Service - Manual - Parte 1 PDF

Phaser 5500 Laser Printer
Service Manual
Book 1 - Print Engine
Warning
The following servicing instructions are for use by qualified service
personnel only. To avoid personal injury, do not perform any servicing other
than that contained in the operating instructions, unless you are qualified to
do so.
First Printing: August 2004
071-0873-00
Copyright
Copyright 2004 Xerox Corporation. All Rights Reserved. Unpublished rights reserved under the
copyright laws of the United States. Contents of this publication may not be reproduced in any form
without permission of Xerox Corporation.
Copyright protection claimed includes all forms of matters of copyrightable materials and information now
allowed by statutory or judicial law or hereinafter granted, including without limitation, material generated
from the software programs which are displayed on the screen such as styles, templates, icons, screen
displays, looks, etc.
XEROX, The Document Company, the stylized X, CentreWare, infoSMART, Made For Each
Other, Phaser, PhaserSMART, and Walk-Up are trademarks of Xerox Corporation in the United
States and/or other countries.
Adobe Reader, Illustrator, PageMaker, Photoshop, PostScript, ATM, Adobe Brilliant Screens,
Adobe Garamond, Adobe Jenson, Birch, Carta, IntelliSelect, Mythos, Quake, and Tekton are
trademarks of Adobe Systems Incorporated in the United States and/or other countries.
Apple, AppleTalk, LaserWriter, LocalTalk, Macintosh, Mac OS, TrueType, Apple Chancery,
Chicago, Geneva, Monaco, New York , and QuickDraw are trademarks of Apple Computer, Inc. in
the United States and/or other countries.
PCL and HP-GL are trademarks of Hewlett-Packard Corporation in the United States and/or other
countries.
IBM is a trademark of International Business Machines Corporation in the United States and/or other
countries.
Windows, Windows NT, and Wingdings are trademarks of Microsoft Corporation in the United States
and/or other countries.
Novell, NetWare, NDPS, NDS, Novell Directory Services , IPX , and Novell Distributed Print
Servicesare trademarks of Novell, Incorporated in the United States and/or other countries.
Sun and Sun Microsystems are trademarks of Sun Microsystems, Incorporated in the United States and/
or other countries.
UNIX is a trademark in the United States and other countries, licensed exclusively through X/Open
Company Limited.
As an ENERGY STAR partner, Xerox Corporation has determined that this product meets the ENERGY
STAR guidelines for energy efficiency. The ENERGY STAR name and logo are registered U.S. marks.
This product uses code for SHA-1 written by John Halleck, which is being used with his permission.
This product includes an implementation of LZW licensed under U.S. Patent 4,558,302.
ii Phaser 5500 Printer Service Manual

Contents Service Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
Product Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv
Power Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
Electrostatic Discharge (ESD) Precautions. . . . . . . . . . . . . . . . . . . . . . . . xvi
Service Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii
Regulatory Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix
Manual Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxi
1 General Information
Printer Introduction and Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Printer Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Parts of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Printer Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Hard Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Additional Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Exit 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Networking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1000-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Stacker / Finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
2000-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Envelope Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Consumables and Routine Maintenance Items. . . . . . . . . . . . . . . . . . . . 1-10
Supply Life Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Printer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Physical Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Memory Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Operational Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Functional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Tray and Media Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Contents iii
2 Theory of Operation
Phaser 5500 Operational Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Summary of the Printing Process . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Paper Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Main Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Drum Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Input Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Output Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Duplex Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Sensor Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Sensors in the Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Xerographics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Drum Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Transfer Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Toner Dispense Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Toner Dispense Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Laser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Major Assemblies and Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Exit 1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Printer Drive and Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
3 Error Messages, Codes, and Procedures

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Servicing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
System Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Power On Self Test (POST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
POST Soft Fault Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
POST Hard Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Service Usage Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Accessing Fault Histories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Interpreting Fault History Error Codes . . . . . . . . . . . . . . . . . . . . . 3-7
Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Using Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Starting Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Service Diagnostics Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Messages, Codes, and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Error Message Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Error Message Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Using the Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . 3-20
Measurement Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Entry Level Fault Isolation Procedure. . . . . . . . . . . . . . . . . . . . . 3-22
Main Motor Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Drum Motor Failure - U1-4 Drum Motor Rotation . . . . . . . . . . . 3-24
iv Phaser 5500 Printer Service Manual
Laser Unit Failure - U3-3 Laser Power . . . . . . . . . . . . . . . . . . . . 3-25
Laser Motor Failure - U3-5 Polygon Motor Rotation. . . . . . . . . . 3-26
Fuser Failure - U4-1 On Time . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Fuser Failure - U4-n Over Heat / Thermistor . . . . . . . . . . . . . . . . 3-29
Fuser Failure - U4-7 Cold Sagging . . . . . . . . . . . . . . . . . . . . . . . 3-30
Fan Failure - U4-9 Fan Defect . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Toner Motor Failure - U5-1 Motor Rotation . . . . . . . . . . . . . . . . 3-33
Fan Failure - U5-9 Fan Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Engine Logic Board Failure - U6-2, 3, 4, 5, 7 . . . . . . . . . . . . . . . 3-35
Paper Size Jam - E1-1 Regi Area Jam. . . . . . . . . . . . . . . . . . . . . 3-35
Jam at A - E1-2 Regi Area Jam . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Jam at A - E1-6 Regi Area Jam . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Jam at A - Fuser Area Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Jam at A - E3-6 Fuser Area Jam . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Jam at A - E4-1 Exit 2 Area Jam . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Jam at E - E4-3 Exit 2 Area Jam . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Jam at E - E4-6 Exit 2 Area Jam . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Jam at E - E8-2 Duplex Area Jam . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Jam at D and A - C6-1 Duplex Area Jam. . . . . . . . . . . . . . . . . . . 3-51
Jam at D and A - C6-2 Duplex Area Jam. . . . . . . . . . . . . . . . . . . 3-53
Jam at Tray n - Pre-Feed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Jam at Tray n - Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
Jam at Tray n - Feed Out #3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
Jam at Tray n - Feed Out #4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
Jam at Tray 5 - C4-0 Tray 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
Jam at Tray 6 - C5-1 Tray 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
Jam at Tray 6 - C5-2 Tray 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
Jam at B - C5-3 Tray 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
Jam at B - C8-2 F/O3 SNR Static Jam. . . . . . . . . . . . . . . . . . . . . 3-76
Jam at C - C8-3 F/O4 SNR Static Jam. . . . . . . . . . . . . . . . . . . . . 3-77
Jam at C - C8-4 F/O5 SNR Static Jam. . . . . . . . . . . . . . . . . . . . . 3-78
Jam at Tray 6 - C8-5 HCF F/O SNR Static Jam . . . . . . . . . . . . . . 3-79
Jam at D - C8-6 Duplex. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
Jam at Tray 1/MPT - C9-3 Tray 1/MPT . . . . . . . . . . . . . . . . . . . . 3-84
Jam at A - F4-12 H-Xport Ent. SNR ON . . . . . . . . . . . . . . . . . . . 3-87
Jam at A or F - F4-n H-Xport Ent. SNR Static. . . . . . . . . . . . . . . 3-89
Jam at A or F - F4-n H-Xport Exit SNR ON. . . . . . . . . . . . . . . . . 3-91
Jam at F - F4-26 H-Xport Exit SNR Static . . . . . . . . . . . . . . . . . 3-93
Jam at F - F4-32 Xport Ent. SNR ON . . . . . . . . . . . . . . . . . . . . . 3-95
Jam at F - F4-36 Xport Ent. SNR Static . . . . . . . . . . . . . . . . . . . 3-98
Jam at G - F4-4n Buffer Path SNR ON . . . . . . . . . . . . . . . . . . . 3-101
Jam at G - F4-4n Buffer Path SNR Static . . . . . . . . . . . . . . . . . 3-106
Jam at F or H - F4-5n Compile Exit SNR OFF . . . . . . . . . . . . . . 3-109
Jam at F or G - F4-5n Compile Exit SNR ON . . . . . . . . . . . . . . . 3-112
Jam at H - F4-56 Compile Exit SNR Static . . . . . . . . . . . . . . . . 3-115
Jam at H - F4-61 Set Eject Jam. . . . . . . . . . . . . . . . . . . . . . . . . 3-118
Contents v
Jam at H - F4-66 Compile Paper SNR Static . . . . . . . . . . . . . . 3-121
Jam at F or G - F4-7n Top Tray Exit SNR ON . . . . . . . . . . . . . . 3-123
Jam at F or Stacker Upper Tray - F4-7nTop Tray SNR OFF . . . 3-126
Jam at F or G - F4-7n Top Tray Exit SNR Static . . . . . . . . . . . . 3-129
Jam at F - F4-82 Gate SNR ON. . . . . . . . . . . . . . . . . . . . . . . . . 3-131
Jam at F or G - Gate SNR Static Jam (Upper Tray) . . . . . . . . . 3-135
Jam at F or G - Gate SNR Static Jam (Lower Tray) . . . . . . . . . 3-138
Tray n Failure - H1 -1/2/3/4 Tray n Fail. . . . . . . . . . . . . . . . . . . 3-141
Tray 6 Failure - H1-5 Tray 6 Fail. . . . . . . . . . . . . . . . . . . . . . . . 3-144
Duplex Unit Failure - H2-7 Duplex Comm Failure. . . . . . . . . . . 3-148
Incorrect Duplex Unit Installed - H2-8 Duplex Type Error . . . . 3-149
Exit Unit Failure - H3-n Offset Error . . . . . . . . . . . . . . . . . . . . . 3-150
Exit Unit Failure - H3-7 Exit Board Comm Failure. . . . . . . . . . . 3-152
Tray 1/MPT Paper Guide Does Not Match Size Menu . . . . . . . 3-154
Tray Paper Guide Does Not Match Size Menu -H4-1/2. . . . . . . 3-155
Tray Paper Guide Does Not Match Size Menu -H4-3/4. . . . . . . 3-157
Finisher Board Failure - H5-4, 7, 8 NVM/Comm/Type Error . . . 3-159
Stacker Lower Tray Failure - H5-11 Low Tray Fail . . . . . . . . . . 3-160
Stacker Lower Tray Failure - H5-12 Low Tray Upper Limit . . . 3-162
Stacker Lower Tray Failure - H5-13 Low Tray Lower Limit . . . 3-165
Stacker Lower Tray Failure - H5-2n Front Home SNR . . . . . . . 3-168
Stacker Lower Tray Failure - H5-2n Rear Home SNR. . . . . . . . 3-170
Punch Failure - H5-3n SNR . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-172
Punch Failure - H5-3n Home SNR . . . . . . . . . . . . . . . . . . . . . . 3-174
Stacker Lower Tray Failure - H5-8n Eject Clamp SNR . . . . . . . 3-176
Stacker Lower Tray Failure - H5-8n Set Clamp SNR . . . . . . . . 3-178
Stacker Lower Tray Failure - H5-86 Side Regi SNR OFF . . . . . 3-181
Stapler Failure - H5-91 Staple Fail . . . . . . . . . . . . . . . . . . . . . . 3-184
Stapler Failure - H5-9n Move SNR . . . . . . . . . . . . . . . . . . . . . . 3-185
Tray 6 Logic Board Failure - H6-4 NVM R/W Error . . . . . . . . . 3-187
Tray 6 Logic Board Failure - H6-7 HCF Comm Failure . . . . . . . 3-188
Tray 4-5 Logic Board Failure - NVM. . . . . . . . . . . . . . . . . . . . . 3-189
Tray 4-5 Logic Board Failure - H7-7 Comm Failure . . . . . . . . . 3-190
Incorrect Tray 4-5 Installed - H7-8 Type Error . . . . . . . . . . . . . 3-191
Tray N Failure - H8-1, 2 Tray Size Sensor Broken . . . . . . . . . . 3-193
Tray N Failure - H8-3, 4 Tray Size Sensor Broken . . . . . . . . . . 3-194
Toner Empty- J1-2 Toner Empty . . . . . . . . . . . . . . . . . . . . . . . 3-197
No Drum Cartridge - J3-1 Drum Not Installed . . . . . . . . . . . . . 3-199
Drum Cartridge Failure - J4-1 ATC SNR Defect . . . . . . . . . . . . 3-200
Replace Drum Cartridge - J6-1 DRUM End of Life . . . . . . . . . . 3-200
Drum Cartridge Failure - J7-n Comm/NVRAM/Type Error . . . . 3-201
Replace Incorrect Drum Cartridge - J7-3 DRUM Mismatch . . . 3-203
Toner Cartridge Failure - J8-n Toner Comm/Read/Write . . . . . 3-204
Replace Incorrect Toner Cartridge - J8-3 Toner Mismatch . . . 3-205
Toner Is Low - Toner Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-206
Drum Cartridge Near End of Life - DRUM Life Near End . . . . . 3-207
vi Phaser 5500 Printer Service Manual

Tray Empty - No Paper in Tray 2 or 3 . . . . . . . . . . . . . . . . . . . . 3-208
Tray Empty - No Paper in Tray 4 or 5 . . . . . . . . . . . . . . . . . . . . 3-209
Tray Empty - No Paper in Tray 6. . . . . . . . . . . . . . . . . . . . . . . . 3-211
Paper Size Jam - Paper Size in Tray 2 or 3 . . . . . . . . . . . . . . . . 3-212
Paper Size Jam - Paper Size in Tray 4 or 5 . . . . . . . . . . . . . . . . 3-214
Paper Size Jam - Paper Size in Tray 6 . . . . . . . . . . . . . . . . . . . 3-217
Drum Cartridge Failure - Drum ATC Value Out of Range. . . . . . 3-218
Temp/Humidity Sensor Failure - Value Out of Range . . . . . . . . 3-219
Face Down Tray Paper Full - Face Down Tray Full. . . . . . . . . . . 3-220
Stacker Upper Tray Full - Finisher Tray Paper Full . . . . . . . . . . 3-222
Stacker Lower Tray Full - Finisher Mix Full Stack . . . . . . . . . . . 3-223
Stapler is Empty - Staple Pin Warning . . . . . . . . . . . . . . . . . . . 3-225
Staple Cartridge is Low or Missing - Staple Pin Misfeed . . . . . 3-226
Stapler Failure - Staple Failure . . . . . . . . . . . . . . . . . . . . . . . . . 3-228
Staple Set Over Count. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-229
Stacker Lower Tray Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-230
Punch Waste Box is Missing . . . . . . . . . . . . . . . . . . . . . . . . . . 3-232
Punch Waste Box is Full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-233
Printer Front Door is Open - Front Cover is Open . . . . . . . . . . . 3-235
Slide In Tray 6 Feeder - Tray 6 Undocked . . . . . . . . . . . . . . . . . 3-236
Close Door A - Door A is Open . . . . . . . . . . . . . . . . . . . . . . . . . 3-237
Close Door B - Door B is Open . . . . . . . . . . . . . . . . . . . . . . . . . 3-238
Close Door C - Door C is Open . . . . . . . . . . . . . . . . . . . . . . . . . 3-239
Close Door D - Door D is Open . . . . . . . . . . . . . . . . . . . . . . . . . 3-240
Close Door E - Door E is Open . . . . . . . . . . . . . . . . . . . . . . . . . 3-242
Close Door F - Door F is Open . . . . . . . . . . . . . . . . . . . . . . . . . 3-243
Close Door G - Door G is Open . . . . . . . . . . . . . . . . . . . . . . . . . 3-245
Close Door H - Door H is Open . . . . . . . . . . . . . . . . . . . . . . . . . 3-247
Close Door J - Door J is Open . . . . . . . . . . . . . . . . . . . . . . . . . 3-248
Replace Maintenance Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-250
Invalid or Missing Configuration Card . . . . . . . . . . . . . . . . . . . 3-250
Duplicate IP Address Detected . . . . . . . . . . . . . . . . . . . . . . . . . 3-251
4 General Troubleshooting
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Network Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Operating System and Application Problems . . . . . . . . . . . . . . . . . . . . . . 4-2
Macintosh Printing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Windows Printing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Front Panel Display Error/Inoperable Buttons . . . . . . . . . . . . . . . . . . . . . 4-4
Low Voltage Power Supply Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 4-5
Print Engine LVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Finisher LVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
AC Power Supply Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Verifying AC Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Contents vii
Print Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Inoperative Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Engine Logic Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Image Processor Board Isolation. . . . . . . . . . . . . . . . . . . . . . . . 4-13
Image Processor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
RAM Memory Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
5 Print-Quality Troubleshooting
Print-Quality Problems Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Analyzing Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Print-Quality Defect Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Deletions (Line, Band, Spots) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Registration (Side to Side). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Skips/Smears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Skew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Other Print Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Print-Quality Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Light (Undertoned) Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Blank Print (No image). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Black Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Vertical Deletions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Horizontal Deletions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Vertical Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Horizontal Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Unfused Image. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Damaged Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
Spot Deletions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Repeating Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Residual Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Uneven Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Skewed Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
Skips and Smears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
viii Phaser 5500 Printer Service Manual

6 Adjustments and Calibrations
Service Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Print Quality Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Checking Registration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Adjusting Simplex Registration. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Adjusting Duplex Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Adjusting Fuser Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Resetting Fuser Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Resetting the Printer to Default Values. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Resetting Connection Setup Values . . . . . . . . . . . . . . . . . . . . . . 6-10
Resetting Paper Handling Setup Values . . . . . . . . . . . . . . . . . . . 6-10
Resetting PostScript Setup Values . . . . . . . . . . . . . . . . . . . . . . . 6-10
Resetting PCL Setup Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Resetting General Setup Values . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Resetting Front Panel Setup Values . . . . . . . . . . . . . . . . . . . . . . 6-11
Resetting Printer Controls Setup Values. . . . . . . . . . . . . . . . . . . 6-11
Resetting File Security Setup Values. . . . . . . . . . . . . . . . . . . . . . 6-12
Resetting Printer Default Settings (PostScript NVRAM) . . . . . . . 6-12
7 Cleaning and Maintenance

Service Preventive Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . 7-2
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
8 FRU Disassembly
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Standard Orientation of the Printer . . . . . . . . . . . . . . . . . . . . . . . . 8-2
General Notes on Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Notations in the Disassembly Text . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Print Engine Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Front Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Top Rear Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Inner Main Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Front Door Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Upper Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Rear Panel Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Lower Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
I/P Board Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Upper Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Tray 1/MPT Rear Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Lower Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Contents ix
Option Interface Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Exit 1 Top Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Upper Transportation and Registration . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Paper Size Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Tray 2 Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Tray 3 Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Feed/Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Tray 2 and 3 No Paper Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Tray 2 and 3 Level Sensor Actuator . . . . . . . . . . . . . . . . . . . . . . 8-25
Tray 2 and 3 Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Tray 2 and 3 Pre-Feed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
Feed Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
Retard Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
Nudger Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
Tray 1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
Tray 1 Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
Tray 1/MPT No Paper Sensor Actuator . . . . . . . . . . . . . . . . . . . 8-33
Tray 1/MPT No Paper Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34
Pick Up Gear Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35
Tray 1 Pick Up Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36
Cam Gear Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36
Feed Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
Retard Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39
Lower Transportation and Registration . . . . . . . . . . . . . . . . . . . . . . . . . 8-40
Take Away Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40
Door B Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41
Take Away Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41
Door B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43
Transfer Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44
Door A Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45
Door A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46
Registration Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46
Registration Transport Assembly. . . . . . . . . . . . . . . . . . . . . . . . 8-49
Registration Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51
Registration Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52
Take Away Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-53
Feed Out Sensor 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54
Xerographics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-56
Drum Cartridge Fan Intake Duct. . . . . . . . . . . . . . . . . . . . . . . . . 8-56
Drum Cartridge Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58
Fuser Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-59
Drum Cartridge Detect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 8-60
Environmental Sensor PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-64
Drum Cartridge CRUM PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-70
Toner Cartridge CRUM PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-71
Toner Dispense Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-71
x Phaser 5500 Printer Service Manual

Toner Dispense Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-73
Laser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-74
Fuser and Exit 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-76
Fuser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-76
Fuser Exit Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-77
Exit Transport Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-78
Exit 1 Offset Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-80
Offset Home Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-81
Full Stack Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-82
Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-83
Main Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-83
Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-84
Print Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-86
High Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-86
Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-86
Exit PWB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-88
Engine Logic Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-89
Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-90
Image Processor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-91
Low Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-92
AC Accessory Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-93
GFI Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-94
9 Parts Lists
Serial Number Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Using the Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Print Engine Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Xerox Supplies and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-44
10 Wiring Diagrams
Print Engine Plug/Jack Designators . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Plug/Jack Locator Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Drum and Toner Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Laser Assembly and Exit PWB . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Fuser and Exit 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Tray 1/MPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Registration Transport Assembly . . . . . . . . . . . . . . . . . . . . . . . 10-10
Tray 2 & 3 Feeder Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Print Engine Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Engine Logic Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Image Processor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
AC Accessory Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
LVPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Print Engine Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
Notations Used in Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . 10-17
Print Engine General Wiring (1/2). . . . . . . . . . . . . . . . . . . . . . . 10-19
Contents xi
Print Engine General Wiring (2/2) . . . . . . . . . . . . . . . . . . . . . . 10-20
LVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
Registration Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
Xerographics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
Drive/CRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
Tray 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
Tray 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
Tray 1/MPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
Laser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29
Exit 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
Engine Logic and Image Processor Board Interface. . . . . . . . . 10-31
Image Processor Board (1/2). . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
Image Processor Board (2/2). . . . . . . . . . . . . . . . . . . . . . . . . . 10-33
A Reference
Phaser 5500 Laser Printer Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Service Diagnostics Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Service Diagnostic Tests and Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
General Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
Test Print Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
Printer NVRAM Adjustments Menu . . . . . . . . . . . . . . . . . . . . . . A-10
Print Engine Motors/Fan Test Menu. . . . . . . . . . . . . . . . . . . . . . A-12
Duplex Unit Motor Tests Menu . . . . . . . . . . . . . . . . . . . . . . . . . A-12
Exit 2 Motor Tests Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13
Trays 4 & 5 Motor Tests Menu . . . . . . . . . . . . . . . . . . . . . . . . . A-13
Tray 6 Motor Tests Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13
Finisher Motor Tests Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-14
Print Engine Sensor/Switch Tests Menu . . . . . . . . . . . . . . . . . . A-15
Duplex Unit Sensor/Switch Tests Menu . . . . . . . . . . . . . . . . . . . A-16
Exit 2 Sensor/Switch Tests Menu . . . . . . . . . . . . . . . . . . . . . . . A-17
Tray 4 & 5 Sensor/Switch Tests Menu. . . . . . . . . . . . . . . . . . . . A-17
Tray 6 Sensor/Switch Tests Menu . . . . . . . . . . . . . . . . . . . . . . . A-18
Finisher Sensor/Switch Tests Menu. . . . . . . . . . . . . . . . . . . . . . A-19
Print Engine Solenoid/Clutch Tests Menu . . . . . . . . . . . . . . . . . A-20
Exit 2 Solenoid/Clutch Test Menu . . . . . . . . . . . . . . . . . . . . . . . A-21
Tray 4 & 5 Solenoid/Clutch Test Menu . . . . . . . . . . . . . . . . . . . A-21
Tray 6 Solenoid/Clutch Test Menu . . . . . . . . . . . . . . . . . . . . . . . A-21
Finisher Solenoid/Clutch Tests Menu. . . . . . . . . . . . . . . . . . . . . A-21
Controller NVRAM Access Menu . . . . . . . . . . . . . . . . . . . . . . . . A-22
Engine Logic Board Replacement Menu . . . . . . . . . . . . . . . . . . A-22
Finisher Board Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-23
Exit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-23
Mode Select Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-24
Index
xii Phaser 5500 Printer Service Manual
Service Terms
Manual Terms
Various terms are used throughout this manual to either provide additional
information on a specific topic or to warn of possible danger present during a
procedure or action. Be aware of all symbols and terms when they are used, and
always read NOTE, CAUTION, and WARNING statements.
Consumable: Ink, toner, or print cartridge that is consumed. Customer is expected
to replace once consumed.
Routine Maintenance Item: Supply item or kit that has a limited life. Customer
is expected to replace at end-of-life.
Accessory: A single component or assembly that may be added to a printer;
however, it is NOT an option to the product.
Common Acronyms:
FRU: Field Replaceable Unit
PL: Corresponds to the FRU Parts List.
CRU: Customer Replaceable Unit
ESD: Electrostatic Discharge
Note
A note indicates an operating or maintenance procedure, practice or condition
that is necessary to efficiently accomplish a task.
A note can provide additional information related to a specific subject or add a
comment on the results achieved through a previous action.
Caution
A caution statement indicates an operating or maintenance procedure, practice or
condition that, if not strictly observed, results in damage to, or destruction of,
equipment.
Warning
A warning statement indicates an operating or maintenance procedure, practice
or condition that, if not strictly observed, results in injury or loss of life.
Safety xiii
Product Terms
Caution: A personal injury hazard exists that may not be apparent. For example, a
panel may cover the hazardous area.
Danger: A personal injury hazard exists in the area where you see the sign.
Symbols Marked on the Product

DANGER high voltage.
Protective ground (earth) symbol.
Hot surface on or in the printer. Use caution to avoid personal

injury.
The surface is hot while the printer is running. After turning off
the power, wait 40 minutes.
00:40
Avoid pinching fingers in the printer. Use caution to avoid

personal injury.
Use caution (or draws attention to a particular component).

Refer to the manual(s) for information.
xiv Phaser 5500 Printer Service Manual

Power Safety Precautions
Power Source
For 110 VAC printers, do not apply more than 135 volts RMS between the supply
conductors or between either supply conductor and ground. For 220 VAC printers, do
not apply more than 254 volts RMS between the supply conductors or between either
supply conductor and ground. Use only the specified power cord. This manual
assumes that the reader is a Xerox-certified service technician.
Plug the three-wire power cord (with grounding prong) into a grounded AC outlet
only. If necessary, contact a licensed electrician to install a properly grounded outlet.
If the product loses its ground connection, contact with conductive parts may cause an
electrical shock.
Disconnecting Power
Turning the power off using the On/Off switch does not completely de-energize the
printer. You must also disconnect the printer power cord from the AC outlet. Position
the power cord so that it is easily accessible during servicing so that you may power
down the printer during an emergency.
Disconnect the power plug by pulling the plug, not the cord.
Disconnect the power cord in the following cases:
if the power cord or plug is frayed or otherwise damaged,

if any liquid or foreign material is spilled into the case,
if the printer is exposed to any excess moisture,
if the printer is dropped or damaged,
if you suspect that the product needs servicing or repair,
whenever you clean the product.
Safety xv
Electrostatic Discharge (ESD) Precautions
Some semiconductor components, and the respective sub-assemblies that contain
them, are vulnerable to damage by Electrostatic discharge (ESD). These components
include Integrated Circuits (ICs), Large-Scale Integrated circuits (LSIs), field-effect
transistors and other semiconductor chip components. The following techniques will
reduce the occurrence of component damage caused by static electricity.
Be sure the power is off to the chassis or circuit board, and observe all other safety
precautions.
Immediately before handling any semiconductor components assemblies, drain

the electrostatic charge from your body. This can be accomplished by touching an
earth ground source or by wearing a wrist strap device connected to an earth
ground source. Wearing a wrist strap will also prevent accumulation of additional
bodily static charges. Be sure to remove the wrist strap before applying power to
the unit under test to avoid potential shock.
After removing a static sensitive assembly from its anti-static bag, place it on a
grounded conductive surface. If the anti-static bag is conductive, you may ground
the bag and use it as a conductive surface.
Do not use freon-propelled chemicals. These can generate electrical charges

sufficient to damage some devices.
Do not remove a replacement component or electrical sub-assembly from its

protective package until you are ready to install it.
Immediately before removing the protective material from the leads of a

replacement device, touch the protective material to the chassis or circuit
assembly into which the device will be installed.
Minimize body motions when handling unpackaged replacement devices. Motion

such as your clothes brushing together, or lifting a foot from a carpeted floor can
generate enough static electricity to damage an electro-statically sensitive device
Handle ICs and EPROMs carefully to avoid bending pins.
Pay attention to the direction of parts when mounting or inserting them on

Printed Circuit Boards (PCBs).
xvi Phaser 5500 Printer Service Manual

Service Safety Summary
General Guidelines
For Xerox-certified service personnel only: Refer also to the preceding Power
Safety Precautions.
Avoid servicing alone: Do not perform internal service or adjustment of this
product unless another person capable of rendering first aid or resuscitation is present.
Use care when servicing with power: Dangerous voltages may exist at several
points in this product. To avoid personal injury, do not touch exposed connections and
components while power is on. Disconnect power before removing the power supply
shield or replacing components.
Do not wear jewelry: Remove jewelry prior to servicing. Rings, necklaces and
other metallic objects could come into contact with dangerous voltages and currents.
Power source: This product is intended to operate from a power source that will
not apply more then 254 volts RMS for a 220 volt AC outlet or 135 volts RMS for a
110 volt AC outlet between the supply conductors or between either supply conductor
and ground. A protective ground connection by way of the grounding conductor in the
power cord is essential for safe operation.
Warning Labels
Read and obey all posted warning labels. Throughout the printer, warning labels are
displayed on potentially dangerous components. As you service the printer, check to
make certain that all warning labels remain in place.
Safety Interlocks
Make sure all covers and the printers Front Panel are in place and all interlock
switches are functioning correctly after you have completed a printer service call. If
you bypass an interlock switch during a service call, use extreme caution when
working on or around the printer.
CLASS 1 LASER PRODUCT

The Phaser 5500 Laser Printer is certified to comply with Laser Product Performance
Standards set by the U.S. Department of Health and Human Services as a Class 1
Laser Product. This means that this is a class of laser product that does not emit
hazardous laser radiation; this is possible only because the laser beam is totally
enclosed during all modes of customer operation. When servicing the printer or laser
unit, follow the procedures specified in this manual and there will be no hazards from
the laser.
Safety xvii
Servicing Electrical Components
Before starting any service procedure, switch off the printer power and unplug the
power cord from the wall outlet. If you must service the printer with power applied,
be aware of the potential for electrical shock.
Warning
Turning the power off by using the On/Off switch does not completely de-
energize the printer. You must also disconnect the printer power cord from the
AC outlet. Position the power cord so that it is easily accessible during servicing.
Warning
Do not touch any electrical component unless you are instructed to do so by a
service procedure.
S7300-02
Servicing Mechanical Components

When servicing mechanical components within the printer, manually rotate drive
assemblies, rollers, and gears.
Warning
Do not try to manually rotate or manually stop the drive assemblies while any
printer motor is running.
S7300-03
Servicing Fuser Components

Warning
This printer uses heat to fuse the toner image to media. The Fuser is VERY HOT.
Turn the printer power off and wait at least 5 minutes for the Fuser to cool before
you attempt to service the Fuser or adjacent components.
xviii Phaser 5500 Printer Service Manual

Regulatory Specifications
Federal Communications Compliance
The equipment described in this manual generates and uses radio frequency energy. If
it is not installed properly in strict accordance with Xerox instructions, it may cause
interference with radio and television reception or may not function properly due to
interference from another device. However, there is no guarantee that interference
will not occur in a particular installation. If this equipment does cause harmful
interference to radio or television reception, which can be determined by turning the
equipment off and on, the user is encouraged to try to correct the interference by one
or more of the following measures:
Reorient or relocate the receiver (device being interfered with).

Increase the separation between the printer and the receiver.
Connect the printer into an outlet on a circuit different from that which the
receiver is connected.
Route the interface cables on the printer away from the receiver
Consult the dealer, Xerox service, or an experienced radio/television technician
for help.
Changes or modifications not expressly approved by Xerox can affect the emission
and immunity compliance and could void the user's authority to operate this product.
To ensure compliance, use shielded interface cables. A shielded parallel cable can be
purchased directly from Xerox at www.xerox.com/office/5500supplies.
Xerox has tested this product to internationally accepted electromagnetic emission
and immunity standards. These standards are designed to mitigate interference caused
or received by this product in a normal office environment. This product is also
suitable for use in a residential environment based on the levels tested.
In the United States this product complies with the requirements of an unintentional
radiator in part 15 of the FCC rules. Operation is subject to the following two
conditions: (1) this device may not cause harmful interference; (2) this device must
accept any interference received, including interference that may cause undesired
operation.
This digital apparatus does not exceed the Class B limits for radio noise emissions
from digital apparatus set out in the Radio Interference Regulations of the Canadian
Department of Communications, ICES-003.
Le prsent appareil numrique n'met pas de bruits radiolectrique dpassant les
limits applicables aux appareils numriques de la classe B prescrites dans le
Rglement sur le brouillage radiolectrique dict par le ministere des
Communications du Canada, NMB-003.
Safety xix
Declaration of Conformity
Xerox Corporation, declares, under our sole responsibility that the printer to which
this declaration relates, is in conformity with the following standards and other
normative documents:
In the European Union

following the provisions of the Low Voltage Directive 73/23/EEC and its
amendments:
EN 60950 Safety of Information Technology Equipment including Electrical Business

(IEC 60950) Equipment
following the provisions of the Electromagnetic Compatibility Directive 89/336/EEC

and its amendments:
EN 55022:1998 Limits and Methods of measurement of radio interference

(CISPR 22) characteristics of Information Technology Equipment. Class B.
EN 61000-3-2:1995 Part 3: Limits - Section 2: Limits for harmonic current emissions

+A1:1998+A2:1998 (equipment input current less than or equal to 16A per phase).
(IEC 61000-3-2)
EN 61000-3-3:1995 Part 3: Limits - Section 3: Limitation of voltage fluctuations and flicker

(IEC 61000-3-3) in low-voltage supply systems for equipment with rated current less
than or equal to 16A.
EN 55024:1998 Information technology equipment - Immunity characteristics - Limits

(CISPR 24) and methods of measurement.
This product, if used properly in accordance with the user's instructions is neither
dangerous for the consumer nor for the environment. A signed copy of the
Declaration of Conformity for this product can be obtained from Xerox.
xx Phaser 5500 Printer Service Manual

Manual Organization
The Phaser 5500 Laser Printer Service Manual is the primary document used for
repairing, maintaining, and troubleshooting the printer. The manual is organized into
two books. This volume, Book 1, focuses on the print engine with the exception of
providing complete diagnostic and troubleshooting procedure for the printer and all
its options. Book 2 focuses on option repair and includes an overview of option
theory, option Field Replaceable Unit (FRU) replacement procedures, parts lists, and
wiring diagrams. Use Book 2 after youve isolated a problem internal to a specific
option or when a problem arises at the engine/option interface.
Book 1 - Print Engine

Use Book 1 as your primary resource for understanding the operational characteristics
of the print engine. Book 1 describes printer specifications, theory and includes
information important to the diagnosis and repair of problems occurring in the print
engine and attached options. Book 1 also provides detailed print engine FRU
replacement procudures, FRU parts lists, and wiring diagrams of print engine
components.
Book 1 contains these sections:
Introductory, Safety, and Regulatory Information: This section contains
important safety information, regulatory requirements, and information about this
manual.
Chapter 1 - General Information: This section contains an overview of the
printers operation, configuration, specifications, and consumable.
Chapter 2 - Theory of Operation: This section contains detailed functional
information on print engine components.
Chapter 3 - Error Codes and Messages: This section describes the resident
diagnostics available to assist the troubleshooting process. These diagnostics include
Power On Self Test (POST), LED indicators, Service Diagnostics error codes and
messages and Service Usage Profile data stored in the printer. This section provides
complete troubleshooting information for the print engine and all its options.
Chapter 4 - General Troubleshooting: This section provides troubleshooting
methods for situations where no error indicator is available.
Chapter 5 - Print-Quality Troubleshooting: This section focuses on
techniques to correct image quality problems associated with printer output.
Chapter 6 - Adjustments and Calibrations: This section provides procedures
for the adjustment of print engine components.
Chapter 7 - Cleaning and Maintenance: This section provides periodic
cleaning procedures for the printer.
Safety xxi
Chapter 8 - FRU Disassembly: This section contains removal procedures for
parts listed in the print engines Field Replaceable Units (FRUs) Parts List. A
replacement procedure is included when necessary.
Chapter 9 - Parts Lists: This section contains exploded views of the print engine
FRUs as well as part numbers for items available as FRUs. Part numbers for printer
options and accessories are also included.
Chapter 10 - Wiring Diagrams: This section contains the plug/jack locations and
the wiring diagrams for the print engine.
Appendix A - Menu Maps: This section provides an illustration of the front-panel
menu as well as a listing of the Service Diagnostics tests available.
Book 2 - Options
Use Book 2 as a reference when servicing printer options. Book 2 includes
information important for the repair or replacement of option components. Use the
troubleshooting procedures in Book 1 to diagnose and isolated the problem.
Book 2 contains these sections:
Introductory, Safety, and Regulatory Information: This section contains
important safety information, regulatory requirements, and information about this
manual.
Chapter 1 - General Information: This section contains an overview of the
options available, configuration, specifications and consumables.
Chapter 2 - Theory of Operation: This section contains functional information
on each option.
Chapter 3 - FRU Disassembly: This section contains removal procedures for
parts listed in the options Field Replaceable Units (FRUs) Parts List. A replacement
procedure is included when necessary.
Chapter 4 - Parts Lists: This section contains exploded views of the option FRUs,
as well as FRU part numbers.
Chapter 5 - Wiring Diagrams: This section contains option plug/jack locations
and wiring diagrams.
xxii Phaser 5500 Printer Service Manual

General
Information
In this chapter...
Printer Introduction and Overview
Printer Configurations
Parts of the Printer
Consumables and Routine Maintenance Items
Printer Specifications
Chapter
1
Printer Introduction and Overview
The Xerox Phaser 5500 Laser Printer Service Manual is the primary document used
to repair, maintain, and troubleshoot this printer. For manual updates, Service
Bulletins, knowledge base, etc., see www.xerox.com/office/partners. For further
technical support, contact your assigned Xerox Technical Support for this product.
To ensure complete understanding of this product, participation in Xerox Phaser 5500
Laser Printer Service Training is strongly recommended. To service this product,
Xerox certification for this product is required.
s5500-006
The Phaser 5500 printer combines a dual-pass, monochrome laser print engine with
an image processor supporting Adobes PostScript 3 description language. The
PCL5e, PCL6 and Oak PCL 5.0 printer languages are also supported. Print speed is
50 pages per minute at either 600 x 600 or True 1200 x 1200 dpi in 1-sided or 2-sided
modes. The printer features a bi-directional parallel interface and a USB port. The
Phaser 5500 printer provides a 100-sheet Tray 1/MPT from which specialty media,
card stock, larger format paper, and envelopes are fed. Tray 1 also supports manual
feeding. Two additional trays, Tray 2 and 3, each provide 500 sheets of capacity. The
Standard Output Tray holds 500 sheets face down.
Phaser 5500 printer options add memory, paper capacity and functionality. For
models not originally equipped, an internal Hard Drive is available for font storage,
storing print files, job collation, proof print and secure print support. A selection of
RAM memory upgrades are available to raise the installed quantity to the 512 MB
maximum. A 1000-Sheet Feeder is available with two, 500-sheet universal media
trays (Trays 4 and 5). A 2000-Sheet Feeder (Tray 6) brings the maximum input
capacity to 4,100 sheets. An Envelope Tray, replacing Tray 2, holds up to 35
envelopes. On the output side, a 3,500-sheet, high-capacity stapler/punch/stacker is
available raising the output total to 4000 sheets. A Configuration Card adds 100baseT
Ethernet networking for host communication.
1-2 Phaser 5500 Printer Service Manual

The following table lists the features of the five Phaser 5500 printer configurations.
Features
5500B 5500N 5500DN 5500DT 5500DX
Maximum Print 50 ppm 50 ppm 50 ppm 50 ppm 50 ppm

Speed (Letter-size
Paper)
Memory 128 MB 128 MB 128 MB 128 MB 256 MB
PostScript Fonts 137 137 137 137 137
Oak PCL 5.0 Yes Yes Yes Yes Yes
PCL5e/PCL6 Yes Yes Yes Yes Yes
Job Pipelining Yes Yes Yes Yes Yes
PDF Direct Print Yes Yes Yes Yes Yes
Resolutions 600 or 600 or 600 or 600 or 600 or

True 1200 dpi True 1200 dpi True 1200 dpi True 1200 dpi True 1200 dpi
USB, Parallel Yes Yes Yes Yes Yes
Ethernet Optional Standard Standard Standard Standard

Capabilities
1000-Sheet Feeder Optional Optional Optional Standard Standard
Automatic 2-Sided Optional Optional Standard Standard Standard

Printing (Requires
Duplex Unit)
Hard Drive Optional Optional Optional Optional Standard
Job Collation Optional Optional Optional Optional Standard

(Hard Drive
Required)
Proof Print, Optional Optional Optional Optional Standard

Personal Print,
Secure Print, Saved
Jobs (Hard Drive
Required)
2,000-Sheet Feeder Optional Optional Optional Optional Standard

(Requires 1000-
Sheet Feeder)
3,500-Sheet Optional Optional Optional Optional Standard

Finisher (Requires
1000-Sheet Feeder)
General Information 1-3

Parts of the Printer
Front View
1. Standard Output Tray
1 8 10 2. Front Door
4
3. Tray 2 and 3
4. Optional Duplex Unit
5. Tray 1/MPT
5 6. 2000-Sheet Feeder (Tray 6)
9 7. 1000-Sheet Feeder (Tray 4 & 5)
8. Finisher
9. Stacker Lower Tray
3
10.Stacker Upper Tray
2
6 5500-107
Rear View
1. Parallel Connection
2. Ethernet Connection
3. USB Connection
4. Configuration Card
5. Mode Select Port
6. Serial Debug Port
7. Ground Fault Interrupt Reset
8. Printer Power Connection
1
9. Finisher Connection
2 10.1000-Sheet Feeder Connection
11 11.Duplex Unit Connector
3 10
9
5 7
6 8
4
s5500-017

Front Panel
The Front Panel consists of one tricolor LED, a display, and six functional buttons.
Listed below are the functions of each Front Panel control and indicator.
4 6
READY TO PRINT.
Information
Walk-Up Features
Printer Setup
Troubleshooting
Shutdown
1 2 3 5 7 8 9
5500-016
1. LED 6. Up Arrow button - scrolls up the menu system
2. Front Panel display 7. Down Arrow button - scrolls down the menu system
3. Toner Gauge 8. OK (select) button
4. Cancel button 9. Information button - for additional explanation or help
5. Back button
LED States
LED State Printer State
Green Ready to Print
Flashing Yellow Warning (but can still print)
Flashing Green In Power Saver mode or busy (receiving or processing data)
Flashing Red Error; cannot print

Printer Options
Phaser 5500 printer options include:
20 GB Hard Drive
Additional RAM and NVRAM
Exit 2
Configuration Card
1000-Sheet Feeder (Tray 4 & 5)
Duplex Unit
3,500-Sheet Stacker (with offset)
3,500-Sheet Finisher (with hole punch, staple, offset)
2,000-Sheet Feeder (Tray 6)
Envelope Tray (replaces Tray 2)
Hard Drive
A 20 GB hard drive is available to enable the Job Collation, Saved Jobs, Proof,
Personal, and Secure Print options. The hard drive installs on the Image Processor
Board with stand-offs and connects to the board with a single data/power connector.
Additional Memory
Options provide additional RAM in 128 MB and 256 MB increments. Also available
is 16 MB of Flash Memory for fonts, forms, and macros. Both RAM and NVRAM
options install to the Image Processing board. The Startup Page and Configuration
Page list the amount of installed RAM. See Memory Specifications on page 1-11.
Exit 2
Exit 2 is required when either the Duplex Unit or Stacker/Finisher is installed. When
used in conjunction with the Duplex Unit, Exit 2 performs as a paper inverter. With
the Stacker/Finisher, Exit 2 serves as the replacement face-down exit to the top tray.
Exit 2 mounts directly above Exit 1 with spring loaded latches and guide pins.
Networking
A Configuration Card is used to enable or disable networking capabilities. This option
provides a replacement card to enable Ethernet on the base model (Phaser 5500B
printer).

1000-Sheet Feeder
The 1000-Sheet Feeder forms a base for the printer and adds two, 500-sheet trays
(Tray 4 and Tray 5). Control signals reach the sheet feeder by a single connection.
The sheet feeder is secured to the print engine with two screws located under the front
edge of Tray 3.
s5500-012
Duplex Unit
The Duplex Unit adds two-sided printing. The Duplex Unit attaches to the left side
above Tray 1 using two twist locks. Installation of the Duplex Unit requires that the
Exit 2 Module also be added to provide reverse drive. Electrical connection to the
printer is made by an interface cable.
A
D
s5500-008

Stacker / Finisher
The Stacker/Finisher increases the output capacity of the printer by 3,500 sheets.
Printer output is directed to the Stacker/Finisher by way of Exit 1 and the Horizontal
Transport. With Exit 2 installed, the top surface of the Horizontal Transport serves as
the top tray and paper output capacity remains at 500 sheets. Depending on the level
of Stacker/Finisher options and job specifications, as paper enters the Stacker/
Finisher it is punched, stapled, offset and stacked. Control signals reach the Stacker/
Finisher through a single connector. Power is supplied from the printers AC
Accessory Panel.
2
1
s5500-009
1. Horizontal Transport 2. Stacker/Finisher

2000-Sheet Feeder
The 2000-Sheet Feeder (Tray 6) nearly doubles the input capacity of the printer. The
feeder attaches to the left side of printers equipped with the 1000-Sheet Feeder option
just below Tray 1/MPT using the supplied docking bracket. Electrical connection to
the printer is made by an interface cable.
s5500-013
Envelope Tray
The Envelope Tray replaces Tray 2 to handle up to 35 envelopes.
s5500-014
Caution
To avoid damage to the Envelope Tray, use the Tray 2 position only.

Consumables and Routine Maintenance Items
1 3
4
2 s5500-010
1. Fuser 3. Drum Cartridge
2. Transfer Roller 4. Toner Cartridge
Supply Life Counters

Counters track the usage of the consumables and routine maintenance items and store
the values in NVRAM. Access the current status of these counters from the Supplies
Info menu. In addition to the counters, a Toner Gauge is provided on the Front Panel
that approximates the Toner Cartridge counter value. As counters near their
minimums, warning messages appear on the Front Panel.
Print life ratings are based on 5% coverage and an average job length of 6 pages.
Consumables Print Life (Number of Images)
Toner Cartridge 30,000
Routine Maintenance Items
Fuser 300,000
Drum Cartridge 60,000
Maintenance Kit (consists of Fuser, 300,000

Transfer Roller and 15 Feed Rollers)

Printer Specifications
Physical Dimensions
Device Height Width Depth Weight
Print Engine 498 mm (19.6 in.) 640 mm (25.2 in.) 525 mm (20.7 in.) 41 kg (90 lbs.)
Duplex Unit 211 mm (8.3 in.) 64 mm (2.52 in.) 458 mm (18.0 in.) 1.8 kg (4 lbs.)
1000-Sheet 280 mm (11.0 in.) 540 mm (21.2 in.) 520 mm (21.1 in.) 23 kg (50 lbs.)
Feeder
Stacker/ 1050 mm 740 mm (29.1 in.) 650 mm (25.6 in.) 49 kg

Finisher (41.3 in.) (108 lbs.)
Exit 2 142 mm (5.6 in.) 130 mm (5.1 in.) 460 mm (18.1 in.) 2 kg (4.4 lbs.)
Envelope Tray 76 mm (3.0 in.) 538 mm (21.2 in.) 521 mm (20.5 in.) 3.2 kg (7 lbs.)
2000-Sheet 363 mm (14.3 in.) 385.5 mm 600 mm (23.6 in.) 50 kg

Feeder (15.1 in.) (110 lbs.)
Memory Specifications
Characteristic Specification
Minimum RAM 128 MB
Maximum RAM 512 MB
Supported RAM SO-DIMM 144-pin module of 128 or 256 MB. All combinations are allowed
for configurations of 128, 256, 384, and 512 MB.
NVRAM Single chip of either PPROM or StrataFlash 16 MB
Operational Clearances
Clearance Specification
Top 890 mm (35.0 in.)
Left 640 mm (25.2 in.)
Right 200 mm (7.9 in.), 1000 mm (39.4 in.) with Finisher
Front 460 mm (18.1 in.)
Rear 200 mm (7.9 in.)
Height 1190 mm (47.0 in.)

requirement

89 cm
(35 in.)
20 cm
(8 in.)
20 cm
(8 in.)
118 cm 46 cm 120 cm
(46 in.) 46 cm (18 in.) (47 in.)
(18 in.)
119 cm
(47 in.) 100 cm
(39 in.)
46 cm
20 cm (18 in.)
(8 in.)
218 cm
(86 in.)
65 cm
(26 in.)
118 cm
(46 in.)
s5500-610

Functional Specifications
Printing process: Recording System: Electrophotography (roller charging, magnetic

dual component toner and DRUM Cartridge)
Exposure System: Semiconductor laser beam scanning
Transfer System: Roller transfer system
Fusing System: Thermal fixing using a heat roller
Resolution / 600/ True 1200 dpi

Addressability
Print-Quality Two choices: 600 x 600 dpi

Modes True 1200 x 1200 dpi
Continuous 50 pages per minute for plain Letter paper, simplex or duplex
Operating Printing 50 pages per minute for A4 paper, simplex or duplex
Speed
Warm-Up Time:
Sleep Mode 45 sec.
Stand By 6 sec.
Electrical Specifications
Primary Line Voltages 120 VAC nominal, min. 99 V, max. 135 V

220/240 VAC nominal, min. 198 V, max. 254 V
Primary Line Voltage 50/60 Hz 3 Hz

Frequency Range
Input Current:
Operating 12 A max. @ 120 V
8 A max. @ 240 V
Rush 100 A max.
Power Consumption:
Operating (5500DX) 1150 W max. @ 120 V, 1300 W max. @ 240 V
Low Power TBD Ron to provide BTU and Wattage
Sleep Mode 10 W max @ 120/240 V
BTUs at 120V: Operating 3924

Power Saver 34
BTUs at 240V: Operating 4436

Power Saver 34

Environmental Specifications
Temperature:
Operating 5 to 32 C (41 to 95 F)
Transportation -20 to 40 C (-4 to 104 F)
Humidity (%RH)
Operating 15 to 85
Transportation 5 to 85
Altitude
Operating 0 to 2,500 meters (8,200) feet)
Transportation* 0 to 15,000 meters (49,200 feet)
Acoustic Noise
LWA(B) Engine only Bystander Position
Standby 4.0 B 22 db
Printing 7.1 B 54 db
* Air transportation in pressurized cargo space
Tray and Media Specifications
Tray Specifications
Characteristic Trays Specifications
Printable Area All Within 4 mm of paper edge guaranteed.

Edge-to-edge printing supported.
Supported Tray 1 or Tray 2 COM-10 (4.1 x 9.5 in.)

Envelopes (with Envelope Tray Monarch (3.8 x 7.5 in)
installed) DL (110 x 220 mm)
C5 (162 x 229 mm)
Supported Media Tray 1,3,4,5,6 60-216 g/m2 (16 lb. bond to 133 lb. card stock)
Weights Tray 2
60-105 g/m2 (16 to 28 lb. bond)
Duplex
60-163 g/m2
Tray Capacity Tray 1 100 Sheets / 15 envelopes

Tray 2 500 Sheets or 35 envelopes with Envelope Tray
Tray 3 500 Sheets
Tray 4 500 Sheets
Tray 5 500 Sheets
Tray 6 2000 Sheets
Top (face-down) 500 Sheets
Stacker/Finisher 3000 elevator, 500 in top tray
Based on 75 g/m2 (20 lb.) paper stock.
Capacity is reduced for heavier/thicker stock.

Supported Paper Specifications
Paper Sizes and Weights
User-Selected Size Input Output

Auto-Sensed Size
Supported
Supported only when Long-Edge Feed
Depending on your region, finishers are
Standard Output Tray

configured with either a 3-hole punch or a
Stacker Lower Tray

Stacker Upper Tray
2-hole and 4-hole punch.
2-Sided Printing
Holes Punched
Envelope Tray
These custom widths are supported with
Tray 1/MPT
stapling and hole punching: 210 mm (8.27
Tray 3-5
in.), 257 mm (10.12 in.), 297 mm (11.70
Staple
Tray 2
Tray 6
in.), 8.50 in. (216 mm), 10.50 in. (267 mm),
11.00 in. (279 mm).
Paper Size
Letter (8.5 x 11 in.) 2, 3, 4

A4 (210 x 297 mm)
Legal (8.5 x 14 in.) 2

US Folio (8.5 x 13 in.)
Executive (7.25 x 10.5 in.) 2, 3, 4
A5 (148 x 210 mm)

Statement (5.5 x 8.5 in.)
Small US Postcard (3.5 x 5.5 in.)
Large US Postcard (4.0 x 6.0 in.)

A6 (105 x 148 mm)
Tabloid (11.0 x 17.0 in.) 2, 3, 4

A3 (297 x 420 mm)
B4 JIS (257 x 364 mm) 2
B5 JIS (182 x 257 mm) 2
B6 JIS (128 x 182 mm)
Envelopes
#10 Commercial (4.12 x 9.5 in.)

Monarch (3.87 x 7.5 in.)
DL (110 x 220 mm)

C5 (162 x 229 mm)
C4 (229 x 324 mm)

Paper Sizes and Weights (Continued)
User-Selected Size Input Output

Auto-Sensed Size
Supported
Supported only when Long-Edge Feed
Depending on your region, finishers are

configured with either a 3-hole punch or a
Stacker Lower Tray

Stacker Upper Tray
2-hole and 4-hole punch.
2-Sided Printing
Holes Punched
Envelope Tray
These custom widths are supported with
Tray 1/MPT
stapling and hole punching: 210 mm (8.27
Tray 3-5
in.), 257 mm (10.12 in.), 297 mm (11.70
Staple
Tray 2
Tray 6
in.), 8.50 in. (216 mm), 10.50 in. (267 mm),
11.00 in. (279 mm).
Custom Width /
Custom Height
89297 mm (3.5011.70 in.)/
98127 mm (3.875.00 in.)
89297 mm (3.5011.70 in.)/

127182 mm (5.007.16 in.)
89140 mm (3.505.50 in.)/

182432 mm (7.1617.00 in.)
140182 mm (5.507.16 in.)/

182432 mm (7.1617.00 in.)
182210 mm (7.168.27 in.)/

182432 mm (7.1617.00 in.)
210297 mm (8.2711.70 in.)

182432 mm (7.1617.00 in.)
Envelope Custom Width /

Envelope Custom Height
148241 mm (5.829.50 in.)/
98162 mm (3.876.38 in.)
Paper Weight
60105 g/m2 (1628 lb. Bond)
105120 g/m2 (2832 lb. Bond)
120176 g/m2 (3247 lb. Bond)
176215 g/m2 (4757 lb. Bond)

Theory of
Operation
In this chapter...
Phaser 5500 Operational Overview
Paper Path
Sensors
Xerographics
Major Assemblies
Chapter
2
Phaser 5500 Operational Overview
The Phaser 5500 base configuration combines a dual-pass, monochrome laser print
engine with a multi-purpose Tray 1/MPT and two universal media trays, trays 2 and 3.
The Standard Output Tray holds 500 sheets facedown. Phaser 5500 options add
memory, paper capacity, and functionality. For models not originally equipped, a 20
GB Hard Drive is available. A selection of memory upgrades can raise the installed
RAM to the 512 MB maximum. Additional paper capacity is also available. Trays 4
and 5 (1000-Sheet Feeder) when installed, add two 500-sheet universal media trays.
An optional high-capacity 2000-Sheet Feeder (Tray 6) brings the maximum paper
capacity to 4,100 sheets. An Envelope Tray, replacing Tray 2, holds up to 35
envelopes. On the output side, 3500 sheet stapler/punch/stacker is available.
This section focuses on the printers operational characteristics providing detailed
descriptions of the paper path, sensors, xerographics and major system assemblies.
Operational details of the available options appear in Book 2, Phaser 5500 Printer
Options Service Manual.
Summary of the Printing Process

The illustration below shows the orientation of the major components associated with
the xerographics process as viewed from the front of the printer.
Pressure Heat Roller

Roller Fuser
Cleaning
Blade
BCR
Detack Saw Drum

Paper Transfer Roller Laser Beam
Transport
Charge Metering Blade
Drum Cartridge Magnetic Roller
Paper s5500-015

The laser print process consists of these steps:
1. Charge The Drum Cartridge contains a Bias Charge Roller that uniformly
distributes a negative electrical charge over the photoconductive drum surface.
2. Exposure The Laser Assembly scans the surface of the photoconductive drum
located inside the Drum Cartridge. The Laser Diode Assembly produces dual
laser beams which are turned on and off according to a data signal. A multi-
faceted polygonal mirror is rotated at a specified speed. The laser beams are
reflected off of the mirror and onto the drum surface through a series of lenses
and mirrors. The laser beams scan the drum surface from one end to the other,
neutralizing the negative charge to create one line of a latent image on the drum
surface. The drum is rotated and the scan process is repeated.
3. The Toner Cartridge supplies toner to the Drum Cartridge. Capacity is
30,000 pages at 5% area coverage.
4. Development A Magnetic Roller in the Drum Cartridge carries a thin layer of
developer and toner supplied by an agitator in the cartridge's toner compartment.
The Charging and Metering (CM) Blade inside the cartridge applies a negative
charge to the toner and spreads the toner onto the Magnetic Roller. The
negatively charged toner is transferred to the Areas of the drum surface that have
been discharged.
5. Paper Transport Paper size sensors determine the length and width of the
media. Movable actuators located in the paper tray indicate the location of the
guides. The Phaser 5500 uses a three-roller system to pick paper. A DC motor
raises the tray's lift plate, along with the paper stack, against the Nudger Roller of
the paper feeder assembly. To pick paper, the Nudger Roller advances the top
sheet to the Feed Roller and Retard Roller. The Retard Roller prevents multi-
picks. The Feed Roller advances the paper to the Take Away Rollers, which feed
the paper to the Registration Rollers.
6. Transfer The pressure of the Transfer Roller against the drum assists in driving
the paper through the transfer area. The Transfer Roller applies a positive charge
to the rear surface of the paper. The negatively charged toner image on the drum
is attracted to the positive charge on the rear surface of the paper, transfers the
image from the surface of the drum onto the paper.
7. Discharge The Detack Saw, located on the Transfer Roller assembly, helps to
separate the paper by partially neutralizing the charge holding the paper to the
drum.
8. Fusing The paper is driven into the Fuser, which uses heat and pressure rolls to
melt and bond the toner onto the surface of the paper. Heat Roller fingers inside
the fuser peel off the leading edge of the paper from the Heat Roller to prevent
the paper from becoming wrapped around the drum. The Fuser Exit Sensor
detects paper exiting from the fuser.
9. Cleaning A cleaning blade in the Drum Cartridge scrapes off toner remaining
on the drum surface after Transfer has occurred. Then, the latent charge pattern
remaining on the photoconductive drum is neutralized to prepare the drum for the
next Exposure cycle.
10. Paper Exit The paper is then advanced upward into the Exit Rollers and into the
selected output tray.
11. Two-sided printing reverses the direction of the exit rollers to route the paper
through the Duplex Unit rollers and back to the Registration Roller. A Wait
Sensor in the Duplex Unit detects the presence of paper.
Theory of Operation 2-3

Paper Handling
Paper is driven along the paper path by various drive motors, belts, gear assemblies
and rollers. Synchronization of these components is managed by the Engine Logic
Board. The operating system monitors sensors located along the paper path
throughout the print engine and attached options. As a sheet travels along the paper
path, sensors change state temporarily to indicate the sheets presence. If the pattern
of sensor state changes differs from the expected timing for a particular paper size and
path, an error is reported.
Main Motor
The Main Motor, through the gear and pulley, drive the Take Away Roller, Feed
Roller, Registration Roller, Fuser, and Exit 1 OCT Roller.
Main Motor
Gear Pulley 25T
Take Away Clutch Gear-Exit
Take Away Bracket Gear-19T
Gear-18T Feed Roller Regi Roller Fuser OCT Roller
Take Away Roller

s5500-020
Drum Motor
The rotating force of the Drum Motor is transmitted through the gears to components
that need mechanical driving force as shown in the following flow.
Drum Motor
Drum Magnetic Roller
Transfer Roller
s5500-021

The driving force transmitted to the Drum Cartridge drives the Drum. The driving
force is then transmitted to the Transfer Roller by direct contact with the Drum.
Input Paper Path

Paper supplied from each tray is transported through the printer along the paper path
shown below.
Tray 1/MPT Tray 2 Tray 3
Feed Roller Nudger Roller Nudger Roller
Drive Roller Feed Roller Feed Roller

Retard Roller Retard Roller
Feeder Assy Feeder Assy
Take Away Roller
Registration Roller
Transfer Roller
Drum
CRU
Heat Roller
Pressure Roller
Fuser
Invert Roller OCT Roller

Face Up Roller Exit Pinch Roller
Exit1
OCT Roller
Exit Pinch Roller Duplex A3L Roller
Option Exit2+OCT2 Duplex Roller
Option Duplex
Exit
s5500-022

The diagram shows the paper path for Trays 1 through 5, the Duplex Unit, Exit 1, and
Exit 2.
Face Up Roller
Invert Roller Exit Pinch Rollers
Exit 2
Duplex Unit OCT Rollers

A3L Rollers
Pressure Roller
Duplex Heat Roller
Roller
Transfer Roller
Pinch
Rollers Drum
Registration
Pinch Roller
Feed Roller Registration Roller
Tray 2
Pinch Roller
Drive Roller Tray 3 Nudger Rollers
Pinch Rollers Tray 4

1000 Sheet Feeder
Tray 5
Take Away Rollers
Feed Rollers
Retard Rollers s5500-233
Tray 1/MPT
When feeding media from Tray 1/MPT, the control logic instructs the mechanical
drive to activate the Feed Roller. When the control logic calls for paper feed, it sends
a feed signal to momentarily energize the Tray 1/MPT Pick-up Solenoid causing the
Feed Roller to rotate. When the Feed Roller contacts the paper, a sheet is fed into the
gap between the Feed Roller and the Pinch Rollers.

Trays 2 through 5
When the control logic calls for paper feed, the Nudger Roller moves a sheet of paper
to the Feed Roller. The Feed Roller moves a single sheet of paper out of the tray and
toward the trays Take Away Roller. The Retard Roller ensures only one sheet of
paper is fed. The paper then moves past the Pre-Feed Sensor and up the vertical path
driven by a sequence of Take Away Rollers. Feed Out Sensors at each feed point
notify the Engine Logic Board that the paper has arrived at the next Take Away Roller
in the path. The paper continues along the path until the sheet of paper arrives at the
Registration Roller.
Output Paper Path

The Phaser 5500 paper path for paper exiting the fuser are:
Direct through Exit 1 to the Output Tray on the Top Cover (facedown).
Direct through Exit 1, the Horizontal Transport to the Stacker Trays.
Direct through Exit 2 to the Output Tray on the Horizontal Transport Cover.
Inverted in Exit 2 back through the Duplex Unit then out Exit 1 or Exit 2.
Inverted in Exit 2 back through the Duplex Unit then out Exit 1 to either the
Stacker Upper or Lower Tray.
Shown below are the possible output paper paths.
Stacker Upper
Tray
Horizontal Stacker Lower

Transport Punch
Exit 2 Tray
Exit 1
Compiler Tray
Stapler
s5500-024

The Standard Output Tray is a face-down, 500-sheet tray located on the printers Top
Cover. The tray receives paper from Exit 1 if the Horizontal Transport is not installed.
The Standard Output Tray becomes the Horizontal Transports Door F (Top Cover)
and receives paper through Exit 2 when the Horizontal Transport is installed.
Horizontal Transport
When either the Stacker Upper or Lower Trays are designated as the output location,
the Exit 1 Exit Gate opens and paper is fed from Exit 1 to the Horizontal Transport.
The Horizontal Transport motor is activated by Horizontal Transport PWB to drive
the two feed belts running between the Left and Right Shaft assemblies. The paper is
held between the belts and pinch rollers located on the inside of Door F.
To Finisher
From Exit 1
Belt
Entrance Sensor Exit Sensor
s5500-025

Finisher/Stacker
What follows is a summary of the output path through the Finisher. A detailed
description of the Finisher paper path appears in Book 2, Chapter 2.
Top Exit Rollers

(Driven by Exit Motor)
Transfer Rollers
(Driven by Regi Motor)
Transfer Gate
Sub Paddle
Gate Sensor (Driven by Finisher Transport
Motor)
Eject Clamp
Entrance Rollers (Driven by Eject Clamp Motor)
(Driven by Finisher
Transport Motor)
Buffer Roller Eject Roller Shaft
(Driven by Regi Motor) (Driven by Eject Motor)
Buffer Gate Lower Exit Rollers
Main Paddle (Driven by Exit Motor)
(Driven by Finisher Transport Motor) s5500-026
Paper fed from the Horizontal Transport is drawn into the Finisher by the Entrance
Roller driven by the Finisher Transport Motor. The paper next passes through the
Punch, if installed, then is directed either up or down by the Transfer Gate. The
Transfer Gate is switched by the Transfer Gate Solenoid controlled by signals
received from the Engine Logic Board.
Paper output to the Stacker Upper Tray is directed upwards by the Transfer Gate and
drawn along the paper path by the two Transfer Rollers. The paper exits the Finisher
by being driven into the Stacker Upper Tray by the Top Exit Rollers.
Paper punched, stapled, offset, or sent to the Stacker Lower Tray is directed down by
the Transfer Gate. For print jobs not receiving any Finisher processing, paper travels
across the Buffer Roller, Buffer Gate, and is drawn out of the Finisher into the Stacker
Lower Tray by the Lower Exit Rollers. For Punch operations, the paper is drawn
across the Buffer or Transfer Rollers, then reversed to back into the Punch guide.
After the sheet is punched, it moves out of the Punch and depending on the job, either
moves upward to the Stacker Upper Tray or continues to the Stapler. For compiled,
stapled, or offset print jobs, the Buffer Gate is raised by the Buffer Gate Solenoid
directing the sheet around the circumference of the Buffer Roller and into the Buffer
Path. The first sheet of each set is held in the Buffer Path until the second sheet arrives
at the Buffer Gate. When the second sheet arrives, both sheets are drawn towards the
Exit Clamp by the lower Exit Rollers and are clamped and either ejected into the
Stacker Lower Tray or loaded into the Compiler Tray for tamping and offset.

Duplex Path
If duplex printing is selected, the Exit 2 Exit Gate Solenoid switches the position of
the Exit gate to direct paper out Exit 2. The Exit 2 Motor reverses direction and feeds
the paper into the Duplex Unit. The paper pauses briefly, detected by the Wait Sensor,
then continues through the Duplex Unit to the Registration Roller for printing on the
opposite side. The purpose of the Duplex Unit is to accept a printed sheet of paper
from the Fuser exit area, effectively flipping the sheet over, wait a period of time for
the second side to develop, then reinsert the sheet back into the printer registration
area to receive an image on the reverse side. The Duplex Unit provides duplex
printing for paper fed from all available paper trays except the Envelope Tray, which
cannot be duplexed.
Exit 2 Exit Sensor
Fuser Exit Sensor
Wait Sensor
Registration Sensor
Pre Feed Sensor s5500-583

Sensors
The printer contains sensors of various types that perform a variety of functions. One
group of sensors track the progress of the paper along the paper path, and detect if a
paper jam occurs. Other sensors detect the presence of the Drum Cartridge, stop
printer activity if a door is open (interlock), and monitor the fusing temperature.
Sensor Types
The types of sensors used vary with function. In general, there are three types in use:
Photo Sensors
Two types of photo sensors are used, photo-reflective and photo-receptive. Photo-
reflective sensors use light reflected back from an object to detect its presence. Photo-
receptive sensors use an actuator or the object itself to block the light path to detect an
object or condition.
Photo-reflective sensors have the light emitter and light receiver aligned on a single
surface. Output of the photo-receptor is High (> +4.5 V) when light is being reflected
back and Low (< +.3 V) when it isnt. Photo-receptive sensors consist of a LED in one
arm of a U-shaped holder, and a photo-transistor in the other arm. When the sensing
area is vacant, nothing is between the arms of the sensor, light falls on the photo-
receptor sending the signal High. If the light is interrupted, the photo-transistor goes
Low. The figure below shows a typical photo-receptive sensor with the Hooks
(catches) used to secure the sensor to its bracket.
Hooks
Hook
Sensor Bracket
Microswitches
Microswitches are used primarily as cover interlocks in the printer. They are in a
normally open state, and close when actuated. A bank of microswitches is used to
detect paper size in the universal trays. Microswitches also employ hooks or catches
for retention in the bracket or frame. The figure illustrates a typical microswitch.

Microswitch
s5500-028
Thermistor
Thermistors have a known value of resistance whose value varies with temperature.
Used primarily in the Fuser for temperature sensing.
A fourth sensor in use is the antenna used to communicate with the Drum and Toner
Cartridge CRUMs.
This list briefly describes the type and function of sensors and switches used to
determine operational status and detect jams or failures.
List of Sensor and Interlock Functions
Name Type Function

Level Sensor Photo-receptive Detects paper stack height in Trays 2~6.
No Paper Photo-receptive Detects no paper condition in all trays.
Paper Size Microswitch array Detects the tray and the paper size.
Pre-Feed Photo-reflective Detects paper jams in the feeder.
Registration Photo-receptive Detects paper at the registration rollers.
Feed Out Photo-reflective Detects paper leaving the feeder.
Exit Photo-receptive Detects paper as it leaves the Exit.
Stack Full Photo-receptive Detects when the output tray is full.
Temperature Thermistor Monitor temperature of the Heat Roller.
Door Interlocks Microswitch Interrupts +24 V to the Main Motor
Drum Cartridge Microswitch Interrupts +5 V to Laser Diode.
Detect switch
Start of scan Photo Detects laser at the start of a scan.
Fuser Thermostats Thermostatic switches Interrupts AC power to the Fuser.
Offset Photo-receptive Senses the position of the Offset Chute.
Environmental Integrated circuit PWB Monitors the printers Temp and humidity.
CRUM antenna Inductive code reader Communicates with the CRUMs.
OCT Home Photo-receptive Detects Offset assembly home position.
Position

Sensors in the Paper Path
The following illustrations show the designations of the various sensors located along
the paper path. Error reporting is dependent on these designators. Error detection is
based on paper transport timing through the sensing area.
Door Interlock Sensors

The Interlock Sensors for Doors A through E and J, as well as selected paper feed
sensors appear in the following diagram.
Front Door Interlock
Door E Interlock
Door A Interlock
Door D Interlock
Door B Interlock
Tray 6
Pre Feed Sensor
Door J Interlock
Tray 6
Paper Size Sensors
Door C Interlock
Tray 6
Docking Interlock
s5500-584

Paper Feed Sensors
The diagram below identifies the remaining paper feed sensors in the Printer,
1000-Sheet and 2000-Sheet Feeders.
Exit 2 Exit Sensor
Duplex Wait Sensor

Fuser Exit Sensor
Registration
Feed Out Sensor #3
Sensor
Pre Feed
Sensor
F/O Sensor #6
Paper Size
Switch
F/O Sensor #5 F/O Sensor #4 s5500-586
Paper Size Sensing

Trays 2 through 5 automatically sense the standard size media loaded in the printer by
using the paper size sensors mounted on the back of the tray frame. When paper is
loaded in the tray and the paper guides are adjusted, the levers on the bottom of the
trays change the size sensor actuator locations.
Actuating different combinations of the paper size sensors produces different
combinations of high and low signals. These signals identify what size of paper has
been loaded and what to display on the Front Panel. Also, any actuation of the paper
size sensor signals the Engine Logic Board that the tray is present and closed.

Paper Level Sensing
As paper is fed from the tray, the paper level drops. When the paper level reaches a
certain point, an actuator unblocks the Level Sensor signaling the control logic to stop
paper feed and raise the tray bottom. Raising the tray bottom pushes the paper up to
achieve optimum force against the Feed Roller and blocks the Level Sensor resuming
paper feed. This loop continues until the No Paper sensor is activated. Paper level
sensing operates the same way for Trays 2 through 6. Tray 1 uses No Paper sensing
only.
Paper Present Sensing

When the last sheet is fed from any of the trays, the No Paper Sensor actuator drops
into an opening in the paper tray, unblocking the sensor. Feeding is inhibited until
paper is loaded into the tray.
Xerographics
Drum Cartridge
The Drum Cartridge is located behind the Front Door and is a customer-replaceable
item. The Drum Cartridge has a maximum drum cycle count of 240,000. The number
of drum cycles per page and the prints available varies according to the customers
usage patterns. The Drum Cartridge Life specification of 60,000 prints is based on an
average job length of six, single-sided pages.
As an example of how job length effects the Drum Cartridge Life count, a continuous
print job having a job length of 500 to 1000 pages results in a drum cycle count of 3.2
cycles per page. At 3.2 drum cycles per page, the Drum Cartridge Life count increases
to 75,000 prints. However, if the customer were to print mostly single page jobs, the
drum cycle count increases to 7.68 drum cycles per page reducing the Drum Cartridge
Life count to 31,250 prints.
To better understand how the Drum Cartridge operates, the name and function for
each Drum Cartridge component is listed below.
Drum Cartridge Components
Component Function
Drum The Drum is an aluminum cylinder coated with a layer of photo-

conductive material that retains electrical charges on its surface
until exposed to light, when electrical conduction occurs.
Bias Charge Roller (BCR) The BCR uniformly distributes electrical charges over the drum
surface, and erases the previous charge pattern.

Drum Cartridge Components (Continued)
Component Function
Magnetic Roller A thin layer of developer and toner adheres to the surface of this
roller, which transports the toner to the Drum surface.
Charging and Metering The CM Blade spreads a thin, even layer of developer and toner
(CM) Blade over the Magnet Roller, and applies negative charges to the
toner triboelectrically.
Cleaning Blade The Cleaning Blade removes toner remaining on the Drum.
Drum Cartridge
s5500-029
Additional details on the Drum Cartridge function appears in the Summary of the
Printing Process on page 2-2.
Transfer Roller
The Transfer Roller is driven by being held in direct contact with the Drum Cartridge.
When paper moves between the Transfer Roller and Drum, the Transfer Roller
applies a positive charge to the rear surface of the paper. The negatively charged,
developed image on the drum is attracted by the positive charge on the rear surface of
the paper. Thus, the developed image is transferred from the surface of the drum to the
surface of the paper. The Detack Saw, located adjacent to the Transfer Roller, helps to
separate the paper from the drum surface.

Transfer Roller
Left
s5500-607
Toner Dispense Assembly

The Toner Dispense Assembly operates the Toner Cartridge dispense door and moves
toner from the cartridge through a dispense tube to the Drum Cartridge.
Toner Dispense
Dispense Assembly
Tube
s5500-594

Toner Dispense Motor
The Toner Dispense Motor drives the Toner Cartridge and dispense tube augers to
deliver toner to the Drum Cartridge.
s5500-596
Laser Assembly
The Laser Assembly interprets signals from the Image Processor Board and scans the
surface of the drum with a dual-beam laser to create a latent image. The dual-beam
laser scans from one end of the drum surface to the other while being turned off and
on forming a single line of a latent image. The resolution of the dual-beam laser is
either 600 dpi or 1200 dpi and is determined by the customer setting. Both beams are
always on. For 600 dpi, both beams receive the same data. For 1200 dpi, the beams
receive different data resulting in a smaller pixel size.
The Scanner Motor turns on when it receives a signal, and turns off after printing
ends. The Scanner Motor remains off in the standby and power-saving states.

Start Of Scan
Dual Beam Laser Diode
Polygon Mirror
Scanner Motor
s5500-030
The Laser Assembly is field replaceable and contains the laser diodes, scanner
motor/mirror, and several lenses and mirrors.
The Laser Assembly reflects the laser beam so it strikes the Drum.
Caution
Never remove the cover from a Laser Assembly for any reason - contamination
may result.
The Laser Assembly consists of four components: the Laser Diode (LD) Assembly,
the Scanner Assembly, Lenses and Mirrors, and the Start of Scan (SOS) board.
Laser Assembly Components
Component Function
Laser Diode Assembly Produces two laser beams that are turned on and off according
to the print data signal.
Scanner Assembly Consists of a faceted polygonal mirror mounted on the shaft of

the scanner motor that reflects the beams to the drum surface
through lenses and mirrors, to scan the beams across the drum.
Start of Scan Board When the laser beams strike the sensor on the SOS board, the
signal generated indicates the initial position of the scan. The
initial position where a scan is started on each line is detected.

Scanner Motor control is performed according to the mode of operation as shown
below.
Scanner Motor Operational Modes
Operational Mode Laser Power On/Off
Standby mode Always Off
Print mode Turns On upon receiving the signal from the controller, and turns
Off after a preset time has passed from the end of printing. Also
turns Off if a print command is not received within 30 seconds
from the reception of the signal.
Sleep mode Always Off
The Scanner Motor starts rotating as the Laser Assembly warms up. The SOS signal
is sampled at intervals of 100 ms. If the obtained value is smaller than the Ready
reference value three consecutive times, the warm-up of the Laser ends. (The Scanner
Motor is rotating at a constant speed.)
Laser Reference Value
Laser Assembly
Reference Value Description
Ready reference value SOS signal interval (equivalent to 98% or more of the rated rpm of
the Scanner Motor)
Fail reference value SOS signal interval (equivalent to 90% or less of the rated rpm of
the Scanner Motor)

Fuser
The Fuser, using a combination of heat and pressure, bonds the toner to the paper. As
an FRU, the Fuser is replaced as a unit.
Rear Thermistor
Main Heater Rod
Center Thermistor
Pressure Roller
Thermistor Heater Rods
Pressure Roller
Heat Roller
Thermostat s5500-032
The Fuser receives its drive from the Motor Assembly. After the toner image is
applied to the paper, the paper passes through the Fuser. The Pressure Roller is
pressed against the Heat Roller to melt the toner and bond the image to the paper.
To better understand Fuser errors, Fuser components are described below.
Fuser Components
Component Function
Heat Roller The Heat Roller is a metal tube with a coated surface and a
Heater Assembly inside. As paper passes between the Heat
Roller and Pressure Roller, the heat fuses the toner to the paper.
Pressure Roller The Pressure Roller is a metal shaft coated with sponge rubber.
It maintains pressure on the paper passing between it and the
Heat Roller. This pressure bonds the melted toner to the paper.

Fuser Components (Continued)
Component Function
Heater Rods The Heater Rods are quartz glass tubes containing heater coils.
The Main Heater Rod heats the entire length of the Heat Roller,
and the Dual Sub-Heater Rods heat the center portion of the
Heat Roller.
Temperature Sensors These are Thermistors having a known value of resistance that
varies with temperature. There are three Temperature Sensors
in the Fuser. One is located at the center of Heat Roller, the
other is located where the edge of a letter size sheet of paper
comes through. The third is located at the center of the Pressure
Roller. The sensors monitor the surface temperature of the Heat
and Pressure Rollers.
Thermostat The Thermostat provides a second-level of protection. If the

Heat Roll temperature exceeds the preset temperature, the
Thermostat cuts off the AC power to the Heater Rods.
Heat-Roller Fingers The fingers peel the leading edge of the paper from the Heat
Roller.
Heat-Roller Diode This diode discharges negative charge on the Heat Roller that
may deteriorate the toner image on the paper during fixing.
Fuser Exit Sensor This sensor detects the arrival of the paper at the exit area
behind the Fuser. When paper is present, the signal /EXIT is
Low.
Fuser Life Expectancy

The life expectancy of the Fuser is 300,000 Letter/A4 size pages. Several factors can
reduce Fuser life:
Greater than 5% coverage
Paper use larger than letter size

Printing on heavy media
Printing short-edge feed
Printing on transparencies or specialty media

Power Shutoff to the Fuser
The printer shuts off power to the Fuser for the following reasons:
Fuser abnormality (U4)
Paper jam
Cover Open - Doors A, B, C, D, Front Door
Laser Assembly abnormality (U3)
CPU or NVRAM abnormality (U6)

Motor Assembly abnormality (U0, U1)
Fuser Fan abnormality (U4)
Fuser Problems (U4 Error Code)

Causes of Fuser errors include:
During the Warm-Up period, the Control Thermistor does not detect the Ready
temperature even when the specified time has passed.
During the Standby period, the Control Thermistor does not detect the required
During the Standby period, the Control Thermistor does not detect the required
During idling after power-on, the Control Thermistor does not detect the idling
stop temperature even after the specified time has passed.
During print, the Control Thermistor does not detect the required temperature
even when the specified time has passed.
During print, the Control Thermistor does not detect the required temperature
even when the specified time has passed.
Fuser Temperature Regulation

Fuser temperature regulation is managed by the Engine Logic Board with input from
the Fusers temperature sensors. The Fuser transits between four operating modes,
Warm-up, Ready, Print, and Low Power. Transitions between these four modes is
dependent on Heat and Pressure Roller surface temperature or printer conditions.
Fuser temperature regulation begins when the Fuser relay on the Low Voltage Power
Supply (LVPS) is switched to apply AC power to the Heat Rods. If the Ready
temperature is not reached within the Warm-up delay period, the Heater Rods are
turned Off, the Fuser relay is turned Off, and Fuser temperature control is stopped.

The Warm-up delay begins when printer power is applied, the interlocks are closed, a
jam is cleared, or returning from Low Power mode. Warm-up ends when the Ready
temperature is attained, when a failure occurs, or when executing diagnostic tests.
The Fuser enters a temperature stabilization process under two circumstances:
When printing on thick paper:
After 50 sheets of continuous printing on thick paper (Thick Paper Mode 1), the
Fuser lamp turns off, the Main Motor stops, and the fans rotate at full speed until
the temperature drops. The process for Thick Paper Mode 2 is the same, except
that it occurs after 30 sheets of continuous printing.
When an abnormally high temperature is detected:
When an abnormally high temperature is detected, the printer stops the print job
and enters the following cool-down process, which continues until the target
Control Temperature is reached.
Front Panel Fuser Temperature Modes by Paper Type
Temperature
Paper Type
Low Medium High Extra High
Plain, Plain Paper Plain Paper Thick Paper Thick Paper
Letterhead, Mode 1 Mode 1 (Default) Mode 1 Mode 2
Colored,
Special
Transparency Transparency Plain Paper Plain Paper Thick Paper
Paper Mode Mode 2 Mode 1 Mode 1
(Default)
Labels Plain Paper Thick Paper Thick Paper Thick Paper
Mode 1 Mode 1 Mode 4 (Default) Mode 2
Card Stock, Plain Paper Plain Paper Thick Paper Thick Paper
Envelopes Mode 2 Mode 1 Mode 1 (Default) Mode 2
Prepunched Plain Paper Plain Paper Thick Paper Thick Paper
Mode 2 Mode 1 and Mode 1 Mode 2
(Default)

Fuser Control Temperatures
The following tables list the control temperatures for the Fuser when different paper
types (Modes) are selected.
Fuser Control Temperatures for Plain Paper Modes and Transparency
Paper Type Plain Paper OHP
1 2 Transparency
Mode
Thin Paper Normal Paper
o
Start Temp ( C) Max (Cold) Min (Hot) Max (Cold) Min (Hot) Max (Cold) Min (Hot)
Number 1~3 208 198 213 203 188 185
of 4 ~ 10 207 197 212 202 187 185
Sheets
11 ~ 30 206 196 211 201 186 185
in
Print 31 ~ 50 205 195 210 200 185 185
Run 51 ~ 99 205 195 210 200 185 185
100 ~ 150 205 195 210 200 185 185
> 150 205 195 210 200 185 185
Fuser Control Temperatures for Thick Paper Modes
Paper Type Thick Paper
1 2 3 4
Mode
Letter, COM10 Label
Start Temp (o C) Max Min Max Min Max Min Max Min
(Cold) (Hot) (Cold) (Hot) (Cold) (Hot) (Cold) (Hot)
Number 1~3 218 210 223 215 225 215 218 215
of 4 ~ 10 217 210 222 215 224 215 217 215
Sheets
11 ~ 30 216 210 221 215 223 215 216 215
in
Print 31 ~ 50 215 210 220 215 222 215 215 215
Run 51 ~ 99 215 210 220 215 222 215 215 215
100 ~ 150 215 210 220 215 222 215 215 215
> 150 215 210 220 215 222 215 215 215

Major Assemblies and Functions
Components of the Phaser 5500 printer described in this section include:
Trays
Exit 1 Assembly
Printer Drive and Electrical
Trays
Standard trays include the 100-sheet, multi-purpose Tray 1/MPT and two 500-sheet
universal trays, Trays 2 and 3. The trays adjust to accept various paper sizes.
Tray 1/MPT
The Tray 1/MPT Feeder feeds paper into the printer. The printers Main Motor drives
the Tray 1/MPT Feed Roller to feed paper from the tray. Tray 1/MPT components
include:
Feed Roller that feeds paper from Tray 1/MPT.
Drive Roller that feeds paper into the printer.
Pick-up Solenoid that engages the Main Motor to the Feed Roller.
No Paper Sensor that detects whether paper is in Tray 1/MPT.
Paper Size Sensor detects the position of the Side Guides and reports the width of
paper in Tray 1.
Drive Roller No Paper Sensor
Feed Roller
Pick Up Solenoid
Paper Size Sensor s5500-035
Tray 1/MPT incorporates a single set of guides to establish paper width. The time
required for the paper to clear the No Paper Sensor identifies the papers length. When
media is placed in Tray 1/MPT, the leading edge strikes the actuator of the No Paper
Sensor indicating the presence of paper. As the last sheet of paper is fed from the tray
the actuator drops through an opening indicating No Paper remains in the tray.

Trays 2 and 3
The universal trays 2 and 3 include end and side guides that manually adjust to the
paper loaded in the tray. These guides come into contact with the front and rear edges
of the paper and hold it in position. Paper size is determined by the position of the
switches in the Paper Size Switch assembly. The signal created by these switches
indicates the paper size setting of the guides.
End Guide
Rear Side Guide
Bottom Plate
Front Side Guide
s5500-033
The following table provides the switch states corresponding to the pre-defined paper
sizes. The switches are denoted by SW1, SW2, SW3, SW4 and SW5,
respectively, when viewed from the left side.
Universal Tray Paper Size Switch Signal States
Paper Size Switch Output

Paper size
SW1 SW2 SW3 SW4 SW5
No tray 0 0 0 0 0
5.5" x 8.5" / A5 SEF 0 0 1 0 0
B5 SEF 0 0 1 1 1
8.5" x 13" SEF 0 1 0 1 0
8.5" x 14" SEF 0 1 0 1 1
A4 SEF 0 1 1 0 0
8.5" x 11" SEF 0 1 1 0 1
A4 LEF 1 0 1 0 0
A3 SEF 1 0 1 1 0
B5 LEF/Executive LEF 1 1 0 0 1
8K SEF(TFX/GCO) 1 1 0 1 0
B4 SEF 1 1 0 1 1
8.5" x 11"LEF 1 1 1 0 0
16K LEF(TFX/GCO) 1 1 1 0 1
11" x 17"LEF 1 1 1 1 1

Trays 2 and 3 are functionally equivalent in terms of the feeder mechanism that moves
paper from the tray into the paper path. The Feeders Feed/Lift Motor drives the Feed
and Nudger Rollers to pick paper from the tray, and also lifts the trays Bottom Plate
to maintain paper contact with the Nudger Roller.
Feed/Lift Motor
Pre Feed Sensor
Level Sensor
No Paper Sensor Page Size Switch
Feeder Assembly
Tray
s5500-036
The Feeders Level Sensor uses an actuator to determine whether paper in the tray is
lifted to the feeding position. As the level of paper drops, the flag of the actuator
enters the Level Sensors sensing area, triggering the Feed/Lift Motor to raise the
Bottom Plate. The Feeders Feed/Lift Motor raises the Bottom Plate by rotating the
Lift-up Shaft through the Gear (13T/60T) and Sector Gear (60T).

Lift Up Shaft
Sector Gear (60T)
Gear
13T/60T s5500-034
The paper supply and path are monitored by these sensors located on the Tray 2 and
Tray 3 Feeders.
Level Sensor
The Level Sensor uses an actuator to determine whether paper in the tray is lifted
to the optimum feeding position. When the flag of the actuator leaves the sensing
area, the sensor detects that the paper has been lifted.
Pre-Feed Sensor
The Pre-Feed Sensor detects a paper jam in the tray by the paper position and
sensor transition time.
No Paper Sensor
The No Paper Sensor uses an actuator to determine whether the tray is empty.
When the actuator lowers, the No Paper Sensor signal goes High indicating an
empty tray.

Exit 1 Assembly
Exit 1 discharges the printed paper out of the printer, sending it either to the Standard
Output Tray or when installed, the optional Horizontal Transport.
Offset Sensor Exit Pinch Rollers

Paper Weight
Stack Full Sensor OCT Roller
Exit Gate
Exit PWB
Fuser Exit
Sensor
Offset
Motor
Belt
Motor Assembly
Rear
s5500-597
Exit 1 components include:
Exit Pinch Rollers

These rollers work together with the OCT Roller to eject paper to the Standard
Output Tray.
OCT (offset) Roller

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

Offset Motor
The Offset Motor acting through the Offset Gear shifts the OCT Roller forward
or backward providing paper offset capability. Forward rotation shifts the OCT
Roller to the front. Reverse rotation shifts it to the rear. The flow diagram shows
the Exit 1 components involved in the Offset process.
OFFSET MOTOR
OFFSET GEAR
OCT CHUTE
OCT ROLLER
s5500-039
Offset Home Position Sensor

The Offset Home Position Sensor detects the OCT Roller position.
Exit PWB
The Exit PWB controls paper feeding and reports sensor/switch information back
to the Engine Logic Board. The Exit PWB also controls the Exit 2 module when
attached.
Paper Weight
Controls paper exiting the Exit module. Removed from printers equipped with a
Horizontal Transport.
Full Stack Sensor

This sensor detects that the Standard Output Tray is full, using an Actuator.
Fuser Exit Sensor

The Fuser Exit Sensor detects whether paper remains in the output rollers.

Printer Drive and Electrical
The Drive subsystem includes motors and their driven assemblies.
Motor Assembly
This assembly includes two motors. One provides the drive for paper transport
and a second drives the Drum Cartridge. The assembly gets +24 VDC power
from the LVPS. The motor enable and speed control signals come from the
microprocessor on the Engine Logic Board.
Main Motor
Drum Motor
Motor Assembly
s5500-040

This drives the Toner Cartridge and dispense tube auger to gradually release toner
to the Drum Cartridge.
s5500-596

Printer Control
Drum Cartridge Detect Interlock
Drum Cartridge
Power
Fan
Switch
Front Door
Interlock Door A
Interlock
Exit PWB
Fuser Fan
Image
Processor
Board
Door B
Interlock
Engine Logic
LVPS Board
HVPS
GFI Breaker s5500-041
Printer control centers on the following:

Power Switch
The Power switch controls main power to the printer.
Engine Logic Board

Manages all mechanical functions.
Image Processor Board

Processes the print data and directs the development of images on the Drum
Cartridge.
Exit PWB
Specialized operational control of both Exit 1 and 2.
Printer parameters are held by non-volatile memory located in both these boards.

The Image Processor Board (I/P Board) is one of the major elements of the
Phaser 5500 printer. The primary function of the I/P Board is to receive host data
through one of the following available ports (Parallel, USB, or Ethernet). The
received host data is buffered and stored and sent to the print engine in a rasterized
format. The secondary function of the I/P Board is to provide print control, Front
Panel control, configuration setup, error reporting, and job recovery.
Before the I/P Board can receive and process data it must first pass the Power On Self
Test (POST). This test process verifies proper operation of the Image Processor and
prepares it for processing the host data by putting the Image Processor in a known
state.
The Image Processor Board connects to the Engine Logic Board directly. The Front
Panel is connected to the Image Processor Board and signals pass through the Engine
Logic Board via the Image Processor.
Hard Drive
Configuration Card RAM DIMMs

s5500-587

Engine Logic Board
The Engine Logic Board manages the printing operation according to information
obtained through communications with the I/P Board and from sensors and switches
located throughout the printer.
The Engine Logic Board performs seven main functions:
Communicates with the Image Processor.
Controls the print sequence.

Distributes low DC voltages to various printer components.
Monitors printer status.
Maintains a running print count.

Writes the NVRAM settings.
Controls printer options.
s5500-042

Exit PWB
The Exit PWB controls timing, feed, and motor operation for Exit 1 and the optional
Exit 2.
Exit PWB
s5500-044
HVPS
The HVPS provides high AC and DC voltages to Xerographic components.
s5500-043

Located behind the Inner Main Cover, the High Voltage Power Supply (HVPS)
provides power to the Bias Charge Roller, Magnetic Roller, Transfer Roller, and
Detack Saw.
LVPS
The Low-Voltage Power Supply (LVPS) generates low voltages (+5 V and +3.3 V for
logic circuits, +5 V for Laser Diodes, and +24 V for motors/clutches) from AC power.
It also contains the Fuser Relay to switch AC power to the Heater Rod of the Fuser.
LVPS
s5500-045

AC Accessory Panel
The AC Accessory Panel provides AC power for the Finisher and accepts the Printer
Power Cord.
AC Accessory Panel
Reset Switch
GFI Breaker
s5500-046

Error Messages,
Codes, and
Procedures
In this chapter...
Introduction
Power On Self Test (POST)
Service Usage Profile
Service Diagnostics
Error Messages, Codes, and Procedures
Chapter
3
Introduction
This chapter describes the printers self-diagnostic capabilities and includes methods
to identify and remedy reported printer problems. The diagnostic routines report
problems using error messages and fault codes displayed on the Front Panel, logged
in the Service Usage Profile, listed on the Startup Page or by flashing LEDs. These
error indications serve as the entry point into the troubleshooting process. Printer
problems not directly indicated by or associated with an error message or fault code
are covered in Chapter 4, General Troubleshooting. Print-quality problems are
covered in Chapter 5, Print-Quality Troubleshooting.
Servicing Instructions
These instructions are an overview of the Steps a service technician should take, using
this manual, to service the print engine and options. If you choose not to use these
Steps, it is recommended that you start at the appropriate troubleshooting procedure
and proceed from there. When servicing the printer, always follow the safety
measures detailed in Service Safety Summary on page xvii.
Step 1: Identify the Problem:
Verify the reported problem does exist.

Check for any error codes and write them down.
Print normal customer prints and service test prints.
Make note of any print-quality problems in the test prints.
Make note of any mechanical or electrical abnormalities present.
Make note of any unusual noise or smell coming from the printer.
Print a Service Usage Profile, if the printer is able to print.
View the Engine Error and Jam Histories under the Service Tools menu.
Verify the AC input from the wall outlet is within specifications.
Step 2: Inspect and Clean the Printer:
Follow the cleaning instructions given in Chapter 7.

Verify that the power cord is in serviceable condition.
Restart the printer to check if the error reoccurs.
Step 3: Find the Cause of the Problem:
Use the troubleshooting procedures to find the root cause of the problem.
Use Service Diagnostics to check the printer and optional components.
Use the Wiring Diagrams and Plug/Jack Locator to locate test points.
Take voltage readings as instructed in the appropriate troubleshooting
procedure.
Step 4: Correct the Problem:
Use the Parts List to locate a part number.

Use the FRU Disassembly procedures to replace the part.
Step 5: Final Checkout:
Test the printer to verify the problem is corrected and no new problems arose.

System Startup
Listed here is a typical printer startup routine from a cold start.
1. When the main power switch is turned on, the Health LED on the Image
Processor board turns on immediately.
2. The boot loader checks for presence and condition of RAM. If an error is
detected, RAM ERROR appears on the display and the Red Front Panel LED
and the Health LED alternately blink at 1/2 second intervals.
3. The boot Loader then loads and runs POST diagnostics.
4. POST turns off the Health LED.
5. POST checks the Front Panel.
6. If buttons have been pushed, the Front Panel displays Processing Input. If no
buttons have been pushed, POST continues execution.
7. The display is reset (addressable area turns Gray).
8. The Front Panel LED cycles: Green, Yellow, Red, and then off.
9. The display backlight turns on (high intensity), with nominal contrast display.
10. The display area is turned on, dark Black for 1 second.
11. The display is cleared.
12. The display backlight turns on with nominal intensity.
13. The POST Vn.nn message appears, and tests are quickly executed.
14. If any tests fail, the display changes to indicate the last test run with line three
reading CALL SERVICE.
15. After the POST tests have successfully finished, the Xerox splash screen
appears on the Front Panel and PostScript begins initialization.
16. The Front Panel LED turns Red while the display reads Warming up - Please
wait.
17. The Front Panel LED turns Green and the display reads Ready to Print.
Error Messages, Codes, and Procedures 3-3

Power On Self Test (POST)
POST diagnostics provide a quick means of isolating a defective subsystem
associated with the Image Processor Board and SDRAM. There are two kinds of
POST faults: soft and hard. A soft fault is any fault that allows the operating system to
initialize. Soft faults do not stop printer operation and are reported on the Startup Page
after the system is running. A hard fault prevents the operating system from
initializing stopping further printer operation. Hard faults are indicated with blinking
LEDs and the failed test appearing on the display.
The following tests execute when the printer is powered on after the Boot Loader
runs, and before the operating system is loaded and initialized. Bypass POST by
pressing the OK button at power on until the splash screen appears.
POST Test Descriptions
Fault Fault
Test Code Type Description
SDRAM 1 Hard This test fails if the Boot Loader finds faulty or no RAM.
I/O ASIC 3 Hard This test determines if the I/O chip is functioning properly.
Memory 4 Hard This test checks 64-bit reads and writes to RAM memory.
EEPROM 10 Hard This test checks addressing of the NVRAM.
Ethernet 11 Hard This test checks the Ethernet core.
CPU 12 Hard This test checks that each CPU interrupt source is
Interrupts functioning.
USB 13 Hard This test checks that the USB core is functioning properly.
RTC (3 tests) 14 Soft These tests check the functionally of the Real Time Clock for
a number of conditions.
RAM DIMM 15 Soft This test examines bad or incompatible RAM DIMMs.
Presence
Install more 16 Soft Checks that there is at least 64 MB of memory installed and
RAM ignores more than 512 MB.
Too much 17 Soft Checks that there is no more than 512 MB of memory
RAM installed.
IDE Disk 20 Soft Checks the disk controller core, and runs a DIAGNOSE
command on the hard drive.
Engine 22 Hard Checks communication between the Image Processor Board

Command and the Engine Logic Board.

POST Soft Fault Messages
When POST detects a soft error, the printer continues the startup process. Before the
printer reaches its Ready to Print state, the Start Page is printed with soft errors
appearing in a gray box. The box contains all soft faults encountered, with the upper
left corner of the box in the center of the Start Page, and extending to the right margin,
similar to the one shown here.
Hardware Failure:
<device>:
General Failure
These messages are substituted for <device>:

Real Time Clock
RAM Memory Slot 1 Checksum
RAM Memory Slot 2 Checksum

RAM Memory Slot 1 Rejected
RAM Memory Slot 2 Rejected
IDE Disk
For Real Time Clock errors, replace the Image Processor Board. For IDE Disk errors,
replace the Hard Drive. For memory errors, see "RAM Memory Fault Isolation" on
page 4-15.

POST Hard Fault Messages
POST indicates a hard fault by displaying a message on the Front Panel and blinking
the fault code on the health and Front Panel LEDs. There are long and short blinks. A
long blink is worth 5 and a short blink is worth 1. As an example, a blink pattern
flashed as long, long, short, short, represents fault code 5+5+1+1=12, indicating a
failure in the CPU interrupt test. Along with the blinking LEDs, the failed test also
appears on the display as:
POWER ON SELF TEST ERROR
12:CPU INTERRUPTS
CALL SERVICE
The exception to this reporting scheme is a RAM test error. The Boot Loader executes
a RAM test prior to loading POST. If the Boot Loader encounters a RAM error, the
Front Panel displays RAM Error and the health and Front Panel LEDs alternately
blink at 1/2-second intervals. POST does not load.
Hard Error LED Blink Patterns and Messages
LED Blink Front Panel

Pattern Message Action
1 RAM ERROR No RAM present, or faulty RAM. Alternate 1/2 second

interval blink at Front Panel and health LEDs.
1+1+1 3: I/O ASIC Image Processor Board ASIC failure. Go to Image

Processor Isolation on page 4-13.
1+1+1+1 4: MEMORY Checks installed memory: walking ones address, walking

one and complement data. Tests RAM memory above
diagnostics code and data addresses. Go to RAM
Troubleshooting Procedure on page 4-15.
5+5 10: EEPROM 1. Switch off printer power.

2. Remove and re-install the NVRAM EEPROM.
3. Switch on printer power.
4. If the error message persists, first replace the NVRAM
EEPROM, then the Image Processor Board (Go to
page 4-13).
5+5+1 11: ETHERNET Image Processor Ethernet Port Failure.

PHY Replace Image Processor Board (page 8-91).
5+5+1+1 12: CPU Replace Image Processor Board (page 8-91).

INTERRUPTS
5+5+1+1+1 13: USB Image Processor USB port failure.

Replace Image Processor Board (page 8-91).
5+5+5+5+1+1 22: ENGINE Communication with print engine has failed. Check the
COMMAND connection to the Engine Logic Board, then go to Image
Processor Isolation on page 4-13.

The Service Usage Profile tracks printer activity, consumable usage and printer
history. This data is stored in NVRAM. Service Usage Profile data includes error logs
that retain detail on the type, date, location and frequency of engine and jam errors.
While the Service Usage Profile includes data on all aspects of the printer, this section
focuses on accessing these two error logs to review printer history.
Accessing Fault Histories

Access Service Usage Profile fault histories by:
Print (if possible) the Service Usage Profile.
a. At the printers Front Panel, go to the Troubleshooting menu and select
Service Tools.
b. From the Service Tools menu, select Service Usage Profile. The
engine and jam error fault histories are detailed at lines 262 and 298
respectively.
Or...
View fault history logs on the Front Panel.
a. At the printers Front Panel, go to the Troubleshooting menu and select
Service Tools.
b. From the Service Tools menu, select Engine Error or Jam History.
Or...
If the printer is operational and connected to a network, view the fault history
using a browser.
a. Open a web browser.
b. Enter the printers IP address as the URL.
c. Select the Troubleshoot link and the Fault History displays.
Interpreting Fault History Error Codes

Fault histories appear on the Front Panel as a list of semi-colon separated codes. A
partial example of the Engine Error Log as it appears on the display:
0,0; 0,0; 0,0; 0,0;13, <pg_count>;13, <pg_count>;13,<pg_count>;...
The fault history logs for the engine and jams each contain 30 entries. Log entries
move right to left. Each successive error shifts the log left, with the oldest code falling
off the left and the latest code added to the right. Note that a value of 0 (zero) or --
in a log indicates no data and <pg_count> indicates the value of the Total Page
counter at the point when the error occurred. For display, the Engine Error Log
combines the error code and page count (lines 262 and 263 of the printed Service
Usage Profile).
A complete log consists of several lines in the Service Usage Profile report (typically
2-5 lines). A log usually has some event code, a corresponding date, a corresponding
page, and a total event counter. In the case of engine errors, there are four lines (261-
264). In the case of jams, there are five lines (291-295 and 298).
Engine Errors
This table lists the fault codes used to identify engine errors in the Service Usage
Profile. Fault codes are numeric for Engine Errors (Line item 262).
Fault History Codes for Engine Errors
Fault Fault
Code Error Code Error
0 No Error 15 Toner Cartridge Failure (J8-1 J8-2)
1 Duplex Unit Failure (H2-7) 16 Drum Cartridge Failure

(J4-1, J7-1, J7-2)
2 Exit Unit Fail (H3-1, H3-3, H3-7) 17 Temperature Sensor Failure

(No error code)
3 Stacker Lower Tray Failure 18 Humidity Sensor Failure

(H5-11~13, 21~24, 81~84, 86) (No error code)
4 Stapler Failure (H5-91, 95, 96) 19 Main Motor Failure (U0-1, U1-1)
5 Punch Failure (H5-31 ~ 34) 20 Drum Motor Failure (U1-4)
6 Finisher Failure (H5-7) 21 Toner Motor Failure (U5-1)
7 Tray 6 Failure (H1-5) 22 Laser Motor Failure (U3-5)
8 Tray 5 Failure (H1-4, H8-4) 23 Laser Unit Failure (U3-3)
9 Tray 4 Failure (H1-3, H8-3) 24 Fuser Failure (U4-1~5, U4-7, U4-8)
10 Tray 3 Failure (H1-2, H8-2) 25 Fan Failure (U4-9, U5-9)
11 Tray 2 Failure (H1-1, H8-1) 26 Engine Logic Board Failure (U6-2,

U6-3, U6-4, U6-5, U6-6 U6-7)
12 Tray 4-5 Logic Board Failure 27 Incorrect Duplex Unit (H2-8)

(H7-3, H7-4, H7-7)
13 Tray 6 Logic Board Failure 28 Incorrect Tray 4 -5 Unit (H7-8)

(H6-4, H6-7)
14 Finisher Logic Board Failure (H5-4) 29 Incorrect Finisher (H5-8)
If Engine Error codes appear in either the Engine Error Log or on the Front Panel, use
the Fault Code to find the corresponding troubleshooting procedure in the Error
Message Summary table.

Jam Errors
The following table lists the fault history codes used in the Service Usage Profile to
record jam errors. Last Jam Location is recorded on line 291. Last Jam Error Codes
appear at line 298, and Last Jam Page number appears on line 294.
A partial example of the Last Jam Error Log as it is displayed on the Front Panel:
--;--;--;--;--;--;--;--;--;--;--;C4-0,<pg_count>;C4-1,<pg_count>;...
Limited to 30 entries, the Last Jam Error Log is a semi-colon separated list of
alphanumeric codes that indicate a specific jam location and page number within the
printer. For display, line items 294 and 298 are combined to provide the error code
and Total Page counter at the time the error occurred.
Fault History Codes for Jams
Last Jam Location Last Jam Error Jam History

(Item 291) (Item 298) Log
Paper Size Jam E1-1, PSE-1 18
Jam at Tray 1 C9-3 1
Jam at Tray 2 C1-2, C1-3 2
Jam at Tray 5 C4-0, C4-1, C4-4 5
Jam at Tray 6 C5-1, C5-2, C8-5 6
Jam at A E1-2, E1-6, E3-1, E3-2, E3-6, E4-1, E4-5, 7

F4-12, F4-16, F4-22
Jam at B C2-3, C3-3, C4-3, C5-3, C8-2 8
Jam at B and C C3-2, C4-2 16
Jam at C C8-3, C8-4 9
Jam at D C8-6 10
Jam at D and A C6-1, C6-2 15
Jam at E E4-3, E4-6, E8-2 11
Jam at F F4-17, F4-23, F4-24, F4-26, F4-32, F4-36, 12

F4-51, F4-52,F4-71, F4-72, F4-76, F4-82,
F4-83, F4-86
Jam at G F4-42, F4-43, F4-46, F4-47,F4-48, F4-53, F4- 13

54, F4-73, F4-74, F4-77, F4-78, F4-84, F4-85,
F4-87, F4-88
Jam at H F4-55, F4-56, F4-61, F4-66 14
Jam at Stacker Upper Tray F4-75 17

Use the Jam History code to find the corresponding troubleshooting procedure in the
Error Message Summary table and the Jam Location Map to locate the jam point.
Jam Location Map

The following illustrates the Door designators that key the jam location error codes
and messages. Refer to this diagram when questions arise regarding the area of the
jam.
Door H
Door E Door F
Door A
Door D
Door G
Door J
Door C Door B
s5500-614

Service Diagnostics
Service Diagnostics provide tests for most electro-mechanical components in the
printer. Service Diagnostics also contains test prints, printer status and some NVRAM
access. Test descriptions appear in the Appendix. The Service Diagnostics Main
menu offers the options listed in the following table.
Service Diagnostics Main Menu
Menu Item Test Target
Print Service Menu Map Prints the Service Diagnostics menu map to aid menu navigation.
General Status Query information about the status, versions, and counts.
Test Prints Isolate problems with Xerographics and paper handling.
Engine NVRAM Adjustments Adjust registration in the process or scan direction on each tray.
Motors/Fan Tests These tests exercise each pint engine motor or fan.
Duplex Unit Motor Tests Tests the Duplex motor at two speeds.
Exit 2 Motor Tests Tests the Exit and Offset motors of Exit 2.
Tray 4 & 5 Motor Tests Tests the Feed/Lift and Take Away motors.
Tray 6 Motor Tests Tests the Feed/Lift and Take Away motors.
Finisher Motor Tests Tests the Horizontal Transport, Finisher, Stapler, and Punch.
Engine Sensor/Switch Test Tests print engine sensor status and operation.
Duplex Sensors/Switch Tests the Wait sensor and Door D Interlock Switch.
Exit 2 Sensor/Switch Tests Exit 2 sensors and the Door E Interlock Switch.
Tray 4 & 5 Sensor/Switch Tests Tray 4 & 5 sensors and the Door C Interlock Switch,
Tray 6 Sensor/Switch Tests the sensors and switches within Tray 6.
Finisher Sensor/Switch Tests the Finisher sensors and switches.
Solenoid/Clutch Tests Tests solenoid and clutch function in the print engine.
Exit 2 Solenoid Test Tests the functionality the Exit 2 Exit Gate solenoid.
Tray 4 & 5 Clutch Test Tests the function of the Take Away Clutch.
Tray 6 Solenoid Test Tests the Tray 6 Nudger solenoid at low and high power.
Finisher Solenoid and Clutch Tests each Finisher solenoid and the Set Clamp Clutch.
Tests
IP NVRAM Access This allows you to reset the PostScript or all NVRAM.
Engine Logic Board Save/Restore NVRAM from the Engine Logic Board.
Replacement
Finisher Board Setup Sets the Finisher/Stacker punch configuration.
Exit Exits Service Diagnostics and reboots the printer.

Using Service Diagnostics
The printers operating system monitors dozens of sensors located throughout the
print engine and attached options. Sensor signals are used to monitor paper handling
and mechanical activity along the entire paper path. As a sheet travels along the paper
path, sensors change state temporarily to indicate the sheets presence. If the pattern
of sensor state changes differs from the expected timing for a particular paper size and
path, the sensor location where the timing difference occurs identifies the error to
report.
However, having the error message information doesnt necessarily pinpoint the
problem. Sensor signals locate where, but often cannot identify why. Motors, belts,
gears, solenoids, and dozens of other parts are involved in paper transport. Even the
sensors themselves sometimes provide erroneous readings. The Service Diagnostics
suite of tests and utilities are the best tools available to pinpoint the root cause behind
the reported error.
If confronted with an error that requires more than a cursory investigation to clear or
when directed by a troubleshooting procedure, use Service Diagnostics to exercise
select parts in the vicinity of the reported error. Tests are controlled from the Front
Panel and are described in detail in the Appendix. See Service Diagnostics Menu
Map on page A-4.
Starting Service Diagnostics

Access the Service Diagnostics menu one of two ways:
Entering without rebooting the printer:
1. From the printers main menu, scroll to Troubleshooting and press the OK
button, then scroll to Service Tools and press the OK button.
2. Hold down both the Up Arrow and Down Arrow buttons for about three
seconds. When the Service Diagnostics menu appears, scroll to Run Service
Diagnostics and press the OK button.
Entering by rebooting the printer:
1. Turn the printer power OFF.
2. Hold down the Back and Information buttons simultaneously and turn the
printer back ON.
3. Continue to hold the buttons until the following message appears on the Front
Panel: Entering Service Diagnostics, and then release the buttons.
4. The Front Panel displays the Service Diagnostics menu.
You can print a Service Diagnostics Menu Map by highlighting Print Service
Menu Map, and pressing the OK button. The printer runs through POST and returns
to Ready. You will need to re-enter Service Diagnostics. The Service Diagnostics
Menu Map also appears in the Appendix. See Service Diagnostics Menu Map on
page A-4.

Service Diagnostics Controls
Button Function
BACK Returns to the prior higher level menu structure, if available.

If help text is displayed, pressing BACK restores the current menu item and
removes the help text.
CANCEL Terminates the current test or cancels current INFO display.
INFO Provides help information, if available.

Pressing INFO again restores the current menu item and removes the help
text.
UP Scrolls up one menu item within a menu list. This control does not wrap.
Used to increment data in tests requiring user input.
DOWN Scrolls down one menu item within a menu list.

This control does not wrap, the end of a menu list is designated by three
asterisks. Used to decrement data in tests requiring user input.
OK Enters the highlighted menu. Executes the current test item.

Used to select a data value entered by the user.
Front Panel Shortcuts
Mode Buttons Pressed at Power On
Skip POST diagnostics OK
Print Service Diagnostics Map Information
Reset PostScript NVRAM Back + OK
Password Bypass Up Arrow + Down Arrow
Enter Service Diagnostics Back + Information
Front Panel Language Cancel + i

Messages, Codes, and Procedures
The error messages and codes generated by the printers operating system, the Service
Usage Profile, and Service Diagnostics are the lead-in to the troubleshooting
procedures that follow in subsequent pages. This section correlates the output of these
three diagnostic aids and provides the troubleshooting procedure to locate and correct
reported errors.
Error Message Abbreviations

Due to limited display space, some error messages include abbreviations. The most
common abbreviations used throughout this chapter are listed here.
Error Message Abbreviations
Term Definition Comment
Reg or REGI Registration Used in designators such as Reg SNR.
SNR Sensor Often seen as SNR1 or Reg SNR.
DUP or DM Duplex Unit Optional for 2-sided printing.
F/O Feed Out Used as sensor designators F/O1 or F/O #2.
T/A Take Away Function designator for roller or motor.
H-Xport Horizontal Transport Horizontal Transport section of the Finisher.
MCU Main Control Unit Engine Logic Board
I/P Board Image Processor Image Processor Board
OCT Offset Catch Tray Offset Rollers at Exit
HCF High-Capacity Feeder Option Tray 6 or 2000-Sheet Feeder
MSI or MPT Multi-Sheet Input Used to describe Tray 1/MPT.
IOT Image Output Terminal Used instead of printer.
2TM Two-tray Module Option Trays 4 and 5 or 1000-Sheet Feeder
P/J Plug/Jack Plug (P) and or Jack (J) designators
EM Exit Module Used for either Exit (1 or optional Exit 2).
SW Switch Appears as a designator.
NVM Non-volatile Memory Used instead of NVRAM.
CRUM Customer-Replaceable Device used to store usage information on the

Unit Monitor Drum and Toner Cartridges.
Comm Communication As in MCU-DM Comm Error.
LVPS Low-Voltage Power Supply Primary power supply.
PWB Printed Wire Board Used to describe a circuit board (Tray 6 PWB).

Error Message Summary
The Error Message Summary below lists possible error messages, along with, the
corresponding Service Diagnostic message and Service Usage Profile fault code. The
Front Panel Message column shows the message as is appears on the printers display
when the error occurs during normal operation. The Service Diagnostics error
message appears when errors occur during testing. The Engine and Jam Errors
columns list fault codes logged by the Service Usage Profile, located in the Service
Tools menu. The Go to Page column references the troubleshooting procedure related
to the error.
In cases where an error message or fault code is generated, use this table to identify
the proper procedure to clear the error. To assist you further, the troubleshooting
procedures that follow this table are named for the associated Front Panel message.
Error Message Summary
Engine Jam Go to
Front Panel Message Service Diagnostics Message Error Error Page
Main Motor Failure U0-1 Main Motor Stop 19 3-23
Main Motor Failure U1-1 Main Motor Rotation 19 3-23

Drum Motor Failure U1-4 Drum Motor Rotation 20 3-24
Laser Unit Failure U3-3 Laser Power 23 3-25

Laser Motor Failure U3-5 Polygon Motor Rotation 22 3-26
Fuser Failure U4-1 On Time 24 3-27

Fuser Failure U4-2 Over Heat Temp 24 3-29
Fuser Failure U4-3 FS1 Thermisitor 24 3-29
Fuser Failure U4-4 FS2 Thermisitor 24 3-29
Fuser Failure U4-5 PR Thermisitor 24 3-29
Fuser Failure U4-7 Cold-Sagging 24 3-30
Fan Failure U4-9 Fan Defect 25 3-32
Toner Motor Failure U5-1 Motor Rotation 21 3-33

Fan Failure U5-9 Fan Failure 25 3-34
Engine Logic Board Failure U6-2 RAM Read/Write 26 3-35

Engine Logic Board Failure U6-3 NVM Data Defect 26 3-35
Engine Logic Board Failure U6-4 NVM Read/Write 26 3-35
Engine Logic Board Failure U6-5 CP/U Power NVM 26 3-35
Engine Logic Board Failure U6-6 ASIC/CRUM 26 3-35
Engine Logic Board Failure U6-7 PPM Data 26 3-35
Paper Size Jam E1-1 Regi Area Jam 18 3-35

Jam at A E1-2 Regi Area Jam 7 3-37
Jam at A E1-6 Regi Area Jam 7 3-38
Jam at A E3-1 Fuser Area Jam 7 3-39


Error Message Summary (Continued)
Engine Jam Go to
Jam at A E4-1 Exit 2 Area Jam 7 3-42

Jam at E E4-3 Exit 2 Area Jam 11 3-44
Jam at A E4-5 Exit 2 Area Jam 7 3-44
Jam at E E4-6 Exit 2 Area Jam 11 3-47
Jam at E E8-2 Duplex Area Jam 11 3-49
Jam at Tray 2 C1-2 Tray 2 2 3-56


Jam at B C2-3 Tray 3 8 3-59

Jam at B and C C3-2 Tray 4 16 3-61

Jam at B and C C4-2 Tray 5 16 3-61

Jam at D and A C6-1 Duplex Area Jam 15 3-51

Jam at D and A C6-2 Duplex Area Jam 15 3-53
Jam at B C8-2 F/O2 SNR Static Jam 8 3-76

Jam at C C8-3 F/O3 SNR Static Jam 9 3-77
Jam at C C8-4 F/O4 SNR Static Jam 9 3-78
Jam at Tray 6 C8-5 HCF F/O SNR Static jam 6 3-79
Jam at D C8-6 Duplex 10 3-83
Jam at Tray 1 (MPT) C9-3 Tray 1/MPT 1 3-84
Jam at A F4-12 H-Xport Ent SNR ON 7 3-87

Jam at A F4-16 H-Xport Ent SNR Static Jam A 7 3-89
Jam at F F4-17 H-Xport Ent SNR Static Jam B 12 3-89
Jam at A F4-22 H-Xport Exit SNR ON Jam A 7 3-91

Jam at F F4-23 H-Xport Exit SNR ON Jam B 12 3-91
Jam at F F4-24 H-Xport Exit SNR ON Jam C 12 3-91
Jam at F F4-26 H-Xport Exit SNR Static 12 3-93
Jam at F F4-32 Xport Ent SNR ON 12 3-95

Jam at F F4-36 Xport Ent SNR Static 12 3-98

Engine Jam Go to
Jam at G F4-42 Buffer Path SNR ON Jam A 13 3-101

Jam at G F4-43 Buffer Path SNR ON Jam B 13 3-101
Jam at G F4-46 Buffer Path SNR Static Jam A 13 3-106
Jam at G F4-47 Buffer Path SNR Static Jam B 13 3-106
Jam at G F4-48 Buffer Path SNR Static Jam C 13 3-106
Jam at F F4-51 Compile SNR OFF Jam A 12 3-109

Jam at F F4-52 Compile SNR ON Jam A 12 3-112
Jam at G F4-53 Compile SNR ON Jam B 13 3-112
Jam at G F4-54 Compile SNR ON Jam C 13 3-112
Jam at H F4-55 Compile SNR OFF Jam B 14 3-109
Jam at H F4-56 Compile SNR Static 14 3-115
Jam at H F4-61 Set Eject Jam 14 3-118

Jam at H F4-66 Compile Paper SNR Static 14 3-121
Jam at F F4-71 Top Tray Exit SNR ON Jam A 12 3-123

Jam at F F4-72 Top Tray Exit SNR OFF Jam A 12 3-126
Jam at G F4-73 Top Tray Exit SNR ON Jam B 13 3-123
Jam at G F4-74 Top Tray Exit SNR ON Jam C 13 3-123
Jam at Stacker Upper Tray F4-75 Top Tray Exit SNR OFF Jam B 17 3-126
Jam at F F4-76 Top Tray Exit SNR Static Jam A 12 3-129
Jam at G F4-77 Top Tray Exit SNR Static Jam B 13 3-129
Jam at G F4-78 Top Tray Exit SNR Static Jam C 13 3-129
Jam at F F4-82 Gate Sensor ON 12 3-131

Jam at F F4-83 Gate Sensor Static Jam A 12 3-135
Jam at G F4-84 Gate Sensor Static Jam B 13 3-135
Jam at G F4-85 Gate Sensor Static Jam C 13 3-135
Jam at F F4-86 Gate Sensor Static Jam A 12 3-138
Jam at G F4-87 Gate Sensor Static Jam B 13 3-138
Jam at G F4-88 Gate Sensor Static Jam C 13 3-138
Tray 2 Failure H1-1 Tray 2 Fail 11 3-141

Duplex Unit Failure H2-7 Duplex Comm Failure 1 3-148

Incorrect Duplex Unit Installed H2-8 Duplex Type Error 27 3-149
Exit Unit Failure H3-1 Offset Error 2 3-150

Exit Unit Failure H3-2 Offset Error 2 3-150
Exit Unit Failure H3-7 Exit Board Comm Failure 2 3-152
Tray 1 /MPT Paper Guide - - 3-154

Does Not Match Size Menu
Tray Paper Guide Does Not H4-1 Tray 2 Paper Size Error - 3-155
Match Size Menu H4-2 Tray 3 Paper Size Error - 3-155
H4-3 Tray 4 Paper Size Error - 3-157
H4-4 Tray 5 Paper Size Error - 3-157

Engine Jam Go to
Finisher Board Failure H5-4 NVM R/W Error 14 3-159

Finisher Failure H5-7 Finisher Comm Failure 6 3-159
Incorrect Finisher Installed H5-8 Type Error 29 3-159
Stacker Lower Tray Failure H5-11 Low Tray Fail 3 3-160
Stacker Lower Tray Failure H5-12 Low Tray Upper Limit 3 3-162
Stacker Lower Tray Failure H5-13 Low Tray Lower Limit 3 3-165
Stacker Lower Tray Failure H5-21 Front Home SNR ON 3 3-168
Stacker Lower Tray Failure H5-22 Rear Home SNR ON 3 3-170
Stacker Lower Tray Failure H5-23 Front Home SNR OFF 3 3-168
Stacker Lower Tray Failure H5-24 Rear Home SNR OFF 3 3-170
Punch Failure H5-31 SNR ON 5 3-172
Punch Failure H5-32 SNR OFF 5 3-172
Punch Failure H5-33 Home SNR ON 5 3-174
Punch Failure H5-34 Home SNR OFF 5 3-174
Stacker Lower Tray Failure H5-81 Eject Clamp SNR ON 3 3-176
Stacker Lower Tray Failure H5-82 Eject Clamp SNR OFF 3 3-176
Stacker Lower Tray Failure H5-83 Set Clamp SNR ON 3 3-178
Stacker Lower Tray Failure H5-84 Set Clamp SNR OFF 3 3-178
Stacker Lower Tray Failure H5-86 Side Reg SNR OFF 3 3-181
Stapler Failure H5-91 Staple Fail 4 3-184
Stapler Failure H5-95 Move SNR ON 4 3-185
Stapler Failure H5-96 Move SNR OFF 4 3-185
Tray 6 Logic Board Failure H6-4 NVM R/W Error 13 3-187

Tray 6 Logic Board Failure H6-7 HCF Comm Failure 13 3-188
Tray 4-5 Logic Board Failure H7-3 NVM out-of-order 12 3-189

Tray 4-5 Logic Board Failure H7-4 NVM R/W Error 12 3-189
Tray 4-5 Logic Board Failure H7-7 Comm Failure 12 3-190
Incorrect Tray 4-5 Unit H7-8 Type Error 28 3-191
Installed
Tray 2 Failure H8-1 Tray 2 Size Sensor Broken 11 3-193

Replace Toner Cartridge J1-2 Toner Empty - - 3-197
Install or Reseat Drum J3-1 Drum not installed - - 3-199

Cartridge
Drum Cartridge Failure J4-1 ATC SNR defect 16 3-200
Replace Drum Cartridge J6-1 DRUM end of life - - 3-200
Drum Cartridge Failure J7-1 DRUM Comm Error 16 3-201

Drum Cartridge Failure J7-2 DRUM NVRAM Error 16 3-200
Non-Xerox Drum Cartridge J7-3 DRUM type mismatch - 3-200

Engine Jam Go to
Install or Reseat Toner J8-1 Toner Comm Error 15 3-204

Cartridge
Toner Cartridge Failure J8-2 Toner Cart. read/write error 15 3-204
Replace Incorrect Toner J8-3 Toner Cart. type mismatch - - 3-205
Cartridge
Non-Xerox Toner Cartridge - - 3-205
Toner Is Low Toner Low - - 3-206
Drum Cartridge Near End of DRUM Life Near End. - - 3-207

Life
No Paper in Tray No Paper in Tray 2 or 3 - - 3-208

No Paper in Tray 4 or 5 - 3-209
No Paper in Tray 6 - 3-211
Paper Size Jam Paper Size in Tray 2 or 3 - - 3-212

Paper Size in Tray 4 or 5 - 3-214
Paper Size in Tray 6 - 3-217
Drum Cartridge Failure DRUM ATC Value Out of Range - - 3-218

Temperature Sensor Failure Temperature Value Out of Range 17 3-219
Humidity Sensor Failure Humidity Value Out of Range 18 3-219
Standard Output Tray is Full Face down Tray 1 full - - 3-220

Face down Tray 2 full - 3-220
Stacker Upper Tray is Full Finisher Tray Paper Full - - 3-222
Stacker Lower Tray is Full Finisher Mix Full Stack - - 3-223
Stapler is Empty Staple Pin Warning - - 3-225
Stapler Cartridge is Low Staple Pin Misfeed - - 3-226
Staple Failure Staple Failure - - 3-228
Finisher Stacker set over Staple Set Over Count - - 3-229

count
Punch Waste Box is Full Punch Waste Box Full - 3-233
Punch Waste Box is Missing Punch Waste Box Missing - - 3-232
Stacker Lower Tray Failure Stacker Lower Safety Fail - - 3-230
Close Door A Door A is Open - - 3-237
Close Printer Front Door Front Cover is Open - - 3-235
Close Door B Door B is Open - - 3-238
Close Door C Door C is Open - - 3-239
Close Door J Door J is Open - - 3-248
Slide in Tray 6 Feeder Tray 6 Undocked - - 3-236
Close Door E Door E is Open - - 3-242

Engine Jam Go to
Close Door D Door D is Open - - 3-240
Close Door G Door G is Open - - 3-245
Close Door F Door F is Open - - 3-243
Close Door H Door H is Open - - 3-247
Maintenance Kit Near End of - - 3-250

Life
Replace Maintenance Kit - - 3-250
Invalid Configuration Card - - 3-250
Configuration Card Missing - - 3-250
Duplicate IP address detected - - 3-251
Using the Troubleshooting Procedures

1. Applicable Error Code(s) lists the error message(s) addressed by each
troubleshooting procedure.
2. Applicable Parts and References assist you in locating all the information
available for a particular part or procedure. Remember that disassembly
procedures, parts lists, and wiring diagrams for printer options appear in the
Phaser 5500 Printer Options Service Manual.
3. Follow each Step in a troubleshooting procedure sequentially in the order given
until the problem is fixed or resolved.
4. The Actions and Questions box instructs you to perform a certain action or
procedure. Also included are precautions and/or additional procedures you must
follow to isolate the problem.
5. When a procedure instructs you to test a component using Service Diagnostics,
see Service Diagnostics on page 3-11 for the detailed steps and functions for
testing parts of the printer.
6. Each action is followed by a question. If your response to the question is Yes,
then follow the instructions for a Yes reply. If your response to the question is
No, then follow the instructions for a No reply.
7. Note that two types of photo sensors are used: photo-reflective and photo-
receptive. Photo-reflective sensors use light reflected back from an object to
detect its presence or absence. Photo-receptive sensors use an actuator or the
object itself to block the light path to detect an object or condition.
8. Troubleshooting procedures frequently ask you to take voltage readings or test
for continuity or resistance at certain test points. The Reference table provides
pointers to the diagrams that provide this information.
9. Troubleshooting Procedures often ask you to replace a printer component. When
instructed to replace a non-spared component and that component is part of a
parent assembly, replace the entire parent assembly.
Measurement Techniques
1. Unless indicated otherwise, the instruction switch On printer main power
means for you to switch On printer power and let the printer proceed through
POST to a Ready condition.
2. When instructed to take voltage, continuity or resistance readings on wiring
harness, proceed as follows: Check P/J 2321 to P/J 2105 by placing the red
probe (+) of your meter on pin 1 of P/J 232, and place the black probe () of your
meter on pin 5 of P/J 210.
3. When instructed to take resistance readings between
P/J 232 <=> P/J 210 (without specified pin numbers), check all pins. See
Wiring Diagrams for the location of all wiring harnesses and pins.
4. When instructed to take a voltage reading, the black probe () is generally
connected to a pin that is either RTN (Return) or SG (Signal Ground). You can
substitute any RTN pin or test point in the printer, and you can use FG (frame
ground) in place of any SG pin or test point. To locate connectors or test points,
see Wiring Diagrams for more information.
5. Before measuring voltages make sure the printer is switched On, the Drum
Cartridge and the paper trays are in place, and the interlock switches are actuated,
unless instructed otherwise.
6. All voltages given in the troubleshooting procedures are approximate values. The
purpose of voltage readings is to determine whether or not a component is
receiving the correct voltage and if gating (a voltage drop) occurs during
component actuation. Gating signals may be nothing more than a pulse, resulting
in a momentary drop in voltage that may be difficult or impossible to read on the
average multi-meter.
Unless otherwise specified, these voltage tolerances are used within this section:
Stated Measured
+3.3 VDC +3.135 to +3.465 VDC
+5.0 VDC +4.75 to +5.25 VDC
+24.0 VDC +21.6 to +26.4 VDC
0.0 VDC Less than +0.5 VDC

Entry Level Fault Isolation Procedure
Use this procedure to quickly locate the general area of the problem.
Entry Level Troubleshooting Procedure
Step Actions and Questions Yes No
1 Cycle printer power. Go to Step 4. Go to Step 2.

Does READY TO PRINT appear on the
Front Panel Within 1 minute?
2 Does the printer display an error Go to the procedure Go to Step 3.

message or code? for that error or
code.
3 Is the Front Panel LCD/LED Display Go to Front Panel Go to Step 4.

defective, or the buttons inoperable? Troubleshooting
page 4-4.
4 Run Test Prints from all input trays: Go to the procedure Go to Step 5.
1. In the Main Menu, select for that error
Troubleshooting and press OK. message or code.
2. Select Print Quality Problems and
press OK.
3. Select Test Prints and press OK.
Does the printer display an error
message or code while printing?
5 Do the test prints print? Go to Step 6. Go to Step 7.
6 Evaluate the test prints. Go to Step 8. Go to Print-Quality

Does the print quality meet the print Troubleshooting on
quality specifications? page 5-2.
7 Enter Service Diagnostics and generate Go to Image Go to Inoperative

Test Prints from all input trays. Processor Isolation Printer page 4-10.
Do the test prints print? on page 4-13.
8 Request the customer send a print job Problem solved; Go to Network

from their application. return to Final Problems
Did the job print successfully? Checkout in the page 4-2.
Service Flowchart.

Main Motor Failure
The Main Motor stopped or didnt start on time.
Applicable Error Codes

Main Motor Failure - U0-1 Main Motor Stop
Main Motor Failure - U1-1 Main Motor Rotation
Main Motor Troubleshooting Reference
Applicable Parts References
Motor Assembly Print Engine P/J Electrical (page 10-12)

Engine Logic Board Print Engine Drive/Crum Wiring (page 10-25)
PL7.1 Print Engine Drive (page 9-38)
PL8.1 Print Engine Electrical (page 9-40)
Main Motor Troubleshooting Procedure
1 Check the Motor Assembly installation. Go to Step 2. Correct the

Remove the Upper Rear Cover installation.
(page 8-15).
Is the Motor Assembly installed
correctly?
2 Test Motor Assembly operation. Go to Step 6. Go to Step 3.

Run the Service Diagnostics Main Motor
test.
Does the motor run?
3 Check the Motor Assembly connection. Go to Step 4. Connect P/J214

Are P/J214 and P/J408 connected? and P/J408.
4 Check continuity between the Motor Go to Step 5. Repair the wiring.

Assembly and Engine Logic Board.
Does each wire conduct between P/
J214 <=> P/J408?
5 Check for +24 V to the Motor Assembly. Replace the Motor Replace the
Is there +24 V across P/J214-1/-2 (+) <=> Assembly Engine Logic
ground? (page 8-84). Board
(page 8-89).

Drum Motor Failure - U1-4 Drum Motor Rotation
The Drum Cartridge drive motor failed.
Applicable Error Code

Drum Motor Failure - U1-4 Drum Motor Rotation
Drum Motor Troubleshooting Reference
Drum Cartridge Print Engine P/J Electrical (page 10-12)

Fuser Print Engine Drive/CRUM Wiring (page 10-25)
Motor Assembly PL5.1 Laser, CRU and Toner Dispense (page 9-32)
Engine Logic Board PL6.1 Fuser and Exit 1 (page 9-34)
Drum Motor Troubleshooting Procedure
1 Check the Fuser installation. Go to Step 2. Correct the Fuser

Is the Fuser installed properly? (page 8-76).
2 Check the Drum Cartridge installation. Go to Step 3. Correct the

Is the Drum Cartridge installed installation.
properly?
3 Test the Drum Motor. Go to Step 4. Verify motor

Run the Service Diagnostics Drum Motor installation. Go to
test. Step 5.
Does the motor run?
4 Check the Motor Assembly installation. Replace the Correct the

Remove the Upper Rear Cover. Engine Logic installation.
Is the Motor installed properly? Board
(page 8-89).
5 Check Drum Motor rotation. Go to Step 6. Verify installation.

Can the rotor be rotated by hand
without excessive load?
6 Check the Motor Assembly connection. Go to Step 7. Connect the

Are P/J214 and P/J408 connected? Motor.
7 Check continuity between the Motor Go to Step 8. Repair the wiring.

Assembly and Engine Logic Board.
Is there continuity on each wire
between P/J214 <=> P/J408?

Drum Motor Troubleshooting Procedure (Continued)
8 Check for +24 V to the Motor Replace the Motor Replace the
Is there +24 V across P/J214-1/-2 (+) <=> Assembly Engine Logic
(page 8-89).
Laser Unit Failure - U3-3 Laser Power

The Laser Assembly has failed.

Laser Assembly Failure - U3-3 Laser Power
Laser Assembly Troubleshooting Reference
Drum Cartridge Print Engine P/J Laser and Exit PWB (page 10-7)
Laser Assembly Print Engine laser Assembly Wiring (page 10-29)
Engine Logic Board PL5.1 Laser, CRU and Toner Dispense (page 9-32)
Laser Assembly Troubleshooting Procedure

properly?
2 Check the Laser Assembly installation. Go to Step 3. Correct the Laser

Is the Laser Assembly installed (page 8-74).
properly?
3 Check the Laser Assembly connection. Go to Step 4. Connect the

Are P/J140 and P/J406 connected? Laser.
4 Check the Laser Assembly connections. Go to Step 5. Connect P/J130,

Are P/J130, P/J620 and P/J406 P/J620 and P/
connected? J406.
5 Check continuity between the Laser Go to Step 6. Repair the wiring.

Assembly and the Engine Logic Board.

Laser Assembly Troubleshooting Procedure (Continued)
6 Check continuity between the Laser Go to Step 7. Repair the wiring.

Assembly and the Engine Logic Board.
7 Check for +5 V to the Laser Assembly. Go to Step 8. Replace the

Is there +5 V across P/J140-8 (+) <=> Engine Logic
ground? Board
(page 8-89).
8 Check for +24 V to the Laser. Replace the Laser Replace the
Is there +24 V across P/J130-5 (+) <=> Assembly Engine Logic
(page 8-89).
Laser Motor Failure - U3-5 Polygon Motor Rotation

The Scanner Motor, located in the Laser Assembly, failed.

Laser Failure - U3-5 Polygon Motor Rotation
Scanner Motor Troubleshooting Reference

Drum Cartridge Print Engine P/J Laser and Exit PWB (page 10-7)
Laser Assembly Print Engine laser Assembly Wiring (page 10-29)
Scanner Motor Troubleshooting Procedure

properly?
2 Test the Scanner Motor. Replace Laser Go to Step 4.

Run the Service Diagnostics Laser Scan Assembly or
Motor test. Engine Logic
Does the motor run? Board.
3 Check the Laser connection. Go to Step 4. Connect the

Are P/J140 and P/J406 connected? Laser Assembly.

Scanner Motor Troubleshooting Procedure (Continued)
4 Check the Laser connections. Go to Step 5. Connect P/J130,

connected? J406.
5 Check continuity between the Laser and Go to Step 6. Repair the wiring.
the Engine Logic Board.
6 Check continuity between the Laser and Go to Step 7. Repair the wiring.
7 Check for +5 V to the Laser. Go to Step 8. Replace the

Is there +5 V across P/J140-8 (+) <=> Engine Logic
ground? Board
(page 8-89).
8 Check for +24 V to the Laser. Replace the Laser Replace the
Is there +24 V across P/J130-5 (+) <=> assembly Engine Logic
(page 8-89).
Fuser Failure - U4-1 On Time

Note
Following display of this error, leave power applied for 7 minutes, then cycle
printer power. If the error reoccurs, procede with troubleshooting procedure.
The Fuser failed to reach temperature within the warm-up period. Possible faults are:
During the Warm-Up period, the Control Thermistor does not detect the
Ready temperature even when the specified time has passed.
During the Standby period, the Control Thermistor does not detect the
required temperature even when the specified time has passed.
During the Standby period, the Control Thermistor does not detect the
required temperature even when the specified time has passed.
During idling after power-on, the Control Thermistor does not detect the
idling stop temperature even after the specified time has passed.
During print, the Control Thermistor does not detect the required

Fuser Failure - U4-1 On Time
Fuser On Time Troubleshooting Reference
Fuser Print Engine P/J Fuser and Exit 1 (page 10-8)

LVPS Print Engine Fuser Wiring (page 10-22)
PL6.1 Fuser and Exit 1 Unit (page 9-34)
Fuser On Time Troubleshooting Procedure
1 Check the Fuser for a paper jam. Remove the Go to Step 2.

Open Door A. paper.
Is there a paper jam in the Fuser?
2 Check the Fuser installation. Go to Step 3. Correct the

Is the Fuser installed properly? installation.
3 Check continuity on the junction connector. Go to Step 4. Replace the

Fuser
Warning: Allow the Fuser to cool.
(page 8-76).
Remove the Fuser.
Is there continuity on the pins?
4 Check Fuser resistance. Go to Step 5. Replace the

Is the resistance across P/J600-1 and P/ Fuser
J600-11 less than or equal to 100 ohms? (page 8-76).

J600-11 less than or equal to 100 ohm? (page 8-76).
6 Check Fuser resistance. Go to Step 7 Replace the

J600-11 less than or equal to 100 ohm? (page 8-76).

J131-2 more than or equal to 3 k-ohm? (page 8-76).

Is the resistance between P/J132-1 and Fuser
P/J132-2 greater than or equal to (page 8-76).
3 k-ohm?

J133-2 greater than or equal to (page 8-76).
3 k-ohm?

Fuser On Time Troubleshooting Procedure (Continued)
10 Check the Fuser connection. Go to Step 11. Connect P/J6.

Is P/J6 connected?
11 Check continuity between the Fuser and Go to Step 12. Repair the wiring.
LVPS.
12 Check for +5 V to the Fuser. Replace the Fuser Replace the

Is there +5 V between these pins? (page 8-76) LVPS
P/J6-1 <=> P6-2 (page 8-92).
P/J6-1 <=> P6-3
P/J6-1 <=> P6-4
13 Check the LVPS and the Engine Logic Replace the Connect P/J401
Board connection. Engine Logic and P/J525.
Are P/J401 and P/J525 connected? Board
(page 8-89).
Fuser Failure - U4-n Over Heat / Thermistor

The Fuser failed to reach temperature within the warm-up period. The control
thermistors has detected a temperature higher than the specified value, or one of the
thermistors has failed.

Fuser Failure - U4-2 Over Heat Temp
Fuser Failure - U4-3 FS1 Thermistor
Fuser Failure - U4-4 FS2 Thermistor
Fuser Failure - U4-5 Pressure Roller Thermistor
Fuser Thermistor Troubleshooting Reference

PL6.1 Fuser and Exit 1 Unit (page 9-34)

Fuser Thermistor Troubleshooting Procedure

Is the Fuser installed properly? installation.
2 For FS1 Thermistor Only. Go to Step 3. Replace the

J131-2 more than or equal to 3 k-ohm? (page 8-76).
3 For FS2 Thermistor Only. Go to Step 4. Replace the

Is the resistance between P/J132-1 and Fuser
P/J132-2 greater than or equal to (page 8-76).
3 k-ohm?
4 For Pressure Roller Thermistor Only. Go to Step 5. Replace the

J133-2 greater than or equal to (page 8-76).
3 k-ohm?
5 Check the Fuser connection. Go to Step 6. Connect P/J6.

Is P/J6 connected?
6 Check continuity between the Fuser and Go to Step 7. Repair the wiring.
LVPS.
7 Check power to the Fuser Replace the Fuser Replace the

Is there +XX V across P/JXXX (+) <=> (page 8-76). LVPS
ground? (page 8-92).
Fuser Failure - U4-7 Cold Sagging

The Fuser temperature regulation failed.
Note
Following display of this error, leave power applied for 7 minutes, then cycle
printer power. If the error reoccurs, proceed with troubleshooting procedure.

Fuser Failure - U4-7 Cold Sagging

Fuser Cold Sagging Troubleshooting Reference

Engine Logic Board PL6.1 Fuser and Exit 1 Unit (page 9-34)
Fuser Cold Sagging Troubleshooting Procedure
1 Check the Fuser for a paper jam. Go to Step 2. Remove the

Open Door A. paper.
2 Check the Fuser installation. Go to Step 3. Install the Fuser

Open Door A. correctly.
Is the Fuser installed correctly?
3 Test the Fuser Exit Sensor operation. Go to Step 5. Go to Step 4.

1. Open Door A.
2. Run the Service Diagnostics Fuser Exit
Sensor test.
Does sensor state change each time the
Fuser is installed or removed?
4 Check the resistance of the Fuser. Go to Step 7. Replace the

Is there an open circuit in the Center Fuser
Thermistor between J131-1 and J131-2? (page 8-76).
Is the resistance of the Rear STS across
J131-1 and J131-2 equal or greater than
3 k-ohm?
5 Check the Pressure Roller Thermistor Go to Step 6. Replace the

resistance. Fuser
Is there an open circuit in the Pressure (page 8-76).
Roller Thermistor between J133-1 and
J133-2?
Is the resistance of the Pressure Roller
Thermistor across J133-1 and J133-2
more than or equal to 3 k-ohm?
6 Check the Fuser for connection. Go to Step 7. Connect P/J6.

Is LVPS P/J6 connected?
7 Check the Fuser connections. Replace Engine Connect P/J410,

Are P/J410, P/J607, P/J600, P131 and Logic Board P/J607, P/J600,
P133 connected? (page 8-89). P131 and P133.

Fan Failure - U4-9 Fan Defect
The Fuser Fan failed.

Fuser Failure - U4-9 Fan Defect
Fuser Fan Failure Troubleshooting Reference
Fuser Fan Print Engine P/J Electrical (page 10-12)

Motor Assembly Print Engine Drive/CRUM Wiring (page 10-25)
Fuser Fan Failure Troubleshooting Procedure
1 Check the Fuser Fan installation. Go to Step 2. Correct the

1. Remove the I/P Board Cover. installation.
2. Remove the Upper Rear Cover.
Is the Fan installed properly (label out)?
2 Check if the Fuser Fan rotates. Go to Step 7. Go to Step 3.

Does the Fan rotate?
3 Test the Fuser Fan. Go to Step 7. Go to Step 4.

Run the Service Diagnostic Fuser Fan test.
Does the Fuser Fan operate properly?
4 Check the Fuser Fan connection (CN102). Go to Step 5. Connect the Fan.
Is the Fan connected?
5 Check continuity between the Fan and Go to Step 6. Replace the Fan
Motor Assembly (CN102). (page 8-59).
Is there continuity on each wire?
6 Check for +24 V to the Fuser Fan. Replace the Fan Replace the
Is there +24 V across CN102-3(+) <=> (page 8-59). Engine Logic
ground? Board
(page 8-89), then
replace the Motor
Assembly.

Toner Motor Failure - U5-1 Motor Rotation
The Toner Dispense Motor failed to rotate.

Toner Motor Failure - U5-1 Motor Rotation
Troubleshooting Reference
Toner Cartridge Print Engine P/J Drum and Toner Cartridge

Toner Dispense (page 10-6)
Assembly Print Engine Xerographics Wiring (page 10-24)
Toner Dispense Motor PL5.1 Laser, CRU and Toner Dispense (page 9-32)
Engine Logic Board PL8.1 Print Engine Electrical (page 9-40)
Troubleshooting Procedure
1 Check the Toner Cartridge installation. Problem solved. Go to Step 2.

Reinstall the Toner Cartridge.
Does it operate properly?
2 Check Toner Dispense Assembly rotation. Go to Step 3. Restore proper

Does the gear located at the lower part operation.
of the Toner Dispense Assembly rotate?
3 Check Toner Dispense Assembly clogging. Go to Step 4. Clean the pipe.

Is the pipe located at the lower part of
the Toner Dispense Assembly clogged?
4 Test Dispense Motor operation. Replace the Go to Step 5.

Run the Service Diagnostics Dispense Engine Logic
Motor test. Board
Does the motor operate? (page 8-89).
5 Check the Dispense Motor for connection. Go to Step 6. Connect P/J216

6 Check continuity between the Dispense Go to Step 7. Repair the wiring.

Motor and Engine Logic Board.
7 Check for +24 V at the Dispense Motor Replace the Replace the
Is there +24 V across P/J216-1 (+) <=> Dispense Motor Engine Logic
(page 8-89).

Fan Failure - U5-9 Fan Failure
The Drum Cartridge Fan failed.

Fan Failure - U5-9 Fan Defect
Drum Cartridge Fan Failure Troubleshooting Reference
Drum Cartridge Print Engine P/J Drum and Toner Cartridge (page 10-6)
Fan Print Engine Xerographics Wiring (page 10-24)
Engine Logic PL5.1 Laser, CRU and Toner Dispense (page 9-32)
Board PL8.1 Print Engine Electrical (page 9-40)
Drum Cartridge Fan Failure Troubleshooting Procedure
1 Check the Drum Fan installation. Go to Step 2. Correct the

1. Remove the I/P Board Cover. installation.
2. Remove the Top Cover.
Is the Fan installed properly (label out)?
2 Check if the Drum Cartridge Fan rotates. Go to Step 7. Go to Step 3.

Does the Fan rotate?
3 Test the Drum Cartridge Fan. Go to Step 7. Go to Step 4.

Run the Service Diagnostic Drum
Cartridge Fan test.
Does the Fan operate properly?
4 Check the Fan connection. Go to Step 5. Connect the Fan.

Is P/J221 connected?
5 Check continuity between the Fan and Go to Step 6. Replace the Fan
Engine Logic Board. (page 8-58).
6 Check for +24 V at the Drum Cartridge Go to Step 7. Replace the

Fan. Engine Logic
Is there +24 V across P/J221 (+) <=> Board
7 Test the Drum Cartridge Fan. Replace the Fan Replace the
Run the Service Diagnostic Drum (page 8-58) Engine Logic
Cartridge Fan test. Board
Does the Fan receive the voltage from (page 8-89).
the test?

Engine Logic Board Failure - U6-2, 3, 4, 5, 6, 7
Engine Logic Board components have failed.

Engine Logic Board Failure - U6-2 RAM Read/Write
Engine Logic Board Failure - U6-3 NVM Data Defect
Engine Logic Board Failure - U6-4 NVM Read/Write
Engine Logic Board Failure - U6-5 CP/U Power NVM
Engine Logic Board Failure - U6-6 ASIC/CRUM
Engine Logic Board Failure - U6-7 PPM Data
Engine Logic Board Troubleshooting Reference
Engine Logic Engine Logic Board P/J Locator (page 10-13)

Engine Logic Board Troubleshooting Procedure
1 Does the error occur when the power is Go to Step 2. Problem solved.
cycled?
2 Check Engine Logic Board connections. Go to Step 3. Connect all

Are all the connectors connected? connectors. Go to
Step 3.
3 Does the error reoccur when power is Replace the Problem solved.
applied? Engine Logic
Board
(page 8-89).
Paper Size Jam - E1-1 Regi Area Jam

Paper did not pass the Registration Sensor located behind Door A, within the
specified time.

Paper Size Jam - E1-1 Regi Area Jam

Paper Size Jam (Registration Sensor) Troubleshooting Reference
Registration Sensor Print Engine P/J Registration Transport (page 10-10)

Registration Clutch Print Engine Registration Transport Wiring
Take Away Roller (page 10-23)
Engine Logic Board PL4.1 Transportation and Registration (page 9-22)
PL4.5 Registration (page 9-30)
Paper Size Jam (Registration Sensor) Troubleshooting Procedure
1 Check paper position at Door A or B. Remove the Go to Step 2.

Does the paper touch the Registration paper.
Sensor or Feeders Pre-Feed Sensor?
2 Check the Take Away Roller. Clean or replace Go to Step 3.

Open Door A. the Take Away
Is the Take Away Roller worn or Roller.
contaminated with paper dust?
3 Test the Registration Sensor. Go to Step 7. Go to Step 4.

1. Open Door A.
2. Run the Service Diagnostics
Registration Sensor test.
Does the sensor change state?
4 Check the Registration Sensor connection. Go to Step 5. Connect the

Are P/J104 and P/J403B connected? sensor.
5 Check continuity between the Registration Go to Step 6. Repair the wiring.

Sensor and Engine Logic Board.
6 Check for +5 V at the Registration Sensor. Replace the Replace the

Is there +5 V across the sensor Registration Engine Logic
connectors P/J104-1 <=> ground? Sensor Board
(page 8-52). (page 8-89).
7 Test the Registration Clutch operation. Replace the Go to Step 8.

Run the Service Diagnostics Registration Engine Logic
Clutch test. Board
Does the clutch operate properly? (page 8-89).
8 Check the Registration Clutch connection. Go to Step 9. Connect P/J215

Are P/J215 and P/J403B connected? and P/J403B.
Clutch and Engine Logic Board.

Paper Size Jam (Registration Sensor) Troubleshooting Procedure (Continued)
10 Check for +24 V to the Registration Clutch. Go to Step 11. Replace the
Is there +24 V across P215-2 (+) <=> Engine Logic
ground? Board
(page 8-89).
11 Check Registration Clutch resistance. Replace the Replace

Is the resistance between J215-1 and Engine Logic Registration
J215-2 approximately 240 ohms? Board Clutch
(page 8-89). (page 8-51).
Jam at A - E1-2 Regi Area Jam

Paper did not activate the Fuser Exit Sensor, located behind Door A, within the
specified time following activation of the Registration Clutch.

E1-2 Regi Area Jam (Fuser Exit Sensor) Troubleshooting Reference
Fuser Exit Sensor Print Engine P/J Drum and Toner Cartridge
Registration Clutch (page 10-6)
Take Away Roller Print Engine Exit 1 Wiring (page 10-30)
Exit PWB PL4.1 Transportation and Registration (page 9-22)
Engine Logic Board PL4.5 Registration (page 9-30)
PL6.1 Laser, CRU, and Toner Dispense (page 9-32)
E1-2 Regi Area Jam (Fuser Exit Sensor) Troubleshooting Procedure
1 Check paper position behind Door A. Remove the Go to Step 2.

Does the paper touch the Fuser Exit paper.
Sensor?

Is the Take Away Roller worn or the Take Away
contaminated with paper dust? Roller.

E1-2 Regi Area Jam (Fuser Exit Sensor) Troubleshooting Procedure (Continued)
3 Test the Fuser Exit Sensor. Go to Step 7. Go to Step 4.

1. Open Door A.
Sensor test.
4 Check the Fuser Exit Sensor connection. Go to Step 5. Connect the

Are P/J125 and P/J410 connected? sensor.
5 Check continuity between the Fuser Exit Go to Step 6. Repair the wiring.
6 Check for +5 V at the Fuser Exit Sensor. Replace the Fuser Replace the
Is there +5 V across the sensor Exit Sensor Engine Logic
connectors P/J125-3 <=> ground? (page 8-77) Board
(page 8-89).
7 Test the Registration Clutch operation. Replace the Go to Step 8.

Clutch test. Board
Does the clutch operate properly? (page 8-89).
8 Check the Registration Clutch connection. Go to Step 9. Connect P/J215

between P/J215 <=> P/J403B?
ground? Board
(page 8-89).
11 Check Registration Clutch resistance. Replace the Replace

Is the resistance between J215-1 and Engine Logic Registration
J215-2 approximately 240 ohms? Board Clutch
(page 8-89). (page 8-51).

Paper remains at the Registration Sensor located behind Door A.


E1-6 Regi Area Jam (Registration Sensor) Troubleshooting Reference
Registration Print Engine P/J Registration Transport (page 10-10)

Sensor Print Engine Registration Transport Wiring (page 10-23)
Engine Logic PL4.5 Registration (page 9-30)
Board
E1-6 Regi Area Jam (Registration Sensor) Troubleshooting Procedure
1 Check paper position at Door A. Remove the Go to Step 2.

Is paper touching the Registration paper.
Sensor?
2 Test the Registration Sensor. Replace the Go to Step 3.

1. Open Door A. Engine Logic
Board
(page 8-89).


5 Check for +5 V at the Registration Sensor. Replace the Replace the

connectors P/J104-1 <=> ground? Sensor Board
(page 8-52). (page 8-89).
Jam at A - Fuser Area Jam

Paper did not actuate the Fuser Exit Sensor, located behind Door A, within the
specified time.

Jam at A - E3-1 Fuser Area Jam

Jam at A (Fuser Exit Sensor) Troubleshooting Reference
Fuser Exit Sensor Print Engine P/J Drum and Toner Cartridge
Take Away Roller (page 10-6)
Engine Logic Board Print Engine Fuser Wiring (page 10-22)
Fuser PL4.1 Transportation and Registration (page 9-22)
PL6.1 Fuser and Exit 1 (page 9-34)
Jam at A (Fuser Exit Sensor) Troubleshooting Procedure
1 Check paper position. Remove the Go to Step 2.

Open Door A. paper.
Does the paper touch the Fuser Exit
Sensor?
2 Check the Fuser for a paper jam. Go to Step 3. Remove the

Open Door A. paper.

Open Door A. installation.
Is the Fuser installed correctly?
4 Check the Take Away Roller. Go to Step 5. Clean or replace

Open Door A. Take Away Roller
Is the Take Away Roller worn or (page 8-41)
5 Test the Fuser Exit Sensor operation. Reconnect the Go to Step 6.

1. Open Door A. connector of the
2. Run the Service Diagnostic Fuser Exit Engine Logic
Board.
Sensor test.
Does the sensor state change each time
paper touches the sensor?
6 Check the Fuser Exit Sensor connection. Go to Step 7. Connect P/J125

8 Check for +5 V to the Fuser Exit Sensor. Replace the Fuser Replace Engine
Is there +5 V across J125-3 (+) <=> Exit Sensor Logic Board
ground? (page 8-77). (page 8-89).

Paper remains at the Fuser Exit Sensor located behind Door A.

E3-6 Fuser Area Jam Troubleshooting Reference
Fuser Exit Print Engine P/J Drum and Toner Cartridge (page 10-6)
Sensor Print Engine Fuser Wiring (page 10-22)
Engine Logic PL6.1 Fuser and Exit 1 (page 9-34)
E3-6 Fuser Area Jam Troubleshooting Procedure

Is paper touching the Fuser Exit paper.
Sensor?
2 Test the Fuser Exit Sensor. Replace the Go to Step 3.

1. Open Door A. Engine Logic
Board
(page 8-89).
Sensor test.

connectors P/J125-3 <=> ground? (page 8-77). Board
(page 8-89).

Jam at A - E4-1 Exit 2 Area Jam
Paper did not reach the Exit 2 Exit Sensor located behind Door E on time.

E4-1 Exit 2 Area Jam Troubleshooting Reference
Fuser Exit Sensor Print Engine P/J Fuser and Exit 1 (page 10-8)
Exit 2 Exit Sensor Print Engine Fuser Wiring (page 10-22)
Exit 1 OCT Roller Exit 2 Plug/Jack Locator (page 5-15)
Exit 1 Motor Exit 2 Sensor/Fan Wiring(page 5-18)
Exit PWB PL6.1 Fuser and Exit 1 (page 9-34)
LVPS PL24.2 Exit 2 Tray Guide Assembly (page 4-40)
E4-1 Exit 2 Area Jam Troubleshooting Procedure

Sensor?
2 Check paper position at Door E. Remove the Go to Step 3.

Is paper touching the Exit Sensor? paper.
3 Check the OCT Roller. Clean or replace Go to Step 4.

Is the OCT Roller worn or contaminated the OCT Roller.
with paper dust?
4 Check the drive transmission. Go to Step 5. Restore proper

Does the OCT Roller and gears rotate operation.
smoothly?
5 Test the Fuser Exit Sensor. Go to Step 9. Go to Step 6.

1. Open Door A.
Sensor test.


E4-1 Exit 2 Area Jam Troubleshooting Procedure (Continued)
connectors P/J125-3 <=> ground? (page 8-77). Board
(page 8-89).
9 Test the Exit 1 Motor operation. Go to Step 18. Go to Step 10.

