Fuji Xerox Phaser 5500 Service Manual

Phaser 5500 Laser Printer

Service Manual Book 1 - Print Engine

arning

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 © 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 Unpublished rights reserved under the copyright laws of the United States.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 Other

States and/or other countries.

Adobe Adobe Garamond

trademarks of Adobe Systems Incorporated in the United States and/or other countries.

Apple Chicago

the United States and/or other countries.

PCL countries.

IBM countries.

Windows and/or other countries.

Novell Services

Sun or other countries.

UNIX Company Limited.

As an E S

, The Document Company®, the stylized X®, CentreWare®, infoSMART®, Made For Each

, Phaser®, PhaserSMART®, and Walk-Up™ are trademarks of Xerox Corporation in the United

Reader®, Illustrator®, PageMaker®, Photoshop®, PostScript®, ATM®, Adobe Brilliant® Screens,

, Adobe Jenson™, Birch®, Carta®, IntelliSelect®, Mythos®, Quake®, and Tekton® are

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and HP-GL® are trademarks of Hewlett-Packard Corporation in the United States and/or other

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™

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is a trademark in the United States and other countries, licensed exclusively through X/Open

NERGY STAR

TAR guidelines for energy efficiency. The ENERGY STAR name and logo are registered U.S. marks.

partner, Xerox Corporation has determined that this product meets the ENERGY

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-X’port Ent. SNR ON . . . . . . . . . . . . . . . . . . . 3-87

Jam at A or F - F4-n H-X’port Ent. SNR Static. . . . . . . . . . . . . . . 3-89

Jam at A or F - F4-n H-X’port Exit SNR ON. . . . . . . . . . . . . . . . . 3-91

Jam at F - F4-26 H-X’port Exit SNR Static . . . . . . . . . . . . . . . . . 3-93

Jam at F - F4-32 X’port Ent. SNR ON . . . . . . . . . . . . . . . . . . . . . 3-95

Jam at F - F4-36 X’port 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

A Reference

Phaser 5500 Laser Printer Menu Map. . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Service Diagnostics Menu Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Service Diagnostic Tests and Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

Mode Select Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-24

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

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

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.

arning

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.

00:40

The surface is hot while the printer is running. After turning off the power, wait 40 minutes.

Avoid pinching fingers in the printer. Use caution to avoid personal injury.

Use caution (or draws attention to a particular component). Refer to the 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 (PCB’s).

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 printer’s 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.

arning

Turning the power off by using the On/Off switch does not completely deenergize 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.

arning

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.

arning

Do not try to manually rotate or manually stop the drive assemblies while any printer motor is running.

S7300-03

Servicing Fuser Components

arning

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 présent appareil numérique n'émet pas de bruits radioélectrique dépassant les limits applicables aux appareils numériques de la classe B prescrites dans le Réglement sur le brouillage radioélectrique édicté 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 (IEC 60950)

“Safety of Information Technology Equipment including Electrical Business Equipment”

following the provisions of the Electromagnetic Compatibility Directive 89/336/EEC and its amendments:

EN 55022:1998 (CISPR 22)

EN 61000-3-2:1995 +A1:1998+A2:1998 (IEC 61000-3-2)

EN 61000-3-3:1995 (IEC 61000-3-3)

EN 55024:1998 (CISPR 24)

“Limits and Methods of measurement of radio interference characteristics of Information Technology Equipment.” Class B.

“Part 3: Limits - Section 2: Limits for harmonic current emissions (equipment input current less than or equal to 16A per phase).”

“Part 3: Limits - Section 3: Limitation of voltage fluctuations and flicker in low-voltage supply systems for equipment with rated current less than or equal to 16A.”

“Information technology equipment - Immunity characteristics - Limits 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 you’ve 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

printer’s 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 it’s 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 engine’s 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:

parts listed in the option’s 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.

This section contains removal procedures for

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

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 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.

www.xerox.com/office/partners. For further

s5500-006

The Phaser 5500 printer combines a dual-pass, monochrome laser print engine with an image processor supporting Adobe’s 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 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.

x 600 or True 1200 x 1200 dpi in 1-sided or 2-sided

1-2 Phaser 5500 Printer Service Manual

Printer Configurations

The following table lists the features of the five Phaser 5500 printer configurations.

Printer Configurations

Features

5500B 5500N 5500DN 5500DT 5500DX

Maximum Print 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 Ye s Ye s Ye s Ye s Ye s

PCL5e/PCL6 Ye s Ye s Ye s Ye s Ye s

Job Pipelining Ye s Ye s Ye s Ye s Ye s

PDF Direct Print Ye s Ye s Ye s Ye s Ye s

Resolutions

USB, Parallel Ye s Ye s Ye s Ye s Ye s

Ethernet Capabilities

1000-Sheet Feeder Optional Optional Optional Standard Standard

Automatic 2-Sided Printing (Requires Duplex Unit)

50 ppm 50 ppm 50 ppm 50 ppm 50 ppm

600 or True 1200 dpi

Optional Standard Standard Standard Standard

Optional Optional Standard Standard Standard

600 or True 1200 dpi

Hard Drive Optional Optional Optional Optional Standard Job Collation

(Hard Drive Required)

Proof Print, Personal Print, Secure Print, Saved Jobs (Hard Drive Required)

2,000-Sheet Feeder (Requires 1000Sheet Feeder)

3,500-Sheet Finisher (Requires 1000-Sheet Feeder)

Optional Optional Optional Optional Standard

General Information 1-3

Parts of the Printer

Front View

1. Standard Output Tray

2. Front Door

3. Tray 2 and 3

4. Optional Duplex Unit

5. Tray 1/MPT

6. 2000-Sheet Feeder (Tray 6)

7. 1000-Sheet Feeder (Tray 4 & 5)

8. Finisher

9. Stacker Lower Tray

10.Stacker Upper Tray

Rear View

6 4

5500-107

s5500-017

1. Parallel Connection

2. Ethernet Connection

3. USB Connection

4. Configuration Card

5. Mode Select Port

6. Serial Debug Port

7. Ground Fault Interrupt Reset

8. Printer Power Connection

9. Finisher Connection

10.1000-Sheet Feeder Connection

11.Duplex Unit Connector

1-4 Phaser 5500 Printer Service Manual

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.

READY TO PRINT.READY TO PRINT.

Information

Information Walk-Up Features

Walk-Up Features Printer Setup

Printer Setup Troubleshooting

Troubleshooting Shutdown

Shutdown

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

2 3

5500-016

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

General Information 1-5

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).

1-6 Phaser 5500 Printer Service Manual

+ 593 hidden pages

Fuji Xerox Phaser 5500 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual