Fuji Xerox Phaser 5500 Service Manual

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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

Page 4

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 Unpublished rights reserved under the copyright laws of the United States.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

, AppleTalk®, LaserWriter®, LocalTalk®, Macintosh®, Mac OS®, TrueType®, Apple Chancery®,

, Geneva®, Monaco®, New York® , and QuickDraw® are trademarks of Apple Computer, Inc. in

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

is a trademark of International Business Machines Corporation in the United States and/or other

, Windows NT®, and Wingdings® are trademarks of Microsoft Corporation in the United States

, NetWare®, NDPS®, NDS®, Novell Directory Services® , IPX™ , and Novell Distributed Print

™

are trademarks of Novell, Incorporated in the United States and/or other countries.

and Sun Microsystems® are trademarks of Sun Microsystems, Incorporated in the United States and/

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

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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

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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

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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

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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

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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

Page 10

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

Page 11

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

Page 12

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

Page 13

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

Page 14

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

Page 15

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

Page 16

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

Page 17

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

Page 18

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

Page 19

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

Page 20

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

Page 21

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

Page 22

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

Page 23

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

Page 24

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

Page 25

General Information

In this chapter...

■ Printer Introduction and Overview

■ Printer Configurations

■ Parts of the Printer

■ Consumables and Routine Maintenance Items

■ Printer Specifications

Chapter

Page 26

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

Page 27

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

Page 28

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

Page 29

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

Page 30

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

Page 31

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.

General Information 1-7

s5500-008

Page 32

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 printer’s AC Accessory Panel.

1. Horizontal Transport 2. Stacker/Finisher

1-8 Phaser 5500 Printer Service Manual

s5500-009

Page 33

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.

Caution

To avoid damage to the Envelope Tray, use the Tray 2 position only.

General Information 1-9

s5500-01

Page 34

Consumables and Routine Maintenance Items

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, Transfer Roller and 15 Feed Rollers)

1-10 Phaser 5500 Printer Service Manual

300,000

Page 35

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 Feeder

Stacker/ Finisher

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 Feeder

280 mm (11.0 in.) 540 mm (21.2 in.) 520 mm (21.1 in.) 23 kg (50 lbs.)

1050 mm (41.3

in.)

363 mm (14.3 in.) 385.5 mm

740 mm (29.1 in.) 650 mm (25.6 in.) 49 kg

(108

600 mm (23.6 in.) 50 kg

in.)

(15.1

(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

To p 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

requirement

General Information 1-11

1190 mm (47.0 in.)

Page 36

89 cm

(35 in.)

20 cm

(8 in.)

20 cm

(8 in.)

119 cm (47 in.)

20 cm

(8 in.)

118 cm

(46 in.)

46 cm

(18 in.)

46 cm

(18 in.)

46 cm

(18 in.)

120 cm (47 in.)

100 cm (39 in.)

118 cm

(46 in.)

1-12 Phaser 5500 Printer Service Manual

218 cm (86 in.)

65 cm

(26 in.)

s5500-610

Page 37

Functional Specifications

Characteristic Specification

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 / Addressability

Print-Quality Modes

Continuous Operating Printing Speed

Warm-Up Time: Sleep Mode Stand By

600/ True 1200 dpi

Two choices: 600 x 600 dpi

True 1200 x 1200 dpi

50 pages per minute for plain Letter paper, simplex or duplex 50 pages per minute for A4 paper, simplex or duplex

45 sec. 6 sec.

Electrical Specifications

Characteristic Specification

Primary Line Voltages 120 VAC nominal, min. 99 V, max. 135 V

220/240 VAC nominal, min. 198 V, max. 254 V

Primary Line Voltage Frequency Range

50/60 Hz ± 3 Hz

Input Current:

Operating

Rush

Power Consumption:

Operating (5500DX) Low Power Sleep Mode

BTU’s at 120V:

BTU’s at 240V:

12 A max. @ 120 V 8 A max. @ 240 V 100 A max.

1150 W max. @ 120 V, 1300 W max. @ 240 V TBD Ron to provide BTU and Wattage 10 W max @ 120/240 V

Operating 3924 Power Saver 34

Operating 4436 Power Saver 34

General Information 1-13

Page 38

Environmental Specifications

Characteristic Specification

Temperature:

Operating Transportation

Humidity (%RH)

Operating Transportation

Altitude

Operating Transportation*

Acoustic Noise LWA(B)

Standby Printing

* Air transportation in pressurized cargo space

5 to 32° C (41 to 95° F)

-20 to 40° C (-4 to 104° F)

15 to 85 5 to 85

0 to 2,500 meters (8,200) feet) 0 to 15,000 meters (49,200 feet)

Engine only

4.0 B

7.1 B

Bystander Position

22 db 54 db

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 Envelopes

Supported Media Weights

Tray Capacity Tr ay 1

Tray 1 or Tray 2 (with Envelope Tray installed)

Tray 1,3,4,5,6 Tray 2 Duplex

Tray 2 Tray 3 Tray 4 Tray 5 Tray 6 Top (face-down) Stacker/Finisher

COM-10 (4.1 x 9.5 in.) Monarch (3.8 x 7.5 in) DL (110 x 220 mm) C5 (162 x 229 mm)

60-216 g/m2 (16 lb. bond to 133 lb. card stock) 60-105 g/m2 (16 to 28 lb. bond) 60-163 g/m2

100 Sheets / 15 envelopes 500 Sheets or 35 envelopes with Envelope Tray 500 Sheets 500 Sheets 500 Sheets 2000 Sheets 500 Sheets 3000 elevator, 500 in top tray

Based on 75 g/m2 (20 lb.) paper stock. Capacity is reduced for heavier/thicker stock.

1-14 Phaser 5500 Printer Service Manual

Page 39

Supported Paper Specifications

Paper Sizes and Weights

■ User-Selected Size

● 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 2-hole and 4-hole punch.

These custom widths are supported with stapling and hole punching: 210 mm (8.27

in.), 257 mm (10.12 in.), 8.50 in. (216 mm), 10.50 in. (267

11.00 in. (279 mm).

in.), 297 mm (11.70

mm),

Paper Size

Letter (8.5 x 11 in.) A4 (210 x 297 mm)

Input Output

Tray 1/MPT

Tray 2

Tray 3-5

Tray 6

Envelope Tray

2-Sided Printing

Standard Output Tray

Stacker Upper Tray

Stacker Lower Tray

■

● ● ● ▲ ▲ ▲ ▲ 2, 3, 4 ▲

Holes Punched

Staple

Legal (8.5 x 14 in.) US Folio (8.5 x 13 in.)

Executive (7.25 x 10.5 in.)

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.) A3 (297 x 420 mm)

B4 JIS (257 x 364 mm)

B5 JIS (182 x 257 mm)

B6 JIS (128 x 182 mm)

Envelopes

#10 Commercial (4.12 x 9.5 in.) Monarch (3.87 x 7.5 in.)

■

● ● ▲ ▲ ▲ ▲ 2 ▲

■

● ● ● ▲ ▲ ▲ ◆ 2, 3, 4 ◆

■

● ● ▲ ▲

■

■ ■

■

● ● ▲ ▲ ▲ ▲ 2, 3, 4 ▲

■

● ● ▲ ▲ ▲ ▲ 2 ▲

■

● ● ● ▲ ▲ ▲ ◆ 2 ◆

■

■ ■

▲

DL (110 x 220 mm) C5 (162 x 229 mm)

C4 (229 x 324 mm)

General Information 1-15

■ ■

▲

Page 40

Paper Sizes and Weights (Continued)

■ User-Selected Size

● 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 2-hole and 4-hole punch.

These custom widths are supported with stapling and hole punching: 210 mm (8.27

in.), 257 mm (10.12 in.), 8.50 in. (216 mm), 10.50 in. (267

11.00 in. (279 mm).

in.), 297 mm (11.70

mm),

Custom Width / Custom Height

89–297 mm (3.50–11.70 in.)/ 98–127 mm (3.87–5.00 in.)

Input Output

Tray 1/MPT

Tray 2

Tray 3-5

Tray 6

Envelope Tray

2-Sided Printing

Standard Output Tray

■

▲

Stacker Upper Tray

Stacker Lower Tray

Holes Punched

Staple

89–297 mm (3.50–11.70 in.)/ 127–182 mm (5.00–7.16 in.)

89–140 mm (3.50–5.50 in.)/ 182–432 mm (7.16–17.00 in.)

140–182 mm (5.50–7.16 in.)/ 182–432 mm (7.16–17.00 in.)

182–210 mm (7.16–8.27 in.)/ 182–432 mm (7.16–17.00 in.)

210–297 mm (8.27–11.70 in.) 182–432 mm (7.16–17.00 in.)

Envelope Custom Width / Envelope Custom Height

148–241 mm (5.82–9.50 in.)/ 98–162 mm (3.87–6.38 in.)

Paper Weight

60–105 g/m2 (16–28 lb. Bond)

105–120 g/m2 (28–32 lb. Bond)

■

■ ■ ■

▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲

▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲

▲ ▲

▲ ▲ ▲

▲ ▲ ▲ ▲

■

▲

120–176 g/m2 (32–47 lb. Bond)

176–215 g/m2 (47–57 lb. Bond)

1-16 Phaser 5500 Printer Service Manual

▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲

▲ ▲ ▲ ▲ ▲ ▲ ▲

Page 41

Theory of Operation

In this chapter...

■ Phaser 5500 Operational Overview

■ Paper Path

■ Sensors

■ Xerographics

■ Major Assemblies

Chapter

Page 42

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 printer’s 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.

Paper Transport

Pressure Roller

Detack Saw

Transfer Roller

Heat Roller

Fuser

Cleaning Blade

BCR

Drum

Laser Beam

Charge Metering Blade

Drum Cartridge

2-2 Phaser 5500 Printer Service Manual

Magnetic Roller

Paper

s5500-015

Page 43

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 multifaceted 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 multipicks. 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

Page 44

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 sheet’s 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

Take Away Clutch

Take Away Bracket

Gear-18T

Take Away Roller

Feed Roller

Gear

Regi Roller

Fuser OCT Roller

Pulley 25T

Gear-Exit

Gear-19T

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

Transfer Roller

2-4 Phaser 5500 Printer Service Manual

Drum Motor

Magnetic Roller

s5500-021

Page 45

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

Feed Roller

Drive Roller

Tray 2

Nudger Roller

Feed Roller

Registration Roller

Transfer Roller

Drum

Tray 3

Nudger Roller

Feed Roller

Retard RollerRetard Roller

Feeder AssyFeeder Assy

Take Away Roller

CRU

Heat Roller

Pressure Roller

Fuser

Invert Roller

Face Up Roller

OCT Roller

Exit Pinch Roller

Exit1

OCT Roller

Exit Pinch Roller

Option Exit2+OCT2

Duplex A3L Roller

Duplex Roller

Option Duplex

Exit

s5500-022

Theory of Operation 2-5

Page 46

The diagram shows the paper path for Trays 1 through 5, the Duplex Unit, Exit 1, and Exit 2.

Face Up Roller

Exit 2

Duplex Unit A3L Rollers

Duplex Roller

Pinch Rollers

Feed Roller

Pinch Roller

Drive Roller

Invert Roller

Exit Pinch Rollers

OCT Rollers

Pressure Roller

Tray 2

Tray 3

Heat Roller Transfer Roller

Drum Registration

Pinch Roller

Registration Roller

Nudger Rollers

Pinch Rollers

Take Away Rollers

Feed Rollers

Retard Rollers

Tray 4

1000 Sheet Feeder

Tray 5

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.

2-6 Phaser 5500 Printer Service Manual

Page 47

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 tray’s 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

Exit 2

Horizontal Transport

Punch

Stacker Lower Tray

xit 1

Compiler Tray

Stapler

Theory of Operation 2-7

s5500-024

Page 48

Standard Output Tray

The Standard Output Tray is a face-down, 500-sheet tray located on the printer’s Top Cover. The tray receives paper from Exit 1 if the Horizontal Transport is not installed. The Standard Output Tray becomes the Horizontal Transport’s 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

Entrance Sensor

Belt

Exit Sensor

s5500-025

2-8 Phaser 5500 Printer Service Manual

Page 49

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

Transfer Rollers (Driven by Regi Motor)

Gate Sensor

Entrance Rollers (Driven by Finisher Transport Motor)

(Driven by Exit Motor)

Transfer Gate

Sub Paddle (Driven by Finisher Transport Motor)

Eject Clamp (Driven by Eject Clamp Motor)

Buffer Roller (Driven by Regi Motor)

Buffer Gate

Main Paddle (Driven by Finisher Transport Motor)

Lower Exit Rollers (Driven by Exit Motor)

Eject Roller Shaft (Driven by Eject 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.

Theory of Operation 2-9

Page 50

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

2-10 Phaser 5500 Printer Service Manual

Page 51

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. Photoreflective sensors use light reflected back from an object to detect its presence. Photoreceptive 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 isn’t. Photo-receptive sensors consist of a LED in one arm of a U-shaped holder, and a photo-transistor in the other arm. When the sensing area is vacant, nothing is between the arms of the sensor, light falls on the photoreceptor 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.

Theory of Operation 2-11

Page 52

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 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 printer’s Temp and humidity.

CRUM antenna Inductive code reader Communicates with the CRUMs.

OCT Home Position

Microswitch Interrupts +5 V to Laser Diode.

Photo-receptive Detects Offset assembly home position.

2-12 Phaser 5500 Printer Service Manual

Page 53

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

Theory of Operation 2-13

Page 54

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

Feed Out Sensor #3

F/O Sensor #6

Registration Sensor

Pre Feed Sensor

Paper Size Switch

F/O Sensor #5

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.

2-14 Phaser 5500 Printer Service Manual

F/O Sensor #4

s5500-586

Page 55

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 customer’s usage patterns. The Drum Cartridge Life specification of 60,000 prints is based on an average job length of six, single-sided pages.

As an example of how job length effects the Drum Cartridge Life count, a continuous print job having a job length of 500 to 1000 pages results in a drum cycle count of 3.2 cycles per 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-

Bias Charge Roller (BCR) The BCR uniformly distributes electrical charges over the drum

Theory of Operation 2-15

conductive material that retains electrical charges on its surface until exposed to light, when electrical conduction occurs.

surface, and erases the previous charge pattern.

Page 56

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 (CM) Blade

Cleaning Blade The Cleaning Blade removes toner remaining on the Drum.

The CM Blade spreads a thin, even layer of developer and toner over the Magnet Roller, and applies negative charges to the toner triboelectrically.

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.

2-16 Phaser 5500 Printer Service Manual

Page 57

Transfer Roller

Left

Toner Dispense Assembly

s5500-607

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

Theory of Operation 2-17

s5500-594

Page 58

Toner Dispense Motor

The Toner Dispense Motor drives the Toner Cartridge and dispense tube augers to deliver toner to the Drum Cartridge.

Toner Dispense Motor

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.

2-18 Phaser 5500 Printer Service Manual

Page 59

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.

Theory of Operation 2-19

Page 60

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

Ready reference value SOS signal interval (equivalent to 98% or more of the rated rpm of

Fail reference value SOS signal interval (equivalent to 90% or less of the rated rpm of

Description

the Scanner Motor)

2-20 Phaser 5500 Printer Service Manual

Page 61

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

Pressure Roller

Heater Rods

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.

Theory of Operation 2-21

Page 62

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

2-22 Phaser 5500 Printer Service Manual

Page 63

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

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 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 Fuser’s 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.

