................. 5-39

Duplex UnitPL 23.1 Duplex Unit ........................................................................................................ 5-40PL 23.2 Inner Chute Assembly Duplex Module............................................................... 5-41

Exit 2PL 24.1 Exit 2 L/H Upper Chute Assembly ..................................................................... 5-42PL 24.2 Exit 2 Tray Guide Assembly............................................................................... 5-43PL 24.2 Exit 2 Tray Guide Assembly (Continued)........................................................... 5-44

Finisher/Stacker PartsPL 25.1 Finisher/Stacker Unit.......................................................................................... 5-45PL 25.2 Horizontal Transport Assembly (1/2) ................................................................. 5-46PL 25.3 Horizontal Transport Assembly (2/2) ................................................................. 5-47PL 25.4 Finisher/Stacker Covers (1/2) ............................................................................ 5-48PL 25.5 Finisher/Stacker Covers (2/2) ............................................................................ 5-49PL 25.6 Finisher Stack .................................................................................................... 5-50PL 25.7 Finisher Punch ................................................................................................... 5-51PL 25.8 Finisher Staple ................................................................................................... 5-52PL 25.9 Finisher Eject (1/3)............................................................................................. 5-53PL 25.10 Finisher Eject (2/3)........................................................................................... 5-54PL 25.11 Finisher Eject (3/3)........................................................................................... 5-55PL 25.12 Finisher Transport (1/2) ................................................................................... 5-56PL 25.13 Finisher Transport (2/2) ................................................................................... 5-57PL 25.14 Finisher Electrical............................................................................................. 5-58PL 25.15 Finisher Harness.............................................................................................. 5-59Xerox Supplies and Accessories..................................................................................... 5-60



March 20085-5Phaser® 5500/5550 Printer 1.1

Parts ListInitial Issue

PL 1.1 Covers (1/2)Item Part Description

1 802K74110 Cover Left FR, 5500 2 802E55372 Cover-FRS FR, PR (Front Left

Cover) 3 802E55362 Cover-Top RR, PR (Top Rear

Cover) 4 – Bracket ILSW 5 110E94770 Switch (Front Door Interlock

Switch) 6 802E64160 Control Panel, 5500– 101K63680 Control Panel, 55507 962K24041 Harn Assy Console Panel8 802K74170 Cover Assy Top PR (Top Cover)9 802K74080 Cover Assy Front (with 10~12)

(Front Door) 5500– 848K16200 Cover Assy Front (with 10~12)

(Front Door) 555010 – Magnet Catch (P/O PL 1.1 Item 9)11 – Cover-Front (P/O PL 1.1 Item 9)12 802E55351 Strip (Stopper) (P/O PL 1.1 Item 9)13 802K58180 Cover Assy Inner, Main (Inner Main

Cover)14 – Foot Front15 – Plate Ser




General TroubleshootingInitial Issue

6 General TroubleshootingIntroduction ..................................................................................................................... 6-3Space Requirements....................................................................................................... 6-3Power On Self Test (POST)............................................................................................ 6-4Service Usage Profile...................................................................................................... 6-6Service Diagnostics......................................................................................................... 6-10Network Problems........................................................................................................... 6-11Operating System and Application Problems.................................................................. 6-12Control Panel Display Error/ Inoperable Buttons ............................................................ 6-12Low Voltage Power Supply Troubleshooting .................................................................. 6-13AC Power Supply Troubleshooting ................................................................................. 6-14Print Engine Troubleshooting.......................................................................................... 6-16Service Diagnostics Menu Map....................................................................................... 6-19Service Diagnostic Tests and Utilities ............................................................................. 6-22




Wiring DataInitial Issue

7 Wiring DataHow to Use Plug/Jack Locations..................................................................................... 7-3Print Engine Plug/Jack Locations.................................................................................... 7-31000-Sheet Feeder Plug/Jack Locations ........................................................................ 7-11Duplex Unit Plug/Jack Locations..................................................................................... 7-13Exit 2 Plug/Jack Locations .............................................................................................. 7-14Tray 6 Plug/Jack Locations ............................................................................................. 7-15Finisher Plug/Jack Locations .......................................................................................... 7-16Print Engine Wiring Diagrams ......................................................................................... 7-221000-Sheet Feeder Wiring Diagrams.............................................................................. 7-31Duplex Unit Wiring Diagrams .......................................................................................... 7-33Exit 2 Wiring Diagrams.................................................................................................... 7-34Tray 6 Wiring Diagrams .................................................................................................. 7-36Finisher Wiring Diagrams................................................................................................ 7-38




Theory of OperationInitial Issue

8 Theory of OperationPhaser 5500/5550 Operational Overview ....................................................................... 8-3Paper Handling ............................................................................................................... 8-4Sensors ........................................................................................................................... 8-7Xerographics ................................................................................................................... 8-10Major Assemblies and Functions .................................................................................... 8-16Phaser 5500/5550 Options Operational Overview.......................................................... 8-24Exit 2 ............................................................................................................................... 8-25Duplex Unit...................................................................................................................... 8-261000-Sheet Feeder ......................................................................................................... 8-282000-Sheet Feeder ......................................................................................................... 8-32Finisher/Stacker .............................................................................................................. 8-37



Phaser 5500 Laser Printer

Service ManualBook 1 - Print Engine

WarningThe 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 d

071-0873-00



Contents iii

ContentsService Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiiiProduct Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xivPower Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvElectrostatic Discharge (ESD) Precautions . . . . . . . . . . . . . . . xviService Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xviiRegulatory Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xixManual Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxi

1 General InformationPrinter Introduction and Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Printer Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Parts of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Printer Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6Hard Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6Additional Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6Exit 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6Networking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61000-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7Stacker / Finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-82000-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9Envelope Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Consumables and Routine Maintenance Items. . . . . . . . . . . . . . . . . . . . 1-10Supply Life Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Printer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11Physical Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11Memory Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11Operational Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11Functional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14Tray and Media Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14



iv Phaser 5500 Printer Service Manual

2 Theory of OperationPhaser 5500 Operational Overview . . . . . . . . . . . . . . . . . . . . 2-2

Summary of the Printing Process . . . . . . . . . . . . . . . 2-2Paper Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Main Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Drum Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Input Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5Output Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7Duplex Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11Sensor Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11Sensors in the Paper Path . . . . . . . . . . . . . . . . . . . . 2-13

Xerographics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15Drum Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15Transfer Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16Toner Dispense Assembly . . . . . . . . . . . . . . . . . . . . 2-17Toner Dispense Motor . . . . . . . . . . . . . . . . . . . . . . . 2-18Laser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Major Assemblies and Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26Trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26Exit 1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30Printer Drive and Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

3 Error Messages, Codes, and ProceduresIntroduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Servicing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2System Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Power On Self Test (POST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4POST Soft Fault Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5POST Hard Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Service Usage Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7Accessing Fault Histories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7Interpreting Fault History Error Codes . . . . . . . . . . . . . . . . . . . . . 3-7

Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11Using Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12Starting Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12Service Diagnostics Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Messages, Codes, and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14Error Message Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14Error Message Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15Using the Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . 3-20Measurement Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21Entry Level Fault Isolation Procedure. . . . . . . . . . . . . . . . . . . . . 3-22Main Motor Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23Drum Motor Failure - U1-4 Drum Motor Rotation . . . . . . . . . . . 3-24