Run the Service Diagnostics Exit 1 Motor
tests.
Does the motor operate properly?
10 Check the Exit 1 Motor connection. Go to Step 11. Connect P/J206

11 Check continuity between the Exit 2 Motor Go to Step 12. Repair the wiring.
and Engine Logic Board.
12 Check for +24 V to the Exit 1 Motor. Replace the Exit 1 Go to Step 13.
Is there +24 V across P206-5 (+) <=> Offset Motor
13 Check the connection between the Exit Go to Step 14. Connect P/J431
PWB and Engine Logic Board, and P/J421.
Are P/J431 and P/J421 connected?
14 Check continuity between the Exit PWB Go to Step 15. Repair the wiring.
and the Engine Logic Board.
PWB and the LVPS. and P/J526.
and the LVPS.
17 Check for +24 V to the Exit PWB. Replace the Exit Replace the
Is there +24 V across P/J430-1 (+) <=> PWB (page 8-88). LVPS
18 Test the Exit 2 Exit Sensor. Replace the Go to Step 19.

1. Open Door E. Engine Logic
Board
2. Run the Service Diagnostics Exit Sensor
(page 8-89).
test.
19 Check the Exit 2 Exit Sensor connection. Go to Step 20. Connect the
Are P/J112, P/J606B, and P/J434 sensor.
connected?

20 Check continuity between the Exit 2 Exit Go to Step 21. Repair the wiring.
Sensor and Exit PWB.
21 Check for +5 V at the Exit 2 Exit Sensor. Replace the Exit Go to Step 22.
Is there +5 V across the sensor Sensor
connectors P/J112-3 <=> ground? (page 3-102).
PWB and Engine Logic Board. and P/J421.
and the LVPS.
Jam at E - E4-3 Exit 2 Area Jam

Paper did not pass the Exit 2 Exit Sensor located behind Door E on time.


Exit 2 Exit Sensor Print Engine P/J Engine Logic Board (page 10-13)
Exit 2 Motor Print Engine Exit 1 Wiring (page 10-30)
Exit 2 OCT Roller PL8.1 Print Engine Electrical (page 9-40)
Exit 2 FU Roller Phaser 5500 Printer Options Service Manual
Exit 2 Inv Roller Exit 2 Plug/Jack Locator (page 5-15)
Exit PWB Exit 2 General Wiring (page 5-7)
Engine Logic Board PL24.1 Exit 2 L/H Upper Chute (page 4-38)
LVPS PL24.2 Exit 2 Tray Guide Assembly (page 4-40)

Is paper touching the Exit 2 Sensor? paper.
2 Check the FU Roller. Clean or replace Go to Step 3.

Is the FU Roller worn or contaminated the FU Roller.
with paper dust?

Does the FU Roller and gears rotate operation.
smoothly?
4 Check the Inv Roller. Clean or replace Go to Step 5.

Is the INV Roller worn or contaminated the INV Roller.
with paper dust?

Does the INV Roller and gears rotate operation.
smoothly?

with paper dust?
7 Check the drive transmission. For E4-5: Go to Restore proper

Does the OCT Roller and gears rotate Step 8. operation.
smoothly? For E4-3: Go to
Step 9.
8 For E4-5 Only: Got to Step 9. Go to Step 10.

Test Exit 2 Gate Solenoid.
Run the Service Diagnostics Exit 2 Gate
Solenoid test.
Does the Solenoid operate the Gate?

9 Test the Exit 2 Sensor. For E4-5: Go to Go to Step12.

1. Open Door E. Step 10.
For E4-3: Go to
2. Run the Service Diagnostics Exit Sensor
Step 12.
test.
10 For E4-5 Only: Go to Step 11. Repair the wiring.

Check Exit 2 Solenoid.
Check continuity on each wire between P/
J209 to P/J433.
between
11 For E4-5 Only: Replace the Exit 2 Replace the Exit

Check for +24 V to the Exit 2 Gate Gate Solenoid PWB (page 8-88).
Solenoid. (page 3-98).
Is there +24 V across P/J433-11 (+) <=>
ground?
12 Check the Exit Sensor connection. Go to Step 13. Connect the

Are P/J112, P/J606B, and P/J434 sensor.
connected?
13 Check continuity between the Exit Sensor Go to Step 14. Repair the wiring.
and Exit PWB.
14 Check for +5 V at the Exit Sensor. Replace the Exit 2 Go to Step 15.
connectors P/J112-3 <=> ground? (page 3-102)
and the LVPS.

20 Test the Exit 2 Motor operation. Replace the Go to Step 21.

Run the Service Diagnostics Exit 2 Output Engine Logic
Motor tests. Board
Does the Exit 2 Motor operate properly? (page 8-89).
21 Check the Exit 2 Motor connection. Go to Step 22. Connect P/J208,

Are P/J208, P/J606A and P/J433 P/J606A and
connected? P/J433.
22 Check continuity between the Exit 2 Motor Go to Step 23. Repair the wiring.
and Exit PWB.
Is there +24 V across P208-5 (+) <=> Motor
and the LVPS.

Paper remains at the Exit 2 Exit Sensor located behind Door E.


Exit 2 Exit Sensor Print Engine P/J Engine Logic Board (page 10-13)
Exit PWB Print Engine P/J Laser and Exit PWB (page 10-7)
Engine Logic Board Print Engine Exit 1 Wiring (page 10-30)
LVPS Phaser 5500 Printer Options Service Manual
Exit 2 Plug/Jack Locator (page 5-15)
Exit 2 General Wiring (page 5-7)
PL24.2 Exit 2 Tray Guide Assembly (page 4-40)

Sensor?
2 Test the Exit Sensor. Replace the Go to Step 3.

Run the Service Diagnostics Exit Sensor Engine Logic
test. Board
Does the sensor change state? (page 8-89).
3 Check the Exit Sensor connection. Go to Step 4. Connect the

Are P/J112, P/J606B and P/J434 sensor.
connected?
4 Check continuity between the Exit Sensor Go to Step 5. Repair the wiring.
and Exit PWB.
between P/J112<=> P/J434?
5 Check for +5 V at the Exit Sensor. Replace the Exit Go to Step 6.

connectors P/J112-3 <=> ground? (page 3-102).

8 Check the connection between Exit PWB Go to Step 9. Connect P/J430

and LVPS. and P/J526.

and LVPS.
Jam at E - E8-2 Duplex Area Jam

Paper being fed into the Duplex Unit did not reach the Wait Sensor on time.

Jam at E - E8-2 Duplex Area Jam
E8-2 Duplex Area Jam Troubleshooting Reference
Duplex Wait Sensor Print Engine P/J Engine Logic Board (page 10-13)
Exit 2 Motor Print Engine Exit 1 Wiring (page 10-30)
Exit 2 OCT Roller PL8.1 Print Engine Electrical (page 9-40)
Exit 2 FU Roller Phaser 5500 Printer Options Service Manual
Exit 2 Inv Roller Exit 2 Plug/Jack Locator (page 5-15)
Exit PWB Exit 2 General Wiring (page 5-7)
Duplex Unit PWB Duplex Unit Plug/Jack Locator (page 5-12)
Engine Logic Board Duplex Unit Wiring (page 5-13)
LVPS PL23.1 Duplex Unit (page 4-34)
PL24.1 Exit 2 L/H Upper Chute (page 4-38)
E8-2 Duplex Area Jam Troubleshooting Procedure

Does paper remain in Exit 2? paper.
2 Check the FU Roller. Clean or replace Go to Step 3.

Is the FU Roller worn or contaminated the FU Roller.
with paper dust?

Does the FU Roller and gears rotate operation.
smoothly?

E8-2 Duplex Area Jam Troubleshooting Procedure (Continued)
4 Check the Inv Roller. Clean or replace Go to Step 5.

Is the INV Roller worn or contaminated the INV Roller.
with paper dust?

Does the INV Roller and gears rotate operation.
smoothly?

with paper dust?

Does the OCT Roller and gears rotate operation.
smoothly?
8 Test the Exit 2 Motor. Go to Step 17. Go to Step 9.

Run the Service Diagnostics Exit 2 Motor
tests.
Does the Exit 2 Motor operate properly?
9 Check the Exit 2 Motor connections. Go to Step 10. Connect P/J208,

Are P/J208, P/J606A and P/J433 P/J606A and P/
connected? J433.
10 Check continuity between the Exit Motor Go to Step 11. Repair the wiring.
and Exit PWB.
Is there +24 V across P208-5 (+) <=> Motor
and the LVPS.

E8-2 Duplex Area Jam Troubleshooting Procedure (Continued)
17 Test the Wait Sensor. Replace the Go to Step 18.

Run the Service Diagnostics Duplex Wait Engine Logic
Sensor test. Board
Does the Wait Sensor operate properly? (page 8-89).
18 Check the Wait Sensor connection. Go to Step 19. Connect P/J123

19 Check continuity between the Wait Sensor Go to Step 20. Repair the wiring.
and Duplex PWB.
20 Check for +5 V to the Wait Sensor. Replace the Wait Go to Step 21.
Is there +5 V across P123-3 (+) <=> Sensor
21 Check the Duplex PWB connection. Go to Step 22. Connect P/J540

Are P/J540 and P/J417 connected? and P/J417
surely.
22 Check continuity between the Duplex PWB Go to Step 23. Repair the wiring.
23 Check for +5 V to the Duplex PWB. Replace the Replace the

Is there +5 V across P/J540-1 (+) <=> Duplex PWB Engine Logic
(page 8-89).
Jam at D and A - C6-1 Duplex Area Jam

Paper being fed from the Duplex Unit did not reach the Registration Sensor, located
behind Door A, on time.


C6-1 Duplex Area Jam Troubleshooting Reference
Duplex A3L Rollers Print Engine P/J Engine Logic Board (page 10-13)
Duplex Roller Print Engine Registration Transport Wiring (page 10-23)
Duplex Motor PL4.5 Registration (page 9-30)
Duplex PWB PL8.1 Print Engine Electrical (page 9-40)
Engine Logic Board Phaser 5500 Printer Options Service Manual
Registration Sensor Duplex Unit Plug/Jack Locator (page 5-12)
Duplex Unit Wiring (page 5-13)
PL23.1 Duplex Unit (page 4-34)
PL23.2 Inner Chute Duplex Unit (page 4-36)
C6-1 Duplex Area Jam Troubleshooting Procedure

Open Door A paper.
Does the paper touch the Registration
Sensor?
2 Check Duplex Unit installation. Go to Step 3. Problem solved.

1. Reinstall the Duplex Unit.
2. Print a 2-sided Test Print.
Does the error reoccur?
3 Check the A3L Rollers. Clean or replace Go to Step 4.

Open Door D. the defective
Are the A3L Rollers worn or roller.
4 Check the roller drive. Go to Step 5. Restore proper

Do the A3L Rollers and gears rotate operation.
smoothly?
5 Check the Duplex Roller. Clean or replace Go to Step 6.

Is the Duplex Roller worn or the roller.

Do the Duplex Roller and gears rotate operation.
smoothly?
7 Test the Duplex Motor. Go to Step 15. Go to Step 8.

Run the Service Diagnostics Duplex Motor
test.
Does the Duplex Motor operate
properly?
8 Check the Duplex Motor for connection. Go to Step 9. Connect P/J212


C6-1 Duplex Area Jam Troubleshooting Procedure (Continued)
9 Check the Duplex Motor for continuity. Go to Step 10. Repair the wiring.
10 Check for +24 V to the Duplex Motor. Go to Step 14. Go to Step 11.
Is the +24 V across P/J212-5 (+) <=>
ground?

(page 8-89).
14 Test the Registration Sensor. Replace the Go to Step 15.

Sensor test. Board
Does the sensor status change? (page 8-89).
15 Check the Registration Sensor connection. Go to Step 16. Connect P/J104

between P/J104 <=> P/J409B?
17 Check for +5 V to the Registration Sensor. Replace the Go to Step 18.

Is there +5 V across P/J104-1 (+) <=> Registration
ground? Sensor
(page 8-52).

(page 8-89).

Paper being fed from the Duplex Unit did not reach the Registration Sensor, located
on behind Door A, on time. Paper didnt stop at the Wait Sensor.

C6-2 Duplex Area Jam Troubleshooting Reference

Duplex A3L Rollers Print Engine P/J Engine Logic Board (page 10-13)
Duplex Roller Print Engine Registration Transport Wiring (page 10-23)
Duplex Motor PL4.5 Registration (page 9-30)
Duplex Wait PL8.1 Print Engine Electrical (page 9-40)
Sensor Phaser 5500 Printer Options Service Manual
Duplex PWB Duplex Unit Plug/Jack Locator (page 5-12)
Engine Logic Board Duplex Unit Wiring (page 5-13)
Registration PL23.1 Duplex Unit (page 4-34)
Sensor PL23.2 Inner Chute Duplex Unit (page 4-36)
C6-2 Duplex Area Jam Troubleshooting Procedure
1 Check the paper position. Remove the Go to Step 2.

Open Door A paper.
Sensor?
2 Check the paper position. Remove the Go to Step 3.

Open Door D paper.
Does the paper touch the Wait Sensor?
3 Check the Duplex Unit installation. Go to Step 4. Problem solved.

1. Reinstall the Duplex Unit.
2. Print a 2-sided Test Print.
4 Check the A3L Rollers. Clean or replace Go to Step 5.

Are the A3L rollers worn or the defective
contaminated with paper dust? roller.

Do the A3L rollers and gears rotate operation.
smoothly?
6 Check the Duplex Roller. Clean or replace Go to Step 7.

Is the Duplex Roller worn or the roller.

Do the Duplex Roller and gears rotate operation.
smoothly?

8 Test the Wait Sensor. Go to Step 14. Go to Step 9.

Run the Service Diagnostics Duplex Wait
Sensor test.
Does the Wait Sensor operate properly?
9 Check the Wait Sensor connection. Go to Step 10. Connect P/J123

and Duplex PWB.
Is there +5 V across P123-3 (+) <=> Sensor

(page 8-89).
14 Test the Duplex Motor. Go to Step 21. Go to Step 15.

Run the Service Diagnostics Duplex Motor
test.
Does the Duplex Motor operate
properly?
15 Check the Duplex Motor for connection. Go to Step 16. Connect P/J212
16 Check the Duplex Motor for continuity. Go to Step 17. Repair the wiring.
17 Check for +24 V to the Duplex Motor. Replace the Go to Step 18.
Is the +24 V across P/J212-5 (+) <=> Duplex Motor


(page 8-89).

21 Check Registration Sensor operation. Replace the Go to Step 22.

Sensor test. Board
Does the sensor status change? (page 8-89).

Are P/J104 and P/J403 connected? and P/J403B.
24 Check for +5 V to the Registration Sensor. Replace the Go to Step 25.

Is there +5 V across P/J104-1 (+) <=> Registration
ground? Sensor
(page 8-52).

(page 8-89).
Jam at Tray n - Pre-Feed

Paper fed from a universal tray did not reach the Pre-Feed Sensor, located on the
trays Feeder, on time.

Jam at Tray 2 - C1-2 Tray 2

Jam at Tray n (Pre-Feed Sensor) Troubleshooting Reference
Feed Roller Print Engine P/J Engine Logic Board (page 10-13)
Retard Roller Print Engine Tray 2 & 3 Wiring (page 10-26)
Nudger Roller PL2.3 Feeder (2/2) (page 9-12)
Pre-Feed Sensor PL8.1 Print Engine Electrical (page 9-40)
Feed/Lift Motor Phaser 5500 Printer Options Service Manual
Engine Logic Board 1000-Sheet Feeder P/J Locator (page 5-5)
Tray 4-5 PWB 1000-Sheet Tray 4 & 5 Wiring (page 5-9)
PL20.6 Tray 4-5 Drive and Electrical (page 4-16)
Jam at Tray n (Pre-Feed Sensor) Troubleshooting Procedure
1 Check the paper condition. Replace the Go to Step 2.

Is the paper in the tray damaged? paper.
2 Check the paper size settings. Go to Step 3. Correct paper

Does the paper size in use match the size settings.
setting for the tray?
3 Remove the tray and check the rollers. Clean or replace Go to Step 4.
Is the Feed, Retard, or Nudger Roller the Rollers.
worn or contaminated with paper dust?
4 Check paper position at Door A, B, or C. Remove the Go to Step 5.

Does the paper touch the Feeders paper.
Registration or Pre-Feed Sensor?
5 Test the Feeders Pre-Feed Sensor. Got to Step 9 Go to Step 6.

1. Open Door A, B, or C.
2. Run the Service Diagnostics Pre-Feed
Sensor test for the appropriate tray.
6 Check the Pre-Feed Sensor connection. Go to Step 7. Connect the

Is the sensors connected? sensor.
7 Check continuity between the Pre-Feed Go to Step 8. Repair the wiring.

sensor and the Engine Logic Board.
between the sensor and board

Jam at Tray n (Pre-Feed Sensor) Troubleshooting Procedure (Continued)
8 Check for +5 V at the Pre-Feed Sensor. Replace the Replace the

Is there +5 V across the sensor sensor. If the error Engine Logic
connectors Pin 1 <=> ground? persists, go to Board
Step 12 for Tray 2 (page 8-89). If the
or 3, or Step 9 for error persists, go
Tray 4 or 5. to Step 12 for
Tray 2 or 3, or
Step 9 for Tray 4
or 5
9 For Trays 4 & 5 Only: Go to Step 10. Connect P/J541

Check connections between the Tray 4-5 and P/J413.
PWB and Engine Logic Board.
10 For Trays 4 & 5 Only: Go to Step 11. Repair the wiring.

Check continuity between the Tray 4-5
11 For Trays 4 & 5 Only: Replace the Tray Replace the

Check for +24 V at the Tray 4-5 PWB. 4-5 PWB. Engine Logic
Is their +24 V across P/J541-7 (+) <=> Board
12 Test the Feed/Lift Motor. Replace the Go to Step 13

Run the Service Diagnostics Lift/Feed Engine Logic
motor test for the appropriate tray. Board
Does the motor operate? (page 8-89).
13 Check the Feed/Lift Motor connections. Go to Step 14. Connect the

Is the Feed/Lift motor connected? motor.
14 Test the Feed/Lift Motor. Replace the Feed/ Go to Step 15.

1. Exchange the Feed/Lift motor with one Lift motor.
from a different feeder.
2. Run the Service Diagnostics Lift/Feed
motor test for the appropriate tray.
Does the replaced motor operate?
15 Check the Feed/Lift Motor for continuity. Go to Step 16. Repair the wiring.
Reinstall the Feed/Lift motors as they
previously were.
between the sensor and P/J409A?
16 Check +24 V power supply to the Feed/Lift Replace the Feed/ Replace the
Motor. Lift Motor. Engine Logic
Is there +24 V across the motor Board
connectors Pin 4 <=> ground? (page 8-89).

Jam at Tray n - Registration
Paper fed from a universal tray did not reach the Registration Sensor on time.

Jam at Tray n (Registration Sensor) Troubleshooting Reference
Registration Sensor PL8.1 Print Engine Electrical (page 9-40)
Tray 2 Pre-Feed Sensor Phaser 5500 Printer Options Service Manual
Tray 3 Pre-Feed Sensor 1000-Sheet Feeder P/J Locator (page 5-5)
Engine Logic Board 1000-Sheet Tray 4 & 5 Wiring (page 5-9)
Tray 4-5 PWB PL20.4 Tray 4-5 Feeders (2/2) (page 4-10)
Tray 4 Feed Out Sensor PL20.6 Tray 4-5 Drive and Electrical (page 4-16)
Tray 5 Feed Out Sensor
Jam at Tray n (Registration Sensor) Troubleshooting Procedure
1 Check paper condition. Replace the Go to Step 2.

2 Check paper size settings. Go to Step 3. Correct paper

Does the paper size in use match the size settings.
setting for the tray?
4 Check paper position at Door A or B. Remove the Go to Step 5.

Does the paper touch the Registration paper.
Sensor or Feeders Pre-Feed Sensor?

1. Open Door A.

Jam at Tray n (Registration Sensor) Troubleshooting Procedure (Continued)


8 Check for +5 V at the Registration Sensor Replace the Replace the

connectors Pin 1 <=> ground? Sensor. If the error Board
persists, go to (page 8-89). If the
Step 9 for Tray 2 error persists, go
or 3, or Step 13 for to Step 9 for Tray
Tray 4 or 5. 2 or 3, or Step 13
for Tray 4 or 5.
9 For Trays 2 and 3 Only: Replace the Go to Step 10.

Test the Feeders Pre-Feed Sensor. Engine Logic
1. Open Door A or B Board
(page 8-89).
2. Run the Service Diagnostics Pre-Feed
10 For Trays 2 and 3 Only: Go to Step 11. Connect the

Check the Pre-Feed Sensor connection. sensor.
Is the sensor connected?
11 For Trays 2 and 3 Only: Go to Step 12. Repair the wiring.

Check continuity between the Pre-Feed
Sensor and the Engine Logic Board.
12 For Trays 2 and 3 Only: Replace the Replace the

Check for +5 V at the Pre-Feed Sensor. sensor. Engine Logic
Is there +5 V across the sensor Board

Test the appropriate Feed Out Sensor. Engine Logic
1. Open Door C Board
(page 8-89).
2. Run the Service Diagnostics Feed Out

Check the appropriate Feed Out Sensor sensor.
connection.
Is the sensors connected?

Jam at Tray n (Registration Sensor) Troubleshooting Procedure (Continued)

Check continuity between the Feed Out
Sensor and the Tray 4-5 PWB.

Check for +5 V at the Feed Out Sensor. sensor.
Is there +5 V across the sensor
connectors Pin 1 <=> ground?


PWB and the Engine Logic Board.

Check for +24 V at the Tray 4-5 PWB 4-5 PWB Engine Logic
Is their +24 V across P/J541-7 (+) <=> (page 3-29). Board
Jam at Tray n - Feed Out #3

Paper fed from a universal tray did not reach Feed Out Sensor #3, located behind
Door B on the Print Engine Take Away Chute, on time.


Jam at Tray n (Feed Out Sensor #3) Troubleshooting Reference
Feed Out Sensor #3 PL8.1 Print Engine Electrical (page 9-40)
Tray 4-5 PWB 1000-Sheet Feeder P/J Locator (page 5-5)
Tray 4 Feed Out Sensor 1000-Sheet Tray 4 & 5 Wiring (page 5-9)
Tray 5 Feed Out Sensor PL20.4 Tray 4-5 Feeder (2/2) (page 4-10)
Jam at Tray n (Feed Out Sensor #3) Troubleshooting Procedure
1 Check the paper condition. Replace the Go to Step 2.

2 Check the paper size settings. Go to Step 3. Correct paper

Does the paper size match the setting? size settings.
4 Check the paper position at Door B or C. Remove the Go to Step 5 for

Does the paper block the Feed Out paper. If the error Tray 2 or 3, or
Sensor? persists, go to Step 9 for Tray 4
Step 5 for Tray 2 or 5.
or 3, or Step 9 for
Tray 4 or 5.
5 Test Feed Out Sensor #3. Go to Step 9. Go to Step 6.

1. Open Door B.
2. Run the Service Diagnostics Tray 3
Feed Out Sensor test.
6 Check the Feed Out Sensor #3 connection. Go to Step 7. Connect the

Are P/J105, P/J608 and P/J410 sensor.
connected?
7 Check continuity between the Feed Out Go to Step 8. Repair the wiring.
Sensor #3 and Engine Logic Board.
8 Check for +5 V at the Feed Out Sensor #3. Replace Feed Out Replace the
Is there +5 V across the sensor Sensor #3. Engine Logic
connectors Pin 1 <=> ground? Board
(page 8-89).

Jam at Tray n (Feed Out Sensor #3) Troubleshooting Procedure (Continued)

Test the trays Feed Out Sensor. Engine Logic
1. Open Door C Board
(page 8-89).
2. Run the Service Diagnostics Feed Out

Check the Feed Out Sensor connection. sensor.
Is the sensor connected?

Check continuity between the Feed Out
Sensor and the Tray 4-5 PWB.

Check for +5 V at the Feed Out Sensor. sensor.
Is there +5 V across the sensor



Check for +24 V at the Tray 4-5 PWB 4-5 PWB Engine Logic
Is their +24 V across P/J541-7 (+) <=> (page 3-29). Board
Jam at Tray n - Feed Out #4

Paper fed from a universal tray did not reach the Tray 4 Feed Out Sensor #4, located
behind Door C on the 1000-Sheet Feeder, on time.


Jam at Tray n (Feed Out Sensor #4) Troubleshooting Reference
Feed Roller Print Engine P/J Engine Logic Board

Retard Roller (page 10-13)
Nudger Roller PL8.1 Print Engine Electrical (page 9-40)
Tray 4-5 PWB 1000-Sheet Feeder P/J Locator (page 5-5)
Tray 4 Feed Out Sensor #4 1000-Sheet Tray 4 & 5 Wiring (page 5-9)
Tray 5 Feed Out Sensor #5 PL20.4 Tray 4-5 Feeder (2/2) (page 4-10)
Jam at Tray n (Feed Out Sensor #4) Troubleshooting Procedure


4 Check paper position at Door C. Remove the Go to Step 5.

Does the paper touch the Feed Out paper.
Sensor?
5 Test Feed Out Sensor #4. Go to Step 9. Go to Step 6.

1. Open Door C.

connected?
Sensor #4 and Tray 4-5 PWB.
8 Check for +5 V at Feed Out Sensor #4. Replace Feed Out Go to Step 9
Is there +5 V across the sensor Sensor #4
9 Check connections between the Tray 4-5 Go to Step 10. Connect P/J541

Jam at Tray n (Feed Out Sensor #4) Troubleshooting Procedure (Continued)
10 Check continuity between the Tray 4-5 and Go to Step 11. Repair the wiring.
11 Check for +24 V at the Tray 4-5 PWB Replace the Tray Replace the
Is their +24 V across P/J541-7 (+) <=> 4-5 PWB Engine Logic
(page 8-89).
12 Test the Feed Out Sensor #5. Replace the Go to Step 13.
1. Open Door C. Engine Logic
Board
(page 8-89).
connected?
Sensor #5 and the Tray 4-5 PWB.
15 Check for +5 V at the Feed Out Sensor #5. Replace Feed Out Go to Step 16.
Is there +5 V across the sensor Sensor #5
17 Check continuity between the Tray 4-5 Go to Step 18. Repair the wiring.
(page 8-89).

Paper did not reach the Tray 5 Feed Out Sensor #5 on time.


Jam at Tray 5 (Feed Out Sensor #5) Troubleshooting Reference
Retard Roller PL8.1 Print Engine Electrical (page 9-40)
Nudger Roller Phaser 5500 Printer Options Service Manual
Tray 4-5 PWB 1000-Sheet Tray 4 & 5 Wiring (page 5-9)
Tray 5 Pre-Feed PL20.4 Tray 4-5 Feeder (2/2) (page 4-10)
Sensor PL20.6 Tray 4-5 Drive and Electrical (page 4-16)
Feed Out Sensor #5
Jam at Tray 5 (Feed Out Sensor #5) Troubleshooting Procedure


4 Check paper position at Door C. Remove the Go to Step 5.

Does the paper touch the Tray 5 Pre- paper.
Feed or Feed Out Sensor #5?
5 Test the Tray 5 Pre-Feed Sensor. Go to Step 12. Go to Step 6.

1. Open Door C.
Pre-Feed Sensor test.
6 Check the Tray 5 Pre-Feed Sensor Go to Step 7. Connect the

connection. sensor.
Are P/J103A, P/J661A and P/J549A
connected?
7 Check continuity between the Tray 5 Pre- Go to Step 8. Repair the wiring.
Feed Sensor and Tray 4-5 PWB.
between P/J103A <=> P/J549A?
8 Check for +5 V at Tray 5 Pre-Feed Sensor Replace the Go to Step 9

Is there +5 V across the sensor sensor.

Jam at Tray 5 (Feed Out Sensor #5) Troubleshooting Procedure (Continued)
(page 8-89).
12 Test Feed Out Sensor #5. Replace the Go to Step 13.

1. Open Door C. Engine Logic
Board
(page 8-89).
connected?
Sensor #5 and the Tray 4-5 PWB.
15 Check for +5 V at the Feed Out Sensor #5. Replace the Go to Step 16.
Is there +5 V across the sensor sensor
(page 8-89).

Paper fed from the 2000-Sheet Feeder did not reach Feed Out Sensor #6, located in
the Lower Feeder Assembly under Door J, on time.

Nudge Roller PL8.1 Print Engine Electrical (page 9-40)
Retard Roller Phaser 5500 Printer Options Service Manual
Feeder Harness 2000-Sheet Tray 6 Feeder P/J Locator (page 5-20)
Main Harness 2000-Sheet Tray 6 Drive P/J Locator (page 5-21)
Tray 6 PWB 2000-Sheet Tray 6 Sensors Wiring (page 5-24)
Pre-Feed Sensor 2000-Sheet Tray 6 Drive Wiring (page 5-25)
Feeder Motor PL22.4 Tray 6 Feeder (1/3) (page 4-24)
Nudger Solenoid PL22.5 Tray 6 Feeder (2/3) (page 4-26)
Engine Logic Board) PL22.6 Tray 6 Feeder (3/3) (page 4-28)
PL22.8 Tray 6 Electrical (page 4-32)
1 Check the paper path. Go to Step 2. Clean or replace

1. Open Door J. the Rollers.
2. Open the Upper Feeder Assembly.
Are the Rollers installed correctly,
clean, and turn freely?
2 Test the Tray 6 Pre-Feed Sensor. Go to Step 10. Go to Step 3.

1. Open Door J.
3 Check the Feeder Harness for connection. Go to Step 4. Connect and go

Are PF61 and PF56B connected? to Step 4.
4 Check the Main Harness for connection Go to Step 6. Connect and go

Are PF56B and JF02 connected? to Step 5.
5 Print a Test Print. Go to Step 6. Problem solved.

Does the error still occur?

6 Check the Feeder Harness for continuity Go to Step 7. Repair the Feeder
1. Disconnect PF61 and PF56B. Harness.
2. Check for continuity of the following:
PF61-1 <=> JF56B-3
PF61-2 <=> JF56B-2
PF61-3 <=> JF56B-1
Are these three conductive?
7 Check the Main Harness for continuity Go to Step 8. Repair the Main
1. Disconnect PF56B and JF02. Harness.
2. Check for continuity at the following:
JF56B-4 <=> JF02-6
JF56B-5 <=> JF02-5
JF56B-6 <=> JF02-4
8 Check for +5 V at the Pre-Feed Sensor. Go to Step 9. Replace the Tray

Is the voltage across PF02-6 <=> PF04-2 6 PWB
on the PWB +5 V? (page 3-67).
9 Check the Pre-Feed Sensor function. Go to Step 27. Replace the Pre-
Does the voltage across JF02-5 <=> Feed Sensor
PF04-2 on the PWB change, when white (page 3-51).
paper is placed over the sensing area?
10 Test the Feed/Lift Motor. Go to Step 18. Go to Step 11.

Run the Service Diagnostics Tray 6
Motor Feed test.
Does the Feed/Lift Motor rotate
normally?
11 Check the Harness connections. Go to Step 13. Connect and go

Are the connectors PF58, PF56, and to Step 12.
JF06 on the PWB connected?

1. Disconnect PF58 and JF56B. harness.
PF58-1 <=> JF56-1
PF58-2 <=> JF56-2
PF58-3 <=> JF56-3
PF58-4 <=> JF56-4
PF58-5 <=> JF56-5
PF58-6 <=> JF56-6
Are these conductive?

14 Check the Main Harness for continuity. Go to Step 15. Repair the Main
1. Disconnect PF56 and JF06. Harness.
PF56-1 <=> JF06-1
PF56-2 <=> JF06-3
PF56-3 <=> JF06-2
PF56-4 <=> JF06-6
PF56-5 <=> JF06-4
PF56-6 <=> JF06-5
15 Check resistance of the Feed/Lift Motor. Go to Step 16. Replace the

Is there some amount of resistance Feed/Lift Motor
across PF58-2/5(COM) and PF58-1/3/4/ (page 3-49).
6?
16 Check for +24 V at the Feed/Lift Motor. Go to Step 17. Replace the Tray
Is there +24 V across PF06-3 <=> PF04-3 6 PWB
and PF06-4 <=> PF04-3 on the PWB? (page 3-67).
17 Replace the Feed/Lift Motor. Go to Step 27. Problem solved.

Print a Test Print.
18 Test the Nudger Solenoid. Go to Step 27. Go to Step 19.

Run the Service Diagnostics Tray 6 Nudger
Solenoid Test at High Power.
Does the Nudger Solenoid activate?
19 Check the harness connections. Go to Step 21. Connect and go

Are the connectors PF59, PF56A, and to Step 20.
P/JF06 on the PWB connected?

1. Disconnect PF59 and JF56A. Harness.
PF59-2 <=> JF56A-1
PF59-1 <=> JF56A-2
1. Disconnect PF56A and JF06. Harness.
PF56A-6 <=> JF06-13
PF56A-5 <=> JF06-14
23 Check Nudger Solenoid resistance. Go to Step 24. Replace the

Is there some amount of resistance Nudger Solenoid
across PF59-1 and PF59-2? (page 3-50).

24 Test for +24 V at the Nudger Solenoid. Go to Step 25. Replace the Tray
Run the Service Diagnostics Tray 6 Nudger 6 PWB
Solenoid Test at High Power. (page 3-67).
Is the voltage across PF06-13 <=>
P/JF04-3 on the PWB, +24 V?
25 Test for +14.7 V at the Nudger Solenoid. Go to Step 26. Replace the Tray
Run the Service Diagnostics Tray 6 Nudger 6 PWB
Solenoid Test at Low Power. (page 3-67).
Is the voltage across PF06-13 <=>
P?JF04-3 on the PWB, +14.7V?
26 Replace the Nudger Solenoid. Go to Step 27. Problem Solved.

Print a Test Print
27 Replace the Tray 6 PWB. Replace the Problem solved.

Print a Test Print Engine Logic
Does the error still occur? Board
(page 8-89).

Paper fed from the 2000-Sheet Feeder did not reach the Tray 3 Feed Out Sensor #3,
located behind Door B, on time.

Nudge Roller PL8.1 Print Engine Electrical (page 9-40)
Retard Roller Phaser 5500 Printer Options Service Manual
Take Away Roller 2000-Sheet Tray 6 Feeder P/J Locator (page 5-20)
Door J 2000-Sheet Tray 6 Drive P/J Locator (page 5-21)
Feed Out Sensor 2000-Sheet Tray 6 Sensors Wiring (page 5-24)
Feeder Harness 2000-Sheet Tray 6 Drive Wiring (page 5-25)
Main Harness PL22.5 Tray 6 Feeder (2/3) (page 4-26)
Tray 6 PWB PL22.6 Tray 6 Feeder (3/3) (page 4-28)
Take Away Motor PL22.7 Drive and Transportation (page 4-30)
Engine Logic Board PL22.8 Tray 6 Electrical (page 4-32)


1. Open Door J. the Rollers.
2 Test the Tray 6 Feed Out Sensor #6. Go to Step 10. Go to Step 3.
Run the Service Diagnostics Tray 6 Feed
Out Sensor test.
3 Check the sensor connections. Go to Step 4. Connect and go

Are P/JF67 and JF54 connected? to Step 4.
4 Check the Main Harness connections. Go to Step 6. Connect and go

Are PF54 and P/JF01 connected? to Step 5.

6 Check the Feeder Harness for continuity Go to Step 7. Repair the

1. Disconnect P/JF67 and PF54. Harness.
P/JF67-1 <=> JF54-3
P/JF67-2 <=> JF54-2
P/JF67-3 <=> JF54-1
1. Disconnect PF54 and P/JF01. Harness.
PF54-1 <=> P/JF01-3
PF54-2 <=> P/JF01-2
PF54-3 <=> P/JF01-1
8 Check for +5 V at the Feed Out Sensor #6 Go to Step 9. Replace the Tray
Is the voltage across PJ01-3 <=> PJ04-2 6 PWB
on the PWB? (page 3-67).
9 Check the Feed Out Sensor #6 signal. Go to Step 17. Replace the Feed
Does the voltage across P/JF01-2 <=> P/ Out Sesnor #6
JF04-2 on the Tray 6 PWB change, when (page 3-63).
sensor is actuated?
10 Test the Take Away Motor. Go to Step 17. Go to Step 11.

Run the Service Diagnostics Tray 6
Take Away Motor Slow test.
Does the motor rotate normally?


Are the connectors PF57 and P/JF06 on to Step 12.
the Main Harness connected?

13 Check the Feeder Harness for continuity Go to Step 14. Repair the Tray 6
1. Disconnect PF57 and JF06. Main harness.
PF57-7 <=> P/JF06-11
PF57-6 <=> P/JF06-8
PF57-5 <=> P/JF06-9
PF57-4 <=> P/JF06-10
PF57-3 <=> P/JF06-12
PF57-2 <=> P/JF06-7
14 Check Take Away Motor resistance. Go to Step 15. Replace the Take
Is there some amount of resistance Away Motor
across F57-3/4(COM) and JF57-1/2/5/6? (page 3-64).
15 Check for +24 V at the Take Away Motor. Go to Step 16. Replace the Tray
Is there +24 V across PF06-9 <=> PF04- 6 PWB
2, and PF06-10 <=> PF04-2 on the Tray 6 (page 3-67).
PWB?
16 Replace the Take Away Motor. Go to Step 17. Problem solved.

Print a Test Print.

Print a Test Print Engine Logic
(page 8-89).
Jam at B - C5-3 Tray 6

Paper fed from the 2000-Sheet Feeder did not reach the Print Engines Registration
Sensor on time.

Jam at B - C5-3 Tray 6

Jam at B (Registration Sensor) Troubleshooting Reference
Take Away Roller Print Engine P/J Engine Logic Board (page 10-13)
Door J PL4.5 Print Engine Registration (page 9-30)
Registration Sensor PL5.1 Laser, CRU and Toner Dispense (page 9-32)
Front Harness A PL8.1 Print Engine Electrical (page 9-40)
Take Away Motor 2000-Sheet Tray 6 Feeder P/J Locator (page 5-20)
Main Harness 2000-Sheet Tray 6 Drive P/J Locator (page 5-21)
Tray 6 PWB 2000-Sheet Tray 6 Drive Wiring (page 5-25)
PL22.7 Drive and Transportation (page 4-30)
Jam at B (Registration Sensor) Troubleshooting Procedure

Open Door J. the Rollers.
Are all the rollers installed correctly,
2 Check the printer paper path. Go to Step 3. Clean the paper

Open Door A. path.
Is the paper path clean?

1. Open Door A
4 Check the Registration Sensor connection Go to Step 6. Connect and go

to the printers Front Harness. to Step 5.
Are P/J104 and P/J403 connected to the
Registration Sensor?

6 Check the Harness for continuity. Go to Step 7. Repair the

1. Disconnect P/J104 and P/J403. printers Front
Harness A.
J104-3 <=> J403B-3
J104-2 <=> J403B-8
J104-1 <=> J403B-13

Jam at B (Registration Sensor) Troubleshooting Procedure (Continued)
7 Check for +5 V to the Registration Sensor. Go to Step 8. Replace the

Is there +5 V across P403-13 <=> Engine Logic
P403-3 on the Engine Logic Board? Board
(page 8-89).
8 Check the Registration Sensor. Go to Step 16. Replace the

Does the voltage across P403-8 <=> Registration
P403-3 on the Engine Logic Board Sensor
change when the sensor actuator is (page 8-52).
operated?
9 Test the Tray 6 Take Away Motor. Go to Step 16. Go to Step 10.
Run the Service Diagnostics Tray 6 Take
Away Motor high speed test.

Are PF57 and P/JF06 connected? to Step 11.

12 Check the Main Harness continuity. Go to Step 13. Repair Main

PF57-7 <=> P/JF06-11
PF57-6 <=> P/JF06-8
PF57-5 <=> P/JF06-9
PF57-4 <=> P/JF06-10
PF57-3 <=> P/JF06-12
PF57-2 <=> P/JF06-7
13 Check the Take Away Motor resistance. Go to Step 14. Replace the Take
Are the resistances across JF57-3/ Away Motor
4(COM) and JF57-1/2/5/6, XXXX ohm? (page 3-64).
14 Check for +24 V to the Take Away Motor. Go to Step 15. Replace the Tray
Is there +24 V across PF06-9 <=> PF04- 6 PWB
2, and PF06-10 <=> PF04-2 on the Tray 6 (page 3-67).
PWB?

Print a Test Print.

Print a Test Print. Engine Logic
(page 8-89).

Jam at B - C8-2 F/O3 SNR Static Jam
Paper remains at Feed Out Sensor #3 located behind Door B.

Jam at B - C8-2 F/O3 SNR Static Jam
Jam at B (Feed Out #3 Sensor) Troubleshooting Reference
Feed Out Sensor #3 Print Engine P/J Tray 2 & 3 Feeder (page 10-11)
Tray 3 Feed/Lift Motor Print Engine Registration Transport Wiring
Engine Logic Board (page 10-23)
PL2.3 Feeder (2/2) (page 9-12)
PL4.5 Registration (page 9-30)
Jam at B (Feed Out #3 Sensor) Troubleshooting Procedure
1 Check the paper path. Remove the Go to Step 2.

Open Door B. paper.
Does the paper touch the Tray 3 Feed
Out Sensor?
2 Test the Feed Out Sensor #3. Replace the Go to Step 3.

1. Open Door B. Engine Logic
Board (8-89).
3 Check the sensor connection. Go to Step 4. Connect the

Are P/J105, P/J608, and P/J410 sensor.
connected?
4 Check continuity between the sensor and Go to Step 5. Repair the wiring.
Engine Logic Board.
5 Check for +5 V to the Feed Out Sensor #3. Replace the Feed Replace the
Is there +5 V across P105-1(+)<=> Out Sensor #3 Engine Logic
(page 8-89).

Jam at C - C8-3 F/O4 SNR Static Jam
Paper remains at Feed Out Sensor #4 located behind Door C.

Jam at C (Feed Out Sensor #4) Troubleshooting Reference

Feed Out Sensor #4 Print Engine P/J Engine Logic Board (page 10-13)
Tray 4-5 PWB PL8.1 Print Engine Electrical (page 9-40)
1000-Sheet P/J Tray 4 & 5 Feeders (page 5-5)
1000-Sheet P/J Tray 4 & 5 Electrical (page 5-6)
1000-Sheet Tray 4 Wiring (page 5-9)
PL20.5 Tray 4-5 Transportation (page 4-14)
Jam at C (Feed Out Sensor #4) Troubleshooting Procedure

Open Door C. paper.
Does the paper touch Feed Out
Sensor #4?

Run the Service Diagnostics Tray 4 Feed Engine Logic
Out Sensor test. Board

connected?
5 Check continuity between the 1000-Sheet Go to Step 6. Repair the wiring.

Feeder and Engine Logic Board.
6 Check for +5 V to the Feed Out Sensor #4. Replace Feed Out Go to Step 7.
Is there +5 V across P/J821-3 (+) <=> Sensor #4

Jam at C (Feed Out Sensor #4) Troubleshooting Procedure (Continued)
7 Check +5 V to the Tray 4-5 PWB Replace the Tray Replace the
Is there +5 V across P/J541-8 (+) <=> 4-5 PWB Engine Logic
(page 8-89).

Paper remains at Feed Out Sensor (F/O#5) located behind Door C.

Jam at C (Feed Out Sensor #5) Troubleshooting Reference

Feed Out Sensor #5 Print Engine P/J Engine Logic Board (page 10-13)
1000-Sheet P/J Tray 4 & 5 Feeders (page 5-5)
PL20.5 Tray 4-5 Transportation (page 4-14)
Jam at C (Feed Out Sensor #5) Troubleshooting Procedure

Open Door C. paper.
Does the paper touch Feed Out
Sensor #5?

Out Sensor test. Board

Are P/J825, P/J842, and P/J548 sensor.
connected?

Jam at C (Feed Out Sensor #5) Troubleshooting Procedure (Continued)
5 Check continuity between 1000-Sheet Go to Step 6. Repair the wiring.

Feeder and Engine Logic Board.
6 Check for +5 V to the Feed Out Sensor #5. Replace the Feed Go to Step 7.
Is there +5 V across P/J825-3 (+) <=> Out Sensor #5
7 Check +5 V to the Tray 4-5 PWB. Replace the Tray Replace the
(page 8-89).
Jam at Tray 6 - C8-5 HCF F/O SNR Static Jam

Remaining paper in the Tray 6 Feed Out Sensor #6, located in the Lower Feeder
Assembly under Door J.

Jam at Tray 6 - C8-5 HCF F/O SNR Static Jam
Retard Roller PL8.1 Print Engine Electrical (page 9-40)
Take Away Roller Phaser 5500 Printer Options Service Manual
Door J 2000-Sheet Tray 6 Feeder P/J (page 5-20)
Pre-Feed Sensor 2000-Sheet Tray 6 Drive P/J (page 5-21)
Feed Out Sensor #6 2000-Sheet Tray 6 Sensors Wiring (page 5-24)
Feeder Harness 2000-Sheet Tray 6 Drive Wiring (page 5-25)
Main Harness PL22.4 Tray 6 Feeder (1/3) (page 4-24)
Take Away Motor PL22.5 Tray 6 Feeder (2/3) (page 4-26)
Feeder Motor PL22.6 Tray 6 Feeder (3/3) (page 4-28)
Tray 6 PWB PL22.7 Drive and Transportation (page 4-30)
Engine Logic Board) PL22.8 Tray 6 Electrical (page 4-32)


1. Open Door J. the rollers.
2 Test the Tray 6 Pre-Feed Sensor Go to Step 10. Go to Step 3.

1. Open Door J.
3 Check the Feeder Harness for connection. Go to Step 4. Connect and go

Are PF61 and PF56B connected? to Step 4.
4 Check the Main Harness for connection. Go to Step 6. Connect and go

Are PF56B and JF02 connected? to Step 5.

6 Check the Feeder Harness for continuity. Go to Step 7. Repair the Feeder
1. Disconnect PF61 and PF56B. Harness.
PF61-1 <=> JF56B-3
PF61-2 <=> JF56B-2
PF61-3 <=> JF56B-1
1. Disconnect PF56B and JF02. Harness.
JF56B-4 <=> JF02-6
JF56B-5 <=> JF02-5
JF56B-6 <=> JF02-4
8 Check for +5 V at the Pre-Feed Sensor. Go to Step 9. Replace the Tray

on the Tray 6 PWB? (page 3-67).
9 Check the Pre-Feed Sensor signal. Go to Step 33. Replace the Pre-
Does the voltage across JF02-5 <=> Feed Sensor
PF04-2 on the Tray 6 PWB change, when (page 3-51).
the sensor is blocked?

10 Test the Feed Out Sensor #6. Go to Step 18. Go to Step 11.
1. Open Door J.
11 Check the Feed Out Sensor #6 Go to Step 12. Connect and go

connections. to Step 12.
Is PF67 and JF54 connected?

Is PF54 and JF01 connected? to Step 13.

14 Check the Harness for continuity. Go to Step 15. Repair the

PF67-1 <=> JF54-3
PF67-2 <=> JF54-2
PF67-3 <=> JF54-1
15 Check the Main Harness continuity. Go to Step 16. Repair the Main
JF54-1 <=> JF01-3
JF54-2 <=> JF01-2
JF54-3 <=> JF01-1
16 Check for +5 V to the Feed Out Sensor #6. Go to Step 17. Replace the Tray
17 Check the Feed Out Sensor #6 signal. Go to Step 33. Replace the Feed
Does the voltage across JF01-2 <=> Out Sensor #6
PF04-2 on the Tray 6 PWB change when (page 3-63).
the Feed Out Sensor is actuated?
18 Test the Tray 6 Feed/Lift Motor. Go to Step 26. Go to Step 19.

Run the Service Diagnostics Feed Motor
test.
Does the Feed Motor rotate normally?

Are PF58 and PF56 on the Feeder and to Step 20.
Main Harnesses, and JF06 on the PWB
connected?


21 Check the Feeder Harness for continuity. Go to Step 22. Repair the Feeder
1. Disconnect PF58 and JF56B. harness.
PF58-1 <=> JF56-1
PF58-2 <=> JF56-2
PF58-3 <=> JF56-3
PF58-4 <=> JF56-4
PF58-5 <=> JF56-5
PF58-6 <=> JF56-6
PF56-1 <=> JF06-1
PF56-2 <=> JF06-3
PF56-3 <=> JF06-2
PF56-4 <=> JF06-6
PF56-5 <=> JF06-4
PF56-6 <=> JF06-5
23 Check resistance of the Feed/Lift Motor. Go to Step 24. Replace the

across PF58-2/5 (COM) and PF58-1/3/4/ (page 3-49).
6?
24 Check for +24 V at the Feed/Lift Motor. Go to Step 25. Replace the Tray
and PF06-4 <=> PF04-3 on the Tray 6 (page 3-67).
PWB?

Print a Test Print.
26 Test the Take Away Motor. Go to Step 33. Go to Step 27.

Run the Service Diagnostics Tray 6 Take
Away Motor test at high speed.
27 Check the Main Harness connection. Go to Step 29. Connect and go

Are PF57 and JF06 connected? to Step 28.


PF57-7 <=> JF06-11
PF57-6 <=> JF06-8
PF57-5 <=> JF06-9
PF57-4 <=> JF06-10
PF57-3 <=> JF06-12
PF57-2 <=> JF06-7
30 Check the Take Away Motor resistance. Go to Step 31. Replace the Take
Is there some amount of resistance Away Motor
across JF57-3/4(COM) and JF57-1/2/5/6? (page 3-64).
31 Check for +24 V to the Take Away Motor. Go to Step 32. Replace the
Is there +24 V across PF06-9 <=> PF04- Tray 6 PWB
3, and PF06-10 <=> PF04-3 on the PWB? (page 3-67).

Print a Test Print.

Print a Test Print. Engine Logic
(page 8-89).
Jam at D - C8-6 Duplex

Paper remains at Duplex Units Wait Sensor located behind Door D.

Jam at D - C8-6 Duplex
Jam at D (Wait Sensor) Troubleshooting Reference
Wait Sensor Print Engine P/J Engine Logic Board (page 10-13)
Duplex Unit PWB PL8.1 Print Engine Electrical (page 9-40)
Engine Logic Phaser 5500 Printer Options Service Manual
Board Duplex Unit Plug/Jack Locator (page 5-12)

Jam at D (Wait Sensor) Troubleshooting Procedure

Open Door D. paper.
Does the paper touch the sensor?
2 Test the Wait Sensor. Replace the Go to Step 3.

Run the Service Diagnostics Duplex Unit Engine Logic
Wait Sensor test. Board
3 Check the Wait Sensor connection. Go to Step 4. Connect the

and Duplex Unit PWB.

Is there +5 V across P/J123-3 (+) <=> Sensor
6 Check continuity between the Duplex Unit Go to Step 7. Repair the wiring.
7 Check for +5 V to the Duplex Unit PWB. Replace the Replace the
Is there +5 V across P/J541-1 (+) <=> Duplex Unit PWB Engine Logic
(page 8-89).
Jam at Tray 1/MPT - C9-3 Tray 1/MPT

Paper fed from Tray 1/MPT did not reach the Registration Sensor, located behind
Door A, on time.

Jam at Tray 1/MPT - C9-3 Tray 1/MPT

Jam at Tray 1/MPT (Registration Sensor) Troubleshooting Reference
Feed Roller Print Engine P/J Tray 1/MPT (page 10-9)

Drive Roller Print Engine P/J Registration Transport (page 10-10)
Registration Sensor Print Engine Tray 1/MPT Wiring (page 10-28)
Pick Up Solenoid PL3.2 Tray 1/MPT Lower Frame (page 9-18)
Engine Logic Board PL4.5 Registration (page 9-30)
Jam at Tray 1/MPT (Registration Sensor) Troubleshooting Procedure

Is the paper in Tray 1 damaged? paper.
2 Check paper size setup. Go to Step 3. Correct the

Does the paper size in use match the setting.
Tray 1 size setting?

Open Door A. paper.
Sensor?
4 Check the size guides. Go to Step 5. Repair or replace

Do the size guides operate smoothly? the guides.
5 Check the Tray 1 Feeder installation. Go to Step 6. Problem solved.

1. Reinstall the Tray 1 Feeder.
2. Print a Test Print from Tray 1.
Does the error occur?
6 Check the Feed Roller. Go to Step 7. Clean or replace

Remove the Tray 1 Feeder. the Feed Roller
Is the Feed Roller worn or contaminated
with paper dust?
7 Check the Drive Roller. Go to Step 8. Clean or replace

Remove the Tray 1 Feeder. the Drive Roller.
Is the Drive Roller worn or

1. Open Door A.
Does the sensor state change?


Jam at Tray 1/MPT (Registration Sensor) Troubleshooting Procedure (Continued)
11 Check for +5 V to the Registration Sensor. Replace the Replace the

Is there +5 V across P/J104-1 (+) <=> Registration Engine Logic
ground? Sensor Board
(page 8-52). (page 8-89.
12 Test the Pick Up Solenoid operation. Replace the Go to Step 13.

Solenoid test. Board
Does the Pick Up Solenoid operate (page 8-89).
properly?
13 Check the Pick Up Solenoid connection. Go to Step 14. Connect P/J205,

connected? J411.
14 Check the Pick Up Solenoid continuity. Go to Step 15. Repair the wiring.
15 Check the Pick Up Solenoid resistance. Go to Step 16. Replace the Pick
Is the resistance across J205-1 and Up Solenoid
J205-2 approximately 90 ohm? (page 8-36).
16 Check for +24 V to the Pick Up Solenoid. Replace the Pick Replace the
Is there +24 V across P205-1 (+) <=> Up Solenoid Engine Logic
(page 8-89).

Jam at A - F4-12 H-Xport Ent. SNR ON
Paper leaving the printer activated the printers Fuser Exit Sensor but did not reach the
Horizontal Transport Entrance Sensor on time.

Jam at A - F4-12 H-Xport Ent. SNR ON
Jam at A (H-Xport Entrance Sensor) Troubleshooting Reference
H-Xport Belts Print Engine P/J Engine Logic Board (page 10-13)
H-Xport Pinch Rollers PL8.1 Print Engine Electrical (page 9-40)
H-Xport Motor Phaser 5500 Printer Options Service Manual
H-Xport Harness Horizontal Transport P/J Locator (page 5-29)
H-Xport Entrance Horizontal Transport Wiring (page 5-39)
Sensor Finisher Main PWB P/J Locator (page 5-35)
Finisher H-Xport PWB PL25.2 Horizontal Transport (1/2) (page 4-46)
Finisher Main PWB PL25.3 Horizontal Transport (2/2) (page 4-48)
Engine Logic Board PL25.14 Finisher Electrical (page 4-70)
Jam at A (H-Xport Entrance Sensor) Troubleshooting Procedure

Open Door F. affected
Are the Belts and Pinch Rollers clean, components.
operate freely, and correctly installed?
2 Test the H-Xport Entrance Sensor. Go to Step 8. Go to Step 3.

1. Open Door F.
2. Run the Service Diagnostic H-Xport
Entrance Sensor test.
3 Check the H-Xport Harness connections. Go to Step 5. Reconnect and

Is the harness connected to the H- go to Step 4.
Xport Entrance Sensor and Finisher
correctly?


Jam at A (H-Xport Entrance Sensor) Troubleshooting Procedure (Continued)
5 Check the H-Xport Harness continuity. Go to Step 6. Repair the

1. Disconnect the Entrance Sensor (J8380) harness.
and P8372 on the H-Xport PWB.
P8372-7 <=> J8380-3
P8372-8 <=> J8380-2
P8372-9 <=> J8380-1
6 Check for +5 V to the Entrance Sensor. Go to Step 7. Replace the H-

Is there +5 V across J8372-9 <=> J8372- Xport PWB
7 on the H-Xport PWB? (page 3-247).
7 Check the Entrance Sensor signal. Replace the H- Replace the

Does the voltage across J8372-8 <=> Xport PWB sensor.
J8372-7 on the H-Xport PWB change (page 3-247).
when the sensor actuator is operated?
8 Check the H-Xport Motor. Replace the H- Go to Step 9.

Run the Service Diagnostics H-Xport Xport PWB
Motor test. (page 3-247).
9 Check the H-Xport Motor connections. Go to Step 11. Connect and go

Is the H-Xport Motor correctly to Step 10.
connected to the harness?

11 Check the harness for continuity. Go to Step 12. Repair the

1. Disconnect P/J8379 of the H-Xport harness.
Motor, and P8372 on the H-Xport PWB.
P8372-13 <=> J8379-6
P8372-12 <=> J8379-4
P8372-11 <=> J8379-1
P8372-10 <=> J8379-3
P8372-15 <=> J8379-2
P8372-3 <=> J8379-5
12 Check the H-Xport Motor resistance. Go to Step 13. Replace the H-

Is there some amount of resistance Xport Motor
across P8379-2/5(COM) and P8379-1/3/ (page 3-113).
4/6?
13 Check for +24 V to the H-Xport Motor. Go to Step 14. Replace the H-
Is there +24 V across J8372-15 <=> Xport PWB
J8372-7, and J8372-14 <=> J8372-7 on (page 3-247).
the H-Xport PWB?

Jam at A (H-Xport Entrance Sensor) Troubleshooting Procedure (Continued)
14 Replace the H-Xport Motor. Go to Step 15. Problem solved.

Print a Test Print.
15 Replace the H-Xport PWB. Replace the Problem solved.

Print a Test Print. Finisher Main
Does the error still occur? PWB
(page 3-248).
Jam at A or F - F4-n H-Xport Ent. SNR Static

The paper did not exit the Horizontal Transport on time.

Jam at A - F4-16 H-Xport Ent. SNR Static Jam A
Jam at F - F4-17 H-Xport Ent. SNR Static Jam B
Jam at A or F (H-Xport Entrance Sensor) Troubleshooting Reference

H-Xport Entrance Horizontal Transport Wiring (page 5-39)
Finisher H-Xport PWB PL25.2 Horizontal Transport (1/2) (page 4-46)
PL25.3 Horizontal Transport (2/2) (page 4-48)
PL25.14 Finisher Electrical (page 4-70)
Jam at A or F (H-Xport Entrance Sensor) Troubleshooting Procedure

1. Open Door F.

Is the harness connected to the H- go to Step 3.
Xport Entrance Sensor and Finisher
correctly?

Jam at A or F (H-Xport Entrance Sensor) Troubleshooting Procedure (Continued)


1. Disconnect the H-Xport Entrance harness.
Sensor (J8380) and P8372 on the H-
Xport PWB.
P8372-7 <=> J8380-3
P8372-8 <=> J8380-2
P8372-9 <=> J8380-1
5 Check for +5 V to the Entrance Sensor. Go to Step 6. Replace the H-

6 Check the H-Xport Entrance Sensor Replace the H- Replace the

signal. Xport PWB sensor
Does the voltage across J8372-8 <=> (page 3-247). (page 3-117).
J8372-7 on the H-Xport PWB change
7 Test the H-Xport Motor. Replace the H- Go to Step 8.




P8372-13 <=> J8379-6
P8372-12 <=> J8379-4
P8372-11 <=> J8379-1
P8372-10 <=> J8379-3
P8372-15 <=> J8379-2
P8372-3 <=> J8379-5

4/6?

Jam at A or F (H-Xport Entrance Sensor) Troubleshooting Procedure (Continued)
J8372-7, and J8372-14 <=> J8372-7 on (page 3-247).
the H-Xport PWB?
13 Replace the H-Xport Motor. Replace the H- Problem solved.

Print a Test Print. Xport PWB
Does the error still occur? (page 3-247).
Jam at A or F - F4-n H-Xport Exit SNR ON

Paper activated the Horizontal Transport Entrance Sensor but did not reach the
Horizontal Transport Exit Sensor on time.

Jam at A - F4-22 H-Xport Exit SNR ON Jam A
Jam at F - F4-23 H-Xport Exit SNR ON Jam B
Jam at F - F4-24 H-Xport Exit SNR ON Jam C
Jam at A or F (H-Xport Exit Sensor) Troubleshooting Reference
H-Xport Belts Print Engine P/J Engine Logic Board (page 10-13)
H-Xport Pinch Rollers PL8.1 Print Engine Electrical (page 9-40)
H-Xport Exit Sensor Horizontal Transport Wiring (page 5-39)
Finisher H-Xport PWB Finisher Main PWB P/J Locator (page 5-35)
Finisher Main PWB PL25.2 Horizontal Transport (1/2) (page 4-46)
Engine Logic Board PL25.3 Horizontal Transport (2/2) (page 4-48)
Jam at A or F (H-Xport Exit Sensor) Troubleshooting Procedure


Jam at A or F (H-Xport Exit Sensor) Troubleshooting Procedure (Continued)
2 Test the H-Xport Exit Sensor. Go to Step 8. Go to Step 3.

1. Open Door F.
2. Run the Service Diagnostic H-Xport Exit
Sensor test.

Is the harness connected to the Exit go to Step 4.
Sensor and Finisher correctly?


1. Disconnect the Exit Sensor (J8381) and harness.
P8372 on the H-Xport PWB.
P8372-4 <=> J8381-3
P8372-5 <=> J8381-2
P8372-6 <=> J8381-1
6 Check for +5 V to the Exit Sensor. Go to Step 7. Replace the H-

7 Check the Exit Sensor signal. Replace the H- Replace the

Does the voltage across J8372-5 <=> Xport PWB sensor
J8372-4 on the H-Xport PWB change (page 3-247). (page 3-118).
8 Test the H-Xport Motor. Replace the H- Go to Step 9.




Jam at A or F (H-Xport Exit Sensor) Troubleshooting Procedure (Continued)

P8372-13 <=> J8379-6
P8372-12 <=> J8379-4
P8372-11 <=> J8379-1
P8372-10 <=> J8379-3
P8372-15 <=> J8379-2
P8372-3 <=> J8379-5

4/6?
J8372-7, and J8372-14 <=> J8372-7 on (page 3-247).
the H-Xport PWB?

Print a Test Print.
15 Replace the H-Xport PWB. Replace the Problem solved.

(page 3-248).
Jam at F - F4-26 H-Xport Exit SNR Static

Remaining paper is detected by the Horizontal Transport Exit Sensor.

Jam at F - F4-26 H-Xport Exit SNR Static
Jam at F (H-Xport Exit Sensor) Troubleshooting Reference

H-Xport Exit Sensor Horizontal Transport Wiring (page 5-39)
Finisher H-Xport Finisher Main PWB P/J Locator (page 5-35)
PWB PL25.3 Horizontal Transport (2/2) (page 4-48)

Jam at F (H-Xport Exit Sensor) Troubleshooting Procedure

1. Open Door F.
Sensor test.



P8372-4 <=> J8381-3
P8372-5 <=> J8381-2
P8372-6 <=> J8381-1
5 Check for +5 V to the H-Xport Exit Sensor. Go to Step 6. Replace the H-

6 Check the H-Xport Exit Sensor signal. Replace the H- Replace the H-
Does the voltage across J8372-5 <=> Xport PWB Xport Exit
J8372-4 on the H-Xport PWB change (page 3-247). Sensor
when the sensor actuator is operated? (page 3-118).
7 Check the H-Xport Motor. Replace the H- Go to Step 8.

8 Test the H-Xport Motor connections. Go to Step 10. Connect and go



Jam at F (H-Xport Exit Sensor) Troubleshooting Procedure (Continued)

P8372-13 <=> J8379-6
P8372-12 <=> J8379-4
P8372-11 <=> J8379-1
P8372-10 <=> J8379-3
P8372-15 <=> J8379-2
P8372-3 <=> J8379-5

4/6?
J8372-7, and J8372-14 <=> J8372-7 on (page 3-247).
the H-Xport PWB?
13 Replace the H-Xport Motor. Replace the H- Problem solved.

Print a Test Print. Xport PWB
Jam at F - F4-32 Xport Ent. SNR ON

Paper does not reach the Finishers Transport Entrance Sensor following the papers
leading edge activating the Horizontal Transport Exit Sensor.

Jam at F - F4-32 Xport Ent. SNR ON

Jam at F (Transport Entrance Sensor) Troubleshooting Reference
H-Xport Belts Phaser 5500 Printer Options Service Manual

H-Xport Pinch Rollers Horizontal Transport P/J Locator (page 5-29)
H-Xport Motor Horizontal Transport Wiring (page 5-39)
H-Xport Harness Finisher Main PWB P/J Locator (page 5-35)
H-Xport Exit Sensor Finisher Sensors (1/2) Wiring (page 5-40)
Finisher Entrance Sensor PL25.2 Horizontal Transport (1/2) (page 4-46)
Harness Main SNR PL25.3 Horizontal Transport (2/2) (page 4-48)
Harness Ent. Sensor PL25.12 Finisher Transport (1/2) (page 4-66)
Finisher H-Xport PWB PL25.14 Finisher Electrical (page 4-70)
Finisher Main PWB PL25.15 Finisher Harness (page 4-72)
Jam at F (Transport Entrance Sensor) Troubleshooting Procedure


1. Open Door F.
Sensor test.



P8372-4 <=> J8381-3
P8372-5 <=> J8381-2
P8372-6 <=> J8381-1


Jam at F (Transport Entrance Sensor) Troubleshooting Procedure (Continued)
7 Check the H-Xport Exit Sensor signal. Replace the H- Replace the H-
when the sensor actuator is operated? (page 3-118).
8 Test the H-Xport Motor. Go to Step 16. Go to Step 9.

Run the Service Diagnostics H-Xport
Motor test.



P8372-13 <=> J8379-6
P8372-12 <=> J8379-4
P8372-11 <=> J8379-1
P8372-10 <=> J8379-3
P8372-15 <=> J8379-2
P8372-3 <=> J8379-5

4/6?
J8372-7, and J8372-14 <=> J8372-7 on (page 3-247).
the H-Xport PWB?

Print a Test Print.
15 Replace the H-Xport PWB. Go to Step 16. Problem solved.

Print a Test Print.
16 Test the X'port Entrance Sensor. Replace the Go to Step 17.

Run the Service Diagnostics Finisher Finisher Main
Transport Entrance Sensor test. PWB
Does the sensor state change? (page 3-248).

Jam at F (Transport Entrance Sensor) Troubleshooting Procedure (Continued)
17 Check the harness connections. Go to Step 19. Reconnect and

Are P/J8319 and P/J8303 of the Xport go to Step 18.
Entrance Sensor, and P/J8302A on the
Main SNR harness connected?

19 Check the sensor harness continuity. Go to Step 20. Repair the Xport
1. Disconnect P/J8319 and P/J8303B on Entrance Sensor
the Xport Entrance Sensor Harness. Harness.
J8319-3 <=> J8303B-1
J8319-2 <=> J8303B-2
J8319-1 <=> J8303B-3
20 Check Main Sensor Harness continuity. Go to Step 21. Repair the Main
Disconnect P/J8303 on the Main Sensor Sensor Harness.
Harness, and P/J8302A on the Finisher
Main PWB.
Check for continuity at the following:
J8303A-3 <=> J8302A-1
J8303A-2 <=> J8302A-2
J8303A-1 <=> J8302A-3
21 Check for +5 V to the Xport Entrance Go to Step 22. Replace the

Sensor Finisher Main
Is there +5 V across J8302A-3 <=> PWB
J8302A-1 on the Finisher Main PWB? (page 3-248).
22 Check the Xport Entrance Sensor signal. Replace the Replace Xport
Does the voltage across P8302A-2 <=> Finisher Main Entrance Sensor
P8302A-1 on the Finisher Main PWB PWB (page 3-117).
change when the sensor is blocked? (page 3-248).
Jam at F - F4-36 Xport Ent. SNR Static

Remaining paper is detected in the Finisher Transport Entrance Sensor.

Jam at F - F4-36 Xport Ent. SNR Static

Static Jam at F (Transport Entrance Sensor) Troubleshooting Reference
Xport Entrance Sensor Phaser 5500 Printer Options Service Manual

Harness Main SNR Finisher Main PWB P/J Locator (page 5-35)
Harness Ent. Sensor Finisher Sensors (1/2) Wiring (page 5-40)
Harness Main Drive Finisher Motors Wiring (page 5-42)
Finisher Main PWB PL25.12 Finisher Transport (1/2) (page 4-66)
Transport Motor PL25.14 Finisher Electrical (page 4-70)
PL25.15 Finisher Harness (page 4-72)
Static Jam at F (Transport Entrance Sensor) Troubleshooting Procedure

1. Open Door F.
2 Check the Sensor Harness connections. Go to Step 4. Connect and go

Is the harness connected to the sensor to Step 3.
and Finisher correctly?

4 Check Sensor Harness continuity. Go to Step 5. Repair the

1. Disconnect P/J8319 and P/J8303B. Sensor Harness.
J8319-3 <=> J8303B-1
J8319-2 <=> J8303B-2
J8319-1 <=> J8303B-3

1. Disconnect P/J8303A on the harness, Sensor Harness.
and P/J8302A on the Finisher Main
PWB.
J8303A-3 <=> J8302A-1
J8303A-2 <=> J8302A-2
J8303A-1 <=> J8302A-3
6 Check for +5 V to the Entrance Sensor. Go to Step 7. Replace the

Is there +5 V across J8302A-3 <=> Finisher Main
J8302A-1 on the Finisher Main PWB? PWB
(page 3-248).

Static Jam at F (Transport Entrance Sensor) Troubleshooting Procedure (Continued)
7 Check Entrance Sensor signal. Replace the Replace the

8 Check the Transport Motor. Go to Step 9. Go to Step 10.

Run the Service Diagnostics Transport
Motor test.
9 Test Entrance Roller drive. Replace the Restore Roller

Run the Service Diagnostics Transport Finisher Main operation.
Motor test. PWB
Do the Entrance Rollers rotate? (page 3-248).
10 Check Main Drive Harness connections. Go to Step 12. Connect and go

Are P/J8342 and P/J8304 connected? to Step 11.

12 Check Main Drive Harness continuity. Go to Step 13. Repair the Main
1. Disconnect P/J8342 and P/J8304. Drive Harness.
J8342-1 <=> J8304-23
J8342-2 <=> J8304-16
J8342-3 <=> J8304-25
J8342-4 <=> J8304-27
J8342-5 <=> J8304-18
J8342-6 <=> J8304-29
13 Check Transport Motor resistance. Go to Step 14. Replace the

Is there some amount of resistance Transport Motor
4/6?
14 Check for +24 V to the Transport Motor. Go to Step 15. Replace the
Is there +24 V across J8304-16 <=> Finisher Main
ground, and J8304-18 <=> ground on PWB
the Finisher Main PWB? (page 3-248).
15 Replace the Transport Motor. Replace the Problem solved.

(page 3-248).

Jam at G - F4-4n Buffer Path SNR ON
Paper does not reach the Buffer Path Sensor in time following the papers leading
edge reaching the Finishers Transport Entrance Sensor.

Jam at G - F4-42 Buffer Path SNR ON Jam A
Jam at G - F4-43 Buffer Path SNR ON Jam B
Jam at G (Buffer Path Sensor ON) Troubleshooting Reference
Entrance Roller Phaser 5500 Printer Options Service Manual

Entrance Pinch Roller Finisher Main PWB P/J Locator (page 5-35)
Buffer Roller Finisher Sensors (1/2) Wiring (page 5-40)
Pinch Roller Finisher Motors Wiring (page 5-42)
Entrance Sensor Harness Finisher Clutch and Solenoids (page 5-43)
Main Sensor Harness PL25.12 Finisher Transport (1/2) (page 4-66)
Xport Entrance Sensor PL25.14 Finisher Electrical (page 4-70)
Main Drive Harness PL25.15 Finisher Harness (page 4-72)
Transport Motor
Xport Gate Sensor
Sensor Harness
Buffer Gate Solenoid
Registration Motor
Buffer Sensor Harness
Buffer Path Sensor
Jam at G (Buffer Path Sensor ON) Troubleshooting Procedure

1. Open Door G. the appropriate
roller.
3. Remove the Top L/H Cover.
4. Open the Upper Entrance Chute.
Are the Rollers attached to the Chute
clean, roll freely, and correctly
installed?

Jam at G (Buffer Path Sensor ON) Troubleshooting Procedure (Continued)

roller.
4. Open the Upper Exit Chute.
Are the Buffer and Pinch Rollers clean,
roll freely, and installed correctly?
3 Test the X'port Entrance Sensor. Go to Step 10. Go to Step 4.

Run the Service Diagnostics Finisher
Transport Entrance Sensor test.
Does the state change when white
paper is placed over the sensing area?
4 Check the harness connections. Go to Step 6. Reconnect and

Are P/J8319 and P/J8303B of the Xport go to Step 5.
Entrance Sensor, and P/J8302A on the
Main SNR harness connected?

6 Check the sensor harness continuity. Go to Step 7. Repair the Xport

1. Disconnect P/J8319 and P/J8303B on Entrance Sensor
the Xport Entrance Sensor Harness. Harness.
J8319-3 <=> J8303B-1
J8319-2 <=> J8303B-2
J8319-1 <=> J8303B-3

Disconnect P/J8303A on the Main Sensor Sensor Harness.
Harness, and P/J8302A on the Finisher
Main PWB.
J8303A-3 <=> J8302A-1
J8303A-2 <=> J8302A-2
J8303A-1 <=> J8302A-3
8 Check for +5 V to the Entrance Sensor. Go to Step 9. Replace the

(page 3-248).
9 Check the Entrance Sensor signal. Replace the Replace Xport


10 Test the Finisher Transport Motor. Go to Step 11. Go to Step 13.

Transport Motor Test.
11 Test the Entrance Roller drive. Go to Step 19. After restoring

Run the Service Diagnostics Finisher operation, go to
Transport Motor Test. Step 12.
Does the Entrance Roller rotate?

13 Check the Main Drive Harness. Go to Step 15. Connect and go


J8342-1 <=> J8304-23
J8342-2 <=> J8304-16
J8342-3 <=> J8304-25
J8342-4 <=> J8304-27
J8342-5 <=> J8304-18
J8342-6 <=> J8304-29
16 Check the Transport Motor resistance. Go to Step 17. Replace the

4/6?
ground and J8304-18 <=> ground on the PWB
Finisher Main PWB? (page 3-248).

Transport Motor Test. PWB
19 Test the Gate Sensor. Go to Step 25. Go to Step 20.

Run the Service Diagnostics Gate Sensor
test.
Does the state change when the sensor
is blocked?

Is the Sensor Harness connected to Step 21.
correctly?


22 Check the Sensor Harness continuity. Go to Step 23. Repair the

1. Disconnect P/J8432 and P/J8376. Sensor Harness.
J8432-3 <=> J8376-1
J8432-2 <=> J8376-2
J8432-1 <=> J8376-3
23 Check +5 V to the Gate Sensor. Go to Step 24. Replace the

Is there +5 V across P8376-3 <=> P8376- Finisher Main
1 on the Finisher Main PWB? PWB
(page 3-248).
24 Check the Gate Sensor. Replace the Replace the Gate

Does the voltage across P8376-2 <=> Finisher Main Sensor
P8376-1 on the Finisher Main PWB PWB (page 3-236).
25 Test the Buffer Gate Solenoid. Go to Step 31. Go to Step 26.

Run both Service Diagnostics Buffer Gate
tests.
Does the Buffer Gate operate?


J8394-1 <=> J8304-35
J8394-2 <=> J8304-34
J8394-3 <=> J8304-36
29 Check for +24 V to the Buffer Gate Go to Step 30. Replace the
Solenoid. Finisher Main
Is there +24 V across J8304-34 <=> PWB
J8304-36 on the Finisher Main PWB? (page 3-248).
30 Replace the Buffer Gate Solenoid. Replace the Problem solved.

(page 3-248).
31 Test the Registration Motor. Go to Step 32. Go to Step 34.

Registration Motor Test.

32 Test the Buffer Roller Drive. Go to Step 40. Restore operation

Run the Service Diagnostics Finisher and go to Step
Registration Motor CCW test. 33.
Does the Buffer Roller rotate?

34 Check Main Drive harness connections. Go to Step 36. Connect and go


J8335-1 <=> J8304-7
J8335-2 <=> J8304-8
J8335-3 <=> J8304-9
J8335-4 <=> J8304-11
J8335-5 <=> J8304-10
J8335-6 <=> J8304-13
37 Check Registration Motor resistance. Go to Step 38. Replace the

Is there some amount of resistance Registration
across P8335-2/5(COM) and P8335-1/3/ Motor
4/6? (page 3-245).
38 Check for +24 V to the Registration Motor. Go to Step 39. Replace the
39 Replace the Registration Motor. Replace the Problem solved.

(page 3-248).
40 Test the Buffer Path Sensor. Replace the Go to Step 41.

Run the Service Diagnostics Buffer Path Finisher Main
Sensor test. PWB
41 Check the Buffer Path Sensor connection. Go to Step 43. Connect and go
Are P/J8392 and P/J8318B connected? to Step 42.

43 Check Main Sensor Harness connections. Go to Step 45. Connect and go

Are P/J8318B and P/J8302A connected? to Step 44.


45 Check Buffer Sensor Harness continuity. Go to Step 46. Repair the Buffer
J8392-3 <=> J8318B-1
J8392-2 <=> J8318B-2
J8392-1 <=> J8318B-3
1. Disconnect P/J8318A from the harness, Sensor Harness.
PWB.
J8318A-3 <=> J8302A-13
J8318A-2 <=> J8302A-14
J8318A-1 <=> J8302A-15
47 Check for +5 V to the Buffer Path Sensor. Go to Step 48. Replace the
(page 3-248).
48 Check Buffer Path Sensor signal. Replace the Replace the

Does the voltage across P8302A-14 <=> Finisher Main Buffer Path
P8302A-13 on the Finisher Main PWB PWB Sensor
change when the actuator is operated? (page 3-248). (page 3-207).
Jam at G - F4-4n Buffer Path SNR Static

Remaining paper is detected in the Buffer Path by the Buffer Path Sensor.

Jam at G - F4-46 Buffer Path SNR Static Jam A
Jam at G - F4-47 Buffer Path SNR Static Jam B
Jam at G - F4-48 Buffer Path SNR Static Jam C

Jam at G (Buffer Path Sensor Static) Troubleshooting Reference
Buffer Path Sensor Phaser 5500 Printer Options Service Manual

Buffer Sensor Harness Finisher Main PWB P/J Locator (page 5-35)
Main Sensor Harness Finisher Sensors (1/2) Wiring (page 5-40)
Finisher Main PWB Finisher Motors Wiring (page 5-42)
Main Drive Harness PL25.12 Finisher Transport (1/2) (page 4-66)
Registration Motor PL25.13 Finisher Transport (2/2) (page 4-68)
Jam at G (Buffer Path Sensor Static) Troubleshooting Procedure
1 Test the Buffer Path Sensor. Go to Step 10. Go to Step 2.

Run the Service Diagnostics Buffer Path
Sensor test.



Are P/J8318A and P/J8302 connected? to Step 5.


P/J8392-3 <=> J8318B-1
P/J8392-2 <=> J8318B-2
P/J8392-1 <=> J8318B-3

1. Disconnect P/J8318 from the harness, Sensor Harness.
PWB.
J8318A-3 <=> P/J8302A-13
J8318A-2 <=> P/J8302A-14
J8318A-1 <=> P/J8302A-15

Jam at G (Buffer Path Sensor Static) Troubleshooting Procedure (Continued)

(page 3-248).
9 Check Buffer Path Sensor signal. Replace the Replace the

10 Test the Registration Motor. Replace the Go to Step 11.

Registration Motor Test. PWB
Does the motor rotate normally? (page 3-248).

Run the Service Diagnostics Finisher and go to
Registration Motor CCW test. Step 12.

13 Check Main Drive harness connections. Go to Step 15. Connect and go


P/J8335-1 <=> P/J8304-7
P/J8335-2 <=> P/J8304-8
P/J8335-3 <=> P/J8304-9
P/J8335-4 <=> P/J8304-11
P/J8335-5 <=> P/J8304-10
P/J8335-6 <=> P/J8304-13

4/6? (page 3-245).

(page 3-248).

Jam at F or H - F4-5n Compile Exit SNR OFF
Paper did not clear the Compile Exit Sensor on time.

Jam at F - F4-51 Compile Exit SNR OFF Jam A
Jam at F - F4-55 Compile Exit SNR OFF Jam B
Jam at F or H (Compile Exit Sensor OFF) Troubleshooting Reference
Lower Exit Roller Phaser 5500 Printer Options Service Manual

Compile Exit Sensor Finisher Main PWB P/J Locator (page 5-35)
Compiler Harness Finisher Sensors (1/2) Wiring (page 5-40)
Main Sensor Harness Finisher Motors Wiring (page 5-42)
Finisher Main PWB PL25.10 Finisher Eject (2/3) (page 4-62)
Main Drive Harness PL25.11 Finisher Eject (3/3) page 4-64)
Exit Motor PL25.13 Finisher Transport (2/2) (page 4-68)
Jam at F (Compile Exit Sensor OFF) Troubleshooting Procedure

Open Door G. the Lower Exit
Is the Lower Exit Roller clean, installed Roller.
correctly and roll freely?
2 Test the Compile Exit Sensor. Go to Step 11. Go to Step 2.

Run the Service Diagnostics Compile Exit
Sensor test.
3 Check the Compile Exit Sensor Go to Step 5. Connect and go

connection. to Step 4.


Are P/J8391 and P/J8302A connected? to Step 6.


Jam at F (Compile Exit Sensor OFF) Troubleshooting Procedure (Continued)
7 Check Compiler Harness continuity. Go to Step 8. Repair the

1. Disconnect P/J8320 and P/J8391. Compiler
Harness.
P/J8320-3 <=> J8391B-1
P/J8320-2 <=> J8391B-2
P/J8320-1 <=> J8391B-3

PWB.
J8391A-3 <=> J8302A-4
J8391A-2 <=> J8302A-5
J8391A-1 <=> J8302A-6
9 Check for +5 V to the Compile Exit Sensor. Go to Step 10. Replace the
(page 3-248).
10 Check Compile Exit Sensor signal. Replace the Replace the

Does the voltage across P8302A-5 <=> Finisher Main Compile Exit
11 Test the Exit Motor. Replace the Go to Step 12.

Run the Service Diagnostics Finisher Exit Finisher Main
Motor Test. PWB
12 Test the Lower Exit Roller Drive. Go to Step 14. Restore operation
Run the Service Diagnostics Finisher Exit and go to Step
Motor CCW test. 13.
Do the Exit Rollers rotate?

14 Check Exit Motor harness connections. Go to Step 16. Connect and go



Jam at F (Compile Exit Sensor OFF) Troubleshooting Procedure (Continued)
16 Check Exit Motor Harness continuity. Go to Step 17. Repair the Main
P/J8334-1 <=> P/J8304-2
P/J8334-2 <=> P/J8304-4
P/J8334-3 <=> P/J8304-1
P/J8334-4 <=> P/J8304-3
P/J8334-5 <=> P/J8304-6
P/J8334-6 <=> P/J8304-5
17 Check Exit Motor resistance. Go to Step 18. Replace the Exit

Is there some amount of resistance Motor
4/6?
18 Check for +24 V to the Exit Motor. Go to Step 19. Replace the
19 Replace the Exit Motor. Replace the Problem solved.

(page 3-248).

Jam at F or G - F4-5n Compile Exit SNR ON
Paper does not reach the Compile Exit Sensor on time.

Jam at F - F4-52 Compile Exit SNR ON Jam A
Jam at G - F4-53 Compile Exit SNR ON Jam B
Jam at G - F4-54 Compile Exit SNR ON Jam C
Jam at F or G (Compile Exit Sensor ON) Troubleshooting Reference
Buffer Roller Phaser 5500 Printer Options Service Manual

Pinch Roller Finisher Main PWB P/J Locator (page 5-35)
Exit Pinch Roller Finisher Sensors (1/2) Wiring (page 5-40)
Buffer Sensor Harness Finisher Motors Wiring (page 5-42)
Main Sensor Harness PL25.10 Finisher Eject (2/3) (page 4-62)
Finisher Main PWB PL25.11 Finisher Eject (3/3) page 4-64)
Buffer Path Sensor PL25.12 Finisher Transport (1/2) (page 4-66)
Main Drive Harness PL25.13 Finisher Transport (2/2) (page 4-68)
Registration Motor PL25.14 Finisher Electrical (page 4-70)
Compiler Harness PL25.15 Finisher Harness (page 4-72)
Compile Exit Sensor
Jam at F or G (Compile Exit Sensor ON) Troubleshooting Procedure

2. Open the Upper Exit Chute (2A). roller.
3. Open the Bottom Buffer Chute (3).

Are the Buffer and Pinch Rollers
attached to the chutes clean, roll freely,
and correctly installed?
2 Test the Buffer Path Sensor. Go to Step 11. Go to Step 3.

Run the Service Diagnostics Buffer Path
Sensor test.




Jam at F or G (Compile Exit Sensor ON) Troubleshooting Procedure (Continued)


P/J8392-3 <=> J8318B-1
P/J8392-2 <=> J8318B-2
P/J8392-1 <=> J8318B-3

PWB.
J8318A-3 <=> P/J8302A-13
J8318A-2 <=> P/J8302A-14
J8318A-1 <=> P/J8302A-15
(page 3-248).
10 Check the Buffer Path Sensor signal. Replace the Replace the
11 Test the Registration Motor. Go to Step 20. Go to Step 12.

Run the Service Diagnostics Registration
Motor CCW Test.

Run the Service Diagnostics Registration and go to
Motor CCW test. Step 13.

14 Check the Registration Motor harness Go to Step 16. Connect and go



P/J8335-1 <=> P/J8304-7
P/J8335-2 <=> P/J8304-8
P/J8335-3 <=> P/J8304-9
P/J8335-4 <=> P/J8304-11
P/J8335-5 <=> P/J8304-10
P/J8335-6 <=> P/J8304-13

4/6? (page 3-245).

(page 3-248).
20 Test the Compile Exit Sensor. Replace the Go to Step 21.

Run the Service Diagnostics Compile Exit Finisher Main
Sensor test. PWB





Harness.
P/J8320-3 <=> J8391B-1
P/J8320-2 <=> J8391B-2
P/J8320-1 <=> J8391B-3


PWB.
J8391A-3 <=> P/J8302A-4
J8391A-2 <=> P/J8302A-5
J8391A-1 <=> P/J8302A-6
(page 3-248).

Jam at H - F4-56 Compile Exit SNR Static

Remaining paper is detected by the Compile Exit Sensor.

Jam at H - F4-56 Compile Exit SNR Static
Static Jam at H (Compile Exit Sensor) Troubleshooting Reference
Compile Exit Sensor Phaser 5500 Printer Options Service Manual

Compiler Harness Finisher Main PWB P/J Locator (page 5-35)
Main Drive Harness PL25.10 Finisher Eject (2/3) (page 4-62)
Exit Motor PL25.11 Finisher Eject (3/3) page 4-64)
PL25.13 Finisher Transport (2/2) (page 4-68)

Static Jam at H (Compile Exit Sensor) Troubleshooting Procedure

Sensor test.





Harness.
P/J8320A-3 <=> J8391B-1
P/J8320A-2 <=> J8391B-2
P/J8320A-1 <=> J8391B-3

PWB.
J8391A-3 <=> P/J8302A-4
J8391A-2 <=> P/J8302A-5
J8391A-1 <=> P/J8302A-6

(page 3-248).

10 Test the Exit Motor. Replace the Go to Step 11.

Run the Service Diagnostics Finisher Exit Finisher Main
Motor Test. PWB

Static Jam at H (Compile Exit Sensor) Troubleshooting Procedure (Continued)
11 Test the Lower Exit Roller Drive. Go to Step 13. Restore operation
Run the Service Diagnostics Finisher Exit and go to
Motor CCW test. Step 12.
Do the Exit Rollers rotate?

13 Check Exit Motor Main Drive harness Go to Step 15. Connect and go

P/J8334-1 <=> P/J8304-2
P/J8334-2 <=> P/J8304-4
P/J8334-3 <=> P/J8304-1
P/J8334-4 <=> P/J8304-3
P/J8334-5 <=> P/J8304-6
P/J8334-6 <=> P/J8304-5
16 Check Exit Motor resistance. Go to Step 17. Replace the Exit

Is there some amount of resistance Motor
4/6?
17 Check for +24 V to the Exit Motor. Go to Step 18. Replace the
18 Replace the Exit Motor. Replace the Problem solved.

(page 3-248).

Jam at H - F4-61 Set Eject Jam
Paper failed to clear the Compile Tray No Paper Sensor on time. Set Eject failed.

Jam a H - F4-61 Set Eject Jam
Jam at H (Compile Tray No Paper Sensor) Troubleshooting Reference

Eject Roller Shaft Phaser 5500 Printer Options Service Manual
Main Drive Harness Finisher Main PWB P/J Locator (page 5-35)
Eject Clamp Motor Finisher Sensors (1/2) Wiring (page 5-40)
Eject Motor Finisher Motors Wiring (page 5-42)
Finisher Main PWB Finisher Clutch and Solenoids (page 5-43)
Compiler Harness Finisher Compiler Tray Wiring (page 5-44)
Main Sensor Harness PL25.9 Finisher Eject (1/3) (page 4-60)
Compile Exit Sensor PL25.10 Finisher Eject (2/3) (page 4-62)
Compile No Paper Sensor PL25.11 Finisher Eject (3/3) page 4-64)
Jam at H (Compile Tray No Paper Sensor) Troubleshooting Procedure

Is the Eject Roller clean, rotate the Eject Roller.
smoothly, and installed correctly?
2 Test the Eject Clamp Motor. Go to Step 7. Go to Step 3.
Run the Service Diagnostics Eject Clamp
Motor Up and Down tests.
Does the motor rotate properly?
Are P/J8339 and P/J 8304 connected? to Step 4.
1. Disconnect P/J8339 and P/J 8304. Drive Harness.
J8339-1 <=> J8304-33
J8339-2 <=> J8304-31
6 Replace the Eject Clamp Motor. Replace the Problem solved.
(page 3-248).

Jam at H (Compile Tray No Paper Sensor) Troubleshooting Procedure (Continued)
7 Test the Eject Motor. Go to Step 14. Go to Step 8.

Run the Service Diagnostics Eject Motor
Low Speed Forward and Reverse tests.
Does the Eject Motor rotate properly?
Are P/J8336 and P/J 8304 connected? to Step 9.
10 Check Eject Motor Main Drive Harness Go to Step 11. Repair the Main
continuity. Drive Harness.
1. Disconnect P/J8336 and P/J 8304.
P/J8336-1 <=> P/J8304-15
P/J8336-2 <=> P/J8304-12
P/J8336-3 <=> P/J8304-17
P/J8336-4 <=> P/J8304-19
P/J8336-5 <=> P/J8304-14
P/J8336-6 <=> P/J8304-21
11 Check Eject Motor resistance. Go to Step 12. Replace the Eject
Is there some amount of resistance Bracket Assembly
across P8336-2/5(COM) <=> P8336-1/3/ (page 3-187).
4/6?
12 Check for +24 V to the Eject Motor. Go to Step 13. Replace the
Is there +24 V across P/J8304-12 <=> Finisher Main
ground, and P/J8304-14 <=> ground on PWB
13 Replace the Eject Bracket Assembly. Replace the Problem solved.
(page 3-248).
Sensor test.

19 Check the Compiler Harness continuity. Go to Step 20. Repair the

Harness.
P/J8320-3 <=> J8391B-1
P/J8320-2 <=> J8391B-2
P/J8320-1 <=> J8391B-3
1. Disconnect P/J8391 on the harness, and Sensor Harness.
P/J8302A on the Finisher Main PWB.
J8391A-3 <=> P/J8302A-4
J8391A-2 <=> P/J8302A-5
J8391A-1 <=> P/J8302A-6
(page 3-248).
22 Check the Compile Exit Sensor signal. Replace the Replace the
23 Test the Compile Tray No Paper Sensor. Replace the Go to Step 24.
Run the Service Diagnostics Compile Tray Finisher Main
No Paper Sensor test. PWB
Does the sensors state change? (page 3-248).
24 Check the Compiler Harness connection. Go to Step 26. Connect and go
Harness.
P/J8359-3 <=>P/J8309-1
P/J8359-2 <=> P/J8309-2
P/J8359-1 <=> P/J8309-3
27 Check for +5 V to the No Paper Sensor. Go to Step 28. Replace the
Is there +5 V across J8309-3 <=> J8309- Finisher Main
(page 3-248).

28 Check the No Paper Sensor signal. Replace the Replace the

Does the voltage across P8309-2 <=> Finisher Main Compile Tray No
P8309-1 on the Finisher Main PWB PWB Paper Sensor
change when the actuator is moved? (page 3-248). (page 3-182).
Jam at H - F4-66 Compile Paper SNR Static

Paper is detected by the Compile Tray No Paper Sensor following an eject operation.

Jam at H - F4-66 Compile Paper SNR Static
Static Jam at H (No Paper Sensor) Troubleshooting Reference
Eject Clamp Motor Phaser 5500 Printer Options Service Manual

Eject Motor Finisher Motors Wiring (page 5-42)
Finisher Main PWB Finisher Clutch and Solenoids (page 5-43)
No Paper Sensor Finisher Compiler Tray Wiring (page 5-44)
Compiler Harness PL25.9 Finisher Eject (1/3) (page 4-60)
PL25.10 Finisher Eject (2/3) (page 4-62)
Static Jam at H (No Paper Sensor) Troubleshooting Procedure
1 Test the Eject Clamp Motor. Go to Step 6. Go to Step 2.

Motor Up and Down tests.
Does the motor rotate properly?
2 Check Eject Clamp Motor Main Drive Go to Step 4. Connect and go

Harness connections. to Step 3.


Static Jam at H (No Paper Sensor) Troubleshooting Procedure (Continued)
4 Check Eject Clamp Motor Main Drive Go to Step 5. Repair the Main
Harness continuity. Drive Harness.
1. Disconnect P/J8339 and P/J8304.
P/J8339-1 <=> P/J8304-33
P/J8339-2 <=> P/J8304-31

(page 3-248).

Run the Service Diagnostics Eject Motor
Low Speed Forward test.
Does the Eject Motor rotate forward?
7 Check Eject Motor Main Drive Harness Go to Step 9. Connect and go


9 Check Eject Motor Main Drive Harness Go to Step 10. Repair the Main
P/J8336-1 <=> P/J8304-15
P/J8336-2 <=> P/J8304-12
P/J8336-3 <=> P/J8304-17
P/J8336-4 <=> P/J8304-19
P/J8336-5 <=> P/J8304-14
P/J8336-6 <=> P/J8304-21

Is there some amount of resistance Bracket Assembly
across P8336-2/5(COM) <=> P8336-1/3/ (page 3-187).
4/6?
12 Replace the Eject Motor. Replace the Problem solved.

(page 3-248).

Static Jam at H (No Paper Sensor) Troubleshooting Procedure (Continued)
13 Test the Compile Tray No Paper Sensor. Replace the Go to Step 14.
Run the Service Diagnostics Compile Tray Finisher Main
No Paper Sensor test. PWB
Does the sensors state change? (page 3-248).
14 Check the Compiler Harness connection. Go to Step 16. Connect and go



Harness.
P/J8359-3 <=> P/J8309-1
P/J8359-2 <=> P/J8309-2
P/J8359-1 <=> P/J8309-3
17 Check for +5 V to the Compile Tray No Go to Step 18. Replace the

Paper Sensor. Finisher Main
Is there +5 V across J8309-3 <=> J8309- PWB
1 on the Finisher Main PWB? (page 3-248).
18 Check the Compile Tray No Paper Sensor) Replace the Replace the
signal. Finisher Main Compile Tray No
Does the voltage across P8309-2 <=> PWB Paper Sensor
P8309-1 on the Finisher Main PWB (page 3-248). (page 3-182).
change when the sensor actuator is
moved?
Jam at F or G - F4-7n Top Tray Exit SNR ON

Paper does not reach the Stacker Upper Tray Exit Sensor on time.

Jam at F - F4-71 Top Tray Exit SNR ON Jam A
Jam at G - F4-73 Top Tray Exit SNR ON Jam B
Jam at G - F4-74 Top Tray Exit SNR ON Jam C

Jam at F or G (Stacker Upper Tray Exit Sensor ON) Troubleshooting Reference
Entrance Roller Phaser 5500 Printer Options Service Manual

Entrance Pinch Roller Finisher Main PWB P/J Locator (page 5-35)
Transport Roller Finisher Sensors (1/2) Wiring (page 5-40)
Pinch Roller Finisher Motors Wiring (page 5-42)
Transport Motor PL25.12 Finisher Transport (1/2) (page 4-66)
Main Drive Harness PL25.13 Finisher Transport (2/2) (page 4-68
Finisher Main PWB PL25.14 Finisher Electrical (page 4-70)
Top Exit Sensor Harness PL25.15 Finisher Harness (page 4-72)
Main Sensor Harness
Top Exit Sensor
Jam at F or G (Stacker Upper Tray Exit Sensor ON) Troubleshooting Procedure

roller.
4. Remove the Knob and open the Upper
Entrance Chute.
Are the Rollers attached to the chute
installed?

Open the Lower Top Exit Chute (2b). the appropriate
Are the Pinch Rollers attached to the roller.
chute and the two Transport Rollers
installed?

4 Test Entrance and Transport Roller drive. Go to Step 11. Restore

Run the Service Diagnostics Finisher operation.
Does the Entrance and Transport
Rollers rotate?
5 Check the Transport Motor Main Drive Go to Step 7. Connect and go

Harness. to Step 6.



P/J8342-1 <=> P/J8304-23
P/J8342-2 <=> P/J8304-16
P/J8342-3 <=> P/J8304-25
P/J8342-4 <=> P/J8304-27
P/J8342-5 <=> P/J8304-18
P/J8342-6 <=> P/J8304-29

4/6?

11 Test the Upper Tray Exit Sensor. Replace the Go to Step 12.
Run the Service Diagnostics Upper Tray Finisher Main
Exit Sensor test. PWB

Are P/J8321 and P/J8312 on the sensor to Step 13.
harness, and P/J8312 and P/J8302 on
the Main Sensor Harness connected?

14 Check Exit Sensor Harness continuity. Go to Step 15. Repair the Upper
1. Disconnect P/J8321 and P/J8312. Tray Exit Sensor
Harness.
P/J8321-3 <=> J8312B-1
P/J8321-2 <=> J8312B-2
P/J8321-1 <=> J8312B-3

PWB.
J8312A-3 <=> P/J8302A-7
J8312A-2 <=> P/J8302A-8
J8312A-1 <=> P/J8302A-9
16 Check for +5 V to the Upper Tray Exit Go to Step 48. Replace the
Sensor. Finisher Main
17 Check the Upper Tray Exit Sensor signal. Replace the Replace the
Does the voltage across P8302A-8 <=> Finisher Main Upper Tray Exit
change when sensor is actuated? (page 3-248). (page 3-226).
Jam at F or Stacker Upper Tray - F4-7nTop Tray SNR OFF

Paper does not leave the Stacker Upper Tray Exit Sensor on time.

Jam at F - F4-72 Top Tray Exit SNR OFF Jam A
Jam at Stacker Upper Tray - F4-75 Top Tray Exit SNR OFF Jam B
Jam at F or Upper Tray (Exit Sensor OFF) Troubleshooting Reference
Transport Roller Phaser 5500 Printer Options Service Manual

Pinch Roller Finisher Main PWB P/J Locator (page 5-35)
Transport Motor Finisher Sensors (1/2) Wiring (page 5-40)
Main Drive Harness Finisher Motors Wiring (page 5-42)
Top Exit Sensor Harness PL25.13 Finisher Transport (2/2) (page 4-68
Main Sensor Harness PL25.14 Finisher Electrical (page 4-70)
Top Exit Sensor PL25.15 Finisher Harness (page 4-72)

Jam at F or Upper Tray (Exit Sensor OFF) Troubleshooting Procedure

Open the Lower Top Exit Chute (2a). the appropriate
Are the Pinch Rollers attached to the roller.
chute and the two Transport Rollers
installed?

3 Test Entrance and Transport Roller drive. Go to Step 10. Restore roller
Run the Service Diagnostics Finisher operation.
Do the Entrance and Transport Rollers
rotate?

Harness. to Step 5.

6 Check Transport Motor Main Drive Go to Step 7. Repair the Main

Harness continuity. Drive Harness.
P/J8342-1 <=> P/J8304-23
P/J8342-2 <=> P/J8304-16
P/J8342-3 <=> P/J8304-25
P/J8342-4 <=> P/J8304-27
P/J8342-5 <=> P/J8304-18
P/J8342-6 <=> P/J8304-29

4/6?



Jam at F or Upper Tray (Exit Sensor OFF) Troubleshooting Procedure (Continued)
10 Test the Upper Tray Exit Sensor. Replace the Go to Step 11.
Exit Sensor test. PWB
11 Check the Upper Tray Exit Sensor Harness Go to Step 13. Connect and go
Are P/J8321 and P/J8312 on the sensor

13 Check Exit Sensor Harness continuity. Go to Step 14. Repair the Upper
1. Disconnect P/J8321 and P/J8312. Tray Exit Sensor
Harness.
P/J8321-3 <=> J8312B-1
P/J8321-2 <=> J8312B-2
P/J8321-1 <=> J8312B-3
14 Check Main Exit Sensor Harness Go to Step 15. Repair the Main
continuity. Sensor Harness.
1. Disconnect P/J8312 from the harness,
PWB.
J8312A-3 <=> P/J8302A-7
J8312A-2 <=> P/J8302A-8
J8312A-1 <=> P/J8302A-9
change when the sensor is actuated? (page 3-248). (page 3-226).

Jam at F or G - F4-7n Top Tray Exit SNR Static
Paper is detected by the Stacker Upper Tray Exit Sensor.

Jam at F - F4-76 Top Tray Exit SNR Static
Jam at G - F4-77 Top Tray Exit SNR Static
Jam at G - F4-78 Top Tray Exit SNR Static
Static Jam at F or G (Stacker Upper Tray Exit Sensor) Troubleshooting Reference
Transport Motor Phaser 5500 Printer Options Service Manual

Finisher Main PWB Finisher Sensors (1/2) Wiring (page 5-40)
Top Exit Sensor Harness Finisher Motors Wiring (page 5-42)
Main Sensor Harness PL25.12 Finisher Transport (1/2) (page 4-66)
Upper Tray Exit Sensor PL25.13 Finisher Transport (2/2) (page 4-68
Static Jam at F or G (Stacker Upper Tray Exit Sensor) Troubleshooting Procedure
1 Test the Upper Tray Exit Sensor. Go to Step 8. Go to Step 2.

Run the Service Diagnostics Upper Tray
Exit Sensor test.
2 Check the Upper Tray Exit Sensor Harness Go to Step 4. Connect and go
Are P/J8321 and P/J8312 on the sensor

4 Check Upper Tray Exit Sensor Harness Go to Step 5. Repair the Top
continuity. Tray Exit Sensor
1. Disconnect P/J8321 and P/J8312. Harness.
P/J8321-3 <=> J8312B-1
P/J8321-2 <=> J8312B-2
P/J8321-1 <=> J8312B-3

5 Check Main Upper Exit Sensor Harness Go to Step 6. Repair the Main
1. Disconnect P/J8312 from the harness,
PWB.
J8312A-3 <=> P/J8302A-7
J8312A-2 <=> P/J8302A-8
J8312A-1 <=> P/J8302A-9

change when the sensor is actuated? (page 3-248). (page 3-226).

9 Test Entrance and Transport Roller drive. Replace the Restore

Run the Service Diagnostics Finisher Finisher Main operation.
Do the Entrance and Transport Rollers (page 3-248).
rotate?
10 Check the Finisher Transport Motor Main Go to Step 12. Connect and go
Drive Harness. to Step 11.

P/J8342-1 <=> P/J8304-23
P/J8342-2 <=> P/J8304-16
P/J8342-3 <=> P/J8304-25
P/J8342-4 <=> P/J8304-27
P/J8342-5 <=> P/J8304-18
P/J8342-6 <=> P/J8304-29


4/6?

(page 3-248).
Jam at F - F4-82 Gate SNR ON

Paper does not reach the Gate Sensor within the specified time.

Jam at F - F4-82 Gate SNR ON
Jam at F (Transport Gate Sensor ON) Troubleshooting Reference
H-Xport Belts Phaser 5500 Printer Options Service Manual

H-Xport Pinch Rollers Horizontal Transport P/J Locator (page 5-29)
Entrance Rollers Horizontal Transport Wiring (page 5-39)
H-Xport Exit Sensor Finisher Main PWB P/J Locator (page 5-35)
H-Xport Harness Finisher Sensors (1/2) Wiring (page 5-40)
Finisher H-Xport PWB Finisher Motors Wiring (page 5-42)
Finisher Entrance Sensor PL25.2 Horizontal Transport (1/2) (page 4-46)
Main Sensor Harness PL25.3 Horizontal Transport (2/2) (page 4-48)
Transport Motor PL25.13 Finisher Transport (2/2) (page 4-68
Main Drive Harness PL25.14 Finisher Electrical (page 4-70)
Transport Gate Sensor PL25.15 Finisher Harness (page 4-72)
Gate Sensor Harness

Jam at F (Transport Gate Sensor ON) Troubleshooting Procedure

Open Door F. the affected parts.
Are the Belts and Pinch Rollers clean,
roll freely, and installed correctly?

1. Open Door G. the affected parts.
2. Remove the Top and Top L/H Covers.
3. Remove the Knob and open the Upper
Entrance Chute.
Are the Pinch Rollers and Entrance
Roller clean, installed correctly, and
operate freely?
3 Test the H-X'port Exit Sensor. Go to Step 9. Go to Step 4.

Run the Service Diagnostics H-Xport Exit
Sensor test.
4 Check the H-Xport Exit Sensor Harness Go to Step 6. Connect and go

Is the H-Xport Exit Sensor Harness
connected to the Exit Sensor and H-
Xport PWB?

6 Check the H-Xport Exit Sensor Harness Go to Step 7. Repair the H-

continuity. Xport Harness.
1. Disconnect J8381 on the Exit Sensor,
and P/J8372 on the H-Xport PWB.
P/J8372-4 <=> P/J8381-3
P/J8372-5 <=> P/J8381-2
P/J8372-6 <=> P/J8381-1

8 Check H-Xport Exit Sensor signal. Replace the H- Replace the H-

when the actuator is operated? (page 3-118).

Jam at F (Transport Gate Sensor ON) Troubleshooting Procedure (Continued)
9 Test the X'port Entrance Sensor. Go to Step 16. Go to Step 10.

Run the Service Diagnostics Transport
Does the sensor change state when the
sensor is blocked?
10 Check harness connections. Go to Step 12. Connect and go

Are P/J8319 and P/J8303 on the to Step 11.
Entrance Sensor Harness and P/J8302A
on the Main Sensor Harness
connected?

12 Check Xport Entrance Sensor Harness Go to Step 13. Repair the

continuity. Entrance Sensor
P/J8319-3 <=> J8303B-1
P/J8319-2 <=> J8303B-2
P/J8319-1 <=> J8303B-3
13 Check Main Xport Entrance Sensor Go to Step 14. Repair the Main
Harness continuity. Sensor Harness.
1. Disconnect P/J8303 on the harness, and
J8303A-3 <=> P/J8302A-1
J8303A-2 <=> P/J8302A-2
J8303A-1 <=> P/J8302A-3
14 Check for +5 V to X'port Entrance Sensor. Go to Step 15. Replace the

(page 3-248).
15 Check the X'port Entrance Sensor signal. Replace the Replace the
change, when the sensor is blocked? (page 3-248).
16 Check the Finisher Transport Motor. Go to Step 25. Go to Step 17.


17 Test Entrance and Transport Roller drive. Go to Step 19. Restore operation
Run the Service Diagnostics Finisher and go to
Transport Motor Test. Step 18.
rotate?

19 Check the Main Drive Harness. Go to Step 21. Connect and go


P/J8342-1 <=> P/J8304-23
P/J8342-2 <=> P/J8304-16
P/J8342-3 <=> P/J8304-25
P/J8342-4 <=> P/J8304-27
P/J8342-5 <=> P/J8304-18
P/J8342-6 <=> P/J8304-29

4/6?

(page 3-248).
25 Test the Gate Sensor. Replace the Go to Step 26.

Run the Service Diagnostics Gate Sensor Finisher Main
test. PWB
Does the sensor state change when the (page 3-248).
sensor is blocked?
26 Check the Gate Sensor Harness. Go to Step 28. Connect and go

Is the harness connected? to Step 27.


28 Check Gate Sensor Harness continuity. Go to Step 29. Repair the Gate
Disconnect P/J8432 and P/J8376. Sensor Harness.
J8432-3 <=> J8376-1
J8432-2 <=> J8376-2
J8432-1 <=> J8376-3
29 Check for +5 V to the Gate Sensor. Go to Step 30. Replace the

Is there +5 V acrossP8376-3 <=> P8376- Finisher Main
(page 3-248).
30 Check Gate Sensor signal. Replace the Replace the Gate

Jam at F or G - Gate SNR Static Jam (Upper Tray)

Paper remains at the Gate Sensor with Finisher in the Stacker Upper Tray exit mode.

Jam at F - F4-83 Gate SNR Static Jam A
Jam at G - F4-84 Gate SNR Static Jam B
Jam at G - F4-85 Gate SNR Static Jam C
Static Jam at F or G (Gate Sensor) Troubleshooting Reference

Top Exit Sensor Harness Finisher Clutch and Solenoids (page 5-43)
Gate Sensor PL25.12 Finisher Transport (1/2) (page 4-66)
Gate Sensor Harness PL25.13 Finisher Transport (2/2) (page 4-68)
Transport Gate Solenoid PL25.14 Finisher Electrical (page 4-70)

Static Jam at F or G (Gate Sensor) Troubleshooting Procedure


Run the Service Diagnostics Finisher and go to Step 4.
rotate?

Harness. to Step 4.

5 Check Transport Motor Main Drive Go to Step 6. Repair the

Harness continuity. Transport Motor
1. Disconnect P/J8342 and P/J8304. Main Drive
Harness.
P/J8342-1 <=> P/J8304-23
P/J8342-2 <=> P/J8304-16
P/J8342-3 <=> P/J8304-25
P/J8342-4 <=> P/J8304-27
P/J8342-5 <=> P/J8304-18
P/J8342-6 <=> P/J8304-29

4/6?


(page 3-248).

test.
Does the sensor state change when the
sensor is blocked?


Static Jam at F or G (Gate Sensor) Troubleshooting Procedure (Continued)

P/J8432-3 <=> P/J8376-1
P/J8432-2 <=> P/J8376-2
P/J8432-1 <=> P/J8376-3

(page 3-248).
14 Check the Gate Sensor signal. Replace the Replace the Gate
15 Test the Buffer Gate Solenoid. Replace the Go to Step 16.

Run both Service Diagnostics Buffer Gate Finisher Main
Solenoid tests. PWB
Does the Buffer Gate open for Path-in (page 3-248).
and close for Path-out?
16 Check Buffer Gate Solenoid Harness Go to Step 18. Connect and go


18 Check Buffer Gate Solenoid Harness Go to Step 19. Repair the Buffer
continuity. Gate Solenoid
P/J8394-1 <=> P/J8304-35
P/J8394-2 <=> P/J8304-34
P/J8394-3 <=> P/J8304-36

(page 3-248).

Jam at F or G - Gate SNR Static Jam (Lower Tray)
Paper remains at the Gate Sensor when the Finisher is in the Stacker Lower Tray exit
mode.

Jam at F - F4-86 Gate SNR Static Jam A
Jam at G - F4-87 Gate SNR Static Jam B
Jam at G - F4-88 Gate SNR Static Jam C
Static Jam at F or G (Gate Sensor) Troubleshooting Reference

Top Exit Sensor Harness Finisher Clutch and Solenoids (page 5-43)
Gate Sensor PL25.12 Finisher Transport (1/2) (page 4-66)
Gate Sensor Harness PL25.13 Finisher Transport (2/2) (page 4-68)
Transport Gate Solenoid PL25.14 Finisher Electrical (page 4-70)
Static Jam at F or G (Gate Sensor) Troubleshooting Procedure


Run the Service Diagnostics Finisher and go to Step 4.
rotate?
3 Check the Transport Motor Drive Harness. Go to Step 5. Connect and go



5 Check Transport Motor Drive Harness Go to Step 6. Repair the

continuity. Transport Motor
P/J8342-1 <=> P/J8304-23
P/J8342-2 <=> P/J8304-16
P/J8342-3 <=> P/J8304-25
P/J8342-4 <=> P/J8304-27
P/J8342-5 <=> P/J8304-18
P/J8342-6 <=> P/J8304-29

4/6?


(page 3-248).

test.
sensor is blocked?


P/J8432-3 <=> P/J8376-1
P/J8432-2 <=> P/J8376-2
P/J8432-1 <=> P/J8376-3

(page 3-248).

14 Check the Gate Sensor signal. Replace the Replace the Gate
15 Test the Buffer Gate Solenoid. Replace the Go to Step 16.

Run both Service Diagnostics Buffer Gate Finisher Main
Solenoid tests. PWB
Does the Buffer Gate open for Path-in (page 3-248).
and close for Path-out?
16 Check Buffer Gate Solenoid Harness Go to Step 18. Connect and go


18 Check Buffer Gate Solenoid Harness Go to Step 19. Repair the Main
P/J8394-1 <=> P/J8304-35
P/J8394-2 <=> P/J8304-34
P/J8394-3 <=> P/J8304-36

(page 3-248).

Tray n Failure - H1 -1/2/3/4 Tray n Fail
Detected lift failure. Paper size detection inoperative.

Tray 2 Failure - H1-1 Tray 2 Fail
Universal Tray Failure Troubleshooting Reference
Tray Print Engine P/J Tray 2 & 3 Feeders (page 10-11)

Feeder Print Engine P/J Engine Logic Board (page 10-13)
Feed/Lift Motor Print Engine Tray 2 & 3 Wiring (page 10-26)
Level Sensor PL2.1 Tray (1/2) and Feeder (1/2) (page 9-8)
Paper Size Switch PL2.2 Tray (2/2) (page 9-10)
Tray 4-5 PWB PL2.3 Feeder (2/2) (page 9-12)
Engine Logic PL8.1 Print Engine Electrical (page 9-40)
Board. Phaser 5500 Printer Options Service Manual
1000-Sheet Feeder P/J Locator (page 5-5)
1000-Sheet Feeder Tray 4 & 5 Wiring (page 5-9)
PL20.2 Tray 4-5 Tray (1/2) Feeder (1/2) (page 4-6)
PL20.3 Tray 4-5 Tray (2/2) (page 4-8)
PL20.4 Tray 4-5 Feeder (2/2) (page 4-10)
Universal Tray Failure Troubleshooting Procedure
1 Check paper supply. Go to Step 2. Load paper and

Is paper loaded in the affected tray? go to Step 2.
2 Check the tray. Go to Step 3. Go to Step 4.

Replace the tray with one from another
position.
Does the replaced tray lift?
3 Check lift components. Replace the tray. Go to Step 4.

Is the Sector Gear or surrounding parts
damaged?

Run the Service Diagnostics Lift Motor test
for the affected tray.

Universal Tray Failure Troubleshooting Procedure (Continued)
5 Check the Feed/Lift Motor connections. Go to Step 6. Connect the

Is the affected Feed/Lift motor properly motor. If error
connected to the harness? continues, go to
Step 6.
6 Test the Feed/Lift Motor. Replace the Feed/ Go to Step 7.

1. Exchange the Feed/Lift Motor with one Lift motor.
from an operational feeder.
2. Run the Service Diagnostics Lift Motor
test on the replacement motor.
7 Check for continuity on the connections. Go to Step 8. Repair the wiring.

Reinstall the motors in the original feeders.
between P/J409 (Trays 2-3) or P/J549
(Trays 4-5) and the Feeder Harness?
8 Check for +24 V to the affected Feed/Lift Replace the Replace the
Motor. motor. Engine Logic
Is there +24 V across the motor Board
connectors Pin 4(+) <=> ground? (page 8-89). If the
error persists
replace Tray 4-5
PWB (page 3-29).
9 Test the affected Level Sensor. Go to Step 13. Go to Step 10.

Run the Service Diagnostics Level Sensor
test for the affected tray.
10 Check the Level Sensor connection. Go to Step 11. Connect the

Is the sensor connected to the harness? sensor. If error
persists, go to
Step 11.
11 Check harness continuity between the Go to Step 12. Repair the wiring.
Level Sensor and Engine Logic Board.
between the Level Sensor <=> P/J409
(Trays 2-3) or P/J549 (Trays 4-5)?
12 Check for +5 V to the affected Level Replace the Replace the

Sensor. sensor. Engine Logic
Is there +5 V across Pin-3 (+) <=> Board. If the error
ground? persists replace
Tray 4-5 PWB
(page 3-29).

Universal Tray Failure Troubleshooting Procedure (Continued)
13 Test the affected Paper Size Switch. Replace the Go to Step 14.
Run the Service Diagnostics Paper Size Engine Logic
Sensor test for the affected tray. Board. If the error
Is the paper size detected correctly persists replace
when the tray, loaded with paper, is Tray 4-5 PWB
moved in and out? (page 3-29).
14 Check the affected Paper Size Switch Go to Step 15. Connect the
connection. switch. If problem
Is the switch connected to the harness? persists, go to
Step 15.
15 Check continuity between the Paper Size Go to Step 16. Repair the wiring.
Switch and the Engine Logic Board (Tray 2-
3) or Tray 4-5 PWB (Tray 4-5).
between the switch <=> P/J412 (Tray 2-
3) or P/J548 (Tray 4-5)?
16 Check for +3.3 V to the Paper Size Switch Replace the Replace the
Is there +5 V across P/J412-1 (+) <=> switch. Engine Logic
ground? for Tray 2-3 or 3.3 V across P/ Board. If the error
J548-1 for Tray 4-5. persists replace
Tray 4-5 PWB
(page 3-29).

Detected lift failure or paper size detection inoperative.

Tray 6 Failure Troubleshooting Reference
Tray In Sensor Print Engine P/J Engine Logic Board (page 10-13)
Tray 6 Main Harness PL2.1 Tray (1/2) and Feeder (1/2) (page 9-8)
Tray 6 Feeder PL2.2 Tray (2/2) (page 9-10)
Harness PL2.3 Feeder (2/2) (page 9-12)
Tray 6 PWB PL8.1 Print Engine Electrical (page 9-40)
Lift Cables Phaser 5500 Printer Options Service Manual
Feed/Lift Motor 2000-Sheet Tray 6 Feeder P/J Locator (page 5-20)
Nudger Solenoid 2000-Sheet Tray 6 Drive P/J Locator (page 5-21)
Level Sensor 2000-Sheet Tray 6 Sensors Wiring (page 5-24)
Engine Logic Board. 2000-Sheet Tray 6 Drive Wiring (page 5-25)
PL22.1 Tray 6 Covers (page 4-18)
PL23.3 Tray (2/2) (page 4-20)
PL22.4 Tray 6 Feeder (1/3) (page 4-24)
PL22.5 Tray 6 Feeder (2/3) (page 4-26)
Tray 6 Failure Troubleshooting Procedure
1 Check Tray In Sensor alignment. Go to Step 2. Repair the

Pull the Tray out. damage and go
Does the actuator enter the sensing to Step 2.
area of the Tray Set Sensor, or is it
deformed or damaged?
2 Check the Tray installation. Go to Step 3. Correct and go to

Is the Tray installed correctly? Step 3.
3 Check the repairs. Go to Step 4. Problem solved.

4 Test the Tray In Sensor. Go to Step 10. Go to Step 5.

Run the Service Diagnostics Tray In
Sensor test.
Does the sensor status change when
the tray is moved in and out?
5 Check the Tray In Sensor Main Harness Go to Step 7. Connect and go

Are PF53 and JF01 connected?

Tray 6 Failure Troubleshooting Procedure (Continued)
6 Check the repairs. Go to Step 7. Problem solved.

7 Check Tray In Sensor Main Harness Go to Step 8. Repair the Tray 6

continuity. Tray Set Sensor
1. Disconnect PF53 and JF01. harness.
PF53-1 <=> JF01-6
PF53-2 <=> JF01-5
PF53-3 <=> JF01-4
8 Check for +5 V to the Tray In Sensor. Go to Step 9. Replace the Tray

9 Check Tray In Sensor signal. Go to Step 36. Replace the

Does the voltage across JF01-5 <=> sensor
10 Check the Tray cables. Go to Step 11. Correct and go to

Remove the Tray from the HCF. Step 11.
Are the two cables installed correctly?
11 Test the Level Sensor. Go to Step 19. Go to Step 12.

Run the Service Diagnostics Tray 6 Level
Sensor test.
12 Check the Level Sensor Harness Go to Step 13. Connect and go

Are PF62 and PF56B connected?
13 Check the Level Sensor Harness Go to Step 15. Connect and go

Are PF56B and JF02 connected?
14 Check the repair. Go to Step 15. Problem solved.

15 Check Level Sensor Harness continuity. Go to Step 16. Repair the Tray 6
1. Disconnect PF62 and JF56B. Feeder Harness.
PF62-1 <=> JF56B-6
PF62-2 <=> JF56B-5
PF62-3 <=> JF56B-4

16 Check Main Harness continuity. Go to Step 17. Repair the Tray 6

1. Disconnect PF56B and JF02. Main Harness.
JF56B-1 <=> JF02-3
JF56B-2 <=> JF02-2
JF56B-3 <=> JF02-1
17 Check for +5 V to the Level Sensor. Go to Step 18. Replace the Tray
Is there +5 V across PF02-3 <=> P/JF04- 6 PWB
2 on the Tray 6 PWB? (page 3-67).
18 Check Level Sensor signal. Go to Step 36. Replace the Level

1. Open Door J. Sensor
(page 3-55).
Does the voltage across PF02-2 <=>
PF04-2 on the Tray 6 PWB change when
19 Test the Nudger Solenoid. Go to Step 28. Go to Step 20.

Run the Service Diagnostics Tray 6 Nudger
Solenoid test.
Does the solenoid activate?
20 Check Nudger Solenoid harness Go to Step 22. Connect and go

Are PF59 and PF56 on the Feeder and
Main Harnesses, and JF06 on the Tray 6
PWB connected?

22 Check Nudger Solenoid Harness Go to Step 23. Repair the Feeder

continuity. Harness.
1. Disconnect PF59 and JF56A.
PF59-2 <=> JF56A-1
PF59-1 <=> JF56A-2
23 Check Nudger Solenoid Main Harness Go to Step 24. Repair the

continuity. Nudger Solenoid
1. Disconnect PF56A and P/JF06. Main Harness.
PF56A-6 <=> P/JF06-13
PF56A-5 <=> P/JF06-14
24 Check Nudger Solenoid resistance. Go to Step 25. Replace the

Is there some amount of resistance Solenoid
across PF59-1 and PF59-2? (page 3-50).

25 Test for +24.5 V to the Nudger Solenoid. Go to Step 26. Replace the Tray
Run the Service Diagnostics Nudger 6 PWB
Solenoid High Power test. (page 3-67).
Is there +24.5 V across PF06-13 <=> P/
JF04-2 on the Tray 6 PWB?
26 Test for +14.7 V Nudger Solenoid. Go to Step 27. Replace the Tray
Run the Service Diagnostics Nudger 6 PWB
Solenoid Low Power test. (page 3-67).
Is there +14.7V across PF06-13 <=> P/
JF04-2 on the Tray 6 PWB?
27 Replace the Nudger Solenoid. Go to Step 36. Problem solved.


Run the Service Diagnostics Tray 6 Lift
Motor test.
Does the Tray raise?

Are PF58 and PF56 on the Feeder and to Step 30.
Main Harness, and JF06 on the Tray 6
PWB connected?

31 Check Feeder Harness continuity. Go to Step 32. Repair the Feeder

PF58-1 <=> JF56-1
PF58-2 <=> JF56-2
PF58-3 <=> JF56-3
PF58-4 <=> JF56-4
PF58-5 <=> JF56-5
PF58-6 <=> JF56-6
32 Check Main Harness continuity. Go to Step 33. Repair the Main

PF56-1 <=> JF06-1
PF56-2 <=> JF06-3
PF56-3 <=> JF06-2
PF56-4 <=> JF06-6
PF56-5 <=> JF06-4
PF56-6 <=> JF06-5

33 Check Feed/Lift Motor resistance. Go to Step 34. Replace the

across PF58-2/5(COM) and PF58-1/3/4/ (page 3-49).
6?
34 Check for +24 V to the Feed/Lift Motor. Go to Step 35. Replace the Tray
Are the voltages across PF06-3 <=> 6 PWB
PF04-3, and PF06-4 <=> PF04-3 on the (page 3-67).
Tray 6 PWB +24 V?

Print a Test Print.

Does the error still occur? Engine Logic
Board
(page 8-89).
Duplex Unit Failure - H2-7 Duplex Comm Failure

Communications failure between the Engine Logic Board and the Duplex Unit.

Duplex Unit Failure - H2-7 Duplex Comm Failure
Duplex Comm Failure Troubleshooting Reference
Duplex Unit PWB Print Engine P/J Engine Logic Board (page 10-13)
Board Phaser 5500 Printer Options Service Manual
Duplex Unit Plug/Jack Locator (page 5-12)
Duplex Comm Failure Troubleshooting Procedure

Reinstall the Duplex Unit.


Duplex Comm Failure Troubleshooting Procedure (Continued)
3 Check Duplex Harness continuity between Go to Step 4. Repair the wiring.

the Duplex PWB and the Engine Logic
Board.
P/J540-1 <=> P/J417-A1
P/J540-2 <=> P/J417-B1
P/J540-3 <=> P/J417-A2
P/J540-4 <=> P/J417-B2
P/J540-5 <=> P/J417-A3
P/J540-6 <=> P/J417-B3
P/J540-7 <=> P/J417-A4
P/J540-8 <=> P/J417-B4
(page 8-89).
Incorrect Duplex Unit Installed - H2-8 Duplex Type Error

Incorrect Duplex Unit installed.

Duplex Unit Failure - H2-8 Duplex Type Error
Incorrect Duplex Unit Installed Troubleshooting Reference
Duplex Unit PWB Print Engine P/J Engine Logic Board (page 10-13)
Phaser 5500 Printer Options Service Manual
Duplex Unit Plug/Jack Locator (page 5-12)
Incorrect Duplex Unit Installed Troubleshooting Procedure

Reinstall the Duplex Unit.

Incorrect Duplex Unit Installed Troubleshooting Procedure (Continued)
(page 8-89).
Exit Unit Failure - H3-n Offset Error

Failure to establish Offset Home Position on Exit1 (H3-1) or Exit 2 (H3-2).

Exit Unit Failure - H3-1 Offset Error
Exit Unit Failure - H3-2 Offset Error
Exit Offset Error (OCT Position Sensor) Troubleshooting Reference

OCT Position Print Engine P/J Engine Logic Board (page 10-13)
Sensor Print Engine P/J Laser and Exit PWB (page 10-7)
Offset Motor Print Engine LVPS Wiring (page 10-21)
Exit PWB Print Engine Exit 1 Wiring (page 10-30)
LVPS PL8.1 Print Engine Electrical (page 9-40)
Board Exit 2 Plug/Jack Locator (page 5-15)
Exit 2 General Wiring (page 5-7)
Exit Offset Error (OCT Position Sensor) Troubleshooting Procedure

1 Test the affected OCT Position Sensor. Go to Step 10. Go to Step 2.
Run the Service Diagnostics Exit 1 or 2
Offset Home Position Sensor test.
2 Check the sensor connection. Go to Step 3. Connect the
Is P/J117 (Exit 1) or P/J111 (Exit 2) sensor.
connected?
3 Check continuity between the affected Go to Step 4. Repair the wiring.
OCT Position Sensor and the Exit PWB P/
J111 <=> P/J434 and SJ1 (Exit2) P/J117
<=> P/J423 (Exit 1).

Exit Offset Error (OCT Position Sensor) Troubleshooting Procedure (Continued)

4 Check for +5 V to the OCT Position Sensor. Replace the Go to Step 5.
Is there +5 V across P/J434-1 (Exit 2) or affected OCT
P/J432-1 (Exit 1) (+) <=> ground? Position Sensor.
PWB and the Engine Logic Board. and P/J421. If
Are P/J431 and P/J421 connected? problem persists,
go to Step 6.
P/J431-1 <=> P/J421-8
P/J431-2 <=> P/J421-7
P/J431-3 <=> P/J421-6
P/J431-4 <=> P/J421-5
P/J431-5 <=> P/J421-4
P/J431-6 <=> P/J421-3
P/J431-7 <=> P/J421-2
P/J431-8 <=> P/J421-1
PWB and the LVPS. and P/J526. If
Are P/J430 and P/J526 connected? problem persists,
go to Step 8.
and the LVPS.
P/J430-3 <=> P/J526-6
P/J430-4 <=> P/J526-5
P/J430-1 <=> P/J526-8
P/J430-2 <=> P/J526-7
10 Test the Offset Motor. Replace the Exit Go to Step 11.
Run the Service Diagnostics Offset Output PWB (page 8-88).
Motor tests for the appropriate Exit. If problem
Does the Offset Motor operate persists, replace
properly? the Engine Logic
Board
(page 8-89).
11 Check the affected Offset Motor Go to Step 12. Connect the
connection. Exit 1 P/J432 <=> J206 or Exit motor. If problem
2 P/J433 <=> J207. persists go to
Is the motor connected? Step 12.

Exit Offset Error (OCT Position Sensor) Troubleshooting Procedure (Continued)

Offset Motor and Exit PWB.
For Exit 1:
1. Disconnect P/J432 and J206.
P/J432-7 <=> J206-1
P/J432-8 <=> J206-2
P/J432-9 <=> J206-3
P/J432-10 <=> J206-4
P/J432-11 <=> J206-5
For Exit 2:
1. Disconnect P/J433 and J207.
P/J433-1 <=> J207-1
P/J433-2 <=> J207-2
P/J433-3 <=> J207-3
P/J433-4 <=> J207-4
P/J433-5 <=> J207-5
13 Check for +24 V to the affected Offset Replace the Offset Replace the Exit
Motor. Motor. PWB (page 8-88).
Is there +24 V across (Exit 2) P/J433-1 or
(Exit 1) P/J432-7(+) <=> ground?
Exit Unit Failure - H3-7 Exit Board Comm Failure

Communications failure between the Engine Logic Board and Exit PWB.

Exit Unit Failure - H3-7 Exit Board Comm Failure
Exit Comm Failure Troubleshooting Reference
Exit PWB Print Engine P/J Engine Logic Board (page 10-13)
LVPS Print Engine P/J Laser and Exit PWB (page 10-7)
Engine Logic Board Print Engine LVPS Wiring (page 10-21)
Print Engine Exit 1 Wiring (page 10-30)
PL8.1 Print Engine Electrical

Exit Comm Failure Troubleshooting Procedure
1 Check the Exit PWB connection. Go to Step 2. Connect P/J431

P/J431-1 <=> P/J421-8
P/J431-2 <=> P/J421-7
P/J431-3 <=> P/J421-6
P/J431-4 <=> P/J421-5
P/J431-5 <=> P/J421-4
P/J431-6 <=> P/J421-3
P/J431-7 <=> P/J421-2
P/J431-8 <=> P/J421-1

and the LVPS.
P/J430-3 <=> P/J526-6
P/J430-4 <=> P/J526-5
P/J430-1 <=> P/J526-8
P/J430-2 <=> P/J526-7

Tray 1/MPT Paper Guide Does Not Match Size Menu
The Tray 1/MPT paper guides do no match the paper size stored in NVRAM for Tray
1/MPT.
Tray 1/MPT Paper Guides (Paper Size Sensor) Troubleshooting Reference
Paper Size Sensor Print Engine Tray 1/MPT P/J Locator (page 10-9)
Paper Guides Print Engine Tray 1/MPT Wiring (page 10-28)
Size Sensor Print Engine P/J Locator Electrical (page 10-12)
Harness PL3.3 Tray 1/MPT Assembly (page 9-20)
Tray 1/MPT Paper Guides (Paper Size Sensor) Troubleshooting Procedure
1 Check the paper in Tray 1/MPT. Go to Step 2. Reload the paper.

Is paper loaded in the tray properly?
2 Check the paper guides. Go to Step 3. Reset the guides.

Are the paper guides set correctly?
3 Test the Paper Size Sensor for Tray 1/MPT. Replace the Go to Step 4.
Run the Service Diagnostics Tray 1 Size Engine Logic
Sensor test. Board
Does the size displayed change as the (page 8-89).
size guides are moved in and out?
4 Check the Paper Size Switch connection. Go to Step 5. Connect the

Are J107, P/J609, P/J605 and J411 Paper Size
connected? Sensor.
5 Check continuity between the Tray 1/MPT Go to Step 6. Repair the wiring.
Paper Size Sensor and the Engine Logic
Board.
1. \Disconnect J107 and J411.
J107-1 <=> J411-1
J107-2 <=> J411-2
J107-3 <=> J411-3
6 Check for +5 V to the Paper Size Sensor. Replace the Replace the
Is there +5 V across J107-1 (+) <=> Tray 1/MPT Engine Logic
ground? Assembly Board
(page 8-32). (page 8-89).

Tray Paper Guide Does Not Match Size Menu -H4-1/2

Tray Paper Guide Does Not Match Size Menu- H4-1 Tray 2 Paper Size Error
Paper Size Failure (Tray 2-3 Paper Size Switch) Troubleshooting Reference
Paper Size Switch Print Engine P/J Engine Logic Board (page 10-13)
Tray Paper Guides Print Engine P/J Locator Electrical (page 10-12)
Engine Logic Board PL2.1 Tray (1/2) Feeder (1/2) (page 9-8)
Paper Size Failure (Tray 2-3 Paper Size Switch) Troubleshooting Procedure
1 Check the paper in the affected tray. Go to Step 2. Reload the paper.
2 Check the tray paper guides. Go to Step 3. Reset the guides.

Are the paper guides set correctly?
3 Check the Paper Size Switch for the Go to Step 4. Correct the
affected tray. installation.
Is the switch installed correctly?
4 Test the Paper Size Switch for the affected Reconnect the Go to Step 5.
tray. connector of the
Run the Service Diagnostics Size Sensor Engine Logic
test for the affected tray. Board.
the loaded tray is moved in or out?

For Tray 2: Paper Size
Are P/J109 and P/J412 connected? Switch.
For Tray 3:


Paper Size Switch and the Engine Logic
Board.
For Tray 2:
P/J109-1 <=> P/J412-4
P/J109-2 <=> P/J412-3
P/J109-3 <=> P/J412-2
P/J109-4 <=> P/J412-1
For Tray 3:
P/J110-1 <=> P/J412-9
P/J110-2 <=> P/J412-8
P/J110-3 <=> P/J412-7
P/J110-4 <=> P/J412-6
7 Check for +5 V to the Paper Size Switch. Replace the paper Replace the
For Tray 2: Size Switch for the Engine Logic
Is there +5 V across J109-1 (+) <=> affected tray. Board
For Tray 3:
Is there +5 V across J110-1 (+) <=>
ground?

Tray Paper Guide Does Not Match Size Menu -H4-3/4

Paper Size Failure (Tray 4-5 Paper Size Switch) Troubleshooting Reference
Tray Paper Guides PL8.1 Print Engine Electrical (page 9-40)
Tray 4-5 PWB Phaser 5500 Printer Options Service Manual
1000-Sheet Feeder P/J Electrical (page 5-6)
1000-Sheet Tray 4 & 5 Wiring (page 5-9)
PL20.2 Tray (1/2) Feeder (1/2) (page 4-6)
1 Check the Paper in the affected tray. Go to Step 2. Reload the paper.
2 Check the tray paper guides. Go to Step 3. Set the guides

Are the paper guides set correctly? properly.

For Tray 5:


Board.
For Tray 4:
P/J820-1 <=> P/J548-14
P/J820-2 <=> P/J548-13
P/J820-3 <=> P/J548-12
P/J820-4 <=> P/J548-11
For Tray 5:
P/J824-1 <=> P/J548-7
P/J824-2 <=> P/J548-6
P/J824-3 <=> P/J548-5
P/J824-4 <=> P/J548-4
7 Check for +3.3 V to the Paper Size Switch. Replace the Paper Replace the
Is there +3.3 V across P/J820-1 (+) <=> affected tray. Board
For Tray 5:
Is there +3.3 V across P/J824-1 (+) <=>
ground?
8 Check the Tray 4-5 PWB connection. Go to Step 9. Connect P/J413

Are P/J413 and P/J541 connected? and P/541.
P/J541-1 <=> P/J413-A1
P/J541-2 <=> P/J413-A2
P/J541-3 <=> P/J413-A3
P/J541-4 <=> P/J413-A4
P/J541-5 <=> P/J413-A5
P/J541-6 <=> P/J413-A6
P/J541-7 <=> P/J413-B1
P/J541-8 <=> P/J413-B2
P/J541-9 <=> P/J413-B3
P/J541-10 <=> P/J413-B4
P/J541-11 <=> P/J413-B5
P/J541-12 <=> P/J413-B6

10 Check for +5 V to the Tray 4-5 PWB Replace the Replace the
Is there +5 V across P/J413-A5 (+) <=> Tray 4-5 PWB Engine Logic
(page 8-89).
Finisher Board Failure - H5-4, 7, 8 NVM/Comm/Type

Error

Finisher Board Failure - H5-4 NVM R/W Error
Finisher Failure - H5-7 MCU-Finisher Comm Error
Incorrect Finisher Installed - H5-8 Finisher Type Error
Finisher Board Error (NVRAM R/W Error) Troubleshooting Reference
Finisher Main PWB Print Engine P/J Engine Logic Board (page 10-13)
Finisher Main PWB P/J Locator (page 5-35)
Finisher Board Error (NVRAM R/W Error) Troubleshooting Procedure
1 Check the Finisher installation. Go to Step 2. Reconnect the

Are the interface cables connected cables and got to
correctly? Step 2.
2 Does the error occur when the power is Go to Step 2. Problem solved.
cycled?
3 Check Finisher Main PWB connections. Go to Step 3. Connect all

Are P/J8300 and P416 connected? connectors. Go to
Step 3.

Finisher Board Error (NVRAM R/W Error) Troubleshooting Procedure (Continued)
4 Check continuity between the Finisher Go to Step 4. Repair the wiring.

Main PWB and the Engine Logic Board.
P/J8300-11 <=> P/J416-1
P/J8300-10 <=> P/J416-2
P/J8300-9 <=> P/J416-3
P/J8300-8 <=> P/J416-4
P/J8300-7 <=> P/J416-5
P/J8300-6 <=> P/J416-6
P/J8300-4 <=> P/J416-7
P/J8300-3 <=> P/J416-8
P/J8300-2 <=> P/J416-9
P/J8300-1 <=> P/J416-10
P/J8300-4 <=> P/J416-11
5 Check for +24 V to the Finisher Main PWB. Replace the Replace the
Is there +24 V across J416-6 (+) <=> Finisher Main Engine Logic
ground? PWB Board
(page 3-248). (page 8-89).
Stacker Lower Tray Failure - H5-11 Low Tray Fail

The Lower Tray No Paper Sensor is not turned Off or On within the specified time
following the Stacker Tray beginning to move.

Stacker Lower Tray Failure - H5-11 Low Tray Fail
Stacker Lower Tray Failure (Stack Height Sensors) Troubleshooting Reference
Lower Tray No Paper Print Engine P/J Engine Logic Board (page 10-13)
Sensor PL8.1 Print Engine Electrical (page 9-40)
Upper Limit Actuator Phaser 5500 Printer Options Service Manual
Finisher Main PWB Finisher Main PWB P/J Locator (page 5-35)
Elevator Motor Finisher Clutch and Solenoids (page 5-43)
Engine Logic Board PL25.6 Finisher Stack (page 4-54)

Stacker Lower Tray Failure (Stack Height Sensors) Troubleshooting Procedure
1 Check the Stacker Lower Tray vertical Remove Go to Step 2.

transport and belts for obstacles and obstacles/replace
deformation. deformed part.
Are there obstacles or belt wear in the
vertical transport mechanism?
2 Check the Actuator installation. Go to Step 3. Repair the

Does the Actuator enter the Upper Limit Actuator.
sensor sensing area?
3 Test the Lower Tray No Paper Sensor. Go to Step 9. Go to Step 4.

Run the Service Diagnostics Lower Tray
No Paper Sensor test.
sensor is blocked?
4 Check the Lower Tray No Paper Sensor Go to Step 6. Connect and go

Harness connection. to Step 5.
Are P/J8326 and P/J8302B connected?

6 Check the Lower Tray No Paper Sensor Go to Step 7. Repair the Lower
Harness continuity. Tray No Paper
1. Disconnect P/J8326 on the Lower Tray Sensor Harness.
No Paper Sensor Harness, and P/ If problem
J8302B on the Finisher Main PWB. persists, go to
Step 7.
P/J8326-3 <=> P/J8302B-15
P/J8326-2 <=> P/J8302B-16
P/J8326-1 <=> P/J8302B-17
7 Check for +5 V to the Lower Tray No Paper Go to Step 8. Replace the

Is there +5 V across J8302B-17 <=> PWB
J8302B-15 on the Finisher Main PWB? (page 3-248).
8 Check Stacker Lower Tray No Paper Replace the Replace the

Sensor. Finisher Main Lower Tray No
Does the voltage across P8302B-16 <=> PWB Paper Sensor
P8302B-15 on the Finisher Main PWB (page 3-248). (page 3-143).
change when the sensor is blocked?
9 Test the Elevator Motor. Replace the Go to Step 10.

Run the Service Diagnostics Stacker Motor Finisher Main
Up and Down tests alternately. PWB
Does the Elevator Motor operate? (page 3-248).
10 Check the Elevator Motor connection. Go to Step 12. Connect and go

Is P/J8305 connected to the Finisher to Step 11.
Main PWB?

Stacker Lower Tray Failure (Stack Height Sensors) Troubleshooting Procedure

12 Replace the Elevator Motor. Go to Step 13. Problem solved.

Print a Test Print.
13 Replace the Finisher Main PWB. Replace the Problem solved.

Board
(page 8-89).
Stacker Lower Tray Failure - H5-12 Low Tray Upper

Limit
The Stacker Lower Tray rose beyond the upper limit position.

Stacker Lower Tray Failure - H5-12 Low Tray Upper Limit
Stacker Lower Tray Failure (Upper Limit Sensor) Troubleshooting Reference
Lower Tray No Paper Print Engine P/J Engine Logic Board (page 10-13)
Sensor PL8.1 Print Engine Electrical (page 9-40)
Lower Tray Upper Limit Phaser 5500 Printer Options Service Manual
Sensor
Upper Limit Actuator Finisher Sensors (2/2) Wiring (page 5-41)
Finisher Main PWB
Finisher Clutch and Solenoids (page 5-43)
Main Sensor Harness
PL25.6 Finisher Stack (page 4-54)
Elevator Motor
Engine Logic Board
Stacker Lower Tray Failure (Upper Limit Sensor) Troubleshooting Procedure
1 Check the Stacker Lower Tray vertical Remove any Go to Step 2.

transport and belts for obstacles and obstacles.
deformation.

2 Check the Actuator installation. Go to Step 3. Replace the

3 Test the Lower Tray No Paper Sensor. Go to Step 9. Go to Step 4.

No Paper Sensor test.
sensor is blocked?
4 Check the Lower Tray No Paper Sensor Go to Step 6. Connect and go



1. Disconnect P/J8326 on the Main Sensor Sensor Harness.
Harness, and P/J8302B on the Finisher
Main PWB.
P/J8326-3 <=> P/J8302B-15
P/J8326-2 <=> P/J8302B-16
P/J8326-1 <=>P/J8302B-17
7 Check for +5 V to the Lower Tray No Paper Go to Step 8. Replace the

8 Check the Lower Tray No Paper Sensor. Replace the Replace the
Does the voltage across P8302B-16 <=> Finisher Main Lower Tray No
P8302B-15 on the Finisher Main PWB PWB Paper Sensor
change when the sensor is blocked? (page 3-248). (page 3-143).
9 Test the Lower Tray Upper Limit Sensor. Go to Step 15. Go to Step 10.
Upper Limit Sensor test.
sensor is blocked?
10 Check Lower Tray Upper Limit Sensor Go to Step 12. Connect and go


12 Check Lower Tray Upper Limit Sensor Go to Step 13. Repair the Lower
Sensor Harness continuity. Tray Upper Limit
P/J8302B on the Finisher Main PWB.
P/J8327-3 <=> P/J8302B-18
P/J8327-2 <=> P/J8302B-19
P/J8327-1 <=> P/J8302B-20
13 Check for +5 Vto the Lower Tray Upper Go to Step 14. Replace the
Limit Sensor. Finisher Main
14 Check Lower Tray Upper Limit Sensor Replace the Replace the
signal. Finisher Main Lower Tray Upper
Does the voltage across P8302B-19 <=> PWB Limit Sensor


Main PWB?


Print a Test Print.

Board
(page 8-89).

Stacker Lower Tray Failure - H5-13 Low Tray Lower
Limit
The Stacker Lower Tray descends beyond the specified lower limit position.

Stacker Lower Tray Failure - H5-13 Low Tray Lower Limit
Stacker Lower Trail Failure (Stacker Encoder Sensor) Troubleshooting Reference
Stack Height Sensor 1 Phaser 5500 Printer Options Service Manual

Stack Height Sensor 2 Finisher Main PWB P/J Locator (page 5-35)
Stacker Encoder Finisher Sensors (2/2) Wiring (page 5-41)
Sensor Finisher Clutch and Solenoids (page 5-43)
Finisher Main PWB PL25.6 Finisher Stack (page 4-54)
Main Sensor Harness PL25.14 Finisher Electrical (page 4-70)
Elevator Motor PL25.15 Finisher Harness (page 4-72)
Stacker Lower Trail Failure (Stacker Encoder Sensor) Troubleshooting Procedure
1 Check the Stacker Lower Tray vertical Remove any Go to Step 2.

transport and belts for obstacles and obstacles.
deformation.
2 Test the Stack Height Sensor 1 (top). Go to Step 8. Go to Step 3.

Run the Service Diagnostics Stack Height
1 test.
sensor is blocked?
NOTE: Sensor requires a 10 second
timeout between sensing events.
3 Check Stack Height Sensor 1 Sensor Go to Step 5. Connect and go



5 Check Stack Height Sensor 1 Sensor Go to Step 6. Repair the Stack

Harness continuity. Height Sensor 1
1. Disconnect P/J8331 on the Main Sensor Sensor Harness.
Harness, and P/J8302B on the Finisher
Main PWB.
P/J8331-5 <=> P/J8302B-1
P/J8331-4 <=> P/J8302B-2
P/J8331-3 <=> P/J8302B-3
P/J8331-2 <=> P/J8302B-4
P/J8331-1 <=> P/J8302B-5
6 Check for +5 V to Stack Height Sensor 1. Go to Step 7. Replace the

Is there +5 V across J8302B-3 <=> Finisher Main
J8302B-1 on the Finisher Main PWB? PWB
(page 3-248).
7 Check Stack Height Sensor 1 signal. Replace the Replace Stack

Does the voltage across P8302B-2 <=> Finisher Main Height Sensor 1
P8302B-1 on the Finisher Main PWB PWB (page 3-140).
8 Test the Stack Height Sensor 2 (bottom). Go to Step 14. Go to Step 9.

Run the Service Diagnostics Stack Height
Sensor 2 test.
NOTE: Sensor requires a 10 second
timeout between sensing events.
sensor is blocked?
9 Check Stack Height Sensor 2 Sensor Go to Step 11. Connect and go

Are P/J8330 and P/J8302A connected?

11 Check Stack Height Sensor 2 Sensor Go to Step 12. Repair the Stack
Harness continuity. Height Sensor 2
1. Disconnect P/J8330 on the harness, and Harness.
P/J8330-5 <=> P/J8302A-16
P/J8330-4 <=> P/J8302A-17
P/J8330-3 <=> P/J8302A-18
P/J8330-2 <=> P/J8302A-19
P/J8330-1 <=> P/J8302A-20

12 Check for +5 V to Stack Height Sensor 2. Go to Step 13. Replace the

(page 3-248).
13 Check Stack Height Sensor 2 signal. Replace the Replace Stack

Does the voltage across P8302A-17 <=> Finisher Main Height Sensor 2
14 Test the Stacker Encoder Sensor. Go to Step 20. Go to Step 15.

Run the Service Diagnostics Stacker
Encoder Sensor test.
Elevator Motor Belt is moved by hand
rotating the Encoder Wheel?
15 Check Stacker Encoder Sensor Harness Go to Step 17. Connect and go


17 Check Stacker Encoder Sensor Harness Go to Step 18. Repair the

continuity. Stacker Encoder
P/J8302B on the Finisher Main PWB.
P/J8328-3 <=> P/J8302B-12
P/J8328-2 <=> P/J8302B-13
P/J8328-1 <=> P/J8302B-14
18 Check for +5 V to Stacker Encoder Sensor. Go to Step 19. Replace the

Is the voltage across J8302B-14 <=> Finisher Main
J8302B-12 on the Finisher Main PWB? PWB
(page 3-248).
19 Check Stacker Encoder Sensor signal. Replace the Replace Stacker

Does the voltage across P8302B-13 and Finisher Main Encoder Sensor


Main PWB?


23 Replace the Elevator Motor. Replace the Problem solved.

(page 3-248).
Stacker Lower Tray Failure - H5-2n Front Home SNR

For H5-21, the Front Tamper Home Sensor is not turned On within 800 ms following
the Front Tamper beginning to move to the Front Tamper Home position. For H5-23,
the Front Tamper Home Sensor is not turned Off in the time specified following the
Front Tamper leaving the home position, or the Front Tamper Home Sensor is turned
On again after the Front Tamper Home Sensor is turned Off and the Front Tamper
stops moving.

Stacker Lower Tray Failure - H5-21 Front Home SNR ON
Stacker Lower Tray Failure - H5-23 Front Home SNR OFF
Tamper (Front Tamper Home Sensor) Troubleshooting Reference
Front Tamper Home Phaser 5500 Printer Options Service Manual

Compiler Tray Assembly Finisher Compiler P/J Locator (page 5-33)
Front Tamper Motor PL25.14 Finisher Electrical (page 4-70)
Tamper (Front Tamper Home Sensor) Troubleshooting Procedure
1 Check the Tamper mechanism. Go to Step 2. Repair or replace

Move the Front Tamper mechanism. the Compiler Tray
Does the Tamper mechanism operate (page 3-177).
smoothly?

Tamper (Front Tamper Home Sensor) Troubleshooting Procedure (Continued)
2 Test the Front Tamper Home Sensor. Go to Step 8. Go to Step 3.

Run the Service Diagnostics Front Tamper
Home Sensor test.
sensor is blocked?
3 Check the Compiler harness connections. Go to Step 5. Connect and go


5 Check Compiler Front Tamper Harness Go to Step 6. Repair the

continuity. Compiler Front
1. Disconnect P/J8360 on the harness and Tamper Harness.
P/J8309 on the Finisher Main PWB.
P/J8360-3 <=> P/J8309-4
P/J8360-2 <=> P/J8309-5
P/J8360-1 <=> P/J8309-6
6 Check for +5 V to the Front Tamper Home Go to Step 7. Replace the

7 Check Front Tamper Home Sensor signal. Replace the Replace the Front
Does the voltage across P8309-5 <=> Finisher Main Tamper Home
P8309-4 on the Finisher Main PWB PWB Sensor
8 Test the Front Tamper Motor. Replace the Go to Step 9.

Run the Service Diagnostics Front Tamper Finisher Main
Motor Low Speed Inboard and Outboard PWB
tests alternately. (page 3-248).
Does the Front Tamper Motor rotate,
and the Tamper move front to rear?
9 Check Compiler Front Tamper Motor Go to Step 11. Connect and go

Are P/J8363B and P/J8309 connected?


Tamper (Front Tamper Home Sensor) Troubleshooting Procedure (Continued)
11 Check Compiler Front Tamper Motor Go to Step 12. Repair the

Harness continuity. Compiler Front
1. Disconnect P/J8363B and P/J8309. Tamper Motor
Harness.
P/J8363B-6 <=> P/J8309-10
P/J8363B-5 <=> P/J8309-11
P/J8363B-4 <=> P/J8309-12
P/J8363B-3 <=> P/J8309-13
P/J8363B-2 <=> No connection
P/J8363B-1 <=> P/J8309-14
12 Check for +24 V to the Front Tamper Motor. Go to Step 13. Replace the
ground on the Finisher Main PWB? PWB
(page 3-248).
13 Replace the Front Tamper Motor. Replace the Problem solved.

(page 3-248).
Stacker Lower Tray Failure - H5-2n Rear Home SNR

For H-22, the Rear Tamper Home Sensor is not turned On within 800 ms following
the Rear Tamper beginning to move to the Rear Tamper Home position. For H5-24,
the Rear Tamper Home Sensor is not turned Off in the time specified following the
Rear Tamper leaving the home position, or the Rear Tamper Home Sensor is turned
On again after the Rear Tamper Home Sensor is turned Off and the Rear Tamper stops
moving.

Stacker Lower Tray Failure - H5-22 Rear Home SNR ON
Stacker Lower Tray Failure - H5-24 Rear Home SNR OFF
Tamper (Rear Tamper Home Sensor) Troubleshooting Reference
Rear Tamper Home Phaser 5500 Printer Options Service Manual

Compiler Tray Assembly Finisher Compiler P/J Locator (page 5-33)
Rear Tamper Motor PL25.14 Finisher Electrical (page 4-70)

Tamper (Rear Tamper Home Sensor) Troubleshooting Procedure
1 Check the Tamper mechanism. Go to Step 2. Repair or replace

Move the Rear Tamper mechanism. the Compiler Tray
Does the Tamper mechanism operate (page 3-177).
smoothly?
2 Test the Rear Tamper Home Sensor. Go to Step 8. Go to Step 3.

Run the Service Diagnostics Rear Tamper
Home Sensor test.
sensor is blocked?
3 Check the Compiler harness connections. Go to Step 5. Connect and go


5 Check Compiler Rear Tamper Harness Go to Step 6. Repair the

continuity. Compiler Rear
1. Disconnect P/J8361 on the harness and Tamper Harness.
P/J8309 on the Finisher Main PWB.
P/J8361-3 <=> P/J8309-7
P/J8361-2 <=> P/J8309-8
P/J8361-1 <=> P/J8309-9
6 Check for +5 V to the Rear Tamper Home Go to Step 7. Replace the

7 Check Rear Tamper Home Sensor signal. Replace the Replace the Rear
Does the voltage across P8309-8 <=> Finisher Main Tamper Home
P8309-7 on the Finisher Main PWB PWB Sensor
8 Test the Rear Tamper Motor. Replace the Go to Step 9.

Run the Service Diagnostics Rear Tamper Finisher Main
Motor Low Speed Inboard and Outboard PWB
tests alternately. (page 3-248).
Does the Rear Tamper Motor rotate, and
the Tamper move front to rear?
9 Check Compiler Rear Tamper Motor Go to Step 11. Connect and go



Tamper (Rear Tamper Home Sensor) Troubleshooting Procedure (Continued)
11 Check Compiler Rear Tamper Motor Go to Step 12. Repair the

Harness continuity. Compiler
J8362B-6 <=> P/J8309-15
J8362B-5 <=> P/J8309-16
J8362B-4 <=> P/J8309-17
J8362B-3 <=> P/J8309-18
J8362B-2 <=> Non connection
J8362B-1 <=> P/J8309-19
12 Check for +24 V to the Rear Tamper Motor. Go to Step 13. Replace the
(page 3-248).
13 Replace the Front Tamper Motor. Replace the Problem solved.

(page 3-248).
Punch Failure - H5-3n SNR

The Punch Home Sensor is not turned On (H5-31) or Off (H5-32) within the specified
time after Punch Motor activation.

Punch Failure - H5-31 SNR ON
Punch Failure - H5-32 SNR OFF
Punch Failure (Punch Home Sensor) Troubleshooting Reference
Punch Home Sensor Phaser 5500 Printer Options Service Manual

Punch Harness Finisher Main PWB P/J Locator (page 5-35)
Punch Sensor Finisher Punch P/J Locator (page 5-31)
Harness Finisher Punch (2/2) Wiring (page 5-47)
Finisher Main PWB PL25.7 Finisher Punch (page 4-56)
Punch Motor PL25.14 Finisher Electrical (page 4-70)
Punch Drive Harness PL25.15 Finisher Harness (page 4-72)

Punch Failure (Punch Home Sensor) Troubleshooting Procedure
1 Check the Punch operation. Go to Step 2. Correct the

Does the punch move smoothly? installation.
2 Test the Punch Home Sensor. Go to Step 9. Go to Step 3.

Run the Service Diagnostics Punch Home
Sensor test.
Does the sensor change state when the
sensor is blocked?
3 Check Punch Home Sensor harness Go to Step 5. Connect and go

Are P/J8348 and P/J8333 on the Punch
Harness, and P/J8333 and P/J8307 on
the Punch Sensor Harness connected?

5 Check Punch Home Sensor Harness Go to Step 6. Repair the Punch

continuity. Home Sensor
P/J8348-3 <=> P/J8333-7
P/J8348-2 <=> P/J8333-8
P/J8348-1 <=> P/J8333-9
6 Check Punch Home Sensor Harness Go to Step 7. Repair the Punch

continuity. Home Sensor
P/J8333-7 <=> P/J8307-B6
P/J8333-8 <=> P/J8307-B5
P/J8333-9 <=> P/J8307-B4
7 Check for +5 V to the Punch Home Sensor. Go to Step 8. Replace the

Is there +5 V across J8307-B6 <=> Finisher Main
J8307-B5 on the Finisher Main PWB? PWB
(page 3-248).
8 Check the Punch Home Sensor signal. Replace the Replace the
Does the voltage across P8307-B4 <=> Finisher Main Punch Home
P8307-B5 on the Finisher Main PWB PWB Sensor
9 Test the Punch Motor. Replace the Go to Step 10.

Run the Service Diagnostics Punch Unit Finisher Main
Motor Front and Rear tests. PWB
Does the Punch Motor rotate? (page 3-248).

Punch Failure (Punch Home Sensor) Troubleshooting Procedure (Continued)

Are P/J8345 and P/J8332 on the Punch to Step 11.
Harness, and P/J8332 and P/J8306 on
the Punch Drive Harness connected?

12 Check Punch Motor Harness continuity. Go to Step 13. Repair the Punch
P/J8345-2 <=> P/J8332-2
P/J8345-1 <=> P/J8332-1
13 Check Punch Motor Drive Harness Go to Step 14. Repair the Punch
continuity. Motor Drive
P/J8332-2 <=> P/J8306-8
P/J8332-1 <=> P/J8306-7
14 Replace the Punch Motor. Replace the Problem solved.

Punch a Test Print. Finisher Main
(page 3-248).
Punch Failure - H5-3n Home SNR

The Punch Unit Move Home Sensor does not change state within the specified time
following activation of the Punch Move Motor or the Move Home sensor changes
state after the Punch Move Motor has stopped.

Punch Failure - H5-33 Home SNR ON
Punch Failure - H5-34 Home SNR OFF

Punch Failure (Punch Move Home Sensor) Troubleshooting Reference
Punch Unit Move Phaser 5500 Printer Options Service Manual

Home Sensor Finisher Main PWB P/J Locator (page 5-35)
Punch Sensor Finisher Punch P/J Locator (page 5-31)
Harness
Finisher Punch (1/2) Wiring (page 5-46)
Punch Motor Bracket
Punch Drive Harness
Punch Failure (Punch Move Home Sensor) Troubleshooting Procedure
1 Check the Punch Unit operation. Go to Step 2. Correct the

Slide the Punch Unit in and out. installation.
Does the Punch Unit move smoothly?
2 Test the Punch Unit Move Home Sensor. Go to Step 8. Go to Step 3.

Run the Service Diagnostics Punch Unit
Move Home Sensor test.
Does the sensor state when the sensor
is blocked?
3 Check Punch Unit Move Home Sensor Go to Step 5. Connect and go


5 Check Punch Unit Move Home Sensor Go to Step 6. Repair the Punch
Harness continuity. Unit Move Home
P/J8352-3 <=> P/J8307-A6
P/J8352-2 <=> P/J8307-A5
P/J8352-1 <=> P/J8307-A4
6 Check for +5 V to the Punch Unit Move Go to Step 7. Replace the

Home Sensor. Finisher Main
Is there +5 V across J8307-A4 <=> PWB
J8307-A6 on the Finisher Main PWB? (page 3-248).
7 Check the Punch Home Sensor signal. Replace the Replace the
Does the voltage across P8307-A5 <=> Finisher Main Punch Unit Move
P8307-A6 on the Finisher Main PWB PWB Home Sensor

Punch Failure (Punch Move Home Sensor) Troubleshooting Procedure (Continued)
8 Test the Punch Move Motor. Replace the Go to Step 9.

Run the Service Diagnostics Front and Finisher Main
Rear Punch Move Motor tests. PWB
Does the Punch Move Motor rotate and (page 3-248).
the Punch frame move?
9 Check Punch Motor Harness connections. Go to Step 11. Connect and go


11 Check Punch Motor Harness continuity. Go to Step 12. Repair the Punch
1. Disconnect P/J8344 and P/J8306. Motor Harness.
P/J8344-1 <=> P/J8306-7
P/J8344-2 <=> P/J8306-3
P/J8344-3 <=> P/J8306-6
P/J8344-4 <=> P/J8306-5
P/J8344-5 <=> P/J8306-2
P/J8344-6 <=> P/J8306-1
12 Replace the Punch Move Motor. Go to Step 13. Problem solved.

Punch a Test Print.

Does the error still occur? Finisher Main
PWB
(page 3-248).
Stacker Lower Tray Failure - H5-8n Eject Clamp SNR

The Eject Clamp Home Sensor does not change state within the time interval
specified following the activation of the Eject Clamp.

Stacker Lower Tray Failure - H5-81 Eject Clamp SNR ON
Stacker Lower Tray Failure - H5-82 Eject Clamp SNR OFF

Eject Clamp Failure (Eject Clamp Home Sensor) Troubleshooting Reference
Eject Clamp Home Phaser 5500 Printer Options Service Manual

Eject Clamp Sensor Finisher Input Drive P/J Locator (page 5-32)
Harness
Finisher Sensors (2/2) Wiring (page 5-41)
Finisher Main PWB Finisher Clutch and Solenoids Wiring (page 5-43)
Eject Clamp Motor
Eject Clamp Motor
Harness PL25.14 Finisher Electrical (page 4-70)
Eject Clamp Failure (Eject Clamp Home Sensor) Troubleshooting Procedure
1 Check the Eject Clamp operation. Go to Step 2. Correct the

Rotate the Eject Clamp Motor. installation.
Does the Eject Clamp move smoothly?
2 Test the Eject Clamp Home Sensor. Go to Step 8. Go to Step 3.

Home Sensor test.
3 Check Eject Clamp Sensor Harness Go to Step 5. Connect and go


5 Check Eject Clamp Sensor Harness Go to Step 6. Repair the Eject

continuity. Clamp Sensor
1. Disconnect P/J8324 and P/J8302B. Harness.
P/J8324-3 <=> P/J8302B-6
P/J8324-2 <=> P/J8302B-7
P/J8324-1 <=> P/J8302B-8
6 Check for +5 V to the Eject Clamp Home Go to Step 7. Replace the

7 Check the Eject Clamp Home Sensor Replace the Replace the Eject
signal. Finisher Main Clamp Home
Does the voltage across P8302B-7 <=> PWB Sensor

Eject Clamp Failure (Eject Clamp Home Sensor) Troubleshooting Procedure
8 Test the Eject Clamp Motor. Replace the Go to Step 9.

Run the Service Diagnostics Up and Down Finisher Main
Eject Clamp Motor tests. PWB
Does the Eject Clamp Motor rotate (page 3-248).
normally?
9 Check Eject Clamp Motor Harness Go to Step 11. Connect and go


11 Check Eject Clamp Motor Harness Go to Step 12. Repair the Eject
continuity. Clamp Motor
P/J8339-1 <=> P/J8304-33
P/J8339-2 <=> P/J8304-31
12 Check Eject Clamp Motor voltage. Go to Step 13. Replace the

Is there +24 V across P/J8304-31 and -33 Finisher Main
<=> P/J8302A-1? PWB
(page 3-248).

(page 3-248).
Stacker Lower Tray Failure - H5-8n Set Clamp SNR

The Set Clamp Home Sensor does not change state within the time interval specified
following the start or stop of the Set Clamp.

Stacker Lower Tray Failure - H5-83 Set Clamp SNR ON
Stacker Lower Tray Failure - H5-84 Set Clamp SNR OFF

Eject Clamp (Set Clamp Home Sensor) Troubleshooting Reference
Set Clamp Home Phaser 5500 Printer Options Service Manual

Main Sensor Harness Finisher Compiler P/J Locator (page 5-33)
Finisher Main PWB Finisher Sensors (2/2) Wiring (page 5-41)
Eject Bracket Finisher Clutch and Solenoids Wiring (page 5-43)
Assembly
Main Drive Harness
Set Clamp Clutch PL25.15 Finisher Harness (page 4-72)
Eject Clamp (Set Clamp Home Sensor) Troubleshooting Procedure
1 Check the Eject Clamp operation. Go to Step 2. Correct the

Rotate the Eject Clamp Motor. installation.
Does the Eject Clamp move smoothly?
2 Test the Set Clamp Home Sensor. Go to Step 8. Go to Step 3.

Run the Service Diagnostics Set Clamp
Home Sensor test.
3 Check the Set Clamp Home Sensor Go to Step 5. Connect and go


5 Check the Set Clamp Home Sensor Go to Step 6. Repair the Set
Harness continuity. Clamp Home
P/J8325-3 <=> P/J8302B-4
P/J8325-2 <=> P/J8302B-9
P/J8325-1 <=> P/J8302B-11
6 Check for +5 V to the Set Clamp Home Go to Step 7. Replace the

J8302B-9 on the Finisher Main PWB for (page 3-248).
H5-83?
Is there +5 V across J8302B-4 <=>

J8302B-9 on the Finisher Main PWB for
H5-84?

Eject Clamp (Set Clamp Home Sensor) Troubleshooting Procedure (Continued)
7 Check the Set Clamp Home Sensor signal. Replace the Replace the Set
Does the voltage across P8302B-11<=> Finisher Main Clamp Home
P8302B-9 on the Finisher Main PWB PWB Sensor

Run the Service Diagnostics Low Speed
Forward and Reverse Eject Motor tests.
Does the Eject Motor rotate normally?
9 Check Eject Motor Harness connections. Go to Step 11. Connect and go


11 Check Eject Motor Harness continuity. Go to Step 12. Repair the Eject
P/J8336-1 <=> P/J8304-15
P/J8336-2 <=> P/J8304-12
P/J8336-3 <=> P/J8304-17
P/J8336-4 <=> P/J8304-19
P/J8336-5 <=> P/J8304-14
P/J8336-6 <=> P/J8304-21

Is there resistance across P8336-2/ Bracket Assembly
5(COM) and P8336-1/3/4/6? (page 3-187).

(page 3-248).
15 Test the Set Clamp Clutch (Clutch Z34). Replace the Go to Step 16.
Run the Service Diagnostics Set Clamp Finisher Main
Clutch test. PWB
Does the Set Clamp Clutch operate? (page 3-248).
16 Check the Set Clamp Clutch Harness Go to Step 18. Connect and go
Are P/J8338B and P/J8304 connected?
17 Print a test Print. Go to Step 18. Problem solved.


Eject Clamp (Set Clamp Home Sensor) Troubleshooting Procedure (Continued)
18 Check Set Clamp Clutch Harness Go to Step 19. Repair the Set
continuity. Clamp Clutch
1. Disconnect P/J8338B and P/J8304. Harness.
J8338B-1 <=> P/J8304-20
J8338B-2 <=> P/J8304-22
19 Check for +24 V to the Set Clamp Clutch. Go to Step 20. Replace the
(page 3-248).
20 Replace the Set Clamp Clutch. Replace the Problem solved.

(page 3-248).
Stacker Lower Tray Failure - H5-86 Side Regi SNR OFF

Either or both Side Registration Sensors do not transition within the time interval
specified (500 ms) following activation of the Punch Move Motor or the state changes
to On after the Punch Move Motor stops.

Stacker Lower Tray Failure - H5-86 Side Regi SNR OFF
Punch Failure (Side Registration Sensors) Troubleshooting Reference
Punch Move Motor Phaser 5500 Printer Options Service Manual

Punch Drive Harness Finisher Main PWB P/J Locator (page 5-35)
Finisher Main PWB Finisher Punch P/J Locator (page 5-31)
Engine Logic Board Finisher Punch (1/2) Wiring (page 5-46)
Side Registration Finisher Punch (2/2) Wiring (page 5-47)
Sensors PL8.1 Print Engine Electrical (page 9-40)
Punch Sensor PL25.7 Finisher Punch (page 4-56)
Harness PL25.14 Finisher Electrical (page 4-70)
Punch Unit Harness PL25.15 Finisher Harness (page 4-72)

Punch Failure (Side Registration Sensors) Troubleshooting Procedure
1 Check the Punch operation. Go to Step 2. Correct the

Move the Punch Unit in and out. installation.
Does the punch move smoothly?
2 Test the Punch Move Motor. Go to Step 8. Go to Step 3.

Run the Service Diagnostics Front and
Rear Punch Move Motor tests.
Does the Punch Move Motor rotate and
the Punch frame move?
3 Check Punch Move Motor Harness Go to Step 5. Connect and go


5 Check Punch Move Motor Harness Go to Step 6. Repair the Punch

continuity. Move Motor
P/J8344-1 <=> P/J8306-7
P/J8344-2 <=> P/J8306-3
P/J8344-3 <=> P/J8306-6
P/J8344-4 <=> P/J8306-5
P/J8344-5 <=> P/J8306-2
P/J8344-6 <=> P/J8306-1
6 Replace the Bracket Assy-Motor, Punch. Go to Step 7. Problem solved.

Print a Test Print.

Does the error still occur? Finisher Main
PWB
(page 3-248).
8 Test the Side Regi Sensor 1. Replace the Go to Step 9.

Run the Service Diagnostics Side Finisher Main
Registration Sensor 1 test. PWB
Does the state change when the sensor (page 3-248).
is blocked?
9 Test the Side Regi Sensor 2. Replace the Go to Step 10.

Run the Service Diagnostics Side Finisher Main
Registration Sensor 2 test. PWB
Does the state change when the senor (page 3-248).
is blocked?

Punch Failure (Side Registration Sensors) Troubleshooting Procedure (Continued)

Are P/J8307, P/J8333 and P/J8350 (for to Step 11.
Side Regi Sensor 1), and P/J8351 (for
Side Regi Sensor 2) connected?

12 Check Main Punch Sensor continuity. Go to Step 13. Repair the Main
Disconnect P/J8307 and P/J8333. Punch Sensor
Is there continuity on each wire Harness.
between J8307 <=> J8333?
13 Check Side Regi Sensor continuity. Go to Step 14. Repair the Punch
1. Disconnect P/J8333, P/J8350 (Side Unit Harness.
Regi Sensor 1), and P/J8351 (Side Regi
Sensor 2).
P/J8333-13 <=> P/J8350-3
P8333-14 <=> P/J8350-2
P8333-15 <=> P/J8350-1
P8333-16 <=>P/J8351-3
P8333-17 <=> P/J8351-2
P8333-18 <=> P/J8351-1
14 Check for +5 V at Side Regi Sensor 1 Go to Step 16 Go to Step 18

Is there +5 V between P/J8307-A10 <=>
P/J8307-A12?
15 Check for +5 V at Side Regi Sensor 2 Go to Step 17 Go to Step 18.

Is there +5 V between P/J8307-A7 <=> P/
J8307-A9?
16 Replace the Side Registration Sensor 1. Go to Step 18. Problem solved.

Print a Test Print.
17 Replace the Side Registration Sensor 2. Go to Step 18. Problem solved.

Print a Test Print.

Board
(page 8-89).

Stapler Failure - H5-91 Staple Fail
The Stapler Home Sensor state is not detected within the specified time after a Stapler
Move Motor forward operation, or the Stapler Home Sensor is not turned ON within
the specified time following a Stapler Move Motor reverse operation.

Stapling Failure - H5-91 Staple Fail
Stapler Failure (Stapler Home Sensor) Troubleshooting Reference
Stapler Assembly Phaser 5500 Printer Options Service Manual

Staple Home Position Finisher Main PWB P/J Locator (page 5-35)
Sensor Finisher Staple P/J Locator (page 5-30)
Staple Motor Finisher Stapler Wiring (page 5-45)
Stapler Harness PL8.1 Print Engine Electrical (page 9-40)
Finisher Main PWB PL25.8 Finisher Staple (page 4-58)
Stapler Failure (Stapler Home Sensor) Troubleshooting Procedure
1 Test the Stapler Assembly. Go to Step 5. Go to Step 2.

Run the Service Diagnostics Staple Motor
Forward and Reverse tests.
Does the Stapler Motor rotate normally?
2 Check the Staple Motor Harness Go to Step 4. Connect and go


4 Check the Staple Motor Harness continuity Go to Step 9. Repair the Staple
P/J8357-1 <=> P/J8308-10
P/J8357-2 <=> P/J8308-9
P/J8357-3 <=> P/J8308-8
P/J8357-4 <=> P/J8308-7
5 Test the Staple Head Home Sensor. Replace the Go to Step 6.

Run the Service Diagnostics Staple Head Finisher Main
Home Sensor test. PWB
staple gear is rotated?

Stapler Failure (Stapler Home Sensor) Troubleshooting Procedure (Continued)
6 Check the Staple Harness connections. Go to Step 8. Connect and go

7 Staple a Test Print. Go to Step 8. Problem solved.

8 Check Staple Harness continuity. Go to Step 9. Repair the Staple

P/J8356-1 <=> P/J8308-15
P/J8356-2 <=> P/J8308-14
P/J8356-3 <=> P/J8308-13
P/J8356-4 <=> P/J8308-12
P/J8356-5 <=> P/J8308-11
9 Replace the Stapler Assembly. Go to Step 10. Problem solved.

Staple a Test Print.

Board
(page 8-89).
Stapler Failure - H5-9n Move SNR

The Staple Move Position Sensor does not change state in the specified time interval
after the Stapler Head starts moving toward or reaching the staple position. This error
also occurs if the Stapler Move Position Sensor is turned OFF again after being ON
and the Stapler Head is stopped.

Stapling Failure - H5-95 Move SNR ON
Stapling Failure - H5-96 Move SNR OFF
Stapler Failure (Staple Move Position Sensor) Troubleshooting Reference
Stapler Lower Carriage Phaser 5500 Printer Options Service Manual

Move Home Position Finisher Main PWB P/J Locator (page 5-35)
Sensor Finisher Staple P/J Locator (page 5-30)
Stapler Harness Finisher Stapler Wiring (page 5-45)
Finisher Main PWB PL25.8 Finisher Staple (page 4-58)

Stapler Failure (Staple Move Position Sensor) Troubleshooting Procedure
1 Check Staple Head motion. Go to Step 2. Remove

Slide the Staple Head across the rails. obstacles or
Does the Staple Head move smoothly? repair motion.
2 Test the Staple Move Motor. Go to Step 7. Go to Step 3.

Run the Service Diagnostics Staple Move
Motor mid speed Front and Rear tests.
Does the Staple Head Jog?
3 Check the Staple Move Motor Harness Go to Step 5. Connect and go


5 Check Staple Move Motor Harness Go to Step 6. Repair the Staple

continuity. Move Motor
P/J8358-1 <=> P/J8308-3
P/J8358-2 <=> P/J8308-6
P/J8358-3 <=> P/J8308-5
P/J8358-4 <=> P/J8308-1
P/J8358-5 <=> P/J8308-4
P/J8358-6 <=> P/J8308-2
6 Replace the Stapler Lower Carriage. Replace the Problem solved.

Staple a Test Print. Finisher Main
(page 3-248).
7 Test the Staple Move Position Sensor. Replace the Go to Step 8.

Run the Service Diagnostics Staple Move Finisher Main
Position Sensor test. PWB
8 Check the Staple Move Position Sensor Go to Step 10. Connect and go


Stapler Failure (Staple Move Position Sensor) Troubleshooting Procedure
10 Check Staple Move Position Sensor Go to Step 11. Repair the Staple
Harness continuity. Move Position
1. DisconnectP/J8354 and P/J8308. Sensor Harness.
P/J8354-1 <=> P/J8308-18
P/J8354-2 <=> P/J8308-17
P/J8354-3 <=> P/J8308-16
11 Check for +5 V to the Stapler Move Go to Step 12. Replace the

Position Sensor. Finisher Main
12 Check the Stapler Move Home Position Replace the Replace the
Sensor signal. Finisher Main Staple Move
Does the voltage across J8308-17 <=> PWB Position Sensor
J8308-16 on the Finisher Main PWB (page 3-248). (page 3-162)
change when the sensor is blocked by
moving the Stapler Head.
Tray 6 Logic Board Failure - H6-4 NVM R/W Error

A read/write error has occurred in the NVRAM located on the Tray 6 PWB.

Tray 6 Logic Board Failure - H6-4 NVM R/W Error
Tray 6 NVRAM Error Troubleshooting Reference
Tray 6 PWB Phaser 5500 Printer Options Service Manual

2000-Sheet Tray 6 Drive P/J Locator (page 5-21)
2000-Sheet Tray 6 Drive Wiring (page 5-25)
Tray 6 Comm Error Troubleshooting Procedure
1 Cycle printer power. Go to Step 2. Problem solved.


Tray 6 Comm Error Troubleshooting Procedure (Continued)
2 Check the Tray 6 PWB connections. Go to Step 4. Connect and go

Are the connectors connected to the to Step 3.
PWB?

4 Disconnect all the connectors connected to Replace the Tray 6 Problem solved.
the Tray 6 PWB and reconnect them. PWB (page 3-67).
Cycle printer power.
Tray 6 Logic Board Failure - H6-7 HCF Comm Failure

A communications error occurred between Tray 6 and the Engine Logic Board.

Tray 6 Logic Board Failure - H6-7 HCF Comm Failure
Tray 6 Comm Error Troubleshooting Reference
Tray 6 PWB Print Engine P/J Engine Logic Board (page 10-13)
2000-Sheet Tray 6 Drive P/J Locator (page 5-21)
2000-Sheet Tray 6 Drive Wiring (page 5-25)
Tray 6 NVRAM Error Troubleshooting Procedure
1 Check the Tray 6 installation. Go to Step 2. Correct the

Is Tray 6 installed correctly? installation. If
problem persists,
go to Step 2.

3 Check the Tray 6 PWB connections. Go to Step 4. Connect and go

Are P/J800A, P/J800B, P/J800 and P/ to Step 4.
J414 connected?

Tray 6 NVRAM Error Troubleshooting Procedure (Continued)
4 Check continuity between the Tray 6 PWB Go to Step 5. Repair the wiring.
P/J800A <=> P/J415
P/J800B <=> P/J415
P/J800 <=> P/J414
5 Disconnect all the connectors connected to Replace the Tray 6 Replace the
the Tray 6 PWB and reconnect them. PWB (page 3-67). Engine Logic
Cycle printer power. Board
Tray 4-5 Logic Board Failure - NVM

A read/write error has occurred in the NVRAM located on the Tray 4-5 PWB.

Tray 4-5 Logic Board Failure - H7-3 NVM out-of-order
Tray 4-5 Logic Board Failure - H7-4 NVM R/W Error
Tray 4-5 NVRAM Error Troubleshooting Reference
Tray 4-5 PWB Print Engine P/J Engine Logic Board (page 10-13)
1000-Sheet Electrical P/J Locator (page 5-6)
1000-Sheet Drive Wiring (page 5-8)
Tray 4-5 NVRAM Error Troubleshooting Procedure
1 Cycle the printer power. Go to Step 3. Problem solved.



Tray 4-5 NVRAM Error Troubleshooting Procedure (Continued)
1. DisconnectP/J413 and P/J541.
P/J413-A1 <=> P/J541-1
P/J413-A2<=> P/J541-2
P/J413-A3 <=> P/J541-3
P/J413-A4 <=> P/J541-4
P/J413-A5 <=> P/J541-5
P/J413-A6 <=> P/J541-6
P/J413-B1 <=> P/J541-7
P/J413-B2 <=> P/J541-8
P/J413-B3 <=> P/J541-9
P/J413-B4 <=> P/J541-10
P/J413-B5 <=> P/J541-11
P/J413-B6 <=> P/J541-12
4 Check for +5 V to the Tray 4-5 PWB. Replace the Tray Replace the
Is there +5 V across P/J413-A5 (+) <=> 4-5 PWB Engine Logic
(page 8-89).
Tray 4-5 Logic Board Failure - H7-7 Comm Failure

Communications error between 1000-Sheet Feeder and the Engine Logic Board.

Tray 4-5 Logic Board Failure - H7-7 Comm Failure
Tray 4-5 Comm Failure Troubleshooting Reference

Tray 4-5 Comm Failure Troubleshooting Procedure
1 Check the 1000-Sheet Feeder installation. Problem solved. Go to Step 2.

Disconnect P/J413 from the Printer and
reconnect it.
Does the 1000-Sheet Feeder operate?
2 Check the Tray 4-5 PWB connection. Go to Step 3. Connect P/J413.

1. DisconnectP/J413 and P/J541.
P/J413-A1 <=> P/J541-1
P/J413-A2<=> P/J541-2
P/J413-A3 <=> P/J541-3
P/J413-A4 <=> P/J541-4
P/J413-A5 <=> P/J541-5
P/J413-A6 <=> P/J541-6
P/J413-B1 <=> P/J541-7
P/J413-B2 <=> P/J541-8
P/J413-B3 <=> P/J541-9
P/J413-B4 <=> P/J541-10
P/J413-B5 <=> P/J541-11
P/J413-B6 <=> P/J541-12
(page 8-89).
Incorrect Tray 4-5 Installed - H7-8 Type Error

The 1000-Sheet Feeder is not recognized as the proper type for the printer.

Incorrect Tray 4-5 Installed - H7-8 Type Error

Incorrect Tray 4-5 Troubleshooting Reference
Incorrect Tray 4-5 Troubleshooting Procedure
1 Check the Tray 4-5 installation. Go to Step 2. Problem solved.

Disconnect the 1000-Sheet Feeder from
the Printer and reconnect it.
2 Check the settings of the Dip Switch SW1 Go to Step 3. Correct the
on the Tray 4-5 PWB. Switch settings. If
SW1-1 is in the Left position problem persists,
SW1-2 is in the Right position go to Step 3.
SW1-3 is in the Right position
SW1-4 is in the Left position
Are the switches set correctly?
3 Check Tray 4-5 PWB connections. Go to Step 4. Connect P/J541.

P/J413-A1 <=> P/J541-1
P/J413-A2<=> P/J541-2
P/J413-A3 <=> P/J541-3
P/J413-A4 <=> P/J541-4
P/J413-A5 <=> P/J541-5
P/J413-A6 <=> P/J541-6
P/J413-B1 <=> P/J541-7
P/J413-B2 <=> P/J541-8
P/J413-B3 <=> P/J541-9
P/J413-B4 <=> P/J541-10
P/J413-B5 <=> P/J541-11
P/J413-B6 <=> P/J541-12
(page 8-89).

Tray N Failure - H8-1, 2 Tray Size Sensor Broken
Paper size detection has failed in Tray 2 or Tray 3.

Tray 2 Failure - H8-1 Tray 2 Size Sensor Broken
Tray Failure (Tray 2-3 Paper Size Switch) Troubleshooting Reference
Paper Size Print Engine P/J Engine Logic Board (page 10-13)
Switch Print Engine P/J Locator Electrical (page 10-12)
Engine Logic PL2.1 Tray (1/2) Feeder (1/2) (page 9-8)
Tray Failure (Tray 2-3 Paper Size Switch) Troubleshooting Procedure

For Tray 3:

Tray Failure (Tray 2-3 Paper Size Switch) Troubleshooting Procedure (Continued)

Board.
For Tray 2:
P/J109-1 <=> P/J412-4
P/J109-2 <=> P/J412-3
P/J109-3 <=> P/J412-2
P/J109-4 <=> P/J412-1
For Tray 3:
P/J110-1 <=> P/J412-9
P/J110-2 <=> P/J412-8
P/J110-3 <=> P/J412-7
P/J110-4 <=> P/J412-6
6 Check for +5 V to the Paper Size Switch. Replace the Paper Replace the
Is there +5 V across J109-1 (+) <=> affected tray Board
For Tray 3:
Is there +5 V across J110-1 (+) <=>
ground?
Tray N Failure - H8-3, 4 Tray Size Sensor Broken

Paper size detection has failed in Tray 4 or Tray 5.


Tray Failure (Tray 4-5 Paper Size Switch) Troubleshooting Reference
1000-Sheet Feeder P/J Locator (page 5-5)
1000-Sheet Feeder P/J Electrical (page 5-6)
1000-Sheet Tray 4 & 5 Wiring (page 5-9)
PL20.2 Tray (1/2) Feeder (1/2) (page 4-6)
Tray Failure (Tray 4-5 Paper Size Switch) Troubleshooting Procedure

For Tray 5:


Board.
For Tray 4:
P/J820-1 <=> P/J548-14
P/J820-2 <=> P/J548-13
P/J820-3 <=> P/J548-12
P/J820-4 <=> P/J548-11
For Tray 5:
P/J824-1 <=> P/J548-7
P/J824-2 <=> P/J548-6
P/J824-3 <=> P/J548-5
P/J824-4 <=> P/J548-4
6 Check for +3.3 V to the Paper Size Switch. Replace the Paper Replace the
Is there +3.3 V across P/J820-1 (+) <=> affected tray. Board
For Tray 5:
ground?

P/J541-1 <=> P/J413-A1
P/J541-2 <=> P/J413-A2
P/J541-3 <=> P/J413-A3
P/J541-4 <=> P/J413-A4
P/J541-5 <=> P/J413-A5
P/J541-6 <=> P/J413-A6
P/J541-7 <=> P/J413-B1
P/J541-8 <=> P/J413-B2
P/J541-9 <=> P/J413-B3
P/J541-10 <=> P/J413-B4
P/J541-11 <=> P/J413-B5
P/J541-12 <=> P/J413-B6

9 Check for +5 V to the Tray 4-5 PWB Replace the Tray Replace the
Is there +5 V across P/J413-A5 (+) <=> 4-5 PWB Engine Logic
(page 8-89).

For Tray 5:
Toner Empty- J1-2 Toner Empty

The Toner Cartridge is empty.

Toner Empty - J1-2 Toner Empty
Toner Empty Troubleshooting Reference
Toner Cartridge Print Engine P/J Drum and Toner (page 10-6)
Toner Dispense Print Engine P/J Engine Logic Board (page 10-13)
Toner Dispense Motor Print Engine Drive/CRUM Wiring (page 10-25)
Toner CRUM PWB PL5.1 Laser, CRU and Toner Dispense (page 9-32)
Toner Empty Troubleshooting Procedure
1 Check remaining toner. Go to Step 2. Replace the

Does the Toner Cartridge contain Toner Cartridge.
sufficient toner?

Remove the Toner Cartridge and reinstall.
3 Check the gear of the Toner Dispense Go to Step 4. Restore proper

Assembly. operation.
Does the gear of the Toner Dispense
Assembly rotate smoothly?

Toner Empty Troubleshooting Procedure (Continued)
4 Check the Toner Dispense Assembly for Clean the tube. Go to Step 5.
clogging.
Is the tube located at the lower part of
5 Check the Toner CRUM PWB installation. Go to Step 6. Correct the

Is the Toner CRUM PWB installed installation.
correctly?
6 Check the Toner CRUM PWB connections. Go to Step 7. Connect P127

Are P127 and P/J419 connected? and P/J419.
7 Check continuity between the Toner CRUM Go to Step 8. Repair the wiring.
1. Disconnect P/127 and P/J419.
P127-6 <=> P/J419-6
P127-5 <=> P/J419-7
P127-4 <=> P/J419-8
P127-3 <=> P/J419-9
P127-2 <=> P/J419-10
P127-1 <=> Not connected
8 Check for +5 V to the Toner CRUM PWB. Go to Step 9. Replace the

ground? Board
(page 8-89).
9 Test the Toner Dispense Motor. Replace the Go to Step 10.

Run the Service Diagnostics Toner Engine Logic
Dispense Motor test. Board
Does the motor rotate? (page 8-89).
10 Check Toner Dispense Motor connections. Go to Step 11. Connect P/J216

11 Check continuity between the Toner Go to Step 12. Repair the wiring.
Dispense Motor and Engine Logic Board.
P/J420-1 <=> P/J216-2
P/J420-2 <=> P/J216-1
12 Check for +24 V to the Toner Dispense Replace the Toner Replace the
Motor Dispense Motor Engine Logic
Is there +24 V across P/J216-1 (+) <=> (page 8-73). Board

No Drum Cartridge - J3-1 Drum Not Installed
The Drum Cartridge is not detected by the Drum Cartridge Detect Switch.

DRUM not installed - J3-1
Drum Cartridge (Drum Cartridge Detect SW) Troubleshooting Reference
Drum Cartridge Print Engine P/J Drum and Toner (page 10-6)
Drum Cartridge Print Engine P/J Engine Logic Board (page 10-13)
Detect Switch Print Engine LVPS Wiring (page 10-21)
Engine Logic Board Print Engine Drive/CRUM Wiring (page 10-25)
PL5.1 Laser, CRU and Toner Dispense (page 9-32)
Drum Cartridge (Drum Cartridge Detect SW) Troubleshooting Procedure
1 Check the Drum Cartridge installation. Go to Step 2. Replace the

Was the Drum Cartridge replaced? Drum Cartridge. If
the error persists,
go to Step 2.
2 Test the Drum Cartridge Detect Switch. Replace the Go to Step 3.

Run the Service Diagnostics Detect DRUM Engine Logic
Cartridge Switch test. Board
Does the switch status change when (page 8-89).
the Drum Cartridge is moved in and
out?
3 Check the Drum Cartridge Detect Switch Go to Step 4. Connect P/J404.

connection.
4 Check Drum Cartridge Detect Switch Go to Step 5. Repair the wiring.

continuity.
Is there continuity between P/J404-1
<=> P/J404-3 when the Drum Cartridge
is installed?
5 Check for +5 V to the Drum Cartridge Replace the Drum Replace the
Detect Switch. Cartridge Detect Engine Logic
Is there +5 V across P/J404-3 (+) <=> Switch Board

Drum Cartridge Failure - J4-1 ATC SNR Defect
The ATC Sensor is defective.

Drum Cartridge Failure - J4-1 ATC SNR Defect
Drum Cartridge Failure (ATC Sensor) Troubleshooting Reference
Front Harness A Print Engine P/J Engine Logic Board (page 10-13)
Drum Cartridge Print Engine LVPS Wiring (page 10-21)
Detect Switch Print Engine Drive/CRUM Wiring (page 10-25)
Drum Cartridge Failure (ATC Sensor) Troubleshooting Procedure
1 Replace the Drum Cartridge. Go to Step 2. Problem solved.

2 Test the Front Harness A. Replace the Go to Step 3.

Run the Service Diagnostics DRUM Engine Logic
Cartridge Detect Switch test. Board
out?
3 Check the DRUM Cartridge Detect Switch Go to Step 4. Connect P/J404.

connection.
4 Check DRUM Cartridge Detect Switch Go to Step 5. Repair the wiring.

continuity.
is installed?
5 Check for +5 V to the DRUM Cartridge Replace the Drum Replace the
Replace Drum Cartridge - J6-1 DRUM End of Life

The Drum Cartridge has reached its end of life count.

DRUM end of life - J6-1
Drum Cartridge End of Life (CRUM PWB) Troubleshooting Reference
CRUM PWB Print Engine Drive/CRUM Wiring (page 10-25)
Drum Cartridge End of Life (CRUM PWB) Troubleshooting Procedure

the error persists,
go to Step 2.
2 Check the Drum Cartridge CRUM PWB Go to Step 3. Correct the

installation. installation.
Is the Drum Cartridge CRUM PWB
installed correctly?
3 Check the Drum Cartridge CRUM PWB Go to Step 4. Connect P/126

connection. and P/J419.
Are P126 and P/J419 connected?
4 Check continuity between the Drum Go to Step 5. Repair the wiring.

Cartridge CRUM PWB and Engine Logic
Board.
P126-6 <=> P/J419-1
P126-5 <=> P/J419-2
P126-4 <=> P/J419-3
P126-3 <=> P/J419-4
P126-2 <=> P/J419-5
5 Check +5 V to the Drum Cartridge CRUM Replace the Drum Replace the
PWB. Cartridge CRUM Engine Logic
Is there +5 V across P126-6 (+) <=> PWB (page 8-70). Board
Drum Cartridge Failure - J7-n Comm/NVRAM/Type Error

The Drum Cartridge CRUM failed to communicate with the Engine Logic Board.
Drum Cartridge Failure - J7-1 DRUM Comm Error
Drum Cartridge Failure - J7-2 DRUM NVRAM Error
Drum Cartridge Comm Failure Troubleshooting Reference
Drum Cartridge Comm Failure Troubleshooting Procedure

the error persists,
go to Step 2.
2 Check the Drum Cartridge CRUM PWB. Go to Step 3. Correct the

Is the Drum Cartridge CRUM PWB installation.


Board.
P126-6 <=> P/J419-1
P126-5 <=> P/J419-2
P126-4 <=> P/J419-3
P126-3 <=> P/J419-4
P126-2 <=> P/J419-5
5 Check +5 V to Drum Cartridge CRUM Replace the Drum Replace the


Replace Incorrect Drum Cartridge - J7-3 DRUM Type
Mismatch
The Drum Cartridge CRUM PWB indicates a non-Xerox Drum Cartridge is installed.

Non-Xerox Drum Cartridge - J7-3 DRUM Type Mismatch
Non-Xerox Drum Cartridge (CRUM PWB) Troubleshooting Reference
Drum CRUM PWB Print Engine P/J Engine Logic Board (page 10-13)
Engine Logic Board Print Engine Drive/CRUM Wiring (page 10-25)
PL5.1 Laser, CRU and Toner Dispense (page 9-32)
Non-Xerox Drum Cartridge (CRUM PWB) Troubleshooting Procedure

the error persists,
go to Step 2.
2 Check the Drum Cartridge CRUM PWB. Go to Step 3. Correct the

Is the Drum Cartridge CRUM PWB installation.


Cartridge CRUM and Engine Logic Board.
P126-6 <=> P/J419-1
P126-5 <=> P/J419-2
P126-4 <=> P/J419-3
P126-3 <=> P/J419-4
P126-2 <=> P/J419-5

Toner Cartridge Failure - J8-n Toner Comm/Read/Write
The Toner CRUM PWB failed to communicate with the Engine Logic Board.

Toner Cartridge Failure - J8-1 Toner Comm Error - J8-1
Toner Cartridge Failure - J8-2 Toner Cart. read/write error
Toner Cartridge Comm Failure Troubleshooting Reference
Toner Cartridge Print Engine P/J Engine Logic Board (page 10-13)
Toner Cartridge Comm Failure Troubleshooting Procedure
1 Check the Toner Cartridge installation. Go to Step 2. Replace the

Was the Toner Cartridge replaced? Toner Cartridge.
If the error
persists, go to
Step 2.
2 Check the Toner Cartridge CRUM PWB. Go to Step 3. Correct the

Is the Toner Cartridge CRUM PWB installation.
3 Check the Toner Cartridge CRUM PWB Go to Step 4. Connect P127

1. Disconnect P127 and P/J419.
P127-6 <=> P/J419-6
P127-5 <=> P/J419-7
P127-4 <=> P/J419-8
P127-3 <=> P/J419-9
P127-2 <=> P/J419-10
5 Check +5 V to the Toner Cartridge CRUM Replace the Toner Replace the

Replace Incorrect Toner Cartridge - J8-3 Toner Cart.
Type Mismatch

Replace Incorrect Toner Cartridge - J8-3 Toner Cart. type mismatch
Non-Xerox Toner Cartridge
Non-Xerox Toner Cartridge Troubleshooting Reference
Toner Cartridge Print Engine P/J Engine Logic Board (page 10-13)
Non-Xerox Toner Cartridge Troubleshooting Procedure
1 Check the Toner Cartridge installation. Go to Step 2. Replace with a

Was a Xerox Toner Cartridge replaced? Xerox Toner
Cartridge. If the
error persists, go
to Step 2.
2 Check the Toner Cartridge CRUM PWB Go to Step 3. Correct the

Is the Toner Cartridge CRUM PWB
3 Check the Toner Cartridge CRUM PWB Go to Step 4. Connect P127

P127-6 <=> P/J419-6
P127-5 <=> P/J419-7
P127-4 <=> P/J419-8
P127-3 <=> P/J419-9
P127-2 <=> P/J419-10

Non-Xerox Toner Cartridge Troubleshooting Procedure (Continued)
5 Check +5 V to the Toner Cartridge CRUM Replace the Toner Replace the
Toner Is Low - Toner Low

The Toner CRUM PWB indicates a Low Toner condition.
Low Toner Troubleshooting Reference
Toner Dispense Print Engine P/J Engine Logic Board (page 10-13)
Toner Dispense Motor Print Engine Drive/CRUM Wiring (page 10-25)
Toner CRUM PWB PL5.1 Laser, CRU and Toner Dispense (page 9-32)
Low Toner Troubleshooting Procedure
1 Check the Toner Cartridge installation. Go to Step 2. Replace the

Was the Toner Cartridge replaced? Toner Cartridge.
If the error
persists, go to
Step 2.

Remove the Toner Cartridge and reinstall.
3 Check the gear of the Toner Dispense Go to Step 4. Restore proper

Assembly. operation.
Does the gear located on the Toner
Dispense Assembly rotate smoothly?
4 Check the Toner Dispense Assembly Tube Go to Step 5. Clean the tube.
for clogging.
Is the tube located at the lower part of
5 Test the Toner Dispense Motor. Replace the Go to Step 6.

Run the Service Diagnostics Toner Engine Logic
Dispense Motor test. Board
Does the motor rotate? (page 8-89).

Low Toner Troubleshooting Procedure (Continued)
6 Check Toner Dispense Motor connections. Go to Step 7. Connect P/J216

7 Check continuity between the Toner Go to Step 8. Repair the wiring.

Dispense Motor and Engine Logic Board.
8 Check for +24 V to Toner Dispense Motor Replace the Toner Replace Engine
Is there +24 V across P/J420-2 (+) <=> Dispense Motor Logic Board
Drum Cartridge Near End of Life - DRUM Life Near End

The Drum Cartridge is near its end of life count or the Drum Cartridge CRUM PWB
has failed to communicate with the Engine Logic Board.
Drum End of Life (Drum CRUM) Troubleshooting Reference
Drum End of Life (Drum CRUM) Troubleshooting Procedure

the error persists,
go to Step 2.
2 Check the Drum Cartridge CRUM PWB Go to Step 3. Correct the

Is the Drum Cartridge CRUM PWB
3 Check the Drum Cartridge CRUM PWB Go to Step 4. Connect P126


Drum End of Life (Drum CRUM) Troubleshooting Procedure (Continued)

Board.
P126-6 <=> P/J419-1
P126-5 <=> P/J419-2
P126-4 <=> P/J419-3
P126-3 <=> P/J419-4
P126-2 <=> P/J419-5
Tray Empty - No Paper in Tray 2 or 3

No paper is detected in either Tray 2 or 3.
No Paper in Tray 2 or 3 (No Paper Sensor) Troubleshooting Reference
No Paper Sensor Print Engine P/J Engine Logic Board (page 10-13)
Engine Logic Board Print Engine Tray 2 & 3 Wiring (page 10-26)
PL2.3 Feeder (2/2) (page 9-12)
No Paper in Tray 2 or 3 (No Paper Sensor) Troubleshooting Procedure
1 Check for paper. Go to Step 2. Load paper.

Is paper loaded in the selected tray?
2 Test the No Paper Sensor. Replace the Go to Step 3.

Run the Service Diagnostics No Paper Engine Logic
Sensor test for the affected tray. Board
sensor is blocked?

No Paper in Tray 2 or 3 (No Paper Sensor) Troubleshooting Procedure (Continued)
3 Check the No Paper Sensor connection. Go to Step 4. Connect the

For Tray 2: sensor.
For Tray 3:
4 Check continuity between the No Paper Go to Step 5. Repair the wiring.

For Tray 2:
P/J101-3 <=> P/J409-A10
P/J101-2 <=> P/J409-A11
P/J101-1 <=> P/J409-A12
For Tray 3:
P/J103-3 <=> P/J409-B10
P/J103-2 <=> P/J409-B11
P/J103-1 <=> P/J409-B12
5 Check for +5 V to the No Paper Sensor. Replace the No Replace the

For Tray 2: Paper Sensor Engine Logic
For Tray 3:
ground?
Tray Empty - No Paper in Tray 4 or 5

No paper is detected in either Tray 4 or 5.
No Paper in Tray 4 or 5 (No Paper Sensor) Troubleshooting Reference
No Paper Sensor Print Engine P/J Engine Logic Board (page 10-13)
Board 1000-Sheet P/J Tray 4 & 5 Feeders (page 5-5)
PL20.4 Tray 4-5 Feeders (page 4-10)

No Paper in Tray 4 or 5 (No Paper Sensor) Troubleshooting Procedure

2 Test the No Paper Sensor. Replace the Go to Step 3.

Run the Service Diagnostics No Paper Engine Logic
Sensor test for the selected tray. Board
sensor is blocked?
3 Check the No Paper Sensor connection. Go to Step 4. Connect the

For Tray 4: sensor.
Are P/J102B, P/J661B and P/J549
connected?
For Tray 5:
Are P/J102A, P/J661A and P/J549
connected?
4 Check continuity between the No Paper Go to Step 5. Repair the wiring.

For Tray 4:
P/J102B-3 <=> P/J549-B10
P/J102B-2 <=> P/J549-B11
P/J102B-1 <=> P/J549-B12
For Tray 5:
P/J102A-3 <=> P/J549-A10
P/J102A-2 <=> P/J549-A11
P/J102A-1 <=> P/J549-A12
5 Check for +5 V to the No Paper Sensor. Replace the No Go to Step 6.

For Tray 4: Paper Sensor.
Is there +5 V across P/J102B-3 (+) <=>
ground?
For Tray 5:
Is there +5 V across P/J102A-3 (+) <=>
ground?
6 Check the Tray 4-5 PWB connections. Go to Step 7. Connect P/J413


No Paper in Tray 4 or 5 (No Paper Sensor) Troubleshooting Procedure (Continued)
P/J541-1 <=> P/J413-A1
P/J541-2 <=> P/J413-A2
P/J541-3 <=> P/J413-A3
P/J541-4 <=> P/J413-A4
P/J541-5 <=> P/J413-A5
P/J541-6 <=> P/J413-A6
P/J541-7 <=> P/J413-B1
P/J541-8 <=> P/J413-B2
P/J541-9 <=> P/J413-B3
P/J541-10 <=> P/J413-B4
P/J541-11 <=> P/J413-B5
P/J541-12 <=> P/J413-B6
(page 8-89).
Tray Empty - No Paper in Tray 6

The Tray 6 No Paper Sensor indicates that the tray is empty.
No Paper in Tray 6 (No Paper Sensor) Troubleshooting Reference
No Paper Sensor Phaser 5500 Printer Options Service Manual

Tray 6 PWB 2000-Sheet Tray 6 Feeder P/J Locator (page 5-20)
Engine Logic 2000-Sheet Tray 6 Drive Wiring (page 5-25)
Board PL22.5 Tray 6 Feeder (2/3) (page 4-26)
No Paper in Tray 6 (No Paper Sensor) Troubleshooting Procedure
1 Check Tray 6 harness connections. Go to Step 2. Connect and if

Are P/JF60, JF56A, PF56A, and P/JF02 error persists, go
connected? to Step 2.

No Paper in Tray 6 (No Paper Sensor) Troubleshooting Procedure (Continued)
2 Test the No Paper Sensor. Replace the Tray 6 Go to Step 3.

1. Open Door J PWB(page 3-67).
2. Run the Service Diagnostics No Paper
Sensor test for the selected tray.
actuator moves and blocks the sensor?
3 Check the Tray 6 No Paper Sensor harness Go to Step 4. Repair the wiring.
continuity.
Is there continuity between P/JF60,
JF56A, PF56A, and P/JF02?
4 Check for +5 V to the No Paper Sensor. Go to Step 5. Replace the Tray 6

Is there +5 V across P/JF02-9 <=> P/ PWB(page 3-67).
JF02-7?
5 Check the Tray 6 No Paper Sensor signal. Replace the Tray 6 Replace the No
Does the voltage across P/JF02-8 <=> P/ PWB(page 3-67). Paper Sensor
JF02-7? change when the sensor is (page 3-54).
blocked
Paper Size Jam - Paper Size in Tray 2 or 3

Paper size mismatch in either Tray 2 or 3.
Note
Custom size papers loaded in the tray must match the custom size paper selected
at the Front Panel or from the print driver.
Paper Size Mismatch in Tray 2 or 3 Troubleshooting Reference
Front Size Guide Print Engine Tray 2 & 3 Wiring (page 10-26)
Rear Side Guide PL2.1 Tray (1/2) and Feeder (1/2) (page 9-8)
End Size Guide PL2.3 Feeder (2/2) (page 9-10)
Paper Size Mismatch in Tray 2 or 3 Troubleshooting Procedure


Paper Size Mismatch in Tray 2 or 3 Troubleshooting Procedure (Continued)
2 Check the trays paper size guides. Go to Step 3. Set the guides
Are the trays paper size guides set properly.
correctly?
3 Check Paper Size Switch installation. Go to Step 4. Correct the

Is the Paper Size Switch installed installation.
correctly?
4 Test the Paper Size Switch. Replace the Go to Step 5.

Run the Service Diagnostics Paper Size Engine Logic
Switch test for the affected tray. Board
Does the paper size displayed match (page 8-89).
the paper size in the tray?
5 Check the Paper Size Switch connections. Go to Step 6. Connect the

For Tray 2: switch.
For Tray 3:
Switch and Engine Logic Board.
For Tray 2:
P/J109-1 <=> P/J412-4
P/J109-2 <=> P/J412-3
P/J109-3 <=> P/J412-2
P/J109-4 <=> P/J412-1
For Tray 3:
P/J110-1 <=> P/J412-9
P/J110-2 <=> P/J412-8
P/J110-3 <=> P/J412-7
P/J110-4 <=> P/J412-6
7 Check for +5 V to the Paper Size Switch. Replace the Paper Replace the
For Tray 2: Size Switch Engine Logic
For Tray 3:
ground?

Paper Size Jam - Paper Size in Tray 4 or 5
Paper size mismatch in either Tray 4 or 5.
Note
Custom size papers loaded in the tray must match the custom size paper selected
at the Front Panel or from the print driver.
Paper Size Mismatch in Tray 4 or 5 Troubleshooting Reference
Front Size Guide Print Engine P/J Registration Transport (page 10-10)
Rear Side Guide Print Engine Registration Transport Wiring (page 10-13)
Registration Sensor PL8.1 Print Engine Electrical (page 9-40)
Registration Clutch Phaser 5500 Printer Options Service Manual
Tray 4-5 PWB 1000-Sheet P/J Tray 4 & 5 Electrical (page 5-6)
Engine Logic Board PL20.6 Tray 4-5 Drive and Electrical (page 4-16)
Paper Size Mismatch in Tray 4 or 5 Troubleshooting Procedure

2 Check the trays paper size guides. Go to Step 3. Set the guides
Are the paper size guides set correctly? properly.
3 Check Paper Size Switch installation. Go to Step 4. Correct the

Is the Paper Size Switch installed installation.
correctly?
4 Test the Paper Size Switch. Go to Step 11. Go to Step 5.

Run the Service Diagnostics Paper Size
Switch test for the affected tray.
Does the paper size displayed match
the paper size in the tray?

For Tray 3: switch.
For Tray 4:

Switch and Tray 4-5 PWB.
For Tray 4:
P/J820-1 <=> P/J548-14
P/J820-2 <=> P/J548-13
P/J820-3 <=> P/J548-12
P/J820-4 <=> P/J548-11
For Tray 5:
P/J824-1 <=> P/J548-7
P/J824-2 <=> P/J548-6
P/J824-3 <=> P/J548-5
P/J824-4 <=> P/J548-4
7 Check for +3.3 V to the Paper Size Switch. Replace the Paper Go to Step 8.
For Tray 4: Size Switch
Is there +3.3 V across P/J820-1 (+) <=> (page 3-10).
ground?
For Tray 5:
ground?
8 Check the Tray 4-5 PWB connections. Go to Step 9. Connect P/J413

P/J541-1 <=> P/J413-A1
P/J541-2 <=> P/J413-A2
P/J541-3 <=> P/J413-A3
P/J541-4 <=> P/J413-A4
P/J541-5 <=> P/J413-A5
P/J541-6 <=> P/J413-A6
P/J541-7 <=> P/J413-B1
P/J541-8 <=> P/J413-B2
P/J541-9 <=> P/J413-B3
P/J541-10 <=> P/J413-B4
P/J541-11 <=> P/J413-B5
P/J541-12 <=> P/J413-B6
(page 8-89).

11 Check the trays rollers. Go to Step 12. Clean or replace

Remove the tray. the affected roller.
Is the Feed, Retard or Nudger Roller
worn or contaminated?
12 Check paper jam position. Remove the paper Go to Step 13.

Open Door A. and go to Step 15.
Sensor?

Open Door C. the Take Away
Is the Take Away Roller worn or Roller.
contaminated?
14 Check the Registration Roller. Clean or replace Go to Step 15.

Open Door A. the rolls.
Is the Registration Roller worn or
contaminated?

2. Open Door A.
the actuator is moved?
16 Check the Registration Sensor connection. Go to Step 17. Connect J104

Are J104 and J403B connected? and J403.
between J104 <=> J403?
18 Check for +5 V to the Registration Sensor. Replace the Replace the

Is there +5 V across J403-B13 (+) <=> Registration Engine Logic
ground? Sensor Board
(page 8-52). (page 8-89).
19 Test the Registration Clutch. Replace the Go to Step 20.

Clutch test. Board
Does the Registration Clutch operate? (page 8-89).
20 Check Registration Clutch connections. Go to Step 21. Connect P215

Are P215 and P/J403 connected? and P/J403.
between P215 <=> P/J403?

Is there +24 V across P/J403-B9 (+) <=> Engine Logic
ground? Board
(page 8-89).
23 Check the Registration Clutch resistance. Replace the Replace the

Is the resistance across J215-1 and Engine Logic Registration
J215-2 approximately 240 ohm? Board Clutch
(page 8-89). (page 8-51).
Paper Size Jam - Paper Size in Tray 6

Paper size mismatch in Tray 6.
Paper Size Jam in Tray 6 (Paper Size Sensors) Troubleshooting Reference
Paper Size Sensors Phaser 5500 Printer Options Service Manual

A and B 2000-Sheet Tray 6 Feeder P/J Locator (page 5-20)
Rear Size Guide 2000-Sheet Tray 6 Sensors Wiring (page 5-24)
Tray 6 PWB PL22.1 Tray 6 Covers (page 4-18)
Paper Size Jam in Tray 6 (Paper Size Sensors) Troubleshooting Procedure
1 Check the installation of Tray 6 Paper Size Go to Step 2. Correct the

Sensors. installation. If the
Remove the Rear and Top Covers. error persists, go
Are the Paper Size Sensors installed to Step 2
correctly?
2 Test the Tray 6 Paper Size Sensors. Replace the Tray 6 Go to Step 4.
Run the Service Diagnostics Paper Size PWB (page 3-67).
Sensor tests for sensors A and B.
Does the displayed state change when
the sensors are blocked?

For Paper Size Sensor A: sensor.
Are P/JF01 and P/JF52 connected?
For Paper Size Sensor B:

Are P/JF01 and P/JF53 connected?

Paper Size Jam in Tray 6 (Paper Size Sensors) Troubleshooting Procedure
Sensors and the Tray 6 PWB.
For Paper Size Sensor A:
1. Disconnect P/JF01 and P/JF52.
P/JF01-9 <=> PF52-1
P/JF01-8 <=> PF52-2
P/JF01-7 <=> PF52-3
1. Disconnect P/JF01 and P/JF53.
P/JF01-12 <=> PF53-1
P/JF01-11 <=> PF53-2
P/JF01-10 <=> PF53-3
5 Check for +5 V to the Paper Size Sensors. Replace the Paper Replace the Tray
For Paper Size Sensor A: Size Sensors 6 PWB
Is there +5 V across PF52-1 (+) <=> (page 3-42). (page 3-67).
ground?
Is there +5 V across PF53-1 (+) <=>
ground?
Drum Cartridge Failure - Drum ATC Value Out of Range

The ATC Sensor in the Drum Cartridge has failed.
Temperature Sensor Failure (ATC Sensor) Troubleshooting Reference
Front Harness A Print Engine P/J Engine Logic Board (page 10-13)
Drum Cartridge Detect Print Engine LVPS Wiring (page 10-21)
Temperature Sensor Failure (ATC Sensor) Troubleshooting Procedure

the error persists,
go to Step 2.

Temperature Sensor Failure (ATC Sensor) Troubleshooting Procedure (Continued)
2 Test the Front Harness A. Replace the Go to Step 3.

Run the Service Diagnostics DRUM Detect Engine Logic
Cartridge Switch test. Board
out?
3 Check the Drum Cartridge Detect Switch Go to Step 4. Connect P/J404.

connection.
4 Check the Drum Cartridge Detect Switch Go to Step 5. Repair the wiring.
continuity.
is installed?
5 Check for +5 V to the Drum Cartridge Replace the Drum Replace the
Temp/Humidity Sensor Failure - Value Out of Range

The Temperature Sensor or Humidity Sensor has failed.
Temp/Humidity Sensor Failure (Environmental PWB) Troubleshooting Reference
Environmental Print Engine P/J Registration Transport (page 10-10)

Sensor PWB Print Engine P/J Engine Logic Board (page 10-13)
Engine Logic Print Engine Xerographics Wiring (page 10-24)
Board
PL5.1 Laser, CRU, and Toner Dispense (page 9-32)
Temp/Humidity Sensor Failure (Environmental PWB) Troubleshooting Procedure
1 Check the harness connections. Go to Step 2. Connect P/J403

Are P/J403 and P/J150 connected? and P/J150. If the
error persists, go
to Step 2.

Temp/Humidity Sensor Failure (Environmental PWB) Troubleshooting Procedure
2 Check continuity between the sensor and Go to Step 3.. Repair the wiring.
P/J403-B15 <=> P/J150-1
P/J403-B7 <=> P/J150-2
P/J403-B4 <=> P/J150-3
P/J403-B6 <=> P/J150-4
3 Check for +5 V to the sensor. Replace the Replace the

Is there +5 V across P/J403-15 <=> and Environmental Engine Logic
P/J403-4? PWB (page 8-64) Board
If the error (page 8-89).
persists, replace
the Engine Logic
Board
(page 8-89).
Face Down Tray Paper Full - Face Down Tray Full

The Full Stack Sensor on Exit 1 or Exit 2 indicates a Stack Full condition for the
Standard Output Tray.
Standard Output Tray Full (Exit Full Stack Sensor) Troubleshooting Reference
Exit PWB Print Engine P/J Laser and Exit PWB (page 10-7)
Engine Logic Print Engine P/J Engine Logic Board (page 10-13)
Board Print Engine Exit 1 Wiring (page 10-30)
Full Stack PL6.2 Exit 1 (page 9-36)
Actuator Link PL8.1 Print Engine Electrical (1/2)
Full Stack
Actuator
Exit 2 P/J Locator (page 5-15)
Full Stack Sensor
Exit 2 Sensor/Fan Wiring (page 5-18)
PL24.2 Exit 2 (page 4-40)
Standard Output Tray Full (Exit Full Stack Sensor) Troubleshooting Procedure
1 Check the actuator installation on the Go to Step 2. Correct the

affected Exit. installation.
Does the Actuator move normally and
pass through the sensing area?

Standard Output Tray Full (Exit Full Stack Sensor) Troubleshooting Procedure
2 Test the Stack Full Sensor. Replace the Go to Step 3.

Run the Service Diagnostics Output Tray Engine Logic
Full test for the appropriate Exit. Board
actuator is moved and sensor is
blocked?
3 Check the Stack Full Sensor connections. Go to Step 4. Connect the

For Exit 1: sensor.
Are P/J118, P/J613 and P/J432
connected?
For Exit 2:
Are P/J113, P/J606B and P/J434
connected?
4 Check continuity between the Stack Full Go to Step 5. Repair the wiring.
Sensor and the Exit PWB.
For Exit 1:
For Exit 2:
5 Check for +5 V to the Stack Full Sensor. Replace the Full Go to Step 6.
For Exit 1: Stack Sensor.
ground?
For Exit 2:
ground?
6 Check the Exit PWB connections. Go to Step 7. Connect P/J421

P/J431-1 <=> P/J421-8
P/J431-2 <=> P/J421-7
P/J431-3 <=> P/J421-6
P/J431-4 <=> P/J421-5
P/J431-5 <=> P/J421-4
P/J431-6 <=> P/J421-3
P/J431-7 <=> P/J421-2
P/J431-8 <=> P/J421-1
Is there +5 V across P/J421-3 (+) <=> PWB (page 8-88). Engine Logic
ground? Board
(page 8-89).

Stacker Upper Tray Full - Finisher Tray Paper Full
The Full Stack Sensor on the Stacker Upper Tray indicates a Stack Full condition.
Upper Tray Full (Upper Tray Full Sensor) Troubleshooting Reference
Finisher Main PWB Phaser 5500 Printer Options Service Manual

Top Sensor Finisher Main PWB P/J Locator (page 5-35)
Harness Finisher Sensors (1/2) Wiring (page 5-40)
Main Sensor PL25.13 Finisher Transport (2/2) (page 4-68)
Harness
Full Stack Sensor
Upper Tray Full (Upper Tray Full Sensor) Troubleshooting Procedure
1 Test the Upper Tray Full Sensor. Replace the Go to Step 2.

Full Sensor test. PWB
sensor area is covered?
2 Check the Top Tray Sensor and Main Go to Step 4. Connect and go
Sensor Harness connections. to Step 3.
Are P/J8322, P/J8393 and P/J8302A of
the Top Tray Sensor Harness
connected?

4 Check Top Sensor Harness continuity. Go to Step 5. Repair the Top

P/J8322-3 <=> J8393B-1
P/J8322-2 <=> J8393B-2
P/J8322-1 <=> J8393B-3
5 Check Top Tray Sensor Harness continuity. Go to Step 6. Repair the Top
1. Disconnect P/J8393 and P/J8302A. Tray Sensor
Harness.
J8393A-3 <=> P/J8302A-10
J8393A-2 <=> P/J8302A-11
J8393A-1 <=> P/J8302A-12

Upper Tray Full (Upper Tray Full Sensor) Troubleshooting Procedure (Continued)
6 Check for +5 V to the Top Tray Full Sensor. Go to Step 7. Replace the
(page 3-248).
7 Check the Top Tray Full Sensor signal. Replace the Replace the
Does the voltage across P8302A-11 <=> Finisher Main Upper Tray Full
P8302A-10 on the Finisher Main PWB PWB sensor
change when the sensor is covered? (page 3-248). (page 3-233).
Stacker Lower Tray Full - Finisher Mix Full Stack

The Stacker Encoder Sensor for the Stacker Lower Tray indicates a Stack Full
condition.
Lower Tray Full (Stack Encoder Sensor) Troubleshooting Reference
Finisher Main Phaser 5500 Printer Options Service Manual

PWB Finisher Main PWB P/J Locator (page 5-35)
Main Sensor Finisher Sensors (2/2) Wiring (page 5-41)
Harness
Finisher Clutch and Solenoids Wiring (page 5-43)
Stacker Encoder
Sensor PL25.6 Finisher Stack (page 4-54)
Elevator Motor
Lower Tray Full (Stack Encoder Sensor) Troubleshooting Procedure
1 Check the Stacker Lower Tray for Remove the Go to Step 2.

obstructions. obstacles.
Are there any obstacles in the path of
the Stacker Lower Tray?
2 Check the Encoder wheel installation. Go to Step 3. Correct and go to

Does the Encoder rotate and enter the Step 3.
sensing area of the Stacker Encode
Sensor?
3 Test the Stacker Encoder Sensor. Go to Step 9. Go to Step 4.

Run the Service Diagnostics Stacker
Encode Sensor test.
Elevator Motor Belt is moved by hand
rotating the Encoder Wheel?

Lower Tray Full (Stack Encoder Sensor) Troubleshooting Procedure (Continued)
4 Check Stacker Encoder Sensor Harness Go to Step 6. Connect and go


6 Check Stacker Encoder Sensor Harness Go to Step 7. Repair the

continuity. Stacker Encoder
1. Disconnect the sensor P/J8328, and P/ Sensor Harness.
J8302B on the Finisher Main PWB.
P/J8328-3 <=> P/J8302B-12
P/J8328-2 <=> P/J8302B-13
P/J8328-1 <=> P/
J8302B-14
7 Check for +5 V to the Stacker Encode Go to Step 8. Replace the

Is the voltage across J8302B-14 <=> PWB
8 Check Stacker Encode Sensor signal. Replace the Replace Stacker

Does the voltage across P8302B-13 and Finisher Main Encode Sensor
change when the sensing area is (page 3-248).
blocked or opened?
9 Check the Elevator Motor. Replace the Go to Step 10.


Main PWB?

12 Replace the Elevator Motor. Replace the Problem solved.

(page 3-248).

Stapler is Empty - Staple Pin Warning
The Low Staple Sensor in the Staple Cartridge indicates no staples remain.
Stapler is Empty (Low Staple Sensor) Troubleshooting Reference

Staple Harness Finisher Main PWB P/J Locator (page 5-35)
Stapler Assembly Finisher Staple P/J Locator (page 5-30)
Engine Logic Finisher Stapler Wiring (page 5-45)
Board. PL25.8 Finisher Staple (page 4-58)
Stapler is Empty (Low Staple Sensor) Troubleshooting Procedure
1 Test the Low Staple Sensor. Go to Step 9. Go to Step 2.

Run the Service Diagnostics Staple Head
Low Staple Sensor test.
Staple Cartridge is removed or
replaced?
2 Check the Staple Cartridge for faulty parts Replace faulty Go to Step 3.
and foreign particles. parts or clean as
Are there damaged parts or foreign needed.
particles?



P/J8356-1 <=> P/J8308-15
P/J8356-2 <=> P/J8308-14
P/J8356-3 <=> P/J8308-13
P/J8356-4 <=> P/J8308-12
P/J8356-5 <=> P/J8308-11
6 Check for +5 V to the Low Staple Sensor. Go to Step 7. Replace the

J8308-15 on the Finisher Main PWB? PWB
(page 3-248).

Stapler is Empty (Low Staple Sensor) Troubleshooting Procedure (Continued)
7 Check the Low Staple Sensor signal. Go to Step 8. Replace the

Does the voltage across P8308-14 <=> Finisher Main
P8308-15 on the Finisher Main PWB PWB
change when the Staple Cartridge is (page 3-248).
removed or replaced?


Board
(page 8-89).
Staple Cartridge is Low or Missing - Staple Pin Misfeed

The Self Priming Sensor in the Staple Cartridge indicates not ready.
Staple Cartridge Low or Missing (Self-Priming Senor) Troubleshooting Reference

Engine Logic Board. Finisher Stapler Wiring (page 5-45)
PL25.8 Finisher Staple (page 4-58)
Staple Cartridge Low or Missing (Self-Priming Senor) Troubleshooting Procedure
1 Test the Self Priming Sensor. Go to Step 11. Go to Step 2.

Self Priming Sensor test.
Staple Cartridge is removed or
replaced?
2 Check the Staple Cartridge for a staple After removal, go Go to Step 4.

jam. to Step 3.
Is there a staple jam?


Staple Cartridge Low or Missing (Self-Priming Senor) Troubleshooting Procedure
4 Check the Staple Cartridge for faulty parts Replace faulty Go to Step 5.
and foreign particles. parts or clean as
Are there damaged parts or foreign needed.
particles?



P/J8356-1 <=> P/J8308-15
P/J8356-2 <=> P/J8308-14
P/J8356-3 <=> P/J8308-13
P/J8356-4 <=> P/J8308-12
P/J8356-5 <=> P/J8308-11
8 Check for +5 V to the Self Priming Sensor. Go to Step 9. Replace the

(page 3-248).
9 Check the Self Priming Sensor signal. Go to Step 10. Replace the
Does the voltage across P8308-14 <=> Finisher Main
P8308-15 on the Finisher Main PWB PWB
change when the Staple Cartridge is (page 3-248).
removed or replaced?


Board
(page 8-89).

Stapler Failure - Staple Failure
The status of the Staple Home Sensor is not determined within the time specified
following a Stapler Move Motor forward operation. For Staple Move Motor reverse,
the Staple Home Sensor is not turned On in the time specified.
Stapler Failure (Staple Head Home Sensor) Troubleshooting Reference

Engine Logic Board. Finisher Stapler Wiring (page 5-45)
PL25.8 Finisher Staple (page 4-58)
Stapler Failure (Staple Head Home Sensor) Troubleshooting Procedure
1 Check the Compiler Tray for obstructions. Remove the Go to Step 2.

Are there any obstructions in the obstacles.
Compiler Tray?
2 Test the Staple Motor in the Staple Head. Go to Step 6. Go to Step 3.

Run the Service Diagnostics Staple Motor
Forward and Reverse tests alternately.
Does the Staple Motor operate?
3 Check the Staple Motor Harness Go to Step 5. Connect and go


5 Check Staple Motor Harness continuity. Go to Step 11. Repair the Staple
J8357-1 <=> J8308-10
J8357-2 <=> J8308-9
J8357-3 <=> J8308-8
J8357-4 <=> J8308-7
6 Test the Staple Head Home Sensor. Go to Step 12. Go to Step 7.

Home Sensor test.
Staple gear is rotated?

Stapler Failure (Staple Head Home Sensor) Troubleshooting Procedure (Continued)
7 Check Staple Harness connections. Go to Step 9. Connect and go



P/J8356-1 <=> P/J8308-15
P/J8356-2 <=> P/J8308-14
P/J8356-3 <=> P/J8308-13
P/J8356-4 <=> P/J8308-12
P/J8356-5 <=> P/J8308-11
10 Check for +5 V to the Staple Assembly. Go to Step 11. Replace the

(page 3-248).


Board
(page 8-89).
Staple Set Over Count

The Stacker Lower Tray set count has reached its limit.
Staple Set Over Count Troubleshooting Reference
Finisher Main Finisher Main PWB P/J Locator (page 5-35)

PWB PL8.1 Print Engine Electrical (page 9-40)
Engine Logic PL25.14 Finisher Electrical (page 4-70)
Board
Staple Set Over Count Troubleshooting Procedure
1 Check the Finisher Main PWB. Go to Step 3. Connect and go

Are all the connectors connected to the to Step 2.
Finisher Main PWB?

Staple Set Over Count Troubleshooting Procedure (Continued)


Board
(page 8-89).
Stacker Lower Tray Failure

The Stacker No Paper Sensor does not change state within the time specified
following the Stacker Lower Tray beginning to lower.
Lower Tray Failure (No Paper Sensor) Troubleshooting Reference
Finisher Main PWB Print Engine P/J Engine Logic Board (page 10-13)
Sensor Actuator PL8.1 Print Engine Electrical (page 9-40)
Stacker No Paper Phaser 5500 Printer Options Service Manual
Main Sensor Finisher Sensors (2/2) Wiring (page 5-41)
Harness
Finisher Clutch and Solenoids (page 5-43)
Elevator Motor PL25.6 Finisher Stack (page 4-54)
Engine Logic
Board.
Lower Tray Failure (No Paper Sensor) Troubleshooting Procedure
1 Check the lower part of the Stacker for Remove any Go to Step 2.
obstacles. obstacles.
Are there any obstacles on the lower
part of the Stacker Tray?
2 Check the Actuator installation. Repair the Go to Step 3.

3 Check the Stacker No Paper Sensor. Go to Step 9. Go to Step 4.

Run the Service Diagnostics Stacker No
Paper Sensor test.
sensor is blocked?

Lower Tray Failure (No Paper Sensor) Troubleshooting Procedure (Continued)
4 Check No Paper Sensor Harness Go to Step 6. Connect and go


6 Check No Paper Sensor Harness Go to Step 7. Repair the Main

1. Disconnect P/J8326 and P/J8302B on
the Finisher Main PWB.
P/J8326-3 <=> P/J8302B-15
P/J8326-2 <=> P/J8302B-16
P/J8326-1 <=> P/J8302B-17
7 Check for +5 V to the Stacker No Paper Go to Step 8. Replace the

Is there +5 V across P/J8302B-17 <=> P/ PWB
8 Check the Stacker No Paper Sensor signal. Replace the Replace the
Does the voltage across P8302B-16 <=> Finisher Main sensor
9 Test the Elevator Motor. Go to Step 13. Go to Step 10.

Run the Service Diagnostics Stacker Motor
Up and Down tests alternately.
Does the Elevator Motor operate?

Main PWB?


Print a Test Print.

Board
(page 8-89).

Punch Waste Box is Missing
The Punch Box Set Sensor indicates the Punch Box is not installed in the Finisher.
Punch Box Missing (Punch Box Set Sensor) Troubleshooting Reference
Punch Box Set Sensor Phaser 5500 Printer Options Service Manual
Punch Box Sensor Finisher Main PWB P/J Locator (page 5-35)
Harness Finisher Punch P/J Locator (page 5-31)
Punch Sensor Finisher Punch (1/2) Wiring (page 5-46)
Harness
Finisher Main PWB
PL25.7 Finisher Punch (page 4-56)
Engine Logic Board.
Punch Box Missing (Punch Box Set Sensor) Troubleshooting Procedure
1 Test the Punch Box Set Sensor. Go to Step 8. Go to Step 2.

1. Open Door G.
2. Remove the Punch Box.
3. Run the Service Diagnostics Punch Box
Set Sensor test.
Punch Box is removed and replaced?

Are P/J8353 and P/J8355 of the Punch to Step 3.
Box Sensor Harness, and P/J8355 and
P/J8307 of the Punch Sensor Harness
connected?

4 Check Punch Box Sensor Harness Go to Step 5. Repair the wiring.

continuity.
J8353-3 <=> P8355-3
J8353-2 <=> P8355-2
J8353-1 <=> P8355-1

Punch Box Missing (Punch Box Set Sensor) Troubleshooting Procedure (Continued)
5 Check Punch Sensor Harness continuity. Go to Step 6. Repair the Punch

J8355-3 <=> J8307-A3
J8355-2 <=> J8307-A2
J8355-1 <=> J8307-A1
6 Check for +5 V to the Punch Box Set Go to Step 7. Replace the

7 Check the Punch Box Set Sensor signal. Go to Step 8. Replace the
Does the voltage across P/J8307-A2 <=> Punch Box Set
P/J8307-A3 on the Finisher Main PWB Sensor
change when the Punch Box is removed (page 3-154).
or replaced?

Board
(page 8-89).
Punch Waste Box is Full

The Punch Box counter has reached its maximum count.
Punch Box Full (Punch Box Counter) Troubleshooting Reference
Punch Box Set Sensor Phaser 5500 Printer Options Service Manual
Punch Box Sensor Finisher Main PWB P/J Locator (page 5-35)
Harness Finisher Punch P/J Locator (page 5-31)
Punch Sensor Finisher Punch (1/2) Wiring (page 5-46)
Harness PL8.1 Print Engine Electrical (page 9-40)
Engine Logic Board.

Punch Box Full (Punch Box Counter) Troubleshooting Procedure
1 Reset the Punch Box Full Counter, Go to Step 2. Problem solved.

1. Open Door G.
2. Remove the Punch Box for a minimum
of four seconds, then replace the Punch
Box.
3. Close Door G.
2 Test the Punch Box Set Sensor. Go to Step 8. Go to Step 3.

1. Open Door G.
2. Remove the Punch Box.
3. Run the Service Diagnostics Punch Box
Set Sensor test.
Punch Box is removed and replaced?

Are P/J8353 and P/J8355 of the Punch to Step 4.
Box Sensor Harness, and P/J8355 and
P/J8307 of the Punch Sensor Harness
connected?

5 Check Punch Box Sensor Harness Go to Step 6. Repair the wiring.

continuity.
J8353-3 <=> P8355-3
J8353-2 <=> P8355-2
J8353-1 <=> P8355-1
6 Check Punch Sensor Harness continuity. Go to Step 7. Repair the Punch

J8355-3 <=> J8307-A3
J8355-2 <=> J8307-A2
J8355-1 <=> J8307-A1
7 Check for +5 V to the Punch Box Set Go to Step 8. Replace the


Punch Box Full (Punch Box Counter) Troubleshooting Procedure (Continued)
8 Check the Punch Box Set Sensor signal. Go to Step 9. Replace the
Does the voltage across P/J8307-A2 <=> Punch Box Set
P/J8307-A3 on the Finisher Main PWB Sensor
change when the Punch Box is removed (page 3-154).
or replaced?

Board
(page 8-89).
Printer Front Door is Open - Front Cover is Open

The Printers Front Door Interlock Switch indicates that the Front Door is open.
Front Door Open (Front Door Interlock) Troubleshooting Reference
Front Cover Interlock Print Engine P/J Engine Logic Board (page 10-13)
Switch Print Engine P/J Locator LVPS (page 10-16)
Engine Logic Board. Print Engine LVPS Wiring (page 10-21)
PL1.1 Covers (2/2) (page 9-6)
Front Door Open (Front Door Interlock) Troubleshooting Procedure
1 Check Front Door operation. Go to Step 2. Correct the

Does the Front Door open and close installation.
normally?
2 Test the Front Door Interlock Switch. Replace the Go to Step 3.

Run the Service Diagnostics Front Cover Engine Logic
Switch test. Board.
the Front Door is opened and closed?
3 Check the switch connections. Go to Step 4. Connect P/J121

4 Check continuity between the switch and Go to Step 5. Repair the wiring.

Front Door Open (Front Door Interlock) Troubleshooting Procedure (Continued)
5 Check for +24 V to the switch. Replace the Replace the

Is there +24 V across P/J121-B1 (+) <=> Switch Engine Logic
ground? Board.
Slide In Tray 6 Feeder - Tray 6 Undocked

The Tray 6 Docking Switch indicates that Tray 6 is separated from the printer.
Tray 6 Undocked (Docking Interlock Switch) Troubleshooting Reference
Tray 6 Main PL8.1 Print Engine Electrical (page 9-40)
Harness Phaser 5500 Printer Options Service Manual
Tray 6 Docking 2000-Sheet Feeder P/J Locator (page 5-20)
Switch
2000-Sheet Feeder Interface Wiring (page 5-23)
Engine Logic
Board PL22.7 Tray 6 Drive and Transportation (page 4-30)
Tray 6 Undocked (Docking Interlock Switch) Troubleshooting Procedure
1 Check the Tray 6 installation. Go to Step 2. Correct and go to

Is Tray 6 installed correctly? Step 2.
2 Check the Docking Switch condition. Replace the Go to Step 3.

Is the Docking Switch damaged? Docking Switch
(page 3-66).
3 Test the Docking Switch. Go to Step 10. Go to Step 4.

1. Pull Tray 6 away from the printer.
Interlock Switch test.
the switch plunger is repeatedly
pushed?
4 Check Tray 6 Docking Switch Harness Go to Step 6. Connect and go

Are FS003, FS004 and P/JF08
connected?


Tray 6 Undocked (Docking Interlock Switch) Troubleshooting Procedure (Continued)
6 Check Tray 6 Docking Switch Harness Go to Step 7. Repair the Tray 6

continuity. Docking Switch
1. Disconnect FS003, FS004 and P/JF08. Harness.
FS003 <=> P/JF08-1
FS004 <=> P/JF08-2
7 Check for +5 V to the Docking Switch. Go to Step 8. Replace the Tray

Is there +5 V across P/JF08-2 <=> P/ 6 PWB
JF04-2 on the Tray 6 PWB? (page 3-67).
8 Check the Docking Switch signal. Go to Step 9. Replace the

Does the voltage across P/JF08-1 <=> P/ Docking Switch
JF04-3 on the Tray 6 PWB change when (page 3-66).
the switch plunger is pushed?

Board
(page 8-89).
Close Door A - Door A is Open

The Door A Interlock Switch indicates that Door A is open.
Door A Open (Door A Interlock Switch) Troubleshooting Reference
Door A Interlock Print Engine P/J Locator Electrical (page 10-12)

Switch Print Engine P/J Engine Logic Board (page 10-13)
Engine Logic Board. Print Engine LVPS Wiring (page 10-21)
PL4.2 L/H Upper Assembly (page 9-24)
Door A Open (Door A Interlock Switch) Troubleshooting Procedure
1 Check Door A operation. Go to Step 2. Correct the

Does Door A open and close normally? installation.
2 Test the Door A Interlock Switch. Replace the Go to Step 3.

Run the Service Diagnostics Door A Engine Logic
Interlock Switch test. Board
Does the sensor status change when (page 8-89).
Door A is opened and closed?

Door A Open (Door A Interlock Switch) Troubleshooting Procedure (Continued)

5 Check for +24 V to the switch. Replace the Door Replace the
Is there +24 V across P/J120-B1 (+) <=> A Interlock Switch Engine Logic
(page 8-89).
Close Door B - Door B is Open

The Door B Interlock Switch indicates that Door B is open.
Door B Open (Door B Interlock Switch) Troubleshooting Reference
Door B Interlock Print Engine P/J Tray 2 & 3 Feeder (page 10-11)
Engine Logic Print Engine Registration Transport Wiring (page 10-23)
Board. PL4.1 L/H Upper Assembly (page 9-22)
Door B Open (Door B Interlock Switch) Troubleshooting Procedure
1 Check Door B operation. Go to Step 2. Correct the

Does Door B open and close normally? installation.
2 Test the Door B Interlock Switch. Replace the Go to Step 3.

Run the Service Diagnostics Door B Engine Logic
Does the sensor status change when (page 8-89).
Door B is opened and closed?


Door B Open (Door B Interlock Switch) Troubleshooting Procedure (Continued)
5 Check for +5 V to the switch. Replace the Replace the

Is there +5 V across P/J106-2 (+) <=> Switch Engine Logic
(page 8-89).
Close Door C - Door C is Open

The Door C Interlock Switch on the 1000-Sheet Feeder indicates that Door C is open.
Door C Open (Door C Interlock Switch) Troubleshooting Reference
Door C Interlock Print Engine P/J Engine Logic Board (page 10-13)
Switch PL8.1 Print Engine Electrical (page 9-40)
Board. 1000-Sheet Feeder P/J Tray 4 & 5 Feeders (page 5-5)
1000-Sheet Feeder Drive Wiring (page 5-8)
PL20.5 Transportation (page 4-14)
Door C Open (Door C Interlock Switch) Troubleshooting Procedure
1 Check Door C operation. Go to Step 2. Correct the

Does Door C open and close normally? installation.
2 Test the Door C Interlock Switch. Replace the Go to Step 3.

Run the Service Diagnostics Door C Engine Logic
Does the sensor state change each time (page 8-89).
the switch is pressed?
3 Check the switch connections. Go to Step 4. Connect FS812,

Are FS812, FS813 and P/J554 FS813 and P/
connected? J554.
the Tray 4-5 PWB.
between FS812 <=> P/J554?
between FS813 <=> P/J554?
5 Check for +24 V to the switch. Replace the Go to Step 6.

Is there +24 V across FS813 <=> switch

Door C Open (Door C Interlock Switch) Troubleshooting Procedure (Continued)

P/J541-1 <=> P/J413-A1
P/J541-2 <=> P/J413-A2
P/J541-3 <=> P/J413-A3
P/J541-4 <=> P/J413-A4
P/J541-5 <=> P/J413-A5
P/J541-6 <=> P/J413-A6
P/J541-7 <=> P/J413-B1
P/J541-8 <=> P/J413-B2
P/J541-9 <=> P/J413-B3
P/J541-10 <=> P/J413-B4
P/J541-11 <=> P/J413-B5
P/J541-12 <=> P/J413-B6
(page 8-89).
Close Door D - Door D is Open

The Door D Interlock Switch in the Duplex Unit indicates that Door D is open.
Door D Open (Door D Interlock Switch) Troubleshooting Reference
Door D Interlock Print Engine P/J Engine Logic Board (page 10-13)
SW PL8.1 Print Engine Electrical (page 9-40)
Duplex PWB Phaser 5500 Printer Options Service Manual
Engine Logic Duplex Unit P/J Locator (page 5-12)
Board. Duplex Unit Wiring (page 5-13)
PL23.1 Transportation (page 4-34)
Door D Open (Door D Interlock Switch) Troubleshooting Procedure
1 Check Door D operation. Go to Step 2. Correct the

Does Door D open and close normally? installation.

Door D Open (Door D Interlock Switch) Troubleshooting Procedure (Continued)
2 Test the Door D Interlock Switch. Replace the Go to Step 3.

Run the Service Diagnostics Door D Engine Logic
Does the sensor state change each time (page 8-89).

Are J124 and P/J541 connected? and P/J541.
the Duplex PWB.
between J124 <=> P/J541?
5 Check for +5 V to the switch. Replace the Go to Step 6.

Is there +5 V across J124-2 <=> ground? switch
(page 3-74).

P/J540-1 <=> P/J417-A1
P/J540-2 <=> P/J417-B1
P/J540-3 <=> P/J417-A2
P/J540-4 <=> P/J417-B2
P/J540-5 <=> P/J417-A3
P/J540-6 <=> P/J417-B3
P/J540-7 <=> P/J417-A4
P/J540-8 <=> P/J417-B4

(page 8-89).

Close Door E - Door E is Open
The Door E Interlock Switch in Exit 2 indicates that Door E is open.
Door E Open (Door E Interlock Switch) Troubleshooting Reference
Door E Interlock Print Engine P/J Laser and Exit PWB (page 10-7)
Exit PWB PL8.1 Print Engine Electrical (page 9-40)
Board.
Exit 2 P/J Locator (page 5-15)
Exit 2 Sensor/Fan Wiring (page 5-18)
Door E Open (Door E Interlock Switch) Troubleshooting Procedure
1 Check Door E operation. Go to Step 2. Correct the

Does Door E open and close normally? installation.
2 Test the Door E Interlock Switch. Reconnect the Go to Step 3.

Run the Service Diagnostics Door E Engine Logic
Interlock Switch test. Board connector.
3 Check the switch connections. Go to Step 4. Connect P/J116,

Are P/J116, P/J606B and P/J434 P/J606B and P/
connected? J434.
the Exit PWB.
between P/J116 and P/J434?
5 Check for +5 V to the switch. Replace the Door Replace the Exit
Is there +5 V across P/J116-2 (+)<=> E Interlock switch PWB (page 8-88).

Close Door F - Door F is Open
The Door F Interlock Sensor in the Horizontal Transport indicates Door F is open.
Door F Open (Door F Interlock Switch) Troubleshooting Reference
H-Xport Top Cover Print Engine P/J Engine Logic Board (page 10-13)
Door F Interlock PL8.1 Print Engine Electrical (page 9-40)
Sensor Phaser 5500 Printer Options Service Manual
H-Xport PWB Finisher Main PWB P/J Locator (page 5-35)
Finisher Main Horizontal Transport Wiring (page 5-39)
PWB PL25.2 Horizontal Transport (1/2) (page 4-46)
Engine Logic
PL25.3 Horizontal Transport (2/2) (page 4-48)
Board.
PL25.14 Finisher Electrical (1/2) (page 4-70)
Door F Open (Door F Interlock Sensor) Troubleshooting Procedure
1 Check Door F operation. Go to Step 2. Correct the

Does Door F open and close smoothly? installation.
2 Check the Door F Interlock Sensor Replace the Top Go to Step 3.

Actuator. Cover
Is the actuator damaged? (page 3-108).
3 Check the Door F Interlock Sensor Go to Step 4. Correct the

Is the sensor installed correctly?
4 Test the sensor. Go to Step 11. Go to Step 5.

Run the Service Diagnostics Door F
Interlock Sensor test.
Does the sensor state change when
Door F is opened and closed?
5 Check the Door F Interlock Sensor Go to Step 7. Connect and go

Are P/J8382 of the harness, and P/
J8372 on the H-Xport PWB connected?


Door F Open (Door F Interlock Sensor) Troubleshooting Procedure (Continued)
7 Check H-Xport Interlock Harness Go to Step 8. Repair the H-

continuity. Xport Harness.
1. Disconnect P/J8382 on the harness, and
P/J8372 on the H-Xport PWB.
P/J8382-3 <=> P/J8372-1
P/J8382-2 <=> P/J8372-2
P/J8382-1 <=> P/J8372-3
8 Check for +5 V to the Door F Interlock Go to Step 9. Replace the

sensor. Finisher Main
Is there +5 V across P/J8372-3 <=> P/ PWB
J8372-1 on the H-Xport PWB? (page 3-248).
9 Check the Door F Interlock Sensor signal. Go to Step 10. Replace the Door
Does the voltage across P/J8372-3 <=> F Interlock
P/J8372-1 on the H-Xport PWB change Sensor
when the sensor is blocked? (page 3-116).
10 Replace the Door F Interlock Sensor. Go to Step 11. Problem solved.

Cycle the printer power.

Cycle the printer power. Engine Logic
(page 8-89).

Close Door G - Door G is Open
The Door G Interlock Switch behind the Finisher Front Door indicates Door G is
open.
Door G Open (Door G Interlock Switch) Troubleshooting Reference
Finisher Front Print Engine P/J Engine Logic Board (page 10-13)
Cover PL8.1 Print Engine Electrical (page 9-40)
Door G Interlock Phaser 5500 Printer Options Service Manual
Switch Finisher P/J Locator Door G Interlock (page 5-30)
Interlock Harness
Eject Cover Sensor
Finisher Power Wiring (page 5-38)
Finisher Main PWB PL25.5 Finisher Covers (2/2) (page 4-52)
Engine Logic
Board.
Door G Open (Door G Interlock Switch) Troubleshooting Procedure
1 Check Door G operation. Go to Step 2. Correct the

Does Door G open and close smoothly? installation.
2 Check the Door G Interlock Switch Go to Step 3. Correct the

3 Test the Door G Interlock Switch. Go to Step 9. Go to Step 4.

Run the Service Diagnostics Door G
Door G is opened and closed?
4 Check the Door G Interlock Harness Go to Step 6. Connect and go

Are J8365 on the harness, J8364 on the
Eject Cover SW, and J8388 and J8314
on the Finisher Main PWB connected?


Door G Open (Door G Interlock Switch) Troubleshooting Procedure (Continued)
6 Check Door G Interlock Harness continuity. Go to Step 7. Repair the

1. Disconnect J8365 on the harness, Interlock
J8364 on the Eject Cover SW, and Harness.
J8388 and J8314 on the Finisher Main
PWB.
J8365-1A <=> J8388-2
J8365-1B <=> J8364-2
J8365-2A <=> J8314-3
J8365-2B <=> J8314-2
J8364-1 <=> J8388-1
J8364-3 <=> J8314-1
7 Check +5/+24 V to the Door G Interlock Go to Step 8. Replace the

Switch. Finisher Main
Is there +5 V across J8314-2 <=> ground PWB
on the Finisher Main PWB? (page 3-248).
Is there +24 V across J8388-1 <=>
ground on the Finisher Main PWB?
8 Check the Door G Interlock Switch signal. Replace the Replace the
Does the voltage across J8314-2 <=> Finisher Main Switch
J8314-3 on the Finisher Main PWB PWB (page 3-127).
change when the switch is pressed? (page 3-248).
9 Check the Eject Cover Switch. Go to Step 10. Replace the Door
Does the voltage across J8365-1B <=> H Interlock Switch
ground on the Door G Interlock Harness (page 3-176).
change when the Eject Cover Switch is
actuated?
10 Check the Door G Interlock signal. Go to Step 11. Replace the Door
Does the voltage across J8388-2 <=> G Interlock
ground on the Finisher Main PWB Switch.
change when the Eject Cover SW and
Door G Interlock Switch are actuated
simultaneously?

Cycle printer power. Engine Logic
(page 8-89).

Close Door H - Door H is Open
The Door H (Finisher Eject Cover) Interlock Switch indicates Door H is open.
Door H Open (Door H Interlock Switch) Troubleshooting Reference
Finisher Front Print Engine P/J Engine Logic Board (page 10-13)
Cover PL8.1 Print Engine Electrical (page 9-40)
Door G Interlock Phaser 5500 Printer Options Service Manual
Switch Finisher P/J Locator Door G Interlock (page 5-30)
Door H Interlock
Finisher P/J Locator Input Drive (page 5-30)
Switch
Interlock Harness Finisher Main PWB P/J Locator (page 5-35)
Finisher Power Wiring (page 5-38)
Finisher Main PWB
PL25.5 Finisher Covers (2/2) (page 4-52)
Engine Logic
Board. PL25.9 Finisher Eject (1/3) (page 4-60)
Door H Open (Door H Interlock Switch) Troubleshooting Procedure
1 Check Door G operation. Go to Step 2. Correct the

Does Door G open nd close correctly? installation.
2 Check the Door H Interlock Sensor Go to Step 3. Correct the

3 Check the Door H Interlock Harness Go to Step 5. Connect and go

Are J8365 on the harness, J8364 on the
Eject Cover SW, and J8388 and J8314
on the Finisher Main PWB connected?

5 Check Door H Interlock Harness continuity. Go to Step 6. Repair the

1. Disconnect J8365 on the harness, Interlock
J8364 on the Eject Cover SW, and Harness.
J8388 and J8314 on the Finisher Main
PWB.
J8365-1A <=> J8388-2
J8365-1B <=> J8364-2
J8365-2A <=> J8314-3
J8365-2B <=> J8314-2
J8364-1 <=> J8388-1
J8364-3 <=> J8314-1

Door H Open (Door H Interlock Switch) Troubleshooting Procedure (Continued)
6 Check +5/+24 V to the Door G switch. Go to Step 7. Replace the

Is there +5 V across J8314-2 <=> ground Finisher Main
on the Finisher Main PWB? PWB
Is there +24 V across J8388-1 <=> (page 3-248).
ground on the Finisher Main PWB?

J8314-3 on the Finisher Main PWB Switch
change when the switch is pressed? (page 3-127).
8 Check the Door H Interlock Sensor. Go to Step 9. Replace the Door

Does the voltage across J8365-1B <=> H Interlock
ground on the Door H Interlock Harness Sensor
change when the Eject Cover Switch is (page 3-176).
actuated?
ground on the Finisher Main PWB Switch
change when the Eject Cover SW and (page 3-127).
Door G Interlock Switch are actuated
simultaneously?

Cycle printer power. Engine Logic
(page 8-89).
Close Door J - Door J is Open

The Door J Interlock Switch on the 2000-Sheet Feeder indicates that Door J is open.
Door J Open (Door J Interlock Switch) Troubleshooting Reference
Door J Interlock PL8.1 Print Engine Electrical (page 9-40)
Switch Phaser 5500 Printer Options Service Manual
Tray 6 Main 2000-Sheet Feeder P/J Locator (page 5-20)
Harness 2000-Sheet Feeder Interface Wiring (page 5-23)
Door J
PL22.7 Tray 6 Drive and Transportation (page 4-30)
Engine Logic Board.

Door J Open (Door J Interlock Switch) Troubleshooting Procedure
1 Check the condition of Door J. Replace Door J. Go to Step 2.

Is the Door J Interlock Switch actuator
damaged?
2 Test the Door J Interlock Switch. Go to Step 9. Go to Step 3.

Run the Service Diagnostics Door J
Door J is opened and closed?
3 Check Door J Interlock Harness Go to Step 5. Connect and go

Are FS001, FS002 and P/JF05
connected?

5 Check Door J Interlock Harness continuity. Go to Step 6. Repair the Door J

1. Disconnect FS001, FS002 and P/JF05. Interlock
Harness.
FS002 <=> P/JF05-2
FS001 <=> P/JF05-1
6 Check for +24 V to the Door J Interlock Go to Step 7. Replace the Tray
Switch. 6 PWB
Is there +24 V across PF05-2 <=> PF04-3 (page 3-67).
on the Tray 6 PWB?
7 Check the Door J Interlock Switch signal. Go to Step 8. Replace the Door
Does the voltage across PF05-1 <=> J Interlock Switch
Door J is opened and closed?


Board
(page 8-89).

Replace Maintenance Kit
The Fuser Life Counter has reached its maximum count.
Replace Maintenance Kit Troubleshooting Reference
Fuser PL6.1 Fuser and Exit 1 Unit (page 9-34)

Routine Maintenane Items (page 9-45)
Replace Maintenance Kit Troubleshooting Procedure
1 Warning: Allow the Fuser to cool. Replace the Problem solved.

1. Install a new Maintenance Kit. Engine Logic
Board
2. Reset the Fuser Life counter (page 6-9).
(page 8-89).
Invalid or Missing Configuration Card

The printers Configuration Card is missing or defective. The printer operates as a
base model (non-networking) until a valid Configuration Card is detected.
Invalid or Missing Configuration Card Troubleshooting Reference
Configuration Card PL8.1 Print Engine Electrical (page 9-40)

I/P Board Upgrade Kits and Options (page 9-45)
Invalid or Missing Configuration Card Troubleshooting Procedure
1 Check the Configuration Card installation. Replace the Problem solved.

Remove and reinsert the Configuration Configuration Card.
Card. If the problem
Does the error still occur? persists, replace the
I/P Board
(page 8-91).

Duplicate IP Address Detected
Another device on the network is using the IP address assigned to this printer.
Duplicate IP Address Detected Troubleshooting Reference
I/P Board Resetting Connection Setup Values (6-10)

Duplicate IP Address Detected Troubleshooting Procedure
1 Check the TCP/IP Address stored in the Advise the Enter the correct
printers NVRAM. customer of the IP address.
Is the address correct for the printer? address conflict.

General
Troubleshooting
In this chapter...
Introduction
Network Problems
Operating System and Application Problems
Front Panel Troubleshooting
Low Voltage Power Supply Troubleshooting
AC Power Supply Troubleshooting
Print Engine Troubleshooting
Chapter
4
Introduction
With the exclusion of POST RAM errors, the procedures in this chapter troubleshoot
problems that are not associated with an error code or Front Panel error message.
Network Problems
The Phaser 5500 printer maintains six logs in memory detailing network functions.
The logs contain TCP/IP, NetWare, and AppleTalk initialization events. The logs can
also be accessed remotely via CentreWare Internet Services.
The logs list events chronologically. The log is limited in length; when the log is full
the printer stops recording data to the log. The logs are stored on the Hard Drive so
only new data is stored each time the printers power is cycled.
There is a Connection Setup Page, Configuration Page, and a network reset available
for troubleshooting Network problems.
To Print an Event Log or Runtime Log:

1. From the main menu, select the Troubleshooting Menu, then select Network
Log Pages.
2. Highlight the appropriate menu item from the list and select the OK button.
3. The page should now print.
Operating System and Application Problems

More troubleshooting tips and information are available on the Xerox web site at:
www.xerox.com/office/support.
Macintosh Printing Problems

Image Never Prints
Printer acts as if it is receiving data, but will not print or returns toReady mode
without printing. The most likely cause is a printer PostScript error.
1. Power cycle the printer and try printing again.
2. Make sure the correct Phaser 5500 printer is selected in the Chooser. Try again.
3. In the Chooser or print dialog, switch background printing off. Try again.

4. If the error persists, turn on the PostScript error handler through the Front Panel
PostScript Error Info in the Support menu, or CentreWare IS and print the
document again. Take note of the information on the error page that just printed.
5. Select the appropriate Phaser 5500 PPD with the LaserWriter Driver or
application. Not selecting the appropriate PPD can cause PostScript errors.
6. Try to print a different document from the application. If the PostScript error
does not occur, then the original document may be causing the problem.
Image Rotated 90 Degrees
In the application's Page Setup, make sure that the image is selected to print in portrait
or landscape orientation to match the document. Also, ensure the selected paper size
is correct.
Windows Printing Problems
Image Never Prints

1. Try printing a test page from the printer drivers properties dialog box.
2. Try printing from another application.
3. Try printing to another printer.
4. Try printing from another computer.
5. If the error returns, turn on the PostScript error handler through the Front Panel
PostScript Error Info in the Support menu, or CentreWare IS and print the
document again. Take note of the information on the error page that just printed.
General Troubleshooting 4-3

Front Panel Display Error/Inoperable Buttons
The Front Panel either fails to illuminate or the buttons fail to operate after the power
switch is turned On.
Front Panel Troubleshooting Reference
Front Panel Image Processor Board P/J Locator (page 10-14)

Front Panel Harness Image Processor Board (1/2) Wiring (page 10-32)
Image Processor Board PL1.1 Covers (1/2) (page 9-4)
LVPS
Front Panel Troubleshooting Procedure
1 Check the Front Panel input DC voltages: Go to Step 2. Replace the Image
On the Image Processor Board measure Processor Board
the voltages at the following test points. (page 8-91).
J150-5 <=> Ground = +5 V
J150-6< => Ground = +3.8V
J150-7 <=> Ground = +5 V
J150-8 <=> Ground = +3.8V
J150-9 <=> Ground = +3.8 V
J150-10 <=> Ground = +5 V
Are the voltages within specification?
2 Check Continuity between the Image Go to Step 3. Repair or replace the

Processor Board and the Front Panel. wiring.
between J150 and the Front Panel
connector?
3 Replace the Front Panel. Problem Replace the Image

Is the problem resolved? solved. Processor Board
(page 8-91).

Low Voltage Power Supply Troubleshooting
Print Engine LVPS
Print Engine LVPS Troubleshooting Reference
LVPS Engine Logic Board Plug/Jack locator (page 10-13)

Engine Logic Image Processor Board Plug/Jack Locator (page 10-14)
Board Print Engine LVPS Plug/Jack locator (page 10-16)
Image Print Engine LVPS Wiring Diagram (page 10-21)
Processor Board
Power Switch
Print Engine LVPS Troubleshooting Procedure
1 Check AC supply voltage to the LVPS. Go to Step 2. Verify correct power

1. Remove the Upper Right Cover. from the AC outlet.
Verify the power cord is
2. Turn the printer power On.
in good condition and
3. Measure AC voltage at the following test plugged into the Printer
points on the LVPS:
and AC outlet. Verify
P/J1-1 <=> P/J1- 4 that the GFI Breaker is
Is the voltage across pins 1 and 4 equal not tripped. Verify
to 120V or 220V (line voltage). correct operation of the
printer power switch
and AC harness.
2 Check DC supply voltage to the I/P Board: Go to Step 3. Replace the LVPS
1. Remove the Upper Right Cover. (page 8-92). If the
problem persists, verify
the wire harness to the
3. Measure the voltage at these points: I/P Board. If the wiring
P/J 521- 1 <=> ground +3.3 V checks out, replace the
P/J 521- 6 <=> ground +3.3 V I/P Board (page 8-91).
P/J 521- 3 <=> ground +5.0 V
Are the voltage levels correct?

Print Engine LVPS Troubleshooting Procedure (Continued)
3 Check DC supply voltage to the Engine Go to Step 4. Replace the LVPS

Logic Board: (page 8-92). If the
1. Remove the I/P Board Cover, Upper, problem persists, verify
and Lower Rear Covers. the wire harness to the
Engine Logic board. If
the wiring checks out,
3. Measure the voltage at these points: replace the Engine
P/J526- 2 <=> ground +5.0 V Logic Board
P/J526- 4 <=> ground +24.0 V (page 8-89).
4 Check DC supply voltage to the Exit PWB: All voltages Replace the LVPS, if
1. Remove the Top Cover. are present problem continues
and problem verify the wire harness
persists, to the Exit PWB. If the
3. Measure the voltage at these points:
replace the wiring checks out,
P/J526- 6 < = > ground +5.0V LVPS replace the Exit PWB
P/J526- 8 < = > ground +24.0V (page 8-92). (page 8-88).
Finisher LVPS
Finisher LVPS Troubleshooting Reference
LVPS Phaser 5500 Printer Options Service Manual

Power Cord Finisher LVPS Plug/Jack Locator (page 5-35)
Printer AC Finisher Power Wiring Diagram (page 5-38)
Accessory Panel PL25.14 Finisher Electrical (page 4-70)
Finisher LVPS Troubleshooting Procedure
1 Check AC supply voltage to the LVPS. Go to Step 2. Verify the

1. Remove the Bottom Cover. printers AC
Accessory Panel
2. Check that the Finisher power cord is
is delivering
connected to the printers AC Accessory
power.
Panel and turn the printer power On.
3. Measure AC voltage at the following test
points on the LVPS:
J2- 3 <=> J2- 4 120 V (120 Volt Printer)
J2- 3 <=> J2- 4 220 V (220 Volt Printer)

Finisher LVPS Troubleshooting Procedure (Continued)
2 Check DC voltages on the LVPS harness. Go to Step 3. Replace the

Measure the voltage at these points: Finisher LVPS
P/J505- 3 <=> ground +2.8V (page 3-250).
P/J505- 4 <=> ground +2.8V
3 Check DC voltages on the LVPS harness. Finisher LVPS is Replace the

Measure the voltage at these points: producing the Finisher LVPS
P/J502- 1 <=> ground +24V correct voltages. If (page 3-250).
P/J502- 2 <=> ground +24V intermittent
Are the voltage levels correct? operation is
suspected, replace
the LVPS
(page 3-250).
AC Power Supply Troubleshooting

There is a possible problem with AC power.
Warning
Improper connection of the grounding conductor can result in the risk of
electrical shock.
The following must be observed:

1. Never use a ground adapter plug to connect the machine to a power source.
2. Never attempt any maintenance function that is not specifically called out in the
service procedures.
3. Never remove any covers that are fastened with screws, unless so instructed in the
service procedures.
Caution
If any of the voltage measurements are not as specified in the following steps, the
cause must be corrected. Caution the customer NOT to connect the machine to
the wall outlet. Advise the customer that a licensed electrician must correct the
wiring. Do not attempt to correct the wiring yourself.

Verifying AC Power
AC Power Troubleshooting Reference
Power Cord Print Engine Electrical Specifications (page 1-13)

AC Accessory Panel AC Accessory Panel Plug/Jack Locator (page 10-15)
Wall Outlet PL8.1 Print Engine Electrical (page 9-40)
AC Power Troubleshooting Procedure

1 For 115 V: Go to Step 2. Inform
1. Disconnect the AC power cord from the wall customer of
outlet. insufficient
voltage or
improper
wiring.
AC Neutral AC Line
s4400-285
2. Measure the AC voltage between AC Line and

Neutral, between AC Line and Ground, and
between AC Neutral and Ground.
3. The voltage between Line and Neutral and
between Line and Ground should range from 99
to 135 VAC and the voltage between Neutral and
Ground should be less than 3 VAC.
Is the AC voltage within specification?
For 220V: Go to Step 2. Inform
voltage or
Earth/GND Earth/GND improper
wiring.
Neutral Line
Neutral Line
s4400-286
2. Measure the AC voltage between Line and

Neutral, between AC Line and Earth/Ground,
and between Neutral and Earth/Ground.
between Line and Earth/Ground should range
from 198 to 254 VAC and the voltage between
Neutral and Ground should be less than 3 VAC.
Is the AC line voltage within specification?

AC Power Troubleshooting Procedure (Continued)
1 For 220V: Go to Step 2. Inform
voltage or
Earth improper
Supply wiring.
Pins
Earth s4400-287
2. Measure the AC voltage between Line and

Neutral, between AC Line and Earth/Ground,
and between Neutral and Earth/Ground.
between Line and Earth/Ground should range
from 198 to 254 VAC and the voltage between
Neutral and Ground should be less than 3 VAC.
Is the AC line voltage within specification?
2 1. Check the continuity through all connections of Test the Print Replace the
the power cord. Engine LVPS power cord.
2. The measurement should be less than 10 ohms (page 4-5)
for each connection.
Does continuity test per specification?

Print Engine Troubleshooting
Inoperative Printer
No response from printer when the main power is switched on.
Initial Actions
Eliminate the possibility that an installed option is the cause of the problem.
1. Power Printer Off.
2. Unplug all installed options (Finisher, 1000-Sheet Feeder, 2000-Sheet Feeder,
Duplex and Exit 2.
3. Power the printer On. If printer powers up normally, plug in the options one at a
time until the defective option is isolated. If the printer remains inoperative, use
the following procedure to locate the problem.
Inoperative Printer Troubleshooting Reference
Power Cord Print Engine Electrical Specifications (page 1-13)

GFI Breaker AC Accessory Panel Plug/Jack Locator (page 10-15)
AC Accessory Panel PL8.1 Print Engine Electrical (page 9-40)
Wall Outlet
Inoperative Printer Troubleshooting Procedure

1 Check the AC Power Cord. Go to Step 2. Plug in the AC
Is the AC Power Cord plugged into the Power Cord or
printer and the AC outlet? reset the GFI
Is the GFI breaker operational? Breaker
2 Check the voltage at the AC outlet. Go to Step 3. Notify customer

Is there approximately 110V (or 220V if a that the power is
220V model) at the AC outlet? out of
specification.
3 Check the AC input Voltage to the LVPS Go to Step 4. Go to Step 5.

1. Remove the Upper Right Cover.
2. Power the Printer on.
points on the LVPS.
T 11 1 <=>T 12 1 + 120V or 220 V

Inoperative Printer Troubleshooting Procedure (Continued)
4 Check AC supply voltage to the LVPS. Go to LVPS Go to Step 6.
1. Remove the Upper Right Cover. Procedure
(page 4-5).
points on the LVPS:
P/J1-1 <=> P/J1- 4
Is the voltage across pins 1 and 4 equal
to 120V or 220V (line voltage).
5 Check AC input continuity. Verify the Power Verify the GFI

1. Power the Printer off. Cord is in good breaker is not
condition and is tripped and is
2. Check for continuity between the printer
the correct cord. If operational. If
AC power inlet connector and
necessary, problem persists,
T 11 <=>T12
replace the cord. repair the AC inlet
Are these conductive? connector wiring.
If necessary,
replace the GFI
Breaker
(page 8-94).
6 Check the AC Voltage from the LVPS to the Verify or repair Replace the LVPS
Power Switch. the wiring from (page 8-92).
Measure AC voltage at the following test the LVPS to the
points on the LVPS Power Switch. If
P/J 1 3 < = > P/J 1 6 + 120V or 220 V necessary,
Are the voltages measured within replace Power
specification? Switch
(page 8-86).

Engine Logic Board
Engine Logic Board Troubleshooting Reference
Applicable Parts Wiring and Plug/Jack Map References
Engine Logic Board Engine Logic Board Plug/Jack locator (page 10-13)
LVPS Print Engine LVPS Plug/Jack locator (page 10-16)
Print Engine LVPS Wiring Diagram (page 10-21)
Engine Logic Board Troubleshooting Procedure
1 Check AC supply voltage to the LVPS. Go to Step 2. Verify the power cord is
1. Remove the Upper Right Cover. in good condition and
plugged into the Printer
and AC outlet. Verify
3. Measure AC voltage at the following test that the GFI breaker is
points on the LVPS:
not tripped. Verify
P/J1-1 <=> P/J1-4 correct operation of the
Is the voltage across pins 1 and 4 equal printer power switch
to 120V or 220V (line voltage). and AC harness. Verify
correct power from the
AC outlet.
2 Check DC supply voltage to the Engine Replace the Go to Step 3.

Logic Board: Engine Logic
1. Remove the I/P Board Cover, Upper, Board
and Lower Rear Covers. (page 8-89).
3. Measure the voltage at these points:
P/J400-3 <=> ground +5.0 V
P/J400-1 <=> ground +24.0 V
3 Check the Engine Logic Board harness Replace the Repair the wiring. If the
continuity: LVPS problem persists,
1. Disconnect P/J526 from the LVPS and (page 8-92). replace the LVPS, and
P/J400 from the Engine Logic Board. if necessary, the
Engine Logic Board
(page 8-89).
P/J526-2 <=> P/J400-3
P/J526-1 <=> P/J400-4
P/J526-4 <=> P/J400-1
P/J526-3 <=> P/J400-2

Image Processor Board Isolation
This procedure is used to isolate the Image Processor Board, or one of its on-board
options as the root cause of the failure.
Image Processor Board Isolation Troubleshooting Reference
Image Processor Board Image Processor Board P/J Locator (page 10-14)
Options Image Processor Board (1/2) Wiring (page 10-32)
Image Processor Board Isolation Troubleshooting Procedure
1 Check option installation. Go to Step 3. Go to Step 2.

NOTE: If no on-board options are installed (Hard
Drive, etc.), go on to Step 2.
1. Switch the printer power Off.
2. Disconnect all cables connected to the Rear
Panel.
3. Remove all on-board options (Hard Drive, etc.)
from the Image Processor Board.
4. Switch the printer power On.
Does the printer boot correctly and is Ready
displayed on the Front Panel?
2 1. Switch the printer power Off. Problem Go to "Image

2. Remove then re-install the cable between P/J590 solved. Processor
on the Image Processor Board and P/J402 on the Board" on
Engine Logic Board. (page 4-14).
3. Switch the printer power On.
Does the printer boot correctly and is Ready
3 Isolate the faulty on-board option. Repeat the last Replace the
1. Switch the printer power Off. Step with the option or
next option or cable just
2. Re-install one of the removed options or cables.
cable until the installed.
3. Switch the printer power On. problem is
Does the printer boot correctly and is Ready found.

Image Processor Board Troubleshooting Reference
Image Processor Board Image Processor Board P/J Locator (page 10-14)
LVPS Image Processor Board (1/2) Wiring (page 10-32)
Image Processor Board Troubleshooting Procedure
1 Check the DC power suppled from the Replace the Go to Print Engine
LVPS. I/P Board LVPS (page 4-5) and
1. Disconnect P/J120 on the Image (page 8-91). verify LVPS operation.
Processor Board. If the LVPS is operating
2. Measure voltages across these points: correctly. Repair the
wiring connecting the
P120-1 <=> ground 3.3 V
LVPS and I/P Board.
P120-4 <=> ground 5 V
P120-6 <=> ground 3.3 V
P120-12 <=> ground 3.3 V
Are the voltages correct?

RAM Memory Fault Isolation
Image Processor Board RAM memory has failed or is not installed. A minimum of
128 MB of RAM must be installed for proper printer operation. The Phaser 5500
supports PC133 SDRAM in 144-pin SO-DIMM form. The printer accepts modules of
128, or 256 MB in combinations to a total of 512 MB.
Applicable POST Error Codes

Hardware Failure: RAM Memory Slot 1 Checksum
Hardware Failure:RAM Memory Slot 2 Checksum
Hardware Failure:RAM Memory Slot 1 Rejected
Hardware Failure:RAM Memory Slot 2 Rejected
Power On Self Test Error 4:Memory
Power On Self Test Error 15:RAM DIMM
Power On Self Test Error RAM ERROR
POST RAM Memory Failure Troubleshooting Reference
SDRAM Memory Image Processor Board P/J Locator (page 10-14)

Image Processor Board PL8.1 Print Engine Electrical (page 9-40)
Initial Actions:
Check that the RAM devices aremaking positive contact with their connectors.
1. Power off the printer.
2. Remove and re-install the RAM memory after verifying it meets the Xerox
specifications. See "Memory Specifications" on page 1-11. If the problem
persists, use the following procedure to correct it.
POST RAM Memory Failure Troubleshooting Procedures
1 Power on the printer. Go to Step 5. Go to Step 2.

Is RAM ERROR displayed on the Front
Panel?
2 Is POWER ON SELF TEST ERROR Go to Step 5. Go to Step 3.

4: MEMORY displayed on the Front
Panel?

POST RAM Memory Failure Troubleshooting Procedures (Continued)
3 Is POWER ON SELF TEST ERROR Go to Step 4. Problem Solved.
15: RAM DIMM displayed on the Front
Panel?
4 Print a Startup Page and review the Replace the DIMM Go to Step 5.
contents. and go to Step 9.
Does the Startup Page identify a failed
memory DIMM?
5 Are there two DIMMs installed in the Go to Step 6. Go to Step 8.

printer?
6 1. Power off the printer and remove one of Go to Step 8. Go to Step 7.

the DIMMs.
2. Power on the printer.
Is a memory fault message displayed?
7 1. Power off the printer and remove the first Go to Step 8. Go to Step 9.
DIMM.
2. Install the second DIMM and power on
the printer.
Is a memory fault message displayed?
8 1. Power off the printer and move the Replace the DIMM Replace the I/P
suspected defective DIMM to the other and go to Step 9. board
memory socket. (page 8-92).
2. Power on the printer.
Does the DIMM fail in the new location?
9 Install all of the DIMMs and power on the Replace the I/P Problem Solved.
printer. board
Is a memory fault message displayed? (page 8-92).

Print-Quality
Troubleshooting
In this chapter...
Print-Quality Problems Overview
Analyzing Test Prints
Print-Quality Troubleshooting
Chapter
5
Print-Quality Problems Overview
Print-quality defects can be attributed to printer components, consumables, media,
internal software, external software applications, and environmental conditions. To
successfully troubleshoot print-quality problems, eliminate as many variables as
possible. The first step is to generate test prints using information pages embedded in
the printer on laser paper from the approved media list. The paper should be from an
unopened ream that has been acclimated to room temperature.
If the print-quality defect is still present after printing on approved media from an
unopened ream of paper, then media, software applications, and environmental
conditions need to be researched.
Print a Configuration Page to determine the temperature and humidity under which
the printer has been operating. Compare this to the environmental specifications for
the printer found in "Environmental Specifications" on page 1-14 of this manual.
Temperature and humidity extremes can adversely affect the Xerographic and fusing
characteristics of the printer.
When analyzing a print-quality defect, first determine if the defect is repeating or
random. Continuous defects in the process direction, such as voids and lines, are the
most difficult to diagnose. The visible surfaces of all rollers should be inspected for
obvious defects.
Analyzing Test Prints

The Test Print analysis procedures explain each of the areas and the print-quality
parameters. Further assistance in evaluating image-quality problems is available in
the Troubleshooting Print Quality Page in the Print-Quality Problems section of the
Troubleshooting menu. These pages contain detailed explanations of print-quality and
image-quality problems along with possible causes and solutions for the problems.
The Print Quality test print shown on page 5-4 is used to evaluate that the printed
image meets specifications.
Note
The printer prints the test print using the job defaults established in the Printer
Setup menu. Insure that Edge-to-Edge Printing, located under the PCL Setup
menu, is set to Off before printing the test print; otherwise, the image will be
shifted left.
To print the Print Quality test print:

1. From the Main menu, scroll to Troubleshooting, then press the OK button.
2. Scroll to Print Quality Problems, then press the OK button.
3. Scroll to Test Prints, then press the OK button.

Print-Quality Defect Definitions
The following table lists the print-quality defect corrective procedures, their
definition, and the page where each procedure is presented.
Defect Definition Go To:
Light Prints The overall image density is too light. page 5-14
Blank Prints Prints with no visible image. page 5-16
Black Prints The print is completely covered with toner with no visible page 5-19
image.
Vertical Deletions There are areas of the image that are extremely light or page 5-21
missing entirely. These areas run vertically along the page in
the direction of paper movement.
Horizontal There are areas of the image that are extremely light or page 5-23
Deletions missing entirely. These areas run horizontally across the
page in the direction of scanning.
Vertical Streaks Extraneous dark lines/bands in the process direction. page 5-25
Horizontal Streaks Extraneous dark lines/bands in the direction of scan. page 5-27
Spots There are spots of toner on the page. page 5-11
Unfused Image Part of or all of the image is unfused. Refer to the page 5-30
specification.
Damaged Prints Creases, wrinkles, excessive curl, cuts, folds or embossed page 5-33
marks.
Resolution At 600 dpi, the two pixel lines and halftone patches cannot be page 5-7
reproduced clearly on the print.
Spot Deletions Solid areas are marked with irregular white areas. page 5-35
Repeating Defects Recurring marks, spots, lines, or voids. page 5-37
Residual Image The image from a previous print appears on the current print. page 5-38
Background Uniform toner contamination in non image areas. See the page 5-40
Background specification.
Uneven Density The text/line darkness and solid area density image varies page 5-42
across the print.
Skewed Image Angular displacement of the image from its intended position page 5-44
on the print. See the specification.
Registration Displacement of the image, in the process or scan direction, page 5-45
from its intended position on the print.
Skip/Smears Skip - Loss or stretching of the image in bands across the page 5-47
process direction.
Smear - The distortion of the image in bands across the
process direction that appears to be blurred or compressed.
Print-Quality Troubleshooting 5-3

Print Quality Test Print
Test Print
Phaser5500-040302-2-L
8.5x11 (LEF Only)
LEAD EDGE
s5500-619

Deletions (Line, Band, Spots)
s5500-048
Line, Band, or Spot Deletions

Line, Band or Spot Deletions Troubleshooting Procedure
1 Inspect the test print for the presence of deletions Go to Step 2. Go to

(missing image). There should be no deletions with a "Fusing" on
diameter larger than 0.5 mm visible on test prints. page 5-6.
Are there deletions on the test prints?
2 Are there vertical (in process direction) Line/ Go to Go to Step 3.

Band deletions present? "Vertical
Deletions" on
page 5-21.
3 Are there Horizontal (in direction of scanning) Go to Go to Step 4.

Line/Band Deletions present? Horizontal
Deletions on
page 5-23.
4 Are there Spot Deletions present? Go to "Spot Go to

Deletions" on "Fusing" on
page 5-35. page 5-6.
Note
The specified operating environment for the printer ranges from 41 degrees F
(5 degrees C) at 15% relative humidity to 95 degrees F (32 degrees C) at 85%
relative humidity. Fusing performance varies according to the environment.

Fusing
Test Print
Phaser5500-040302-2-L
8.5x11 (LEF Only)
LEAD EDGE
s5500-049
A cold environment affects the warm-up time, while high humidity has an
adverse effect on the fusing of prints.
The paper weight or composition or transparency affects the fusing of prints.
Fusing Errors Troubleshooting Procedure
Actions and Questions Yes No
Rub the image three times at the marked check points with a Go to Go to
soft cloth or tissue. The image should not lift off of the "Resolution" "Unfused
surface. on page 5-7. Image" on
Does the fusing quality of the image appear acceptable? page 5-30.

Resolution
Test Print
Phaser5500-040302-2-L
8.5x11 (LEF Only)
LEAD EDGE
s5500-050
Resolution Troubleshooting Procedure
Observe the three resolution check points on several test The printed Go to
prints. Check the image resolution in each of these areas: test patterns "Resolution"
Arrow 1: The two pixel vertical, horizontal, and diagonal meet the on
lines should be clear and continuous. The diagonal lines Resolution page 5-34.
might appear to be narrower than the others. Specification
Arrow 2: The text paragraphs should be roughly equal . Go to
in density. page 5-8.
Arrow 3: The half-tone patches adjacent to the solid
blocks in the corners should be uniform in appearance.
Are the check points (arrows 1, 2, and 3) within
specification?

Registration
s5500-051
Leading Edge to Trailing Edge (Process) Registration Troubleshooting Procedure
Measure the registration on two consecutive test prints. Fold The test prints Go to
the paper in half (leading edge to trailing edge). Observe the meet the "Registration"
fold line of the paper with reference to the cross hairs of the Leading Edge on page 5-45.
target. to Trailing
Is the fold within +/- 2.5 mm of the target cross hairs Edge
(each line on the target is 1 mm). Registration
Specification.
Go to
"Registration
(Side to Side)"
on page 5-9.

Registration (Side to Side)
s5500-052
Side to Side (Scan Direction) Registration Troubleshooting Procedure
Measure the registration on two consecutive test prints: The printed Go to

1. Fold the paper in half (side to side). test patterns "Registration"
meet the Side on page 5-45.
2. Observe the fold line of the paper with reference to the
to Side
cross hairs of the target.
Registration
Is the fold within +/- 2.0 mm of the target cross hairs Specification.
(each line on the target is 1 mm).
Go to
"Skewed
Image" on
page 5-44.

Skips/Smears
Test Print
Phaser5500-040302-2-L
8.5x11 (LEF Only)
LEAD EDGE
Skip
Smear
s5500-053
Skips or Smears Troubleshooting Procedure
Inspect the ladder chart test pattern as shown in the figure. Go to "Spots" Go to "Skips
Is the pattern free from skips and smears? on page 5-11. and Smears"
on page 5-47.

Spots
s5500-054
Spots Troubleshooting Procedure
1. From the Main Menu, select Information, then press the Go to "Light Go to "Spots"
OK button. (Undertoned) on page 5-29.
2. Scroll to Information Pages, then press the OK button. Print" on
page 5-14.
3. Scroll to Configuration Page, then press the OK button.
4. Inspect the print for spots. Within a 289 X 95 mm square:
There should be no spots larger than or equal to
0.5 mm visible on the prints.
There should be no more than 1 spot measuring
between 0.4 mm and 0.5 mm visible on the print.
There should be no more than 16 spots measuring
between 0.25 mm and 0.4 mm visible on the print.
Any spot measuring less than 0.25 mm is
acceptable.
Are the prints free of spots or the spots that are visible
fall within the acceptable range?

Skew
Test Print
Phaser5500-040302-2-L
8.5x11 (LEF Only)
Lead Edge of Paper

LEAD EDGE
s5500-055
Skew Troubleshooting Procedure
1. Select Troubleshooting, then press the OK button. The printed Go to

2. Scroll to Print Quality Problems, then press the OK test patterns "Skewed
button. meet the Image" on
Skew page 5-44.
3. Select Test Prints, then press the OK
specifications.
4. Measure the dimensions A and B on two consecutive
Go to "Skips
test patterns. and Smears"
Is the difference between A and B 1.25 mm or less? on page 5-47.

Other Print Defects
Other Print Defects Troubleshooting Procedure
1 Inspect the Test Patterns for other Print Defects. Return to Go to Step 2.
Are the test prints free of defects? "Analyzing
Test Prints"
on page 5-2.
2 Are there dark streaks present on the test prints? Go to Go to Step 3.

"Vertical
Streaks" on
page 5-25 or
"Horizontal
Streaks" on
page 5-27.
3 Is there a residual image (ghost) on the test print? Go Go to Step 4.

to"Residual
Image" on
page 5-38.
4 Is the paper damage: wrinkles, creases, tears, etc.? Go to Problem

"Damaged solved.
Print" on
page 5-33.

Print-Quality Troubleshooting
Light (Undertoned) Print

The overall image density is too light.
Initial Actions
Inspect the paper path for items, such as staples, paper clips, and paper
scraps.
Check the installation of the Drum Cartridge.
Check that the Drum Cartridge ground contact points are clean.
Ensure that there are no obstructions in the Laser path.
Ensure that draft mode is turned off.
Light Print Troubleshooting Reference
Applicable Parts Example Print

Durm Cartridge
Toner Cartridge
Transfer Roller
High-Voltage Power
Supply
Engine Logic Board
s5500-056
Light Print Troubleshooting Procedure
1 Checking paper condition Problem solved. Go to Step 2.

Load new, dry recommended paper,
and perform Test Print.
Is the image density normal?

Light Print Troubleshooting Procedure (Continued)
2 Check the Drum Cartridge. Problem solved. Go to Step 3.

1. Install a new Drum Cartridge.
2. Print a Test Print.
3 Checking the Transfer Roller. Replace the Go to Step 4.

1. Remove the Transfer Roller. Transfer Roller
(page 8-44).
2. Check for contamination or wear.
Is there any contamination or
wear on the Transfer Roller?
4 Check Drum Cartridge installation. Go to Step 5. Clean High-Voltage

Remove the Drum Cartridge and Contacts.
check the Drum Cartridge High-
Voltage contacts.
Are the contacts clean?.
5 Check the Drum Cartridge ground. Correct and clean Go to Step 6.

Remove the Drum Cartridge and Earth Plate or
check the Earth Plate located behind replace the Drum
the Drum Cartridge. Cartridge.
Is the Earth Plate contaminated or
deformed?
6 Check image development. Go to Step 7. Go to Step 9.

2. Turn off the power while printing.
3. Carefully remove the Drum
Cartridge and check the image
formed on the drum right before
the Transfer Roller.
Is the image completely formed
on the drum? Is it clear, black, and
easy to read?
7 Check image transfer. Go to Step 9. Go to Step 8.

Check the image formed on the
drum, right after the Transfer Roller.
Is the image completely
transferred on the paper?
8 Check the HVPS. Problem solved. Go to Step 9.

1. Replace the HVPS (page 8-86).
Is the Test Print normal?
9 Check the Engine Logic Board. Problem solved. Replace the I/P Board
1. Replace the Engine Logic Board (page 8-91).
(page 8-89).

Blank Print (No image)
No visible image anywhere on the output print as shown here.
Initial Actions
scraps.
Ensure there are no obstructions in the Laser path.
Ensure the blank prints are not the result of multi-sheet feeds.
Blank Print Troubleshooting Reference

Laser Assembly
Drum Cartridge
Transfer Roller
High-Voltage Power
Supply
Engine Logic Board
s5500-057
Blank Print Troubleshooting Procedure
1 Check the Print Engine. Print a Configuration Go to Step 4.

Print a Test Print. Page. Go to Step 2.
Is the Test Print Normal?
2 Check Confirguration Page. Verfiy the Go to Step 4.

Print the Configuration Page. Customers print job.
Is the Configuration Page normal? Go to Step 3.
3 Check the Customers Print Job. Verify printer Go to Step 4.

Is the Customers Print Job connections. If
blank? problem persists,
Replace the I/P
Board (page 8-91).

Blank Print Troubleshooting Procedure (Continued)

2. Run a Test Print.

(page 8-44).
6 Check Drum Cartridge installation. Go to Step 7. Clean the contacts.

Remove the Drum Cartridge and
check the Drum Cartridge High
Voltage contacts.
Are the contacts clean?

Remove the Drum Cartridge and the Earth Plate or
deformed?
8 Check laser beam path. Remove obstacles Go to Step 9.

1. Check that there are no obstacles or clean the Laser
between the Laser Assembly and Assembly window.
Drum.
2. Check the Laser Assembly
window for contamination.
Is there any obstacle in the laser
beam path or in the window?
9 Check Laser Assembly installation. Go to Step 11. Go to Step 10.

Is the Laser Assembly installed
securely with four screws?
10 Check Laser Assembly installation. Problem solved. Go to Step 11.

1. Install the Laser Assembly.
Is the trouble rectified?
11 Check Laser Assembly connections. Go to Step 12. Connect P/J130, P/

Are P/J130, P/J140, P/J160, P/ J140, P/J160, P/J170
J170, P/J406, and P/J620 P/J406, and P/J620.
connected?
CAUTION: Excessive force applied
to the board can cause a
Laser misalignment.

Blank Print Troubleshooting Procedure (Continued)

easy to read?


(page 8-89).

Black Prints
A totally black output print. There is toner on the paper with no visible image.
Initial Actions
scraps.
Check that the Drum Cartridge ground contacts are clean.
Ensure the covers are in place and no outside light enters the printer.
Black Print Troubleshooting Reference

Drum Cartridge
High-Voltage Power
Supply
Engine Logic Board
s5500-058
Black Print Troubleshooting Procedures
1 Check the Print Engine. Print a Go to Step 4.

Print a Test Print. Configuration
Is the Test Print Normal? Page, Go to
Step 2.
2 Check Confirguration Page. Verfiy the Go to Step 4.

Print the Configuration Page. Customers print
Is the Configuration Page normal? job. Go to
Step 3.

Black Print Troubleshooting Procedures (Continued)
3 Check the Customers Print Job. Verify printer Go to Step 4.
Is the Customers Print Job blank? connections. If
the problem
persists, replace
the I/P Board
(page 8-91).

2. Run a Test Print.

6 Check the Engine Logic Board. Problem solved. Replace the I/P
1. Replace the Engine Logic Board (page 8-89). Board
(page 8-91).

Vertical Deletions
A vertical band in the scan direction where the image is missing or extremely light.
Initial Actions
Check that the paper supply is dry and meets specifications.
scraps.
Check installation of the Drum Cartridge.
Check Transfer Roller for wear or contamination.
Ensure there are no obstructions in the laser path.
Check that rollers and other paper path components are clean and
unobstructed.
Vertical Deletions Troubleshooting Reference

Drum Cartridge
Transfer Roller
Laser Assembly
Fuser
Engine Logic Board
s5500-059
Vertical Deletions Troubleshooting Procedure
1 Check paper condition. Go to Step 2. Problem solved.

1. Load new, dry paper.
Does the problem still occur?
2 Check the paper path. Go to Step 3. Remove obstacles or

Is the paper path clear? contamination.

Vertical Deletions Troubleshooting Procedure (Continued)
3 Check laser beam path. Go to Step 4. Remove obstacles or

1. Check that there are no obstacles clean the Laser
Drum.
Is there obstacles in the laser
beam path or window?
4 Check Laser Assembly installation. Go to Step 6. Go to Step 5.

Is the Laser Assembly installed
securely with four screws?
5 Check Laser Assembly installation. Problem solved. Go to Step 6.

1. Install the Laser Assembly.


(page 8-44).
8 Check the Heat and Pressure Replace the Fuser Go to Step 9.

Rollers. (page 8-76).
WARNING: Allow the Fuser to cool
before removing it.
Remove the Fuser.
Is there contamination or defects
on the Heat or Pressure Roller?
9 Check the Engine Logic Board. Problem solved. Go to Step 10.

1. Replace the Engine Logic Board
(page 8-89).
10 Check Laser Assembly connections. Replace the I/P Connect P/J130, P/

Are P/J130, P/J140, P/J160, Board (page 8-91). J140, P/J160, P/J170
P/J170, P/J620 and P/J406 P/J620, and P/J406 .
connected?
Laser misalignment.

Horizontal Deletions
A deletion is an area of the print where the image is missing or extremely light.
Horizontal deletions extend across the page.
Initial Actions
scraps.
Check the Transfer Roller for contamination or wear.
unobstructed.
Horizontal Deletions Troubleshooting Reference

Drum Cartridge
Transfer Roller
Laser Assembly
Fuser
Engine Logic Board
s5500-060
Horizontal Deletions Troubleshooting Procedure



Horizontal Deletions Troubleshooting Procedure (Continued)

4 Check the Transfer Roller. Replace the Go to Step 5.

(page 8-44).
2. Check the Transfer Roller for
contamination and wear.
5 Check the Heat and Pressure Roller. Replace the Fuser Go to Step 6.
(page 8-76).
before attempting to
remove it.
Remove the Fuser.
crack on Heat or Pressure Roller?

easy to read?


(page 8-89).

Vertical Streaks
Extraneous dark lines/bands in the scan direction.
Initial Actions
scraps.
Inspect the paper path for contamination or obstructions.
Vertical Streaks Troubleshooting Reference

Drum Cartridge
Transfer Roller
Laser Assembly
Fuser
Engine Logic Board
s5500-061
Vertical Streaks Troubleshooting Procedure



Vertical Streaks Troubleshooting Procedure (Continued)


(page 8-44).

check the Drum Cartridge High-
Voltage contacts.

Remove the Drum Cartridge and Earth Plate or
deformed?
7 Check laser beam path. Remove obstacles Go to Step 8.

1. Check that there are no obstacles or clean the Laser
Drum.
Is there obstacles in the laser
beam path or window?
WARNING: Allow the Fuser to cool (page 8-76).
before removing it.
Remove the Fuser.
(page 8-89).
Is the Test print normal?

Horizontal Streaks
There are black lines running horizontally across the page in the process direction.
Initial Actions
scraps.
Check the Drum Cartridge Drum surface for scratches.
Horizontal Streaks Troubleshooting Reference

Drum Cartridge
Transfer Roller
Laser Assembly
Fuser
Engine Logic Board
s5500-062
Horizontal Streaks Troubleshooting Procedure




Horizontal Streaks Troubleshooting Procedure (Continued)

(page 8-44).
(page 8-76).
before removing it.
Remove the Fuser.
crack on Heat or Pressure Roller?

easy to read?


9 Check the Engine Logic Board. Problem solved. Go to Step 10.

1. Replace the Engine Logic Board
(page 8-89).
10 Check Laser Assembly connections. Replace the I/P Connect P/J130, P/

Are P/J130, P/J140, P/J160, P/J170 Board (page 8-91). J140, P/J160, P/J170
P/J620 and P/J406 connected? P/J620 and P/J406 .
Laser misalignment.

Spots
There are spots of toner randomly scattered on the page.
Initial Actions
Check that the paper is clean, dry, and meets specifications.
If using recycled paper, it may have spots.
scraps.
Check Drum surface for spots or contamination.
Check the Fuser for wear or contamination.
Spots Troubleshooting Reference

Drum Cartridge
Transfer Roller
Fuser
Engine Logic Board
s5500-063
Spots Troubleshooting Procedure



Spots Troubleshooting Procedure (Continued)

4 Check the Transfer Roller. Go to Step 5. Replace the Transfer

1. Remove the Transfer Roller. Roller (page 8-44).
Is there contamination or wear?
before removing it.
Remove the Fuser.
on Heat or Pressure Roller?
6 Replace the Engine Logic Board Problem solved. Replace the I/P Board
(page 8-89). (page 8-91).
Print a Test Print.
Unfused Image
The printed image is not fully fused to the paper. The image rubs off easily.
Initial Actions
Check to ensure that the printer installation meets environmental
specifications. A location thats too cold or too humid reduces fusing
performance.
scraps.
Check to ensure that the paper is dry and within specifications.
Verify that the paper type is set correctly for the Fuser temperature
configuration.

Fuser Temperature Defaults
Paper Type Fuser Temperature Setting

Plain Medium
Letterhead Medium
Transparency Low
Labels High
Colored Paper Medium
Card Stock High
Envelope High
Special Medium
Unfused Image Troubleshooting Reference

Fuser
High-Voltage Power
Supply
Engine Logic Board
s5500-064
Unfused Image Troubleshooting Procedure
1 1. Replace the paper with new, dry Problem solved. Go to Step 2.

paper from an unopened ream.

Unfused Image Troubleshooting Procedure (Continued)
2 1. Check that the thumbscrews on Problem solved. Go to Step 3.

on the Fuser Assembly are tight.
Handle
E
Knob
s5500-065

before removing it.
Remove the Fuser.
Is there contamination or cracks
on Heat or Pressure Roller?

easy to read?


(page 8-89).
Is the tTest print normal?

Damaged Print
The page comes out of the Standard Output Tray either wrinkled, creased, or torn.
Note
If paper damage occurs within an installed option, determine the location where
the damage occurs an correct as necessary to eliminate the problem.
Initial Actions
Verify that the Drum Shutter operates properly when Door A is opened or
closed.
scraps.
unobstructed.
Damaged Print Troubleshooting Reference

Fuser
Feed Rollers
Tray
s5500-066
Damaged Print Troubleshooting Procedure
1 Check the installation location. Go to Step 2. Correct the installation.

Check that the printer is level, has its If the problem persists,
feet, and is in alignment. go to Step 2.
Is the installation adaquate?

Damaged Print Troubleshooting Procedure (Continued)
2 Check paper feeding. Go to Step 3. Problem solved.

1. Remove the source Tray.
2. Reload paper in the tray.


5 Check rollers in the paper path. Replace defective Go to Step 6.

1. Check Feed and paper path rollers.
rollers for contamination, wear, or
damage.
2. Check whether pinch rollers rotate
freely and spring pressure is
applied evenly.
Is there any contamination, wear
or damage to the rollers?
(page 8-76).
before removing it.
Remove the Fuser.
7 Replace the following, in order, until

the defective component is found.
Paper Feed Rollers
Fuser (page 8-76)
Transfer Roller (page 8-44)
Exit Assembly (page 8-78)
Resolution
The two pixel lines and halftone patches cannot be reproduced clearly on the test
print.
Initial Actions
Ensure the NVRAM Laser Power adjustment is set to the default, which is 4.

Resolution Troubleshooting Procedure
1 1. Install a new Drum Cartridge. Problem solved. Go to Step 2.

Is the test print output resolution good?
2 Replace the following, in order until the

defective component is found:
Laser Assembly (page 8-74)
Engine Logic Board (page 8-89)
Spot Deletions
Solid areas are marked with irregular white areas.
Initial Actions
scraps.
Spot Deletions Troubleshooting Reference

Drum Cartridge
Transfer Roller
Fuser
Engine Logic Board
Image Processor Board.
s5500-067

Spot Deletions Troubleshooting Procedure

1. Load fresh, dry paper.

Check the paper path for contamination.
contamination or obstacles.
Is the paper path clear?

2. Re-print the defective image.

(page 8-44).
before removing it.
Remove the Fuser.
(page 8-89).

Repeating Defects
Recurring marks, spots, lines, or voids.
Initial Actions
scraps.
Repeating Defects Troubleshooting Procedure
1 1. Replace paper with new paper. Go to Step 2. Problem solved.

2. Print a test print.
Do the repeating defects still
appear?
2 Do the defects occur every: Install a new Drum Go to Step 3.

44 mm (1.7 in.) Cartridge.
56.5 mm (2.2 in.)
94.2 mm (3.7 in.)
3 Do the defects occur every Replace the Go to Step 4.

58.7 mm (2.3 in.)? Transfer Roller
(page 8-44).
4 Do the defects occur every: Replace the Fuser

78.5 mm (3.1 in.)? (page 8-76).
Xerographic Component Specifications

The following table lists measurements of critical printer components. Refer to these
measurements when diagnosing a repeating print-quality problem.
Component Circumference
Charge Roller (Drum Cartridge) 44.0 mm (1.7 in.)
Developer Roller (Drum Cartridge) 56.5 mm (2.2 in.)
Photoreceptor (Drum Cartridge) 94.2 mm (3.7 in.)
Transfer Roller (Door A) 58.7 mm (2.3 in.)
Fuser Heat Roller (Fuser) 78.5 mm (3.1 in.)

Residual Image
The image from a previous print appears on the current print.
Initial Actions
scraps.
Verify the paper is within the specifications on the Paper Tips Page.
Residual Image Troubleshooting Reference

Fuser
Engine Logic Board
HVPS
s5500-068
Residual Image Troubleshooting Procedure
1 Check image quality. Go to Step 2. Go to Step 3.

Is the customer printing the same
image in large quantity?
2 Print 30 Test Prints. Go to Step 3. Print 30 customer

Does the residual image appear? prints and go to Step 3.

2. Print 30 Test Prints.

Residual Image Troubleshooting Procedure (Continued)

check the Drum Cartridge High
Voltage contacts.

Remove the Drum Cartridge and the Earth Plate or
deformed?
6 Check the Drum Cartridge. Go to Step 7. Problem solved.

2. Print 30 Test Prints.
Does the residual image appear?
(page 8-76).
before attempting to
remove it.
Remove the Fuser.
defects on Heat or Pressure
Roller?
8 Check that the HVPS is installed Replace the HVPS. Go to Step 9.

correctly?
Is the HVPS installed correctly?
(page 8-89).

Background
There is toner contamination on all or part of the page. The contamination appears as
a very light gray dusting.
Initial Actions
Verify the Toner Cartridge is a Xerox manufactured part. If a non-Xerox
Toner Cartridge is being used, this could be the problem.
Check that the Laser Window is clean.
scraps.
Ensure the covers are in place and no outside light enters the printer.
Background Troubleshooting Reference

Drum Cartridge
Transfer Roller
High-Voltage Power
Supply
Engine Logic Board
s5500-069
Background Troubleshooting Procedure


Background Troubleshooting Procedure (Continued)


2. Re-print the defective image.

(page 8-44).

easy to read?


(page 8-89).

Uneven Density
Image density varies across the page in either direction.
Initial Actions:
Load new, dry paper that meets specifications.
Check that the Toner Cartridge is properly installed and not empty.
Ensure that the printer is reasonably level.
Check to make sure the Laser path is clean and unobstructed.
Remove the Drum Cartridge and check for wear, contamination, or
obstructions.
Uneven Density Troubleshooting Reference

Drum Cartridge
Transfer Roller
Fuser
s5500-070
Uneven Density Troubleshooting Procedure
1 1. Install a new Drum Cartridge. Go to Step 2. Problem solved.

2. Print a test print.
Does the test print output image
contain uneven print?

Uneven Density Troubleshooting Procedure
2 Check image development. Go to Step 3. Repair or replace the

1. Print a Test Print. Transfer Roller
(page 8-44).
easy to read?
3 Check image transfer. Go to Step 4. Repair or replace the

Check the image formed on the Transfer Roller
drum, right after the Transfer Roller. (page 8-44).
4 Look at the print on the paper before Replace the Fuser Replace the Transfer
the Fuser. Assembly Roller (page 8-44).
Does the print on the paper have (page 8-76).
even density?

Skewed Image
The image is not parallel to the edges of the print sheet.
Initial Actions
Check that the paper guides are set correctly.
Load new, dry paper that meets specifications.
Check the rollers in the paper path for any obstructions, damage, or debris.
Ensure the Drum Cartridge is properly installed.
Skewed Image Troubleshooting Reference

Drum Cartridge
Engine Logic Board
Tray
s5500-071
Skewed Image Troubleshooting Procedure
1 Check the installation site. Go to Step 2. Correct the installation.

Is the printer insalled on a level If problem persists, go
surface? to Step 2.
2 Check the paper. Go to Step 3. Problem solved.

1. Reload new, dry paper in the
source tray.


Skewed Image Troubleshooting Procedure (Continued)
4 Check rollers in the paper path. Replace defective Go to Step 5.

1. Check the rollers in the paper path rollers.
for contamination, wear, or
damage.
2. Check whether pinch rollers rotate
freely and spring pressure is
applied evenly.
Is there any contamination, wear
or damage to the rollers?
Registration
The image is positioned incorrectly in either the process or scan direction.
Initial Actions:
Check to ensure that the paper is within specification.
Check that the paper supply is new, dry, and loaded correctly.
Check that the paper tray guides are set correctly.
Check that components in the paper path are clean and unobstructed.
Registration Troubleshooting Reference

If Duplex only, replace Duplex Unit.
From all trays in the process

direction, replace the Registration
Transport Assembly.
From a specific tray in the process

direction, replace in sequence as
necessary:
Feed, Nudger, Retard
Rollers
Take Away Clutch
Feeder Assembly
Registration Transport
Assembly,
In the scan direction, replace in s5500-072
sequence as necessary:
Laser Assembly
Drum Cartridge
Tray

Registration Troubleshooting Procedure
1 Print Test Prints from all paper trays. Go to Step 3. Go to Step 2.

Print duplex prints if a duplex option
is installed.
Is the image registration within
specifications?
2 Perform the registration adjustment Problem solved. Replace the Engine

procedure. Logic Board
Is the image registration correct (page 8-89). If the
after the adjustment? problem persists,
replace the I/P Board
(page 8-91).
3 Have the customer run a print job. Problem solved. Problem may be
Are the customers prints application related.
correctly registered? Have the customer
contact Xerox
Customer Support.

Skips and Smears
Initial Actions:
Check to ensure that the paper is within specification.
Check that the paper supply is new, dry, and loaded correctly.
Check the paper path for any obstructions or debris.
Skips/Smears Troubleshooting Reference

Drum Cartridge
Transfer Roller
Fuser
XEROX
XEROX
XEROX
Skips/Smears Troubleshooting Procedure
1 Replace the Drum Cartridge. Go to Step 2. Problem solved.

Does the printed image still have
skips/smears?
2 Replace the Transfer Roller. Go to Step 3. Problem solved.

skips/smears?
3 Replace the Fuser. Go to Step 4. Problem solved.

skip/smears?
4 Replace in sequence as necessary:

Assembly (page 8-49)
Main Motor (page 8-84)
Take Away Bracket
(page 8-40)

Adjustments and
Calibrations
In this chapter...
Service Test Prints
Adjustments
Resetting the Printer to Default Values
Chapter
6
Service Test Prints
There are five test prints stored in the printer that are primarily intended for service
use:
Engine Test Prints (from Service Diagnostics)
Grid Pattern
Stripe pattern
Dark pattern
Blank - Laser off

The Print Quality test print contains blocks, lines, patterns, and text, as shown in the
sample on the following page. The Print Quality test print aids in the evaluation of
print quality and in making registration adjustments. For more details about analyzing
Test Prints, see page 5-2.
To print a Print Quality Test Print:
1. From the Main menu, select Troubleshooting, then press the OK button.
2. Select Print Quality Problems, then press the OK button.
3. Select Test Prints, then press the OK button.
The printer automatically doubles the image quality selected. As an example, if
one page is selected, the printer prints two images.
Note
The printer prints the test print using the job defaults established in the
Printer Setup menu. Insure that Edge-to-Edge Printing, located under the
PCL Setup menu, is set to Off before printing the test print; otherwise, the
image is shifted left. If the default Print Quantity (in the General Setup
submenu) is 5, the printer prints 10 pages when duplexing is off (in the Paper
Handling Setup submenu) or five 2-sided prints when duplexing is on.
To set or change the job defaults:

1. From the Main menu, select Printer Setup, then press the OK button.
2. Select the submenu containing the print parameter that you want to change, then
press the OK button. For example, to change Edge-to-Edge Printing, select the
PCL Setup submenu.
3. Select the print parameter that you want to change, then press the OK button. In
the example, select Edge-to-Edge Printing.

4. In most cases, you make a choice from several alternatives, then press the OK
button. In other cases, you press the OK button to toggle the setting between On
and Off.
5. When you have finished setting all the parameters, select Exit and press the OK
button to return the printer to the Ready state.
Test Print
Phaser5500-040302-2-L
8.5x11 (LEF Only)
LEAD EDGE
s5500-619
Adjustments and Calibrations 6-3

Adjustments
Checking Registration
This procedure checks the printer registration in the horizontal (scan) direction and
the vertical (process) direction for both simplex and duplex printing. If any
registration measurement does not meet the specification, use the Printer NVRAM
Adjustments utilities found in Service Diagnostics to make the necessary registration
adjustments.
Start the registration adjustment procedure by verifying that the current settings in
NVRAM are at the factory defaults of 50 for the scan direction and 33 for the process
direction. Once set to factory defaults, perform registration testing on all input trays in
both simplex and duplex modes. Use the job defaults to change the supply tray and
mode to generate Print Quality test prints from each source.
2. Select Print Quality Problems, then press the OK button.
3. Select Test Prints, then press the OK button. Depending on your job settings,
two or more Print Quality Test prints should print.
4. For the scan direction, side-to-side, fold the test print like this:
s5500-052

5. For the Process direction, leading to trailing edge, fold the test print as shown
below.
s5500-051
6. Check the point where the fold line intersects the target. Maximum deflection
from the centerline is 2.5 mm in either direction. The target lines are graduated in
1 mm. increments.
If the fold line falls more than 2.5 mm from the target, use the following procedure to
realign the image on the paper.

Adjusting Simplex Registration
Note
When making scan direction adjustments, or for all trays in the process direction,
adjustment changes are automatically replicated for duplex prints. Following a
scan or all tray process direction adjustment, check that duplex registration
remains within specification.
In general, it is best to make registration adjustments for individual trays. Limit use of
the All Trays utilities to only those instances when testing indicates a general mis-
alignment condition exists.
Registration changes are made by increasing or decreasing the stored value that
controls the image position on the page. For scan direction adjustments, each variable
is set at the factory to a value of 50. The maximum for scan direction adjustments is
99 with a minimum of 1. Increasing or decreasing a scan direction value by one (1)
results in a .254 mm change in the image position. For the process direction the
factory default is 33. The maximum is 66 and the minimum is zero (0).
Changes to the current value for process direction variables by one (1) moves the
leading edge of the image .363mm closer or further from the edge of the paper.
1. Enter Service Diagnostics.
2. Select Printer NVRAM Adjustments, then press the OK button.
3. Select either the process adjustment (Tray [#] Proc Dir) or scan adjustment
(Tray [#] Scan Dir) for the desired tray, then press the OK button.
4. Use the Up Arrow and Down Arrow buttons to set the new value based on
measurements taken from the target area.
Note
In the scan direction, increasing the value moves the image down and decreasing
the value moves the image up.
In the process direction, increasing the value moves the image toward the trail
edge and decreasing the value moves the image towards the lead edge.
5. Press the OK button to save the setting.

6. Press the Back button.
7. Exit Service Diagnostics and reprint the Print Quality test print.
8. Fold as before to verify your adjustments.
9. Repeat Steps 1 through 8 until simplex registration is corrected.

Adjusting Duplex Registration
Duplex registration adjustment follows a similar procedure to simplex adjustments.
Use the job defaults under the Printer Setup menu to print multiple copies of the Print
Quality Test print in two-sided (duplex) mode. Fold these prints as before and
measure deflection of the fold line on the target. If deflection of the fold line in either
direction exceeds 2.5 mm, use the following procedure to make the necessary duplex
registration adjustments.
2. Select Printer NVRAM Adjustments, then press the OK button.
3. Select either the duplex process adjustment (Duplex Proc Dir) or scan
adjustment (Duplex Scan Dir), then press the OK button.
4. Use the Up Arrow and Down Arrow buttons to set the new value based on
measurements taken from the target area.
5. Press the OK button to save the setting.
6. Press the Back button.
7. Exit Service Diagnostics and reprint the Print Quality test print.
8. Fold as before to verify your adjustments.
9. Repeat Steps 1 through 8 until duplex registration is corrected.

Adjusting Fuser Temperature
Four temperature settings, listed in the following table, are available for each paper
type supported by the printer. The default fuser temperature setting for each paper
type is also noted. See "Fuser" on page 2-21 for additional information on Fuser
temperature settings.
Front Panel Fuser Temperature Modes by Paper Type
Temperature
Paper Type
Low Medium High Extra High
Plain, Plain Paper Plain Paper Thick Paper Thick Paper
Letterhead, Mode 1 Mode 1 (Default) Mode 1 Mode 2
Colored,
Special
Transparency Transparency Plain Paper Plain Paper Thick Paper
Paper Mode Mode 2 Mode 1 Mode 1
(Default)
Labels Plain Paper Thick Paper Thick Paper Thick Paper
Mode 1 Mode 1 Mode 4 (Default) Mode 2
Card Stock, Plain Paper Plain Paper Thick Paper Thick Paper
Envelopes Mode 2 Mode 1 Mode 1 (Default) Mode 2
Prepunched Plain Paper Plain Paper Thick Paper Thick Paper
Mode 2 Mode 1 and Mode 1 Mode 2
(Default)
To change the Fuser setting for a particular paper type:

2. Select Paper Handling Setup, then press the OK button.
3. Select Fuser Configuration, then press the OK button.
4. Select Temperature for [paper type], then press the OK button.
5. Select a temperature setting from the four available, then press the OK button to
place a check mark by that setting.
Note
You must scroll up to see the Extra High setting.
6. Select Exit, then press the OK button.

Resetting Fuser Life
This procedure restarts the counter that tracks Fuser life. Perform this procedure after
you install a new Maintenance Kit.
Note
Resetting the Fuser Life counter also resets the Transfer Roller counter and all
Tray Page counters to zero.
To reset the Fuser:

1. From the Main menu, select Information, then press the OK button.
2. Select Supplies Info, then press the OK button.
3. Select Reset Fuser Life, then press the OK button.
4. Select Reset Fuser Life NOW, then press the OK button to reset the fuser life.
Resetting the Printer to Default Values

You can reset printer values on the following menus to the factory default settings:
Connection Setup
Paper Handling Setup
PostScript Setup
PCL Setup
General Setup
Front Panel Setup
Printer Controls
File Security (available if the printer has a hard drive)
You can reset all of the Image Processor Board NVRAM-stored parameters to their
factory default values by resetting the PostScript NVRAM. Instructions for resetting
PostScript NVRAM are in "Resetting Printer Default Settings (PostScript NVRAM)"
on page 6-12.
Note
There is no single reset for the Print Engine NVRAM.

Resetting Connection Setup Values
Resetting the connection setup values resets the Printer Name, TCP/IP address, TCP/
IP address menu settings (gateway, broadcast, etc.), CentreWare IS, EtherTalk,
NetWare, set IPX frame type, IPP, and Ethernet speed to their default values.
Caution
Before resetting the connection setup values to factory default values, make note
of the current network settings or print a Configuration Page to record the
printers current network settings.
2. Select Connection Setup, then press the OK button.
3. Select Reset Connection Setup, then press the OK button.
4. Select Reset Connection Setup NOW, then press the OK button.
Resetting Paper Handling Setup Values

Resetting the paper handling setup values resets the default paper source, 2-sided
printing, tray setup (default paper type/size), load paper timeout, tray sequence, tray
prompt, custom size paper units, default paper destination, job offset, output tray
switch, fuser temperature configuration, and reprint jammed pages settings.
2. Select Paper Handling Setup, then press the OK button.
3. Select Reset Paper Handling Setup, then press the OK button.
4. Select Reset Paper Handling Setup NOW, then press the OK button.
Resetting PostScript Setup Values

Resetting the PostScript setup values resets the PostScript Error Info, Image
Smoothing, and Edge-to-Edge Printing settings.
2. Select PostScript Setup, then press the OK button.
3. Select Reset PostScript Setup, then press the OK button.
4. Select Reset PostScript Setup NOW, then press the OK button.

Resetting PCL Setup Values
Resetting the PCL Setup values resets the default font number, pitch, point size,
symbol set, orientation, form length, line termination character, and Edge-to-Edge
Printing settings.
2. Select PCL Setup, then press the OK button.
3. Select Reset PCL Setup, then press the OK button.
4. Select Reset PCL Setup NOW, then press the OK button.
Resetting General Setup Values

Resetting the General setup values resets the Print-Quality Mode, Print Quantity, and
Print with Low Toner settings.
2. Select General Setup, then press the OK button.
3. Select Reset General Setup, then press the OK button.
4. Select Reset General Setup NOW, then press the OK button.
Resetting Front Panel Setup Values

Resetting the Front Panel values resets the Front Panel Language, Front Panel
Brightness, Front Panel Contrast, and Accessible Front Panel settings.
2. Select Front Panel Setup, then press the OK button.
3. Select Reset Front Panel Setup, then press the OK button.
4. Select Reset Front Panel Setup NOW, then press the OK button.
Resetting Printer Controls Setup Values

Resetting the Printer Controls values resets the Startup Page, Power Saver Timeout,
and Power Saver settings.
2. Select Printer Controls, then press the OK button.
3. Select Reset Printer Controls, then press the OK button.
4. Select Reset Printer Controls NOW, then press the OK button.

Resetting File Security Setup Values
The File Security settings are only available when the printer has a hard drive.
Resetting the File Security values resets the settings that control making files deleted
from the hard drive unrecoverable and control when old Proof and Secure Job Print
files are removed from the hard drive.
2. Select File Security Setup, then press the OK button.
3. Select Reset File Security, then press the OK button.
4. Select Reset File Security NOW, then press the OK button.
Resetting Printer Default Settings (PostScript NVRAM)

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

Using the Main menu
Using the Service Diagnostics menu
Using the Front Panel Shortcut
Using the Main Menu

2. Select Service Tools, then press the OK button.
3. Select Reset NVRAM, press the OK button.
4. Select Reset NVRAM and Reset Printer NOW, then press the OK button to
reset all the settings to their factory default values.

Using the Service Diagnostics Menu
2. Select IP NVRAM Access, then press the OK button.
3. With PostScript NVRAM Reset highlighted, press the OK button.
4. When Resetting NVRAM! Are you sure? is displayed, highlight Yes and
press the OK button.
The printer then exits Service Diagnostics and reboots. While booting, NVRAM
is reset.
Using the Front Panel Shortcut

1. At power-on, press the Back + OK buttons together.
2. When Password appears, press and hold the Up Arrow + Down Arrow buttons
together within 2 seconds.

Cleaning and
Maintenance
In this chapter...
Service Preventive Maintenance Procedure
Recommended Tools
Cleaning
Chapter
7
Service Preventive Maintenance Procedure
Perform the following procedures whenever you check, service, or repair a printer.
Cleaning the printer, as outlined in the following steps, assures proper operation of the
printer and reduces the probability of having to service the printer in the future.
The frequency of use and the type of paper a customer prints on determines how
critical and how often cleaning is necessary.
Recommended Tools
5.5 mm hex-head Nut Driver
Toner vacuum cleaner
Clean water
Clean, dry, lint-free cloth
Black, light protective bag
Cleaning
Caution
Never apply alcohol to any parts in the printer.
If you remove the Drum Cartridge, place it in a light protective bag.
Note
Never use a damp cloth to clean up toner.
1. Record number of sheets printed.

2. Print several sheets of paper to check for problems or defects. Print to all output
trays and staple or punch if Finisher is installed.
3. Turn off the printer and disconnect the Power Cord.
4. Remove the I/P Board and Upper Rear covers and clean the Fuser Fan with a
brush or dry cloth to remove excess dust and toner.
5. Remove any debris or foreign objects from the Transfer Roller, Fuser, Laser
Assembly, and paper path.
6. Vacuum out any loose toner with a Type II toner vacuum only.
7. Remove and clean all paper trays.
8. Clean feed rollers with a lint-free cloth lightly dampened with water.
9. Inspect the interior of the printer for damaged wires, loose connections, toner
leakage, and damaged or obviously worn parts.
10. If the Drum or Toner Cartridges appear damaged, replace with a new one.

FRU
Disassembly
In this chapter...
Overview
General Notes on Disassembly
Print Engine FRU Removal Procedures
Chapter
8
Overview
This section contains the removal and replacement procedures for spared parts
according to the Field Replaceable Units (FRUs) Parts List. Replacement procedures
are not provided for most of the FRUs because in most cases, re-installing a part only
requires reversing the removal procedure. Where the replacement process is not a
simple reversal of the removal, a replacement procedure is included. Replacement
Notes provide tips and suggestions that can aid in reassembling the part.
Standard Orientation of the Printer

Locations given in the repairs, such as left, right, front, or rear, assume you are facing
the printer Front Panel. When needed the orientation of the printer is called out in the
procedure for locating printer parts, refer to the printer orientation graphic for
locating the right, left, front and back sides of the printer
Rear
Right
Left
Front
s5500-075

General Notes on Disassembly
Removal and replacement procedures are organized in eight major categories. these
categories roughly correspond to classification of FRU parts list in Chapter 10.
Print Engine Covers

Upper Transportation and Registration
Trays and Feeders
Tray 1
Lower Transportation and Registration
Xerographics
Fuser and Exit 1

Drive
Electrical
Parts are controlled as spare parts. When servicing for parts for which no procedures
are described, observe their assembling condition before starting the service.
Preparation
Before you begin any Removal and Replacement Procedure:
1. Switch Off the printer power and disconnect the power cord from the wall outlet.
2. Remove the Drum Cartridge and protect it from exposure to light by covering it
with a light proof bag or by placing it in a light-tight container. Disconnect all
computer interface cables from the printer.
3. Wear an electrostatic discharge wrist strap to help prevent damage to the sensitive
electronics of the printer circuit boards.
4. Remove the Fuser Assembly or wait at least 5 minutes after you have switched
Off printer power for the Fuser to cool before you work on or around the Fuser.
Caution
Many parts are secured by plastic tabs or hooks. DO NOT over Flex or force
these parts. Do not over torque the screws threaded into plastic parts.
Note
Names of parts that appear in the disassembly procedures may not be exactly the
same as the names that appear in the Parts List. For example; a part called the
Registration Chute Assembly may appear on the Parts List as Assembly, Chute
REGI.
FRU Disassembly 8-3

Caution
Always use the correct type and size screw. Using the wrong screw can damage
tapped holes. Do not use excessive force to either remove or install either a screw
or a printer part.
Caution
Do not remove red screws. Frame mis-alignment will result.
Warning
Unplug the AC power cord from the wall outlet before removing any printer part.
Notations in the Disassembly Text

The notation PLX.X.X at the top of each Figure references the FRU parts list
containing this part or assembly.
Page number references are given in-line for procedural steps previously
described.
Bold arrows in an illustration show direction of movement when removing or

replacing a component.
Numbered arrows indicate manipulation steps for removal of the part.

Print Engine Covers
Front Left Cover

1. Open the Front Door.
PL1.1.2
Front Left Cover

s5500-076
2. Remove the one screw securing the Front Left Cover.

3. Remove the Front Left Cover.
FRU Disassembly 8-5

Top Rear Cover
PL1.1.3
Top Rear Cover
Upper Rear Cover

s5500-077
1. Remove the Rear Panel Cover (page 8-12).

2. Remove the Upper Rear Cover (page 8-15).
3. Remove the screw securing the Top Rear Cover.
4. Remove the Top Rear Cover by sliding it left then lifting as shown.

Top Cover
Caution
Use care not to catch the the Stack Full sensor flag while removing the cover.
2. Remove the Front Left Cover (page 8-5).
PL1.1.8
Top Cover
Connector
s5500-078
3. Remove the two screws securing the Top Cover.

4. Remove the Top Rear Cover by first lifting the right edge while sliding the cover
to the right, then pulling the cover forward and left.
5. Disconnect the Front Panel connector from the Top Cover.
Replacement Note
Make sure the spur and tab on the rear side of the cover engage the frame.
FRU Disassembly 8-7

Front Door
PL1.1.9
Front Cover
A
s5500-079
2. Release the Stopper from the Inner Main Cover.

3. Open Tray 2 halfway.
4. Lower the Front Door perpendicular to the printer and slide the Front Door to the
right to release the lower right holder from the boss on the right of the printer.
5. With the lower right holder released, hold the cover at a slight angle to the printer
and slide it to the left to release the lower left holder from the boss.

Inner Main Cover
1. Remove the Top Cover (page 8-7).
2. Remove the Front Door (page 8-8).
3. Remove the Left Front Cover (page 8-5).
PL1.1.13
Hook
Hook
Inner Main Cover s5500-081
4. Open Door A.
5. Remove the Drum Cartridge.
6. Remove the three screws securing the Inner Main Cover to the frame.
7. Remove the Inner Main Cover by tilting the cover outwards and lifting to release
the hooks.
Replacement Note
When installing, put the four lower hooks on the Inner Main Cover inside the
rolled edge of the printer frame.
FRU Disassembly 8-9

Front Door Interlock Switch
4. Remove the Inner Main Cover (page 8-9).
PL1.1.5
Bracket
Switch
s5500-082
5. Remove the screw securing the Interlock Switch Bracket.

6. Remove the switch together with the bracket.
7. Disconnect the connector from the switch.
8. Release the switch by pressing the hooks.
9. Remove the switch.

Upper Right Cover
PL1.2.1
Upper Right
Cover
Lower Right
Cover
s5500-083
1. Remove the two screws securing the Upper Right Cover.

2. Lower the Upper Right Cover to release the upper rib.
3. Remove the Upper Right Cover.
Replacement Note
Be sure to secure the lower rib on the Upper Right Cover to the upper part of
the Lower Right Cover.
FRU Disassembly 8-11

Rear Panel Cover
PL1.2.4
Rear Panel Cover s5500-084
1. Open the Rear Panel Cover.

2. Remove the lower boss securing the Rear Panel Cover to the printer. It is easier to
remove by pushing down the retainer of the boss.

Lower Right Cover
1. Remove the Upper Right Cover (page 8-11).
2. Pull out Trays 2 and 3 at least partially.
PL1.2.2
Lower Right
Cover
s5500-
3. Remove the Lower Right Cover by lifting upwards to release the hooks, then
outward.

I/P Board Cover
PL8.1.20
I/P Board Cover
s5500-087
1. Loosen the two captive thumbscrews securing the I/P Board Cover.
2. Remove the I/P Board Cover by moving it in the direction of the arrow.

Upper Rear Cover
1. Remove the I/P Board Cover (page 8-14).
PL1.2.5
Upper Rear Cover s5500-088
2. Remove the two screws securing the Upper Rear Cover to the printer.
3. Remove the Upper Rear Cover by moving it in the direction of the arrow.

Tray 1/MPT Rear Cover
PL3.1.14)
Tray 1/MPT Cover
s5500-089
1. Remove the one screw securing the Tray 1/MPT Rear Cover to the frame.
Lower Rear Cover

PL1.2.6
Rear
Lower Rear Cover s5500-627

3. Remove the two screws securing the Lower Rear Cover to the frame.
4. Remove the Lower Rear Cover by tilting the top outwards slightly then lifting the
cover up and out.
Replacement Note
Attach the four lower hooks on the Lower Rear Cover to the bracket on the
printer.
Option Interface Cover

PL1.2.7
Option Interface Cover

s5500-090
1. Remove the Option Interface Cover from the Lower Rear Cover by moving the
Option Interface Cover in the direction of the arrow.

Exit 1 Top Cover
PL6.2.22
Exit 1 Top Cover
s5500-091
1. Remove the Exit 1 Top Cover by moving it in the direction of the arrow.

Upper Transportation and Registration
Paper Size Switches

Both paper size sensing switch arrays are located behind the AC Accessory Panel.
Use this procedure to replace either the Tray 2 or Tray 3 Paper Size switches.
Note
To remove the Tray 2 switch, remove the Engine Logic Board (page 8-89), and
loosen the Engine Logic Board Bracket.

3. Remove the Lower Rear Cover (page 8-16).
PL2.1.4
AC Accessory Panel
Paper Size Switch
Switch Bracket s5500-092
4. Remove the three screws securing the AC Accessory Panel.

5. Release the harness clamps on the AC Accessory Panel.
6. Remove the two screws securing the switch bracket.
7. Remove the switch together with the bracket.
9. Remove the one screw securing the switch to the bracket.
Tray 2 Feeder
1. Remove the Tray 1/MPT Rear Cover (page 8-16)
2. Remove the Tray 1/MPT Feeder (page 8-32).
3. Remove Door A (page 8-46).
4. Remove the Take Away Bracket (page 8-40).
5. Remove Tray 2.
6. Release the harness from the two clamps on the frame.
Clamp
Harness
Connector
Tray 2 Feeder
s5500-094
7. Disconnect the connector.

8. Remove the two screws securing the Feeder to the frame.
9. Remove the Feeder by moving it in the direction of the arrow.
Replacement Note
When installing the Feeder, fit the two bosses on the frame into the holes on
the Feeder, and transfer the Feed Out Chute to the new Feeder.

Tray 3 Feeder
1. Remove the Tray 1/MPT Rear Cover (page 8-16).
4. Open Door B.
6. Pull out Tray 3.
PL2.1.7
Boss
Boss
Feed Out Chute

Door B
s5500-095
7. Release the boss on the both ends on the Feed Out Chute securing it to the frame.
Release the right side first and remove the chute.
8. Remove the two screws securing the Take Away Chute to the frame.
Caution
The Take Away Chute is easily damaged if the latches located on the backside of
the chute are not released before attempting to remove the chute from the frame.
Release these latches before attempting to remove the Take Away Chute.

9. Reach in and release the latch at the center of the Take Away Chute from behind
and remove the chute.
Take Away Chute
Bearing
Gear-18T
Take Away Roller

E-Ring
Bearing Sleeve s5500-096

10. Remove the Take Away Roller assembly (page 8-41).
Harness
Connector
Tray 3 Feeder
s5500-097
11. Release the harness from the two clamps on the frame.
12. Disconnect the connector.
13. Remove the two screws securing the Feeder to the frame.
14. Remove the Feeder by moving it in the direction of the arrow.
Replacement Note
When installing the Feeder, fit the two bosses on the frame into the holes on
the Feeder. When installing the Take Away Chute, fit the bosses on the Take
Away Chute into the holes on the frame.
Feed/Lift Motor

5. Remove the Tray 2 Feeder (page 8-20) or Tray 3 Feeder (page 8-21).
PL2.3.2
Feeder Assembly
Feed/Lift Up
Motor
Connector
s5500-104
6. Disconnect the connector from the Feed/Lift Motor.

7. Remove the two Phillips screws securing the Feed/Lift Motor to the Feeder.
8. Remove the Feed/Lift Motor.
Tray 2 and 3 No Paper Sensor


PL2.3.14
Feeder
No Paper Sensor
Harness
Hooks
Upper Frame
s5500-109
6. Release the hooks securing the Sensor to the Upper Frame as shown in the figure.
7. Disconnect the connector from the No Paper Sensor.
8. Remove the No Paper Sensor.
Tray 2 and 3 Level Sensor Actuator


PL2.3.13
Feeder
Upper Frame
Bosses Actuator
s5500-108
6. Release the two bosses on the Actuator securing the Actuator to the Upper
Frame.
7. Remove the Actuator.
Note
As an alternate procedure, remove Trays 2 and 3, then reach in and release the
actuator bosses from the feeder assembly.

Tray 2 and 3 Level Sensor
6. Remove the Level Sensor Actuator (page 8-25).
PL2.3.14
Feeder
Harness
Level Sensor
Hook
Upper Frame
Hooks
s5500-110
7. Release the hooks securing the Level Sensor to the Upper Frame as shown in the
figure.
8. Disconnect the connector from the Level Sensor and remove the sensor.

Tray 2 and 3 Pre-Feed Sensor
PL2.3.15
Feeder
Pre Feed Sensor

s5500-111
6. Remove the Pre-Feed Sensor from the Front Chute as shown in the figure.
7. Disconnect the connector from the Pre-Feed Sensor.

Feed Roller
1. Remove the tray.
PL2.3.20
Shaft
Oneway Gear (22T)
Oneway Clutch
Feed Roll
Front Chute
s5500-114
2. Move the Front Chute in the direction of the arrow.

3. Release the hook securing the Feed Roller to the Shaft and remove the Feed
Roller.

Retard Roller
1. Remove the tray;
PL2.3.28
Front Chute
Support Assembly
Retard Roller
s5500-117
2. Release the hook securing the Retard Roller to the Shaft as shown in the figure.
3. Remove the Retard Roller.

Nudger Roller
1. Remove the tray.
PL2.3.32
Support Assembly
Nudger Roller
Front Chute
s5500-120
2. Move the Front Chute in the direction of the arrow.

3. Release the hook securing the Nudger Roller to the Shaft as shown in the figure.
4. Remove the Nudger Roller.

Tray 1 Disassembly
Tray 1 Feeder
PL3.1.1
Tray 1 Feeder
s5500-124
2. Disconnect the connector from the printer.

3. Release the harness from the clamp.
4. Remove the two screws securing the Tray 1/MPT Feeder to the frame.
5. Remove the Tray 1 Feeder.
Replacement Note
Place the harness along the slot on the left of the Feeder to avoid pinching
the harness between the Feeder and the Frame

Tray 1/MPT No Paper Sensor Actuator
PL3.1.3
Upper Frame
Hook
(Upper Frame)
Slot
Actuator
s5500-125
3. Remove the two hooks securing the upper frame to the printer.
4. Remove the upper frame by moving it in the direction of the arrow.
5. Pull the right side of the Actuator toward you, then pull it out of the hole in the
upper frame.
Replacement Note
When installing the actuator into the Upper Frame, press on both sides of the
actuator pivot point to avoid breaking the part.

Tray 1/MPT No Paper Sensor
PL3.1.4)
Upper Frame
Connector
Hook
(Upper Frame)
Slot
No Paper Sensor
s5500-126
3. Release the two hooks securing the Upper Frame to the Tray 1 Feeder, and move
the Upper Frame in the direction of the arrow to remove.
4. Disconnect the connector from the sensor.
5. Release the hooks securing the sensor to the Tray 1 upper frame.
6. Remove the sensor.

Pick Up Gear Spring
PL3.2.6
Tray 1 Feeder
Pick Up Gear
Pick Up Gear Hook

Spring
Pick Up Shaft
Gear Bracket
s5500-129
3. Remove the Spring from the Gear Bracket and Pick Up Gear.
Replacement Note
Slide the Pick Up Gear until it locks on the Stopper Lever.

Tray 1 Pick Up Solenoid
2. Remove the Tray 1 Feeder (page 8-32).
3. Remove the Pick Up Gear (page 8-35).
4. Remove the Cam Gear and Spring (page 8-36).
PL3.2.15
Gear Lever
Pick Up Solenoid
Lower Frame s5500-131
5. Remove the three screws securing the Gear Bracket to the Tray 1 Lower Frame.
6. Remove the one screw securing the Pick Up Solenoid to the Gear Bracket.
7. Disconnect the connector from the Pick Up Solenoid.
8. Lower the Gear Lever in the direction of the arrow and remove the Pick Up
Solenoid.
Cam Gear Spring

3. Remove the Feed Roller (page 8-38).
4. Remove the Spring from the Gear Bracket. Leave the other end of the Spring
connected to the Pick Up Gear.
5. Remove the three screws securing the Gear Bracket to the Tray 1 Feeder to
remove the Gear Bracket.

6. While releasing the hooks securing the Pick Up Gear to the Pick Up Shaft,
remove the Pick Up Gear together with the Spring, Cam Gear and Stopper Lever.
7. Remove the Cam Gear Spring securing the Pick Up Gear to the Cam Gear.
PL3.2.16
Stopper Hook
Cam Gear
Lever
E-Ring
Spring
Pick Up Shaft
Bearing 8 Bearing 8
Cam Gear E-Ring
Pick Up Gear
Pick Up Cam
Lower Frame
Gear Bracket s5500-132

Feed Roller Assembly
PL3.2.20)
Pinch Chute
Feed Roller
Hook
Hook Pin Roller Core
Pick Up Shaft
Lower Frame Roller Core s5500-133
3. Remove the two screws securing the Pinch Chute to the Tray 1/MPT Lower
Frame. Note the orientation of the roller and remove the Pinch Chute.
4. While releasing the two hooks of the Roller Core left and right securing the Feed
Roller to the Pick Up Shaft as shown in the figure, and slide the Feed Roller
outward.
5. Remove the Feed Roller from the Pick Up Shaft by moving it in the direction of
the arrow (to the front).

Retard Pad
3. Remove the Feed Roller (page 8-38).
PL3.2.12
Retard Pad
Pad Spring
Retard Shaft
Lower Frame
Retard Shaft
s5500-134
Caution
The Retard pad springs are easily lost. Grip each spring firmly when removing
them. The Retard Pad is held down by the force of the Feed Roller.
4. Remove two Pad Springs under the Retard Pad.
5. Remove the Retard Pad and the Retard Shaft by moving it in the direction of the
arrow, from the backside.
Lower Transportation and Registration
Take Away Bracket

4. Open Door B.
PL4.1.1
Take Away Bracket
Door B
s5500-139
5. Remove the two screws securing the Take Away Bracket to the printer.
6. Disconnect the harness and release the harness from the clamp on the Take Away
Bracket.
7. Disconnect the Door B Interlock Switch from the harness and remove the Take
Away Bracket.

Door B Interlock Switch
1. Open Door B.
PL4.1.3
Take Away Bracket
Door B Interlock
Switch
Door B
s5500-140
2. Release the hooks securing the switch to the Take Away Bracket.
4. Remove the Door B Interlock Switch.
Take Away Roller Assembly


4. Open Door B.
PL4.1.8
Take Away Chute
Bearing
Gear-18T
Take Away Roller

E-Ring
Bearing Sleeve s5500-096
Caution
7. Remove the K-clip on the right side, securing the Take Away Roller to the frame.
Caution
The Take Away Bearing and Gear 18T are not captive on the shaft. Use care to
capture these parts as you remove the shaft.
8. Remove the Take Away Roller by moving it in the direction of the arrow.

Door B
1. Open Door B.
PL4.1.10
Door B
Lower Chute
s5500-141
2. Remove the two screws securing the Lower Chute to the frame.
3. Remove Door B together with the Lower Chute.

Transfer Roller
1. Open Door A.
PL4.2.1
Transfer Roller
Hook
Hook
Left
s5500-598
2. Pinch the hooks at each end of the Transfer Roller and lift to remove the Transfer
Roller from the chute.

Door A Interlock Switch
Door A
Interlock Switch
Bracket
Rear
s5500-623
3. Remove the single screw securing the Door A Interlock Switch to the frame.
4. Disconnect the switch from the harness and remove the switch and bracket from
the Printer.
5. Remove the switch from the bracket by compressing the hooks.

Door A
1. Open Door A.
PL4.2.8
Door A
s5500-144
2. Remove the screw securing the Stopper to the Door.

3. Remove Door A by moving it in the direction of the arrow.
Registration Roller
1. Remove the Door A (page 8-46).

2. Release the two hooks, one on each side, securing the chute to Door A as shown.
L/H Chute
Door A
Hooks
s5500-145
3. Remove the Transfer Roller (page 8-44).

4. Remove the hooks of the two Pinch Out Bearings on the left and right securing
the Registration Rollers to the Chute as shown in the figure.
PL4.3.3
Bearing
Transfer Roller
Registration Pinch Roller
L/H Chute
Door A
Hooks
s5500-146
5. Move the Registration Rollers in the direction of the arrow to remove.

Registration Transport Assembly
PL4.5.1
Registration
Transport
Assembly
Pinch Roller
Chute-R Registration
Transport
Assembly
Pinch Roller
Boss
Feed Out Chute

Boss
Connector Clamp
Connector
Left View s5500-147
4. Release the bosses on each end of the Feed Out Chute starting with the right end
and remove the Feed Out Chute.

5. Remove the two tapping screws securing the Chute-R to the Registration
Transport Assembly to remove the Chute-R.
6. Remove the Pinch Roller in the center of the Registration Transport Assembly to
provide access to the locking retaining tab behind the Registration Transport
Assembly.
7. Remove the two screws securing the Registration Transport Assembly to the
frame.
8. Using a small screwdriver, or something similar, push on the retaining tab to
unlock it from the notch in the frame while pushing the Registration Transport
Assembly to the left, and lifting the center upward to release the retaining tab
from the frame. Extract the Registration Transport Assembly from the frame by
moving it in the direction of the arrow. Use care to avoid damage to the wiring
connected on the back.
Note
It could require significant force to flex the Registration Transport Assembly to
clear the retaining tab and remove it from the frame.

10. Disconnect the connector from the Registration Trans Assembly.
11. Disconnect the connector from the printer.
Replacement Note
Make sure the retaining tab fits over the frame rather than under it.

Registration Clutch
4. Remove the Registration Transport Assembly (page 8-49).
PL4.5.2
Registration Clutch
E-Ring
Boss
Assembly
s5500-148
5. Remove the E-ring securing the Registration Clutch to the Registration Roller.
6. Remove the Registration Clutch together with the harness.
Replacement Note
Route the harness through the hole as shown. Avoid pinching the harness.

Registration Sensor
PL4.5.7
Hook
Registration
Sensor
Assembly
Registration Hooks
Sensor
s5500-150
5. Release the three hooks securing the sensor to the Registration Transport
Assembly and remove.

Take Away Clutch
PL4.5.14
Notch
Rear
E-Ring Take Away Clutch
Protrusion
Take Away Bracket

s5500-599
3. Remove the screws securing the Take Away Clutch Bracket to the frame and
Motor Assembly and remove the bracket.
4. Disconnect the Take Away Clutch connector from the harness.
5. Remove the E-clip securing the Take Away Clutch and remove the Clutch.
Replacement Note
Make sure the notch in the clutch fits over the protrusion.
Feed Out Sensor 3
1. Remove the Tray 1 Feeder (page 8-32).
3. Open Door B.
PL4.5.18
Take Away Chute
Feed Out
Sensor 3
Take Away Chute

Hook
s5500-152
Caution

7. Disconnect the connector from the Feed Out Sensor.
8. Release the hook securing the sensor to the Take Away Chute and remove.
Replacement Note
When installing, fit the bosses on the Take Away Chute into the holes on the
frame.

Xerographics
Drum Cartridge Fan Intake Duct

2. Disconnect the harness from the junction connector on the Intake Duct.
PL5.1.117
Connector
Hooks
Junction
Connector
Intake Duct Holes
Front
Clamps
Connector
s5500-624

3. Release the hook holding the Intke Duct to the Toner Dispense Assembly.
Hook
Intake Duct Front
Toner Dispense
Assembly
Intake Duct
Hook
Front View
s5500-625
4. Move the Intake Duct in the direction of the arrow while lifting the left side.

Drum Cartridge Fan
2. Remove the Drum Cartridge Fan Intake Duct (page 8-56).
3. Disconnect the Drum Cartridge Fan from the junction connector.
PL5.1.18
Junction Connector
Intake Duct
Hooks
Front
Drum Cartridge Fan
Connector
s5500-626
4. Release the two hooks holding the fan to the Intake Duct and remove the fan.

Fuser Fan
PL5.1.13
Hooks
Fuser Fan
Label
CN102
CN102
Motor Assembly
s5500-163
3. Disconnect the Fan connector from the Motor Assembly.

4. Release the hooks left and right securing the Fan to the duct as shown and remove
the Fan.
Replacement Note
Install the Fan with the label facing outward. Also, route the Fan harness in
the slot as shown in the figure.
Drum Cartridge Detect Switch
Note
Replacing this part requires major disassembly of the printer. Be sure this part is
defective before begining this procedure.

4. Remove the Toner Cartridge.
7. Remove the HVPS (page 8-86).
9. Remove the Toner Dispense Assembly (page 8-71).
PL5.1.4
P404
P403
Engine Logic Board s5500-153
11. Disconnect the two connectors (P403 and P404) from the Engine Logic Board.

Laser C
Connector Clamps Toner Dispense

Assembly
s5500-154
13. Remove the two screws securing the Laser C to the frame.
14. Release the harness from the clamp on the Laser C.

15. Disconnect the connector from the Laser C.
Connector
Sub Guide Assembly
Junction Connector
Screws s5500-155
16. Remove the Laser C by moving it in the direction of the arrow.

17. Remove the four screws securing the SUB Guide Assembly to the frame.

18. Slide the SUB Guide Assembly toward the left side and disconnect the connector
from the Front Harness A.
Drum Motor Gear
Hook
Hook
Sub Guide Assembly

Contact Cover
s5500-156
19. Remove the two hooks securing the Contact Cover to the frame.
20. While pressing the Drum Motor gear located on the rear side of the Motor
Assembly, lift the left side of the SUB Guide Assembly upward.
21. Release the harness from the clamp on the rear side of the SUB Guide Assembly.
22. While pressing the Drum Motor gear located on the rear side of Motor Assembly,
lower the left side (left) of the SUB Guide Assembly.

23. Lift the right side of the SUB Guide Assembly.
Connector
Sub Guide Assembly
Drum Cartridge Detect Switch
Screw s5500-157
24. Remove the screw securing the Drum Cartridge Detect Switch and the Switch
Plate to the SUB Guide Assembly.
25. Remove the Drum Cartridge Detect Switch together with the Switch Plate.
Environmental Sensor PWB

7. Remove the HVPS (page 8-86).

PL5.1.5
P404
P403
11. Disconnect the two connectors (P403 and P404) from the Engine Logic Board.
12. Release the harness from the clamp on the printer.
13. Open Door A.

14. Remove the Registration Trans Assembly (page 8-49).
Laser C
Connector Clamps Toner Dispense

Assembly
s5500-154
15. Remove the two screws securing the Laser C to the frame.

16. Release the harness from the clamp on the Laser C.
Connector
Sub Guide Assembly
Junction Connector
Screws s5500-155
17. Remove the Laser C by moving it in the direction of the arrow.

18. Remove the four screws securing the SUB Guide Assembly to the frame.

19. Slide the SUB Guide Assembly toward the left side and disconnect the connector
from the Front Harness A.
Drum Motor Gear
Hook
Hook
Sub Guide Assembly

Contact Cover
s5500-156
20. Remove the two hooks securing the Contact Cover to the frame.

21. While pressing the Drum Motor gear located on the rear side of the Motor
Assembly, lift the left side of the SUB Guide Assembly upward.
Sub Guide Assembly
Connector
Humidity And Temperature

Sensor
s5500-159
22. Disconnect the connector from the Environmental Sensor PWB.

23. Remove the screw securing the Environmental Sensor PWB to the SUB Guide
Assembly.
24. Remove the Environmental Sensor PWB.

Drum Cartridge CRUM PWB
PL5.1.8
Toner Dispense
Drum Cartridge CRUM PWB Assembly
s5500-158
2. Disconnect the connector from the Drum Cartridge CRUM PWB.

3. Remove the Drum Cartridge CRUM PWB by moving it in the direction of the
arrow.

Toner Cartridge CRUM PWB
PL5.1.8
Toner Cartridge
CRUM PWB
s5500-589
2. Disconnect the connector from the Toner Cartridge CRUM PWB.

3. Move the Toner Cartridge CRUM PWB in the direction of the arrow to remove.

7. Remove the Duplex Unit if present.

PL5.1.10
Harness Clamps
Screw
Toner Dispense
Motor
Toner Dispense
Assembly
Shaft
s5500-161
10. Release the harness from the clamps on the left side of the Toner Dispense
Assembly.
11. Disconnect the harness Toner Cartridge CRUM PWB on the right side.
12. Remove the two screws securing the Toner Dispense Assembly to the frame.

13. While pushing the Toner Dispense Assembly toward the left side, reach in from
the Left end and remove the screw securing the Dispense Tube to the frame.
Toner Dispense
Dispense Assembly
Tube
s5500-594
Replacement Note
Fit the hole on the Toner Dispense Assembly to the Toner Dispense Motor.
Also, fit the shaft into the hole on the Toner Dispense Motor.

7. Remove the Drum Cartridge Fan Intake Duct (

PL5.1.11
Toner Dispense
Motor
Connector
s5500-162
9. Disconnect the connector from the Toner Dispense Motor.

10. Remove the four screws securing the Toner Dispense Motor to the frame and
remove.
Laser Assembly

PL5.1.14
Laser Assembly
s5500-164
7. Disconnect the three connectors from the Laser Assembly.

8. Disconnect the connector from the junction connector.
9. Remove the four screws securing the Laser Assembly to the frame.
10. Lift the Laser Assembly from the frame.
Fuser and Exit 1
Fuser Assembly
1. Open Door A.
PL6.1.7
Fuser
Handle
Knob
s5500-165
2. Loosen the two knobs securing the Fuser to the frame.

3. Pull the Fuser toward you by holding the two handles.

Fuser Exit Sensor
1. Open Door A.
2. Remove the Fuser (page 8-76).
PL6.1.4
Fuser Exit Sensor
Hook
Sensor Bracket
s5500-166
3. Remove the screw securing the bracket to the frame.

4. Disconnect the connector from the sensor.
5. Release the three hooks securing the sensor to the bracket.

Exit Transport Assembly
2. Remove the Top Rear Cover (page 8-6).
3. Open Door A.
4. Remove the Exit 1 Top Cover (page 8-18).
PL6.2.1
Exit Bracket
Upper Rear Cover Door A s5500-167
7. Remove the two screws securing the Exit Bracket to the frame.
8. Remove the Exit bracket.
Replacement Note
Make sure the Stack Full Actuator rotates freely.

9. Remove the Main Drive Belt (page 8-83).
Harness
Connectors
Exit Transport
Assembly
s5500-168
10. Disconnect the connector from the Offset Motor.

11. Disconnect the two connectors from the two sensors.
12. Remove the two screws securing the Exit Transport Assembly to the frame.
13. Remove the Exit Transport Assembly by lifting upward.

Exit 1 Offset Motor
3. Open Door A.
7. Remove the Exit Transport Assembly (page 8-78).
PL6.2.3
Connector
Clamps
Offset Motor
Exit Transport
Assembly
s5500-169
8. Disconnect the connector from the Offset Motor.

9. Remove the two standard, Phillips-head screws securing the Offset Motor to the
Exit.

Offset Home Position Sensor
3. Open Door A.
7. Remove the Exit Transport Assembly (page 8-78).
PL6.2.5
Offset Home
Position Sensor
Hooks
Hook
Sensor Bracket
s5500-170
8. Remove the Exit 1 Offset Motor.

9. Remove the two screws securing the sensor bracket to the Exit Transport
Assembly.
10. Release the three hooks securing the Offset Home Position Sensor to the sensor
bracket.
11. Remove the Offset Home Position Sensor.

Full Stack Sensor
3. Open Door A.
7. Remove the two screws securing the Exit Bracket to the frame.
8. Remove the Exit Bracket.
PL6.2.5
Hook
Hooks
Full Stack Sensor

s5500-171
9. Remove the two screws securing the bracket to the Exit Transport Assembly.
10. Release the three hooks securing the sensor to the bracket.
11. Remove the sensor.

Drive
Main Drive Belt

PL7.1.5
Main Drive Belt
Exit Flange
Rear
s5500-176
4. Release the hook on the Exit Flange securing the belt to the Motor Assembly to
remove the Exit Flange.

5. Remove the Belt from the Pulley 25T and Exit Gear.
Replacement Note
Its easier to install the Belt if the Motor is rotated slowly by hand. Fit the
flange to the D-shaped shaft and install the flange until the hook locks.
Motor Assembly
5. Pull out the Drum Cartridge.
Main Drive Belt
s5500-177

6. Remove the Main Drive Belt (page 8-83).
PL7.1.7
Main Drive Belt
Motor Assembly
CN102
CN101
Exit Flange
Take Away Clutch Bracket s5500-178
7. Disconnect the two connectors from the Motor Assembly.

8. Remove the two screws securing the Take Away Clutch bracket to the frame and
to the Motor Assembly to remove the bracket.
9. Remove the four screws securing the Motor Assembly to the frame.
Replacement Note
Install the Motor Assembly by pushing the Gear on the upper part of the
Motor in the direction of the arrow.

Print Engine Electrical
High Voltage Power Supply

3. Pull out the Drum Cartridge.
PL8.1.1
Clamp
HVPS
Clamp s5500-179
6. Disconnect the connector from the HVPS.

7. Release the harness from the clamps.
8. Remove the two screws securing the HVPS to the frame.
9. Carefully remove the HVPS by moving it in the direction of the arrow.
Replacement Note
Insert the board into the guides on both sides.
Power Switch
1. Remove the Top Cover .(page 8-7).

PL8.1.2
Power Switch
Hook
Hook
Notch
Switch Bracket
Connector
s5500-180
4. Remove the screw securing the bracket to the frame.

5. Remove the bracket and switch to the left to remove from the frame.
6. Disconnect the four connectors from the Power Switch.
7. Release the hooks securing the Power Switch to the bracket as shown.
Replacement Note
Fit the notch on the Power Switch to the boss on the frame.

Exit PWB
PL8.1.4
Supports
Connectors
Exit PWB
Lower Bracket
s5500-181
2. Disconnect all connectors from the Exit PWB. Connector P/J403 has a hook.
Disconnect it by pushing the hook.
3. Remove the two screws securing the Lower Bracket to the frame.
4. Release the locks of the supports holding the Exit PWB to the frame as shown in
the figure.
5. Remove the Exit PWB together with Lower Bracket from the frame.
6. Remove the two screws securing the Exit PWB to the Lower Bracket.
7. Remove the Exit PWB.
Replacement Note
Fit the tips of the supports into the holes on the Exit PWB.

Engine Logic Board
PL8.1.5
Connectors
4. Mark and disconnect all connectors from the Engine Logic Board. Connectors P/
J400, P/J401, and TTM/2TM have a hook. Disconnect by pushing the hook.
5. Remove the six screws securing the Engine Logic Board to the frame.
6. Remove the Engine Logic Board.

Front Panel
PL1.1.6
Front Panel
Top Cover
Hooks
Hooks
Hooks
Hooks
Bottom View
s5500-185
2. Place the Top Cover up side down, and remove the Front Panel Cover by
releasing the four hooks securing the Cover to the Top Cover.
3. Move the Front Panel Cover in the arrow direction (right side) to remove.

2. Disconnect all external interface connections.
PL8.1.5
Screws
Screw
Image Processor Board s5500-613
3. Disconnect the four connectors from the I/P Board.

4. Remove the three 5.5mm, hex-head screws securing the I/P Board to the frame.
5. Remove the I/P Board and its carrier using the knob provided on the rear panel.
Replacement Note
Tighten the back panel screw before tightening the board mounting screws.
If installing a new I/P Board, be sure to transfer NVRAM, Configuration
Card, and if installed, the Flash Memory and Hard Drive to the new board.

Low Voltage Power Supply
PL8.1.8
LVPS
s5500-186
2. Mark and disconnect all connectors from the LVPS. Connectors P1, P2, P6, P521
and P526 have a hook. Disconnect by pushing the hook.
3. Remove the nine screws securing the LVPS to the frame.
4. Remove the LVPS.
Replacement Note
Fit the holes on the board to the two bosses on the frame. P7 is unused.
Caution
J11 (Black wire), J12 (White wire) are interchangeable. Use the designators
printed on the board to identify the proper connection.

AC Accessory Panel
PL8.1.10
RIGHT VIEW
Connectors
Harness Clamps
s5500-187

6. Disconnect the three connectors (P2, J11 (Black wire), J12 (White wire) from the
LVPS.
7. Release the four harnesses from the three clamps.
8. Remove the three screws securing the AC Accessory Panel to the printer.
10. Remove the AC Accessory Panel.
GFI Breaker
PL8.1.13
GFI Breaker
s5500-188
4. Remove the three screws securing the AC Accessory Panel to the frame.
5. Disconnect the two connectors from the GFI Breaker.
6. Remove the two screws securing the GFI Breaker to the AC Accessory Panel.

Parts Lists
In this chapter...
Serial Number Format
Using the Parts List
Print Engine Parts
Xerox Supplies and Accessories
Chapter
9
Serial Number Format
Changes to Xerox products are made to accommodate improved components as they
become available. It is important when ordering parts to include the following
information:
Component's part number
Product type or model number
Serial number of the printer
The serial number is found on a label located on the rear frame of the printer just
inside Door A. Open Door A to see it.
The nine-digit serial number has the following format:
PPP-SSSSSS
PPP = product code, as shown in the following table.
Product Code Product Configuration
RET 5500/B Phaser 5500, 110 V, Base
RET 5500/N Phaser 5500, 110V, Network
REU 5500V/B Phaser 5500, 220V, Base
REU 5500V/N Phaser 5500, 220V, Network
SSSSSS = Numeric serial number.

For example, a printer having RET219638 as its Serial Number:
Is a 110 V Phaser 5500 Printer
Has a 219638 serial number

Using the Parts List
No.: The callout number from the exploded part diagram.
Name/Description: The name of the part to be ordered, appearing in

UPPERCASE letters, and the number of parts supplied per order.
Part Number: The material part number used to order that specific part.
Parts identified throughout this manual are referenced PL#.#.#; For example,
PL3.1.10 means the part is item 10 of Parts List 3.1.
A black triangle preceding a number followed by a parenthetical statement in an

illustrated parts list means the item is a parent assembly, made up of the
individual parts called out in parentheses.
The notation with X~Y following a part name indicates an assembly that is
made up of components X through Y. For example, 1 (with 2~4) means part 1
consists of part 2, part 3, and part 4.
An asterisk (*) following a part name indicates the page contains a note about
this part.
Note
Only parts showing part numbers are available for ordering by support. Parts
not showing part numbers are only available as part of a parent assembly.
Abbreviations
Abbreviation Meaning
C C-ring
E E-ring
KL K-clip
S Screw
Parts Lists 9-3

Print Engine Parts
Parts List 1.1 Covers 1/2
4
3 7
5
S
S
15 8
S
9 (with 10-12)
10 11
S
12
14 S
14
1 S
S
S
2
Lef
t Front
13
s5500-190

No. Name/Description Part Number
1 COVER LEFT FR 802K74110
2 COVER-FRS FR, PR (Front Left Cover) 802E55371
3 COVER-TOP RR, PR (Top Rear Cover) 802E55361
4 BRACKET ILSW
5 SWITCH (Front Door Interlock Switch) 110E94770
6 CONSOLE PANEL (Front Panel) 802E64160
7 HARN ASSY CONPANEL 962K24041
8 COVER ASSY TOP PR (Top Cover) 802K74170
9 COVER ASSY FRONT (with 10~12) (Front Door) 802K74080
10 MAGNET CATCH
11 COVER-FRONT
12 STRIP (Stopper) 802E55351
13 COVER ASSY INNER,MAIN (Inner Main Cover) 802K58180
14 FOOT FRONT
15 PLATE SER
Parts Lists 9-5

5
1
9 S
8 S
4
3
2
6
Rig
ht Rear
7 s5500-191

1 COVER RIGHT UPR (Upper Right Cover) 802E55230
2 COVER RIGHT LOW] (Lower Right Cover) 802E55241
3 COVER ESS RH 802E55260
4 COVER-CAP ESS,PR (Rear Panel Cover) 802E55381
5 COVER REAR UPR (Upper Rear Cover) 802E55271
6 COVER REAR LOW PR (Lower Rear Cover 110V) 802K74120
- COVER REAR LOW PR (Lower Rear Cover 220V) 802K74130
7 COVER-CAP MCU (Option Interface Cover) 802E55292
8 FOOT FRONT
9 FOOT REAR LEFT
Parts Lists 9-7

Parts List 2.1 Tray 1/2 and Feeder 1/2
5 S
15
S
7 2 2
6 1
12
3
S
15
14 7
13 10
14 11
9 (with 13,14) Lef
t Front
99 (with 3, 12, PL20.2.2, PL20.2.3) s5500-192

Parts List 2.1 Tray 1/2 and Feeder 1/2
1 STOPPER-TRAY 003E58700
2 SPACER TRAY G 014E44710
3 TRAY ASSY (PL 2.2, included with 99)
4 SWITCH ASSY P S (Paper Size Switch) 110K11680
5 BRACKET-SW
6 CHUTE ASSY FEEDER 054K24091
7 FEEDER ASSY (PL2.3.2.1) 059K26934
9 CHUTE FEED OUT (with 13, 14) 054K27550
10 LABEL, TRAY NO1 (included with 97)
11 LABEL, TRAY NO2 (included with 97)
12 LABEL INST,M/N
13 CHUTE FEED OUT
14 PAD ASSY LH LOW
15 COVER SENSOR
97 KIT LABEL (with 10, 11, PL20.2.2, PL20.2.3) 604K23370
98 TRAY, ENVELOPE (as option, not shown) 604K24320
99 500 TRAY 109R00733
Parts Lists 9-9

Parts List 2.2 Tray 2/2
1 (with 2-26)
4 17
A E 16
E
10
B
13
12
14 C
8
5
24
9
S 15 8
S
25 15
18
20 23 A
C
B
6
S
S
D 11
21
22
D
25 S 26
2 Left Front
S
19 s5500-193

Parts List 2.2 Tray 2/2
1 TRAY ASSEMBLY (with 2~26) 109R00733
2 TRAY COVER
3 -
4 LABEL (MAX)
5 BOTTOM PAD
6 FRONT SIDE GUIDE
7 -
8 TRAY PAD
9 REAR SIDE GUIDE
10 BOTTOM PLATE
11 TRAY
12 SIDE GUIDE ACTUATOR
13 GUIDE ACTUATOR
14 SPRING
15 PINION GEAR
16 END GUIDE
17 SPRING
18 END GUIDE ACTUATOR
19 LINK
20 COUPLING GEAR (13T)
21 GEAR (13T/60T)
22 SECTOR GEAR (60T)
23 BRACKET
24 LIFT UP SHAFT
25 STOPPER
26 SEAL
99 KIT, LABEL
Parts Lists 9-11

Parts List 2.3 Feeder 2/2
1 (with 2-50) Pre Feed

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

1 FEEDER ASSEMBLY (with 2~50) 059K26934
2 TRAY FEED LIFT UP MOTOR 127K38170
3 BRACKET
4 SPACER
5 GEAR (31T)
6 SPRING
7 ONEWAY CLUTCH
8 ONEWAY GEAR
9 GEAR (13T)
10 BEARING
11 SHAFT
12 FRONT CHUTE
13 ACTUATOR (No Paper Sensor Actuator) 120E22481
14 SENSOR (No Paper or Level Sensor) 930W00113
15 SENSOR (Pre-Feed Sensor) 930W00211
16 WIRE HARNESS
17 GEAR (28T/21T)
18 GEAR (29T)
19 SPRING 809E51070
20 ROLLER ASSY--Periodic replacement part per 300k prints (included

with 99) (Feed Roller)
21 ONEWAY CLUTCH
22 ONEWAY GEAR (22T)
23 SHAFT
24 CHUTE
25 SPRING
26 FRICTION CLUTH
27 SHAFT-RETARD
28 --
Parts Lists 9-13

29 SPACER
30 GEAR (33T)
31 SHAFT-NUDGER
32 --
33 GEAR (25T)
34 LOWER FRAME
35 BEARING
36 GEAR (27T)
37 LEVER
38 BEARING
39 WASHER
40 UPPER FRAME
41 -
42 HOLDER HARNESS CTR
43 HOLDER HARNESS REAR
44 HOLDER HARNESS UPPER
45 HOLDER HARNESS PS1 (ALT)
- CLAMP MINI-SADDLE (ALT)
46 RAIL
47 SUPPORT RETARD
48 SUPPORT NUDGER
49 HOLDER
50 SPRING
99 KIT ROLLS (with 20 x 3 pcs.)Periodic replacement (per 300k print) 604K20530

This page intentionally left blank.
Parts Lists 9-15

Parts List 3.1 Tray 1/MPT Assembly
14
20
1 (with 2-12,15-19) 20
2
3 15 (with 8,9,16-19)
S
8
4 16 13
5 6 7 17
18
9
S
9
19
17
18
12 (PL3.3.1) 11 (PL3.2.1)
10
Lef
t Front
S
s5500-195

1 FEEDER ASSEMBLY MSI (with 2~12, 15~19) (Tray 1/MPT Feeder) 059K31460
2 FRAME UPPER
3 ACTUATOR (No Paper Sensor Acutator) 120E22230
4 SENSOR-PHOTO IN (No Paper Sensor) 930W00113
5 HARNESS ASSY MSI
6 SPRING MSI (Pick-Up Gear Spring) 809E38160
7 BRKT ASSY-GEAR
8 CHUTE PINCH
9 ROLL ASSY-PINCH
10 CHUTE LOW
11 FRAME ASSY LOWER (PL3.2)
12 TRAY ASSY-MSI (PL3.3)
13 COVER MSI FR (Tray 1/MPT Front Cover) 802K74140
14 COVER MSI RR (Tray 1/MPT Rear Cover) 802E55211
15 CHUTE ASSY PINCH
16 GUIDE PINCH
17 SPRING PINCH
18 SPACER SPRING PINCH
19 SHAFT PINCH
20 WIRE SADDLE
Parts Lists 9-17

Parts List 3.2 Tray 1/MPT Lower Frame Assembly
1 (with 2-28)
17
19
14
20
6
22 16
7
4 19
21 13
18
26 E
S 3 12
15 9
5
8
24 24
23
2
25
10
25 21
E
11 28
E
Lef
t Front
27 9
s5500-196

Parts List 3.2 Tray 1/MPT Lower Frame Assembly
1 FRAME ASSY LOWER (with 2~28)
2 FRAME LOWER MSI
3 STOPPER LEVER
4 COLLAR
5 SHAFT-RETARD
6 GEAR PICK UP
7 GEAR 18T
8 LEVER-GEAR
9 BEARING 8
10 PAD BOTTOM 019E56551
11 PLATE BOTTOM
12 PAD ASSY-RETARD 019K07085
13 GUIDE PAPER MSI
14 ROLL ASSY-DRIVE
15 SOLENOID PICK UP 121E92780
16 SHAFT ASSY PICK UP
17 CAM PICK UP 2 008E93831
18 CAM PICK UP FRONT 008E94270
19 ROLL CORE
20 ROLLER ASSY-FEED (Feed Roller with installation instructions) 604K23380
21 BEARING SLEEVE
22 GEAR CAM
23 SPRING LEVER GE
24 SPRING PAD (Retard Pad Spring) 809E27650
25 SPRING N F
26 SPRING-GEAR CAM 809E54530
27 PLATE EARTH BOTTOM
28 PLATE EARTH FRONT
Parts Lists 9-19

1 (with 2-13)
7
13
6
5 4
8
10
12
S
2
3
11
Lef
t Front
9 S
s5500-197

1 TRAY ASSY MSI (with 2~13)] 050K49741
2 GEAR-PINION
3 RACK-FRONT
4 RACK-REAR
5 LINK-SENSOR
6 GUIDE-SIDE FRONT
7 GUIDE-SIDE REAR
8 TRAY MSI
9 TRAY EXT
10 SENSOR ASSY-MSI (Paper Size Sensor)
11 COVER TRAY
12 SPRING-SENSOR
13 HARNESS ASSY SIZE
Parts Lists 9-21

Parts List 4.1 Transportation and Registration L/H Lower
1 (with 2, 3)
3
2
Door B
Interlock
4 Switch
S 6
7
5
8
10 (with 11-22)
E
16 (with 17-22)
S
9
19
11
21 17
18 19
20 21
22
12
13
14
Lef
t Front
15 s5500-198

Parts List 4.1 Transportation and Registration L/H Lower
1 BRKT ASSY TA (with 2,3) (Take Away Bracket) 015K61010
2 BRACKET ASSY IDLER
3 SWITCH-I/L, CAB (Door B Interlock Switch) 110E11580
4 RIVET 029E31600
5 CHUTE-LOWER
6 BEARING TA 013E26990
7 GEAR - 18T 007E79270
8 ROLLER ASSY-TA (Take Away Roller) 059K26840
9 BEARING SLEEVE 413W77559
10 COVER ASSY LH LOW C (with 11~22) (Door B) 802K58280
11 CHUTE LH LOW C
12 HANDLE LH LOW
13 SPRING-COMP LH LOW
14 COVER LH LOW C
15 PLATE-EARTH
16 BRKT ASSY LH LOW C (with 17~22)
17 BRKT LH LOW
18 ROLLER-TA PINCH
19 BEARING-OUT
20 BEARING-IN
21 SPRING LH LOW
22 SPRING
Parts Lists 9-23

Parts List 4.2 L/H Upper Assembly
Door A
Interlock Switch 5
4 S
3
S
6
1
7
(PL4.3.1)
8 Lef
t Front
(PL4.4.1)
s5500-199

Parts List 4.2 L/H Upper Assembly
1 HSG ASSY-BTR -- Periodic replacement part (per 300k prints) 802K56094

(Transfer Roller)
2 COVER ASSY-CONTACT 802K49240
3 LINK ASSY-SHUTTER 012K94341
4 SWITCH (Door A Interlock Switch) 110E94770
5 BRACKET ILSW
6 STUD 826E08440
7 CHUTE ASSY LH (PL4.3.1)
8 COVER ASSY-LH (PL4.4.1)
Parts Lists 9-25

Parts List 4.3 L/H Chute Assembly
1 (with 2-9)
2
3
4
5
5
6 7
6
7
5 5
7
S
6 6
8
Lef
t Front
9 s5500-200

Parts List 4.3 L/H Chute Assembly
1 CHUTE ASSY LH (with 2~9 054K24051
2 BEARING-PINCH OUT
3 ROLLER ASSY-REGI-P
4 CHUTE-ASSY
5 SPRING COMP FL
6 GUIDE
7 SPRING COMP PINCH
8 PLATE-TIE
9 PLATE-EARTH
Parts Lists 9-27

Parts List 4.4 L/H Cover Assembly
1 (with 2-10)
10
S
3
S 7
2
9
8 Lef
t Front
s5500-201

Parts List 4.4 L/H Cover Assembly
1 COVER ASSY-L/H (with 2~10) (Door A) 802K58260
2 HANDLE L/H 003E59832
3 ROD CRU SHUTTER 024E03250
4 CHUTE LHCOV
5 -
6 CHUTE ASSY-DUP 054K24060
7 FRAME ASSY LH
8 COVER-LH
9 SPRING COMP LH 809E42460
10 SUPPORT - LH COVER (Door A Stopper) 849E13981
Parts Lists 9-29

Parts List 4.5 Registration
S
15
14
16 E
13
20
12
E
S 11
10
E
1 (with 2-8)
2
E 3 7
6 4
5 7
S
19
8
E
6
9 18
Lef
t Front
S
17 (with 9, 18, 19)
s5500-202

Parts List 4.5 Registration
1 TRANS ASSY REGI (with 2~8) (Registration Transport Assembly) 059K26820
2 CLUTCH ASSY REGI H (Registration Clutch) 121K32660
3 CHUTE-REGI
4 ROLLER REGI IDLER
5 ROLLER ASSY REGI
6 BEARING REGI E
7 SNR ASSY REGI (Registration Sensor) 130K64270
8 PLATE-EARTH F G
9 CHUTE-TA 054E23910
10 CHUTE ASSY-R 054K23940
11 BEARING 013E26090
12 SHAFT TA
13 GEAR-19T 007E79320
14 CLUTCH ASSY-TA (Take Away Clutch) 121K31640
15 BRACKET-TA
16 BEARING 013E26060
17 CHUTE-TA (with 9, 18, 19) (Take Away Chute)
18 SENSOR (Feed Out Sensor #3) 930W00211
19 HARNESS
20 PUSH TIE
Parts Lists 9-31

Parts List 5.1 Laser, CRU and Toner Dispense
15 16
17
11 S
9 18
8 8
7 S
S S
10
13
6
12
S
4 5
S
3 14
2
1
98
Front ight
R
s5500-203

Parts List 5.1 Laser, CRU and Toner Dispense
1 BLOCK STOPPER CRU ] 014E44733
2 SCREW
3 PLATE-SW-INTLK 815E05030
4 SWITCH ASSY XERO INTLK (Drum Cartridge Detect Switch) 110K11810
5 SENSOR HUM & TE (Environmental Sensor Temp/Humidity PWB) 130K87980
6 GUIDE ASSY SUB 032K96910
7 HSG ASSY LASER C 802K73190
8 PWBA CRUM CP1 (Drum Cartridge/Toner Cartridge CRUM) 160K95830
9 HARN ASSY FRONT A
10 GUIDE ASSY CTG30 SUB (Toner Dispense Assembly) 032K96951
11 MOTOR ASSY-DISP 30K (Toner Dispense Motor) 127K38040
12 DUCT FUSER
13 FAN FUSER 127K37880
14 ROS ASSY-12 (Laser Assembly) 062K13614
15 CRU DRUM CARTRIDGE 113R00670
16 TONER CARTRIDGE 113R00668
17 DUCT INTAKE
18 CRU FAN (Drum Cartridge Fan 927W00112
98 DRUM CARTRIDGE CONN (Drum Cartridge Connector) 114E14880
Parts Lists 9-33

Parts List 6.1 Fuser and Exit 1 Unit
8
(PL6.2)
99 S
6
4
E
3 E
5
1
7
Lef
t Front
s5500-204

Parts List 6.1 Fuser and Exit 1
1 SHAFT-ACTUATOR
2 --
3 ACTUATOR-EXIT (included with 99)
4 SENSOR PHOTO (Fuser Exit Sensor included with 99)
5 SPRING-ACTUATOR (included with 99)
6 BRKT-SENSOR, EXIT (included with 99)
7 FUSER ASSY 120V --- Periodic replacement part (per 300k prints) 126K18300
7 FUSER ASSY 220V --- Periodic replacement part (per 300k prints) 126K18310
8 TRANS ASSY EXIT (PL6.2)
99 KIT EXIT SENSOR (with 3~6) (Fuser Exit Sensor Kit) 015K60900
Parts Lists 9-35

Parts List 6.2 Exit 1
22
32 25 1 (with 2-21,34,35)
2
30
26
27
33
3 S
28
23 31 29 18 4 7
5 6
24 17
19 5
S
35
34 8
16 9
E
20 14
15
13 10
E
21 11
Fron ht
12 t Rig
10
s5500-205

Parts List 6.2 Exit 1

1 TRANS ASSY EXIT (with 2~21, 34, 35) (Exit Transport Assembly) 059K31550
2 HARN ASSY EXIT 1 C
3 MOTOR ASSY-OFFSET (Offset Motor) 127K37951
4 PLATE-EARTH MOTOR
5 SENSOR-PHOTO IN (Offset Home Position or Full Stack Sensor) 930W00113
6 BEARING
7 GEAR-19T
8 CAP
9 GEAR-EXIT
10 BEARING ROLL
11 CHUTE-OCT1
12 SPRING-PINCH EXIT
13 RLR-PINCH EXIT
14 ROLL ASSTY OCT
15 CHUTE-LOW
16 BRACKET SENSOR
17 GEAR-OFFSET
18 SPRING-GATE 809E42370
19 GATE-EXIT 1 (Exit Gate) 050E19802
20 BEARING
21 PLATE-EARTH
22 COVER-TOP, EXIT 1 802E55151
23 BRKT-EXIT 2
24 ELIMINATOR EXIT
25 GUIDE-TRAY EXIT 1
26 ACTUATOR FULLSTACK 120E22171
27 ACTUATOR 120E24670
28 WEIGHT-ASSY PAPER 036K91600
29 PAD EXIT A
30 PAD EXIT B
31 PAD EXIT C
32 LABEL EXIT 1 XC
33 LABEL CAUTION XC
34 SEAL A
35 SEAL B
Parts Lists 9-37

Parts List 7.1 Drive
6 (with 7, 8)
7 PL6.2.9
5
99 (with 1 - 4)
9
4
3
1
2
Rig
ht Rear
s5500-206

Parts List 7.1 Drive
1 COLLAR
2 GEAR 21/21T MSI
3 GEAR 18T MSI
4 GEAR 28T TA
5 BELT-SYNCHRONOUS BAN (Main Drive Belt) 423W13155
6 DRIVE ASSY 242 (with 7, 8number) (Motor Assembly) 007K88596
7 MOTOR ASSY 242
8 PULLEY 25T 020E36600
9 FLANGE EXIT 005E17860
99 KIT, GEAR (with 1, 2, 3, 4) 604K23270
Parts Lists 9-39

Parts List 8.1 Electrical
23
25
33
6
S
4
32
22
2
S S 29
3 35
1 S
24 34
30, 31
S
9 S
21
8 26
20
10 (with 11-16)
11
14 16 S
S S
13 12 S
15
7 Rig
ht Rear
28
27 s5500-207

Parts List 8.1 Electrical

1 PSHV-Y2 High-Voltage Power Supply (HVPS) 105E11420
2 SWITCH-POWER 110E11320
3 BRACKET-SW CPR
4 PWB A EXIT (Exit PWB) 160K94216
5 PWBA MCU F 110V/220V (Engine Logic Board) 960K06080
6 PWB SUPP EDGE
7 BRACKET MCU
8 POWER UNIT-C1(100/127) Low-Voltage Power Supply (LVPS) 105E11390
POWER UNIT C1H(200/240) Low-Voltage Power Supply (LVPS) 115E11400
9 CHOKE COIL (220/240) 104E94080
10 CHAS ASSY AC XC (with 11~16) (AC Accessory Panel)
11 SCREW
12 BRACKET-CONN AC
13 BREAKER GFI INL (GFI Breaker) 908W01201
14 HARNESS ASSY F/G,E
15 HARN ASSY AC US EU
16 OUTLET MN
17
18
19
20 COVER ASSY ESS (I/P Board Cover) 802K73070
21 PANEL ASSY CONN HCF
22 BRKT GUIDE PRX
23 CHASSIS ASSY ESS PRX
24 BRKT-EXIT LOW
25 IMAGE PROCESSOR BOARD (with NVRAM) 650-4341-00
26 PLATE ASSY LVPS
27 PKG POWER CORD (110V) 673K44480
28 PKG POWER CORD (220V) 673K55640
29 NVRAM DEVICE (I/P Board NVRAM) 163-1459-00
30 BASE CONFIG CARD (Networking disabled) 163-1518-00
31 NETWORK CONFIG CARD (Networking enabled) 163-1519-00
32 HARD DRIVE 650-4343-00
33 FLASH RAM (Optional flash memory) 671-5338-0A
34 128 MB DIMM 156-4860-00
35 256 MB DIMM 156-4663-00
Parts Lists 9-41

Parts List 8.2 Harness
4
5
6
9
7
10
11
8
13 12
Rig
ht Rear
s5500-2

Parts List 8.2 Harness
1 HARN ASSY FEEDER C
2 HARN ASSY MSI A
3 HARN ASSY SIZE A
4 HARN ASSY ESS C
5 HARN ASSY ROS C
6 HARN ASSY EXIT C
7 HARN ASSY PH C
8 HARN ASSY FUSER AC C 962K18991
9 HARN ASSY LV PWR C
10 HARN ASSY INTLK A
11 HARN ASSY MAIN SW C
12 HARN ASSY DRIVE A
13 WIRE HARNESS CRUM B
Parts Lists 9-43

Xerox Supplies and Accessories
User Documentation and Kit Instructions
Description Part Number
1000-Sheet Feeder Instructions 075-0909-00
2,000-Sheet Feeder Instructions 075-0910-00
Duplex Unit Instructions 075-0911-00
Maintenance Kit Instructions 075-0906-00
3,500-Sheet Stacker/Finisher 075-0912-00
Printer Repacking Instructions 075-0918-00
Envelope Tray instructions 075-0913-00
User Guide (English only) 001-1581-00
User Documentation CD-ROM 063-3455-00
B to N Upgrade Instructions 075-0917-00
Tray 1/MPT Feed Roller Replacement 075-0908-00
Printer Installer and Utilities CD-ROM 063-3456-00
Adding Memory Instructions 075-0915-00
Flash Memory DIMM Instructions 075-0916-00
Hard Drive Instructions 075-9914-00
Toner Cartridge Instruction Sheet (on box) 075-0904-00
Drum Cartridge Instruction Sheet (on box) 075-0907-00
Staple Pack Instruction Sheet (on box) 075-0905-00

Consumables
Toner Cartridge (30K) 113R00668
Staple Pack 008R12941
Upgrade Kits and Options
128 MB Memory Option 097S03123
256 MB Memory Option 097S03225
16 MB Flash Memory DIMM 097S03125
20 GB Hard Drive Option 097S03227
B to N Upgrade Kit 097S03222
1000-Sheet Feeder (Trays 4 & 5) 097S03218
2000-Sheet Feeder (Tray 6) 097S03219
Duplex Unit 097S03220
3,500-Sheet Stacker 097S03221
3,500-Sheet Finisher (w/ 2 or 4-hole punch) 097S03281
3,500-Sheet Finisher (w/ 3-hole punch) 097S03282
Envelope Tray (replaces Tray 2) 097S03286
Routine Maintenance Items
Maintenance Kit, 110 V 109R00731
Maintenance Kit, 220 V 109R00732
Drum Cartridge (60K) 113R00670
500-Sheet Universal Replacement Tray 109R00733
Hardware Kit 600K65640
Common Clip Kit 600K65630
Electrical Kit (2 ea. interconnects) 604K23340
Parts Lists 9-45

Wiring Diagrams
In this chapter...
Print Engine Plug/Jack Designators
Print Engine Plug/Jack Locator Diagrams
Notations Used in Wiring Diagrams
Print Engine Wiring Diagrams
Chapter
10
The Plug/Jack locators consist of the P/J Locator Tables and the P/J Locator
Diagrams. The table lists the plug/jack numbers in numerical order. The co-ordinates
column lists the diagram coordinates for the location of the connector. A brief
description of each connection is included in the remarks column.
P/J Coordinates Remarks
1 D-204 Connects the LVPS and Main Switch Harness.
2 D-243 Connects the LVPS and Finisher Outlet.
3 D-245 Connects the LVPS and Heater Harness.
6 E-245 Connects the LVPS and Fuser AC Harness.
7 E-245 Not Connected
11 D-245 Connects the LVPS and GFI Breaker.
12 D-245 Connects the LVPS and GFI Breaker
20 J-141 Connects the Fuser Main Lamp (Heat Rod) and Fuser Harness.
21 J-141 Connects the Fuser Sub Lamp 1 and Fuser Harness.
22 J-141 Connects the Fuser Sub Lamp 2 and Fuser Harness.
50 F-229 Connects the GFI Breaker and LVPS.
56 B-238 Connects the Power Switch and Power Switch Harness.
72 F-230 Connects the GFI Breaker and Ground (Earth).
73 G-230 Connects the Finisher Outlet and LVPS.
74 G-230 Connects the Finisher Outlet and LVPS.
75 G-230 Connects the Finisher Outlet and Ground (Earth).
100 G-180 Connects the Tray 2 Level Sensor and the Tray 2 Feeder Harness.
101 G-180 Connects the Tray 2 No Paper Sensor and the Tray 2 Feeder Harness.
102 G-180 Connects the Tray 3 Level Sensor and Tray 3 Feeder Harness.

103 G-180 Connects the Tray 3 No Paper Sensor and Tray 3 Feeder Harness.
104 F-167 Connects the Registration Sensor and Registration Harness.
105 F-186 Connects the Feed Out #3 Sensor and Feed Out #3 Sensor Harness.
106 D-183 Connects the LHL Switch and the PH Harness.
107 D-153 Connects the Tray 1/MPT Size Sensor and Tray 1/MPT Sensor
Harness.
108 G-152 Connects the Tray 1/MPT No Paper Sensor and Tray 1/MPT Harness.
109 D-200 Connects the Tray 2 Size Sensor and Size Sensor Harness.
110 D-201 Connects the Tray 3 Size Sensor and Size Sensor Harness.
117 B-134 Connects the OCT Home 1 Sensor and OCT Harness.
118 B-134 Connects the Full Stack Sensor and OCT Harness.
120 H-196 Connects the Door A Interlock Switch and Engine Logic Board.
120 C-119 Connects the I/P Board to the LVPS.
121 C-244 Connects the Front Door Interlock Switch and INTLK Harness.
125 C-106 Connects the Fuser Exit Sensor and PH Harness.
126 D-122 Connects the Drum Cartridge and CRUM Harness.
127 F-108 Connects the Toner Cartridge and CRUM Harness.
130 E-124 Connects the Laser (Scanner) and Laser Harness.
131 B-139 Connects the Center STS and Fuser Outlet.
132 B-139 Connects the 2nd STS and Fuser Outlet.
133 B-139 Connects the Rear STS and Fuser Outlet.
133 H-181 Connects the Tray 2 Pre Feed Sensor and Tray 2 Feeder Harness.
134 H-181 Connects the Tray 3 Pre Feed Sensor and Tray 2 Feeder Harness.
140 F-123 Connects the Laser Assembly and Laser Harness.
150 G-166 Connects the Hum & Temp (Environmental) Sensor and REGI Harness.
150 F-119 Connects the I/P Board to the Front Panel.
201 E-180 Connects the Tray 2 Feed/Lift Motor and Tray 2 Feeder Harness.
Wiring Diagrams 10-3

202 E-180 Connects the Tray 3 Feed/Lift Motor and Tray 2 Feeder Harness.
204 H-199 Connects the Takeaway Clutch and PH Harness.
205 D-151 Connects the Tray 1/MPT Feed Solenoid and MSI Harness.
206 G-196 Connects the Exit 1 Offset Motor and EXIT Harness.
214 G-198 Connects the Drive Assembly and Drive Harness.
215 E-166 Connects the Registration Clutch and Registration Harness.
216 H-106 Connects the Toner Dispense Motor and LV PWR Harness.
221 E-107 Connects the Engine Logic Board and Drum Cartridge Fan.
311 B-242 Connects the Front Panel and Front Panel Harness.
400 C-214 Connects the Engine Logic Board and LV PWR Harness.
402 D-212 Connects the Engine Logic Board and I/P Board Harness.
403 F-211 Connects the Engine Logic Board and Registration Harness.
404 E-212 Connects the Engine Logic Board and Xerographics Harness.
405 G-212 Connects the Engine Logic Board and Interlink Harness.
406 D-212 Connects the Engine Logic Board and Laser Harness.
407 C-212 Connects the Engine Logic Board and Laser Harness.
408 G-211 Connects the Engine Logic Board and Drive Harness.
409 G-213 Connects the Engine Logic Board and Feeder Harness.
410 G-212 Connects the Engine Logic Board and PH Harness.
411 G-214 Connects the Engine Logic Board and Tray 1/MPT Harness.
412 C-213 Connects the Engine Logic Board and Size Harness.
413 D-214 Connects the Engine Logic Board and Tray 4-5 Harness.
414 F-214 Connects the Engine Logic Board and Tray 6 Harness.
415 F-214 Connects the Engine Logic Board and Tray 6 Harness.
416 D-214 Connects the Engine Logic Board and Output Unit.
417 E-214 Connects the Engine Logic Board and Duplex Unit Harness.
419 D-212 Connects the Engine Logic Board and CRUM Harness.

430 H-120 Connects the Exit PWB and LV PWR Harness.
431 H-120 Connects the Exit PWB and LV PWR Harness.
432 H-120 Connects the Exit PWB and EXIT Harness.
433 I-120 Connects the Exit PWB and EXIT Harness.
434 I-120 Connects the Exit PWB and EXIT Harness.
490 I-121 Connects the Flash ROM device to the I/P Board.
500 C-110 Connects the HVPS and Registration Harness.
521 I-246 Connects the LVPS and LV PWR Harness.
540 E-122 Connects the Hard Drive to the I/P Board.
590 J-123 Connects the I/P Board and Engine Logic Board.
600 A-139 Connects the Fuser and Fuser AC Harness.
600 H-196 Connects the Fuser and Fuser Harness.
601 C-183 Connects the Tray 2 Feeder Harness and Feeder Harness.
602 C-184 Connects the Tray 3 Feeder Harness and Feeder Harness.
605 I-199 Connects the Tray 1/MPT and Tray 1/MPT Harness.
606 G-195 Connects the EXIT 2 Harness and EXIT Harness.
607 G-199 Connects the Fuser Harness and PH Harness.
608 C-184 Connects the Take Away Sensor Harness and PH Harness.
609 D-151 Connects the Tray 1/MPT Sensor Harness and Tray 1/MPT Harness.
610 B-109 Connects the ATC Sensor and Registration Harness.
613 G-196 Connects the OCT Harness and EXIT Harness.
830 C-125 Connects the RAM DIMM to the I/P Board.
831 C-125 Connects the RAM DIMM to the I/P Board.
890 I-125 Connects the I/P Board to the Laser Assembly.

Plug/Jack Locator Diagrams
The Print Engine P/J Locator diagrams show the location of primary connections
within the printer. Use these illustrations to locate connections called out in the
troubleshooting procedures presented in Chapters 3, 4, and 5.
Drum and Toner Cartridge

A B C D E F G H I J K L
101
102
103
104
125 221 127
105
106
107
108
109
216
110
111 610
112 500
113
114
115
s5500-209

Laser Assembly and Exit PWB
116
117
118
Exit PWB
432
119
430 434
433
120
121 126 431
122
123
124
125
160
126
170
127 140
130 620
128
129
130
s5500-210

Fuser and Exit 1
131
132
117
133 118
134 Exit 1
135
136
137
131
600 132
138 133
139
20 21
140
22
141
Fuser Assembly
142
143
144
145
s5500-211

Tray 1/MPT
146
147
148
149
150
205
609 108
151
152
153
154
107
155
156
157
158
159
160
s5500-212

Registration Transport Assembly
161
162
163
150
164 215 104
165
166
167
168
169
170
171
172
173
174
175
s5500-213

Tray 2 & 3 Feeder Assemblies
176
177
178 Tray 2 : 201

Tray 3 : 202 Tray 2 : 100
179
Tray 3 : 102
Tray 2 : 101
Tray 3 : 103
180
Tray 2 : 133
Tray 3 : 134
181
182
601
183
106
184
602
185
608
186
187
105
188
189
190
s5500-214

Print Engine Electrical
191
192
193 613 606

206
194 120
195
600
196
197
198
214
199
200
605
201
204
202 800
607
109
203 110
204
205
s5500-215

Engine Logic Board
206
207
208
209
408
403
404
402
406
210
407 405
211
419 410
212
420
213 409
421
214
412 411
215
415
401 414
216 417
413
400
217 416
218
219
220
s5500-216

116
117
120 150
118
119
120
121
122 490
123
540
124
590
125
126
890
127
128 830 831
129
130
s5500-620

AC Accessory Panel
221
222
223
224
225
226
74
227
228
50 73
229
230 75
231
72
232
233
234
235
s5500-217

LVPS
236
Power Switch
237 56
238
239
68 69 57
240
311
241
242 2
243 121
526
244 1
245 11
246
521
247
248
12
525
3 7 6
249
250
s5500-218

Print Engine Wiring Diagrams
Notations Used in Wiring Diagrams

The symbols in the interconnection wiring diagram are described below. Note that the
description of general symbols is omitted.
Symbol Description
Represents an interconnection between parts using

wiring harness or wire, and indicates its signal name/
contents. The arrow > or < on the line represents the
direction of signal flow.
Represents an interconnection between parts using

wiring harness or wire, which differs according to the
specifications, and indicates its signal name/contents.
The arrow > or < on the line represents the direction
of signal flow.
Represents a connection between parts using a

conductive member such as a plate spring, and
indicates its signal name/contents. The arrow > or <
on the line represents the direction of signal flow.
Represents a function and a logical value (High (H) or

Low (L)) of a signal when the function is activated. The
voltage indicates a value when the signal is High. The
arrow indicates the direction of signal flow.
Represents a function and a logical value (High (H) or

Low (L)) of a signal when the function is in a detectable
state. The voltage indicates a value when the signal is
High. The arrow indicates the direction of signal flow.
Represents a connection between lead wires.
Represents a connection between parts by tightening of

a screw.
Represents a connection between A and A.
The DC voltage indicates an approximate value

24 VDC measured when the negative side is connected to a
signal ground (SG).
Indicates a signal ground (SG).

Symbol Description
Indicates a frame ground (FG).
Indicates a return.
RTN
Represents a connector. The connector and PIN Nos.

are shown at the upper and lower parts respectively.
P,- indicates the plug side of the connector.
J,> indicates the jack side of the connector.
Represents a connection terminal with a plate spring on

the printed circuit board. The connector No. is indicated
inside the box.
Represents a connector directly connected to the

printed circuit board. The connector No. is indicated
inside the box.
Represents a part.
PL X.Y.Z indicates the item Z of the plate (PL) X.Y
described in Chapter 5 Parts List.
Represents a functional part within a part, and indicates

the name of the functional part.
Indicates a reference item associated with the section.

Print Engine General Wiring (1/2)
1 LVPS 10
LVPS P/J432 P/J613 P/J117 OCT Home Sensor
P/J526 P/J430
P/J1 Power Switch

Exit PWB P/J118 Full Stack Sensor
Outlet MN Exit 1
P/J2
P/J206 Offset Motor
P/J431
P/J5 Choke Coil
Laser Assembly 9
11
P/J302 P/J160
LD PWB
I/P Board P/J421 Laser Assembly P/J170
P/J400 P/J140 P/J406 SOS Sensor
P/J521 P/J300 P/J301 P/J402 P/J406 P/J620 P/J130 ROS Motor
Drum Cartridge Detect Sw P/J404 P/J411 P/J605 P/J609 P/J107 Tray 1 Paper Size 8
Front Door P/J120 P/J405 P/J205 Solenoid Pick Up

Interlock Switch
Tray 1
Door A P/J121
Interlock Switch P/J108 Tray 1 No Paper Sensor
2 P/J525 P/J401
P/J6 Fuser
Engine
Logic
Fuser Assembly P/J600 P/J607 P/J410 Board
P/J125
Fuser Exit Sensor
s5500-219

Print Engine General Wiring (2/2)
Engine
Logic
Board
P/J409 P/J602 P/J202 Tray 3 Feed Lift Up Motor 7
P/J102 Tray 3 Level Sensor
Tray 3
P/J103 Tray 3 No Paper Sensor
P/J134 Tray 3 Pre Feed Sensor
3 Feed Out #3 Sensor P/J105 P/J608

P/J412 P/J110 Tray 3 Size Sensor
Door B Interlock Switch P/J106
P/J409 P/J601 P/J201 Tray 2 Feed Lift Up Motor 6

Take Away Clutch P/J204
Registration P/J100 Tray 2 Level Sensor
Registration Sensor P/J104 P/J403
Tray 2 P/J101 Tray 2 No Paper Sensor

Registration Clutch P/J215
P/J133 Tray 2 Pre Feed Sensor

4 Chute-Assembly P/J500
DTS
HVPS P/J412 P/J109 Tray 2 Size Sensor

Transfer Roller
BTR
Drum DRUM 5
Cartridge BCR
Mag Roll Main Motor Fuser Fan
P/J408 P/J214 CN102
Drum Motor
ATC Sensor P/J610
Environmental Sensor P/J150 P/J419 P/J126 Drum Cartridge CRUM

Xerographics
Toner Dispense Motor P/J216 P/J420 Drive/CRUM P/J127 Toner Cartridge CRUM
P/J417 P/J221 CRU Fan
s5500-628

LVPS
LVPS I/P Board
P/J521 P/J300
Main Power On
ON/OFF 5 12
+3.3VDC
1 1
+3.3VDC
+3.3VDC 6 6
Supply SG
2 2
SG
7 7
+5VDC
3 4
SG
8 9
+5VDC Exit PWB
Supply P/J526 P/J430
+5VDC
6 3
SG
5 4
+24VDC
8 1
RTN
7 2
Engine
Logic Board
Door A
Interlock Interlock Switch
+24VDC
P/J405 P/J121
I/L +24VDC
4 B1
+24VDC
3 A1
Supply
Front Door
P/J526 P/J400 Interlock Switch
+5VDC
2 3 P/J405 P/J120
SG
1 4 2 B1
+24VDC +24VDC
4 1 1 A1
RTN
3 2
Choke Coil Drum Cartridge

Detect Switch
P/J5
From P/J404
1
XERO 1
2 LD +5VDC
To 3
ROS
Outlet MN
P/J2
1
5
Power Switch
P/J1
1 2
NUT
6 1
4 3
HOT
3 4
Breaker GFI INL

T11 P/J50
HOT
1 1
NUT
1 2
T12
s5500-220

Fuser
Engine Logic LVPS Fuser

Board
P/J401 P/J525 P/J6 P/J600

Main Lamp On(H)+5VDC
5 1 2 1
Sub Lamp1 On(H)+5VDC
4 2 3 4
Sub Lamp2 On(H)+5VDC Heater
3 3 4 7
Relay On(L)+24VDC Control
2 4 1 11
Zero Cross
1 5
P/J410 P607 J607 P/J600 P131

Center STS Signal
7 1 6 2 2 Center
SG
6 2 5 3 1 STS
P132
2ND STS Signal
5 3 4 5 1 2nd
SG
4 4 3 6 2 STS
P133
Rear STS Signal
3 5 2 8 1 Rear
SG
2 6 1 9 2 STS
+5VDC
P/J410 P/J125
+5VDC
8 3
SG
9 2 Fuser Exit Sensor
Fuser Exit Paper Sensed(L)+5VDC
10 1
s5500-221

Engine
Logic Board
+24VDC
P/J403 P215
+24VDC
B9 2 1
Registration Clutch ON (L)+24VDC
B10 1 2
Registration Clutch
+5VDC
J403 J104
+5VDC
B13 1
Registration Sensor Paper Sensed (L)+5VDC
B8 2
SG
B3 3
Registration Sensor
Door B
Interlock Switch
P/J410 J106
Door B Open (H)+5VDC
12 1
SG
11 2
+5VDC
J410 P608 J608 J105
+5VDC
15 1 3 1
F/O #3 Sensor Sensed (L)+5VDC
14 2 2 2
SG
15 3 1 3
+24VDC Feed out #3 Sensor
P/J410 P204
+24VDC
16 2 1
Takeaway Clutch ON (L)+24VDC
17 1 2
Take Away Clutch
s5500-222

Xerographics
Engine
Logic Board
Interlock HVPS
+24VDC
P/J403 P/J500
I/L +24VDC
A1 15
I/L +24VDC
A2 14
RTN
A3 13
RTN
A4 12
DTS ON
A5 11
BTR Monitor
A6 10
AGND
A7 9
BTR SEL
A8 8
BTR Remote
A9 7
BCR AC Clock
A10 6
BCR AC ON
A11 5
BCR DC Remote
A12 4
A13 3
DEVE BIAS DC Remote
A14 2
DEVE BIAS DC ON
A15 1
Drum
Chute-Assembly Cartridge
DTS
BCR
BTR
Drum
Transfer Roller
Mag
Roll
+5VDC P/J403 P610 J610
ATC Sensor Signal
B5 6 2
+5VDC
B11 5 3
+5VDC ATC
B12 4 4
SG Sensor
B2 3 5
LD +5VDC
To B1 1 7
Power
+5VDC
P/J403 P/J150
+5VDC
B15 1 Environmental
Humidity Signal
B7 2 Sensor
SG
B4 3
Temperature Signal
B6 4

+24VDC P/J420 P/J216
Dispense Motor On(L) +24VDC
1 2
+24VDC M
2 1
s5500-223

Drive/CRUM
Engine
Logic Board
Interlock Motor Assembly

+24VDC
P/J408 P/J214
I/L +24VDC
14 1
I/L +24VDC
13 2
RTN
+5VDC 12 3
RTN
11 4 CN102
+5VDC
10 5 2
Fuser Fan On
2 13 3
Fuser Fan Fail
1 14 1
M/C Clock
9 6
Main Motor Ref Clock Main Fuser Fan
8 7 M
Main Motor On(L)+5VDC Motor
3 12
Drum Motor Fail(H)+5VDC
7 8
Drum Motor Ref Clock
6 9 Drum
Drum Motor On(L)+5VDC M
5 10 Motor
Drum Motor CW/CCW
4 11
Drum Cartridge
CRUM PWB
+5VDC
P/J419 P126
+5VDC
1 6 1
SG
2 5 2
TX DATA
3 4 3
MUTE
4 3 4
CDET
5 2 5
1 6
Toner Cartridge
CRUM PWB
+5VDC
P/J419 P127
+5VDC
6 6 1
SG
7 5 2
TX DATA
8 4 3
MUTE
9 3 4
CDET
10 2 5
1 6
P/J417 P221 J221

RTN
2
Drum Cartridge Fan On
3
Drum Cartridge Fan Fail
1
Drum Cartridge Fan s5500-224

Tray 2
Engine
Logic Board Tray 2 Feed/Lift
Motor
+24VDC
P/J409 P601 J601 P/J201
FMOT1 /B
A1 15 1 6
FMOT1 /A
A2 14 2 5
+24VDC
A3 13 3 4
+24VDC M
A4 12 4 3
FMOT1 B
A5 11 5 2
FMOT1 A
A6 10 6 1
+5VDC
P/J409 P601 J601 P/J100
+5VDC
A7 9 7 3
SG
A8 8 8 2
Tray 2 Level Up(H)+5VDC
A9 7 9 1
Tray 2 Level Sensor
+5VDC
P/J409 P601 J601 P/J101
+5VDC
A10 6 10 3
SG
A11 5 11 2
Tray 2 Paper Sensed(L)+5VDC
A12 4 12 1
Tray 2 No Paper Sensor
+5VDC
P/J409 P601 J601 P/J133
SG
A13 3 13 3
Tray 2 Pre Feed Sensed(L)+5VDC
A14 2 14 2
+5VDC
A15 1 15 1
Tray 2 Pre Feed Sensor
+5VDC
P/J412 P/J109
+5VDC
4 1
Tray 2 Size Switch Signal
3 2
SG
2 3
Tray 2 Size Switch S5 On(L)+5VDC
1 4
Tray 2 Size Sensor
s5500-225

Tray 3
Engine
Logic Board Tray 3
Feed/Lift Motor
+24VDC
P/J409 P602 J602 P/J202
FMOT2 /B
B1 15 1 6
FMOT2 /A
B2 14 2 5
+24VDC
B3 13 3 4 M
+24VDC
B4 12 4 3
FMOT2 B
B5 11 5 2
FMOT2 A
B6 10 6 1
+5VDC
P/J409 P602 J602 P/J102
+5VDC
B7 9 7 3
SG
B8 8 8 2
Tray 3 Level Up(H)+5VDC
B9 7 9 1
Tray 3 Level Sensor

+5VDC
P/J409 P602 J602 P/J103
+5VDC
B10 6 10 3
B11 SG 5 11 2
Tray 3 Paper Sensed(L)+5VDC
B12 4 12 1

+5VDC
P/J409 P602 J602 P/J134
SG
A13 3 13 3
Tray 3 Pre Feed Sensed(L)+5VDC
A14 2 14 2
+5VDC
A15 1 15 1
Tray 3 Pre Feed Sensor

+5VDC
P/J412 P/J110
+5VDC
9 1
Tray 3 Size Switch Signal
8 2
SG
7 3
Tray 3 Size Switch S5 On(L)+5VDC
6 4
Tray 3 Size Sensor
s5500-226

Tray 1/MPT
Engine
Logic Board
+5VDC
J411 P605 J605 P609 J609 J107
+5VDC
1 8 1 3 1 1
SG
2 7 2 2 2 2
Tray 1/MPT Size Sensor Signal
3 6 3 1 3 3
Tray 1/MPT
Paper Size Sensor
+24VDC
P/J411 P605 J605 P205

Pick Up Solenoid On(L)+24VDC
4 5 4 2 1
+24VDC
5 4 5 1 2
Pick Up Solenoid
+5VDC
P/J411 P605 J605 P/J108
+5VDC
6 3 6 3
SG
7 2 7 2
Tray 1/MPT Paper Sensed(L)+5VDC
8 1 8 1
Tray 1/MPT
No Paper Sensor
s5500-227

Laser Assembly
Laser Assembly
I/P Board
LD PWB
P/J890 P/J160
/VD01
2 2
VD01
1 1
P/J170
/VD02
4 2
VD02
3 1
Engine
Logic Board
P/J406 P/J140
ROS Valid
1 9 P/J406
From LD+5VDC
Power 2 8 1
SG
3 7 3
4 SOS Signal 6 2
Power Control1 On(L)+5VDC
5 5
ROS VREF Out Signal SOS Sensor
6 4
ROS Monitor
7 3
Power Control2 On(L)+5VDC
8 2
LD Enable On(L)+5VDC
+24VDC 9 1
P/J406 P620 J620 P/J130

+24VDC
10 4 1 5
RTN
11 3 2 4 M Scanner Motor
Scanner Motor On(L)+5VDC
12 2 3 3
Scanner Motor Clock
13 1 4 1
s5500-228

Exit 1
Exit PWB
+5VDC
P/J432 P613 J613 P/J117
+5VDC
1 6 1 3
SG
2 5 2 2
OCT Home Sensed(L)+5VDC
3 4 3 1
OCT Home Sensor
+5VDC
P/J432 P613 J613 P/J118
+5VDC
4 3 4 3
SG
5 2 5 2
Full Stack Sensed(L)+5VDC
6 1 6 1
Full Stack Sensor
Offset Motor
+24VDC
P/J432 P206 J206
+24VDC
7 5 1
Offset Motor A
8 4 2
Offset Motor B M
9 3 3
Offset Motor /A
10 2 4
Offset Motor /B
11 1 5
Engine
Logic Board
P/J431 P/J421
SG
1 8
Engine To Exit
2 7
Exit To Engine
3 6
SG
4 5
Fuser Exit Paper Sensed(H)+5VDC
5 4
Full Stack Sensed(L)+5VDC
6 3
Registration Clutch On(L)+5VDC
7 2
Exit Gate Solenoid On(H)+5VDC
8 1
s5500-229

Engine Logic and Image Processor Board Interface
Engine I/P Board

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

Image Processor Board (1/2)
I/P Board LVPS

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

Image Processor Board (2/2)
I/P Board Engine Logic Board

P/J590
/RDY
1
/CPRDY
2
/PPRDY
3
/PRFD
4
/START
5
/BD
6
/TOP
7
No Connection
8
No Connection
9
No Connection
10
/CCLK
11
/CBSY
12
/SBSY
13
/STA
14
/CMD
15
GND
16
GND
17
GND
18
Laser Assembly
P/J890 P/J160
VDO1
1
/VDO1
2
P/J890 P/J170
VDO2
3
/VDO2
4
J700
VX_RXD
1
N/C
2 Serial
3.3V
3 Debug Port
VX_TXD
4
GND
5
s5500-622

Reference
Contents...
Phaser 5500 Laser Printer Menu Map
Service Diagnostics Menu Map
Service Diagnostics Tests and Utilities
Mode Select Port
Appendix
A
Phaser 5500 Laser Printer Menu Map
Front Panel Buttons: Up Arrow

Main Menu: READY TO PRINT.
Information
Cancel OK
Walk-Up Features
Printer Setup
Troubleshooting Back Information
Down Arrow
Model Help Guide

Printer Name Configuration Page
Information Print Server* Paper Tips Page
IP Address* Supplies Usage Page
Menu Map Serial # Connection Setup Page
Printer Identification Activation Date Startup Page
Usage Profile
Information Pages
PostScript Font List
Sample Pages PCL Font List
Billing Meters Disk Directory
Serial #
Flash Directory
Supplies Info Total Impressions
Black Impressions
Large Black Impressions Office Demonstration
2-Sided Demonstration**
Walk-Up Features*,
Supplies Usage Page
Personal Print Jobs Toner Cartridge Life
Drum Cartridge Life
Secure Print Jobs
Staple Cartridge Life
Proof Print Jobs Fuser Life
Saved Print Jobs Reset Fuser Life
Total Print Count
Walk-Up Printing*
Select for Installation*
TCP/IP Setup TCP/IP

NetWare Setup DHCP/BOOTP
Printer Setup Ethernet Speed AutoIP
EtherTalk TCP/IP Address
Configuration Page Connection Setup Page
TCP/IP Network Mask
Network Setup*
Connection Setup TCP/IP Gateway
Parallel Setup Parallel Port Port 9100
USB Setup Wait Timeout LPR
Reset Connection Setup Page Description Language IPP
SLP
= prints an information page. SSDP
USB Port
Requires: CentreWare IS
Wait Timeout
* Networked printer
Page Description Language
** Duplex Unit
Hard Drive NetWare
Hard Drive with stored jobs present IPX Frame Type
Optional Tray(s)
Flash Memory
Stacker
Finisher
s5500-615
A-2 Phaser 5500 Printer Service Manual

Paper Source
2-Sided Printing**
Tray 1 (MPT) Setup
Tray 2 Setup
Tray 3 Setup
Tray 4 Setup
Tray 5 Setup
Tray 6 Setup
Load Paper Timeout
Tray Sequence
PostScript Error Info
Tray Prompt
Image Smoothing
MPT Prompt
Edge-to-Edge Printing
Custom Units
Reset PostScript Setup
Paper Destination ,
Job Offset
Stapling Options
Font Number
Punch
Pitch
Punch Holes ||
Point Size
Printer Setup Output Tray Switch ,
Symbol Set
(continued) Fuser Configuration
Orientation
Reprint Jammed Pages
Form Length Print-Quality Mode
Paper Handling Setup Reset Paper Handling Setup
Line Termination Print Quantity
PostScript Setup Edge-to-Edge Printing Print with Low Toner
PCL Setup Reset PCL Setup Reset General Setup
General Setup
Front Panel Setup Front Panel Language

Printer Controls Startup Page Front Panel Brightness
Power Saver Timeout Front Panel Contrast
File Security Overwrite Removals
Date and Time Accessible Front Panel
Remove Job Files
Metric Defaults Reset Front Panel Setup
Daily Removal
Power Saver
Remove At HH:MM
Reset Printer Controls
Reset File Security
Troubleshooting
Help Guide Paper Tips Page

Troubleshooting Print Quality
Paper Jams Online Jam Prevention Guide Page
Print Quality Problems Test Prints
Network Log Pages*

Service Tools NetWare Start Log
Engine Error History
NetWare Runtime Log
Jam History
TCP/IP Start Log
Hexadecimal Mode
= prints an information page. TCP/IP Runtime Log
Requires: AppleTalk Start Log
Email Service Report*
* Networked printer AppleTalk Runtime Log
Reset NVRAM
** Duplex Unit
Hard Drive
Hard Drive with stored jobs present
Optional Tray(s)
Flash Memory
Stacker
Finisher
|| 220 V Finisher s5500-616
Reference A-3
Service Diagnostics Menu Map
The Service Diagnostic Menu Map lists all the tests and utilities available within
Service Diagnostics. To access a test or utility, select the test type (motor, sensor,
solenoid), the specific part (Duplex Unit, Exit 2, Finisher), then the individual test.
For example, to access the list of Finisher motor tests, first select Motor/Fans, then
select the Finisher.
Service Diagnostics Tests

Print Service Menu Map This prints a 3-page Service Diagnostics Menu Map.
General Status Printer Version

Provides current print engine Duplex Version
and option firmware version Exit Version
and counter values. Trays 4 & 5 Feeder Version
Finisher Version
Tray 6 Feeder Version
Total Print Count
Transfer Roller Count
Drum Cartridge Count
Drum Cartridge Cycles
Tray 1/MPT Feed Count
Tray 2 Feed Count
Tray 3 Feed Fount
Tray 4 Feed Count
Tray 5 Feed Count
Tray 6 Feed Count
Test Print Print Pattern
Starts the Test Print. Print Quantity
Input Tray
Output Tray
Duplex
Staple Selection
Pages Per Set
Punch Selection
Select Pattern
Printer NVRAM Adjustments Scan Direction All Trays
Perform NVRAM adjustment Scan Direction Tray 1/MPT
essential to the performance Scan Direction Tray 2
of the printer. Scan Direction Tray 3
Scan Direction Tray 4
Scan Direction Tray 5
Scan Direction Tray 6/HCF
Scan Direction Duplex All Trays
Scan Direction Duplex Tray 1/MPT
Scan Direction Duplex Tray 2
Scan Direction Duplex Tray6/HCF

Service Diagnostics Tests (Continued)
Printer NVRAM Adjustments Process Direction All Trays
Perform NVRAM adjustment Process Direction Tray 1/MPT
essential to the performance Process Direction Tray 2
of the printer. Process Direction Trays 3-6
Process Direction Duplex All Trays
Motor/Fans Tests Printer Main Motor On
Print Engine Motor Tests: Fuser Fan Motor High
Tests motor/fans functionality. Drum Fan Motor
Laser Scan Motor
Tray 2 Lift Motor
Tray 2 Feed Motor
Tray 3 Lift Motor
Tray 3 Feed Motor
Drum Cartridge Motor On
Offset Output Motor 1 Front
Offset Output Motor 1 Rear
Duplex Assembly Motor Duplex Motor
Test
Exit 2 Assembly Motor Tests Offset Output Motor 2 Front
Offset Output Motor 2 Rear
Exit Output Motor 2 Forward
Exit Output Motor 2 Reverse
Exit 2 Fan
Trays 4 & 5 Motor Tests Tray 4 Lift Motor
Tray 4 Feed Motor
Tray 5 Lift Motor
Tray 5 Feed Motor
Take Away Drive Motor
Tray 6 Motor Tests Tray 6 Lift Motor
Tray 6 Feed Motor
Tray 6 Take Away Motor-Slow
Tray 6 Take Away Motor-Fast
Finisher Motor Tests Horizontal Transport Motor-Fast
Horizontal Transport Motor-Slow
Transport Motor
Registration Motor-Fast-CW
Registration Motor-Slow-CW
Registration Motor- CCW
Exit Motor-Fast-CW
Exit Motor-Slow-CW
Exit Motor-CCW
Punch Unit Motor Front
Punch Unit Motor Rear
Punch Motor - 3 hole
Reference A-5
Finisher Motor Tests Front Tamper Motor
Motor Low Speed Outboard
Motor Mid Speed Outboard
Motor High Speed Outboard
Motor Low Speed Inboard
Motor Mid Speed Inboard
Motor High Speed Inboard
Rear Tamper Motor
Motor Low Speed Outboard
Motor Mid Speed Outboard
Motor High Speed Outboard
Motor Low Speed Inboard
Motor Mid Speed Inboard
Motor High Speed Inboard
Staple Head Move Motor
Motor Low Speed Front
Motor Medium Speed Front
Motor High Speed Front
Motor Low Speed Rear
Motor Medium Speed Rear
Motor High Speed Rear
Stapler Motor Forward
Stapler Motor Reverse
Eject Clamp Motor - Up
Eject Clamp Motor - Down
Eject Motor
Motor Low Speed Forward
Motor High Speed Forward
Motor Low Speed Reverse
Motor High Speed Reverse
Stacker Motor - Up
Stacker Motor - Down
Printer Sensor/Switch Tests Door A Interlock Switch
Print Engine Sensor/Switch Door B Interlock Switch
Tests: Front Cover Interlock Switch
Tests the function of sensors/ Tray 1/MPT Size Sensor (displays paper size for tray)
switches by manually toggling Tray 2 Size Sensor (displays paper size for tray)
each sensor/switch. Tray 3 Size Sensor (displays paper size for tray)
Tray 1/MPT No Paper Sensor
Tray 2 Level Sensor
Tray 3 Level Sensor
Tray 2 Pre-Feed Sensor
Registration Sensor
Fuser Exit Sensor
Standard Output Tray Full Sensor
Exit Offset 1 Home Position Sensor
Detect Drum Cartridge Switch
Duplex Sensor/Switch Tests Door D Interlock Switch
Wait Sensor

Exit 2 Sensor/Switch Tests Door E Interlock Switch
Exit Sensor
Exit 2 Full Stack Sensor
Exit Offset 2 Home Position Sensor
Tray 4 & 5 Sensor/Switch Door C Interlock Switch
Tests Tray 4 Size Sensor (displays paper size for tray)
Tray 5 Size Sensor (displays paper size for tray)
Tray 5 No Paper sensor
Tray 4 Level Sensor
Tray 5 Level Sensor
Tray 6 Sensor/Switch Test Door J Interlock Switch
Tray 6 Paper Size Sensor
Tray 6 Level Sensor
Tray 6 Interlock Switch
Tray 6 Size Sensor A
Tray 6 Size Sensor B
Tray 6 Tray In Sensor
Finisher Sensor/Switch Door F Interlock Sensor
Tests Door G Interlock Switch
Test the sensors and switches Door H Interlock Switch
for the Finisher/Stacker, punch Horizontal Transport Entrance Sensor
and stapler. Horizontal Transport Exit Sensor
Transport Entrance Sensor
Gate Sensor
Buffer Path Sensor
Upper Tray Exit Sensor
Lower Tray Full Sensor
Compiler Exit Sensor
Compiler Tray No Paper Sensor
Side Registration Sensor 1
Side Registration Sensor 2
Eject Clamp Home Sensor
Set Clamp Home Sensor
Punch Unit Move Home Sensor
Punch Home Sensor
Punch Front Sensor
Punch Hole Select Sensor
Punch Motor Encoder Sensor
Punch Box Set Sensor
Reference A-7
Finisher Sensor/Switch Front Tamper Home Sensor
Tests Rear Tamper Home Sensor
Test the sensors and switches Staple Move Position Sensor
for the Finisher/Stacker, punch Staple Head Low Staple Sensor
and stapler. Staple Head Self Priming Sensor
Staple Head Home Sensor
Lower Tray No Paper Sensor
Lower Tray Upper Limit Sensor
Stacker Encoder Sensor
Stack Height Sensor 1
Stack Height Sensor 2
Solenoid/Clutch Tests Registration Clutch
Print Enegine Solenoid/ Tray 1/MPT Feed Solenoid
Clutch Test: Take Away Clutch
Test the functionality of
Solenoids and Clutches.
Exit 2 Solenoid/Clutch Test Exit 2 Gate Solenoid
Tray 4 & 5 Clutch Test Take Away Clutch
Tray 6 Solenoid Tests Tray 6 Nudger Solenoid - High Power
Tray 6 Nudger Solenoid - Low Power
Finisher Solenoid/Clutch Buffer Gate Solenoid (Path Out)
Tests Buffer Gate Solenoid (Path In)
Transport Gate Solenoid (Upper Tray)
Transport Gate Solenoid (Lower Tray)
Sub Paddle Solenoid
Set Clamp Clutch
IP NVRAM Access: PostScript NVRAM Reset
This menu lets you reset Factory NVRAM Reset
NVRAM locations.
Engine Logic Board Save from Engine Board
Replacement Restore to Engine Board
Saves/restores NVRAM
locations from Engine Logic
Board when replaced.
Finisher Board Setup Read Current Status
Sets the Finisher/Stacker Set 3-Hole Punch & Staple (Finisher)
board configuration. Set 2/4-Hole Punch & Staple (Finisher)
Set No Punch & No Staple (Stacker Only)
Exit Reboots Printer out of Diagnostics.

Service Diagnostic Tests and Utilities
These descriptions cover each grouping listed in the Service Diagnostics menu.
Described within each group are special instructions, conditions, or other information
necessary to successfully run individual tests or utilities and interpret the results.
Similar tests or utilities are grouped together for convenience. The "Service
Diagnostics Menu Map" on page A-4 lists all the tests and utilities as they appear on
the display. When attempting to test a device that is not installed the Option Not
Installed message appears.
General Status Menu

The General Status menu provides a number of status queries about the printer and
any installed options. These values are read-only and cannot be changed.
General Status Utilities
Utility Action/Requirement
Printer Version Displays code version and release data stored in the Print Engine.
Duplex Version Displays code version and release data stored in the Duplex Unit.
Exit Version Displays code version and release data stored in the Exit 2 Module.
Tray 4-5 Feeder Displays code version and release data for the 1000-Sheet Feeder.
Version
Finisher Version Displays code version and release data stored in the Finisher.
Tray 6 Feeder Version Displays code version and release data for the 2000-Sheet Feeder.
Total Print Count Displays the number of prints made since the printers activation.
Transfer Roller Count Displays the total count through the Transfer Roller since last reset.
Drum Cartridge Count Displays the total count of the Drum Cartridge.
Drum Cartridge Cycles Displays the Drum Cartridge total cycle count (240,000 max.). The
value updates each 154 cycles.
Tray 1/MPT Feed Displays the number of sheets fed since the last Fuser reset.
Count
Tray 2 Feed Count Displays the number of sheets fed since the last Fuser reset.
Reference A-9
Test Print Menu
Use Test Print options to identify, repair, and validate the operability of xerographics
and paper handling from all paper sources, options and outputs. Configure your test
using the options provided. Service Diagnostics generates an error for failures that
occur during these tests. If multiple faults/jams are detected, only one error message
appears at a time. The next message appears when the current fault is cleared.
Test Print Utilities
Print Pattern Print one of the stored Engine test pages: Grid, Chart, Dark Dusting
or Blank. Start or Stop printing tests.
Print Quantity Select the number of test prints to run. Select a quantity of two or
more when the Stacker Lower Tray is the selected output tray. If
Duplex is set to On, the quantity selected indicates the number of
two-sided prints.
Input Tray Sets the input tray. Printing is disabled in Diagnostic mode if
Tray 1/MPT is the selected input tray and the output is set anything
other than the Standard Output Tray.
Output Tray Sets the output tray. Test prints fed from Tray 1/MPT output to the
Standard Output Tray only.
Duplex Turns Duplex printing on or off. Test prints fed from Tray 1/MPT do
not Duplex as Tray 1/MPT is set to irregular size in Diagnostic mode.
Staple Selection Sets staple on or off and displays the currents staple position setting
(Dual, Front, or Rear).
Pages Per Set Sets the number of pages per stapled set.
Punch Selection Sets punch on or off.
Select Pattern Select the number of holes to be punched.
Printer NVRAM Adjustments Menu

Registration variables are stored in NVRAM to manage image registration for the
scan and process directions on paper supplied from each input tray for simplex or
duplex operations. This allows for the correction of minor variations as a result of
wear or mis-alignment. When making adjustments for scan direction, or for all trays
in the process direction, adjustment changes are automatically replicated for duplex
prints. Following a scan or all tray process direction adjustment, check that duplex
registration remains within specification. See "Checking Registration" on page 6-4
for detailed instructions for using these utilities to adjust image registration.
For convenience, similar registration adjustment utilities have been grouped together
in the following table. However, all 19 adjustments appear on the Service Diagnostics
Menu Map on page A-4.

Printer NVRAM Registration Adjustment Utilities
Scan Direction All Trays Sets scan direction image registration on all trays for both simplex
and duplex prints.
Scan Direction Tray 1~6 Sets scan direction image registration on the tray selected for
both simplex and duplex prints.
Scan Direction Duplex Sets scan direction image registration on all trays for duplex
All prints.
Scan Direction Duplex Sets scan direction image registration for duplex prints from the
Trays 1~6 tray selected.
Process Direction All Sets process direction image registration on all trays for both
simplex and duplex prints.
Process Direction Tray 1 Sets process direction image registration on Tray 1 for simplex
prints only.
Process Direction Tray 2 Sets process direction image registration on Tray 2 for simplex
prints only.
Process Direction Tray Sets process direction image registration on Trays 3~6 for simplex
3~6 prints only.
Process Direction Sets process direction image registration for duplex prints for all
Duplex All Trays trays.
These utilities access Engine Logic Board NVRAM to modify the stored value for
each variable. Changes are made by increasing or decreasing the stored value
changing the image position on the page. For Scan direction adjustments, each
variable is set at the factory to a value of 50. The maximum for scan direction
adjustments is 99 with a minimum of 1. Any change in the scan direction value by one
(1) results in a .254 mm change in the image position.
For the process direction the factory default is 33. The maximum is 66 and the
minimum is zero (0). Changes to the current value for process direction variables by
one (1) moves the leading edge of the image .363 mm closer or further from the edge
of the paper.
Use the Printer NVRAM Adjustment utilities in conjunction with the Print Quality
test print, to modify the general (All Trays) or specific (Tray 1~6) values to realign the
image. See "Adjusting Simplex Registration" on page 6-6 for instructions on using
the Print Quality test print to evaluate image registration performance.
Reference A-11
Print Engine Motors/Fan Test Menu
Individually activate each motor or fan. Most motor rotational tests run for two or
three seconds then stop. In some cases, the sound of the motor running indicates that
the item passed or failed. In other cases, movement of the mechanism is the indicator.
Engine Motor and Fan Tests
Test Action / Requirement
Printer Main Motor On Runs the main motor. Press the Back button to halt the test. This
test requires the printers covers closed and the Drum Cartridge
installed.
Fuser Fan Runs the fan at high speed. Press the Back button to halt the test.
The test runs with covers open.
Drum Fan Motor Runs the Drum Cartridge Fan at high speed.
Laser Scan Motor Runs the laser scan motor. Press the Back button to halt the test.
Tray 2 Lift Motor Runs the Feed/Lift motor in a clockwise direction. Press the Back
button to halt the test.
Tray 3 Lift Motor Runs the Feed/Lift motor in a clockwise direction. Press the Back
button to halt the test.
Tray 2 Feed Motor Runs the Feed/Lift motor in a counter clockwise direction for about 2
seconds.
Tray 3 Feed Motor Runs the Feed/Lift motor in a counter clockwise direction for about 2
seconds.
Drum Cartridge Motor Runs the Drum Cartridge Motor.

On
Offset Output Motor 1 Runs the Front Output Motor shifting the shaft forward.
Front
Offset Output Motor 1 Runs the Rear Output Motor shifting the shaft reward.
Rear
Toner Dispense Motor Runs the Toner Dispense Motor.
Duplex Unit Motor Tests Menu

Run the Duplex Motor.
Duplex Unit Motor Tests
Duplex Motor Runs the Duplex Unit motor. Press the Back button to halt the test.
Test will run with the Duplex Unit open.

Exit 2 Motor Tests Menu
Test the Exit and Offset Motors in the Exit 2 Module. These tests run with the Exit.2
cover, Door E, open.
Exit 2 Motor Tests
Offset Output Motor 2 Runs the Exit 2 Offset motor shifting the OCT Roller shaft forward.
Front
Offset Output Motor 2 Runs the Exit 2 Offset motor shifting the OCT Roller shaft rearward.
Rear
Exit Output Motor 2 Runs the Exit 2 Output Motor in the forward direction for two
Forward seconds.
Exit Output Motor 2 Runs the Exit 2 Output Motor in reverse for two seconds.
Reverse
Exit 2 Fan Runs the Exit 2 fan.
Trays 4 & 5 Motor Tests Menu

Test the Feed and Take Away motors in each tray feeder assembly.
Tray 4 & 5 Motor Tests
Tray 4 Lift Motor Runs the Feed/Lift motor in the Lift direction for two seconds.
Tray 4 Feed Motor Runs the Feed/Lift motor in the Feed direction for two seconds.
Take Away Drive Runs the Take Away Drive Motor for five seconds.
Tray 6 Motor Tests Menu

Test the Feed/Lift and Take Away motors in Tray 6.
Tray 6 Motor Tests
Reference A-13
Tray 6 Motor Tests (Continued)
Tray 6 Take Away Runs the Take Away Motor at low speed for two seconds.
Motor -Slow
Tray 6 Take Away Runs the Take Away Motor at high speed for two seconds.
Motor - Fast
Finisher Motor Tests Menu

Individually activate each Finisher motor. Most motor rotational tests run for two or
three seconds then stop.
Finisher Motor Tests
Horizontal Transport Runs the Horizontal Transport motor at high speed.

Motor - Fast
Horizontal Transport Runs the Horizontal Transport motor at low speed.

Motor - Slow
Transport Motor Runs the Transport motor.
Registration Motor- Runs the Registration motor clockwise at high speed.

Fast-CW
Registration Motor- Runs the Registration motor clockwise at slow speed.

Slow-CW
Registration Motor- Runs the Registration motor counter clockwise.

CCW
Exit Motor-Fast-CW Runs the Exit motor at high speed in the clockwise direction.
Exit Motor-Slow-CW Runs the Exit motor at slow speed in the clockwise direction.
Exit Motor-CCW Runs the Exit motor in the counter clockwise direction.
Punch Unit Motor Moves the Punch forward.

Front
Punch Unit Motor Moves the Punch to the rear.

Rear
Punch Motor- 3 hole Performs a 3-hole punch.
Front Tamper Motor Provides a sub-directory that includes tests to run the Front Tamper
motor at the speed and position selected (Low Speed Outboard,
Mid Speed Outboard, High Speed Outboard, Low Speed Inboard,
Mid Speed Inboard, High Speed Inboard).

Finisher Motor Tests (Continued)
Rear Tamper Motor Provides a sub-directory that includes tests to run the Rear Tamper
motor at the speed and position selected (Low Speed Outboard,
Mid Speed Outboard, High Speed Outboard, Low Speed Inboard,
Mid Speed Inboard, High Speed Inboard).
Staple Head Move Provides a sub-directory that includes tests to run the Staple Head
Motor motor at the speed and position selected (Low Speed Front,
Medium Speed Front, High Speed Front, Low Speed Rear, Medium
Speed Rear, High Speed Rear).
Stapler Motor Forward Runs the motor in forward. Place the staple head in its home
position prior to testing. A loose staple is generated in the forward
direction.
Stapler Motor Reverse Runs the Staple Motor in reverse, opening the clamp. If the clamp is
already open, no movement occurs. To close the clamp, rotate the
black gear on the Staple Head until the clamp is closed (down
position). The clamp returns to the open position following the test.
To repeat the test, re-close the clamp.
Eject Clamp Motor - Opens the Eject Clamp.

Up
Eject Clamp Motor - Closes the Eject Clamp.

Down
Eject Motor Provides a sub-directory that includes tests to run the Eject motor at
the speed and direction selected (Low Speed Forward, High Speed
Forward, Low Speed Reverse, High Speed Reverse).
Stacker Motor - Up Lifts the Stacker Lower Tray to its upper limit.
Stacker Motor - Down Lowers the Stacker Lower Tray to its lower limit.
Print Engine Sensor/Switch Tests Menu

Tests the functionality of sensors and switches located in the print engine. For the
Environmental Sensor, print a Configuration Page and check for the presence of
Temperature and Humidity readings. Test each device by manually toggling the
sensor or switch and viewing the results on the display.
Sensor / Switch Tests
Door A Interlock SW Displays the status, Open or Closed, of the Door A Switch.
Door B Interlock SW Displays the status, Open or Closed, of the Door B Switch.
Front Cover Interlock Displays the status, Open or Closed, of the Front Door Switch.
Tray 1/MPT Size Displays the paper size indicated by the guides.
Sensor
Reference A-15
Sensor / Switch Tests (Continued)
Tray 2 Size Sensor Displays the paper size indicated by the guides.
Tray 3 Size Sensor Displays the paper size indicated by the guides.
Tray 1/MPT No Paper Reports Without Paper in the resting position, and With Paper
Sensor when lifted.
Tray 2 No Paper Reports Without Paper in the resting position, and With Paper
Sensor when lifted. Test the sensor by removing all paper from the tray and
reinserting it.
Sensor when lifted. You can test the sensor by removing all paper from the
cassette in that tray and reinserting it.
Tray 2 Level Sensor Reports Not Low in the resting position, and Low when lifted. You
can test the sensor by removing all but three or four sheets of paper
from the tray and reinserting it.
Tray 3 Level Sensor Reports Not Low in the resting position, and Low when lifted.
Test the sensor by removing all but three or four sheets of paper
from the tray and reinserting it.
Tray 2 Pre-Feed Displays the status, With or Without Paper.

Sensor
Tray 3 Pre-Feed Displays the status, With or Without Paper.

Sensor
Tray 3 Feed Out Displays the status, Withor Without Paper.
Registration Sensor Displays the status, With or Without Paper.
Fuser Exit Sensor Displays the status, With or Without Paper, of the Exit sensor.
Standard Output Tray Reports Empty when the actuator is in the resting position, and
Full Sensor Full when the actuator is raised.
Exit Offset 1 Home Displays Homeor Not Home, when actuated.

Position Sensor
Detect Drum Displays, Installedor Not Installed when actuated.

Cartridge Switch
Duplex Unit Sensor/Switch Tests Menu

Test the Duplex Unit sensors by toggling each sensor while viewing the results.
Duplex Unit Sensor/Switch Tests
Door D Interlock Shows the status, Open or Closed, when manually toggled.
Switch

Duplex Unit Sensor/Switch Tests (Continued)
Wait Sensor Displays With Paper or Without Paper when manually toggled.
Exit 2 Sensor/Switch Tests Menu

Test the Exit 2 sensors by manually toggling each sensor while viewing the results.
Exit 2 Sensor/Switch Tests
Door E Interlock Shows the status, Open or Closed, when manually toggled.
Switch
Exit Sensor Displays With Paper or Without Paper when manually toggled.
Exit 2 Full Stack Displays the status of the Full Stack sensor on the Standard Output
Sensor Tray.
Exit Offset 2 Home Displays the sensor status, Home or Not Home when toggled.
Position Sensor
Tray 4 & 5 Sensor/Switch Tests Menu

Tests the functionality of the sensors and switches located in Trays 4 and 5 by
displaying the current state while you manually toggle the selected device.
Tray 4 & 5 Sensor/Switch Tests
Door C Interlock Displays the status, Open or Closed, of the Door C Interlock Switch.
Tray 4 Size Sensor Displays the size indicated by the guide position.
Tray 5 Size Sensor Displays the size indicated by the guide position.
reinserting it. Another method is to reach into the tray cavity and
operate the actuator manually.
reinserting it. Another method is to reach into the tray cavity and
operate the actuator manually.
Tray 4 Level Sensor Reports Up in the resting position, and Down when lifted. Test
the sensor by removing all but three or four sheets of paper from the
tray and reinserting it. Another method is to reach into the tray
cavity and operate the actuator manually.
Reference A-17
Tray 4 & 5 Sensor/Switch Tests (Continued)
Tray 5 Level Sensor Reports Up in the resting position, and Down when lifted. Test
the sensor by removing all but three or four sheets of paper from the
tray and reinserting it. Another method is to reach into the tray
cavity and operate the actuator manually.
Tray 4 Pre Feed Displays the status, With or Without Paper when actuated.
Sensor
Tray 5 Pre Feed Displays the status, With or Without Paper when actuated.
Sensor
Tray 4 Feed Out Displays the status, With or Without Paper when actuated.
Sensor
Tray 5 Feed Out Displays the status, With or Without Paper when actuated.
Sensor
Tray 6 Sensor/Switch Tests Menu

Tests the functionality of Tray 6 sensors and switches by displaying the current state
while you manually toggle the selected device.
Tray 6 Sensor/Switch Tests
Door J Interlock Displays Open or Closed when actuated.

Switch
Tray 6 Paper Size Displays the paper size indicated by the guide position.
Sensor
Sensor when lifted.
Tray 6 Level Sensor Reports Up in the resting position, and Down when lifted.
Tray 6 Pre Feed Displays the status, With Paper or Without Paper of the sensor.
Tray 6 Feed Out Displays the status, With Paper or Without Paper of the sensor.
Tray 6 Interlock Switch Display the status, Docked or Undocked of the Docking Switch.
Tray 6 Paper Size Displays Guide is on a Sensor or Guide is off a sensor.

Sensor A
Tray 6 Paper Size Displays Guide is on a Sensor or Guide is off a sensor.

Sensor B
Tray 6 Tray In Sensor Displays the status, In or Out of the Tray-in sensor.

Finisher Sensor/Switch Tests Menu
Tests the functionality of Finisher sensors and switches by displaying the sensors
current state while you manually toggle the device.
Finisher Sensor / Switch Tests
Door F Interlock Displays the status as Open or Closed.

Sensor
Door G Interlock Displays the status as Open or Closed.

Switch
Door H Interlock Displays the status as Open or Closed.

Switch
Horizontal Transport Displays the status as, With Paper or Without Paper.
Entrance Sensor
Horizontal Transport Displays the status as, With Paper or Without Paper.
Exit Sensor
Transport Entrance Displays the Transport Entrance sensor status as, With Paper or
Sensor Without Paper.
Gate Sensor Displays status as, With Paper or Without Paper.
Buffer Path Sensor Displays the status, With Paper or Without Paper when toggled.
Upper Tray Exit Displays the status, With Paper or Without Paper.
Sensor
Upper Tray Full Displays the sensor status, Empty or Full.

Sensor
Compiler Exit Sensor Displays the sensor status as, With Paper or Without Paper.
Compiler Tray No Displays the sensor state as, With Paper or Without Paper.
Paper Sensor
Side Registration Displays the sensor state, With Paper or Without Paper.
Sensor 1
Side Registration Displays the state, With Paper or Without Paper.

Sensor 2
Eject Clamp Home Displays the sensor status as, Home or Not Home when toggled.
Sensor
Set Clamp Home Displays the sensor status as, Home or Not Home when toggled.
Sensor
Punch Move Home Displays the sensor status as, Home or Not Home when toggled.
Punch Unit Move Displays the sensor status as, Home or Not Home when toggled.
Home Sensor
Punch Home Sensor Displays the sensor status as, Home or Not Home when toggled.
Punch Front Sensor Displays the sensor status as, Home or Not Home when toggled.
Reference A-19
Finisher Sensor / Switch Tests (Continued)
Punch Hole Select Displays the sensor status as Selected or Not Selected.
Sensor
Punch Motor Encoder Displays the sensor status as, Pulse on slit or Pulse not on slit.
Sensor
Punch Box Set Sensor Displays the sensor status as either With Box or Without Box.
Front Tamper Home Displays the sensor status, Home or Not Home when toggled.
Sensor
Rear Tamper Home Displays the sensor status, Home or Not Home when toggled.
Sensor
Staple Move Position Displays sensor status as Staple Position or Non Staple Position.
Sensor
Staple Head Low Displays the sensor state as Low or Not Low.
Staple Sensor
Staple Head Self Displays the sensor state as ready or Not Ready.
Prime Sensor
Staple Head Home Displays the sensor status, Home or Not Home when toggled.
Sensor
Lower Tray No Paper Displays the sensor output as Blocked or Unblocked.

Sensor
Lower Tray Upper Display the sensor output as At upper limit or Not at upper limit.
Limit Sensor
Stacker Encoder Displays sensor output as Pulse not past slit or Pulse past slit.
Sensor
Stack Height Sensor 1 Displays the status, With Paper or Without Paper.
Stack Height Sensor 2 Displays the status, With Paper or Without Paper.
Print Engine Solenoid/Clutch Tests Menu

Activates the selected clutch to test the drive.The clicking made by the clutch when
energized is an indication of its condition.
Print Engine Solenoid/Clutch Tests
Registration Clutch Energize The Registration Clutch to check activity.
Tray 1/MPT Feed Energize the Tray 1/MPT Feed Solenoid.

Solenoid
Take Away Clutch Energize the Take Away Clutch on Tray 1/MPT.

Exit 2 Solenoid/Clutch Test Menu
Activates the Exit 2 Gate Solenoid. The clicking made by the solenoid when
energized indicates its condition.
Exit 2 Solenoid Test
Exit Gate Solenoid Energize the Exit Gate Solenoid. This test runs with Door E open.
Tray 4 & 5 Solenoid/Clutch Test Menu

Activates the Take Away Clutch. The clicking made by the clutch when energized
indicates its condition.
Tray 4 & 5 Clutch Test
Take Away Clutch Energize the Take Away Clutch on the optional tray module.
Tray 6 Solenoid/Clutch Test Menu

Tests the functionality of the optional Tray 6 solenoid.
Tray 6 Solenoid/Clutch Tests
Nudger (High Power) Energize the Nudger Solenoid at high power.
Nudger (Low Power) Energize the Nudger Solenoid at low power.
Finisher Solenoid/Clutch Tests Menu

Activates the selected clutch or solenoid. The clicking made by the part when
energized indicates its condition
Finisher Solenoid/Clutch Tests
Buffer Gate Solenoid Energize the Buffer Gate Solenoid moving the Buffer Gate to direct
(path out) paper over the Buffer Roller.
Buffer Gate Solenoid Energize the Buffer Gate Solenoid moving the Buffer Gate to direct
(path-in) paper into the Buffer Path.
Reference A-21
Finisher Solenoid/Clutch Tests (Continued)
Transfer Gate Activate the Transfer Gate Solenoid moving the Transfer Gate to
Solenoid (Path Out) direct paper to the Stacker Upper Tray.
Transfer Gate Activate the Transfer Gate Solenoid moving the Transfer Gate to
Solenoid (Path In) direct paper to the Stacker Lower Tray.
Sub Paddle Solenoid Activate the Sub Paddle Solenoid.
Set Clamp Clutch Energize the Finisher Set Clamp Clutch.
Controller NVRAM Access Menu

This menu allows you to reset the PostScript NVRAM locations to factory defaults.
Controller NVRAM Utilities
Utility Action / Requirement
Reset PostScript NVM Resets the PS NVRAM. You are prompted to confirm your decision
to perform a reset operation.
Factory Reset Reset NVRAM to factory defaults. This utility is password protected.
NVRAM The password to access the reset functions is 4370. Use the Front
Panel buttons to enter the password. After you enter the password,
you are prompted to confirm your decision to perform a reset.
Engine Logic Board Replacement Menu

These commands transfer the contents of a defected Engine Logic Boards NVRAM
to the Image Processor Board and return it to the new Engine Logic board after
installation.
Engine Logic Board Replacement Utilities
Save from Engine Saves the NVRAM contents of the Engine Logic Board to a
Board reserved area of NVRAm on the Image Processor Board.
Restore to Engine Writes the Engine Logic Board NVRAM data to the replacement
Board board from the NVRAM of the Image Processor Board.
The following provides instructions for using these utilities during an Engine Logic
Board replacement.

Saving Engine Logic Board NVRAM
To save the Engine Logic Boards NVRAM contents to the I/P Board:

2. Select Save from Engine Board from the Engine Logic Board Replacement
menu and press OK.
Data is transferred from the Engine Logic Board to a reserved location on the
Image Processor Board. During the process the Front Panel will display "Saving
NVRAM" once the routine is completed the front panel will display "Save
Complete"
3. Power the printer off and replace the Engine Logic Board
Restoring Engine Logic Board NVRAM

To restore the Engine Logic Board NVRAM to the new board:
1. Re-enter Service Diagnostics.
2. Select Restore to Engine Board from the Engine Logic Board Replacement
menu and press OK.
Data is transferred from the reserved location on the Image Processor to the
replaced Engine Logic board. During the process the front panel will display
"Restoring NVRAM" once the routine is completed the front panel will display
"Restore Complete"
3. Exit diagnostics.
Finisher Board Setup Menu

This menu allows you to reset the Punch configuration of the Finisher/Stacker.
Finisher Board Setup Utilities
Read Current Status Displays the current Punch setting of the Finisher Main PWB.
Set 3-Hole Punch & Sets the Finisher Main PWB to support a 3-hole Punch and Stapler.
Staple
Set 2- /4-Hole Punch Sets the Finisher Main PWB to support a 2- /4-hole Punch and
& Staple Stapler.
Set No Punch & Sets the Finisher Main PWB to a Stacker configuration with no
Staple Punch or Stapler.
Exit
Reboot the printer out of Service Diagnostics.
Reference A-23
Mode Select Port
The Mode Select Port, accessible from the Rear Panel, is a 6-pin header used to place
the printer in one of five operational modes or to reset the Image Processor Board.
These modes are set by connecting one or more pins to ground. The six pins are
arranged in numeric order with Pin 1 at the top of the connector. Pins 1 and 6 are tied
to a common ground with the Rear Panel. Pins 2 through 5, when grounded, set the
printer to the mode indicated in the following table.
Caution
To reset the I/P Board, momentarily ground pin 5, then immediately re-open the
connection. Grounding pin 5 for more than a few seconds could damage the
processor.
Mode Select Port Settings
Mode 1 2 3 4 5 6
Printer Reset GND GND GND
Customer GND GND
Service GND GND GND GND
Disaster Recovery GND GND GND GND
Developer GND GND GND GND GND
Customer Debug GND GND GND
Reset is a hardware reset of the Image Processor Board.
Customer Mode is the normal mode for printing. The Serial Debug Port is
receiving PostScript back channel information.
Service Mode inhibits printing of the Startup page and causes POST to treat all
errors as Hard Faults. See "Power On Self Test (POST)" on page 3-4. Service
mode also switches the Serial Debug Port from PostScript back channel
information to the printers operating system console.
Disaster Recovery mode instructs the printer to load only its operating system
bypassing the networking and PostScript code. The Serial Debug Port is
receiving PostScript back channel information.
Developer mode inhibits the execution of POST and allows for the introduction
of startup scripts. Not typically used for servicing procedures.
Customer Debug mode instructs the printer to boot normally but switches the
Serial Debug Port from PostScript back channel information to the printers
operating system console.

Index
Numerics A
1000-Sheet Feeder, 1-7 abbreviations, 3-14
dimensions, 1-11 AC Accessory Panel
Door C Interlock GFI Breaker
location, 2-13 part number, 9-41
testing, A-17 removal, 8-94
Door C open, 3-239 operational description, 2-38
Feed Out Sensor #4, 2-14 plug/jack locator, 10-15
Feed Out Sensor #5, 2-14 removal, 8-93
interconnect location, 1-4 AC power supply troubleshooting, 4-7
motor tests, A-13 AC power tests, 4-8
option part number, 9-45 adjustment
paper handling, 2-7 adjustment utilities, A-10
roller locations, 2-6 duplex registration, 6-7
sensor locations, 2-14 fuser temperature, 6-8
sensor tests, A-17 process direction, 6-6
Take Away Clutch test, A-21 scan direction, 6-6
tray empty, 3-209 simplex registration, 6-6
2000-Sheet Feeder, 1-9 analyzing test prints, 5-2
dimensions, 1-11 AppleTalk event logging, 4-2
Docking Interlock
location, 2-13
testing, A-18 B
Docking Interlock open, 3-236 black prints, 5-19
Door J Interlock blank prints, 5-16
location, 2-13 Boot Loader, 3-6
testing, A-18 operational description, 3-3
Door J open, 3-248 Buffer Gate, 2-9
Feed Out Sensor #6, 2-14 Buffer Gate Solenoid, 2-9
motor tests, A-13 testing, A-21
Nudger Solenoid testing, A-21 Buffer Path, 2-9
option part number, 9-45 Buffer Roller, 2-9
sensor locations, 2-13
sensor tests, A-18
tray empty, 3-211
Index Index-1
C D
CentreWare setup, 6-10 damaged prints, 5-33
character settings, 6-11 DC power supply testing, 4-5
cleaning, 7-2 default character set, 6-11
clearance requirements, 1-12 Detack Saw, 2-16
Compiler Tray, 2-9 Diagnostics. See Service Diagnostics
location, 2-7 disaster recovery mode, A-24
sensor tests, A-19 display, 1-5
testing, A-14 brightness, 6-11
Configuration Card, 1-2 contrast, 6-11
failure, 3-250 language, 6-11
location, 1-4 testing, 4-4
operational description, 1-6 Door A Interlock
part number, 9-41 close Door A, 3-237
upgrade kit, 9-45 location, 2-13
connection setup, 6-10 part number, 9-25
consumables, 1-10 removal, 8-45
location, 1-10 testing, A-15
Staple Pack, 9-45 wiring, 10-21
Toner Cartridge, 1-10 Door B Interlock
part number, 9-33 close Door B, 3-238
counters location, 2-13
drum cycle count, 2-15 part number, 9-23
feed count, A-9 removal, 8-41
life cycle, A-9 testing, A-15
page count, A-9 wiring, 10-23
punch waste box, 3-233 Door C Interlock
reset fuser life, 6-9 close Door C, 3-239
supply life, 1-10 location, 2-13
Toner Gauge, 1-10 testing, A-17
total pages, 3-9 Door D Interlock
view count, 1-10 close Door D, 3-240
CPU interrupts error, 3-6 location, 2-13
CRUM, 3-14 testing, A-16
Drum Cartridge CRUM Door designations, 3-10
connector, 10-3 Door E Interlock
part number, 9-33 close Door E, 3-242
removal, 8-70 location, 2-13
Toner Cartridge CRUM testing, A-17
connector, 10-3 Door F Interlock
part number, 9-33 close Door F, 3-243
removal, 8-71 testing, A-19
customer debug mode, A-24 Door G Interlock
customer mode, A-24 close Door G, 3-245
testing, A-19
Index-2 Phaser 5500 Printer Service Manual

Door H Interlock Duplex Unit (cont.)
close Door H, 3-247 operational description, 2-10
testing, A-19 option part number, 9-45
Door J Interlock paper path, 2-10
close Door J, 3-248 registration adjustment, 6-7
location, 2-13 roller location, 2-6
testing, A-18 sensor tests, A-16
Drum Cartridge, 2-3 set duplex printing default, 6-10
ATC Sensor failure, 3-218 type error, 3-149
circumference, 5-37 Wait Sensor, 2-10
components, 2-15 duplicate IP address, 3-251
CRUM, 3-14
connector, 10-3
failure, 3-201 E
part number, 9-33 EEPROM error, 3-6
removal, 8-70 engine command error, 3-6
wiring, 10-25 engine error log
end of life, 3-200 display, 3-7
fan failure, 3-34 error codes, 3-8
fan wiring, 10-25 format, 3-7
location, 1-10 Engine Logic Board
non-Xerox cartridge, 3-203 data transfer, A-22
part number, 9-33 failure, 3-35
plug/jack locator, 10-6 I/P Board interface, 10-31
precaution, 7-2 location, 2-33
print life, 1-10 operational description, 2-35
testing, A-12 part number, 9-41
wiring diagram, 10-24 plug/jack locator, 10-13
Drum Cartridge Detect Switch, 2-12 power supply wiring, 10-21
location, 2-31, 2-33 removal, 8-89
part number, 9-33 restore NVRAM, A-23
removal, 8-60 save NVRAM, A-23
testing, A-15 testing, 4-12
wiring, 10-21 engine test prints, A-10
Drum Motor, 2-4 Envelope Tray, 1-9
drive train, 2-4 part number, 9-9
failure, 3-24 precautions, 1-9
part number, 9-39 Environmental Sensor, 2-12
removal, 8-84 part number, 9-33
Dual-beam Laser Diode, 2-21 testing, A-15
Duplex Unit, 1-7 wiring diagram, 10-24
Door D open, 3-240 error message summary, 3-15
Duplex PWB failure, 3-148
interconnect location, 1-4
motor tests, A-12
Index Index-3
error messages Exit 2 (cont.)
abbreviations used, 3-14 roller location, 2-6
corrective actions, 3-15 sensor tests, A-17
front panel, 3-15 Exit PWB, 2-31
list of errors, 3-15 failure, 3-152
Service Diagnostics, 3-15 location, 2-33
Ethernet Port, 1-2 operational description, 2-36
failure, 3-6 part number, 9-41
location, 1-4 plug/jack locator, 10-7
settings, 6-10 power supply wiring, 10-21
EtherTalk setup, 6-10 removal, 8-88
event log, 4-2 Exit Sensor, 2-12
printing, 4-2 wiring, 10-22
Exit 1, 2-7
components, 2-30
Exit Gate, 2-30 F
operation, 2-8 Fan, 2-33
part number, 9-37 location, 2-33
Full Stack Sensor, 2-31 part number, 9-33
part number, 9-37 removal
removal, 8-82 Drum Cartridge Fan, 8-58
wiring, 10-30 Fuser Fan, 8-59
Offset Gear, 2-31 testing, A-12
Offset Home Position Sensor, 2-31 wiring diagram, 10-25
part number, 9-37 fault history, 3-7
removal, 8-81 accessing, 3-7
wiring, 10-30 engine error codes, 3-7
Offset Motor, 2-31 interpreting, 3-7
part number, 9-37 Feed Out Sensor #3
removal, 8-80 connector designator, 10-3
wiring, 10-30 function, 2-7
Paper Weight, 2-31 part number, 9-31
part number, 9-37 removal, 8-54
plug/jack locator, 10-8 testing, A-16
removal, 8-78 wiring, 10-23
roller location, 2-6 Feed Out Sensor #4, 2-14
wiring diagram, 10-30 testing, A-18
Exit 2, 1-6 Feed Out Sensor #5, 2-14
Door E open, 3-242 testing, A-18
Exit Gate Solenoid, 2-10 Feed Out Sensor #6, 2-14
testing, A-21 testing, A-18
Exit Motor, 2-10 Feed Roller
fan testing, A-13 function, 2-28
location, 2-7 location, 2-6
motor tests, A-13 part number, 9-14
operational description, 2-10

Feed/lift Motor Front Door Interlock
operational description, 2-28 location, 2-13
part number, 9-13 part number, 9-5
removal, 8-24 printer front door is open, 3-235
Feeder wiring, 10-21
operational description, 2-28 Front Panel
part number, 9-13 brightness, 6-11
plug/jack locator, 10-11 buttons, 1-5
sensor locations, 2-28 contrast, 6-11
testing, A-15 error messages, 3-15
wiring diagram, 10-26 harness part number, 9-5
file security, 6-12 language, 6-11
setup, 6-12 LED indications, 1-5
Finisher, 1-8 lockout, 6-11
AC power connection, 2-38 part number, 9-5
Buffer Gate, 2-9 removal, 8-90
Buffer Path, 2-9 service shortcuts, 3-13
Compiler Tray, 2-9 setup, 6-11
dimensions, 1-11 testing, 4-4
Door F open, 3-243 Toner Gauge, 1-10
Door G open, 3-245 wiring diagram, 10-32
Door H open, 3-247 Fuser, 2-3
interconnect location, 1-4 change setting, 6-8
major components, 2-7 components, 2-21
motor tests, A-14 control temperatures, 2-25
operational description, 2-9 default temperatures, 6-8
option part number, 9-45 Exit Sensor, 2-22
Punch, 2-9 wiring, 10-22
punch box full, 3-233 failures, 3-27
punch box missing, 3-232 fan failure, 3-32
sensor and switch testing, A-19 fault conditions, 2-23
Set Clamp Clutch testing, A-21 harness part number, 9-43
set punch configuration, A-23 Heat Roller, 2-21
solenoid testing, A-21 Heater Rods, 2-22
Stacker Lower Tray, 2-9 location, 1-10
Stacker Upper Tray, 2-9 operating modes, 2-23
Transfer Gate, 2-9 operational description, 2-21
Transfer Gate Solenoid, 2-9 part number, 9-35
Transport Motor, 2-9 performance evaluation, 5-6
Finisher LVPS plug/jack locator, 10-8
testing, 4-6 Pressure Roller, 2-21
firmware print life, 1-10
version information, A-9 removal, 8-76
set temperature, 6-8
Fuser (cont.)
Index Index-5
temperature HVPS, 2-36
adjusting, 6-8 part number, 9-41
configuration, 6-10 removal, 8-86
defaults, 6-8 wiring diagram, 10-24
modes, 2-24
regulation, 2-23
sensing, 2-12 I
unfused image, 5-30 I/O ASIC error, 3-6
wiring diagram, 10-22 IDE disk error, 3-5
image adjustment
adjustment utilities, A-11
G factory defaults, A-11
GFI Breaker process direction, 6-6
part number, 9-41 registration, 6-6
plug/jack locator, 10-15 scan direction, 6-6
removal, 8-94 image data wiring, 10-29
reset location, 2-38 image defects
wiring, 10-21 background contamination, 5-40
black prints, 5-19
blank prints, 5-14
H horizontal deletions, 5-23
Hard Drive, 1-6 horizontal streaks, 5-27
file security setup, 6-12 light prints, 5-14
IDE disk error, 3-5 registration, 5-45
location, 2-34 repeating defects, 5-37
log storage, 4-2 residual image, 5-38
part number, 9-41 resolution, 5-34
plug/jack locator, 10-14 skewed image, 5-44
Health LED, 3-3 skips and smears, 5-47
Heat Roller, 2-21 spot deletions, 5-35
Heater Rods, 2-22 spots, 5-29
Horizontal Transport, 1-8 uneven density, 5-42
Door F open, 3-243 unfused image, 5-30
location, 1-8 vertical deletions, 5-21
motor testing, A-14 vertical streaks, 5-25
operational description, 2-8 Image Processor Board
PWB, 2-8 CPU interrupts error, 3-6
sensor locations, 2-8 EEPROM error, 3-6
sensor tests, A-19 engine command error, 3-6
Humidity Sensor Engine Logic Board interface, 10-31
part number, 9-33 Ethernet Port failure, 3-6
removal, 8-64 fault isolation, 4-13
testing, A-15 Front Panel connector, 10-3
I/O ASIC error, 3-6
image data wiring, 10-29
location, 2-33

Image Processor Board (cont.) Laser Assembly (cont.)
memory error, 3-6 part number, 9-33
NVRAM part number, 9-41 plug/jack locator, 10-7
operational description, 2-34 removal, 8-74
part number, 9-41 Scanner Motor, 2-20
plug/jack locator, 10-14 wiring diagram, 10-29
power supply wiring, 10-21 Laser Diode, 2-21
removal, 8-91 LED
reset, A-24 blink patterns, 3-6
troubleshooting, 4-14 color definitions, 1-5
USB Port failure, 3-6 Front Panel start-up, 3-3
image quality analysis Health LED, 3-3
fusing, 5-6 Level Sensor, 2-12
lead edge-to-trail edge, 5-9 part number, 9-13
line, band, or spot deletions, 5-5 removal, 8-27
resolution, 5-7 load paper timeout, 6-10
side-to-side registration, 5-8 low toner printing, 6-11
skew, 5-12 LVPS, 2-37
skips/smears, 5-10 finisher testing, 4-6
spots, 5-11 Fuser power, 10-22
image smoothing, 6-10 part number, 9-41
IPX frame type setup, 6-10 plug/jack locator, 10-16
removal, 8-92
testing, 4-5
J wiring diagram, 10-21
jam error log
display format, 3-9
error codes, 3-9 M
format, 3-7 Macintosh printing problems, 4-2
jam location map, 3-10 Main Drive Belt
jammed page reprint, 6-10 location, 2-30
job default settings, 6-2 part number, 9-39
job offset setup, 6-10 removal, 8-83
Main Motor, 2-4
drive train, 2-4
K failure, 3-23
Keypad. See Front Panel gear kit, 9-39
part number, 9-39
removal, 8-84
L testing, A-12
Laser Assembly, 2-3
components, 2-19
failure, 3-25
Laser Diode, 2-21
laser diode assembly, 2-19
Index Index-7
maintenance, 1-10 Motor Assembly (cont.)
counters, 1-10 Main Motor, 2-4
Drum Cartridge, 2-15 part number, 9-39
part number, 9-33 plug/jack locator, 10-12
Drum Cartridge print life, 1-10 removal, 8-84
Fuser wiring diagram, 10-25
part number, 9-35
removal, 8-76
Fuser print life, 1-10 N
preventive, 7-2 NetWare setup, 6-10
service procedures, 3-2 network
tools, 7-2 ethernet speed setting, 6-10
Transfer Roller, 2-16 IP setup, 6-10
part number, 9-25 logging, 4-2
removal, 8-44 option part number, 9-41
Maintenance Kit reset, 4-2
contents, 1-10 troubleshooting, 4-2
part number, 9-45 network setup, 6-10
print life, 1-10 No Paper Sensor, 2-12
replacement message, 3-250 Nudger Roller
reset fuser life, 6-9 function, 2-28
measurement techniques, 3-21 location, 2-6
Memory part number, 9-14
connectors, 10-14 removal, 8-31
errors, 3-6 NVRAM
maximum, 1-11 option part number, 9-41
minimum, 1-11 part number, 9-41
options, 1-6 password, A-22
part number, 9-41 PostScript, 6-12
RAM error, 3-6 reset factory defaults, A-22
requirements, 4-15 reset PostScript, A-22
supported types, 1-11 restore, A-23
troubleshooting, 4-15 save, A-23
menu map, A-2 supported types, 1-11
Microswitch, 2-11
Mode Select Port
location, 1-4 O
operational description, A-24 Offset Motor
wiring diagram, 10-32 drive train, 2-31
Motor Assembly part number, 9-37
Belt removal, 8-80
part number, 9-39 wiring diagram, 10-30
removal, 8-83 operating environment, 5-5
description, 2-32 options, 1-6
Drum Motor, 2-4 ordering parts, 9-2
gear kit, 9-39

P test descriptions, 3-4
paper power saver
custom size setup, 6-10 setup, 6-11
damage, 5-33 timeout, 6-11
fuser temperature settings, 6-8 Power Switch
loading timeout, 6-10 location, 2-33
set default destination, 6-10 part number, 9-41
set default source, 6-10 plug/jack locator, 10-16
supported types, 1-15 removal, 8-86
Paper Size Switch, 2-12 wiring diagram, 10-21
locations, 2-14 Pre-Feed Sensor, 2-12
part number, 9-9 locations, 2-14
plug/jack locator, 10-12 part number, 9-13
removal, 8-19 removal, 8-28
Tray 2-3 testing, A-15 Pressure Roller, 2-21
Tray 4-5 testing, A-17 print defects, 5-3
wiring diagram, 10-26 damaged print, 5-33
paper types, 6-8 fusing, 5-6
Parallel Port, 2-34 lead edge-to-trail edge, 5-9
location, 1-4 line, band, or spot deletions, 5-5
parts list repeating defects, 5-37
availability, 9-3 resolution, 5-7
conventions, 9-3 side-to-side registration, 5-8
PCL setup, 6-11 skew, 5-12
personal print setup, 6-12 skip/smears, 5-10
PostScript NVRAM, 6-12 spots, 5-11
PostScript setup, 6-10 types, 5-3
Power Cord print quality test print
connector, 1-4 analysis, 5-2
part number, 9-41 print quantity setup, 6-11
testing, 4-8 Printer
Power On Self Test (POST) components, 1-4
configurations, 1-3
bypass testing, 3-4
connections, 1-4
description, 3-4
controls setup, 6-11
error indications, 3-4
DC power supply testing, 4-5
fault types, 3-4
dimensions, 1-11
hard faults, 3-6
display setup, 6-11
error display, 3-6
Door A open, 3-237
LED blink patterns, 3-6
Door B open, 3-238
types, 3-6
door designations, 3-10
Health LED, 3-3
Drum Cartridge, 2-15
memory error correction, 4-15
Drum Motor, 2-4
soft faults, 3-5
electrical specifications, 1-13
corrective actions, 3-5
environmental specifications, 1-14
Start Page format, 3-5
firmware versions, A-9
types, 3-5
Index Index-9
Printer (cont.) Punch, 2-9
Front Door open, 3-235 configuration settings, A-23
functional specifications, 1-13 location, 2-7
installation clearance, 1-11 sensor tests, A-19
Laser Assembly, 2-18 testing, A-14
Main Motor, 2-4 waste box full, 3-233
menu map, A-2 waste box missing, 3-232
motor tests, A-12
network setup, 6-10
operational modes R
customer debug, A-24 RAM DIMM fault isolation, 4-15
customer mode, A-24 real time clock errors, 3-5
developer mode, A-24 registration
disaster recovery, A-24 adjustment parameters, A-11
service mode, A-24 adjustment utilities, A-10
options, 1-6 duplex adjustment, 6-7
paper outputs, 2-7 factory defaults, A-11
paper transport, 2-5 simplex adjustment, 6-6
power connections, 2-38 troubleshooting, 5-45
print process, 2-2 verification, 6-4
reset factory defaults, A-22 Registration Clutch
resolution, 2-18 part number, 9-31
sensor types, 2-11 removal, 8-51
sensor/switch testing, A-15 testing, A-20
start-up routine, 3-3 wiring, 10-23
supported media, 1-15 Registration Sensor, 2-12
testing, A-4 location, 2-14
transport components, 2-6 part number, 9-31
tray capacity, 1-14 removal, 8-52
printing problems testing, A-15
Macintosh, 4-2 wiring, 10-23
Windows, 4-3 Registration Transport Assembly
process direction, 6-4 part number, 9-31
factory default, A-11 plug/jack locator, 10-10
image adjustment, 6-6 removal, 8-49
image deletions, 5-23 reset
image streaking, 5-27 all printer defaults, 6-12
measurement, 6-5 default paper destination, 6-10
registration verification, 5-8 factory defaults, A-22
proof print setup, 6-12 file security, 6-12
Front Panel setup, 6-11
fuser life counter, 6-9
general setup, 6-11
job defaults, 6-2
network configuration, 6-10
paper default source, 6-10

reset (cont.) Sensor (cont.)
PCL setup, 6-11 microswitch, 2-11
PostScript NVRAM, 6-12 operational description, 2-11
PostScript setup, 6-10 paper detection, 2-15
setup values, 6-11 paper size detection, 2-14
residual image, 5-38 photo-receptive, 2-11
resolution photo-reflective, 2-11
operational description, 2-18 testing, A-15
performance evaluation, 5-7 thermistor, 2-12
setting, 6-11 Tray 1/MPT sensors, 2-26
settings, 1-13 types, 2-11
troubleshooting, 5-34 Serial Debug Port
Retard Roller location, 1-4
location, 2-6 operational description, A-24
runtime log, 4-2 serial number
printing, 4-2 interpretation, 9-2
location, 9-2
Service Diagnostics, 3-11
S available tests, A-4
scan direction, 6-4 button functions, 3-13
factory default, A-11 engine test prints, A-10
image adjustment, 6-6 error messages, 3-15
image deletions, 5-21 main menu, 3-11
image streaking, 5-25 menu map, A-4
measurement, 6-4 print job setup, A-10
registration verification, 5-9 print menu map, 3-12
Scanner Motor registration adjustment, A-10
failure, 3-26 starting, 3-12
operating modes, 2-20 test descriptions, A-9
testing, A-12 using, 3-12
wiring diagram, 10-29 service mode, A-24
secure job setup, 6-12 Service Usage Profile
Sensor browser access, 3-7
ATC sensor failure, 3-218 description, 3-7
CRUM, 2-12 display a log, 3-7
Duplex Wait Sensor, 2-10 engine error log, 3-7
Environmental Sensor display format, 3-8
failure, 3-219 fault codes, 3-8
part number, 9-33 jam error log, 3-9
removal, 8-64 display format, 3-9
Exit 1 sensors, 2-31 history codes, 3-9
Feed Out, 2-7 jam errors, 3-9
functions, 2-12 format, 3-9
interlocks, 2-13 print a profile, 3-7
level sensing, 2-15 skew, 5-12
Index Index-11
specifications Take Away Clutch
dimensions, 1-11 part number, 9-31
electrical, 1-13 removal, 8-53
environmental, 1-14 testing, A-20
functional, 1-13 wiring, 10-23
image registration, 6-5 Take Away Roller, 2-7
memory, 4-15 part number, 9-23
operating environment, 5-5 Temperature Sensor, 2-12
operational clearances, 1-11 removal, 8-64
supported media, 1-15 test prints, 6-2
tray capacity, 1-14 analyzing, 5-2
spots, 5-11 print job setup, A-10
Stack Full Sensor, 2-12 Thermistor, 2-12
Stacker, 1-8 timeout
option part number, 9-45 loading paper, 6-10
Stacker Lower Tray, 2-9 power saver, 6-11
location, 2-7 Toner Cartridge, 2-3
sensor tests, A-19 CRUM, 3-14
testing, A-14 connector, 10-3
Stacker Upper Tray, 2-9 failure, 3-204
location, 2-7 low toner, 3-206
Standard Output Tray, 2-8 part number, 9-33
stack full, 3-220 removal, 8-71
Stapler wiring, 10-25
location, 2-7 empty, 3-197
sensor tests, A-19 location, 1-10
Staple Cartridge low, 3-226 part number, 9-33
Staple Pack plug/jack locator, 10-6
part number, 9-45 print life, 1-10
stapler is empty, 3-225 Toner Dispense Assembly, 2-17
testing, A-14 Dispense Tube, 2-17
Startup Page part number, 9-33
setting, 6-11 removal, 8-71
start-up routine, 3-3 Toner Dispense Motor
streaking, 5-25 description, 2-32
supply voltage testing, 4-8 failure, 3-33
part number, 9-33
T removal, 8-73
Take Away Chute testing, A-12
precautions, 8-21 Toner Gauge, 1-5
removal, 8-55 Transfer Gate, 2-9
operation, 2-9
Transfer Gate Solenoid, 2-9
Testing, A-22

Transfer Roller, 2-3 Tray 1/MPT (cont.)
circumference, 5-37 operation description, 2-26
location, 1-10 Paper Size Sensor, 2-26
operational description, 2-16 testing, A-15
part number, 9-25 parts, 9-16
removal, 8-44 Pick Up Gear Spring
Tray part number, 9-17
capacities, 1-14 removal, 8-35
Feeder plug/jack locator, 10-11 Pick-up Solenoid, 2-6
Front Panel prompt, 6-10 location, 2-26
jam errors, 3-9 part number, 9-19
media specifications, 1-15 removal, 8-36
paper level detection, 2-15 testing, A-20
paper size detection, 2-14 plug/jack locator, 10-9
part number (universal tray), 9-9 removal, 8-32
sequencing, 6-10 Retard Pad
set default destination, 6-10 part number, 9-19
set default source, 6-10 removal, 8-39
Standard Output, 2-8 Retard Pad Spring
supported envelopes, 1-14 part number, 9-19
supported paper weights, 1-14 removal, 8-39
Tray 2-3 Feeder, 2-28 sensor tests, A-15
Tray 2-3 sensors, 2-28 Tray part number, 9-21
Tray 4-5, 1-7 wiring diagram, 10-28
Tray 6, 1-9 Tray 2-3
Tray 6 undocked, 3-236 Feed Out Sensor #3
universal feeders, 2-28 part number, 9-31
universal tray paper handling, 2-7 removal, 8-54
universal trays, 2-27 Feed Roller
Tray 1/MPT, 2-6 removal, 8-29
Cam Gear Spring Feed/lift Motor
part number, 9-19 location, 2-28
removal, 8-36 part number, 9-13
components, 2-26 removal, 8-23
Drive Roller, 2-26 Feeder
Feed Roller, 2-6 components, 2-28
part number, 9-19 feed operation, 2-28
Feeder, 2-26 sensors, 2-28
part number, 9-17 Level Sensor, 2-29
No Paper Sensor part number, 9-13
connector designator, 10-3 removal, 8-27
location, 2-26 No Paper Sensor, 2-29
part number, 9-17 part number, 9-13
testing, A-15
Index Index-13
Nudger Roller W
removal, 8-31
Wait Sensor, 2-10
paper guides, 2-27
testing, A-16
Paper Size Switch signals, 2-27
wall outlet testing, 4-8
Pre-Feed Sensor, 2-29
warm-up time, 1-13
part number, 9-13
Windows printing problems, 4-3
removal, 8-28
wiring diagram conventions, 10-17
replacement rollers, 9-14
Retard Roller
removal, 8-30 X
Tray 6 xerographics
connection, 1-9 component dimensions, 5-37
Docking Interlock Drum Cartridge, 2-15
location, 2-13 part number, 9-33
Door J Interlock wiring, 10-24
location, 2-13 Fuser, 2-21
motor tests, A-13 part number, 9-35
Nudger Solenoid testing, A-21 removal, 8-76
sensor tests, A-18 Laser Assembly, 2-18
slide in Tray 6, 3-236 image data wiring, 10-33
tray empty, 3-211 part number, 9-33
troubleshooting removal, 8-74
AC power supply, 4-7 wiring, 10-29
Engine Logic Board, 4-12 Laser C
Image Processor Board, 4-14 part number, 9-33
RAM DIMM, 4-15 removal, 8-61
part numbers, 9-33
U power supply, 2-36
Toner Cartridge
USB Port, 2-34
part number, 9-33
error, 3-6
Toner Dispense Assembly, 2-17
location, 1-4
part number, 9-33
removal, 8-71
V Toner Dispense Motor, 2-18
part number, 9-33
version status, A-9
removal, 8-73
voltage requirements, 1-13
wiring, 10-24
voltage tolerances, 3-21
Transfer Roller, 2-16
part number, 9-25
removal, 8-44

071-0873-00 A

Service - Manual - Parte 1 PDF

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Service - Manual - Parte 1 PDF

Caricato da

Copyright:

Formati disponibili

Phaser 5500 Laser Printer

First Printing: August 2004

ii Phaser 5500 Printer Service Manual

3 Error Messages, Codes, and Procedures

vi Phaser 5500 Printer Service Manual

viii Phaser 5500 Printer Service Manual

7 Cleaning and Maintenance

x Phaser 5500 Printer Service Manual

Symbols Marked on the Product

Protective ground (earth) symbol.

Hot surface on or in the printer. Use caution to avoid personal

Avoid pinching fingers in the printer. Use caution to avoid

Use caution (or draws attention to a particular component).

xiv Phaser 5500 Printer Service Manual

Disconnect the power cord in the following cases:

if the power cord or plug is frayed or otherwise damaged,

Immediately before handling any semiconductor components assemblies, drain

Do not use freon-propelled chemicals. These can generate electrical charges

Do not remove a replacement component or electrical sub-assembly from its

Immediately before removing the protective material from the leads of a

Minimize body motions when handling unpackaged replacement devices. Motion

Handle ICs and EPROMs carefully to avoid bending pins.

Pay attention to the direction of parts when mounting or inserting them on

xvi Phaser 5500 Printer Service Manual

CLASS 1 LASER PRODUCT

Servicing Mechanical Components

Servicing Fuser Components

xviii Phaser 5500 Printer Service Manual

Reorient or relocate the receiver (device being interfered with).

In the European Union

EN 60950 Safety of Information Technology Equipment including Electrical Business

following the provisions of the Electromagnetic Compatibility Directive 89/336/EEC

EN 55022:1998 Limits and Methods of measurement of radio interference

EN 61000-3-2:1995 Part 3: Limits - Section 2: Limits for harmonic current emissions

EN 61000-3-3:1995 Part 3: Limits - Section 3: Limitation of voltage fluctuations and flicker

EN 55024:1998 Information technology equipment - Immunity characteristics - Limits

xx Phaser 5500 Printer Service Manual

Book 1 - Print Engine

xxii Phaser 5500 Printer Service Manual

1-2 Phaser 5500 Printer Service Manual

Maximum Print 50 ppm 50 ppm 50 ppm 50 ppm 50 ppm

Memory 128 MB 128 MB 128 MB 128 MB 256 MB

PostScript Fonts 137 137 137 137 137

Oak PCL 5.0 Yes Yes Yes Yes Yes

PCL5e/PCL6 Yes Yes Yes Yes Yes

Job Pipelining Yes Yes Yes Yes Yes

PDF Direct Print Yes Yes Yes Yes Yes

Resolutions 600 or 600 or 600 or 600 or 600 or

USB, Parallel Yes Yes Yes Yes Yes

Ethernet Optional Standard Standard Standard Standard

1000-Sheet Feeder Optional Optional Optional Standard Standard

Automatic 2-Sided Optional Optional Standard Standard Standard

Hard Drive Optional Optional Optional Optional Standard

Job Collation Optional Optional Optional Optional Standard

Proof Print, Optional Optional Optional Optional Standard

2,000-Sheet Feeder Optional Optional Optional Optional Standard

3,500-Sheet Optional Optional Optional Optional Standard

General Information 1-3

1-4 Phaser 5500 Printer Service Manual

1. LED 6. Up Arrow button - scrolls up the menu system

3. Toner Gauge 8. OK (select) button

4. Cancel button 9. Information button - for additional explanation or help

LED State Printer State