Theory of Operation 2-23

Page 64

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

Paper Type

Low Medium High Extra High

Plain, Letterhead, Colored, Special

Transparency Transparency

Labels Plain Paper

Card Stock, Envelopes

Prepunched Plain Paper

Plain Paper Mode 1

Paper Mode (Default)

Mode 1 Plain Paper

Mode 2

Temperature

Plain Paper Mode 1 (Default)

Plain Paper Mode 2

Thick Paper Mode 1

Plain Paper Mode 1

Plain Paper Mode 1 and (Default)

Thick Paper Mode 1

Plain Paper Mode 1

Thick Paper Mode 4 (Default)

Thick Paper Mode 1 (Default)

Thick Paper Mode 1

Thick Paper Mode 2

Thick Paper Mode 1

Thick Paper Mode 2

2-24 Phaser 5500 Printer Service Manual

Page 65

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

Mode

1 2 Transparency

Thin Paper Normal Paper

Start Temp (o C) Number

of Sheets in Print Run

1 ~ 3 208 198 213 203 188 185

4 ~ 10 207 197 212 202 187 185 11 ~ 30 206 196 211 201 186 185 31 ~ 50 205 195 210 200 185 185 51 ~ 99 205 195 210 200 185 185

100 ~ 150 205 195 210 200 185 185

> 150 205 195 210 200 185 185

Max (Cold) Min (Hot) Max (Cold) Min

Fuser Control Temperatures for Thick Paper Modes

Paper Type Thick Paper

Mode

Start Temp (o C)

Number of Sheets in Print Run

1 ~ 3 218 210 223 215 225 215 218 215

4 ~ 10 217 210 222 215 224 215 217 215 11 ~ 30 216 210 221 215 223 215 216 215 31 ~ 50 215 210 220 215 222 215 215 215 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

Max (Cold)

1234

Min (Hot)

Max (Cold)

Min

(Hot)

(Hot) Max (Cold) Min (Hot)

Letter, COM10 Label

Max (Cold)

Min

(Hot)

Max (Cold)

Min

(Hot)

Theory of Operation 2-25

Page 66

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 printer’s 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

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 paper’s 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.

2-26 Phaser 5500 Printer Service Manual

Paper Size Sensor

s5500-035

Page 67

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

Theory of Operation 2-27

Page 68

Trays 2 and 3 are functionally equivalent in terms of the feeder mechanism that moves paper from the tray into the paper path. The Feeder’s Feed/Lift Motor drives the Feed and Nudger Rollers to pick paper from the tray, and also lifts the tray’s Bottom Plate to maintain paper contact with the Nudger Roller.

Feed/Lift Motor

Pre Feed Sensor

Level Sensor

No Paper Sensor

Feeder Assembly

Tray

Page Size Switch

s5500-036

The Feeder’s Level Sensor uses an actuator to determine whether paper in the tray is lifted to the feeding position. As the level of paper drops, the flag of the actuator enters the Level Sensor’s sensing area, triggering the Feed/Lift Motor to raise the Bottom Plate. The Feeder’s Feed/Lift Motor raises the Bottom Plate by rotating the Lift-up Shaft through the Gear (13T/60T) and Sector Gear (60T).

2-28 Phaser 5500 Printer Service Manual

Page 69

Sector Gear (60T)

Lift Up Shaft

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.

Theory of Operation 2-29

Page 70

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 Motor

Belt

Offset Sensor

Stack Full Sensor

Exit PWB

Exit Pinch Rollers

Paper Weight

OCT Roller

Exit Gate

Fuser Exit Sensor

Motor Assembly

Rear

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.

s5500-59

2-30 Phaser 5500 Printer Service Manual

Page 71

■ 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

■ Offset Home Position Sensor

The Offset Home Position Sensor detects the OCT Roller position.

s5500-039

■ 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.

Theory of Operation 2-31

Page 72

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 from the LVPS. The motor enable and speed control signals come from the microprocessor on the Engine Logic Board.

Main Motor

VDC power

Drum Motor

Motor Assembly

s5500-040

■ Toner Dispense Motor

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

Toner Dispense Motor

2-32 Phaser 5500 Printer Service Manual

s5500-596

Page 73

Printer Control

Power Switch

Drum Cartridge Detect Interlock Drum Cartridge Fan

Front Door Interlock

Exit PWB

LVPS

HVPS

GFI Breaker

Printer control centers on the following:

Door A Interlock

Fuser Fan

Image Processor Board

Door B Interlock

Engine Logic Board

s5500-041

■ 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.

Theory of Operation 2-33

Page 74

Image Processor Board

The Image Processor Board (I/P Board) is one of the major elements of the Phaser 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.

5500 printer. The primary function of the I/P Board is to receive host data

Configuration Card

Hard Drive

RAM DIMMs

s5500-587

2-34 Phaser 5500 Printer Service Manual

Page 75

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.

Theory of Operation 2-35

s5500-042

Page 76

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.

2-36 Phaser 5500 Printer Service Manual

s5500-043

Page 77

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

Theory of Operation 2-37

s5500-045

Page 78

AC Accessory Panel

The AC Accessory Panel provides AC power for the Finisher and accepts the Printer Power Cord.