Contents v

Laser Unit Failure - U3-3 Laser Power . . . . . . . . . . . . . . . . . . . . 3-25Laser Motor Failure - U3-5 Polygon Motor Rotation. . . . . . . . . . 3-26Fuser Failure - U4-1 On Time . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27Fuser Failure - U4-n Over Heat / Thermistor . . . . . . . . . . . . . . . . 3-29Fuser Failure - U4-7 Cold Sagging . . . . . . . . . . . . . . . . . . . . . . . 3-30Fan Failure - U4-9 Fan Defect . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32Toner Motor Failure - U5-1 Motor Rotation . . . . . . . . . . . . . . . . 3-33Fan Failure - U5-9 Fan Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34Engine Logic Board Failure - U6-2, 3, 4, 5, 7 . . . . . . . . . . . . . . . 3-35Paper Size Jam - E1-1 Regi Area Jam. . . . . . . . . . . . . . . . . . . . . 3-35Jam at A - E1-2 Regi Area Jam . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37Jam at A - E1-6 Regi Area Jam . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38Jam at A - Fuser Area Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39Jam at A - E3-6 Fuser Area Jam . . . . . . . . . . . . . . . . . . . . . . . . . 3-41Jam at A - E4-1 Exit 2 Area Jam . . . . . . . . . . . . . . . . . . . . . . . . . 3-42Jam at E - E4-3 Exit 2 Area Jam . . . . . . . . . . . . . . . . . . . . . . . . . 3-44Jam at E - E4-6 Exit 2 Area Jam . . . . . . . . . . . . . . . . . . . . . . . . . 3-47Jam at E - E8-2 Duplex Area Jam . . . . . . . . . . . . . . . . . . . . . . . . 3-49Jam at D and A - C6-1 Duplex Area Jam. . . . . . . . . . . . . . . . . . . 3-51Jam at D and A - C6-2 Duplex Area Jam. . . . . . . . . . . . . . . . . . . 3-53Jam at Tray n - Pre-Feed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56Jam at Tray n - Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59Jam at Tray n - Feed Out #3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61Jam at Tray n - Feed Out #4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63Jam at Tray 5 - C4-0 Tray 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65Jam at Tray 6 - C5-1 Tray 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68Jam at Tray 6 - C5-2 Tray 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71Jam at B - C5-3 Tray 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73Jam at B - C8-2 F/O3 SNR Static Jam. . . . . . . . . . . . . . . . . . . . . 3-76Jam at C - C8-3 F/O4 SNR Static Jam. . . . . . . . . . . . . . . . . . . . . 3-77Jam at C - C8-4 F/O5 SNR Static Jam. . . . . . . . . . . . . . . . . . . . . 3-78Jam at Tray 6 - C8-5 HCF F/O SNR Static Jam . . . . . . . . . . . . . . 3-79Jam at D - C8-6 Duplex. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83Jam at Tray 1/MPT - C9-3 Tray 1/MPT . . . . . . . . . . . . . . . . . . . . 3-84Jam at A - F4-12 H-X’port Ent. SNR ON . . . . . . . . . . . . . . . . . . . 3-87Jam at A or F - F4-n H-X’port Ent. SNR Static. . . . . . . . . . . . . . . 3-89Jam at A or F - F4-n H-X’port Exit SNR ON. . . . . . . . . . . . . . . . . 3-91Jam at F - F4-26 H-X’port Exit SNR Static . . . . . . . . . . . . . . . . . 3-93Jam at F - F4-32 X’port Ent SNR ON . . . . . . . . . . . . . . . . . . . 3-95

. . . . . . . . . . . . . . . . . . . 3-98 . . . . . . . . . . . . . . . . . . 3-101 c . . . . . . . . . . . . . . . . . 3-106

Jam at F or H - F4-5n Compile Exit SNR OFF . . . . . . . . . . . . . . 3-109Jam at F or G - F4-5n Compile Exit SNR ON . . . . . . . . . . . . . . . 3-112Jam at H - F4-56 Compile Exit SNR Static . . . . . . . . . . . . . . . . 3-115Jam at H - F4-61 Set Eject Jam. . . . . . . . . . . . . . . . . . . . . . . . . 3-118



vi Phaser 5500 Printer Service Manual

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



Contents vii

Tray Empty - No Paper in Tray 2 or 3 . . . . . . . . . . . . . . . . . . . . 3-208Tray Empty - No Paper in Tray 4 or 5 . . . . . . . . . . . . . . . . . . . . 3-209Tray Empty - No Paper in Tray 6. . . . . . . . . . . . . . . . . . . . . . . . 3-211Paper Size Jam - Paper Size in Tray 2 or 3 . . . . . . . . . . . . . . . . 3-212Paper Size Jam - Paper Size in Tray 4 or 5 . . . . . . . . . . . . . . . . 3-214Paper Size Jam - Paper Size in Tray 6 . . . . . . . . . . . . . . . . . . . 3-217Drum Cartridge Failure - Drum ATC Value Out of Range. . . . . . 3-218Temp/Humidity Sensor Failure - Value Out of Range . . . . . . . . 3-219Face Down Tray Paper Full - Face Down Tray Full. . . . . . . . . . . 3-220Stacker Upper Tray Full - Finisher Tray Paper Full . . . . . . . . . . 3-222Stacker Lower Tray Full - Finisher Mix Full Stack . . . . . . . . . . . 3-223Stapler is Empty - Staple Pin Warning . . . . . . . . . . . . . . . . . . . 3-225Staple Cartridge is Low or Missing - Staple Pin Misfeed . . . . . 3-226Stapler Failure - Staple Failure . . . . . . . . . . . . . . . . . . . . . . . . . 3-228Staple Set Over Count. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-229Stacker Lower Tray Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-230Punch Waste Box is Missing . . . . . . . . . . . . . . . . . . . . . . . . . . 3-232Punch Waste Box is Full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-233Printer Front Door is Open - Front Cover is Open . . . . . . . . . . . 3-235Slide In Tray 6 Feeder - Tray 6 Undocked . . . . . . . . . . . . . . . . . 3-236Close Door A - Door A is Open . . . . . . . . . . . . . . . . . . . . . . . . . 3-237Close Door B - Door B is Open . . . . . . . . . . . . . . . . . . . . . . . . . 3-238Close Door C - Door C is Open . . . . . . . . . . . . . . . . . . . . . . . . . 3-239Close Door D - Door D is Open . . . . . . . . . . . . . . . . . . . . . . . . . 3-240Close Door E - Door E is Open . . . . . . . . . . . . . . . . . . . . . . . . . 3-242Close Door F - Door F is Open . . . . . . . . . . . . . . . . . . . . . . . . . 3-243Close Door G - Door G is Open . . . . . . . . . . . . . . . . . . . . . . . . . 3-245Close Door H - Door H is Open . . . . . . . . . . . . . . . . . . . . . . . . . 3-247Close Door J - Door J is Open . . . . . . . . . . . . . . . . . . . . . . . . . 3-248Replace Maintenance Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-250Invalid or Missing Configuration Card . . . . . . . . . . . . . . . . . . . 3-250Duplicate IP Address Detected . . . . . . . . . . . . . . . . . . . . . . . . . 3-251

4 General TroubleshootingIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Network Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Operating System and Application Problems . . . . . . . . . . . . . . . . . . . . . . 4-2

Macintosh Printing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Wi d Printing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

ay Error/Inoperable Buttons . . . . . . . . . . . . . . . . . . . . . 4-4 er Supply Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 4-5

ne LVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5Finisher LVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

AC Power Supply Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7Verifying AC Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8



viii Phaser 5500 Printer Service Manual

Print Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10Inoperative Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10Engine Logic Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12Image Processor Board Isolation. . . . . . . . . . . . . . . . . . . . . . . . 4-13Image Processor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14RAM Memory Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

5 Print-Quality TroubleshootingPrint-Quality Problems Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2Analyzing Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Print-Quality Defect Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3Deletions (Line, Band, Spots) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8Registration (Side to Side). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9Skips/Smears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11Skew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12Other Print Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Print-Quality Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14Light (Undertoned) Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14Blank Print (No image). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16Black Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19Vertical Deletions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21Horizontal Deletions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23Vertical Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25Horizontal Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29Unfused Image. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30Damaged Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34Spot Deletions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35Repeating Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37Residual Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40Uneven Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42Skewed Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45Skips and Smears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47



Contents ix

6 Adjustments and CalibrationsService Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Print Quality Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Checking Registration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4Adjusting Simplex Registration. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6Adjusting Duplex Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7Adjusting Fuser Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8Resetting Fuser Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Resetting the Printer to Default Values. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9Resetting Connection Setup Values . . . . . . . . . . . . . . . . . . . . . . 6-10Resetting Paper Handling Setup Values . . . . . . . . . . . . . . . . . . . 6-10Resetting PostScript Setup Values . . . . . . . . . . . . . . . . . . . . . . . 6-10Resetting PCL Setup Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11Resetting General Setup Values . . . . . . . . . . . . . . . . . . . . . . . . . 6-11Resetting Front Panel Setup Values . . . . . . . . . . . . . . . . . . . . . . 6-11Resetting Printer Controls Setup Values. . . . . . . . . . . . . . . . . . . 6-11Resetting File Security Setup Values. . . . . . . . . . . . . . . . . . . . . . 6-12Resetting Printer Default Settings (PostScript NVRAM) . . . . . . . 6-12

7 Cleaning and MaintenanceService Preventive Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . 7-2Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

8 FRU DisassemblyOverview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Standard Orientation of the Printer . . . . . . . . . . . . . . . . . . . . . . . . 8-2General Notes on Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3Notations in the Disassembly Text . . . . . . . . . . . . . . . . . . . . . . . . 8-4

Print Engine Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5Front Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5Top Rear Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8Inner Main Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9Front Door Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

. . . . . . . . . . . . . . . . . 8-11 . . . . . . . . . . . . . . . . . 8-12

. . . . . . . . . . . . . . . . . 8-13I/P Board Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14Upper Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15Tray 1/MPT Rear Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16Lower Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16



x Phaser 5500 Printer Service Manual

Option Interface Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17Exit 1 Top Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

Upper Transportation and Registration . . . . . . . . . . . . . . . . . . . . . . . . . 8-19Paper Size Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19Tray 2 Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20Tray 3 Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21Feed/Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23Tray 2 and 3 No Paper Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24Tray 2 and 3 Level Sensor Actuator . . . . . . . . . . . . . . . . . . . . . . 8-25Tray 2 and 3 Level Sensor . . . . . . . . . . . . . . . . . . . . 8-27Tray 2 and 3 Pre-Feed Sensor . . . . . . . . . . . . . . . . . 8-28Feed Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29Retard Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30Nudger Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31

Tray 1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32Tray 1 Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32Tray 1/MPT No Paper Sensor Actuator . . . . . . . . . . 8-33Tray 1/MPT No Paper Sensor . . . . . . . . . . . . . . . . . 8-34Pick Up Gear Spring. . . . . . . . . . . . . . . . . . . . . . . . . 8-35Tray 1 Pick Up Solenoid. . . . . . . . . . . . . . . . . . . . . . 8-36Cam Gear Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36Feed Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . 8-38Retard Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39

Lower Transportation and Registration . . . . . . . . . . . . . . . . 8-40Take Away Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40Door B Interlock Switch . . . . . . . . . . . . . . . . . . . . . . 8-41Take Away Roller Assembly . . . . . . . . . . . . . . . . . . . 8-41Door B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43Transfer Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44Door A Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45Door A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46Registration Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46Registration Transport Assembly. . . . . . . . . . . . . . . . . . . . . . . . 8-49Registration Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51Registration Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52Take Away Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-53Feed Out Sensor 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54

Xerographics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-56Drum Cartridge Fan Intake Duct. . . . . . . . . . . . . . . . . . . . . . . . . 8-56Drum Cartridge Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58Fuser Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-59Drum Cartridge Detect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 8-60Environmental Sensor PWB. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-64Drum Cartridge CRUM PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-70Toner Cartridge CRUM PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-71Toner Dispense Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-71



Contents xi

Toner Dispense Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-73Laser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-74

Fuser and Exit 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-76Fuser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-76Fuser Exit Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-77Exit Transport Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-78Exit 1 Offset Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-80Offset Home Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-81Full Stack Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-82

Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-83Main Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-83Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-84

Print Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-86High Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-86Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-86Exit PWB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-88Engine Logic Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-89Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-90Image Processor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-91Low Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-92AC Accessory Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-93GFI Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-94

9 Parts ListsSerial Number Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2Using the Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3Print Engine Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4Xerox Supplies and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-44

10 Wiring DiagramsPrint Engine Plug/Jack Designators . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2Plug/Jack Locator Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

Drum and Toner Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6Laser Assembly and Exit PWB . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7Fuser and Exit 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8Tray 1/MPT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9Registration Transport Assembly . . . . . . . . . . . . . . . . . . . . . . . 10-10Tray 2 & 3 Feeder Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . 10-11

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14

AC Accessory Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15LVPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16

Print Engine Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17Notations Used in Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . 10-17Print Engine General Wiring (1/2). . . . . . . . . . . . . . . . . . . . . . . 10-19



xii Phaser 5500 Printer Service Manual

Print Engine General Wiring (2/2) . . . . . . . . . . . . . . . . . . . . . . 10-20LVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22Registration Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23Xerographics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24Drive/CRUM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25Tray 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26Tray 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27Tray 1/MPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28Laser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29Exit 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30Engine Logic and Image Processor Board Interface. . . . . . . . . 10-31Image Processor Board (1/2). . . . . . . . . . . . . . . . . . . . . . . . . . 10-32Image Processor Board (2/2). . . . . . . . . . . . . . . . . . . . . . . . . . 10-33

A ReferencePhaser 5500 Laser Printer Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2Service Diagnostics Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4Service Diagnostic Tests and Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

General Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9Test Print Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10Printer NVRAM Adjustments Menu . . . . . . . . . . . . . . . . . . . . . . A-10Print Engine Motors/Fan Test Menu. . . . . . . . . . . . . . . . . . . . . . A-12Duplex Unit Motor Tests Menu . . . . . . . . . . . . . . . . . . . . . . . . . A-12Exit 2 Motor Tests Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13Trays 4 & 5 Motor Tests Menu . . . . . . . . . . . . . . . . . . . . . . . . . A-13Tray 6 Motor Tests Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13Finisher Motor Tests Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-14Print Engine Sensor/Switch Tests Menu . . . . . . . . . . . . . . . . . . A-15Duplex Unit Sensor/Switch Tests Menu . . . . . . . . . . . . . . . . . . . A-16Exit 2 Sensor/Switch Tests Menu . . . . . . . . . . . . . . . . . . . . . . . A-17Tray 4 & 5 Sensor/Switch Tests Menu. . . . . . . . . . . . . . . . . . . . A-17Tray 6 Sensor/Switch Tests Menu . . . . . . . . . . . . . . . . . . . . . . . A-18Finisher Sensor/Switch Tests Menu. . . . . . . . . . . . . . . . . . . . . . A-19Print Engine Solenoid/Clutch Tests Menu . . . . . . . . . . . . . . . . . A-20Exit 2 Solenoid/Clutch Test Menu . . . . . . . . . . . . . . . . . . . . . . . A-21Tray 4 & 5 Solenoid/Clutch Test Menu . . . . . . . . . . . . . . . . . . . A-21Tray 6 Solenoid/Clutch Test Menu . . . . . . . . . . . . . . . . . . . . . . . A-21Fi i S l i /Cl T enu. . . . . . . . . . . . . . . . . . . . . A-21

. . . . . . . . . . . . . . . . . . . . . . . . A-22 t Menu . . . . . . . . . . . . . . . . . . A-22 . . . . . . . . . . . . . . . . . . . . . . . . A-23

Exit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-23Mode Select Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-24

Index



Phaser 5500 Laser er

Service ManualBook 2 - Options

WarningThe 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 d

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Contents iii

ContentsService Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiProduct Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiiPower Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . xiiiElectrostatic Discharge (ESD) Precautions . . . . . . . . . . . . . . . xivService Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvRegulatory Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . xviiManual Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix

1 General InformationPrinter Introduction and Overview . . . . . . . . . . . . . . . . . . . . . 1-2

Printer Configurations. . . . . . . . . . . . . . . . . . . . . . . . . 1-3Available Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Hard Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Additional Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Exit 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Networking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41000-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5Stacker / Finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62000-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7Envelope Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Consumables and Routine Maintenance Items. . . . . . . . . . . . . . . . . . . . . 1-8Option Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9Option Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Physical Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10Tray and Media Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

2 Theory of OperationPhaser 5500 Options Operational Overview . . . . . . . . . . . . . . . . . . . . . . . 2-2Exit 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Exit 2 Paper Path Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Exit 2 Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5Exit 2 Drive and Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Path Components . . . . . . . . . . . . . . . . . . . . . . 2-8

Duplex Unit Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8Duplex Unit Drive and Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8



iv Phaser 5500 Printer Options Service Manual

1000-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101000-Sheet Feeder Paper Path Compon . . . . . . . . . . 2-111000-Sheet Feeder Sensors . . . . . . . . . . . . . . . . . . . 2-141000-Sheet Feeder Drive and Electrical . . . . . . . . . . 2-16

Finisher/Stacker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18Finisher Paper Path Components. . . . . . . . . . . . . . . 2-19Finisher Paper Path Sensors . . . . . . . . . . . . . . . . . . 2-24Punch Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25Compiler Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28Stapler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33Stacker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

2000-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42Tray 6 Paper Path Components . . . . . . . . . . . . . . . . 2-42Tray 6 Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44Tray Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-462000-Sheet Feeder Drive and Electrical . . . . . . . . . . 2-49

3 FRU DisassemblyOverview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Standard Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2General Notes on Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Notations in the Disassembly Text . . . . . . . . . . . . . . . . . . . . . . . . 3-3

1000-Sheet Feeder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6Foot Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8Casters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9Paper Size Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10Tray Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11Feed/Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13Tray 4 and 5 No Paper Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14Tray 4 and 5 Level Sensor Actuator . . . . . . . . . . . . . . . . . . . . . . 3-15Tray 4 and 5 Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16Tray 4 and 5 Pre-Feed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17Feed Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18Retard Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19Nudger Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20Tray 4 Feed Out Sensor #4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21Tray 5 Feed Out Sensor #5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22Upper Take Away Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23Lower Take Away Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24Upper Pinch Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25Lower Pinch Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26Pinch Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27



Contents v

Door C Interlock Switch . . . . . . . . . . . . . . . . . . . . . . 3-28Tray 4-5 PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29Take Away Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30Take Away Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

2000-Sheet Feeder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32Docking the 2000-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . 3-32Tray 6 Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33Tray 6 Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33Tray 6 Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35Tray 6 Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36Tray 6 Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37Door J. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37Tray Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39Tray 6 Casters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40Tray 6 Tray In Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41Tray 6 Paper Size Sensors A/B . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42Tray 6 End Guide Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43Tray 6 Gear Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44Tray 6 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45Tray 6 Feeder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48Tray 6 Feed/Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49Tray 6 Drive Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49Tray 6 Nudger Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50Tray 6 Pre-Feed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51Tray 6 No Paper Sensor Actuator . . . . . . . . . . . . . . . . . . . . . . . . 3-53Tray 6 No Paper Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54Tray 6 Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55Tray 6 Nudger Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56Tray 6 Feeder Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57Tray 6 Feed Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58Tray 6 Retard Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59Tray 6 Lower Feeder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 3-59Tray 6 Retard Clutch, Bracket or Spring . . . . . . . . . . . . . . . . . . . 3-60Door J Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62Tray 6 Feed Out Sensor #6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63Tray 6 Take Away Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64Take Away Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65Docking Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66Tray 6 PWB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67



vi Phaser 5500 Printer Options Service Manual

Duplex Unit Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68Duplex Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68Duplex Unit Chutes and Cover . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70Door D Latch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72Door D Interlock Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74Wait Sensor Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75Duplex Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76Duplex Unit PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77Duplex Wait Sensor . . . . . . . . . . . . . . . . . . . . . . . . . 3-78

Exit 2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79Exit 2 Transport Assembly . . . . . . . . . . . . . . . . . . . . 3-79Face-Up Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80Invert Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83Exit 2 Tray Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86Stack Full Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87Offset Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89OCT (Offset) Roller . . . . . . . . . . . . . . . . . . . . . . . . . 3-90Exit 2 Pinch Roller . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91Exit Sensor Actuator . . . . . . . . . . . . . . . . . . . . . . . . 3-92Exit 2 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93Door E Interlock Switch . . . . . . . . . . . . . . . . . . . . . . 3-95Face-Up Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96Exit Gate Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98Offset Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100Exit Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-102OCT Home Position Sensor . . . . . . . . . . . . . . . . . . 3-103Exit 2 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-104Full Stack Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105

Finisher/Stacker Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106Horizontal Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106Horizontal Transport Rear Cover . . . . . . . . . . . . . . . . . . . . . . . 3-107Door F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108Horizontal Transport Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . 3-109Horizontal Transport Right Shaft . . . . . . . . . . . . . . . . . . . . . . . 3-110Horizontal Transport Left Shaft . . . . . . . . . . . . . . . . . . . . . . . . 3-111Horizontal Transport Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . 3-112Horizontal Transport Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113Horizontal Transport Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113Horizontal Transport Top Cover . . . . . . . . . . . . . . . . . . . . . . . . 3-115Door F Interlock Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-116Horizontal Transport Entrance Sensor . . . . . . . . . . . . . . . . . . . 3-117Horizontal Transport Exit Sensor . . . . . . . . . . . . . . . . . . . . . . . 3-118Finisher Docking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-119Finisher Upper Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-120Finisher Lower Rear Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121Finisher Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-122



Contents vii

Finisher Bottom Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123Finisher Door G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-124Finisher Inner Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-125Finisher Top Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-126Door G Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-127Finisher L/H Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-128Finisher Top L/H Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-129Stacker Upper Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-130Finisher Eject Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-131Stacker Lower Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132Stacker Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132Stacker Left Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-136Stacker Right Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-138Stack Height Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-140Stack Height Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-141Stacker Encoder Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-142Lower Tray Upper Limit and No Paper Sensors . . . . . . . . . . . . 3-143Elevator Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-144Finisher Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-145Punch Move Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-147Finisher Punch Side Registration Sensors 1 & 2 . . . . . . . . . . . 3-148Punch Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-148Punch Motor Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . 3-149Punch Hole Select, Punch Front and Home Sensors . . . . . . . . 3-151Punch Unit Move Home Sensor . . . . . . . . . . . . . . . . . . . . . . . . 3-153Finisher Punch Box Set Sensor. . . . . . . . . . . . . . . . . . . . . . . . . 3-154Finisher Stapler Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-155Stapler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-158Stapler Lower Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . 3-159Stapler Upper Rail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-161Stapler Move Position Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . 3-162Finisher Eject Chute Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-163Sub Paddle Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-166Cyclone Paddles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-168Cyclone Paddle Drive Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-168Eject Clamp Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-172Eject Clamp Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-174Eject Clamp Home Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-175Door H Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-176

er Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-177 mper Home Sensors . . . . . . . . . . . . . . . . . . . . . . 3-180

No Paper Sensor . . . . . . . . . . . . . . . . . . . . . . . . 3-182Eject Roller Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-184Set Clamp Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-186Eject Motor Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-187Set Clamp Home Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-188



viii Phaser 5500 Printer Options Service Manual

Compile Exit Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-189Lower Exit Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-191Lower Exit Chute R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-196Paddle Shaft/Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-200Exit Pinch Rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-201Lower Exit Chute (2b) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-202Lower Exit Chute Pinch Rollers . . . . . . . . . . . . . . . . . . . . . . . . 3-204Transfer Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-204Buffer Gate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-206Buffer Path Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-207Buffer Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-208Bottom Buffer Chute (3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-211Exit Pinch Rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-213Upper Entrance Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-214Upper Entrance Chute Pinch Rollers . . . . . . . . . . . . . . . . . . . . 3-216Transport Entrance Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-217Entrance Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-218Finisher Transport Motor and Belt . . . . . . . . . . . . . . . . . . . . . . 3-222Transfer Gate Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-223Buffer Gate Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-225Stacker Upper Tray Exit Sensor . . . . . . . . . . . . . . . . . . . . . . . . 3-226Top Exit Pinch Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-227Top Exit Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-227Stacker Upper Tray Full Stack Sensor . . . . . . . . . . . . . . . . . . . 3-233Upper Exit Chute (2a). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-234Upper Exit Chute Pinch Rollers . . . . . . . . . . . . . . . . . . . . . . . . 3-236Gate Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-236Transport Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-238Finisher Exit Motor and Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-243Finisher Registration Motor and Belt . . . . . . . . . . . . . . . . . . . . 3-245Horizontal Transport PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-247Finisher Main PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-248Low Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-250

4 Parts ListsPhaser 5500 Printer Option Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Using the Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2000 S F . . . . . . . . . . . . . . . . . . 4-4

. . . . . . . . . . . . . . . . . 4-18 . . . . . . . . . . . . . . . . . 4-34

. . . . . . . . . . . . . . . . . 4-38Finisher/Stacker Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44



Contents ix

5 Wiring DiagramsPhaser 5500 Option Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Notations Used in Wiring Diagrams . . . . . . . . . . . . . . . 5-2Phaser 5500 Printer Option Plug/Ja ation. . . . . . . . . . . . 5-3

1000-Sheet Feeder Plug/Jack Designators . . . . . . . . . . . . . . . 5-41000-Sheet Feeder Plug/Jack Locators . . . . . . . . . . . . . . . . . 5-5

Trays 4 and 5 Feeders. . . . . . . . . . . . . . . . . . . . . . . . . 5-5Trays 4 and 5 Electrical. . . . . . . . . . . . . . . . . . . . . . . . 5-6

1000-Sheet Feeder Wiring Diagrams . . . . . . . . . . . . . . . . . . . 5-7General Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8Tray 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9Tray 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Duplex Unit Plug/Jack Designators . . . . . . . . . . . . . . . . . . . 5-11Duplex Unit Plug/Jack Locator . . . . . . . . . . . . . . . . . . . . . . . 5-12Duplex Unit Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . 5-13Exit 2 Plug/Jack Designators . . . . . . . . . . . . . . . . . . . . . . . . 5-14Exit 2 Plug/Jack Locator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15Exit 2 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

General Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16Exit 2 Motor/Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17Exit 2 Sensor/Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Tray 6 Plug/Jack Designators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19Tray 6 Plug/Jack Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Tray 6 Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20Tray 6 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

Tray 6 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22General Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22Tray 6 Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23Tray 6 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24Tray 6 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

Finisher Plug/Jack Designators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26Finisher Plug/Jack Locators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

Horizontal Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29Stapler and Door G Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30Punch and Punch Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31Input Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32Compiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33Upper Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34Finisher Main PWB, H-X’Port PWB and LVPS. . . . . . . . . . . . . . . 5-35



x Phaser 5500 Printer Options Service Manual

Finisher Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36General Wiring (1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36General Wiring (2/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38Horizontal Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39Sensors (1/2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40Sensors (2/2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42Clutch and Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43Compiler Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44Stapler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45Punch (1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46Punch (2/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47

Index



Documents

Phaser 5500/5550 Service Documentation · How to Use this Documentation ... Laser Unit Failure - U3-3 Laser Power ... Exit Unit Failure - H3-n Offset Error