Reset Switch

GFI Breaker

AC Accessory Panel

s5500-046

2-38 Phaser 5500 Printer Service Manual

Page 79

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

Page 80

Introduction

This chapter describes the printer’s 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.

3-2 Phaser 5500 Printer Service Manual

Page 81

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

Page 82

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

Test

SDRAM 1 Hard This test fails if the Boot Loader finds faulty or no RAM.

I/O ASIC 3 Hard This test determines if the I/O chip is functioning properly.

Memory 4 Hard This test checks 64-bit reads and writes to RAM memory.

EEPROM 10 Hard This test checks addressing of the NVRAM.

Ethernet 11 Hard This test checks the Ethernet core.

CPU Interrupts

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

RAM DIMM Presence

Install more RAM

Code

12 Hard This test checks that each CPU interrupt source is

15 Soft This test examines bad or incompatible RAM DIMMs.

16 Soft Checks that there is at least 64 MB of memory installed and

Fault Type

Description

functioning.

a number of conditions.

ignores more than 512 MB.

Too much RAM

IDE Disk 20 Soft Checks the disk controller core, and runs a DIAGNOSE

Engine Command

17 Soft Checks that there is no more than 512 MB of memory

22 Hard Checks communication between the Image Processor Board

3-4 Phaser 5500 Printer Service Manual

installed.

command on the hard drive.

and the Engine Logic Board.

Page 83

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.

Error Messages, Codes, and Procedures 3-5

Page 84

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 Pattern

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

1+1+1 3: I/O ASIC Image Processor Board ASIC failure. Go to “Image

1+1+1+1 4: MEMORY Checks installed memory: walking ones address, walking

5+5 10: EEPROM 1. Switch off printer power.

5+5+1 11: ETHERNET

Front Panel Message

PHY

Action

interval blink at Front Panel and health LEDs.

Processor Isolation” on

one and complement data. Tests RAM memory above diagnostics code and data addresses. Go to “RAM Troubleshooting Procedure” on

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).

Image Processor Ethernet Port Failure. Replace Image Processor Board (page 8-91).

page 4-13.

page 4-15.

5+5+1+1 12: CPU

INTERRUPTS

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

5+5+5+5+1+1 22: ENGINE

COMMAND

3-6 Phaser 5500 Printer Service Manual

Replace Image Processor Board (page 8-91).

Communication with print engine has failed. Check the connection to the Engine Logic Board, then go to “Image Processor Isolation” on

page 4-13.

Page 85

Service Usage Profile

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 printer’s 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 printer’s 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 printer’s 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).

Error Messages, Codes, and Procedures 3-7

Page 86

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 Code

0 No Error 15 Toner Cartridge Failure (J8-1 J8-2)

1 Duplex Unit Failure (H2-7) 16 Drum Cartridge Failure

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

3 Stacker Lower Tray Failure

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)

Error

(H5-11~13, 21~24, 81~84, 86)

Fault Code

18 Humidity Sensor Failure

Error

(J4-1, J7-1, J7-2)

(No error code)

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,

12 Tray 4-5 Logic Board Failure

(H7-3, H7-4, H7-7)

13 Tray 6 Logic Board Failure

(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.

3-8 Phaser 5500 Printer Service Manual

U6-3, U6-4, U6-5, U6-6 U6-7)

27 Incorrect Duplex Unit (H2-8)

28 Incorrect Tray 4 -5 Unit (H7-8)

Page 87

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 (Item 291)

Paper Size Jam E1-1, PSE-1 18

Jam at Tray 1 C9-3 1

Jam at Tray 2 C1-2, C1-3 2

Jam at Tray 3 C2-1, C2-2 3

Jam at Tray 4 C3-0, C3-1 4

Jam at Tray 5 C4-0, C4-1, C4-4 5

Jam at Tray 6 C5-1, C5-2, C8-5 6

Jam at A E1-2, E1-6, E3-1, E3-2, E3-6, E4-1, E4-5,

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

Last Jam Error (Item 298)

F4-12, F4-16, F4-22

Jam History Log

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,

Jam at G F4-42, F4-43, F4-46, F4-47,F4-48, F4-53, F4-

Jam at H F4-55, F4-56, F4-61, F4-66 14

Jam at Stacker Upper Tray F4-75 17

Error Messages, Codes, and Procedures 3-9

12 F4-51, F4-52,F4-71, F4-72, F4-76, F4-82, F4-83, F4-86

13 54, F4-73, F4-74, F4-77, F4-78, F4-84, F4-85, F4-87, F4-88

Page 88

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 J

Door A Door D

Door E

Door H

Door F

Door G

Door BDoor C

s5500-614

3-10 Phaser 5500 Printer Service Manual

Page 89

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

Tests each Finisher solenoid and the Set Clamp Clutch.

IP NVRAM Access This allows you to reset the PostScript or all NVRAM.

Engine Logic Board Replacement

Finisher Board Setup Sets the Finisher/Stacker punch configuration.

Exit Exits Service Diagnostics and reboots the printer.

Error Messages, Codes, and Procedures 3-11

Save/Restore NVRAM from the Engine Logic Board.

Page 90

Using Service Diagnostics

The printer’s 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 sheet’s 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 doesn’t 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. Map” on page A-4.

See “Service Diagnostics Menu

Starting Service Diagnostics

Access the Service Diagnostics menu one of two ways:

Entering without rebooting the printer:

1. From the printer’s main menu, scroll to 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. page A-4.

See “Service Diagnostics Menu Map” on

3-12 Phaser 5500 Printer Service Manual

Page 91

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

Error Messages, Codes, and Procedures 3-13

Page 92

Messages, Codes, and Procedures

The error messages and codes generated by the printer’s 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 Ta ke A way 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

Unit Monitor

Comm Communication As in MCU-DM Comm Error.

LVP S Low-Voltage Power Supply Primary power supply.

PWB Printed Wire Board Used to describe a circuit board (Tray 6 PWB).

3-14 Phaser 5500 Printer Service Manual

Device used to store usage information on the Drum and Toner Cartridges.

Page 93

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 printer’s 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

Front Panel Message Service Diagnostics Message

Main Motor Failure U0-1 Main Motor Stop 19 3-23

Main Motor Failure Drum Motor Failure

Laser Unit Failure Laser Motor Failure

Fuser Failure Fuser Failure Fuser Failure Fuser Failure Fuser Failure Fuser Failure Fan Failure

Toner Motor Failure Fan Failure

Engine Logic Board Failure Engine Logic Board Failure Engine Logic Board Failure Engine Logic Board Failure Engine Logic Board Failure Engine Logic Board Failure

U1-1 Main Motor Rotation U1-4 Drum Motor Rotation

U3-3 Laser Power U3-5 Polygon Motor Rotation

U4-1 On Time U4-2 Over Heat Temp U4-3 FS1 Thermisitor U4-4 FS2 Thermisitor U4-5 PR Thermisitor U4-7 Cold-Sagging U4-9 Fan Defect

U5-1 Motor Rotation U5-9 Fan Failure

U6-2 RAM Read/Write U6-3 NVM Data Defect U6-4 NVM Read/Write U6-5 CP/U Power NVM U6-6 ASIC/CRUM U6-7 PPM Data

Error

19 20

23 22

24 24 24 24 24 24 25

21 25

26 26 26 26 26 26

Jam Error

Go to Page

3-23 3-24

3-25 3-26

3-27 3-29 3-29 3-29 3-29 3-30 3-32

3-33 3-34

3-35 3-35 3-35 3-35 3-35 3-35

Paper Size Jam Jam at A Jam at A

Jam at A Jam at A Jam at A

Error Messages, Codes, and Procedures 3-15

E1-1 Regi Area Jam E1-2 Regi Area Jam E1-6 Regi Area Jam

E3-1 Fuser Area Jam E3-2 Fuser Area Jam E3-6 Fuser Area Jam

18 7 7

7 7 7

3-35 3-37 3-38

3-39 3-39 3-41

Page 94

Error Message Summary (Continued)

Engine

Front Panel Message Service Diagnostics Message

Jam at A Jam at E Jam at A Jam at E

Jam at E E8-2 Duplex Area Jam 11 3-49

Jam at Tray 2 Jam at Tray 2

Jam at Tray 3 Jam at Tray 3 Jam at B

Jam at Tray 4 Jam at Tray 4 Jam at B and C Jam at B

Jam at Tray 5 Jam at Tray 5 Jam at B and C Jam at B Jam at Tray 5

E4-1 Exit 2 Area Jam E4-3 Exit 2 Area Jam E4-5 Exit 2 Area Jam E4-6 Exit 2 Area Jam

C1-2 Tray 2 C1-3 Tray 3

C2-1 Tray 3 C2-2 Tray 3 C2-3 Tray 3

C3-0 Tray 4 C3-1 Tray 4 C3-2 Tray 4 C3-3 Tray 4

C4-0 Tray 5 C4-1 Tray 5 C4-2 Tray 5 C4-3 Tray 5 C4-4 Tray 5

Error

Jam Error

7 11 7 11

2 2

3 3 8

4 4 16 8

5 5 16 8 5

Go to Page

3-42 3-44 3-44 3-47

3-56 3-59

3-56 3-61 3-59

3-56 3-63 3-61 3-59

3-65 3-63 3-61 3-59 3-56

Jam at Tray 6 Jam at Tray 6 Jam at B

Jam at D and A Jam at D and A

Jam at B Jam at C Jam at C Jam at Tray 6 Jam at D

Jam at Tray 1 (MPT) C9-3 Tray 1/MPT 1 3-84

Jam at A Jam at A Jam at F

Jam at A Jam at F Jam at F Jam at F

Jam at F Jam at F

C5-1 Tray 6 C5-2 Tray 6 C5-3 Tray 6

C6-1 Duplex Area Jam C6-2 Duplex Area Jam

C8-2 F/O2 SNR Static Jam C8-3 F/O3 SNR Static Jam C8-4 F/O4 SNR Static Jam C8-5 HCF F/O SNR Static jam C8-6 Duplex

F4-12 H-Xport Ent SNR ON F4-16 H-Xport Ent SNR Static Jam A F4-17 H-Xport Ent SNR Static Jam B

F4-22 H-Xport Exit SNR ON Jam A F4-23 H-Xport Exit SNR ON Jam B F4-24 H-Xport Exit SNR ON Jam C F4-26 H-Xport Exit SNR Static

F4-32 X’port Ent SNR ON F4-36 X’port Ent SNR Static

6 6 8

15 15

8 9 9 6 10

7 7 12

7 12 12 12

12 12

3-68 3-71 3-73

3-51 3-53

3-76 3-77 3-78 3-79 3-83

3-87 3-89 3-89

3-91 3-91 3-91 3-93

3-95 3-98

3-16 Phaser 5500 Printer Service Manual

Page 95

Error Message Summary (Continued)

Front Panel Message Service Diagnostics Message

Jam at G Jam at G Jam at G Jam at G Jam at G

Jam at F Jam at F Jam at G Jam at G Jam at H Jam at H

Jam at H Jam at H

Jam at F Jam at F Jam at G Jam at G Jam at Stacker Upper Tray Jam at F Jam at G Jam at G

F4-42 Buffer Path SNR ON Jam A F4-43 Buffer Path SNR ON Jam B F4-46 Buffer Path SNR Static Jam A F4-47 Buffer Path SNR Static Jam B F4-48 Buffer Path SNR Static Jam C

F4-51 Compile SNR OFF Jam A F4-52 Compile SNR ON Jam A F4-53 Compile SNR ON Jam B F4-54 Compile SNR ON Jam C F4-55 Compile SNR OFF Jam B F4-56 Compile SNR Static

F4-61 Set Eject Jam F4-66 Compile Paper SNR Static

F4-71 Top Tray Exit SNR ON Jam A F4-72 Top Tray Exit SNR OFF Jam A F4-73 Top Tray Exit SNR ON Jam B F4-74 Top Tray Exit SNR ON Jam C F4-75 Top Tray Exit SNR OFF Jam B F4-76 Top Tray Exit SNR Static Jam A F4-77 Top Tray Exit SNR Static Jam B F4-78 Top Tray Exit SNR Static Jam C

Engine Error

Jam Error

13 13 13 13 13

12 12 13 13 14 14

14 14

12 12 13 13 17 12 13 13

Go to Page

3-101 3-101 3-106 3-106 3-106

3-109 3-112 3-112 3-112 3-109 3-115

3-118 3-121

3-123 3-126 3-123 3-123 3-126 3-129 3-129 3-129

Jam at F Jam at F Jam at G Jam at G Jam at F Jam at G Jam at G

Tray 2 Failure Tray 3 Failure Tray 4 Failure Tray 5 Failure Tray 6 Failure

Duplex Unit Failure Incorrect Duplex Unit Installed

Exit Unit Failure Exit Unit Failure Exit Unit Failure

Tray 1 /MPT Paper Guide Does Not Match Size Menu

Tray Paper Guide Does Not Match Size Menu

F4-82 Gate Sensor ON F4-83 Gate Sensor Static Jam A F4-84 Gate Sensor Static Jam B F4-85 Gate Sensor Static Jam C F4-86 Gate Sensor Static Jam A F4-87 Gate Sensor Static Jam B F4-88 Gate Sensor Static Jam C

H1-1 Tray 2 Fail H1-2 Tray 3 Fail H1-3 Tray 4 Fail H1-4 Tray 5 Fail H1-5 Tray 6 Fail

H2-7 Duplex Comm Failure H2-8 Duplex Type Error

H3-1 Offset Error H3-2 Offset Error H3-7 Exit Board Comm Failure

- - 3-154

H4-1 Tray 2 Paper Size Error H4-2 Tray 3 Paper Size Error H4-3 Tray 4 Paper Size Error H4-4 Tray 5 Paper Size Error

11 10 9 8 7

1 27

2 2 2

12 12 13 13 12 13 13

3-131 3-135 3-135 3-135 3-138 3-138 3-138

3-141 3-141 3-141 3-141 3-144

3-148 3-149

3-150 3-150 3-152

3-155 3-155 3-157 3-157

Error Messages, Codes, and Procedures 3-17

Page 96

Error Message Summary (Continued)

Front Panel Message Service Diagnostics Message

Finisher Board Failure Finisher Failure Incorrect Finisher Installed Stacker Lower Tray Failure Stacker Lower Tray Failure Stacker Lower Tray Failure Stacker Lower Tray Failure Stacker Lower Tray Failure Stacker Lower Tray Failure Stacker Lower Tray Failure Punch Failure Punch Failure Punch Failure Punch Failure Stacker Lower Tray Failure Stacker Lower Tray Failure Stacker Lower Tray Failure Stacker Lower Tray Failure Stacker Lower Tray Failure Stapler Failure Stapler Failure Stapler Failure

H5-4 NVM R/W Error H5-7 Finisher Comm Failure H5-8 Type Error H5-11 Low Tray Fail H5-12 Low Tray Upper Limit H5-13 Low Tray Lower Limit H5-21 Front Home SNR ON H5-22 Rear Home SNR ON H5-23 Front Home SNR OFF H5-24 Rear Home SNR OFF H5-31 SNR ON H5-32 SNR OFF H5-33 Home SNR ON H5-34 Home SNR OFF H5-81 Eject Clamp SNR ON H5-82 Eject Clamp SNR OFF H5-83 Set Clamp SNR ON H5-84 Set Clamp SNR OFF H5-86 Side Reg SNR OFF H5-91 Staple Fail H5-95 Move SNR ON H5-96 Move SNR OFF

Engine Error

14 6 29 3 3 3 3 3 3 3 5 5 5 5 3 3 3 3 3 4 4 4

Jam Error

Go to Page

3-159 3-159 3-159 3-160 3-162 3-165 3-168 3-170 3-168 3-170 3-172 3-172 3-174 3-174 3-176 3-176 3-178 3-178 3-181 3-184 3-185 3-185

Tray 6 Logic Board Failure Tray 6 Logic Board Failure

Tray 4-5 Logic Board Failure Tray 4-5 Logic Board Failure Tray 4-5 Logic Board Failure Incorrect Tray 4-5 Unit Installed

Tray 2 Failure Tray 3 Failure Tray 4 Failure Tray 5 Failure

Replace Toner Cartridge J1-2 Toner Empty - - 3-197

Install or Reseat Drum 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 Drum Cartridge Failure Non-Xerox Drum Cartridge

H6-4 NVM R/W Error H6-7 HCF Comm Failure

H7-3 NVM out-of-order H7-4 NVM R/W Error H7-7 Comm Failure H7-8 Type Error

H8-1 Tray 2 Size Sensor Broken H8-2 Tray 3 Size Sensor Broken H8-3 Tray 4 Size Sensor Broken H8-4 Tray 5 Size Sensor Broken

J3-1 Drum not installed - - 3-199

J7-1 DRUM Comm Error J7-2 DRUM NVRAM Error J7-3 DRUM type mismatch

13 13

12 12 12 28

11 10 9 8

16 16

3-187 3-188

3-189 3-189 3-190 3-191

3-193 3-193 3-194 3-194

3-201 3-200 3-200

3-18 Phaser 5500 Printer Service Manual

Page 97

Error Message Summary (Continued)

Engine

Front Panel Message Service Diagnostics Message

Install or Reseat Toner Cartridge Toner Cartridge Failure Replace Incorrect Toner Cartridge Non-Xerox Toner Cartridge

Toner Is Low Toner Low - - 3-206

Drum Cartridge Near End of Life

No Paper in Tray No Paper in Tray 2 or 3

Paper Size Jam Paper Size in Tray 2 or 3

Drum Cartridge Failure Temperature Sensor Failure Humidity Sensor Failure

J8-1 Toner Comm Error

J8-2 Toner Cart. read/write error J8-3 Toner Cart. type mismatch

DRUM Life Near End. - - 3-207

No Paper in Tray 4 or 5 No Paper in Tray 6

Paper Size in Tray 4 or 5 Paper Size in Tray 6

DRUM ATC Value Out of Range Temperature Value Out of Range Humidity Value Out of Range

Error

17 18

Jam Error

- 3-208

- 3-212

- 3-218

Go to Page

3-204

3-204 3-205

3-205

3-209 3-211

3-214 3-217

3-219 3-219

Standard Output Tray is Full Face down Tray 1 full

Face down Tray 2 full

Stacker Upper Tray is Full Finisher Tray Paper Full - - 3-222

Stacker Lower Tray is Full Finisher Mix Full Stack - - 3-223

Stapler is Empty Staple Pin Warning - - 3-225

Stapler Cartridge is Low Staple Pin Misfeed - - 3-226

Staple Failure Staple Failure - - 3-228

Finisher Stacker set over count

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

Staple Set Over Count - - 3-229

- 3-220 3-220

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

Error Messages, Codes, and Procedures 3-19

Page 98

Error Message Summary (Continued)

Engine

Front Panel Message Service Diagnostics Message

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 Life

Replace Maintenance Kit - - 3-250

Invalid Configuration Card - - 3-250

Configuration Card Missing - - 3-250

Duplicate IP address detected - - 3-251

Error

- - 3-250

Jam Error

Go to Page

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 “Ye s” 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.

3-20 Phaser 5500 Printer Service Manual

Page 99

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 232–1 to P/J 210–5 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

Error Messages, Codes, and Procedures 3-21

Page 100

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

Cycle printer power.

Does READY TO PRINT appear on the Front Panel Within 1 minute?

Does the printer display an error

message or code?

Is the Front Panel LCD/LED Display

defective, or the buttons inoperable?

Run Test Prints from all input trays:

1. In the Main Menu, select

Troubleshooting and press OK.

2. Select Print Quality Problems and press OK.

3. Select Test Prints and press OK.

Does the printer display an error message or code while printing?

Do the test prints print? Go to Step 6. Go to Step 7.

Evaluate the test prints.

Does the print quality meet the print quality specifications?

Go to Step 4. Go to Step 2.

Go to the procedure for that error or code.

Go to Front Panel Troubleshooting page 4-4.

Go to the procedure for that error message or code.

Go to Step 8. Go to “Print-Quality

Go to Step 3.

Go to Step 4.

Go to Step 5.

Troubleshooting” on page 5-2.

Enter Service Diagnostics and generate

Test Prints from all input trays.

Do the test prints print?

Request the customer send a print job

from their application.

Did the job print successfully?

Go to “Image Processor Isolation” on

page 4-13.

Problem solved; return to Final Checkout in the Service Flowchart.

Go to “Inoperative Printer”

Go to “Network Problems” page 4-2.

page 4-10.

3-22 Phaser 5500 Printer Service Manual

Fuji Xerox Phaser 5500 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual