24713694-Phaser-5500-Series-Book1 | Electrostatic Discharge | Electrical Engineering

Phaser 5500 Laser Printer

Service Manual Book 1 - Print Engine

Warning The following servicing instructions are for use by qualified service personnel only. To avoid personal injury, do not perform any servicing other than that contained in the operating instructions, unless you are qualified to do so. First Printing: August 2004 071-0873-00

Copyright
Copyright © 2004 Xerox Corporation. All Rights Reserved. Unpublished rights reserved under the copyright laws of the United States. Contents of this publication may not be reproduced in any form without permission of Xerox Corporation. Copyright protection claimed includes all forms of matters of copyrightable materials and information now allowed by statutory or judicial law or hereinafter granted, including without limitation, material generated from the software programs which are displayed on the screen such as styles, templates, icons, screen displays, looks, etc. XEROX®, The Document Company®, the stylized X®, CentreWare®, infoSMART®, Made For Each Other®, Phaser®, PhaserSMART®, and Walk-Up™ are trademarks of Xerox Corporation in the United States and/or other countries. Adobe® Reader®, Illustrator®, PageMaker®, Photoshop®, PostScript®, ATM®, Adobe Brilliant® Screens, Adobe Garamond®, Adobe Jenson™, Birch®, Carta®, IntelliSelect®, Mythos®, Quake®, and Tekton® are trademarks of Adobe Systems Incorporated in the United States and/or other countries. Apple®, AppleTalk®, LaserWriter®, LocalTalk®, Macintosh®, Mac OS®, TrueType®, Apple Chancery®, Chicago®, Geneva®, Monaco®, New York® , and QuickDraw® are trademarks of Apple Computer, Inc. in the United States and/or other countries. PCL® and HP-GL® are trademarks of Hewlett-Packard Corporation in the United States and/or other countries. IBM® is a trademark of International Business Machines Corporation in the United States and/or other countries. Windows®, Windows NT®, and Wingdings® are trademarks of Microsoft Corporation in the United States and/or other countries. Novell®, NetWare®, NDPS®, NDS®, Novell Directory Services® , IPX™ , and Novell Distributed Print Services™are trademarks of Novell, Incorporated in the United States and/or other countries. Sun® and Sun Microsystems® are trademarks of Sun Microsystems, Incorporated in the United States and/ or other countries. UNIX® is a trademark in the United States and other countries, licensed exclusively through X/Open Company Limited. As an ENERGY STAR® partner, Xerox Corporation has determined that this product meets the ENERGY STAR guidelines for energy efficiency. The ENERGY STAR name and logo are registered U.S. marks.

This product uses code for SHA-1 written by John Halleck, which is being used with his permission. This product includes an implementation of LZW licensed under U.S. Patent 4,558,302.

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Phaser 5500 Printer Service Manual

Contents
Service Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii Product Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv Power Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv Electrostatic Discharge (ESD) Precautions. . . . . . . . . . . . . . . . . . . . . . . . xvi Service Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii Regulatory Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix Manual Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxi

1 General Information
Printer Introduction and Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Printer Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Parts of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Printer Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Hard Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Additional Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Exit 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Networking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 1000-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Stacker / Finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 2000-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Envelope Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Consumables and Routine Maintenance Items. . . . . . . . . . . . . . . . . . . . 1-10 Supply Life Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Printer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Physical Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Memory Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Operational Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Functional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Tray and Media Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Contents

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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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Phaser 5500 Printer Service Manual

Laser Unit Failure - U3-3 Laser Power . . . . . . . . . . . . . . . . . . . . 3-25 Laser Motor Failure - U3-5 Polygon Motor Rotation. . . . . . . . . . 3-26 Fuser Failure - U4-1 On Time . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Fuser Failure - U4-n Over Heat / Thermistor . . . . . . . . . . . . . . . . 3-29 Fuser Failure - U4-7 Cold Sagging . . . . . . . . . . . . . . . . . . . . . . . 3-30 Fan Failure - U4-9 Fan Defect . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 Toner Motor Failure - U5-1 Motor Rotation . . . . . . . . . . . . . . . . 3-33 Fan Failure - U5-9 Fan Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 Engine Logic Board Failure - U6-2, 3, 4, 5, 7 . . . . . . . . . . . . . . . 3-35 Paper Size Jam - E1-1 Regi Area Jam. . . . . . . . . . . . . . . . . . . . . 3-35 Jam at A - E1-2 Regi Area Jam . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 Jam at A - E1-6 Regi Area Jam . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 Jam at A - Fuser Area Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 Jam at A - E3-6 Fuser Area Jam . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 Jam at A - E4-1 Exit 2 Area Jam . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 Jam at E - E4-3 Exit 2 Area Jam . . . . . . . . . . . . . . . . . . . . . . . . . 3-44 Jam at E - E4-6 Exit 2 Area Jam . . . . . . . . . . . . . . . . . . . . . . . . . 3-47 Jam at E - E8-2 Duplex Area Jam . . . . . . . . . . . . . . . . . . . . . . . . 3-49 Jam at D and A - C6-1 Duplex Area Jam. . . . . . . . . . . . . . . . . . . 3-51 Jam at D and A - C6-2 Duplex Area Jam. . . . . . . . . . . . . . . . . . . 3-53 Jam at Tray n - Pre-Feed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 Jam at Tray n - Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59 Jam at Tray n - Feed Out #3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61 Jam at Tray n - Feed Out #4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63 Jam at Tray 5 - C4-0 Tray 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65 Jam at Tray 6 - C5-1 Tray 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68 Jam at Tray 6 - C5-2 Tray 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71 Jam at B - C5-3 Tray 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73 Jam at B - C8-2 F/O3 SNR Static Jam. . . . . . . . . . . . . . . . . . . . . 3-76 Jam at C - C8-3 F/O4 SNR Static Jam. . . . . . . . . . . . . . . . . . . . . 3-77 Jam at C - C8-4 F/O5 SNR Static Jam. . . . . . . . . . . . . . . . . . . . . 3-78 Jam at Tray 6 - C8-5 HCF F/O SNR Static Jam . . . . . . . . . . . . . . 3-79 Jam at D - C8-6 Duplex. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83 Jam at Tray 1/MPT - C9-3 Tray 1/MPT . . . . . . . . . . . . . . . . . . . . 3-84 Jam at A - F4-12 H-X’port Ent. SNR ON . . . . . . . . . . . . . . . . . . . 3-87 Jam at A or F - F4-n H-X’port Ent. SNR Static. . . . . . . . . . . . . . . 3-89 Jam at A or F - F4-n H-X’port Exit SNR ON. . . . . . . . . . . . . . . . . 3-91 Jam at F - F4-26 H-X’port Exit SNR Static . . . . . . . . . . . . . . . . . 3-93 Jam at F - F4-32 X’port Ent. SNR ON . . . . . . . . . . . . . . . . . . . . . 3-95 Jam at F - F4-36 X’port Ent. SNR Static . . . . . . . . . . . . . . . . . . . 3-98 Jam at G - F4-4n Buffer Path SNR ON . . . . . . . . . . . . . . . . . . . 3-101 Jam at G - F4-4n Buffer Path SNR Static . . . . . . . . . . . . . . . . . 3-106 Jam at F or H - F4-5n Compile Exit SNR OFF . . . . . . . . . . . . . . 3-109 Jam at F or G - F4-5n Compile Exit SNR ON . . . . . . . . . . . . . . . 3-112 Jam at H - F4-56 Compile Exit SNR Static . . . . . . . . . . . . . . . . 3-115 Jam at H - F4-61 Set Eject Jam. . . . . . . . . . . . . . . . . . . . . . . . . 3-118

Contents

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Jam at H - F4-66 Compile Paper SNR Static . . . . . . . . . . . . . . Jam at F or G - F4-7n Top Tray Exit SNR ON . . . . . . . . . . . . . . Jam at F or Stacker Upper Tray - F4-7nTop Tray SNR OFF . . . Jam at F or G - F4-7n Top Tray Exit SNR Static . . . . . . . . . . . . Jam at F - F4-82 Gate SNR ON. . . . . . . . . . . . . . . . . . . . . . . . . Jam at F or G - Gate SNR Static Jam (Upper Tray) . . . . . . . . . Jam at F or G - Gate SNR Static Jam (Lower Tray) . . . . . . . . . Tray n Failure - H1 -1/2/3/4 Tray n Fail. . . . . . . . . . . . . . . . . . . Tray 6 Failure - H1-5 Tray 6 Fail. . . . . . . . . . . . . . . . . . . . . . . . Duplex Unit Failure - H2-7 Duplex Comm Failure. . . . . . . . . . . Incorrect Duplex Unit Installed - H2-8 Duplex Type Error . . . . Exit Unit Failure - H3-n Offset Error . . . . . . . . . . . . . . . . . . . . . Exit Unit Failure - H3-7 Exit Board Comm Failure. . . . . . . . . . . Tray 1/MPT Paper Guide Does Not Match Size Menu . . . . . . . Tray Paper Guide Does Not Match Size Menu -H4-1/2. . . . . . . Tray Paper Guide Does Not Match Size Menu -H4-3/4. . . . . . . Finisher Board Failure - H5-4, 7, 8 NVM/Comm/Type Error . . . Stacker Lower Tray Failure - H5-11 Low Tray Fail . . . . . . . . . . Stacker Lower Tray Failure - H5-12 Low Tray Upper Limit . . . Stacker Lower Tray Failure - H5-13 Low Tray Lower Limit . . . Stacker Lower Tray Failure - H5-2n Front Home SNR . . . . . . . Stacker Lower Tray Failure - H5-2n Rear Home SNR. . . . . . . . Punch Failure - H5-3n SNR . . . . . . . . . . . . . . . . . . . . . . . . . . . Punch Failure - H5-3n Home SNR . . . . . . . . . . . . . . . . . . . . . . Stacker Lower Tray Failure - H5-8n Eject Clamp SNR . . . . . . . Stacker Lower Tray Failure - H5-8n Set Clamp SNR . . . . . . . . Stacker Lower Tray Failure - H5-86 Side Regi SNR OFF . . . . . Stapler Failure - H5-91 Staple Fail . . . . . . . . . . . . . . . . . . . . . . Stapler Failure - H5-9n Move SNR . . . . . . . . . . . . . . . . . . . . . . Tray 6 Logic Board Failure - H6-4 NVM R/W Error . . . . . . . . . Tray 6 Logic Board Failure - H6-7 HCF Comm Failure . . . . . . . Tray 4-5 Logic Board Failure - NVM. . . . . . . . . . . . . . . . . . . . . Tray 4-5 Logic Board Failure - H7-7 Comm Failure . . . . . . . . . Incorrect Tray 4-5 Installed - H7-8 Type Error . . . . . . . . . . . . . Tray N Failure - H8-1, 2 Tray Size Sensor Broken . . . . . . . . . . Tray N Failure - H8-3, 4 Tray Size Sensor Broken . . . . . . . . . . Toner Empty- J1-2 Toner Empty . . . . . . . . . . . . . . . . . . . . . . . No Drum Cartridge - J3-1 Drum Not Installed . . . . . . . . . . . . . Drum Cartridge Failure - J4-1 ATC SNR Defect . . . . . . . . . . . . Replace Drum Cartridge - J6-1 DRUM End of Life . . . . . . . . . . Drum Cartridge Failure - J7-n Comm/NVRAM/Type Error . . . . Replace Incorrect Drum Cartridge - J7-3 DRUM Mismatch . . . Toner Cartridge Failure - J8-n Toner Comm/Read/Write . . . . . Replace Incorrect Toner Cartridge - J8-3 Toner Mismatch . . . Toner Is Low - Toner Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drum Cartridge Near End of Life - DRUM Life Near End . . . . .

3-121 3-123 3-126 3-129 3-131 3-135 3-138 3-141 3-144 3-148 3-149 3-150 3-152 3-154 3-155 3-157 3-159 3-160 3-162 3-165 3-168 3-170 3-172 3-174 3-176 3-178 3-181 3-184 3-185 3-187 3-188 3-189 3-190 3-191 3-193 3-194 3-197 3-199 3-200 3-200 3-201 3-203 3-204 3-205 3-206 3-207

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Phaser 5500 Printer Service Manual

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

4 General Troubleshooting
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Network Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Operating System and Application Problems . . . . . . . . . . . . . . . . . . . . . . 4-2 Macintosh Printing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Windows Printing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Front Panel Display Error/Inoperable Buttons . . . . . . . . . . . . . . . . . . . . . 4-4 Low Voltage Power Supply Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 4-5 Print Engine LVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Finisher LVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 AC Power Supply Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Verifying AC Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

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Print Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inoperative Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Logic Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Image Processor Board Isolation. . . . . . . . . . . . . . . . . . . . . . . . Image Processor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RAM Memory Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10 4-10 4-12 4-13 4-14 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

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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

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Option Interface Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exit 1 Top Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upper Transportation and Registration . . . . . . . . . . . . . . . . . . . . . . . . . Paper Size Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tray 2 Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tray 3 Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feed/Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tray 2 and 3 No Paper Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . Tray 2 and 3 Level Sensor Actuator . . . . . . . . . . . . . . . . . . . . . . Tray 2 and 3 Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tray 2 and 3 Pre-Feed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . Feed Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Retard Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nudger Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tray 1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tray 1 Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tray 1/MPT No Paper Sensor Actuator . . . . . . . . . . . . . . . . . . . Tray 1/MPT No Paper Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . Pick Up Gear Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tray 1 Pick Up Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cam Gear Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feed Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Retard Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lower Transportation and Registration . . . . . . . . . . . . . . . . . . . . . . . . . Take Away Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door B Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Take Away Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door A Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Registration Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Registration Transport Assembly. . . . . . . . . . . . . . . . . . . . . . . . Registration Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Registration Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Take Away Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feed Out Sensor 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Xerographics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drum Cartridge Fan Intake Duct. . . . . . . . . . . . . . . . . . . . . . . . . Drum Cartridge Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuser Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drum Cartridge Detect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . Environmental Sensor PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drum Cartridge CRUM PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . Toner Cartridge CRUM PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . Toner Dispense Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-17 8-18 8-19 8-19 8-20 8-21 8-23 8-24 8-25 8-27 8-28 8-29 8-30 8-31 8-32 8-32 8-33 8-34 8-35 8-36 8-36 8-38 8-39 8-40 8-40 8-41 8-41 8-43 8-44 8-45 8-46 8-46 8-49 8-51 8-52 8-53 8-54 8-56 8-56 8-58 8-59 8-60 8-64 8-70 8-71 8-71

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Toner Dispense Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-73 Laser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-74 Fuser and Exit 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-76 Fuser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-76 Fuser Exit Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-77 Exit Transport Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-78 Exit 1 Offset Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-80 Offset Home Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-81 Full Stack Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-82 Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-83 Main Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-83 Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-84 Print Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-86 High Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-86 Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-86 Exit PWB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-88 Engine Logic Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-89 Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-90 Image Processor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-91 Low Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-92 AC Accessory Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-93 GFI Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-94

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

10 Wiring Diagrams
Print Engine Plug/Jack Designators . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 Plug/Jack Locator Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 Drum and Toner Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 Laser Assembly and Exit PWB . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7 Fuser and Exit 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 Tray 1/MPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9 Registration Transport Assembly . . . . . . . . . . . . . . . . . . . . . . . 10-10 Tray 2 & 3 Feeder Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . 10-11 Print Engine Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 Engine Logic Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13 Image Processor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14 AC Accessory Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15 LVPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16 Print Engine Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17 Notations Used in Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . 10-17 Print Engine General Wiring (1/2). . . . . . . . . . . . . . . . . . . . . . . 10-19

Contents

xi

Print Engine General Wiring (2/2) . . . . . . . . . . . . . . . . . . . . . . LVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Registration Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Xerographics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive/CRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tray 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tray 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tray 1/MPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Laser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exit 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Logic and Image Processor Board Interface. . . . . . . . . Image Processor Board (1/2). . . . . . . . . . . . . . . . . . . . . . . . . . Image Processor Board (2/2). . . . . . . . . . . . . . . . . . . . . . . . . .

10-20 10-21 10-22 10-23 10-24 10-25 10-26 10-27 10-28 10-29 10-30 10-31 10-32 10-33

A Reference
Phaser 5500 Laser Printer Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Service Diagnostics Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Service Diagnostic Tests and Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9 General Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9 Test Print Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10 Printer NVRAM Adjustments Menu . . . . . . . . . . . . . . . . . . . . . . A-10 Print Engine Motors/Fan Test Menu. . . . . . . . . . . . . . . . . . . . . . A-12 Duplex Unit Motor Tests Menu . . . . . . . . . . . . . . . . . . . . . . . . . A-12 Exit 2 Motor Tests Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13 Trays 4 & 5 Motor Tests Menu . . . . . . . . . . . . . . . . . . . . . . . . . A-13 Tray 6 Motor Tests Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13 Finisher Motor Tests Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-14 Print Engine Sensor/Switch Tests Menu . . . . . . . . . . . . . . . . . . A-15 Duplex Unit Sensor/Switch Tests Menu . . . . . . . . . . . . . . . . . . . A-16 Exit 2 Sensor/Switch Tests Menu . . . . . . . . . . . . . . . . . . . . . . . A-17 Tray 4 & 5 Sensor/Switch Tests Menu. . . . . . . . . . . . . . . . . . . . A-17 Tray 6 Sensor/Switch Tests Menu . . . . . . . . . . . . . . . . . . . . . . . A-18 Finisher Sensor/Switch Tests Menu. . . . . . . . . . . . . . . . . . . . . . A-19 Print Engine Solenoid/Clutch Tests Menu . . . . . . . . . . . . . . . . . A-20 Exit 2 Solenoid/Clutch Test Menu . . . . . . . . . . . . . . . . . . . . . . . A-21 Tray 4 & 5 Solenoid/Clutch Test Menu . . . . . . . . . . . . . . . . . . . A-21 Tray 6 Solenoid/Clutch Test Menu . . . . . . . . . . . . . . . . . . . . . . . A-21 Finisher Solenoid/Clutch Tests Menu. . . . . . . . . . . . . . . . . . . . . A-21 Controller NVRAM Access Menu . . . . . . . . . . . . . . . . . . . . . . . . A-22 Engine Logic Board Replacement Menu . . . . . . . . . . . . . . . . . . A-22 Finisher Board Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-23 Exit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-23 Mode Select Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-24

Index
xii Phaser 5500 Printer Service Manual

however. or print cartridge that is consumed. CAUTION. A note can provide additional information related to a specific subject or add a comment on the results achieved through a previous action. Accessory: A single component or assembly that may be added to a printer.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. it is NOT an option to the product. practice or condition that. results in injury or loss of life. and always read NOTE. toner. or destruction of. Warning A warning statement indicates an operating or maintenance procedure. Common Acronyms: FRU: Field Replaceable Unit PL: Corresponds to the FRU Parts List. Customer is expected to replace once consumed. Routine Maintenance Item: Supply item or kit that has a limited life. 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. Consumable: Ink. practice or condition that. Caution A caution statement indicates an operating or maintenance procedure. Be aware of all symbols and terms when they are used. if not strictly observed. if not strictly observed. results in damage to. Customer is expected to replace at end-of-life. and WARNING statements. Safety xiii . equipment.

Refer to the manual(s) for information. 00:40 Avoid pinching fingers in the printer. Symbols Marked on the Product DANGER high voltage.Product Terms Caution: A personal injury hazard exists that may not be apparent. The surface is hot while the printer is running. After turning off the power. Use caution to avoid personal injury. wait 40 minutes. Use caution to avoid personal injury. Use caution (or draws attention to a particular component). For example. Protective ground (earth) symbol. Hot surface on or in the printer. a panel may cover the hazardous area. Danger: A personal injury hazard exists in the area where you see the sign. xiv Phaser 5500 Printer Service Manual .

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

Electrostatic Discharge (ESD) Precautions Some semiconductor components. place it on a grounded conductive surface. and the respective sub-assemblies that contain them. Pay attention to the direction of parts when mounting or inserting them on Printed Circuit Boards (PCB’s). Do not use freon-propelled chemicals. If the anti-static bag is conductive. Large-Scale Integrated circuits (LSIs). Immediately before removing the protective material from the leads of a replacement device. Minimize body motions when handling unpackaged replacement devices. Be sure to remove the wrist strap before applying power to the unit under test to avoid potential shock. touch the protective material to the chassis or circuit assembly into which the device will be installed. ■ ■ ■ ■ ■ ■ ■ xvi Phaser 5500 Printer Service Manual . Wearing a wrist strap will also prevent accumulation of additional bodily static charges. and observe all other safety precautions. This can be accomplished by touching an earth ground source or by wearing a wrist strap device connected to an earth ground source. Be sure the power is off to the chassis or circuit board. These components include Integrated Circuits (ICs). drain the electrostatic charge from your body. field-effect transistors and other semiconductor chip components. ■ Immediately before handling any semiconductor components assemblies. are vulnerable to damage by Electrostatic discharge (ESD). Do not remove a replacement component or electrical sub-assembly from its protective package until you are ready to install it. These can generate electrical charges sufficient to damage some devices. 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. Motion such as your clothes brushing together. After removing a static sensitive assembly from its anti-static bag. The following techniques will reduce the occurrence of component damage caused by static electricity. you may ground the bag and use it as a conductive surface.

To avoid personal injury. Do not wear jewelry: Remove jewelry prior to servicing. As you service the printer. Throughout the printer. When servicing the printer or laser unit. If you bypass an interlock switch during a service call. A protective ground connection by way of the grounding conductor in the power cord is essential for safe operation. Disconnect power before removing the power supply shield or replacing components. use extreme caution when working on or around the printer. Department of Health and Human Services as a Class 1 Laser Product. 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. necklaces and other metallic objects could come into contact with dangerous voltages and currents. Use care when servicing with power: Dangerous voltages may exist at several points in this product. warning labels are displayed on potentially dangerous components. 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.Service Safety Summary General Guidelines For Xerox-certified service personnel only: Refer also to the preceding Power Safety Precautions. Safety xvii . follow the procedures specified in this manual and there will be no hazards from the laser. 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. Rings. CLASS 1 LASER PRODUCT The Phaser 5500 Laser Printer is certified to comply with Laser Product Performance Standards set by the U.S. Warning Labels Read and obey all posted warning labels. This means that this is a class of laser product that does not emit hazardous laser radiation. do not touch exposed connections and components while power is on. check to make certain that all warning labels remain in place. this is possible only because the laser beam is totally enclosed during all modes of customer operation.

be aware of the potential for electrical shock. rollers. and gears. You must also disconnect the printer power cord from the AC outlet. manually rotate drive assemblies.Servicing Electrical Components Before starting any service procedure. If you must service the printer with power applied. Warning Turning the power off by using the On/Off switch does not completely deenergize the printer. switch off the printer power and unplug the power cord from the wall outlet. S7300-02 Servicing Mechanical Components When servicing mechanical components within the printer. Warning Do not touch any electrical component unless you are instructed to do so by a service procedure. 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. Warning Do not try to manually rotate or manually stop the drive assemblies while any printer motor is running. S7300-03 Servicing Fuser Components Warning This printer uses heat to fuse the toner image to media. Position the power cord so that it is easily accessible during servicing. xviii Phaser 5500 Printer Service Manual . The Fuser is VERY HOT.

com/office/5500supplies. NMB-003. ICES-003. Operation is subject to the following two conditions: (1) this device may not cause harmful interference. If this equipment does cause harmful interference to radio or television reception. which can be determined by turning the equipment off and on. 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. use shielded interface cables. To ensure compliance. Route the interface cables on the printer away from the receiver Consult the dealer. ■ ■ 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. In the United States this product complies with the requirements of an unintentional radiator in part 15 of the FCC rules. If it is not installed properly in strict accordance with Xerox instructions.xerox. Xerox service. Xerox has tested this product to internationally accepted electromagnetic emission and immunity standards. including interference that may cause undesired operation. (2) this device must accept any interference received. Connect the printer into an outlet on a circuit different from that which the receiver is connected. Increase the separation between the printer and the receiver. 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). it may cause interference with radio and television reception or may not function properly due to interference from another device.Regulatory Specifications Federal Communications Compliance The equipment described in this manual generates and uses radio frequency energy. Safety xix . or an experienced radio/television technician for help. However. 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. This product is also suitable for use in a residential environment based on the levels tested. there is no guarantee that interference will not occur in a particular installation. A shielded parallel cable can be purchased directly from Xerox at www. These standards are designed to mitigate interference caused or received by this product in a normal office environment.

xx Phaser 5500 Printer Service Manual .Section 3: Limitation of voltage fluctuations and flicker in low-voltage supply systems for equipment with rated current less than or equal to 16A.Section 2: Limits for harmonic current emissions (equipment input current less than or equal to 16A per phase). A signed copy of the Declaration of Conformity for this product can be obtained from Xerox.” Class B. “ This product. “Part 3: Limits .Immunity characteristics . declares.” “Information technology equipment . if used properly in accordance with the user's instructions is neither dangerous for the consumer nor for the environment.” “Part 3: Limits .Declaration of Conformity Xerox Corporation. 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.Limits and methods of measurement. under our sole responsibility that the printer to which this declaration relates.

Chapter 2 . and wiring diagrams of print engine components. and Regulatory Information: This section contains important safety information. maintaining. This section provides complete troubleshooting information for the print engine and all it’s options. Book 1 describes printer specifications. and consumable. 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. Book 1. This volume. Chapter 4 . Chapter 3 . specifications. and information about this manual. Use Book 2 after you’ve isolated a problem internal to a specific option or when a problem arises at the engine/option interface. Chapter 5 .Cleaning and Maintenance: This section provides periodic cleaning procedures for the printer. Book 1 contains these sections: Introductory.Print Engine Use Book 1 as your primary resource for understanding the operational characteristics of the print engine. LED indicators. and wiring diagrams. Safety. theory and includes information important to the diagnosis and repair of problems occurring in the print engine and attached options.Theory of Operation: This section contains detailed functional information on print engine components.Print-Quality Troubleshooting: This section focuses on techniques to correct image quality problems associated with printer output.General Troubleshooting: This section provides troubleshooting methods for situations where no error indicator is available. The manual is organized into two books. Chapter 6 . These diagnostics include Power On Self Test (POST). parts lists. option Field Replaceable Unit (FRU) replacement procedures. Chapter 7 . Book 1 also provides detailed print engine FRU replacement procudures. Safety xxi .Error Codes and Messages: This section describes the resident diagnostics available to assist the troubleshooting process.Adjustments and Calibrations: This section provides procedures for the adjustment of print engine components.Manual Organization The Phaser 5500 Laser Printer Service Manual is the primary document used for repairing. FRU parts lists. Service Diagnostics error codes and messages and Service Usage Profile data stored in the printer.General Information: This section contains an overview of the printer’s operation. regulatory requirements. Book 1 . configuration. Chapter 1 . and troubleshooting the printer.

Part numbers for printer options and accessories are also included. Chapter 4 . Chapter 9 .Theory of Operation: This section contains functional information on each option. and Regulatory Information: This section contains important safety information.Wiring Diagrams: This section contains option plug/jack locations and wiring diagrams. Book 2 . Book 2 includes information important for the repair or replacement of option components.Parts Lists: This section contains exploded views of the print engine FRUs as well as part numbers for items available as FRUs. xxii Phaser 5500 Printer Service Manual . and information about this manual. Chapter 3 . configuration.Chapter 8 . regulatory requirements. Chapter 1 . Chapter 10 .General Information: This section contains an overview of the options available.Wiring Diagrams: This section contains the plug/jack locations and the wiring diagrams for the print engine. Chapter 5 . as well as FRU part numbers. Appendix A .Options Use Book 2 as a reference when servicing printer options. A replacement procedure is included when necessary. Safety. Use the troubleshooting procedures in Book 1 to diagnose and isolated the problem.Parts Lists: This section contains exploded views of the option FRUs.FRU Disassembly: This section contains removal procedures for parts listed in the option’s Field Replaceable Units (FRUs) Parts List. Book 2 contains these sections: Introductory.Menu Maps: This section provides an illustration of the front-panel menu as well as a listing of the Service Diagnostics tests available. specifications and consumables. Chapter 2 .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.

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

An Envelope Tray. paper capacity and functionality. 500-sheet universal media trays (Trays 4 and 5).. 1-2 Phaser 5500 Printer Service Manual . s5500-006 The Phaser 5500 printer combines a dual-pass. a 3. The PCL5e. Service Bulletins. A 1000-Sheet Feeder is available with two. For models not originally equipped. larger format paper. see www. Tray 1 also supports manual feeding.500-sheet. each provide 500 sheets of capacity. A Configuration Card adds 100baseT Ethernet networking for host communication. Xerox certification for this product is required. Two additional trays. and envelopes are fed.Printer Introduction and Overview The Xerox Phaser 5500 Laser Printer Service Manual is the primary document used to repair. monochrome laser print engine with an image processor supporting Adobe’s PostScript 3 description language. Print speed is 50 pages per minute at either 600 x 600 or True 1200 x 1200 dpi in 1-sided or 2-sided modes.100 sheets. replacing Tray 2. Phaser 5500 printer options add memory.xerox. Tray 2 and 3. holds up to 35 envelopes. A 2000-Sheet Feeder (Tray 6) brings the maximum input capacity to 4. etc. and troubleshoot this printer. The printer features a bi-directional parallel interface and a USB port. contact your assigned Xerox Technical Support for this product. card stock. For further technical support. The Phaser 5500 printer provides a 100-sheet Tray 1/MPT from which specialty media. To ensure complete understanding of this product. proof print and secure print support. For manual updates. On the output side. The Standard Output Tray holds 500 sheets face down. storing print files. high-capacity stapler/punch/stacker is available raising the output total to 4000 sheets.0 printer languages are also supported. job collation.com/office/partners. an internal Hard Drive is available for font storage. To service this product. A selection of RAM memory upgrades are available to raise the installed quantity to the 512 MB maximum. knowledge base. PCL6 and Oak PCL 5. maintain. participation in Xerox Phaser 5500 Laser Printer Service Training is strongly recommended.

Parallel Ethernet Capabilities 1000-Sheet Feeder Automatic 2-Sided Printing (Requires Duplex Unit) Hard Drive Job Collation (Hard Drive Required) Proof Print. Printer Configurations Features 5500B Maximum Print Speed (Letter-size Paper) Memory PostScript Fonts Oak PCL 5. Saved Jobs (Hard Drive Required) 2. Personal Print.Printer Configurations The following table lists the features of the five Phaser 5500 printer configurations.500-Sheet Finisher (Requires 1000-Sheet Feeder) 50 ppm 5500N 50 ppm 5500DN 50 ppm 5500DT 50 ppm 5500DX 50 ppm 128 MB 137 Yes Yes Yes Yes 600 or True 1200 dpi 128 MB 137 Yes Yes Yes Yes 600 or True 1200 dpi 128 MB 137 Yes Yes Yes Yes 600 or True 1200 dpi 128 MB 137 Yes Yes Yes Yes 600 or True 1200 dpi 256 MB 137 Yes Yes Yes Yes 600 or True 1200 dpi Yes Optional Optional Optional Yes Standard Optional Optional Yes Standard Optional Standard Yes Standard Standard Standard Yes Standard Standard Standard Optional Optional Optional Optional Optional Optional Optional Optional Standard Standard Optional Optional Optional Optional Standard Optional Optional Optional Optional Standard Optional Optional Optional Optional Standard General Information 1-3 .0 PCL5e/PCL6 Job Pipelining PDF Direct Print Resolutions USB.000-Sheet Feeder (Requires 1000Sheet Feeder) 3. Secure Print.

Finisher 9. Parallel Connection 2.Duplex Unit Connector 9 7 8 10 1-4 Phaser 5500 Printer Service Manual . Tray 2 and 3 4. 1000-Sheet Feeder (Tray 4 & 5) 8. Configuration Card 5.1000-Sheet Feeder Connection 11.Stacker Upper Tray 7 6 2 5500-107 Rear View 1. USB Connection 4. Tray 1/MPT 5 6. Standard Output Tray 2.Parts of the Printer Front View 4 1 8 10 1. Stacker Lower Tray 10. Serial Debug Port 7. Printer Power Connection 1 2 11 3 5 6 4 s5500-017 9. Ground Fault Interrupt Reset 8. Ethernet Connection 3. 2000-Sheet Feeder (Tray 6) 9 3 7. Finisher Connection 10. Optional Duplex Unit 5. Front Door 3. Mode Select Port 6.

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

Also available is 16 MB of Flash Memory for fonts.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 Finisher (with hole punch.500-Sheet Stacker (with offset) 3. This option provides a replacement card to enable Ethernet on the base model (Phaser 5500B printer). When used in conjunction with the Duplex Unit. Exit 2 Exit 2 is required when either the Duplex Unit or Stacker/Finisher is installed. and Secure Print options. offset) 2. forms.000-Sheet Feeder (Tray 6) Envelope Tray (replaces Tray 2) Hard Drive A 20 GB hard drive is available to enable the Job Collation. Proof. The Startup Page and Configuration Page list the amount of installed RAM. 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. See “Memory Specifications” on page 1-11. 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. With the Stacker/Finisher. Saved Jobs. and macros. 1-6 Phaser 5500 Printer Service Manual . Exit 2 performs as a paper inverter. Personal. Networking A Configuration Card is used to enable or disable networking capabilities. staple. Both RAM and NVRAM options install to the Image Processing board.

Installation of the Duplex Unit requires that the Exit 2 Module also be added to provide reverse drive. The sheet feeder is secured to the print engine with two screws located under the front edge of Tray 3.1000-Sheet Feeder The 1000-Sheet Feeder forms a base for the printer and adds two. Electrical connection to the printer is made by an interface cable. s5500-012 Duplex Unit The Duplex Unit adds two-sided printing. E A D s5500-008 General Information 1-7 . The Duplex Unit attaches to the left side above Tray 1 using two twist locks. 500-sheet trays (Tray 4 and Tray 5). Control signals reach the sheet feeder by a single connection.

Stacker/Finisher 1-8 Phaser 5500 Printer Service Manual . the top surface of the Horizontal Transport serves as the top tray and paper output capacity remains at 500 sheets. With Exit 2 installed. Control signals reach the Stacker/ Finisher through a single connector.Stacker / Finisher The Stacker/Finisher increases the output capacity of the printer by 3. offset and stacked. 2 1 s5500-009 1. Printer output is directed to the Stacker/Finisher by way of Exit 1 and the Horizontal Transport. Horizontal Transport 2. stapled. Power is supplied from the printer’s AC Accessory Panel. Depending on the level of Stacker/Finisher options and job specifications.500 sheets. as paper enters the Stacker/ Finisher it is punched.

2000-Sheet Feeder The 2000-Sheet Feeder (Tray 6) nearly doubles the input capacity of the printer. s5500-013 Envelope Tray The Envelope Tray replaces Tray 2 to handle up to 35 envelopes. s5500-014 Caution To avoid damage to the Envelope Tray. 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. General Information 1-9 . Electrical connection to the printer is made by an interface cable. use the Tray 2 position only.

000 300. a Toner Gauge is provided on the Front Panel that approximates the Toner Cartridge counter value.000 1-10 Phaser 5500 Printer Service Manual . Print life ratings are based on 5% coverage and an average job length of 6 pages. Transfer Roller 3. warning messages appear on the Front Panel. Transfer Roller and 15 Feed Rollers) 300.000 Print Life (Number of Images) 30. Consumables Toner Cartridge Routine Maintenance Items Fuser Drum Cartridge Maintenance Kit (consists of Fuser. Access the current status of these counters from the Supplies Info menu. In addition to the counters. As counters near their minimums. Drum Cartridge 4.000 60. Toner Cartridge s5500-010 Supply Life Counters Counters track the usage of the consumables and routine maintenance items and store the values in NVRAM. Fuser 2.Consumables and Routine Maintenance Items 1 3 4 E 2 1.

Printer Specifications Physical Dimensions Device Print Engine Duplex Unit 1000-Sheet Feeder Stacker/ Finisher Exit 2 Envelope Tray 2000-Sheet Feeder Height 498 mm (19.) with Finisher 460 mm (18.) 520 mm (21.) 1.7 in.1 in.) 740 mm (29.) 363 mm (14.) 76 mm (3.0 in.1 in.2 in.0 in.) 3.) 521 mm (20. All combinations are allowed for configurations of 128. and 512 MB.) 650 mm (25.2 in.0 in.1 in.3 in.) 1050 mm (41.) Depth 525 mm (20.).) 460 mm (18.) 280 mm (11.3 in.6 in. 1000 mm (39. Single chip of either PPROM or StrataFlash 16 MB Operational Clearances Clearance Top Left Right Front Rear Height requirement Specification 890 mm (35.) 2 kg (4. 256.2 kg (7 lbs.0 in.) 49 kg (108 lbs.) Width 640 mm (25. 384.) 200 mm (7.) 640 mm (25.) 600 mm (23.) 142 mm (5.52 in.) 64 mm (2.2 in.) 130 mm (5.4 in.) Memory Specifications Characteristic Minimum RAM Maximum RAM Supported RAM NVRAM Specification 128 MB 512 MB SO-DIMM 144-pin module of 128 or 256 MB.9 in.5 in.) 538 mm (21.) 50 kg (110 lbs.9 in.4 lbs.) 385.1 in.8 kg (4 lbs.5 mm (15.) 458 mm (18.) 540 mm (21.2 in.) General Information 1-11 .) Weight 41 kg (90 lbs.1 in.) 23 kg (50 lbs.0 in.) 1190 mm (47.3 in.) 200 mm (7.) 211 mm (8.1 in.6 in.6 in.6 in.

) 46 cm (18 in.) s5500-610 1-12 Phaser 5500 Printer Service Manual .) 20 cm (8 in.) 20 cm (8 in.) 119 cm (47 in.) 20 cm (8 in.) 46 cm (18 in.) 118 cm (46 in.) 218 cm (86 in.) 100 cm (39 in.) 65 cm (26 in.) 120 cm (47 in.) 118 cm (46 in.89 cm (35 in.) 46 cm (18 in.

@ 240 V 100 A max. simplex or duplex 45 sec. @ 120 V. min. 198 V. 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 600/ True 1200 dpi Two choices: 600 x 600 dpi True 1200 x 1200 dpi Resolution / Addressability Print-Quality Modes Continuous Operating Printing Speed Warm-Up Time: Sleep Mode Stand By 50 pages per minute for plain Letter paper. max. 1300 W max. simplex or duplex 50 pages per minute for A4 paper. min. 99 V. Electrical Specifications Characteristic Primary Line Voltages Primary Line Voltage Frequency Range Input Current: Operating Rush Power Consumption: Operating (5500DX) Sleep Mode BTU’s at 120V: Specification 120 VAC nominal. 254 V 50/60 Hz ± 3 Hz 12 A max. 6 sec. @ 240 V 10 W max @ 120/240 V Operating 3924 Power Saver 34 Operating 4436 Power Saver 34 BTU’s at 240V: General Information 1-13 . 135 V 220/240 VAC nominal. 1150 W max. max.Functional Specifications Characteristic Printing process: Specification Recording System: Electrophotography (roller charging. @ 120 V 8 A max.

200) feet) 0 to 15.1 x 9. Edge-to-edge printing supported.5. Supported Media Weights Tray Capacity 1-14 Phaser 5500 Printer Service Manual . 500 in top tray Based on 75 g/m2 (20 lb. COM-10 (4.5 in.) Monarch (3.) paper stock. Capacity is reduced for heavier/thicker stock.000 meters (49.Environmental Specifications Characteristic Temperature: Operating Transportation Humidity (%RH) Operating Transportation Altitude Operating Transportation* Acoustic Noise LWA(B) Standby Printing Specification 5 to 32° C (41 to 95° F) -20 to 40° C (-4 to 104° F) 15 to 85 5 to 85 0 to 2.4.200 feet) Engine only 4.1 B Bystander Position 22 db 54 db * Air transportation in pressurized cargo space Tray and Media Specifications Tray Specifications Characteristic Printable Area Supported Envelopes Trays All Tray 1 or Tray 2 (with Envelope Tray installed) Tray 1. bond to 133 lb.0 B 7.8 x 7.500 meters (8. 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.3.6 Tray 2 Duplex Tray 1 Tray 2 Tray 3 Tray 4 Tray 5 Tray 6 Top (face-down) Stacker/Finisher Specifications Within 4 mm of paper edge guaranteed. card stock) 60-105 g/m2 (16 to 28 lb.5 in) DL (110 x 220 mm) C5 (162 x 229 mm) 60-216 g/m2 (16 lb.

3.12 x 9.) Monarch (3.27 in. Paper Size Letter (8.5 in.25 x 10.) A6 (105 x 148 mm) Tabloid (11. 11.0 x 17.5 x 11 in. 4 ▲ ▲ ▲ 2 ▲ ▲ ◆ ▲ ▲ 2.5 in. (267 mm). finishers are configured with either a 3-hole punch or a 2-hole and 4-hole punch.) 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. 4 ▲ ▲ ▲ 2 ▲ ▲ ◆ ▲ 2 ▲ ▲ ◆ ■ ● ● ● ● ● ● ● ■ ■ ■ ▲ ▲ ▲ General Information 1-15 Staple These custom widths are supported with stapling and hole punching: 210 mm (8. 10.) Large US Postcard (4.70 Holes Punched Depending on your region.0 x 6.5 x 5.5 x 14 in. 8.).5 x 8.) US Folio (8.Supported Paper Specifications Paper Sizes and Weights ■ User-Selected Size ● Auto-Sensed Size Input Output ▲ Supported ◆ Supported only when Long-Edge Feed Standard Output Tray Stacker Lower Tray Stacker Upper Tray 2-Sided Printing Tray 1/MPT Tray 2 in.) Executive (7.00 in.87 x 7. Tray 3-5 Tray 6 Envelope Tray .12 in.) A4 (210 x 297 mm) Legal (8. 297 mm (11.) Small US Postcard (3.50 in.0 in.) DL (110 x 220 mm) C5 (162 x 229 mm) C4 (229 x 324 mm) ■ ■ ■ ■ ■ ■ ■ ● ● ● ● ● ● ● ● ● ● ▲ ▲ ▲ ▲ ▲ ▲ ▲ 2.5 x 13 in.). (279 mm). (216 mm). 4 ▲ ▲ ◆ ■ ■ ■ ■ ■ ■ ▲ ▲ ▲ ▲ ▲ ▲ ▲ 2.). 3.5 in.5 in. 3.50 in. 257 mm (10.0 in.5 in.) A5 (148 x 210 mm) Statement (5.

82–9.) 140–182 mm (5.00 in.00 in.00–7. finishers are configured with either a 3-hole punch or a 2-hole and 4-hole punch.16–17.16–17.50 in.50 in.50–5.) ■ ▲ ▲ ▲ ■ ■ ■ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ■ ■ ▲ ▲ ▲ ■ ■ ■ ■ ■ ■ Envelope Custom Width / Envelope Custom Height 148–241 mm (5.70 in.87–5. 8.27 in.).)/ 127–182 mm (5.38 in.)/ 182–432 mm (7. Bond) ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ 1-16 Phaser 5500 Printer Service Manual Staple These custom widths are supported with stapling and hole punching: 210 mm (8.70 in.) ■ ▲ Paper Weight 60–105 g/m2 (16–28 lb.16–8.)/ 98–162 mm (3.)/ 182–432 mm (7.).16 in.) 182–210 mm (7.70 Holes Punched Depending on your region. (267 mm). Tray 3-5 Tray 6 Envelope Tray .) 89–140 mm (3.50–11. Custom Width / Custom Height 89–297 mm (3.)/ 98–127 mm (3. Bond) 120–176 g/m2 (32–47 lb. (216 mm).87–6.27–11.50–11. (279 mm).16 in.50–7.16–17.) 89–297 mm (3.).00 in.)/ 182–432 mm (7. Bond) 105–120 g/m2 (28–32 lb.70 in.) 210–297 mm (8. 297 mm (11. Bond) 176–215 g/m2 (47–57 lb.00 in.16–17.Paper Sizes and Weights (Continued) ■ User-Selected Size ● Auto-Sensed Size Input Output ▲ Supported ◆ Supported only when Long-Edge Feed Standard Output Tray Stacker Lower Tray Stacker Upper Tray 2-Sided Printing Tray 1/MPT Tray 2 in. 10.00 in.) 182–432 mm (7.00 in.12 in.50 in.27 in. 11. 257 mm (10.50 in.

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

paper capacity. Pressure Roller Heat Roller Fuser Cleaning Blade BCR Detack Saw Transfer Roller Drum Laser Beam Charge Metering Blade Magnetic Roller Paper s5500-015 Paper Transport Drum Cartridge 2-2 Phaser 5500 Printer Service Manual . 3500 sheet stapler/punch/stacker is available. On the output side. Phaser 5500 Printer Options Service Manual. holds up to 35 envelopes. This section focuses on the printer’s operational characteristics providing detailed descriptions of the paper path. and functionality. Operational details of the available options appear in Book 2. Phaser 5500 options add memory. A selection of memory upgrades can raise the installed RAM to the 512 MB maximum. monochrome laser print engine with a multi-purpose Tray 1/MPT and two universal media trays. Trays 4 and 5 (1000-Sheet Feeder) when installed. a 20 GB Hard Drive is available. trays 2 and 3.Phaser 5500 Operational Overview The Phaser 5500 base configuration combines a dual-pass. xerographics and major system assemblies. Additional paper capacity is also available. For models not originally equipped. An optional high-capacity 2000-Sheet Feeder (Tray 6) brings the maximum paper capacity to 4. add two 500-sheet universal media trays. sensors.100 sheets. 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. The Standard Output Tray holds 500 sheets facedown. An Envelope Tray. replacing Tray 2.

To pick paper. The negatively charged toner is transferred to the Areas of the drum surface that have been discharged. Theory of Operation 2-3 . 9. 3. Charge – The Drum Cartridge contains a Bias Charge Roller that uniformly distributes a negative electrical charge over the photoconductive drum surface. 6. A Wait Sensor in the Duplex Unit detects the presence of 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. Discharge – The Detack Saw. located on the Transfer Roller assembly. The Transfer Roller applies a positive charge to the rear surface of the paper. along with the paper stack. 5. 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. The Retard Roller prevents multipicks. The Fuser Exit Sensor detects paper exiting from the fuser. 10. 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. Transfer – The pressure of the Transfer Roller against the drum assists in driving the paper through the transfer area. The Toner Cartridge supplies toner to the Drum Cartridge. which feed the paper to the Registration Rollers. A DC motor raises the tray's lift plate. Exposure – The Laser Assembly scans the surface of the photoconductive drum located inside the Drum Cartridge. 2. against the Nudger Roller of the paper feeder assembly. neutralizing the negative charge to create one line of a latent image on the drum surface. The Feed Roller advances the paper to the Take Away Rollers. 7. helps to separate the paper by partially neutralizing the charge holding the paper to the drum. which uses heat and pressure rolls to melt and bond the toner onto the surface of the paper. 8. the latent charge pattern remaining on the photoconductive drum is neutralized to prepare the drum for the next Exposure cycle. Paper Exit – The paper is then advanced upward into the Exit Rollers and into the selected output tray. 11.000 pages at 5% area coverage. Movable actuators located in the paper tray indicate the location of the guides. The drum is rotated and the scan process is repeated. The negatively charged toner image on the drum is attracted to the positive charge on the rear surface of the paper. Fusing – The paper is driven into the Fuser. the Nudger Roller advances the top sheet to the Feed Roller and Retard Roller. Cleaning – A cleaning blade in the Drum Cartridge scrapes off toner remaining on the drum surface after Transfer has occurred. A multifaceted polygonal mirror is rotated at a specified speed. The Phaser 5500 uses a three-roller system to pick paper. The laser beams scan the drum surface from one end to the other. transfers the image from the surface of the drum onto the paper. Capacity is 30. 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 laser print process consists of these steps: 1. 4. Then. The Laser Diode Assembly produces dual laser beams which are turned on and off according to a data signal. Paper Transport – Paper size sensors determine the length and width of the media. The laser beams are reflected off of the mirror and onto the drum surface through a series of lenses and mirrors.

Registration Roller. Main Motor Gear Take Away Clutch Take Away Bracket Gear-18T Take Away Roller s5500-020 Pulley 25T Gear-Exit Gear-19T Regi Roller Fuser OCT Roller Feed Roller 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. drive the Take Away Roller. through the gear and pulley. Drum Motor Drum Transfer Roller Magnetic Roller s5500-021 2-4 Phaser 5500 Printer Service Manual . The operating system monitors sensors located along the paper path throughout the print engine and attached options. Synchronization of these components is managed by the Engine Logic Board. and Exit 1 OCT Roller. Main Motor The Main Motor. Fuser. gear assemblies and rollers. an error is reported.Paper Handling Paper is driven along the paper path by various drive motors. Feed Roller. sensors change state temporarily to indicate the sheet’s presence. belts. As a sheet travels along the paper path. If the pattern of sensor state changes differs from the expected timing for a particular paper size and path.

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. Tray 1/MPT Feed Roller Drive Roller Tray 2 Nudger Roller Feed Roller Retard Roller Feeder Assy Tray 3 Nudger Roller Feed Roller Retard Roller Feeder Assy Take Away Roller Registration Roller Transfer Roller Drum CRU Heat Roller Pressure Roller Fuser Invert Roller Face Up Roller OCT Roller Exit Pinch Roller Option Exit2+OCT2 Exit OCT Roller Exit Pinch Roller Exit1 Duplex A3L Roller Duplex Roller Option Duplex s5500-022 Theory of Operation 2-5 . Input Paper Path Paper supplied from each tray is transported through the printer along the paper path shown below.

When the Feed Roller contacts the paper. and Exit 2. a sheet is fed into the gap between the Feed Roller and the Pinch Rollers. the Duplex Unit. 2-6 Phaser 5500 Printer Service Manual . Exit 1. 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.The diagram shows the paper path for Trays 1 through 5. Face Up Roller Invert Roller Exit 2 Duplex Unit A3L Rollers Pressure Roller Duplex Roller Pinch Rollers Heat Roller Transfer Roller Drum Registration Pinch Roller Registration Roller Tray 2 Nudger Rollers Exit Pinch Rollers OCT Rollers Feed Roller Pinch Roller Drive Roller Tray 3 Pinch Rollers Tray 4 1000 Sheet Feeder Tray 5 Take Away Rollers Feed Rollers Retard Rollers s5500-233 Tray 1/MPT When feeding media from Tray 1/MPT. the control logic instructs the mechanical drive to activate the Feed Roller.

the Horizontal Transport to the Stacker Trays. 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 Feed Roller moves a single sheet of paper out of the tray and toward the tray’s Take Away Roller. Stacker Upper Tray Horizontal Transport Punch Stacker Lower Tray Exit 2 Exit 1 Compiler Tray Stapler s5500-024 Theory of Operation 2-7 . the Nudger Roller moves a sheet of paper to the Feed Roller. Shown below are the possible output paper paths.Trays 2 through 5 When the control logic calls for paper feed. 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. Inverted in Exit 2 back through the Duplex Unit then out Exit 1 or Exit 2. The Retard Roller ensures only one sheet of paper is fed. Inverted in Exit 2 back through the Duplex Unit then out Exit 1 to either the Stacker Upper or Lower Tray. Direct through Exit 2 to the Output Tray on the Horizontal Transport Cover. The paper then moves past the Pre-Feed Sensor and up the vertical path driven by a sequence of Take Away Rollers. The paper continues along the path until the sheet of paper arrives at the Registration Roller.

The Horizontal Transport motor is activated by Horizontal Transport PWB to drive the two feed belts running between the Left and Right Shaft assemblies. 500-sheet tray located on the printer’s Top Cover. To Finisher From Exit 1 Entrance Sensor Belt Exit Sensor s5500-025 2-8 Phaser 5500 Printer Service Manual . Horizontal Transport When either the Stacker Upper or Lower Trays are designated as the output location. The paper is held between the belts and pinch rollers located on the inside of Door F. the Exit 1 Exit Gate opens and paper is fed from Exit 1 to the Horizontal Transport.Standard Output Tray The Standard Output Tray is a face-down. 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.

Top Exit Rollers (Driven by Exit Motor) Transfer Gate Sub Paddle (Driven by Finisher Transport Motor) Eject Clamp (Driven by Eject Clamp Motor) Transfer Rollers (Driven by Regi Motor) Gate Sensor Entrance Rollers (Driven by Finisher Transport Motor) Buffer Roller (Driven by Regi Motor) Buffer Gate Eject Roller Shaft (Driven by Eject Motor) Lower Exit Rollers (Driven by Exit Motor) Main Paddle (Driven by Finisher Transport Motor) s5500-026 Paper fed from the Horizontal Transport is drawn into the Finisher by the Entrance Roller driven by the Finisher Transport Motor. The paper next passes through the Punch. A detailed description of the Finisher paper path appears in Book 2. paper travels across the Buffer Roller. Theory of Operation 2-9 . The first sheet of each set is held in the Buffer Path until the second sheet arrives at the Buffer Gate. 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. offset. and is drawn out of the Finisher into the Stacker Lower Tray by the Lower Exit Rollers. The Transfer Gate is switched by the Transfer Gate Solenoid controlled by signals received from the Engine Logic Board. For print jobs not receiving any Finisher processing. 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. it moves out of the Punch and depending on the job. then is directed either up or down by the Transfer Gate. 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. then reversed to back into the Punch guide. The paper exits the Finisher by being driven into the Stacker Upper Tray by the Top Exit Rollers. stapled. Paper punched. When the second sheet arrives.Finisher/Stacker What follows is a summary of the output path through the Finisher. Buffer Gate. or offset print jobs. For Punch operations. After the sheet is punched. the paper is drawn across the Buffer or Transfer Rollers. either moves upward to the Stacker Upper Tray or continues to the Stapler. stapled. For compiled. if installed. or sent to the Stacker Lower Tray is directed down by the Transfer Gate. Chapter 2.

then continues through the Duplex Unit to the Registration Roller for printing on the opposite side. The Duplex Unit provides duplex printing for paper fed from all available paper trays except the Envelope Tray. Exit 2 Exit Sensor Fuser Exit Sensor Wait Sensor Registration Sensor Pre Feed Sensor s5500-583 2-10 Phaser 5500 Printer Service Manual . The paper pauses briefly. wait a period of time for the second side to develop. detected by the Wait Sensor. the Exit 2 Exit Gate Solenoid switches the position of the Exit gate to direct paper out Exit 2. which cannot be duplexed. effectively flipping the sheet over. then reinsert the sheet back into the printer registration area to receive an image on the reverse side. The purpose of the Duplex Unit is to accept a printed sheet of paper from the Fuser exit area.Duplex Path If duplex printing is selected. The Exit 2 Motor reverses direction and feeds the paper into the Duplex Unit.

Other sensors detect the presence of the Drum Cartridge.Sensors The printer contains sensors of various types that perform a variety of functions. A bank of microswitches is used to detect paper size in the universal trays. stop printer activity if a door is open (interlock). photo-reflective and photo-receptive. Photo-receptive sensors consist of a LED in one arm of a U-shaped holder. Hooks Hook Sensor Bracket Microswitches Microswitches are used primarily as cover interlocks in the printer. there are three types in use: Photo Sensors Two types of photo sensors are used. Photo-reflective sensors have the light emitter and light receiver aligned on a single surface. One group of sensors track the progress of the paper along the paper path. and close when actuated. The figure illustrates a typical microswitch. They are in a normally open state. light falls on the photoreceptor sending the signal High. and a photo-transistor in the other arm. Photoreceptive sensors use an actuator or the object itself to block the light path to detect an object or condition.3 V) when it isn’t. Photoreflective sensors use light reflected back from an object to detect its presence.5 V) when light is being reflected back and Low (< +. Theory of Operation 2-11 . If the light is interrupted. Output of the photo-receptor is High (> +4. nothing is between the arms of the sensor. The figure below shows a typical photo-receptive sensor with the Hooks (catches) used to secure the sensor to its bracket. the photo-transistor goes Low. and monitor the fusing temperature. In general. When the sensing area is vacant. and detect if a paper jam occurs. Sensor Types The types of sensors used vary with function. Microswitches also employ hooks or catches for retention in the bracket or frame.

Detects when the output tray is full. Detects paper jams in the feeder. Monitors the printer’s Temp and humidity. Communicates with the CRUMs. Detects laser at the start of a scan. Used primarily in the Fuser for temperature sensing.Microswitch s5500-028 Thermistor Thermistors have a known value of resistance whose value varies with temperature. Detects paper as it leaves the Exit. A fourth sensor in use is the antenna used to communicate with the Drum and Toner Cartridge CRUMs. Interrupts +24 V to the Main Motor Interrupts +5 V to Laser Diode. Senses the position of the Offset Chute. Detects the tray and the paper size. 2-12 Phaser 5500 Printer Service Manual . Detects paper at the registration rollers. Monitor temperature of the Heat Roller. List of Sensor and Interlock Functions Name Level Sensor No Paper Paper Size Pre-Feed Registration Feed Out Exit Stack Full Temperature Door Interlocks Drum Cartridge Detect switch Start of scan Fuser Thermostats Offset Environmental CRUM antenna OCT Home Position Type Photo-receptive Photo-receptive Microswitch array Photo-reflective Photo-receptive Photo-reflective Photo-receptive Photo-receptive Thermistor Microswitch Microswitch Photo Thermostatic switches Photo-receptive Integrated circuit PWB Inductive code reader Photo-receptive Function Detects paper stack height in Trays 2~6. Detects no paper condition in all trays. Interrupts AC power to the Fuser. Detects Offset assembly home position. Detects paper leaving the feeder. This list briefly describes the type and function of sensors and switches used to determine operational status and detect jams or failures.

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. as well as selected paper feed sensors appear in the following diagram. Door Interlock Sensors The Interlock Sensors for Doors A through E and J. Error detection is based on paper transport timing through the sensing area. 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 .

Also. Actuating different combinations of the paper size sensors produces different combinations of high and low signals. 1000-Sheet and 2000-Sheet Feeders. the levers on the bottom of the trays change the size sensor actuator locations. 2-14 Phaser 5500 Printer Service Manual .Paper Feed Sensors The diagram below identifies the remaining paper feed sensors in the Printer. When paper is loaded in the tray and the paper guides are adjusted. These signals identify what size of paper has been loaded and what to display on the Front Panel. any actuation of the paper size sensor signals the Engine Logic Board that the tray is present and closed. Exit 2 Exit Sensor Duplex Wait Sensor Fuser Exit Sensor Registration Sensor Pre Feed Sensor Feed Out Sensor #3 F/O Sensor #6 Paper Size Switch F/O Sensor #5 F/O Sensor #4 s5500-586 Paper Size Sensing Trays 2 through 5 automatically sense the standard size media loaded in the printer by using the paper size sensors mounted on the back of the tray frame.

When the paper level reaches a certain point. Raising the tray bottom pushes the paper up to achieve optimum force against the Feed Roller and blocks the Level Sensor resuming paper feed. if the customer were to print mostly single page jobs. The Drum Cartridge has a maximum drum cycle count of 240. At 3. Paper Present Sensing When the last sheet is fed from any of the trays.250 prints. Drum Cartridge Components Component Drum Function The Drum is an aluminum cylinder coated with a layer of photoconductive material that retains electrical charges on its surface until exposed to light.68 drum cycles per page reducing the Drum Cartridge Life count to 31. an actuator unblocks the Level Sensor signaling the control logic to stop paper feed and raise the tray bottom. the Drum Cartridge Life count increases to 75. Xerographics Drum Cartridge The Drum Cartridge is located behind the Front Door and is a customer-replaceable item.000. the paper level drops. However. a continuous print job having a job length of 500 to 1000 pages results in a drum cycle count of 3. unblocking the sensor. the name and function for each Drum Cartridge component is listed below. and erases the previous charge pattern. Bias Charge Roller (BCR) Theory of Operation 2-15 .2 drum cycles per page.000 prints is based on an average job length of six. the drum cycle count increases to 7. The BCR uniformly distributes electrical charges over the drum surface. single-sided pages. This loop continues until the No Paper sensor is activated.2 cycles per page.Paper Level Sensing As paper is fed from the tray. the No Paper Sensor actuator drops into an opening in the paper tray. Tray 1 uses No Paper sensing only. As an example of how job length effects the Drum Cartridge Life count. The number of drum cycles per page and the prints available varies according to the customer’s usage patterns. when electrical conduction occurs.000 prints. The Drum Cartridge Life specification of 60. Feeding is inhibited until paper is loaded into the tray. To better understand how the Drum Cartridge operates. Paper level sensing operates the same way for Trays 2 through 6.

and applies negative charges to the toner triboelectrically. even layer of developer and toner over the Magnet Roller. When paper moves between the Transfer Roller and Drum. helps to separate the paper from the drum surface. Charging and Metering (CM) Blade Cleaning Blade Drum Cartridge s5500-029 Additional details on the Drum Cartridge function appears in the “Summary of the Printing Process” on page 2-2. which transports the toner to the Drum surface. The Cleaning Blade removes toner remaining on the Drum. Transfer Roller The Transfer Roller is driven by being held in direct contact with the Drum Cartridge. The Detack Saw. Thus. located adjacent to the Transfer Roller. The negatively charged. 2-16 Phaser 5500 Printer Service Manual . the Transfer Roller applies a positive charge to the rear surface of the paper. developed image on the drum is attracted by the positive charge on the rear surface of the paper.Drum Cartridge Components (Continued) Component Magnetic Roller Function A thin layer of developer and toner adheres to the surface of this roller. The CM Blade spreads a thin. the developed image is transferred from the surface of the drum to the surface of the paper.

Dispense Tube Toner Dispense Assembly s5500-594 Theory of Operation 2-17 .Transfer Roller Left s5500-607 Toner Dispense Assembly The Toner Dispense Assembly operates the Toner Cartridge dispense door and moves toner from the cartridge through a dispense tube to the Drum Cartridge.

The Scanner Motor remains off in the standby and power-saving states. 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 resolution of the dual-beam laser is either 600 dpi or 1200 dpi and is determined by the customer setting.Toner Dispense Motor The Toner Dispense Motor drives the Toner Cartridge and dispense tube augers to deliver toner to the Drum Cartridge. For 600 dpi. The Scanner Motor turns on when it receives a signal. For 1200 dpi. and turns off after printing ends. the beams receive different data resulting in a smaller pixel size. Both beams are always on. both beams receive the same data. 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. 2-18 Phaser 5500 Printer Service Manual .

The initial position where a scan is started on each line is detected. and the Start of Scan (SOS) board. the Scanner Assembly. to scan the beams across the drum.Start Of Scan Dual Beam Laser Diode Polygon Mirror Scanner Motor s5500-030 ■ The Laser Assembly is field replaceable and contains the laser diodes. The Laser Assembly consists of four components: the Laser Diode (LD) Assembly. Lenses and Mirrors. scanner motor/mirror. Laser Assembly Components Component Laser Diode Assembly Function Produces two laser beams that are turned on and off according to the print data signal. the signal generated indicates the initial position of the scan. ■ Caution Never remove the cover from a Laser Assembly for any reason . and several lenses and mirrors. The Laser Assembly “reflects” the laser beam so it strikes the Drum.contamination may result. When the laser beams strike the sensor on the SOS board. Scanner Assembly Start of Scan Board Theory of Operation 2-19 . 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.

(The Scanner Motor is rotating at a constant speed. and turns Off after a preset time has passed from the end of printing. the warm-up of the Laser ends.) Laser Reference Value Laser Assembly Reference Value Ready reference value Fail reference value Description SOS signal interval (equivalent to 98% or more of the rated rpm of the Scanner Motor) SOS signal interval (equivalent to 90% or less of the rated rpm of the Scanner Motor) 2-20 Phaser 5500 Printer Service Manual . If the obtained value is smaller than the Ready reference value three consecutive times. Always Off Sleep mode The Scanner Motor starts rotating as the Laser Assembly warms up. Also turns Off if a print command is not received within 30 seconds from the reception of the signal. The SOS signal is sampled at intervals of 100 ms. Scanner Motor Operational Modes Operational Mode Standby mode Print mode Laser Power On/Off Always Off Turns On upon receiving the signal from the controller.Scanner Motor control is performed according to the mode of operation as shown below.

Pressure Roller Theory of Operation 2-21 . the Fuser is replaced as a unit. using a combination of heat and pressure. Fuser components are described below. Fuser Components Component Heat Roller Function The Heat Roller is a metal tube with a coated surface and a Heater Assembly inside. The Pressure Roller is pressed against the Heat Roller to melt the toner and bond the image to the paper. It maintains pressure on the paper passing between it and the Heat Roller. This pressure bonds the melted toner to the paper. the heat fuses the toner to the paper. 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. As an FRU. As paper passes between the Heat Roller and Pressure Roller. The Pressure Roller is a metal shaft coated with sponge rubber. To better understand Fuser errors. the paper passes through the Fuser. bonds the toner to the paper.Fuser The Fuser.

These are Thermistors having a known value of resistance that varies with temperature. When paper is present. and the Dual Sub-Heater Rods heat the center portion of the Heat Roller. the signal /EXIT is Low. One is located at the center of Heat Roller. Temperature Sensors Thermostat Heat-Roller Fingers Heat-Roller Diode Fuser Exit Sensor Fuser Life Expectancy The life expectancy of the Fuser is 300. The Thermostat provides a second-level of protection. the other is located where the edge of a letter size sheet of paper comes through. The Main Heater Rod heats the entire length of the Heat Roller. the Thermostat cuts off the AC power to the Heater Rods.Fuser Components (Continued) Component Heater Rods Function The Heater Rods are quartz glass tubes containing heater coils. There are three Temperature Sensors in the Fuser.000 Letter/A4 size pages. The sensors monitor the surface temperature of the Heat and Pressure Rollers. This sensor detects the arrival of the paper at the exit area behind the Fuser. The fingers peel the leading edge of the paper from the Heat Roller. This diode discharges negative charge on the Heat Roller that may deteriorate the toner image on the paper during fixing. The third is located at the center of the Pressure Roller. If the Heat Roll temperature exceeds the preset temperature. 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 .

the Heater Rods are turned Off. the Control Thermistor does not detect the Ready temperature even when the specified time has passed. and Fuser temperature control is stopped. C. and Low Power.Doors A. Theory of Operation 2-23 . During the Standby period. During the Standby period. D. Front Door Laser Assembly abnormality (U3) CPU or NVRAM abnormality (U6) Motor Assembly abnormality (U0. ■ ■ ■ ■ ■ Fuser Temperature Regulation Fuser temperature regulation is managed by the Engine Logic Board with input from the Fuser’s temperature sensors. the Fuser relay is turned Off. the Control Thermistor does not detect the required temperature even when the specified time has passed. If the Ready temperature is not reached within the Warm-up delay period. 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. the Control Thermistor does not detect the required temperature even when the specified time has passed. The Fuser transits between four operating modes. U1) Fuser Fan abnormality (U4) Fuser Problems (U4 Error Code) Causes of Fuser errors include: ■ During the Warm-Up period. During print. the Control Thermistor does not detect the required temperature even when the specified time has passed. the Control Thermistor does not detect the required temperature even when the specified time has passed. Warm-up.Power Shutoff to the Fuser The printer shuts off power to the Fuser for the following reasons: ■ ■ ■ ■ ■ ■ ■ Fuser abnormality (U4) Paper jam Cover Open . Print. Ready. During idling after power-on. During print. Transitions between these four modes is dependent on Heat and Pressure Roller surface temperature or printer conditions. the Control Thermistor does not detect the idling stop temperature even after the specified time has passed. B.

Warm-up ends when the Ready temperature is attained. or returning from Low Power mode. Front Panel Fuser Temperature Modes by Paper Type Temperature Paper Type Low Plain. Envelopes Prepunched 2-24 Phaser 5500 Printer Service Manual . ■ When an abnormally high temperature is detected: When an abnormally high temperature is detected. the interlocks are closed. and the fans rotate at full speed until the temperature drops. when a failure occurs. 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 printer stops the print job and enters the following cool-down process. Colored. or when executing diagnostic tests. Special Transparency Plain Paper Mode 1 Medium Plain Paper Mode 1 (Default) High Thick Paper Mode 1 Extra High Thick Paper Mode 2 Transparency Paper Mode (Default) Plain Paper Mode 1 Plain Paper Mode 2 Plain Paper Mode 2 Plain Paper Mode 2 Thick Paper Mode 1 Plain Paper Mode 1 Plain Paper Mode 1 and (Default) Plain Paper Mode 1 Thick Paper Mode 4 (Default) Thick Paper Mode 1 (Default) Thick Paper Mode 1 Thick Paper Mode 1 Thick Paper Mode 2 Thick Paper Mode 2 Thick Paper Mode 2 Labels Card Stock. The process for Thick Paper Mode 2 is the same. a jam is cleared. the Fuser lamp turns off. which continues until the target Control Temperature is reached. the Main Motor stops. except that it occurs after 30 sheets of continuous printing. Letterhead.The Warm-up delay begins when printer power is applied.

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 Mode Start Temp (o C) Number of Sheets in Print Run 1~3 4 ~ 10 11 ~ 30 31 ~ 50 51 ~ 99 100 ~ 150 > 150 Plain Paper 1 Thin Paper Max (Cold) Min (Hot) Max (Cold) 208 207 206 205 205 205 205 198 197 196 195 195 195 195 213 212 211 210 210 210 210 OHP 2 Transparency Min (Hot) 203 202 201 200 200 200 200 Max (Cold) 188 187 186 185 185 185 185 Min (Hot) 185 185 185 185 185 185 185 Normal Paper Fuser Control Temperatures for Thick Paper Modes Paper Type Mode Start Temp ( C) Number of Sheets in Print Run 1~3 4 ~ 10 11 ~ 30 31 ~ 50 51 ~ 99 100 ~ 150 > 150 o Thick Paper 1 Max (Cold) 218 217 216 215 215 215 215 Min (Hot) 210 210 210 210 210 210 210 Max (Cold) 223 222 221 220 220 220 220 2 Min (Hot) 3 Letter. COM10 Max (Cold) 225 224 223 222 222 222 222 Min (Hot) 4 Label Max (Cold) 218 217 216 215 215 215 215 Min (Hot) 215 215 215 215 215 215 215 215 215 215 215 215 215 215 215 215 215 215 215 215 215 Theory of Operation 2-25 .

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. The time required for the paper to clear the No Paper Sensor identifies the paper’s length. Drive Roller that feeds paper into the printer. 2-26 Phaser 5500 Printer Service Manual . The printer’s Main Motor drives the Tray 1/MPT Feed Roller to feed paper from the tray. 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. Drive Roller No Paper Sensor Feed Roller Pick Up Solenoid Paper Size Sensor s5500-035 Tray 1/MPT incorporates a single set of guides to establish paper width. Trays 2 and 3. The trays adjust to accept various paper sizes. When media is placed in Tray 1/MPT. Pick-up Solenoid that engages the Main Motor to the Feed Roller. Paper Size Sensor detects the position of the Side Guides and reports the width of paper in Tray 1. multi-purpose Tray 1/MPT and two 500-sheet universal trays. No Paper Sensor that detects whether paper is in Tray 1/MPT. Tray 1/MPT components include: ■ ■ ■ ■ ■ Feed Roller that feeds paper from Tray 1/MPT. Tray 1/MPT The Tray 1/MPT Feeder feeds paper into the printer.

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.5" x 8. SW4 and “SW5”.5" x 11"LEF 16K LEF(TFX/GCO) 11" x 17"LEF 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 SW2 0 0 0 1 1 1 1 0 0 1 1 1 1 1 1 SW3 0 1 1 0 0 1 1 1 1 0 0 0 1 1 1 SW4 0 0 1 1 1 0 0 0 1 0 1 1 0 0 1 SW5 0 0 1 0 1 0 1 0 0 1 0 1 0 1 1 Theory of Operation 2-27 . Universal Tray Paper Size Switch Signal States Paper Size Switch Output Paper size SW1 No tray 5.5" x 14" SEF A4 SEF 8. These guides come into contact with the front and rear edges of the paper and hold it in position. “SW3”.5" x 11" SEF A4 LEF A3 SEF B5 LEF/Executive LEF 8K SEF(TFX/GCO) B4 SEF 8. 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. “SW2”. respectively. The switches are denoted by “SW1”.5" / A5 SEF B5 SEF 8. The signal created by these switches indicates the paper size setting of the guides.5" x 13" SEF 8. when viewed from the left side. Paper size is determined by the position of the switches in the Paper Size Switch assembly.

and also lifts the tray’s Bottom Plate to maintain paper contact with the Nudger Roller. As the level of paper drops. Feed/Lift Motor Pre Feed Sensor Level Sensor No Paper Sensor Feeder Assembly Page Size Switch Tray s5500-036 The Feeder’s Level Sensor uses an actuator to determine whether paper in the tray is lifted to the feeding position. 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). the flag of the actuator enters the Level Sensor’s sensing area.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. 2-28 Phaser 5500 Printer Service Manual .

Lift Up Shaft Sector Gear (60T) Gear 13T/60T s5500-034 The paper supply and path are monitored by these sensors located on the Tray 2 and Tray 3 Feeders. When the actuator lowers. When the flag of the actuator leaves the sensing area. No Paper Sensor The No Paper Sensor uses an actuator to determine whether the tray is empty. the No Paper Sensor signal goes High indicating an empty tray. Pre-Feed Sensor The Pre-Feed Sensor detects a paper jam in the tray by the paper position and sensor transition time. the sensor detects that the paper has been lifted. ■ ■ Theory of Operation 2-29 . ■ Level Sensor The Level Sensor uses an actuator to determine whether paper in the tray is lifted to the optimum feeding position.

to the Standard Output Tray. sending it either to the Standard Output Tray or when installed.Exit 1 Assembly Exit 1 discharges the printed paper out of the printer. the optional Horizontal Transport. ■ ■ 2-30 Phaser 5500 Printer Service Manual . OCT (offset) Roller This roller transports the printed paper sent out from the Fuser. Offset Sensor Paper Weight Stack Full Sensor Exit Pinch Rollers OCT Roller Exit PWB Exit Gate Fuser Exit Sensor Offset Motor Belt Rear Motor Assembly s5500-597 Exit 1 components include: ■ Exit Pinch Rollers These rollers work together with the OCT Roller to eject paper to the Standard Output Tray. The Exit Gate is operated by the Exit Gate Solenoid located in the Exit 2 module. When it is lowered by the Exit Gate Solenoid. When the Exit Gate is in its resting position. Exit Gate The Exit Gate switches the paper path. paper is fed to Exit 2. paper is fed to the Standard Output Tray or Horizontal Transport.

Exit PWB The Exit PWB controls paper feeding and reports sensor/switch information back to the Engine Logic Board. Forward rotation shifts the OCT Roller to the front. Removed from printers equipped with a Horizontal Transport. using an Actuator. OFFSET MOTOR OFFSET GEAR OCT CHUTE OCT ROLLER s5500-039 ■ Offset Home Position Sensor The Offset Home Position Sensor detects the OCT Roller position. Fuser Exit Sensor The Fuser Exit Sensor detects whether paper remains in the output rollers. ■ ■ ■ ■ Theory of Operation 2-31 . Full Stack Sensor This sensor detects that the Standard Output Tray is full. The flow diagram shows the Exit 1 components involved in the Offset process.■ Offset Motor The Offset Motor acting through the Offset Gear shifts the OCT Roller forward or backward providing paper offset capability. The Exit PWB also controls the Exit 2 module when attached. Paper Weight Controls paper exiting the Exit module. Reverse rotation shifts it to the rear.

One provides the drive for paper transport and a second drives the Drum Cartridge. Main Motor 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. ■ Motor Assembly This assembly includes two motors. Toner Dispense Motor s5500-596 2-32 Phaser 5500 Printer Service Manual . The motor enable and speed control signals come from the microprocessor on the Engine Logic Board. The assembly gets +24 VDC power from the LVPS.Printer Drive and Electrical The Drive subsystem includes motors and their driven assemblies.

■ ■ ■ Printer parameters are held by non-volatile memory located in both these boards.Printer Control Drum Cartridge Detect Interlock Drum Cartridge Fan Door A Interlock Fuser Fan Image Processor Board Door B Interlock LVPS HVPS GFI Breaker Printer control centers on the following: ■ s5500-041 Power Switch Front Door Interlock Exit PWB Engine Logic Board Power Switch The Power switch controls main power to the printer. Image Processor Board Processes the print data and directs the development of images on the Drum Cartridge. Theory of Operation 2-33 . Exit PWB Specialized operational control of both Exit 1 and 2. Engine Logic Board Manages all mechanical functions.

The secondary function of the I/P Board is to provide print control. The primary function of the I/P Board is to receive host data through one of the following available ports (Parallel. Before the I/P Board can receive and process data it must first pass the Power On Self Test (POST). and job recovery. The Front Panel is connected to the Image Processor Board and signals pass through the Engine Logic Board via the Image Processor. 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. Hard Drive Configuration Card RAM DIMMs s5500-587 2-34 Phaser 5500 Printer Service Manual . The Image Processor Board connects to the Engine Logic Board directly. Front Panel control. configuration setup. error reporting.Image Processor Board The Image Processor Board (I/P Board) is one of the major elements of the Phaser 5500 printer. or Ethernet). The received host data is buffered and stored and sent to the print engine in a rasterized format. USB.

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. Writes the NVRAM settings. Maintains a running print count. Monitors printer status. The Engine Logic Board performs seven main functions: ■ ■ ■ ■ ■ ■ ■ Communicates with the Image Processor. Distributes low DC voltages to various printer components. s5500-042 Theory of Operation 2-35 . Controls the print sequence. Controls printer options.

feed. s5500-043 2-36 Phaser 5500 Printer Service Manual . Exit PWB s5500-044 HVPS The HVPS provides high AC and DC voltages to Xerographic components.Exit PWB The Exit PWB controls timing. and motor operation for Exit 1 and the optional Exit 2.

Magnetic Roller. the High Voltage Power Supply (HVPS) provides power to the Bias Charge Roller. and Detack Saw. and +24 V for motors/clutches) from AC power. LVPS s5500-045 Theory of Operation 2-37 . LVPS The Low-Voltage Power Supply (LVPS) generates low voltages (+5 V and +3. Transfer Roller. It also contains the Fuser Relay to switch AC power to the Heater Rod of the Fuser. +5 V for Laser Diodes.Located behind the Inner Main Cover.3 V for logic circuits.

AC Accessory Panel The AC Accessory Panel provides AC power for the Finisher and accepts the Printer Power Cord. Reset Switch AC Accessory Panel GFI Breaker s5500-046 2-38 Phaser 5500 Printer Service Manual .

Codes. and Procedures Chapter 3 .. and Procedures In this chapter.Error Messages. Codes.. ■ ■ ■ ■ ■ Introduction Power On Self Test (POST) Service Usage Profile Service Diagnostics Error Messages.

logged in the Service Usage Profile. Make note of any print-quality problems in the test prints. Check for any error codes and write them down. listed on the Startup Page or by flashing LEDs.” Servicing Instructions These instructions are an overview of the Steps a service technician should take. If you choose not to use these Steps. Restart the printer to check if the error reoccurs. Print normal customer prints and service test prints.” Print-quality problems are covered in Chapter 5. These error indications serve as the entry point into the troubleshooting process. 3-2 Phaser 5500 Printer Service Manual . it is recommended that you start at the appropriate troubleshooting procedure and proceed from there. The diagnostic routines report problems using error messages and fault codes displayed on the Front Panel. Take voltage readings as instructed in the appropriate troubleshooting procedure. Print a Service Usage Profile. Use the Wiring Diagrams and Plug/Jack Locator to locate test points. Verify the AC input from the wall outlet is within specifications. “Print-Quality Troubleshooting. Verify that the power cord is in serviceable condition. always follow the safety measures detailed in “Service Safety Summary” on page xvii. Step 4: Correct the Problem: ■ ■ Use the Parts List to locate a part number. 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 FRU Disassembly procedures to replace the part. Make note of any mechanical or electrical abnormalities present. Step 2: Inspect and Clean the Printer: ■ ■ ■ Follow the cleaning instructions given in Chapter 7. Step 5: Final Checkout: ■ Test the printer to verify the problem is corrected and no new problems arose. When servicing the printer. Printer problems not directly indicated by or associated with an error message or fault code are covered in Chapter 4. Make note of any unusual noise or smell coming from the printer. to service the print engine and options. if the printer is able to print. using this manual. View the Engine Error and Jam Histories under the Service Tools menu. Step 1: Identify the Problem: ■ ■ ■ ■ ■ ■ ■ ■ ■ Verify the reported problem does exist.Introduction This chapter describes the printer’s self-diagnostic capabilities and includes methods to identify and remedy reported printer problems. “General Troubleshooting.

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

Soft faults do not stop printer operation and are reported on the Startup Page after the system is running. The following tests execute when the printer is powered on after the Boot Loader runs. Checks communication between the Image Processor Board and the Engine Logic Board. A soft fault is any fault that allows the operating system to initialize. This test checks 64-bit reads and writes to RAM memory. Hard faults are indicated with blinking LEDs and the failed test appearing on the display. This test checks that the USB core is functioning properly. This test determines if the I/O chip is functioning properly. This test checks that each CPU interrupt source is functioning. and before the operating system is loaded and initialized. This test checks addressing of the NVRAM. These tests check the functionally of the Real Time Clock for a number of conditions. 3-4 Phaser 5500 Printer Service Manual . A hard fault prevents the operating system from initializing stopping further printer operation. POST Test Descriptions Test SDRAM I/O ASIC Memory EEPROM Ethernet CPU Interrupts USB RTC (3 tests) RAM DIMM Presence Install more RAM Too much RAM IDE Disk Engine Command Fault Code 1 3 4 10 11 12 13 14 15 16 17 20 22 Fault Type Hard Hard Hard Hard Hard Hard Hard Soft Soft Soft Soft Soft Hard Description This test fails if the Boot Loader finds faulty or no RAM. There are two kinds of POST faults: soft and hard. Checks that there is at least 64 MB of memory installed and ignores more than 512 MB. Checks that there is no more than 512 MB of memory installed. This test checks the Ethernet core. This test examines bad or incompatible RAM DIMMs. Bypass POST by pressing the OK button at power on until the splash screen appears. Checks the disk controller core. and runs a DIAGNOSE command on the hard drive.Power On Self Test (POST) POST diagnostics provide a quick means of isolating a defective subsystem associated with the Image Processor Board and SDRAM.

replace the Image Processor Board. Codes. similar to the one shown here. For IDE Disk errors. Before the printer reaches its “Ready to Print” state. 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. the printer continues the startup process. For memory errors. and Procedures 3-5 . with the upper left corner of the box in the center of the Start Page.POST Soft Fault Messages When POST detects a soft error. see "RAM Memory Fault Isolation" on page 4-15. the Start Page is printed with soft errors appearing in a gray box. Error Messages. The box contains all soft faults encountered. and extending to the right margin. replace the Hard Drive.

Checks installed memory: walking ones address. short. Tests RAM memory above diagnostics code and data addresses. then go to “Image Processor Isolation” on page 4-13. If the Boot Loader encounters a RAM error. Go to “Image Processor Isolation” on page 4-13. 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. 1. Replace Image Processor Board (page 8-91). A long blink is worth 5 and a short blink is worth 1. Image Processor USB port failure. Alternate 1/2 second interval blink at Front Panel and health LEDs. As an example. 3-6 Phaser 5500 Printer Service Manual . 4. 5+5 10: EEPROM 5+5+1 5+5+1+1 5+5+1+1+1 5+5+5+5+1+1 11: ETHERNET PHY 12: CPU INTERRUPTS 13: USB 22: ENGINE COMMAND Image Processor Ethernet Port Failure. There are long and short blinks. Along with the blinking LEDs. first replace the NVRAM EEPROM. Replace Image Processor Board (page 8-91). Communication with print engine has failed. Switch on printer power. Image Processor Board ASIC failure. POST does not load. 2. If the error message persists. Go to “RAM Troubleshooting Procedure” on page 4-15. represents fault code 5+5+1+1=12. a blink pattern flashed as long. 3. Hard Error LED Blink Patterns and Messages LED Blink Pattern 1 1+1+1 1+1+1+1 Front Panel Message RAM ERROR 3: I/O ASIC 4: MEMORY Action No RAM present. The Boot Loader executes a RAM test prior to loading POST. Switch off printer power. Check the connection to the Engine Logic Board. long. Replace Image Processor Board (page 8-91). then the Image Processor Board (Go to page 4-13). indicating a failure in the CPU interrupt test.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. the Front Panel displays “RAM Error” and the health and Front Panel LEDs alternately blink at 1/2-second intervals. walking one and complement data. or faulty RAM. Remove and re-install the NVRAM EEPROM. short.

Or. At the printer’s Front Panel. c. go to the Troubleshooting menu and select Service Tools... 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. view the fault history using a browser. b.13. go to the Troubleshooting menu and select Service Tools. From the Service Tools menu. and Procedures 3-7 . If the printer is operational and connected to a network..13. The engine and jam error fault histories are detailed at lines 262 and 298 respectively. View fault history logs on the Front Panel. this section focuses on accessing these two error logs to review printer history. <pg_count>. select Service Usage Profile. consumable usage and printer history. 0. date. 0. A partial example of the Engine Error Log as it appears on the display: 0.<pg_count>. The fault history logs for the engine and jams each contain 30 entries. b. with the oldest code falling off the left and the latest code added to the right.0. Codes.0. Log entries move right to left. Error Messages. 0. This data is stored in NVRAM. the Engine Error Log combines the error code and page count (lines 262 and 263 of the printed Service Usage Profile). Enter the printer’s IP address as the URL. Each successive error shifts the log left.. Select the Troubleshoot link and the Fault History displays.0. a.Service Usage Profile The Service Usage Profile tracks printer activity. Interpreting Fault History Error Codes Fault histories appear on the Front Panel as a list of semi-colon separated codes. Service Usage Profile data includes error logs that retain detail on the type. Or. a. Open a web browser.. select Engine Error or Jam History. At the printer’s Front Panel. While the Service Usage Profile includes data on all aspects of the printer. <pg_count>. For display..0.. From the Service Tools menu.13. location and frequency of engine and jam errors. Accessing Fault Histories Access Service Usage Profile fault histories by: Print (if possible) the Service Usage Profile. b. a.

U6-3. 95. a corresponding date. U5-9) Engine Logic Board Failure (U6-2. a corresponding page. H7-4. U6-4. In the case of jams. H3-3. U6-6 U6-7) Incorrect Duplex Unit (H2-8) 2 Exit Unit Fail (H3-1. 3-8 Phaser 5500 Printer Service Manual . there are five lines (291-295 and 298). there are four lines (261264). A log usually has some event code. H8-2) Tray 2 Failure (H1-1. H8-3) Tray 3 Failure (H1-2. U6-5. U4-8) Fan Failure (U4-9. Engine Errors This table lists the fault codes used to identify engine errors in the Service Usage Profile. H8-1) 18 4 5 6 7 8 9 10 11 19 20 21 22 23 24 25 26 12 Tray 4-5 Logic Board Failure (H7-3. U4-7. J7-1. 96) Punch Failure (H5-31 ~ 34) Finisher Failure (H5-7) Tray 6 Failure (H1-5) Tray 5 Failure (H1-4. 86) Stapler Failure (H5-91. 21~24. Fault History Codes for Engine Errors Fault Code 0 1 Error No Error Duplex Unit Failure (H2-7) Fault Code 15 16 Error Toner Cartridge Failure (J8-1 J8-2) Drum Cartridge Failure (J4-1. use the Fault Code to find the corresponding troubleshooting procedure in the Error Message Summary table. H7-7) Tray 6 Logic Board Failure (H6-4. H6-7) Finisher Logic Board Failure (H5-4) 27 13 28 Incorrect Tray 4 -5 Unit (H7-8) 14 29 Incorrect Finisher (H5-8) If Engine Error codes appear in either the Engine Error Log or on the Front Panel. In the case of engine errors. 81~84. and a total event counter. H8-4) Tray 4 Failure (H1-3.A complete log consists of several lines in the Service Usage Profile report (typically 2-5 lines). U1-1) Drum Motor Failure (U1-4) Toner Motor Failure (U5-1) Laser Motor Failure (U3-5) Laser Unit Failure (U3-3) Fuser Failure (U4-1~5. J7-2) Temperature Sensor Failure (No error code) Humidity Sensor Failure (No error code) Main Motor Failure (U0-1. H3-7) 17 3 Stacker Lower Tray Failure (H5-11~13. Fault codes are numeric for Engine Errors (Line item 262).

F4-56.--. F4-85. E4-5. line items 294 and 298 are combined to provide the error code and Total Page counter at the time the error occurred. C4-4 C5-1. C3-3. C6-2 E4-3. F4-47. A partial example of the Last Jam Error Log as it is displayed on the Front Panel: --. Fault History Codes for Jams Last Jam Location (Item 291) Paper Size Jam Jam at Tray 1 Jam at Tray 2 Jam at Tray 3 Jam at Tray 4 Jam at Tray 5 Jam at Tray 6 Jam at A Jam at B Jam at B and C Jam at C Jam at D Jam at D and A Jam at E Jam at F Last Jam Error (Item 298) E1-1... F4-24. F4-74. F4-32.F4-48.--.<pg_count>. F4-51.C4-0.--.Jam Errors The following table lists the fault history codes used in the Service Usage Profile to record jam errors. E4-1. F4-87.F4-71. E8-2 F4-17. E1-6. F4-66 F4-75 Jam History Log 18 1 2 3 4 5 6 7 8 16 9 10 15 11 12 Jam at G 13 Jam at H Jam at Stacker Upper Tray 14 17 Error Messages. C3-1 C4-0. F4-23. E3-1. E3-2. F4-36. E3-6. F4-16. C5-2. 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. C8-2 C3-2.--. F4-77.<pg_count>. and Last Jam Page number appears on line 294. C5-3. For display.C4-1. C4-1. F4-53. F4-76. C4-2 C8-3. F4-86 F4-42.--. F4-61.--.. F4-43. F454. F4-82.--. Limited to 30 entries. F4-46. Codes. F4-83. C4-3.--. C2-2 C3-0. Last Jam Location is recorded on line 291. C1-3 C2-1. C8-5 E1-2. F4-73. Last Jam Error Codes appear at line 298. PSE-1 C9-3 C1-2. F4-72. F4-78.--. F4-52. E4-6. F4-26. F4-84. C8-4 C8-6 C6-1.--. F4-88 F4-55. F4-22 C2-3. and Procedures 3-9 . F4-12.

Refer to this diagram when questions arise regarding the area of the jam. Door E Door A Door D Door F Door H Door G Door J Door C Door B s5500-614 3-10 Phaser 5500 Printer Service Manual . Jam Location Map The following illustrates the Door designators that key the jam location error codes and messages.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.

Tests the Feed/Lift and Take Away motors. versions. Tests the Horizontal Transport. The Service Diagnostics Main menu offers the options listed in the following table. Tests each Finisher solenoid and the Set Clamp Clutch. Tests the Feed/Lift and Take Away motors. Tests the Exit and Offset motors of Exit 2. Exits Service Diagnostics and reboots the printer. Stapler. Error Messages. Tests Tray 4 & 5 sensors and the Door C Interlock Switch. Save/Restore NVRAM from the Engine Logic Board. This allows you to reset the PostScript or all NVRAM. Tests the functionality the Exit 2 Exit Gate solenoid. Sets the Finisher/Stacker punch configuration. Codes. and counts. Tests the Finisher sensors and switches. Isolate problems with Xerographics and paper handling. Tests the Wait sensor and Door D Interlock Switch. Tests solenoid and clutch function in the print engine. and Procedures 3-11 . Service Diagnostics also contains test prints. Tests Exit 2 sensors and the Door E Interlock Switch. Tests the sensors and switches within Tray 6. Query information about the status. Tests the function of the Take Away Clutch. Adjust registration in the process or scan direction on each tray. Tests print engine sensor status and operation. and Punch. Service Diagnostics Main Menu Menu Item Print Service Menu Map General Status Test Prints Engine NVRAM Adjustments Motors/Fan Tests Duplex Unit Motor Tests Exit 2 Motor Tests Tray 4 & 5 Motor Tests Tray 6 Motor Tests Finisher Motor Tests Engine Sensor/Switch Test Duplex Sensors/Switch Exit 2 Sensor/Switch Tray 4 & 5 Sensor/Switch Tray 6 Sensor/Switch Finisher Sensor/Switch Solenoid/Clutch Tests Exit 2 Solenoid Test Tray 4 & 5 Clutch Test Tray 6 Solenoid Test Finisher Solenoid and Clutch Tests IP NVRAM Access Engine Logic Board Replacement Finisher Board Setup Exit Test Target Prints the Service Diagnostics menu map to aid menu navigation. printer status and some NVRAM access. Tests the Duplex motor at two speeds. Test descriptions appear in the Appendix. Finisher. These tests exercise each pint engine motor or fan. Tests the Tray 6 Nudger solenoid at low and high power.Service Diagnostics Service Diagnostics provide tests for most electro-mechanical components in the printer.

Continue to hold the buttons until the following message appears on the Front Panel: Entering Service Diagnostics. sensors change state temporarily to indicate the sheet’s presence. Tests are controlled from the Front Panel and are described in detail in the Appendix. 2. 4. and pressing the OK button. Even the sensors themselves sometimes provide erroneous readings. From the printer’s main menu. Starting Service Diagnostics Access the Service Diagnostics menu one of two ways: Entering without rebooting the printer: 1. the sensor location where the timing difference occurs identifies the error to report. Turn the printer power OFF. Sensor signals are used to monitor paper handling and mechanical activity along the entire paper path. 3. If the pattern of sensor state changes differs from the expected timing for a particular paper size and path. gears. You can print a Service Diagnostics Menu Map by highlighting Print Service Menu Map. then scroll to Service Tools and press the OK button. As a sheet travels along the paper path. If confronted with an error that requires more than a cursory investigation to clear or when directed by a troubleshooting procedure. scroll to Troubleshooting and press the OK button. but often cannot identify why. Hold down both the Up Arrow and Down Arrow buttons for about three seconds. having the error message information doesn’t necessarily pinpoint the problem. When the Service Diagnostics menu appears. You will need to re-enter Service Diagnostics.Using Service Diagnostics The printer’s operating system monitors dozens of sensors located throughout the print engine and attached options. See “Service Diagnostics Menu Map” on page A-4. solenoids. and then release the buttons. However. The Front Panel displays the Service Diagnostics menu. See “Service Diagnostics Menu Map” on page A-4. 3-12 Phaser 5500 Printer Service Manual . The printer runs through POST and returns to Ready. The Service Diagnostics Menu Map also appears in the Appendix. Sensor signals locate where. Entering by rebooting the printer: 1. and dozens of other parts are involved in paper transport. scroll to Run Service Diagnostics and press the OK button. Motors. The Service Diagnostics suite of tests and utilities are the best tools available to pinpoint the root cause behind the reported error. belts. Hold down the Back and Information buttons simultaneously and turn the printer back ON. use Service Diagnostics to exercise select parts in the vicinity of the reported error. 2.

Codes. This control does not ‘wrap’. if available. Executes the current test item. If help text is displayed. CANCEL INFO UP DOWN OK Front Panel Shortcuts Mode Skip POST diagnostics Print Service Diagnostics Map Reset PostScript NVRAM Password Bypass Enter Service Diagnostics Front Panel Language Buttons Pressed at Power On OK Information Back + OK Up Arrow + Down Arrow Back + Information Cancel + i Error Messages.Service Diagnostics Controls Button BACK Function Returns to the prior higher level menu structure. Scrolls down one menu item within a menu list. if available. Enters the highlighted menu. Used to increment data in tests requiring user input. pressing BACK restores the current menu item and removes the help text. and Procedures 3-13 . Used to select a data value entered by the user. the end of a menu list is designated by three asterisks. Terminates the current test or cancels current INFO display. Used to decrement data in tests requiring user input. This control does not ‘wrap’. Scrolls up one menu item within a menu list. Pressing INFO again restores the current menu item and removes the help text. Provides help information.

3-14 Phaser 5500 Printer Service Manual . Used as sensor designators F/O1 or F/O #2. Codes. Engine Logic Board Image Processor Board Offset Rollers at Exit Option Tray 6 or 2000-Sheet Feeder Used to describe Tray 1/MPT. Used instead of printer. Error Message Abbreviations Due to limited display space.Messages. Often seen as SNR1 or Reg SNR. some error messages include abbreviations. Optional for 2-sided printing. Function designator for roller or motor. As in MCU-DM Comm Error. Used to describe a circuit board (Tray 6 PWB). Used instead of NVRAM. Primary power supply. Appears as a designator. and Procedures The error messages and codes generated by the printer’s operating system. The most common abbreviations used throughout this chapter are listed here. This section correlates the output of these three diagnostic aids and provides the troubleshooting procedure to locate and correct reported errors. Error Message Abbreviations Term Reg or REGI SNR DUP or DM F/O T/A H-Xport MCU I/P Board OCT HCF MSI or MPT IOT 2TM P/J EM SW NVM CRUM Comm LVPS PWB Definition Registration Sensor Duplex Unit Feed Out Take Away Horizontal Transport Main Control Unit Image Processor Offset Catch Tray High-Capacity Feeder Multi-Sheet Input Image Output Terminal Two-tray Module Plug/Jack Exit Module Switch Non-volatile Memory Customer-Replaceable Unit Monitor Communication Low-Voltage Power Supply Printed Wire Board Comment Used in designators such as Reg SNR. Device used to store usage information on the Drum and Toner Cartridges. and Service Diagnostics are the lead-in to the troubleshooting procedures that follow in subsequent pages. Horizontal Transport section of the Finisher. Option Trays 4 and 5 or 1000-Sheet Feeder Plug (P) and or Jack (J) designators Used for either Exit (1 or optional Exit 2). the Service Usage Profile.

The Service Diagnostics’ error message appears when errors occur during testing. Codes. use this table to identify the proper procedure to clear the error. the corresponding Service Diagnostic message and Service Usage Profile fault code. The Engine and Jam Errors columns list fault codes logged by the Service Usage Profile. along with. located in the Service Tools menu. To assist you further. The Front Panel Message column shows the message as is appears on the printer’s display when the error occurs during normal operation.Error Message Summary The Error Message Summary below lists possible error messages. In cases where an error message or fault code is generated. the troubleshooting procedures that follow this table are named for the associated Front Panel message. and Procedures 3-15 . The Go to Page column references the troubleshooting procedure related to the error. Error Message Summary Front Panel Message Main Motor Failure 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 Paper Size Jam Jam at A Jam at A Jam at A Jam at A Jam at A Service Diagnostics Message U0-1 Main Motor Stop 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 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 Engine Jam Go to Error Error Page 19 19 20 23 22 24 24 24 24 24 24 25 21 25 26 26 26 26 26 26 18 7 7 7 7 7 3-23 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 3-35 3-37 3-38 3-39 3-39 3-41 Error Messages.

Error Message Summary (Continued) Front Panel Message Jam at A Jam at E Jam at A Jam at E Jam at E 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 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) 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 Service Diagnostics Message E4-1 Exit 2 Area Jam E4-3 Exit 2 Area Jam E4-5 Exit 2 Area Jam E4-6 Exit 2 Area Jam E8-2 Duplex 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 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 C9-3 Tray 1/MPT 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 Engine Jam Go to Error Error Page 7 11 7 11 11 2 2 3 3 8 4 4 16 8 5 5 16 8 5 6 6 8 15 15 8 9 9 6 10 1 7 7 12 7 12 12 12 12 12 3-42 3-44 3-44 3-47 3-49 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 3-68 3-71 3-73 3-51 3-53 3-76 3-77 3-78 3-79 3-83 3-84 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 .

Error Message Summary (Continued) Front Panel 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 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 Service Diagnostics Message 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 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 Engine Jam Go to Error Error Page 13 13 13 13 13 12 12 13 13 14 14 14 14 12 12 13 13 17 12 13 13 12 12 13 13 12 13 13 11 10 9 8 7 1 27 2 2 2 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 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 3-154 3-155 3-155 3-157 3-157 Duplex Unit Failure H2-7 Duplex Comm Failure Incorrect Duplex Unit Installed H2-8 Duplex Type Error 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 H3-1 Offset Error H3-2 Offset Error H3-7 Exit Board Comm Failure 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 Error Messages. and Procedures 3-17 . Codes.

Error Message Summary (Continued) Front Panel 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 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 Install or Reseat Drum Cartridge Drum Cartridge Failure Replace Drum Cartridge Drum Cartridge Failure Drum Cartridge Failure Non-Xerox Drum Cartridge Service Diagnostics Message 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 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 J1-2 Toner Empty J3-1 Drum not installed J4-1 ATC SNR defect J6-1 DRUM end of life J7-1 DRUM Comm Error J7-2 DRUM NVRAM Error J7-3 DRUM type mismatch Engine Jam Go to Error Error Page 14 6 29 3 3 3 3 3 3 3 5 5 5 5 3 3 3 3 3 4 4 4 13 13 12 12 12 28 11 10 9 8 16 16 16 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 3-187 3-188 3-189 3-189 3-190 3-191 3-193 3-193 3-194 3-194 3-197 3-199 3-200 3-200 3-201 3-200 3-200 3-18 Phaser 5500 Printer Service Manual .

Codes. type mismatch Engine Jam Go to Error Error Page 15 15 3-204 3-204 3-205 3-205 3-206 3-207 3-208 3-209 3-211 3-212 3-214 3-217 3-218 3-219 3-219 3-220 3-220 3-222 3-223 3-225 3-226 3-228 3-229 3-233 3-232 3-230 3-237 3-235 3-238 3-239 3-248 3-236 3-242 - Toner Low DRUM Life Near End.Error Message Summary (Continued) Front Panel Message Install or Reseat Toner Cartridge Toner Cartridge Failure Replace Incorrect Toner Cartridge Non-Xerox Toner Cartridge Toner Is Low Drum Cartridge Near End of Life No Paper in Tray Service Diagnostics Message J8-1 Toner Comm Error J8-2 Toner Cart. read/write error J8-3 Toner Cart. and Procedures 3-19 . No Paper in Tray 2 or 3 No Paper in Tray 4 or 5 No Paper in Tray 6 Paper Size in Tray 2 or 3 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 Face down Tray 1 full Face down Tray 2 full Finisher Tray Paper Full Finisher Mix Full Stack Staple Pin Warning Staple Pin Misfeed Staple Failure Staple Set Over Count Punch Waste Box Full Punch Waste Box Missing Stacker Lower Safety Fail Door A is Open Front Cover is Open Door B is Open Door C is Open Door J is Open Tray 6 Undocked Door E is Open 17 18 - Paper Size Jam - Drum Cartridge Failure Temperature Sensor Failure Humidity Sensor Failure Standard Output Tray is Full Stacker Upper Tray is Full Stacker Lower Tray is Full Stapler is Empty Stapler Cartridge is Low Staple Failure Finisher Stacker set over count Punch Waste Box is Full Punch Waste Box is Missing Stacker Lower Tray Failure Close Door A Close Printer Front Door Close Door B Close Door C Close Door J Slide in Tray 6 Feeder Close Door E - - Error Messages.

6. Note that two types of photo sensors are used: photo-reflective and photoreceptive. 9. then follow the instructions for a “No” reply. Troubleshooting Procedures often ask you to replace a printer component. then follow the instructions for a “Yes” reply. 2. Troubleshooting procedures frequently ask you to take voltage readings or test for continuity or resistance at certain test points. 7. 5. Photo-reflective sensors use light reflected back from an object to detect its presence or absence. When a procedure instructs you to test a component using Service Diagnostics. If your response to the question is “Yes”. Applicable Parts and References assist you in locating all the information available for a particular part or procedure. When instructed to replace a non-spared component and that component is part of a parent assembly. replace the entire parent assembly. Also included are precautions and/or additional procedures you must follow to isolate the problem. Remember that disassembly procedures. Applicable Error Code(s) lists the error message(s) addressed by each troubleshooting procedure. If your response to the question is “No”. see “Service Diagnostics” on page 3-11 for the detailed steps and functions for testing parts of the printer. The Actions and Questions box instructs you to perform a certain action or procedure. parts lists. The Reference table provides pointers to the diagrams that provide this information. 3-20 Phaser 5500 Printer Service Manual . Photo-receptive sensors use an actuator or the object itself to block the light path to detect an object or condition.Error Message Summary (Continued) Front Panel Message Close Door D Close Door G Close Door F Close Door H Maintenance Kit Near End of Life Replace Maintenance Kit Invalid Configuration Card Configuration Card Missing Duplicate IP address detected Service Diagnostics Message Door D is Open Door G is Open Door F is Open Door H is Open Engine Jam Go to Error Error Page 3-240 3-245 3-243 3-247 3-250 3-250 3-250 3-250 3-251 Using the Troubleshooting Procedures 1. 8. Follow each Step in a troubleshooting procedure sequentially in the order given until the problem is fixed or resolved. 4. and wiring diagrams for printer options appear in the Phaser 5500 Printer Options Service Manual. Each action is followed by a question. 3.

Gating signals may be nothing more than a pulse. unless instructed otherwise. check all pins. 2. the Drum Cartridge and the paper trays are in place. Codes. 3.3 VDC +5. 5.0 VDC 0. You can substitute any RTN pin or test point in the printer.135 to +3. and place the black probe (–) of your meter on pin 5 of P/J 210. All voltages given in the troubleshooting procedures are approximate values. 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. and Procedures 3-21 . When instructed to take resistance readings between “P/J 232 <=> P/J 210” (without specified pin numbers). 6.4 VDC Less than +0.Measurement Techniques 1. Unless indicated otherwise. When instructed to take a voltage reading. resulting in a momentary drop in voltage that may be difficult or impossible to read on the average multi-meter.0 VDC Measured +3. Before measuring voltages make sure the printer is switched On. When instructed to take voltage. 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. Unless otherwise specified. continuity or resistance readings on wiring harness.25 VDC +21. To locate connectors or test points. 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 232.465 VDC +4. 4.0 VDC +24.6 to +26. see “Wiring Diagrams” for more information. the black probe (–) is generally connected to a pin that is either RTN (Return) or SG (Signal Ground).5 VDC Error Messages. and you can use FG (frame ground) in place of any SG pin or test point. these voltage tolerances are used within this section: Stated +3.75 to +5. See “Wiring Diagrams” for the location of all wiring harnesses and pins. and the interlock switches are actuated.

Do the test prints print? Request the customer send a print job from their application. Does the print quality meet the print quality specifications? Enter Service Diagnostics and generate Test Prints from all input trays. 3. Does the printer display an error message or code while printing? Yes Go to Step 4. No Go to Step 2. Did the job print successfully? Go to Step 6. 4 Go to Step 5.Entry Level Fault Isolation Procedure Use this procedure to quickly locate the general area of the problem. Select Print Quality Problems and press OK. Go to the procedure for that error message or code. 2. Go to “Network Problems” page 4-2. Go to Step 8. 2 Go to the procedure for that error or code. 3 Go to Step 4. Go to “Inoperative Printer” page 4-10. In the Main Menu. 5 6 Do the test prints print? Evaluate the test prints. Select Test Prints and press OK. Go to “Print-Quality Troubleshooting” on page 5-2. 7 Go to “Image Processor Isolation” on page 4-13. 8 3-22 Phaser 5500 Printer Service Manual . return to Final Checkout in the Service Flowchart. or the buttons inoperable? Run Test Prints from all input trays: 1. Go to Step 7. Problem solved. 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. Go to Front Panel Troubleshooting page 4-4. Go to Step 3. Entry Level Troubleshooting Procedure Step 1 Actions and Questions Cycle printer power. select Troubleshooting and press OK.

1 Print Engine Electrical (page 9-40) Main Motor Troubleshooting Procedure Step 1 Actions and Questions Check the Motor Assembly installation. Go to Step 5. Are P/J214 and P/J408 connected? Check continuity between the Motor Assembly and Engine Logic Board. Run the Service Diagnostics Main Motor test. Connect P/J214 and P/J408. and Procedures 3-23 . Is the Motor Assembly installed correctly? Test Motor Assembly operation. Does each wire conduct between P/ J214 <=> P/J408? Check for +24 V to the Motor Assembly. Error Messages.U1-1 Main Motor Rotation Main Motor Troubleshooting Reference Applicable Parts ■ ■ References ■ ■ ■ ■ Motor Assembly Engine Logic Board Print Engine P/J Electrical (page 10-12) Print Engine Drive/Crum Wiring (page 10-25) PL7. 5 Replace the Motor Assembly (page 8-84). 2 Go to Step 6. Does the motor run? Check the Motor Assembly connection. Is there +24 V across P/J214-1/-2 (+) <=> ground? Yes Go to Step 2.U0-1 Main Motor Stop Main Motor Failure .1 Print Engine Drive (page 9-38) PL8. Remove the Upper Rear Cover (page 8-15). Applicable Error Codes Main Motor Failure .Main Motor Failure The Main Motor stopped or didn’t start on time. Replace the Engine Logic Board (page 8-89). 3 4 Go to Step 4. No Correct the installation. Go to Step 3. Codes. Repair the wiring.

4 Replace the Engine Logic Board (page 8-89). Are P/J214 and P/J408 connected? Check continuity between the Motor Assembly and Engine Logic Board. Go to Step 8. Is the Fuser installed properly? Check the Drum Cartridge installation. Verify motor installation. Go to Step 3. Is there continuity on each wire between P/J214 <=> P/J408? Yes Go to Step 2. Does the motor run? Check the Motor Assembly installation.Drum Motor Failure . Correct the installation.U1-4 Drum Motor Rotation The Drum Cartridge drive motor failed. 3 Go to Step 4. Connect the Motor.1 Print Engine Electrical (page 9-40) Drum Motor Troubleshooting Procedure Step 1 2 Actions and Questions Check the Fuser installation. Remove the Upper Rear Cover. Is the Drum Cartridge installed properly? Test the Drum Motor. Applicable Error Code Drum Motor Failure .1 Print Engine Drive (page 9-38) PL8. Is the Motor installed properly? Check Drum Motor rotation. No Correct the Fuser (page 8-76). Run the Service Diagnostics Drum Motor test. Correct the installation. 3-24 Phaser 5500 Printer Service Manual .1 Fuser and Exit 1 (page 9-34) PL7. 5 Verify installation. Repair the wiring. Can the rotor be rotated by hand without excessive load? Check the Motor Assembly connection. Go to Step 6.1 Laser.U1-4 Drum Motor Rotation Drum Motor Troubleshooting Reference Applicable Parts ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ Drum Cartridge Fuser Motor Assembly Engine Logic Board Print Engine P/J Electrical (page 10-12) Print Engine Drive/CRUM Wiring (page 10-25) PL5. 6 7 Go to Step 7. Go to Step 5. CRU and Toner Dispense (page 9-32) PL6.

Drum Motor Troubleshooting Procedure (Continued) Step 8 Actions and Questions Check for +24 V to the Motor Is there +24 V across P/J214-1/-2 (+) <=> ground? Yes Replace the Motor Assembly (page 8-84). Correct the Laser (page 8-74).U3-3 Laser Power The Laser Assembly has failed. P/J620 and P/J406 connected? Check continuity between the Laser Assembly and the Engine Logic Board. P/J620 and P/ J406. Is the Laser Assembly installed properly? Check the Laser Assembly connection. Codes. Laser Unit Failure . Repair the wiring. Is there continuity on each wire between P/J140 <=> P/J406? Yes Go to Step 2. Applicable Error Code Laser Assembly Failure . No Replace the Engine Logic Board (page 8-89).1 Laser. Are P/J130. Go to Step 5.1 Print Engine Electrical (page 9-40) Laser Assembly Troubleshooting Procedure Step 1 Actions and Questions Check the Drum Cartridge installation. and Procedures 3-25 . 5 Go to Step 6. Connect P/J130. CRU and Toner Dispense (page 9-32) PL8. 2 Go to Step 3. Is the Drum Cartridge installed properly? Check the Laser Assembly installation. Error Messages. 3 4 Go to Step 4.U3-3 Laser Power Laser Assembly Troubleshooting Reference Applicable Parts ■ ■ ■ References ■ ■ ■ ■ Drum Cartridge Laser Assembly Engine Logic Board Print Engine P/J Laser and Exit PWB (page 10-7) Print Engine laser Assembly Wiring (page 10-29) PL5. No Correct the installation. Connect the Laser. Are P/J140 and P/J406 connected? Check the Laser Assembly connections.

Is there +5 V across P/J140-8 (+) <=> ground? Check for +24 V to the Laser. Laser Motor Failure . located in the Laser Assembly. Is there continuity on each wire between P/J130 <=> P/J406? Check for +5 V to the Laser Assembly. 3 Connect the Laser Assembly. Are P/J140 and P/J406 connected? Yes Go to Step 2. Is the Drum Cartridge installed properly? Test the Scanner Motor.1 Print Engine Electrical (page 9-40) Scanner Motor Troubleshooting Procedure Step 1 Actions and Questions Check the Drum Cartridge installation. 7 Go to Step 8.1 Laser. Run the Service Diagnostics Laser Scan Motor test. failed. Replace the Engine Logic Board (page 8-89). No Repair the wiring. Does the motor run? Check the Laser connection. No Correct the installation.U3-5 Polygon Motor Rotation Scanner Motor Troubleshooting Reference Applicable Parts ■ ■ ■ References ■ ■ ■ ■ Drum Cartridge Laser Assembly Engine Logic Board Print Engine P/J Laser and Exit PWB (page 10-7) Print Engine laser Assembly Wiring (page 10-29) PL5. Is there +24 V across P/J130-5 (+) <=> ground? Yes Go to Step 7. 3-26 Phaser 5500 Printer Service Manual . 8 Replace the Laser Assembly (page 8-74). Applicable Error Code Laser Failure .U3-5 Polygon Motor Rotation The Scanner Motor. Go to Step 4. CRU and Toner Dispense (page 9-32) PL8. Replace the Engine Logic Board (page 8-89). Go to Step 4.Laser Assembly Troubleshooting Procedure (Continued) Step 6 Actions and Questions Check continuity between the Laser Assembly and the Engine Logic Board. 2 Replace Laser Assembly or Engine Logic Board.

the Control Thermistor does not detect the idling stop temperature even after the specified time has passed. Is there +5 V across P/J140-8 (+) <=> ground? Check for +24 V to the Laser. P/J620 and P/ J406. 5 Go to Step 6. During the Standby period. Replace the Engine Logic Board (page 8-89). Is there +24 V across P/J130-5 (+) <=> ground? Yes Go to Step 5. the Control Thermistor does not detect the Ready temperature even when the specified time has passed. Error Messages. Replace the Engine Logic Board (page 8-89). 8 Replace the Laser assembly (page 8-74). Are P/J130. P/J620 and P/J406 connected? Check continuity between the Laser and the Engine Logic Board. Repair the wiring. 7 Go to Step 8. the Control Thermistor does not detect the required temperature even when the specified time has passed. the Control Thermistor does not detect the required temperature even when the specified time has passed. The Fuser failed to reach temperature within the warm-up period. then cycle printer power. leave power applied for 7 minutes. Codes. the Control Thermistor does not detect the required temperature even when the specified time has passed. Possible faults are: ■ ■ ■ ■ ■ During the Warm-Up period. If the error reoccurs. During print. 6 Go to Step 7.Scanner Motor Troubleshooting Procedure (Continued) Step 4 Actions and Questions Check the Laser connections. During the Standby period. Repair the wiring. Is there continuity on each wire between P/J140 <=> P/J406? Check continuity between the Laser and the Engine Logic Board. Is there continuity on each wire between P/J130 <=> P/J406? Check for +5 V to the Laser. procede with troubleshooting procedure. During idling after power-on. Fuser Failure .U4-1 On Time Note Following display of this error. No Connect P/J130. and Procedures 3-27 .

Go to Step 4. 3-28 Phaser 5500 Printer Service Manual . Replace the Fuser (page 8-76).1 Fuser and Exit 1 Unit (page 9-34) PL8. Remove the Fuser. 9 Go to Step 10. No Go to Step 2. Replace the Fuser (page 8-76). 6 Go to Step 7 7 Go to Step 8. Warning: Allow the Fuser to cool. 2 3 Correct the installation. Is the resistance across P/J600-4 and P/ J600-11 less than or equal to 100 ohm? Check Fuser resistance. Is there a paper jam in the Fuser? Check the Fuser installation.Applicable Error Code Fuser Failure .1 Print Engine Electrical (page 9-40) Fuser On Time Troubleshooting Procedure Step 1 Actions and Questions Check the Fuser for a paper jam. Go to Step 3. Is the resistance across P/J131-1 and P/ J131-2 more than or equal to 3 k-ohm? Check Fuser resistance. 5 Go to Step 6. Is the resistance across P/J600-1 and P/ J600-11 less than or equal to 100 ohms? Check Fuser resistance. Is there continuity on the pins? Yes Remove the paper.U4-1 On Time Fuser On Time Troubleshooting Reference Applicable Parts ■ ■ References ■ ■ ■ ■ Fuser LVPS Print Engine P/J Fuser and Exit 1 (page 10-8) “Print Engine Fuser Wiring (page 10-22) PL6. Replace the Fuser (page 8-76). Replace the Fuser (page 8-76). Is the Fuser installed properly? Check continuity on the junction connector. Is the resistance across P/J133-1 and P/ J133-2 greater than or equal to 3 k-ohm? Go to Step 5. Is the resistance across P/J600-7 and P/ J600-11 less than or equal to 100 ohm? Check Fuser resistance. Replace the Fuser (page 8-76). Open Door A. Replace the Fuser (page 8-76). Replace the Fuser (page 8-76). Is the resistance between P/J132-1 and P/J132-2 greater than or equal to 3 k-ohm? Check Fuser resistance. 4 Check Fuser resistance. 8 Go to Step 9.

1 Fuser and Exit 1 Unit (page 9-34) PL8. and Procedures 3-29 . Is P/J6 connected? Check continuity between the Fuser and LVPS.U4-2 Over Heat Temp Fuser Failure .U4-3 FS1 Thermistor Fuser Failure . 12 Replace the Fuser (page 8-76) Replace the LVPS (page 8-92). Applicable Error Codes Fuser Failure .U4-n Over Heat / Thermistor The Fuser failed to reach temperature within the warm-up period. Is there continuity on each wire between P/J600 <=> P/J6? Check for +5 V to the Fuser. Codes.U4-4 FS2 Thermistor Fuser Failure . Are P/J401 and P/J525 connected? Yes Go to Step 11. No Connect P/J6. The control thermistors has detected a temperature higher than the specified value. Repair the wiring. Fuser Failure . Connect P/J401 and P/J525.1 Print Engine Electrical (page 9-40) Error Messages. Is there +5 V between these pins? P/J6-1 <=> P6-2 P/J6-1 <=> P6-3 P/J6-1 <=> P6-4 Check the LVPS and the Engine Logic Board connection. 13 Replace the Engine Logic Board (page 8-89). Go to Step 12.Fuser On Time Troubleshooting Procedure (Continued) Step 10 11 Actions and Questions Check the Fuser connection. or one of the thermistors has failed.U4-5 Pressure Roller Thermistor Fuser Thermistor Troubleshooting Reference Applicable Parts ■ ■ References ■ ■ ■ ■ Fuser LVPS Print Engine P/J Fuser and Exit 1 (page 10-8) “Print Engine Fuser Wiring (page 10-22) PL6.

proceed with troubleshooting procedure. 3 Go to Step 4. If the error reoccurs. Go to Step 3. Is the resistance across P/J133-1 and P/ J133-2 greater than or equal to 3 k-ohm? Check the Fuser connection. Replace the Fuser (page 8-76). Is the resistance across P/J131-1 and P/ J131-2 more than or equal to 3 k-ohm? For FS2 Thermistor Only. 5 6 Go to Step 6. then cycle printer power.U4-7 Cold Sagging The Fuser temperature regulation failed. Is the resistance between P/J132-1 and P/J132-2 greater than or equal to 3 k-ohm? For Pressure Roller Thermistor Only. Is there continuity on each wire between P/J600 <=> P/J6? Check power to the Fuser Is there +XX V across P/JXXX (+) <=> ground? Yes Go to Step 2. Is the Fuser installed properly? For FS1 Thermistor Only. Applicable Error Code Fuser Failure . leave power applied for 7 minutes. Note Following display of this error. No Correct the installation.U4-7 Cold Sagging 3-30 Phaser 5500 Printer Service Manual .Fuser Thermistor Troubleshooting Procedure Step 1 2 Actions and Questions Check the Fuser installation. Replace the LVPS (page 8-92). Replace the Fuser (page 8-76). Connect P/J6. 4 Go to Step 5. Repair the wiring. Fuser Failure . Is P/J6 connected? Check continuity between the Fuser and LVPS. 7 Replace the Fuser (page 8-76). Replace the Fuser (page 8-76). Go to Step 7.

2. Replace the Fuser (page 8-76). Install the Fuser correctly. Open Door A. Is there an open circuit in the Center Thermistor between J131-1 and J131-2? Is the resistance of the Rear STS across J131-1 and J131-2 equal or greater than 3 k-ohm? Check the Pressure Roller Thermistor resistance. 5 Go to Step 6. P/J600. 3 Go to Step 5. P131 and P133. Is there an open circuit in the Pressure Roller Thermistor between J133-1 and J133-2? Is the resistance of the Pressure Roller Thermistor across J133-1 and J133-2 more than or equal to 3 k-ohm? Check the Fuser for connection. Connect P/J410. Run the Service Diagnostics Fuser Exit Sensor test. 4 Check the resistance of the Fuser. No Remove the paper. Are P/J410. Replace Engine Logic Board (page 8-89). P/J607.1 Print Engine Electrical (page 9-40) Fuser Cold Sagging Troubleshooting Procedure Step 1 Actions and Questions Check the Fuser for a paper jam. and Procedures 3-31 . Does sensor state change each time the Fuser is installed or removed? Yes Go to Step 2. 6 7 Go to Step 7. Connect P/J6. Open Door A. Is the Fuser installed correctly? Test the Fuser Exit Sensor operation. 2 Go to Step 3. P131 and P133 connected? Go to Step 7. 1. Replace the Fuser (page 8-76). Go to Step 4. Open Door A.1 Fuser and Exit 1 Unit (page 9-34) PL8. P/J600. Is there a paper jam in the Fuser? Check the Fuser installation.Fuser Cold Sagging Troubleshooting Reference Applicable Parts ■ ■ ■ References ■ ■ ■ ■ Fuser LVPS Engine Logic Board Print Engine P/J Fuser and Exit 1 (page 10-8) “Print Engine Fuser Wiring (page 10-22) PL6. P/J607. Error Messages. Codes. Is LVPS P/J6 connected? Check the Fuser connections.

Applicable Error Codes Fuser Failure . Does the Fuser Fan operate properly? Check the Fuser Fan connection (CN102). Remove the Upper Rear Cover. Replace the Fan (page 8-59). Remove the I/P Board Cover.U4-9 Fan Defect Fuser Fan Failure Troubleshooting Reference Applicable Parts ■ ■ ■ References ■ ■ ■ ■ ■ Fuser Fan Motor Assembly Engine Logic Board Print Engine P/J Electrical (page 10-12) Print Engine Drive/CRUM Wiring (page 10-25) PL5. Go to Step 4. Is there continuity on each wire? Check for +24 V to the Fuser Fan. Go to Step 3. Connect the Fan.U4-9 Fan Defect The Fuser Fan failed.1 Print Engine Drive (page 9-38) PL8. 6 Replace the Fan (page 8-59). Is there +24 V across CN102-3(+) <=> ground? Go to Step 7. 3-32 Phaser 5500 Printer Service Manual . No Correct the installation. 2 3 Check if the Fuser Fan rotates.1 Print Engine Electrical (page 9-40) Fuser Fan Failure Troubleshooting Procedure Step 1 Actions and Questions Check the Fuser Fan installation. Does the Fan rotate? Test the Fuser Fan. Go to Step 7.Fan Failure . Run the Service Diagnostic Fuser Fan test. Replace the Engine Logic Board (page 8-89). 2. Is the Fan installed properly (label out)? Yes Go to Step 2. 4 5 Go to Step 5. Go to Step 6. Is the Fan connected? Check continuity between the Fan and Motor Assembly (CN102).1 Laser. CRU and Toner Dispense (page 9-32) PL7. 1. then replace the Motor Assembly.

Repair the wiring. Run the Service Diagnostics Dispense Motor test. 5 6 Connect P/J216 and P/J420. Restore proper operation.Toner Motor Failure .U5-1 Motor Rotation The Toner Dispense Motor failed to rotate. Are P/J216 and P/J420 connected? Check continuity between the Dispense Motor and Engine Logic Board. Codes. No Go to Step 2. Is the pipe located at the lower part of the Toner Dispense Assembly clogged? Test Dispense Motor operation. 7 Replace the Dispense Motor (page 8-73). 3 Go to Step 4. Is there continuity on each wire between P/J216 <=> P/J420? Check for +24 V at the Dispense Motor Is there +24 V across P/J216-1 (+) <=> ground? Yes Problem solved. Applicable Error Codes Toner Motor Failure . Reinstall the Toner Cartridge. 4 Replace the Engine Logic Board (page 8-89). Go to Step 6. Clean the pipe. Error Messages.1 Print Engine Electrical (page 9-40) Troubleshooting Procedure Step 1 Actions and Questions Check the Toner Cartridge installation. 2 Go to Step 3.U5-1 Motor Rotation Troubleshooting Reference Applicable Parts ■ ■ ■ ■ References ■ ■ ■ ■ Toner Cartridge Toner Dispense Assembly Toner Dispense Motor Engine Logic Board Print Engine P/J Drum and Toner Cartridge (page 10-6) Print Engine Xerographics Wiring (page 10-24) PL5. and Procedures 3-33 . Does the gear located at the lower part of the Toner Dispense Assembly rotate? Check Toner Dispense Assembly clogging. Replace the Engine Logic Board (page 8-89). Go to Step 7. Go to Step 5.1 Laser. Does the motor operate? Check the Dispense Motor for connection. Does it operate properly? Check Toner Dispense Assembly rotation. CRU and Toner Dispense (page 9-32) PL8.

Fan Failure . Replace the Engine Logic Board (page 8-89).1 Laser. 2. Does the Fan operate properly? Check the Fan connection. Replace the Fan (page 8-58). Is there +24 V across P/J221 (+) <=> ground? Test the Drum Cartridge Fan. 4 5 Go to Step 5. Is the Fan installed properly (label out)? Yes Go to Step 2. 2 3 Check if the Drum Cartridge Fan rotates. Run the Service Diagnostic Drum Cartridge Fan test. Replace the Engine Logic Board (page 8-89). Connect the Fan. Is P/J221 connected? Check continuity between the Fan and Engine Logic Board. Is there continuity on each wire? Check for +24 V at the Drum Cartridge Fan. Go to Step 6.U5-9 Fan Defect Drum Cartridge Fan Failure Troubleshooting Reference Applicable Parts ■ ■ References ■ ■ ■ ■ Drum Cartridge Fan Engine Logic Board Print Engine P/J Drum and Toner Cartridge (page 10-6) Print Engine Xerographics Wiring (page 10-24) PL5. Go to Step 7. 7 Replace the Fan (page 8-58) 3-34 Phaser 5500 Printer Service Manual . CRU and Toner Dispense (page 9-32) PL8. 6 Go to Step 7.U5-9 Fan Failure The Drum Cartridge Fan failed. 1. Does the Fan rotate? Test the Drum Cartridge Fan. Applicable Error Code Fan Failure . Go to Step 4. Remove the Top Cover. Run the Service Diagnostic Drum Cartridge Fan test.1 Print Engine Electrical (page 9-40) Drum Cartridge Fan Failure Troubleshooting Procedure Step 1 Actions and Questions Check the Drum Fan installation. Go to Step 3. Remove the I/P Board Cover. No Correct the installation. Does the Fan receive the voltage from the test? Go to Step 7.

U6-4 NVM Read/Write Engine Logic Board Failure . 4. Are all the connectors connected? Does the error reoccur when power is applied? Yes Go to Step 2.U6-3 NVM Data Defect Engine Logic Board Failure . within the specified time. No Problem solved.U6-7 PPM Data Engine Logic Board Troubleshooting Reference Applicable Parts ■ References ■ ■ Engine Logic Board Engine Logic Board P/J Locator (page 10-13) PL8. Applicable Error Code Paper Size Jam .U6-2 RAM Read/Write Engine Logic Board Failure .U6-6 ASIC/CRUM Engine Logic Board Failure . and Procedures 3-35 . Applicable Error Codes Engine Logic Board Failure . Connect all connectors. Paper Size Jam .Engine Logic Board Failure . 5.E1-1 Regi Area Jam Error Messages.1 Print Engine Electrical (page 9-40) Engine Logic Board Troubleshooting Procedure Step 1 2 Actions and Questions Does the error occur when the power is cycled? Check Engine Logic Board connections. Go to Step 3.U6-2. Codes. 3 Replace the Engine Logic Board (page 8-89). 6. Problem solved. Go to Step 3.U6-5 CP/U Power NVM Engine Logic Board Failure .E1-1 Regi Area Jam Paper did not pass the Registration Sensor located behind Door A. 3. 7 Engine Logic Board components have failed.

Replace the Engine Logic Board (page 8-89). 3-36 Phaser 5500 Printer Service Manual . Go to Step 9. Go to Step 8. 2. No Go to Step 2. 3 Go to Step 4.5 Registration (page 9-30) PL8. 7 8 9 Connect P/J215 and P/J403B. Clean or replace the Take Away Roller. Is there +5 V across the sensor connector’s P/J104-1 <=> ground? Test the Registration Clutch operation. Are P/J104 and P/J403B connected? Check continuity between the Registration Sensor and Engine Logic Board. Go to Step 6. Open Door A. Open Door A. 1. Repair the wiring. Is there continuity on each wire between P/J104 <=> P/J403? Check for +5 V at the Registration Sensor. Connect the sensor. Does the paper touch the Registration Sensor or Feeder’s Pre-Feed Sensor? Check the Take Away Roller. Run the Service Diagnostics Registration Sensor test. 6 Replace the Registration Sensor (page 8-52).1 Print Engine Electrical (page 9-40) Paper Size Jam (Registration Sensor) Troubleshooting Procedure Step 1 Actions and Questions Check paper position at Door A or B. Go to Step 7. 2 Go to Step 3. Replace the Engine Logic Board (page 8-89). 4 5 Check the Registration Sensor connection. Does the sensor change state? Yes Remove the paper. Is the Take Away Roller worn or contaminated with paper dust? Test the Registration Sensor. Is there continuity on each wire between P/J215 <=> P/J403? Go to Step 5. Does the clutch operate properly? Check the Registration Clutch connection.Paper Size Jam (Registration Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ References ■ ■ ■ ■ ■ Registration Sensor Registration Clutch Take Away Roller Engine Logic Board Print Engine P/J Registration Transport (page 10-10) Print Engine Registration Transport Wiring (page 10-23) PL4. Go to Step 10.1 Transportation and Registration (page 9-22) PL4. Are P/J215 and P/J403B connected? Check continuity between the Registration Clutch and Engine Logic Board. Run the Service Diagnostics Registration Clutch test. Repair the wiring.

Jam at A . 11 Replace the Engine Logic Board (page 8-89). located behind Door A. Is the resistance between J215-1 and J215-2 approximately 240 ohms? Yes Go to Step 11. and Procedures 3-37 . No Replace the Engine Logic Board (page 8-89). Replace Registration Clutch (page 8-51).5 Registration (page 9-30) PL6. Is there +24 V across P215-2 (+) <=> ground? Check Registration Clutch resistance. Error Messages. No Go to Step 2. Applicable Error Code Jam at A .1 Transportation and Registration (page 9-22) PL4.E1-2 Regi Area Jam E1-2 Regi Area Jam (Fuser Exit Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ Fuser Exit Sensor Registration Clutch Take Away Roller Exit PWB Engine Logic Board Print Engine P/J Drum and Toner Cartridge (page 10-6) Print Engine Exit 1 Wiring (page 10-30) PL4. 2 Go to Step 3. and Toner Dispense (page 9-32) PL8. within the specified time following activation of the Registration Clutch. Is the Take Away Roller worn or contaminated with paper dust? Yes Remove the paper.E1-2 Regi Area Jam Paper did not activate the Fuser Exit Sensor. Does the paper touch the Fuser Exit Sensor? Check the Take Away Roller. Clean or replace the Take Away Roller. CRU.1 Print Engine Electrical (page 9-40) E1-2 Regi Area Jam (Fuser Exit Sensor) Troubleshooting Procedure Step 1 Actions and Questions Check paper position behind Door A. Codes.Paper Size Jam (Registration Sensor) Troubleshooting Procedure (Continued) Step 10 Actions and Questions Check for +24 V to the Registration Clutch.1 Laser.

E1-6 Regi Area Jam Paper remains at the Registration Sensor located behind Door A. Jam at A . Repair the wiring. 10 Go to Step 11. Is the resistance between J215-1 and J215-2 approximately 240 ohms? Go to Step 5.E1-6 Regi Area Jam 3-38 Phaser 5500 Printer Service Manual . 6 Replace the Fuser Exit Sensor (page 8-77) Replace the Engine Logic Board (page 8-89). Repair the wiring.E1-2 Regi Area Jam (Fuser Exit Sensor) Troubleshooting Procedure (Continued) Step 3 Actions and Questions Test the Fuser Exit Sensor. Connect the sensor. 4 5 Check the Fuser Exit Sensor connection. Replace Registration Clutch (page 8-51). Run the Service Diagnostics Registration Clutch test. Is there +5 V across the sensor connector’s P/J125-3 <=> ground? Test the Registration Clutch operation. Run the Service Diagnostics Fuser Exit Sensor test. Go to Step 8. 11 Replace the Engine Logic Board (page 8-89). Replace the Engine Logic Board (page 8-89). Is there continuity on each wire between P/J215 <=> P/J403B? Check for +24 V to the Registration Clutch. Does the sensor change state? Yes Go to Step 7. Is there +24 V across P215-2 (+) <=> ground? Check Registration Clutch resistance. Open Door A. Replace the Engine Logic Board (page 8-89). Are P/J125 and P/J410 connected? Check continuity between the Fuser Exit Sensor and Engine Logic Board. Are P/J215 and P/J403B connected? Check continuity between the Registration Clutch and Engine Logic Board. Go to Step 9. No Go to Step 4. Go to Step 10. 7 8 9 Connect P/J215 and P/J403B. Go to Step 6. Applicable Error Code Jam at A . 2. 1. Does the clutch operate properly? Check the Registration Clutch connection. Is there continuity on each wire between P/J125 <=> P/J410? Check for +5 V at the Fuser Exit Sensor.

3 4 Check the Registration Sensor connection. and Procedures 3-39 . 2 Go to Step 3.Fuser Area Jam Paper did not actuate the Fuser Exit Sensor. Are P/J104 and P/J403 connected? Check continuity between the Registration Sensor and Engine Logic Board. Does the sensor change state? Yes Remove the paper. 2. Run the Service Diagnostics Registration Sensor test. 5 Replace the Registration Sensor (page 8-52). Go to Step 5. within the specified time. 1. Is there +5 V across the sensor connector’s P/J104-1 <=> ground? Go to Step 4.E3-2 Fuser Area Jam Error Messages. Is there continuity on each wire between P/J104 <=> P/J403? Check for +5 V at the Registration Sensor. Replace the Engine Logic Board (page 8-89).1 Print Engine Electrical (page 9-40) E1-6 Regi Area Jam (Registration Sensor) Troubleshooting Procedure Step 1 Actions and Questions Check paper position at Door A. Jam at A .E3-1 Fuser Area Jam Jam at A . Replace the Engine Logic Board (page 8-89).5 Registration (page 9-30) PL8. Is paper touching the Registration Sensor? Test the Registration Sensor. Applicable Error Codes Jam at A . Connect the sensor.E1-6 Regi Area Jam (Registration Sensor) Troubleshooting Reference Applicable Parts ■ ■ References ■ ■ ■ ■ Registration Sensor Engine Logic Board Print Engine P/J Registration Transport (page 10-10) Print Engine Registration Transport Wiring (page 10-23) PL4. No Go to Step 2. Repair the wiring. located behind Door A. Codes. Open Door A.

Open Door A. Is the Take Away Roller worn or contaminated with paper dust? Test the Fuser Exit Sensor operation.1 Transportation and Registration (page 9-22) PL6. Open Door A. 2. Replace Engine Logic Board (page 8-89). 3 Go to Step 4. Repair the wiring. Run the Service Diagnostic Fuser Exit Sensor test. Connect P/J125 and P/J410. 3-40 Phaser 5500 Printer Service Manual . 6 7 Check the Fuser Exit Sensor connection. Does the sensor state change each time paper touches the sensor? Yes Remove the paper. 1. Clean or replace Take Away Roller (page 8-41) Go to Step 6. Is there +5 V across J125-3 (+) <=> ground? Go to Step 7. Open Door A.Jam at A (Fuser Exit Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ References ■ ■ ■ ■ ■ Fuser Exit Sensor Take Away Roller Engine Logic Board Fuser Print Engine P/J Drum and Toner Cartridge (page 10-6) Print Engine Fuser Wiring (page 10-22) PL4. 8 Replace the Fuser Exit Sensor (page 8-77). 5 Reconnect the connector of the Engine Logic Board. Is the Fuser installed correctly? Check the Take Away Roller. Correct the installation. Go to Step 8. Remove the paper. 2 Go to Step 3.1 Print Engine Electrical (page 9-40) Jam at A (Fuser Exit Sensor) Troubleshooting Procedure Step 1 Actions and Questions Check paper position. Is there a paper jam in the Fuser? Check the Fuser installation. Is there continuity on each wire between P/J125 <=> P/J410? Check for +5 V to the Fuser Exit Sensor. Are P/J125 and P/J410 connected? Check continuity between the Fuser Exit Sensor and Engine Logic Board. Does the paper touch the Fuser Exit Sensor? Check the Fuser for a paper jam.1 Fuser and Exit 1 (page 9-34) PL8. No Go to Step 2. 4 Go to Step 5. Open Door A. Open Door A.

and Procedures 3-41 . Is there continuity on each wire between P/J125 <=> P/J410? Check for +5 V at the Fuser Exit Sensor. Go to Step 5. Run the Service Diagnostics Fuser Exit Sensor test.Jam at A .1 Fuser and Exit 1 (page 9-34) PL8. Replace the Engine Logic Board (page 8-89). Open Door A.E3-6 Fuser Area Jam Paper remains at the Fuser Exit Sensor located behind Door A. 2 Go to Step 3. No Go to Step 2.1 Print Engine Electrical (page 9-40) E3-6 Fuser Area Jam Troubleshooting Procedure Step 1 Actions and Questions Check paper position at Door A. 2. Applicable Error Code Jam at A . Connect the sensor.E3-6 Fuser Area Jam E3-6 Fuser Area Jam Troubleshooting Reference Applicable Parts ■ ■ References ■ ■ ■ ■ Fuser Exit Sensor Engine Logic Board Print Engine P/J Drum and Toner Cartridge (page 10-6) Print Engine Fuser Wiring (page 10-22) PL6. Is there +5 V across the sensor connector’s P/J125-3 <=> ground? Go to Step 4. Does the sensor change state? Yes Remove the paper. Error Messages. 1. Repair the wiring. Replace the Engine Logic Board (page 8-89). Is paper touching the Fuser Exit Sensor? Test the Fuser Exit Sensor. Are P/J125 and P/J410 connected? Check continuity between the Fuser Exit Sensor and Engine Logic Board. 3 4 Check the Fuser Exit Sensor connection. 5 Replace the Fuser Exit Sensor (page 8-77). Codes.

2 Exit 2 Tray Guide Assembly (page 4-40) E4-1 Exit 2 Area Jam Troubleshooting Procedure Step 1 Actions and Questions Check paper position at Door A. 3-42 Phaser 5500 Printer Service Manual . Is paper touching the Exit Sensor? Check the OCT Roller. Go to Step 5. Are P/J125 and P/J410 connected? Check continuity between the Fuser Exit Sensor and Engine Logic Board. 4 Restore proper operation. Does the OCT Roller and gears rotate smoothly? Test the Fuser Exit Sensor. 2 3 Go to Step 3. Does the sensor change state? Yes Remove the paper. Connect the sensor. Run the Service Diagnostics Fuser Exit Sensor test. Go to Step 6. Go to Step 4. Is there continuity on each wire between P/J125 <=> P/J410? Go to Step 7.1 Print Engine Electrical (page 9-40) PL24. 1. Is paper touching the Fuser Exit Sensor? Check paper position at Door E. Open Door A.1 Fuser and Exit 1 (page 9-34) PL8.Jam at A . Applicable Error Code Jam at A . 2. No Go to Step 2. Repair the wiring.E4-1 Exit 2 Area Jam E4-1 Exit 2 Area Jam Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ Fuser Exit Sensor Exit 2 Exit Sensor Exit 1 OCT Roller Exit 1 Motor Exit PWB Engine Logic Board LVPS Print Engine P/J Fuser and Exit 1 (page 10-8) Print Engine Fuser Wiring (page 10-22) Exit 2 Plug/Jack Locator (page 5-15) Exit 2 Sensor/Fan Wiring(page 5-18) PL6. Go to Step 8. Clean or replace the OCT Roller. 5 Go to Step 9. Is the OCT Roller worn or contaminated with paper dust? Check the drive transmission.E4-1 Exit 2 Area Jam Paper did not reach the Exit 2 Exit Sensor located behind Door E on time. Remove the paper. 6 7 Check the Fuser Exit Sensor connection.

Repair the wiring. Are P/J430 and P/J526 connected? Check continuity between the Exit PWB and the LVPS. Repair the wiring. Go to Step 14. 9 10 11 Go to Step 11. 12 Replace the Exit 1 Offset Motor (page 8-80). and P/J434 connected? Go to Step 20. Open Door E. Repair the wiring. Go to Step 18. Run the Service Diagnostics Exit Sensor test. 15 Go to Step 16. Is there continuity on each wire between P/J430 <=> P/J526? Check for +24 V to the Exit PWB. Go to Step 10. Is there continuity on each wire between P/J431 <=> P/J421? Check the connection between the Exit PWB and the LVPS. No Replace the Engine Logic Board (page 8-89). Is there +5 V across the sensor connector’s P/J125-3 <=> ground? Test the Exit 1 Motor operation. 18 19 Check the Exit 2 Exit Sensor connection. Does the motor operate properly? Check the Exit 1 Motor connection. Replace the Engine Logic Board (page 8-89). 1. 13 Connect P/J431 and P/J421. Are P/J206 and P/J432 connected? Check continuity between the Exit 2 Motor and Engine Logic Board. 17 Replace the Exit PWB (page 8-88). 16 Go to Step 17. Are P/J112. Is there continuity on each wire between P/J206 <=> P/J432? Check for +24 V to the Exit 1 Motor. 2. Go to Step 12. Connect P/J430 and P/J526.E4-1 Exit 2 Area Jam Troubleshooting Procedure (Continued) Step 8 Actions and Questions Check for +5 V at the Fuser Exit Sensor. Are P/J431 and P/J421 connected? Check continuity between the Exit PWB and the Engine Logic Board. Is there +24 V across P/J430-1 (+) <=> ground? Test the Exit 2 Exit Sensor. Go to Step 13. Connect P/J206 and P/J432. and Procedures 3-43 . Does the sensor change state? Yes Replace the Fuser Exit Sensor (page 8-77). Replace the LVPS (page 8-92). P/J606B. Run the Service Diagnostics Exit 1 Motor tests. Connect the sensor. Go to Step 19. Codes. 14 Go to Step 15. Is there +24 V across P206-5 (+) <=> ground? Check the connection between the Exit PWB and Engine Logic Board. Error Messages.

Connect P/J430 and P/J526. 23 Go to Step 24. 24 Go to Step 25. Replace the LVPS (page 8-92). Repair the wiring. 21 Replace the Exit Sensor (page 3-102). Is there +24 V across P/J430-1 (+) <=> ground? Yes Go to Step 21. 22 Connect P/J431 and P/J421. Is there continuity on each wire between P/J112 <=> P/J434? Check for +5 V at the Exit 2 Exit Sensor. Are P/J431 and P/J421 connected? Check continuity between the Exit PWB and Engine Logic Board. Is there continuity on each wire between P/J430 <=> P/J526? Check for +24 V to the Exit PWB. Is there +5 V across the sensor connector’s P/J112-3 <=> ground? Check the connection between the Exit PWB and Engine Logic Board. Repair the wiring. 25 Go to Step 26. Go to Step 23.E4-3 Exit 2 Area Jam Paper did not pass the Exit 2 Exit Sensor located behind Door E on time. No Repair the wiring. Applicable Error Codes Jam at E .E4-1 Exit 2 Area Jam Troubleshooting Procedure (Continued) Step 20 Actions and Questions Check continuity between the Exit 2 Exit Sensor and Exit PWB. Is there continuity on each wire between P/J431 <=> P/J421? Check the connection between the Exit PWB and the LVPS.E4-5 Exit 2 Area Jam 3-44 Phaser 5500 Printer Service Manual . Are P/J430 and P/J526 connected? Check continuity between the Exit PWB and the LVPS. Jam at E . 26 Replace the Exit PWB (page 8-88).E4-3 Exit 2 Area Jam Jam at A . Go to Step 22.

6 Clean or replace the OCT Roller. Is the OCT Roller worn or contaminated with paper dust? Check the drive transmission. Go to Step 6. Error Messages.E4-3 Exit 2 Area Jam Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ Exit 2 Exit Sensor Exit 2 Motor Exit 2 OCT Roller Exit 2 FU Roller Exit 2 Inv Roller Exit PWB Engine Logic Board LVPS Print Engine P/J Engine Logic Board (page 10-13) Print Engine Exit 1 Wiring (page 10-30) PL8. For E4-5: Go to Step 8.1 Exit 2 L/H Upper Chute (page 4-38) PL24. No Go to Step 2. Does the Solenoid operate the Gate? Yes Remove the paper. 3 Restore proper operation. Go to Step 7. 5 Restore proper operation. Go to Step 5.2 Exit 2 Tray Guide Assembly (page 4-40) E4-3 Exit 2 Area Jam Troubleshooting Procedure Step 1 2 Actions and Questions Check paper position at Door E. Is the FU Roller worn or contaminated with paper dust? Check the drive transmission. 7 Restore proper operation. Does the FU Roller and gears rotate smoothly? Check the Inv Roller. Does the OCT Roller and gears rotate smoothly? For E4-5 Only: Test Exit 2 Gate Solenoid. Codes. Run the Service Diagnostics Exit 2 Gate Solenoid test. Is paper touching the Exit 2 Sensor? Check the FU Roller. Does the INV Roller and gears rotate smoothly? Check the OCT Roller. 8 Go to Step 10.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual Exit 2 Plug/Jack Locator (page 5-15) Exit 2 General Wiring (page 5-7) PL24. Go to Step 3. and Procedures 3-45 . Got to Step 9. Clean or replace the FU Roller. Is the INV Roller worn or contaminated with paper dust? Check the drive transmission. Go to Step 4. For E4-3: Go to Step 9. 4 Clean or replace the INV Roller.

and P/J434 connected? Check continuity between the Exit Sensor and Exit PWB. Does the sensor change state? Yes For E4-5: Go to Step 10. 10 For E4-5 Only: Check Exit 2 Solenoid. 12 Go to Step 13.E4-3 Exit 2 Area Jam Troubleshooting Procedure (Continued) Step 9 Actions and Questions Test the Exit 2 Sensor. Connect P/J430 and P/J526. Is there +24 V across P/J430-1 (+) <=> ground? Go to Step 11. Connect the sensor. For E4-3: Go to Step 12. Is there continuity on each wire between P/J430 <=> P/J526? Check for +24 V to the Exit PWB. 15 Connect P/J431 and P/J421. Replace the LVPS (page 8-92). No Go to Step12. 17 Go to Step 18. 19 Replace the Exit PWB (page 8-88). Repair the wiring. Repair the wiring. Are P/J112. P/J606B. Go to Step 15. 11 Replace the Exit 2 Gate Solenoid (page 3-98). 13 Go to Step 14. Is there +5 V across the sensor connector’s P/J112-3 <=> ground? Check the connection between the Exit PWB and Engine Logic Board. Is there continuity on each wire between For E4-5 Only: Check for +24 V to the Exit 2 Gate Solenoid. Repair the wiring. 1. Check continuity on each wire between P/ J209 to P/J433. Is there +24 V across P/J433-11 (+) <=> ground? Check the Exit Sensor connection. Run the Service Diagnostics Exit Sensor test. 2. 3-46 Phaser 5500 Printer Service Manual . Are P/J430 and P/J526 connected? Check continuity between the Exit PWB and the LVPS. Repair the wiring. Is there continuity on each wire between P/J431 <=> P/J421? Check the connection between the Exit PWB and the LVPS. 14 Replace the Exit 2 Sensor (page 3-102) Go to Step 16. Replace the Exit PWB (page 8-88). 16 Go to Step 17. Open Door E. Is there continuity on each wire between P/J112 <=> P/J434? Check for +5 V at the Exit Sensor. Are P/J431 and P/J421 connected? Check continuity between the Exit PWB and the Engine Logic Board. 18 Go to Step 19.

28 Replace the Exit PWB (page 8-88). 22 Go to Step 23. Are P/J430 and P/J526 connected? Check continuity between the Exit PWB and the LVPS. 27 Go to Step 28. 25 Go to Step 26. 21 Connect P/J208. P/J606A and P/J433 connected? Check continuity between the Exit 2 Motor and Exit PWB. Go to Step 22. Replace the LVPS (page 8-92). P/J606A and P/J433.E4-6 Exit 2 Area Jam Paper remains at the Exit 2 Exit Sensor located behind Door E. Connect P/J430 and P/J526. Is there continuity on each wire between P/J430 <=> P/J526? Check for +24 V to the Exit PWB. Repair the wiring. Jam at E . Are P/J208. Repair the wiring. Applicable Error Codes Jam at E .E4-3 Exit 2 Area Jam Troubleshooting Procedure (Continued) Step 20 Actions and Questions Test the Exit 2 Motor operation. 24 Connect P/J431 and P/J421. Is there +24 V across P/J430-1 (+) <=> ground? Yes Replace the Engine Logic Board (page 8-89). 26 Go to Step 27. Repair the wiring. Go to Step 24. Codes. No Go to Step 21. Are P/J431 and P/J421 connected? Check continuity between the Exit PWB and Engine Logic Board. Is there +24 V across P208-5 (+) <=> ground? Check the connection between the Exit PWB and Engine Logic Board. Is there continuity on each wire between P/J208 <=> P/J433? Check for +24 V to the Exit 2 Motor. Go to Step 25. and Procedures 3-47 . Run the Service Diagnostics Exit 2 Output Motor tests. Does the Exit 2 Motor operate properly? Check the Exit 2 Motor connection. Is there continuity on each wire between P/J431 <=> P/J421? Check the connection between the Exit PWB and the LVPS. 23 Replace the Exit 2 Motor (page 3-104).E4-6 Exit 2 Area Jam Error Messages.

Is there continuity on each wire between P/J112<=> P/J434? Check for +5 V at the Exit Sensor. Replace the Engine Logic Board (page 8-89). 2 Go to Step 3. Are P/J112.1 Print Engine Electrical (page 9-40) PL24. 3-48 Phaser 5500 Printer Service Manual . 5 Replace the Exit Sensor (page 3-102).2 Exit 2 Tray Guide Assembly (page 4-40) E4-6 Exit 2 Area Jam Troubleshooting Procedure Step 1 Actions and Questions Check paper position at Door A. Are P/J430 and P/J526 connected? Yes Remove the paper.E4-6 Exit 2 Area Jam Troubleshooting Reference Applicable Parts ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ Exit 2 Exit Sensor Exit PWB Engine Logic Board LVPS Print Engine P/J Engine Logic Board (page 10-13) Print Engine P/J Laser and Exit PWB (page 10-7) Print Engine Exit 1 Wiring (page 10-30) Phaser 5500 Printer Options Service Manual Exit 2 Plug/Jack Locator (page 5-15) Exit 2 General Wiring (page 5-7) PL8. Repair the wiring. Is there +5 V across the sensor connector’s P/J112-3 <=> ground? Check the connection between the Exit PWB and Engine Logic Board. Repair the wiring. 4 Go to Step 5. Is there continuity on each wire between P/J431 <=> P/J421? Check the connection between Exit PWB and LVPS. Are P/J431 and P/J421 connected? Check continuity between the Exit PWB and Engine Logic Board. 8 Go to Step 9. 6 Connect P/J431 and P/J421. Go to Step 7. Is paper touching the Fuser Exit Sensor? Test the Exit Sensor. Go to Step 6. No Go to Step 2. 7 Go to Step 8. Connect P/J430 and P/J526. 3 Connect the sensor. Go to Step 4. Run the Service Diagnostics Exit Sensor test. Does the sensor change state? Check the Exit Sensor connection. P/J606B and P/J434 connected? Check continuity between the Exit Sensor and Exit PWB.

3 Restore proper operation.1 Duplex Unit (page 4-34) PL24. Jam at E .1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual Exit 2 Plug/Jack Locator (page 5-15) Exit 2 General Wiring (page 5-7) Duplex Unit Plug/Jack Locator (page 5-12) Duplex Unit Wiring (page 5-13) PL23. No Go to Step 2. Error Messages. and Procedures 3-49 . Codes. Applicable Error Codes Jam at E . Clean or replace the FU Roller. Is the FU Roller worn or contaminated with paper dust? Check the drive transmission.2 Exit 2 Tray Guide Assembly (page 4-40) E8-2 Duplex Area Jam Troubleshooting Procedure Step 1 2 Actions and Questions Check paper position at Door E.E4-6 Exit 2 Area Jam Troubleshooting Procedure (Continued) Step 9 Actions and Questions Check continuity between the Exit PWB and LVPS. Is there +24 V across P/J430-1 (+) <=> ground? Yes Go to Step 10. Does the FU Roller and gears rotate smoothly? Yes Remove the paper. Go to Step 3. Is there continuity on each wire between P/J430 <=> P/J526? Check for +24 V to the Exit PWB.1 Exit 2 L/H Upper Chute (page 4-38) PL24.E8-2 Duplex Area Jam Paper being fed into the Duplex Unit did not reach the Wait Sensor on time. 10 Replace the Exit PWB (page 8-88). Does paper remain in Exit 2? Check the FU Roller. Replace the LVPS (page 8-92). No Repair the wiring. Go to Step 4.E8-2 Duplex Area Jam E8-2 Duplex Area Jam Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ Duplex Wait Sensor Exit 2 Motor Exit 2 OCT Roller Exit 2 FU Roller Exit 2 Inv Roller Exit PWB Duplex Unit PWB Engine Logic Board LVPS Print Engine P/J Engine Logic Board (page 10-13) Print Engine Exit 1 Wiring (page 10-30) PL8.

Is the OCT Roller worn or contaminated with paper dust? Check the drive transmission. Go to Step 12. 10 Go to Step 11. Go to Step 13. Repair the wiring. 13 Go to Step 14. Run the Service Diagnostics Exit 2 Motor tests. Go to Step 8. Is there continuity on each wire between P/J208 <=> P/J433? Check for +24 V to the Exit 2 Motor. P/J606A and P/ J433. Are P/J430 and P/J526 connected? Check continuity between the Exit PWB and the LVPS. 16 Replace the Exit PWB (page 8-88). Connect P/J208. Is there continuity on each wire between P/J431 <=> P/J421? Check the connection between the Exit PWB and the LVPS. Replace the LVPS (page 8-92). Are P/J431 and P/J421 connected? Check continuity between the Exit PWB and the Engine Logic Board. Go to Step 7. 8 Go to Step 17. Is there +24 V across P208-5 (+) <=> ground? Check the connection between the Exit PWB and Engine Logic Board. 9 Go to Step 10. No Go to Step 5. 11 Replace the Exit 2 Motor (page 3-104). 3-50 Phaser 5500 Printer Service Manual . Does the INV Roller and gears rotate smoothly? Check the OCT Roller. Go to Step 9. Go to Step 6. Repair the wiring. 14 Go to Step 15. 12 Connect P/J431 and P/J421. Is there +24 V across P/J430-1 (+) <=> ground? Yes Clean or replace the INV Roller. 15 Go to Step 16.E8-2 Duplex Area Jam Troubleshooting Procedure (Continued) Step 4 Actions and Questions Check the Inv Roller. Connect P/J430 and P/J526. Repair the wiring. P/J606A and P/J433 connected? Check continuity between the Exit Motor and Exit PWB. Does the Exit 2 Motor operate properly? Check the Exit 2 Motor connections. 6 Clean or replace the OCT Roller. Does the OCT Roller and gears rotate smoothly? Test the Exit 2 Motor. 5 Restore proper operation. Is there continuity on each wire between P/J430 <=> P/J526? Check for +24 V to the Exit PWB. 7 Restore proper operation. Are P/J208. Is the INV Roller worn or contaminated with paper dust? Check the drive transmission.

No Go to Step 18. Is there +5 V across P123-3 (+) <=> ground? Check the Duplex PWB connection. 22 Go to Step 23. Repair the wiring. and Procedures 3-51 . Jam at D and A . Go to Step 19. Go to Step 20. Run the Service Diagnostics Duplex Wait Sensor test. Are P/J123 and P/J541 connected? Check continuity between the Wait Sensor and Duplex PWB. located behind Door A. Codes. on time. Repair the wiring. 23 Replace the Duplex PWB (page 3-77). 20 Replace the Wait Sensor (page 3-78). 21 Connect P/J540 and P/J417 surely. Is there +5 V across P/J540-1 (+) <=> ground? Yes Replace the Engine Logic Board (page 8-89).C6-1 Duplex Area Jam Error Messages. Replace the Engine Logic Board (page 8-89). Is there continuity on each wire between P/J540 <=> P/J417? Check for +5 V to the Duplex PWB.E8-2 Duplex Area Jam Troubleshooting Procedure (Continued) Step 17 Actions and Questions Test the Wait Sensor. Go to Step 22. 18 19 Connect P/J123 and P/J541.C6-1 Duplex Area Jam Paper being fed from the Duplex Unit did not reach the Registration Sensor. Applicable Error Code Jam at D and A . Go to Step 21. Are P/J540 and P/J417 connected? Check continuity between the Duplex PWB and Engine Logic Board. Does the Wait Sensor operate properly? Check the Wait Sensor connection. Is there continuity on each wire between P/J123 <=> P/J541? Check for +5 V to the Wait Sensor.

Run the Service Diagnostics Duplex Motor test. Is the Duplex Roller worn or contaminated with paper dust? Check the roller drive. 6 Restore proper operation. 4 Restore proper operation. 2. No Go to Step 2. Connect P/J212 and P/J542. Are the A3L Rollers worn or contaminated with paper dust? Check the roller drive. Open Door D. Go to Step 5. Go to Step 6. Print a 2-sided Test Print. Problem solved. 1. 7 Go to Step 15. Do the Duplex Roller and gears rotate smoothly? Test the Duplex Motor. Does the Duplex Motor operate properly? Check the Duplex Motor for connection.C6-1 Duplex Area Jam Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ ■ Duplex A3L Rollers Duplex Roller Duplex Motor Duplex PWB Engine Logic Board Registration Sensor Print Engine P/J Engine Logic Board (page 10-13) Print Engine Registration Transport Wiring (page 10-23) PL4. Does the error reoccur? Yes Remove the paper. Go to Step 4. Reinstall the Duplex Unit.1 Duplex Unit (page 4-34) PL23. Do the A3L Rollers and gears rotate smoothly? Check the Duplex Roller. 5 Clean or replace the roller. 3-52 Phaser 5500 Printer Service Manual . Are P/J212 and P/J542 connected? Clean or replace the defective roller.2 Inner Chute Duplex Unit (page 4-36) C6-1 Duplex Area Jam Troubleshooting Procedure Step 1 Actions and Questions Check paper position. 3 Check the A3L Rollers. 2 Go to Step 3. Go to Step 8. Open Door A Does the paper touch the Registration Sensor? Check Duplex Unit installation. 8 Go to Step 9. Go to Step 7.5 Registration (page 9-30) PL8.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual Duplex Unit Plug/Jack Locator (page 5-12) Duplex Unit Wiring (page 5-13) PL23.

19 Replace the Duplex PWB (page 3-77). Run the Service Diagnostics Registration Sensor test. 17 Replace the Registration Sensor (page 8-52). Repair the wiring. Go to Step 17. Repair the wiring. Is there +24 V across P/J540-2 (+) <=> ground? Test the Registration Sensor. Error Messages.C6-2 Duplex Area Jam Paper being fed from the Duplex Unit did not reach the Registration Sensor. 18 Repair the wiring. Go to Step 11. Replace the Engine Logic Board (page 8-89). Codes. 10 Go to Step 14. Jam at D and A . Is there continuity on each wire between P/J104 <=> P/J409B? Check for +5 V to the Registration Sensor. 13 Replace the Duplex PWB (page 3-77). Are P/J104 and P/J403B connected? Check continuity between the Registration Sensor and Engine Logic Board. Is there +5 V across P/J104-1 (+) <=> ground? Check continuity between the Duplex PWB and Engine Logic Board. 14 15 16 Connect P/J104 and P/J403B. Connect P/J540 and P/J417. and Procedures 3-53 . located on behind Door A. Is there continuity on each wire between P/J540 <=> P/J417? Check for +5 V to the Duplex PWB. Replace the Engine Logic Board (page 8-89). No Repair the wiring. 11 12 Go to Step 12. Go to Step 15. Is there +5 V across P/J540-1 (+) <=> ground? Yes Go to Step 10. Does the sensor status change? Check the Registration Sensor connection. Go to Step 13. Are P/J540 and P/J417 connected? Check continuity between the Duplex PWB and Engine Logic Board. on time. Is there continuity on each wire between P/J540 <=> P/J417? Check for +24 V to the Duplex PWB. Paper didn’t stop at the Wait Sensor. Go to Step 18. Replace the Engine Logic Board (page 8-89). Go to Step 16.C6-1 Duplex Area Jam Troubleshooting Procedure (Continued) Step 9 Actions and Questions Check the Duplex Motor for continuity. Is there continuity on each wire between P/J212 <=> P/J542? Check for +24 V to the Duplex Motor. Is the +24 V across P/J212-5 (+) <=> ground? Check the Duplex PWB connection. Go to Step 19.

1. 6 Clean or replace the roller. 3-54 Phaser 5500 Printer Service Manual . Go to Step 5. Print a 2-sided Test Print. Do the A3L rollers and gears rotate smoothly? Check the Duplex Roller. 5 Restore proper operation. Does the error reoccur? Yes Remove the paper.5 Registration (page 9-30) PL8. Reinstall the Duplex Unit.Applicable Error Code Jam at D and A . No Go to Step 2. Go to Step 3. Open Door D Does the paper touch the Wait Sensor? Check the Duplex Unit installation. 2. 4 Check the A3L Rollers. Go to Step 7. Is the Duplex Roller worn or contaminated with paper dust? Check the roller drive. Are the A3L rollers worn or contaminated with paper dust? Check the roller drive.C6-2 Duplex Area Jam C6-2 Duplex Area Jam Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ ■ Duplex A3L Rollers Duplex Roller Duplex Motor Duplex Wait Sensor Duplex PWB Engine Logic Board Registration Sensor Print Engine P/J Engine Logic Board (page 10-13) Print Engine Registration Transport Wiring (page 10-23) PL4. 7 Restore proper operation. Do the Duplex Roller and gears rotate smoothly? Clean or replace the defective roller. 3 Problem solved.1 Duplex Unit (page 4-34) PL23. Open Door A Does the paper touch the Registration Sensor? Check the paper position.2 Inner Chute Duplex Unit (page 4-36) C6-2 Duplex Area Jam Troubleshooting Procedure Step 1 Actions and Questions Check the paper position. Go to Step 4. Go to Step 6. Go to Step 8. 2 Remove the paper.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual Duplex Unit Plug/Jack Locator (page 5-12) Duplex Unit Wiring (page 5-13) PL23.

C6-2 Duplex Area Jam Troubleshooting Procedure (Continued) Step 8 Actions and Questions Test the Wait Sensor. Go to Step 19. Codes. 20 Replace the Duplex PWB (page 3-77). 17 Replace the Duplex Motor (page 3-76). Connect P/J123 and P/J541. Go to Step 11. 13 Replace the Duplex PWB (page 3-77). Is the +24 V across P/J212-5 (+) <=> ground? Check the Duplex PWB connection. Run the Service Diagnostics Duplex Motor test. Is there continuity on each wire between P/J540 <=> P/J417? Check for +5 V to the Duplex PWB. and Procedures 3-55 . Are P/J540 and P/J417 connected? Check continuity between the Duplex PWB and Engine Logic Board. Is there +5 V across P123-3 (+) <=> ground? Check continuity between the Duplex PWB and Engine Logic Board. Is there continuity on each wire between P/J212 <=> P/J542? Check for +24 V to the Duplex Motor. Is there +5 V across P/J540-1 (+) <=> ground? Yes Go to Step 14. Replace the Engine Logic Board (page 8-89). Go to Step 18. Error Messages. Run the Service Diagnostics Duplex Wait Sensor test. Go to Step 13. Go to Step 20. 12 Repair the wiring. Does the Wait Sensor operate properly? Check the Wait Sensor connection. Repair the wiring. Go to Step 21. Repair the wiring. Are P/J212 and P/J542 connected? Check the Duplex Motor for continuity. Go to Step 12. Go to Step 15. 11 Replace the Wait Sensor (page 3-78). No Go to Step 9. Is there continuity on each wire between P/J123 <=> P/J541? Check for +5 V to the Wait Sensor. Is there continuity on each wire between P/J540 <=> P/J417? Check for +5 V to the Duplex PWB. Is there +5 V across P/J540-1 (+) <=> ground? Test the Duplex Motor. 18 19 Connect P/J540 and P/J417. Are P/J123 and P/J541 connected? Check continuity between the Wait Sensor and Duplex PWB. 9 10 Go to Step 10. Connect P/J212 and P/J542. Go to Step 17. Replace the Engine Logic Board (page 8-89). Repair the wiring. Does the Duplex Motor operate properly? Check the Duplex Motor for connection. 14 15 16 Go to Step 16.

Go to Step 23. Go to Step 26.C2-1 Tray 3 Jam at Tray 4 . 25 Repair the wiring. Run the Service Diagnostics Registration Sensor test. Replace the Engine Logic Board (page 8-89). Does the sensor status change? Check the Registration Sensor connection.Pre-Feed Paper fed from a universal tray did not reach the Pre-Feed Sensor. Is there +5 V across P/J104-1 (+) <=> ground? Check continuity between the Duplex PWB and Engine Logic Board. Is there continuity on each wire between P/J104 <=> P/J403? Check for +5 V to the Registration Sensor. 24 Replace the Registration Sensor (page 8-52). 26 Replace the Duplex PWB (page 3-77). Applicable Error Codes Jam at Tray 2 . on time. located on the tray’s Feeder.C4-4 Tray 5 3-56 Phaser 5500 Printer Service Manual . Go to Step 24.C6-2 Duplex Area Jam Troubleshooting Procedure (Continued) Step 21 Actions and Questions Check Registration Sensor operation. Jam at Tray n . Is there +5 V across P/J540-1 (+) <=> ground? Yes Replace the Engine Logic Board (page 8-89). Are P/J104 and P/J403 connected? Check continuity between the Registration Sensor and Engine Logic Board. Go to Step 25. Repair the wiring.C1-2 Tray 2 Jam at Tray 3 . Is there continuity on each wire between P/J540 <=> P/J417? Check for +5 V to the Duplex PWB. No Go to Step 22.C3-0 Tray 4 Jam at Tray 5 . 22 23 Connect P/J104 and P/J403B.

B. Error Messages. Does the paper touch the Feeder’s Registration or Pre-Feed Sensor? Test the Feeder’s Pre-Feed Sensor. and Procedures 3-57 . Remove the paper. Is the paper in the tray damaged? Check the paper size settings. Does the sensor change state? Yes Replace the paper. 3 Clean or replace the Rollers. Codes. Connect the sensor. Go to Step 4.3 Feeder (2/2) (page 9-12) PL8.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual 1000-Sheet Feeder P/J Locator (page 5-5) 1000-Sheet Tray 4 & 5 Wiring (page 5-9) PL20. 6 7 Check the Pre-Feed Sensor connection. Retard. Run the Service Diagnostics Pre-Feed Sensor test for the appropriate tray. Is the sensor’s connected? Check continuity between the Pre-Feed sensor and the Engine Logic Board. or C. Open Door A. Go to Step 8. Is there continuity on each wire between the sensor and board Go to Step 7. or C. No Go to Step 2. Does the paper size in use match the setting for the tray? Remove the tray and check the rollers. Repair the wiring. 5 Go to Step 6. or Nudger Roller worn or contaminated with paper dust? Check paper position at Door A. Got to Step 9 4 Go to Step 5. Go to Step 3. Correct paper size settings. B.Jam at Tray n (Pre-Feed Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ Feed Roller Retard Roller Nudger Roller Pre-Feed Sensor Feed/Lift Motor Engine Logic Board Tray 4-5 PWB Print Engine P/J Engine Logic Board (page 10-13) Print Engine Tray 2 & 3 Wiring (page 10-26) PL2. 1.6 Tray 4-5 Drive and Electrical (page 4-16) Jam at Tray n (Pre-Feed Sensor) Troubleshooting Procedure Step 1 2 Actions and Questions Check the paper condition. 2. Is the Feed.

If the error persists. Run the Service Diagnostics Lift/Feed motor test for the appropriate tray. 16 Replace the Feed/ Lift Motor. or Step 9 for Tray 4 or 5. 11 Replace the Tray 4-5 PWB. 1. Repair the wiring. Is the Feed/Lift motor connected? Test the Feed/Lift Motor. go to Step 12 for Tray 2 or 3. Replace the Engine Logic Board (page 8-89).Jam at Tray n (Pre-Feed Sensor) Troubleshooting Procedure (Continued) Step 8 Actions and Questions Check for +5 V at the Pre-Feed Sensor. or Step 9 for Tray 4 or 5 Connect P/J541 and P/J413. 15 Check the Feed/Lift Motor for continuity. go to Step 12 for Tray 2 or 3. 3-58 Phaser 5500 Printer Service Manual . 9 For Trays 4 & 5 Only: Check connections between the Tray 4-5 PWB and Engine Logic Board. Go to Step 14. Exchange the Feed/Lift motor with one from a different feeder. No Replace the Engine Logic Board (page 8-89). Replace the Feed/ Lift motor. Are P/J541 and P/J413 connected? For Trays 4 & 5 Only: Check continuity between the Tray 4-5 PWB and Engine Logic Board. Run the Service Diagnostics Lift/Feed motor test for the appropriate tray. 2. Is there continuity on each wire between the sensor and P/J409A? Check +24 V power supply to the Feed/Lift Motor. Go to Step 15. Is there +24 V across the motor connector’s Pin 4 <=> ground? Go to Step 16. If the error persists. Does the replaced motor operate? Go to Step 10. Is there +5 V across the sensor connector’s Pin 1 <=> ground? Yes Replace the sensor. Replace the Engine Logic Board (page 8-89). 10 Go to Step 11. Reinstall the Feed/Lift motors as they previously were. Does the motor operate? Check the Feed/Lift Motor connections. Repair the wiring. 13 14 Connect the motor. Is there continuity on each wire between P/J541 <=> P/J413? For Trays 4 & 5 Only: Check for +24 V at the Tray 4-5 PWB. Is their +24 V across P/J541-7 (+) <=> ground? Test the Feed/Lift Motor. Go to Step 13 12 Replace the Engine Logic Board (page 8-89).

Is the Feed.4 Tray 4-5 Feeders (2/2) (page 4-10) PL20. Is the paper in the tray damaged? Check paper size settings. Applicable Error Codes Jam at Tray 2 . Remove the paper.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual 1000-Sheet Feeder P/J Locator (page 5-5) 1000-Sheet Tray 4 & 5 Wiring (page 5-9) PL20. Go to Step 4. 1. Run the Service Diagnostics Registration Sensor test. No Go to Step 2.C1-3 Tray 2 Jam at Tray 3 .C2-3 Tray 3 Jam at Tray 4 . and Procedures 3-59 . 3 Clean or replace the Rollers. or Nudger Roller worn or contaminated with paper dust? Check paper position at Door A or B.Jam at Tray n .C3-3 Tray 4 Jam at Tray 5 . Codes. Error Messages. Correct paper size settings. Does the sensor change state? Yes Replace the paper.6 Tray 4-5 Drive and Electrical (page 4-16) Jam at Tray n (Registration Sensor) Troubleshooting Procedure Step 1 2 Actions and Questions Check paper condition. Retard. Does the paper touch the Registration Sensor or Feeder’s Pre-Feed Sensor? Test the Registration Sensor. 5 Go to Step 6. Go to Step 3. 2.3 Feeder (2/2) (page 9-12) PL8. Does the paper size in use match the setting for the tray? Remove the tray and check the rollers. Open Door A.C4-3 Tray 5 Jam at Tray n (Registration Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ ■ Feed Roller Retard Roller Nudger Roller Registration Sensor Tray 2 Pre-Feed Sensor Tray 3 Pre-Feed Sensor Engine Logic Board Tray 4-5 PWB Tray 4 Feed Out Sensor Tray 5 Feed Out Sensor Print Engine P/J Engine Logic Board (page 10-13) Print Engine Tray 2 & 3 Wiring (page 10-26) PL2. 4 Go to Step 5.Registration Paper fed from a universal tray did not reach the Registration Sensor on time. Go to Step 9.

Is the sensor’s connected? Go to Step 15. 8 Replace the Registration Sensor. Is there continuity on each wire between P/J104 <=> P/J403? Check for +5 V at the Registration Sensor Is there +5 V across the sensor connector’s Pin 1 <=> ground? Yes Go to Step 7. Run the Service Diagnostics Feed Out Sensor test for the appropriate tray. Open Door A or B 2. go to Step 9 for Tray 2 or 3. Connect the sensor. If the error persists. If the error persists. Is the sensor connected? For Trays 2 and 3 Only: Check continuity between the Pre-Feed Sensor and the Engine Logic Board. 14 For Trays 4 and 5 Only: Check the appropriate Feed Out Sensor connection. Go to Step 14. Are P/J104 and P/J403 connected? Check continuity between the Registration Sensor and Engine Logic Board. 11 Go to Step 12. or Step 13 for Tray 4 or 5. go to Step 9 for Tray 2 or 3. 13 Replace the Engine Logic Board (page 8-89). Repair the wiring. Does the sensor change state? 10 For Trays 2 and 3 Only: Check the Pre-Feed Sensor connection. 12 Replace the sensor. 9 For Trays 2 and 3 Only: Test the Feeder’s Pre-Feed Sensor. Go to Step 8. or Step 13 for Tray 4 or 5. Run the Service Diagnostics Pre-Feed Sensor test for the appropriate tray. Open Door C 2. Is there +5 V across the sensor connector’s Pin 1 <=> ground? For Trays 4 and 5 Only: Test the appropriate Feed Out Sensor. No Connect the sensor. Replace the Engine Logic Board (page 8-89). 1. Go to Step 10.Jam at Tray n (Registration Sensor) Troubleshooting Procedure (Continued) Step 6 7 Actions and Questions Check the Registration Sensor connection. Replace the Engine Logic Board (page 8-89). Repair the wiring. 1. Replace the Engine Logic Board (page 8-89). 3-60 Phaser 5500 Printer Service Manual . Is there continuity on each wire between the sensor and board For Trays 2 and 3 Only: Check for +5 V at the Pre-Feed Sensor. Does the sensor change state? Go to Step 11. Connect the sensor.

and Procedures 3-61 . Jam at Tray n . Connect P/J541 and P/J413. No Repair the wiring. 18 Go to Step 19.C2-2 Tray 3 Jam at Tray 4 . on time.Jam at Tray n (Registration Sensor) Troubleshooting Procedure (Continued) Step 15 Actions and Questions For Trays 4 and 5 Only: Check continuity between the Feed Out Sensor and the Tray 4-5 PWB. Replace the Engine Logic Board (page 8-89). Applicable Error Codes Jam at Tray 3 . Go to Step 17. 19 Replace the Tray 4-5 PWB (page 3-29). Is there continuity on each wire between the sensor and board For Trays 4 and 5 Only: Check for +5 V at the Feed Out Sensor. Is there +5 V across the sensor connector’s Pin 1 <=> ground? For Trays 4 & 5 Only: Check connections between the Tray 4-5 PWB and Engine Logic Board.C3-2 Tray 4 Jam at Tray 5 . Are P/J541 and P/J413 connected? For Trays 4 & 5 Only: Check continuity between the Tray 4-5 PWB and the Engine Logic Board. 17 Go to Step 18. located behind Door B on the Print Engine Take Away Chute.C4-2 Tray 5 Error Messages. Codes. Repair the wiring. 16 Replace the sensor. Is there continuity on each wire between P/J541 <=> P/J413? For Trays 4 & 5 Only: Check for +24 V at the Tray 4-5 PWB Is their +24 V across P/J541-7 (+) <=> ground? Yes Go to Step 16.Feed Out #3 Paper fed from a universal tray did not reach Feed Out Sensor #3.

Is there +5 V across the sensor connector’s Pin 1 <=> ground? Go to Step 7. go to Step 5 for Tray 2 or 3. If the error persists. No Go to Step 2. Connect the sensor. Open Door B. Clean or replace the Rollers. 7 Go to Step 8. Does the paper size match the setting? Remove the tray and check the rollers.6 Tray 4-5 Drive and Electrical (page 4-16) Jam at Tray n (Feed Out Sensor #3) Troubleshooting Procedure Step 1 2 3 Actions and Questions Check the paper condition. 1. Go to Step 3. Is the Feed. Remove the paper. P/J608 and P/J410 connected? Check continuity between the Feed Out Sensor #3 and Engine Logic Board. Correct paper size settings. Does the paper block the Feed Out Sensor? Yes Replace the paper. Retard. 2. 3-62 Phaser 5500 Printer Service Manual . Repair the wiring. or Step 9 for Tray 4 or 5. Is the paper in the tray damaged? Check the paper size settings.3 Feeder (2/2) (page 9-12) PL8. Replace the Engine Logic Board (page 8-89). Run the Service Diagnostics Tray 3 Feed Out Sensor test. 8 Replace Feed Out Sensor #3. or Step 9 for Tray 4 or 5. Does the sensor change state? Go to Step 6.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual 1000-Sheet Feeder P/J Locator (page 5-5) 1000-Sheet Tray 4 & 5 Wiring (page 5-9) PL20. Go to Step 9. 5 Test Feed Out Sensor #3. 6 Check the Feed Out Sensor #3 connection.4 Tray 4-5 Feeder (2/2) (page 4-10) PL20. Are P/J105. Go to Step 4. or Nudger Roller worn or contaminated with paper dust? Check the paper position at Door B or C. 4 Go to Step 5 for Tray 2 or 3. Is there continuity on each wire between P/J105 <=> P/J410? Check for +5 V at the Feed Out Sensor #3.Jam at Tray n (Feed Out Sensor #3) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ ■ Feed Roller Retard Roller Nudger Roller Feed Out Sensor #3 Engine Logic Board Tray 4-5 PWB Tray 4 Feed Out Sensor Tray 5 Feed Out Sensor Print Engine P/J Engine Logic Board (page 10-13) Print Engine Tray 2 & 3 Wiring (page 10-26) PL2.

Are P/J541 and P/J413 connected? For Trays 4 & 5 Only: Check continuity between the Tray 4-5 PWB and the Engine Logic Board. Codes. Applicable Error Codes Jam at Tray 4 . 15 Replace the Tray 4-5 PWB (page 3-29).C3-1 Tray 4 Jam at Tray 5 .C4-1 Tray 5 Error Messages. Is there continuity on each wire between P/J541 <=> P/J413? For Trays 4 & 5 Only: Check for +24 V at the Tray 4-5 PWB Is their +24 V across P/J541-7 (+) <=> ground? Go to Step 11. Jam at Tray n . Is the sensor connected? For Trays 4 and 5 Only: Check continuity between the Feed Out Sensor and the Tray 4-5 PWB. Open Door C 2. on time. located behind Door C on the 1000-Sheet Feeder. Repair the wiring. 10 For Trays 4 and 5 Only: Check the Feed Out Sensor connection. Connect P/J541 and P/J413. 12 Replace the sensor. Connect the sensor.Feed Out #4 Paper fed from a universal tray did not reach the Tray 4 Feed Out Sensor #4. Replace the Engine Logic Board (page 8-89). Repair the wiring.Jam at Tray n (Feed Out Sensor #3) Troubleshooting Procedure (Continued) Step 9 Actions and Questions For Trays 4 and 5 Only: Test the tray’s Feed Out Sensor. 13 Go to Step 14. 14 Go to Step 15. Is there continuity on each wire between the sensor and board For Trays 4 and 5 Only: Check for +5 V at the Feed Out Sensor. Go to Step 13. Is there +5 V across the sensor connector’s Pin 3 <=> ground? For Trays 4 & 5 Only: Check connections between the Tray 4-5 PWB and Engine Logic Board. 11 Go to Step 12. Does the sensor change state? Yes Replace the Engine Logic Board (page 8-89). No Go to Step 10. 1. Run the Service Diagnostics Feed Out Sensor test for the appropriate tray. and Procedures 3-63 .

Go to Step 9. Are P/J825. Go to Step 9 9 Connect P/J541 and P/J413. Does the paper size match the setting? Remove the tray and check the rollers. 7 Go to Step 8. Go to Step 4.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual 1000-Sheet Feeder P/J Locator (page 5-5) 1000-Sheet Tray 4 & 5 Wiring (page 5-9) PL20. Are P/J541 and P/J413 connected? Go to Step 7. Retard. Is there +5 V across the sensor connector’s Pin 3 <=> ground? Check connections between the Tray 4-5 PWB and Engine Logic Board. Clean or replace the Rollers.Jam at Tray n (Feed Out Sensor #4) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ Feed Roller Retard Roller Nudger Roller Engine Logic Board Tray 4-5 PWB Tray 4 Feed Out Sensor #4 Tray 5 Feed Out Sensor #5 Print Engine P/J Engine Logic Board (page 10-13) PL8. Remove the paper. Is the Feed.4 Tray 4-5 Feeder (2/2) (page 4-10) PL20. Correct paper size settings. P/J842 and P/J548 connected? Check continuity between the Feed Out Sensor #4 and Tray 4-5 PWB. or Nudger Roller worn or contaminated with paper dust? Check paper position at Door C.6 Tray 4-5 Drive and Electrical (page 4-16) Jam at Tray n (Feed Out Sensor #4) Troubleshooting Procedure Step 1 2 3 Actions and Questions Check paper condition. 6 Check the Feed Out Sensor #4 connection. Does the paper touch the Feed Out Sensor? Test Feed Out Sensor #4. Connect the sensor. No Go to Step 2. Go to Step 10. 4 Go to Step 5. 1. Run the Service Diagnostics Tray 4 Feed Out Sensor test. 3-64 Phaser 5500 Printer Service Manual . 5 Go to Step 6. Go to Step 3. Is the paper in the tray damaged? Check paper size settings. 2. Does the sensor change state? Yes Replace the paper. Is there continuity on each wire between P/J825 <=> P/J548? Check for +5 V at Feed Out Sensor #4. 8 Replace Feed Out Sensor #4 (page 3-21). Open Door C. Repair the wiring.

C4-0 Tray 5 Paper did not reach the Tray 5 Feed Out Sensor #5 on time. 14 Go to Step 15. Applicable Error Code Jam at Tray 5 . 1.Jam at Tray n (Feed Out Sensor #4) Troubleshooting Procedure (Continued) Step 10 Actions and Questions Check continuity between the Tray 4-5 and the Engine Logic Board. Replace the Engine Logic Board (page 8-89). 2. 12 13 Check the Feed Out Sensor #5 connection. Is there continuity on each wire between P/J541 <=> P/J413? Check for +24 V at the Tray 4-5 PWB Is their +24 V across P/J541-7 (+) <=> ground? Go to Step 14. Is there continuity on each wire between P/J825 <=> P/J548? Check for +5 V at the Feed Out Sensor #5. P/J842 and P/J548 connected? Check continuity between the Feed Out Sensor #5 and the Tray 4-5 PWB. Open Door C. Does the sensor change state? Yes Go to Step 11. Go to Step 13. Jam at Tray 5 .C4-0 Tray 5 Error Messages. Is there +5 V across the sensor connector’s Pin 3 <=> ground? Check connections between the Tray 4-5 PWB and Engine Logic Board. and Procedures 3-65 . Repair the wiring. Are P/J541 and P/J413 connected? Check continuity between the Tray 4-5 PWB and the Engine Logic Board. 15 Replace Feed Out Sensor #5 (page 3-22). 17 Go to Step 18. Go to Step 16. Connect the sensor. Go to Step 17. Replace the Engine Logic Board (page 8-89). Codes. Is there continuity on each wire between P/J541 <=> P/J413? Check for +24 V at the Tray 4-5 PWB Is their +24 V across P/J541-7 (+) <=> ground? Test the Feed Out Sensor #5. Repair the wiring. 11 Replace the Tray 4-5 PWB (page 3-29). Are P/J825. 16 Connect P/J541 and P/J413. Run the Service Diagnostics Tray 5 Feed Out Sensor test. 18 Replace the Tray 4-5 PWB (page 3-29). No Repair the wiring. Replace the Engine Logic Board (page 8-89).

Is there continuity on each wire between P/J103A <=> P/J549A? Check for +5 V at Tray 5 Pre-Feed Sensor Is there +5 V across the sensor connector’s Pin 1 <=> ground? Check connections between the Tray 4-5 PWB and Engine Logic Board.6 Tray 4-5 Drive and Electrical (page 4-16) Jam at Tray 5 (Feed Out Sensor #5) Troubleshooting Procedure Step 1 2 3 Actions and Questions Check paper condition. 4 Go to Step 5. Go to Step 4. Retard. Go to Step 3. 5 Go to Step 6. Repair the wiring. Go to Step 12. Run the Service Diagnostics Tray 5 Pre-Feed Sensor test. Remove the paper. 2. Correct paper size settings. 7 Go to Step 8.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual 1000-Sheet Feeder P/J Locator (page 5-5) 1000-Sheet Tray 4 & 5 Wiring (page 5-9) PL20. Is the Feed. Does the paper size match the setting? Remove the tray and check the rollers. Does the sensor change state? Yes Replace the paper. Connect the sensor. Go to Step 9 9 Connect P/J541 and P/J413. Go to Step 10. No Go to Step 2.Jam at Tray 5 (Feed Out Sensor #5) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ Feed Roller Retard Roller Nudger Roller Engine Logic Board Tray 4-5 PWB Tray 5 Pre-Feed Sensor Feed Out Sensor #5 Print Engine P/J Engine Logic Board (page 10-13) PL8. or Nudger Roller worn or contaminated with paper dust? Check paper position at Door C. Is the paper in the tray damaged? Check paper size settings. 1. Does the paper touch the Tray 5 PreFeed or Feed Out Sensor #5? Test the Tray 5 Pre-Feed Sensor. Open Door C. P/J661A and P/J549A connected? Check continuity between the Tray 5 PreFeed Sensor and Tray 4-5 PWB. Clean or replace the Rollers. 6 Check the Tray 5 Pre-Feed Sensor connection. 3-66 Phaser 5500 Printer Service Manual .4 Tray 4-5 Feeder (2/2) (page 4-10) PL20. Are P/J541 and P/J413 connected? Go to Step 7. 8 Replace the sensor. Are P/J103A.

Jam at Tray 5 (Feed Out Sensor #5) Troubleshooting Procedure (Continued) Step 10 Actions and Questions Check continuity between the Tray 4-5 PWB and the Engine Logic Board. Error Messages. Replace the Engine Logic Board (page 8-89). Are P/J541 and P/J413 connected? Check continuity between the Tray 4-5 PWB and the Engine Logic Board. Go to Step 16. Repair the wiring. 11 Replace the Tray 4-5 PWB (page 3-29). Connect the sensor. No Repair the wiring. Replace the Engine Logic Board (page 8-89). 12 13 Check the Feed Out Sensor #5 connection. 15 Replace the sensor (page 3-22). Run the Service Diagnostics Tray 5 Feed Out Sensor test. Is there continuity on each wire between P/J541 <=> P/J413? Check for +24 V at the Tray 4-5 PWB Is their +24 V across P/J541-7 (+) <=> ground? Test Feed Out Sensor #5. P/J842 and P/J548 connected? Check continuity between the Feed Out Sensor #5 and the Tray 4-5 PWB. Replace the Engine Logic Board (page 8-89). Is there continuity on each wire between P/J825 <=> P/J548? Check for +5 V at the Feed Out Sensor #5. 18 Replace the Tray 4-5 PWB (page 3-29). Repair the wiring. 2. Open Door C. Codes. 16 Connect P/J541 and P/J413. 14 Go to Step 15. Go to Step 13. 17 Go to Step 18. Are P/J825. 1. Go to Step 17. Is there continuity on each wire between P/J541 <=> P/J413? Check for +24 V at the Tray 4-5 PWB Is their +24 V across P/J541-7 (+) <=> ground? Go to Step 14. Is there +5 V across the sensor connector’s Pin 3 <=> ground? Check connections between the Tray 4-5 PWB and Engine Logic Board. and Procedures 3-67 . Does the sensor change state? Yes Go to Step 11.

3-68 Phaser 5500 Printer Service Manual . No Clean or replace the Rollers.8 Tray 6 Electrical (page 4-32) Jam at Tray 6 (Feed Out Sensor #6) Troubleshooting Procedure Step 1 Actions and Questions Check the paper path.4 Tray 6 Feeder (1/3) (page 4-24) PL22. Problem solved.6 Tray 6 Feeder (3/3) (page 4-28) PL22. Does the error still occur? Go to Step 4. Does the sensor change state? Go to Step 10. Connect and go to Step 5. Connect and go to Step 4. Are PF61 and PF56B connected? Check the Main Harness for connection Are PF56B and JF02 connected? Print a Test Print. 2.5 Tray 6 Feeder (2/3) (page 4-26) PL22. Open Door J. 3 4 5 Check the Feeder Harness for connection. Go to Step 6.C5-1 Tray 6 Jam at Tray 6 (Feed Out Sensor #6) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ Feed Roller Nudge Roller Retard Roller Feeder Harness Main Harness Tray 6 PWB Pre-Feed Sensor Feeder Motor Nudger Solenoid Engine Logic Board) Print Engine P/J Engine Logic Board (page 10-13) PL8. and turn freely? Yes Go to Step 2. Run the Service Diagnostics Tray 6 Pre-Feed Sensor test. 3. Are the Rollers installed correctly. 2. Go to Step 6. on time. 1.C5-1 Tray 6 Paper fed from the 2000-Sheet Feeder did not reach Feed Out Sensor #6.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual 2000-Sheet Tray 6 Feeder P/J Locator (page 5-20) 2000-Sheet Tray 6 Drive P/J Locator (page 5-21) 2000-Sheet Tray 6 Sensors Wiring (page 5-24) 2000-Sheet Tray 6 Drive Wiring (page 5-25) PL22. Go to Step 3. Open the Upper Feeder Assembly. located in the Lower Feeder Assembly under Door J. 1. Open Door J. Open the Upper Feeder Assembly. 2 Test the Tray 6 Pre-Feed Sensor.Jam at Tray 6 . clean. Applicable Error Code Jam at Tray 6 .

7 Check the Main Harness for continuity 1. when white paper is placed over the sensing area? Test the Feed/Lift Motor. Is the voltage across PF02-6 <=> PF04-2 on the PWB +5 V? Check the Pre-Feed Sensor function. Problem solved. Disconnect PF56B and JF02. and JF06 on the PWB connected? Print a Test Print. and Procedures 3-69 . Check for continuity at the following: JF56B-4 <=> JF02-6 JF56B-5 <=> JF02-5 JF56B-6 <=> JF02-4 Are these three conductive? Go to Step 8. Does the voltage across JF02-5 <=> PF04-2 on the PWB change. Does the Feed/Lift Motor rotate normally? Check the Harness connections. Connect and go to Step 12. 9 Go to Step 27. Repair the Feeder harness. No Repair the Feeder Harness. Error Messages. Check for continuity of the following: PF61-1 <=> JF56B-3 PF61-2 <=> JF56B-2 PF61-3 <=> JF56B-1 Are these three conductive? Yes Go to Step 7. PF56. 2. 2. Replace the Tray 6 PWB (page 3-67). Go to Step 11. Does the error still occur? Check the Feeder Harness for continuity 1. 12 13 Go to Step 13. Codes. Replace the PreFeed Sensor (page 3-51). Are the connectors PF58. Disconnect PF58 and JF56B. Disconnect PF61 and PF56B. Run the Service Diagnostics Tray 6 Motor Feed test. 11 Go to Step 13. Check for continuity at the following: PF58-1 <=> JF56-1 PF58-2 <=> JF56-2 PF58-3 <=> JF56-3 PF58-4 <=> JF56-4 PF58-5 <=> JF56-5 PF58-6 <=> JF56-6 Are these conductive? Go to Step 9. 10 Go to Step 18.Jam at Tray 6 (Feed Out Sensor #6) Troubleshooting Procedure (Continued) Step 6 Actions and Questions Check the Feeder Harness for continuity 1. 2. Go to Step 14. 8 Check for +5 V at the Pre-Feed Sensor. Repair the Main Harness.

23 Check Nudger Solenoid resistance. 19 Go to Step 21. 3-70 Phaser 5500 Printer Service Manual . Problem solved. Disconnect PF56 and JF06. Run the Service Diagnostics Tray 6 Nudger Solenoid Test at High Power. Disconnect PF59 and JF56A. Check for continuity at the following: PF59-2 <=> JF56A-1 PF59-1 <=> JF56A-2 Are these conductive? Go to Step 16.Jam at Tray 6 (Feed Out Sensor #6) Troubleshooting Procedure (Continued) Step 14 Actions and Questions Check the Main Harness for continuity. Connect and go to Step 20. PF56A. 18 Go to Step 27. Does the Nudger Solenoid activate? Check the harness connections. 2. Print a Test Print. 20 21 Go to Step 21. Does the error still occur? Test the Nudger Solenoid. Check for continuity at the following: PF56A-6 <=> JF06-13 PF56A-5 <=> JF06-14 Are these conductive? Go to Step 23. 2. 22 Check the Main Harness for continuity 1. No Repair the Main Harness. Repair the Main Harness. Go to Step 19. Check for continuity at the following: PF56-1 <=> JF06-1 PF56-2 <=> JF06-3 PF56-3 <=> JF06-2 PF56-4 <=> JF06-6 PF56-5 <=> JF06-4 PF56-6 <=> JF06-5 Are these conductive? Yes Go to Step 15. 16 Go to Step 17. Is there +24 V across PF06-3 <=> PF04-3 and PF06-4 <=> PF04-3 on the PWB? Replace the Feed/Lift Motor. Are the connectors PF59. 1. and P/JF06 on the PWB connected? Print a Test Print. Disconnect PF56A and JF06. 17 Go to Step 27. Replace the Tray 6 PWB (page 3-67). Replace the Nudger Solenoid (page 3-50). Does the error still occur? Check the Feeder Harness for continuity 1. 15 Check resistance of the Feed/Lift Motor. 2. Go to Step 22. Replace the Feed/Lift Motor (page 3-49). Is there some amount of resistance across PF59-1 and PF59-2? Go to Step 24. Is there some amount of resistance across PF58-2/5(COM) and PF58-1/3/4/ 6? Check for +24 V at the Feed/Lift Motor. Repair the Feeder Harness. Problem solved.

Problem solved. Applicable Error Code Jam at Tray 6 . Replace the Tray 6 PWB (page 3-67).7V? Replace the Nudger Solenoid. No Replace the Tray 6 PWB (page 3-67). 27 Replace the Engine Logic Board (page 8-89). Print a Test Print Does the error still occur? Yes Go to Step 25.8 Tray 6 Electrical (page 4-32) Error Messages.C5-2 Tray 6 Paper fed from the 2000-Sheet Feeder did not reach the Tray 3 Feed Out Sensor #3. located behind Door B.C5-2 Tray 6 Jam at Tray 6 (Feed Out Sensor #6) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ Feed Roller Nudge Roller Retard Roller Take Away Roller Door J Feed Out Sensor Feeder Harness Main Harness Tray 6 PWB Take Away Motor Engine Logic Board Print Engine P/J Engine Logic Board (page 10-13) PL8.Jam at Tray 6 (Feed Out Sensor #6) Troubleshooting Procedure (Continued) Step 24 Actions and Questions Test for +24 V at the Nudger Solenoid. Problem Solved.5 Tray 6 Feeder (2/3) (page 4-26) PL22. Jam at Tray 6 . on time. Run the Service Diagnostics Tray 6 Nudger Solenoid Test at High Power. +24 V? Test for +14.6 Tray 6 Feeder (3/3) (page 4-28) PL22. Codes.7 V at the Nudger Solenoid. Is the voltage across PF06-13 <=> P?JF04-3 on the PWB. 25 Go to Step 26. 26 Go to Step 27. +14.7 Drive and Transportation (page 4-30) PL22. Print a Test Print Does the error still occur? Replace the Tray 6 PWB.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual 2000-Sheet Tray 6 Feeder P/J Locator (page 5-20) 2000-Sheet Tray 6 Drive P/J Locator (page 5-21) 2000-Sheet Tray 6 Sensors Wiring (page 5-24) 2000-Sheet Tray 6 Drive Wiring (page 5-25) PL22. Is the voltage across PF06-13 <=> P/JF04-3 on the PWB. Run the Service Diagnostics Tray 6 Nudger Solenoid Test at Low Power. and Procedures 3-71 .

Disconnect PF54 and P/JF01.Jam at Tray 6 (Feed Out Sensor #6) Troubleshooting Procedure Step 1 Actions and Questions Check the paper path. 2 Test the Tray 6 Feed Out Sensor #6. when sensor is actuated? Test the Take Away Motor. 8 Check for +5 V at the Feed Out Sensor #6 Is the voltage across PJ01-3 <=> PJ04-2 on the PWB? Check the Feed Out Sensor #6 signal. Go to Step 11. clean. Are the Rollers installed correctly. Check for continuity at the following: PF54-1 <=> P/JF01-3 PF54-2 <=> P/JF01-2 PF54-3 <=> P/JF01-1 Are these three conductive? Go to Step 8. 2. 9 Go to Step 17. 10 Go to Step 17. Run the Service Diagnostics Tray 6 Take Away Motor Slow test. Does the voltage across P/JF01-2 <=> P/ JF04-2 on the Tray 6 PWB change. Go to Step 6. Connect and go to Step 4. and turn freely? Yes Go to Step 2. Replace the Tray 6 PWB (page 3-67). 3 4 5 6 Go to Step 4. Repair the Main Harness. 1. Replace the Feed Out Sesnor #6 (page 3-63). Check for continuity of the following: P/JF67-1 <=> JF54-3 P/JF67-2 <=> JF54-2 P/JF67-3 <=> JF54-1 Are these three conductive? Go to Step 10. Does the motor rotate normally? Go to Step 9. Go to Step 3. Disconnect P/JF67 and PF54. Does the error still occur? Check the Feeder Harness for continuity 1. 2. 3-72 Phaser 5500 Printer Service Manual . Open Door J. Connect and go to Step 5. 7 Check the Main Harness for continuity 1. Go to Step 7. No Clean or replace the Rollers. Are P/JF67 and JF54 connected? Check the Main Harness connections. Run the Service Diagnostics Tray 6 Feed Out Sensor test. Open the Upper Feeder Assembly. 2. Go to Step 6. Repair the Harness. Are PF54 and P/JF01 connected? Print a Test Print. Problem solved. Does the sensor change state? Check the sensor connections.

17 Replace the Engine Logic Board (page 8-89). Repair the Tray 6 Main harness. Applicable Error Code Jam at B . 12 13 Go to Step 13. Problem solved. Is there +24 V across PF06-9 <=> PF042. Print a Test Print. Does the error still occur? Check the Feeder Harness for continuity 1. 14 Check Take Away Motor resistance. Disconnect PF57 and JF06. Codes. 15 Go to Step 16.C5-3 Tray 6 Error Messages. and Procedures 3-73 . No Connect and go to Step 12. Replace the Take Away Motor (page 3-64). Check for continuity at the following: PF57-7 <=> P/JF06-11 PF57-6 <=> P/JF06-8 PF57-5 <=> P/JF06-9 PF57-4 <=> P/JF06-10 PF57-3 <=> P/JF06-12 PF57-2 <=> P/JF06-7 Are these conductive? Yes Go to Step 12. and PF06-10 <=> PF04-2 on the Tray 6 PWB? Replace the Take Away Motor.C5-3 Tray 6 Paper fed from the 2000-Sheet Feeder did not reach the Print Engine’s Registration Sensor on time. Does the error still occur? Replace the Tray 6 PWB. Print a Test Print Does the error still occur? Go to Step 15. Are the connectors PF57 and P/JF06 on the Main Harness connected? Print a Test Print. 16 Go to Step 17. Problem solved. Go to Step 14. Problem solved. Is there some amount of resistance across F57-3/4(COM) and JF57-1/2/5/6? Check for +24 V at the Take Away Motor.Jam at Tray 6 (Feed Out Sensor #6) Troubleshooting Procedure (Continued) Step 11 Actions and Questions Check the Main Harness connections. 2. Jam at B . Replace the Tray 6 PWB (page 3-67).

3 Go to Step 9. 2. Connect and go to Step 5. Run the Service Diagnostics Registration Sensor test. Disconnect P/J104 and P/J403. 4 Check the Registration Sensor connection to the printer’s Front Harness. Problem solved. clean.8 Tray 6 Electrical (page 4-32) Jam at B (Registration Sensor) Troubleshooting Procedure Step 1 Actions and Questions Check the paper path. Open Door A 2. Does the error still occur? Check the Harness for continuity. 5 6 Go to Step 6. Check for continuity at the following: J104-3 <=> J403B-3 J104-2 <=> J403B-8 J104-1 <=> J403B-13 Are these conductive? Go to Step 6. 1. 3-74 Phaser 5500 Printer Service Manual . 2 Go to Step 3. Go to Step 4. Go to Step 7.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual 2000-Sheet Tray 6 Feeder P/J Locator (page 5-20) 2000-Sheet Tray 6 Drive P/J Locator (page 5-21) 2000-Sheet Tray 6 Drive Wiring (page 5-25) PL22. Repair the printer’s Front Harness A. CRU and Toner Dispense (page 9-32) PL8. and turn freely? Check the printer paper path. Open Door J. Is the paper path clean? Test the Registration Sensor. Clean the paper path. 1. Does the sensor change state? Yes Go to Step 2.1 Laser.5 Print Engine Registration (page 9-30) PL5. Are all the rollers installed correctly. Open Door A. No Clean or replace the Rollers. Are P/J104 and P/J403 connected to the Registration Sensor? Print a Test Print.Jam at B (Registration Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ Take Away Roller Door J Registration Sensor Front Harness A Engine Logic Board Take Away Motor Main Harness Tray 6 PWB Print Engine P/J Engine Logic Board (page 10-13) PL4.7 Drive and Transportation (page 4-30) PL22.

Problem solved. Are the resistances across JF57-3/ 4(COM) and JF57-1/2/5/6. Does the error still occur? Go to Step 14. Are PF57 and P/JF06 connected? Print a Test Print. Run the Service Diagnostics Tray 6 Take Away Motor high speed test. Repair Main Harness. Error Messages. Codes. 8 Go to Step 16. 2. Print a Test Print. Is there +24 V across PF06-9 <=> PF042. Is there +5 V across P403-13 <=> P403-3 on the Engine Logic Board? Check the Registration Sensor. 13 Check the Take Away Motor resistance. 1. 15 Go to Step 16. Print a Test Print. Replace the Tray 6 PWB (page 3-67). Does the error still occur? Replace the Tray 6 PWB. 9 Go to Step 16. Go to Step 13. Does the voltage across P403-8 <=> P403-3 on the Engine Logic Board change when the sensor actuator is operated? Test the Tray 6 Take Away Motor. XXXX ohm? Check for +24 V to the Take Away Motor. and Procedures 3-75 . Check for continuity at the following: PF57-7 <=> P/JF06-11 PF57-6 <=> P/JF06-8 PF57-5 <=> P/JF06-9 PF57-4 <=> P/JF06-10 PF57-3 <=> P/JF06-12 PF57-2 <=> P/JF06-7 Are these conductive? Yes Go to Step 8. Does the error still occur? Check the Main Harness continuity. Does the motor rotate normally? Check the Main Harness connections.Jam at B (Registration Sensor) Troubleshooting Procedure (Continued) Step 7 Actions and Questions Check for +5 V to the Registration Sensor. 14 Go to Step 15. Replace the Take Away Motor (page 3-64). Go to Step 10. Problem solved. Problem solved. No Replace the Engine Logic Board (page 8-89). Go to Step 12. Replace the Registration Sensor (page 8-52). Connect and go to Step 11. 10 11 12 Go to Step 12. 16 Replace the Engine Logic Board (page 8-89). Disconnect PF57 and JF06. and PF06-10 <=> PF04-2 on the Tray 6 PWB? Replace the Take Away Motor.

Replace the Engine Logic Board (page 8-89). 1. Is there continuity on each wire between P/J105 <=> P/J410? Check for +5 V to the Feed Out Sensor #3. Run the Service Diagnostics Tray 3 Feed Out Sensor test. 5 Replace the Feed Out Sensor #3 (page 8-54). Does the paper touch the Tray 3 Feed Out Sensor? Test the Feed Out Sensor #3. Open Door B. Does the sensor change state? Yes Remove the paper.3 Feeder (2/2) (page 9-12) PL4. and P/J410 connected? Check continuity between the sensor and Engine Logic Board.5 Registration (page 9-30) PL8. 3-76 Phaser 5500 Printer Service Manual . P/J608.Jam at B . 2. Open Door B. Go to Step 3. 4 Go to Step 5. Connect the sensor. Are P/J105. Is there +5 V across P105-1(+)<=> ground? Go to Step 4.C8-2 F/O3 SNR Static Jam Paper remains at Feed Out Sensor #3 located behind Door B. Applicable Error Code Jam at B . 2 Replace the Engine Logic Board (8-89).C8-2 F/O3 SNR Static Jam Jam at B (Feed Out #3 Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ References ■ ■ ■ ■ ■ Feed Out Sensor #3 Tray 3 Feed/Lift Motor Engine Logic Board Print Engine P/J Tray 2 & 3 Feeder (page 10-11) Print Engine Registration Transport Wiring (page 10-23) PL2.1 Print Engine Electrical (page 9-40) Jam at B (Feed Out #3 Sensor) Troubleshooting Procedure Step 1 Actions and Questions Check the paper path. 3 Check the sensor connection. No Go to Step 2. Repair the wiring.

Open Door C. 3 Connect the sensor. 6 Replace Feed Out Sensor #4 (page 3-21). Is there continuity on each wire between P/J541 <=> P/J413? Check for +5 V to the Feed Out Sensor #4. No Go to Step 2. Repair the wiring.6 Tray 4-5 Drive and Electrical (page 4-16) Jam at C (Feed Out Sensor #4) Troubleshooting Procedure Step 1 Actions and Questions Check the paper path. Run the Service Diagnostics Tray 4 Feed Out Sensor test. Go to Step 3. and Procedures 3-77 . Go to Step 4. Codes.C8-3 F/O4 SNR Static Jam Paper remains at Feed Out Sensor #4 located behind Door C. Is there +5 V across P/J821-3 (+) <=> ground? Yes Remove the paper. Go to Step 7. Applicable Error Code Jam at C . Are P/J821. 5 Go to Step 6.Jam at C . Does the paper touch Feed Out Sensor #4? Test Feed Out Sensor #4. Error Messages. P/J841 and P/J548 connected? Check continuity between the Feed Out Sensor #4 and Tray 4-5 PWB. Is there continuity on each wire between P/J821 <=> P/J548? Check continuity between the 1000-Sheet Feeder and Engine Logic Board.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual 1000-Sheet P/J Tray 4 & 5 Feeders (page 5-5) 1000-Sheet P/J Tray 4 & 5 Electrical (page 5-6) 1000-Sheet Tray 4 Wiring (page 5-9) PL20. Does the sensor change state? Check the Feed Out Sensor #4 connection. 2 Replace the Engine Logic Board (page 8-89). Repair the wiring.5 Tray 4-5 Transportation (page 4-14) PL20. 4 Go to Step 5.C8-3 F/O4 SNR Static Jam Jam at C (Feed Out Sensor #4) Troubleshooting Reference Applicable Parts ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ Feed Out Sensor #4 Tray 4-5 PWB Engine Logic Board Print Engine P/J Engine Logic Board (page 10-13) PL8.

Go to Step 4. Open Door C. 3-78 Phaser 5500 Printer Service Manual . Is there continuity on each wire between P/J825 <=> P/J548? Yes Remove the paper.Jam at C (Feed Out Sensor #4) Troubleshooting Procedure (Continued) Step 7 Actions and Questions Check +5 V to the Tray 4-5 PWB Is there +5 V across P/J541-8 (+) <=> ground? Yes Replace the Tray 4-5 PWB (page 3-29).5 Tray 4-5 Transportation (page 4-14) PL20. and P/J548 connected? Check continuity between the Feed Out Sensor #5 and Tray 4-5 PWB. Are P/J825. 4 Go to Step 5. 2 Replace the Engine Logic Board (page 8-89). Jam at C . 3 Connect the sensor. Does the paper touch Feed Out Sensor #5? Test Feed Out Sensor #5.C8-4 F/O5 SNR Static Jam Paper remains at Feed Out Sensor (F/O#5) located behind Door C. P/J842. Repair the wiring. No Go to Step 2.6 Tray 4-5 Drive and Electrical (page 4-16) Jam at C (Feed Out Sensor #5) Troubleshooting Procedure Step 1 Actions and Questions Check the paper path. Go to Step 3.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual 1000-Sheet P/J Tray 4 & 5 Feeders (page 5-5) 1000-Sheet P/J Tray 4 & 5 Electrical (page 5-6) 1000-Sheet Tray 4 Wiring (page 5-9) PL20. No Replace the Engine Logic Board (page 8-89).C8-4 F/O5 SNR Static Jam Jam at C (Feed Out Sensor #5) Troubleshooting Reference Applicable Parts ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ Feed Out Sensor #5 Tray 4-5 PWB Engine Logic Board Print Engine P/J Engine Logic Board (page 10-13) PL8. Run the Service Diagnostics Tray 5 Feed Out Sensor test. Does the sensor change state? Check the Feed Out Sensor #5 connection. Applicable Error Code Jam at C .

Applicable Error Code Jam at Tray 6 . located in the Lower Feeder Assembly under Door J.6 Tray 6 Feeder (3/3) (page 4-28) PL22. Replace the Tray 4-5 PWB (page 3-29).C8-5 HCF F/O SNR Static Jam Jam at Tray 6 (Feed Out Sensor #6) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ Feed Roller Retard Roller Take Away Roller Door J Pre-Feed Sensor Feed Out Sensor #6 Feeder Harness Main Harness Take Away Motor Feeder Motor Tray 6 PWB Engine Logic Board) Print Engine P/J Engine Logic Board (page 10-13) PL8. Jam at Tray 6 . Is there +5 V across P/J548-1 (+) <=> ground? Yes Go to Step 6. Go to Step 7.8 Tray 6 Electrical (page 4-32) Error Messages.7 Drive and Transportation (page 4-30) PL22. 6 Replace the Feed Out Sensor #5 (page 3-22).Jam at C (Feed Out Sensor #5) Troubleshooting Procedure (Continued) Step 5 Actions and Questions Check continuity between 1000-Sheet Feeder and Engine Logic Board. Is there +5 V across P/J825-3 (+) <=> ground? Check +5 V to the Tray 4-5 PWB. and Procedures 3-79 . Codes.5 Tray 6 Feeder (2/3) (page 4-26) PL22.4 Tray 6 Feeder (1/3) (page 4-24) PL22.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual 2000-Sheet Tray 6 Feeder P/J (page 5-20) 2000-Sheet Tray 6 Drive P/J (page 5-21) 2000-Sheet Tray 6 Sensors Wiring (page 5-24) 2000-Sheet Tray 6 Drive Wiring (page 5-25) PL22. 7 Replace the Engine Logic Board (page 8-89). Is there continuity on each wire between P/J541 <=> P/J413? Check for +5 V to the Feed Out Sensor #5. No Repair the wiring.C8-5 HCF F/O SNR Static Jam Remaining paper in the Tray 6 Feed Out Sensor #6.

3. Problem solved. Are the Rollers installed correctly. Repair the Feeder Harness. Is there +5 V across PF02-6 <=> PF04-2 on the Tray 6 PWB? Check the Pre-Feed Sensor signal. 2. 3-80 Phaser 5500 Printer Service Manual . Go to Step 6. 1. Check for continuity of the following: PF61-1 <=> JF56B-3 PF61-2 <=> JF56B-2 PF61-3 <=> JF56B-1 Are these three conductive? Go to Step 4. No Clean or replace the rollers. 3 4 5 6 Check the Feeder Harness for connection. and turn freely? Yes Go to Step 2. Open Door J. 2. 1. Does the sensor change state? Go to Step 10. Connect and go to Step 4. when the sensor is blocked? Go to Step 9. Disconnect PF56B and JF02. Replace the Tray 6 PWB (page 3-67). Check for continuity at the following: JF56B-4 <=> JF02-6 JF56B-5 <=> JF02-5 JF56B-6 <=> JF02-4 Are these three conductive? Go to Step 8. clean. 9 Go to Step 33. Connect and go to Step 5. Go to Step 7. Go to Step 6. Open the Upper Feeder Assembly. Open the Upper Feeder Assembly. Run the Service Diagnostics Tray 6 Pre-Feed Sensor test. 2. 2. 2 Test the Tray 6 Pre-Feed Sensor 1.Jam at Tray 6 (Feed Out Sensor #6) Troubleshooting Procedure Step 1 Actions and Questions Check the paper path. Go to Step 3. 8 Check for +5 V at the Pre-Feed Sensor. 1. Repair the Main Harness. Disconnect PF61 and PF56B. 7 Check the Main Harness for continuity. Are PF61 and PF56B connected? Check the Main Harness for connection. Replace the PreFeed Sensor (page 3-51). Open Door J. Does the voltage across JF02-5 <=> PF04-2 on the Tray 6 PWB change. Does the error still occur? Check the Feeder Harness for continuity. Are PF56B and JF02 connected? Print a Test Print.

No Go to Step 11. Does the error still occur? Check the Harness for continuity. 19 Go to Step 21. Open Door J. 2. Repair the Main Harness. Error Messages. 1. Check for continuity at the following: JF54-1 <=> JF01-3 JF54-2 <=> JF01-2 JF54-3 <=> JF01-1 Are these three conductive? Go to Step 16. Does the error still occur? Go to Step 17. Does the sensor change state? Yes Go to Step 18. Connect and go to Step 20. 16 Check for +5 V to the Feed Out Sensor #6. 20 Go to Step 21. and JF06 on the PWB connected? Print a Test Print. 12 13 14 Go to Step 14.Jam at Tray 6 (Feed Out Sensor #6) Troubleshooting Procedure (Continued) Step 10 Actions and Questions Test the Feed Out Sensor #6. Does the Feed Motor rotate normally? Check the harness connections. Replace the Feed Out Sensor #6 (page 3-63). Run the Service Diagnostics Feed Motor test. Replace the Tray 6 PWB (page 3-67). Disconnect PF54 and JF01. 2. 18 Go to Step 26. Repair the Harness. 17 Go to Step 33. Is PF54 and JF01 connected? Print a Test Print. Does the voltage across JF01-2 <=> PF04-2 on the Tray 6 PWB change when the Feed Out Sensor is actuated? Test the Tray 6 Feed/Lift Motor. Connect and go to Step 12. Go to Step 14. Connect and go to Step 13. Go to Step 15. Check for continuity at the following: PF67-1 <=> JF54-3 PF67-2 <=> JF54-2 PF67-3 <=> JF54-1 Are these three conductive? Go to Step 12. Problem solved. Is PF67 and JF54 connected? Check the Main Harness connections. Run the Service Diagnostics Tray 6 Feed Out Sensor test. Problem solved. and Procedures 3-81 . Disconnect PF67 and JF54. 11 Check the Feed Out Sensor #6 connections. Are PF58 and PF56 on the Feeder and Main Harnesses. 2. Go to Step 19. Is there +5 V across PF01-3 <=> PF04-2 on the Tray 6 PWB? Check the Feed Out Sensor #6 signal. 1. 15 Check the Main Harness continuity. Codes. 1.

2. 27 28 Go to Step 29. Print a Test Print. Check for continuity at the following: PF56-1 <=> JF06-1 PF56-2 <=> JF06-3 PF56-3 <=> JF06-2 PF56-4 <=> JF06-6 PF56-5 <=> JF06-4 PF56-6 <=> JF06-5 Are these conductive? Go to Step 23. Is there +24 V across PF06-3 <=> PF04-3 and PF06-4 <=> PF04-3 on the Tray 6 PWB? Replace the Feed/Lift Motor.Jam at Tray 6 (Feed Out Sensor #6) Troubleshooting Procedure (Continued) Step 21 Actions and Questions Check the Feeder Harness for continuity. Does the error still occur? Go to Step 24. Run the Service Diagnostics Tray 6 Take Away Motor test at high speed. Disconnect PF56 and JF06. 25 Go to Step 33. Is there some amount of resistance across PF58-2/5 (COM) and PF58-1/3/4/ 6? Check for +24 V at the Feed/Lift Motor. Problem solved. 1. Replace the Tray 6 PWB (page 3-67). Are PF57 and JF06 connected? Print a Test Print. No Repair the Feeder harness. Replace the Feed/Lift Motor (page 3-49). Does the error still occur? Test the Take Away Motor. Problem solved. Go to Step 29. 23 Check resistance of the Feed/Lift Motor. 24 Go to Step 25. 1. Repair the Main Harness. 3-82 Phaser 5500 Printer Service Manual . Does the motor rotate normally? Check the Main Harness connection. Disconnect PF58 and JF56B. 26 Go to Step 33. 2. 22 Check the Main Harness for continuity. Check for continuity at the following: PF58-1 <=> JF56-1 PF58-2 <=> JF56-2 PF58-3 <=> JF56-3 PF58-4 <=> JF56-4 PF58-5 <=> JF56-5 PF58-6 <=> JF56-6 Are these conductive? Yes Go to Step 22. Connect and go to Step 28. Go to Step 27.

1 Duplex Unit (page 4-34) Error Messages. Problem solved. No Repair the Main Harness. Disconnect PF57 and JF06.Jam at Tray 6 (Feed Out Sensor #6) Troubleshooting Procedure (Continued) Step 29 Actions and Questions Check the Main Harness for continuity. Print a Test Print. Does the error still occur? Go to Step 31. Check for continuity at the following: PF57-7 <=> JF06-11 PF57-6 <=> JF06-8 PF57-5 <=> JF06-9 PF57-4 <=> JF06-10 PF57-3 <=> JF06-12 PF57-2 <=> JF06-7 Are these conductive? Yes Go to Step 30. and PF06-10 <=> PF04-3 on the PWB? Replace the Take Away Motor.C8-6 Duplex Jam at D (Wait Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ References ■ ■ ■ ■ ■ ■ Wait Sensor Duplex Unit PWB Engine Logic Board Print Engine P/J Engine Logic Board (page 10-13) PL8. Codes. 1.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual Duplex Unit Plug/Jack Locator (page 5-12) Duplex Unit Wiring (page 5-13) PL23. Does the error still occur? Replace the Tray 6 PWB. 32 Go to Step 33. Jam at D . Replace the Tray 6 PWB (page 3-67). Print a Test Print. Problem solved. Replace the Take Away Motor (page 3-64). Applicable Error Code Jam at D . 33 Replace the Engine Logic Board (page 8-89). 31 Go to Step 32. Is there +24 V across PF06-9 <=> PF043. Is there some amount of resistance across JF57-3/4(COM) and JF57-1/2/5/6? Check for +24 V to the Take Away Motor.C8-6 Duplex Paper remains at Duplex Unit’s Wait Sensor located behind Door D. 2. and Procedures 3-83 . 30 Check the Take Away Motor resistance.

Jam at Tray 1/MPT .Jam at D (Wait Sensor) Troubleshooting Procedure Step 1 Actions and Questions Check the paper path. Repair the wiring. 7 Replace the Duplex Unit PWB (page 3-77). Is there continuity on each wire between P/J123 <=> P/J541? Check for +5 V to the Wait Sensor. on time. Is there +5 V across P/J123-3 (+) <=> ground? Check continuity between the Duplex Unit PWB and Engine Logic Board. Open Door D. Go to Step 7. 5 Replace the Wait Sensor (page 3-78).C9-3 Tray 1/MPT 3-84 Phaser 5500 Printer Service Manual . No Go to Step 2. Replace the Engine Logic Board (page 8-89). Replace the Engine Logic Board (page 8-89). Go to Step 4. Does the sensor change state? Check the Wait Sensor connection. 2 Go to Step 3. Run the Service Diagnostics Duplex Unit Wait Sensor test. Go to Step 6. Go to Step 5. Applicable Error Code Jam at Tray 1/MPT . 6 Repair the wiring.C9-3 Tray 1/MPT Paper fed from Tray 1/MPT did not reach the Registration Sensor. Is there continuity on each wire between P/J540 <=> P/J417? Check for +5 V to the Duplex Unit PWB. Are P/J123 and P/J541 connected? Check continuity between the Wait Sensor and Duplex Unit PWB. Does the paper touch the sensor? Test the Wait Sensor. located behind Door A. Is there +5 V across P/J541-1 (+) <=> ground? Yes Remove the paper. 3 4 Connect the sensor.

Go to Step 4. Does the sensor state change? Go to Step 7. Does the error occur? Yes Replace the paper. Does the paper touch the Registration Sensor? Check the size guides. 1. 8 Go to Step 12. Error Messages. 6 Check the Feed Roller. Go to Step 3.Jam at Tray 1/MPT (Registration Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ Feed Roller Drive Roller Registration Sensor Pick Up Solenoid Engine Logic Board Print Engine P/J Tray 1/MPT (page 10-9) Print Engine P/J Registration Transport (page 10-10) Print Engine Tray 1/MPT Wiring (page 10-28) PL3. Print a Test Print from Tray 1. Connect P/J104 and P/J403. Open Door A. Are P/J104 and P/J403 connected? Go to Step 10. 1. Is the Drive Roller worn or contaminated with paper dust? Test the Registration Sensor. Do the size guides operate smoothly? Check the Tray 1 Feeder installation. No Go to Step 2. Clean or replace the Drive Roller.1 Print Engine Electrical (page 9-40) Jam at Tray 1/MPT (Registration Sensor) Troubleshooting Procedure Step 1 2 Actions and Questions Check paper condition. Remove the Tray 1 Feeder. Go to Step 6. Go to Step 9. and Procedures 3-85 . 3 Remove the paper.5 Registration (page 9-30) PL8. 4 5 Go to Step 5. Run the Service Diagnostics Registration Sensor test. 2. Does the paper size in use match the Tray 1 size setting? Check paper position. 9 Check the Registration Sensor connection. Is the Feed Roller worn or contaminated with paper dust? Check the Drive Roller. Problem solved.2 Tray 1/MPT Lower Frame (page 9-18) PL4. Repair or replace the guides. Open Door A. Reinstall the Tray 1 Feeder. Remove the Tray 1 Feeder. Is the paper in Tray 1 damaged? Check paper size setup. Correct the setting. 2. Codes. Clean or replace the Feed Roller 7 Go to Step 8.

Go to Step 13. Replace the Engine Logic Board (page 8-89. Replace the Pick Up Solenoid (page 8-36). Are P/J205. Replace the Engine Logic Board (page 8-89). 15 Go to Step 16. 3-86 Phaser 5500 Printer Service Manual . Run the Service Diagnostics Tray 1 Feed Solenoid test. Is there +5 V across P/J104-1 (+) <=> ground? Test the Pick Up Solenoid operation. Repair the wiring. P/J605 and P/ J411. No Repair the wiring. 16 Replace the Pick Up Solenoid (page 8-36). Replace the Engine Logic Board (page 8-89). Is there continuity on each wire between P/J205 <=> P/J411? Check the Pick Up Solenoid resistance.Jam at Tray 1/MPT (Registration Sensor) Troubleshooting Procedure (Continued) Step 10 Actions and Questions Check continuity between the Registration Sensor and Engine Logic Board. 12 13 Connect P/J205. Go to Step 14. Is the resistance across J205-1 and J205-2 approximately 90 ohm? Check for +24 V to the Pick Up Solenoid. P/J605 and P/J411 connected? Check the Pick Up Solenoid continuity. 14 Go to Step 15. Does the Pick Up Solenoid operate properly? Check the Pick Up Solenoid connection. Is there continuity on each wire between P/J104 <=> P/J403? Check for +5 V to the Registration Sensor. Is there +24 V across P205-1 (+) <=> ground? Yes Go to Step 11. 11 Replace the Registration Sensor (page 8-52).

4 Go to Step 5.F4-12 H-X’port Ent.2 Horizontal Transport (1/2) (page 4-46) PL25.3 Horizontal Transport (2/2) (page 4-48) PL25. and Procedures 3-87 .14 Finisher Electrical (page 4-70) Jam at A (H-X’port Entrance Sensor) Troubleshooting Procedure Step 1 Actions and Questions Check the paper path. Error Messages. 2 Go to Step 8. Applicable Error Code Jam at A . Does the sensor change state? Yes Go to Step 2. Reconnect and go to Step 4. 1. SNR ON Paper leaving the printer activated the printer’s Fuser Exit Sensor but did not reach the Horizontal Transport Entrance Sensor on time. Open Door F. Run the Service Diagnostic H-’Xport Entrance Sensor test. operate freely. 2. 3 Check the H-’Xport Harness connections.Jam at A . Go to Step 3. SNR ON Jam at A (H-X’port Entrance Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ ■ H-X’port Belts H-X’port Pinch Rollers H-X’port Motor H-X’port Harness H-X’port Entrance Sensor Finisher H-X’port PWB Finisher Main PWB Engine Logic Board Print Engine P/J Engine Logic Board (page 10-13) PL8.F4-12 H-X’port Ent. Is the harness connected to the HX’port Entrance Sensor and Finisher correctly? Print a Test Print. Problem solved.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual Horizontal Transport P/J Locator (page 5-29) Horizontal Transport Wiring (page 5-39) Finisher Main PWB P/J Locator (page 5-35) PL25. Codes. Open Door F. Are the Belts and Pinch Rollers clean. and correctly installed? Test the H-’Xport Entrance Sensor. Does the error still occur? Go to Step 5. No Clean or replace affected components.

Replace the H’Xport PWB (page 3-247). 1. Is there +5 V across J8372-9 <=> J83727 on the H-’Xport PWB? Check the Entrance Sensor signal. 9 Connect and go to Step 10. Replace the H’Xport PWB (page 3-247). Disconnect the Entrance Sensor (J8380) and P8372 on the H-’Xport PWB.Jam at A (H-X’port Entrance Sensor) Troubleshooting Procedure (Continued) Step 5 Actions and Questions Check the H-’Xport Harness continuity. and J8372-14 <=> J8372-7 on the H-’Xport PWB? Go to Step 13. 7 Replace the H’Xport PWB (page 3-247). Check for continuity at the following: P8372-7 <=> J8380-3 P8372-8 <=> J8380-2 P8372-9 <=> J8380-1 Are these conductive? Yes Go to Step 6. 1. 10 11 Go to Step 11. 2. Is there +24 V across J8372-15 <=> J8372-7. Run the Service Diagnostics H-’Xport Motor test. Check for continuity at the following: P8372-13 <=> J8379-6 P8372-12 <=> J8379-4 P8372-11 <=> J8379-1 P8372-10 <=> J8379-3 P8372-15 <=> J8379-2 P8372-3 <=> J8379-5 Are these conductive? Go to Step 7. 3-88 Phaser 5500 Printer Service Manual . Does the error still occur? Check the harness for continuity. Replace the H’Xport Motor (page 3-113). 8 Go to Step 9. Does the voltage across J8372-8 <=> J8372-7 on the H-’Xport PWB change when the sensor actuator is operated? Check the H-’Xport Motor. Replace the sensor. 13 Go to Step 14. Go to Step 11. 2. 12 Check the H-’Xport Motor resistance. Problem solved. Does the motor rotate normally? Check the H-’Xport Motor connections. and P8372 on the H-’Xport PWB. Go to Step 12. Is the H-’Xport Motor correctly connected to the harness? Print a Test Print. No Repair the harness. Replace the H’Xport PWB (page 3-247). Is there some amount of resistance across P8379-2/5(COM) and P8379-1/3/ 4/6? Check for +24 V to the H-’Xport Motor. Disconnect P/J8379 of the H-’Xport Motor. Repair the harness. 6 Check for +5 V to the Entrance Sensor.

Jam at A or F . No Go to Step 2. and Procedures 3-89 . Open Door F. Is the harness connected to the HX’port Entrance Sensor and Finisher correctly? Go to Step 4.2 Horizontal Transport (1/2) (page 4-46) PL25. Does the sensor change state? Yes Go to Step 7.F4-17 H-X’port Ent. 2. Run the Service Diagnostic H-’Xport Entrance Sensor test. Does the error still occur? Replace the H-’Xport PWB.3 Horizontal Transport (2/2) (page 4-48) PL25. Problem solved. SNR Static Jam A Jam at F .F4-n H-X’port Ent. Codes. 15 Replace the Finisher Main PWB (page 3-248).14 Finisher Electrical (page 4-70) Jam at A or F (H-X’port Entrance Sensor) Troubleshooting Procedure Step 1 Actions and Questions Test the H-’Xport Entrance Sensor. SNR Static Jam B Jam at A or F (H-X’port Entrance Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ H-X’port Motor H-X’port Harness H-X’port Entrance Sensor Finisher H-X’port PWB Phaser 5500 Printer Options Service Manual Horizontal Transport P/J Locator (page 5-29) Horizontal Transport Wiring (page 5-39) Finisher Main PWB P/J Locator (page 5-35) PL25. 1. Reconnect and go to Step 3.F4-16 H-X’port Ent. SNR Static The paper did not exit the Horizontal Transport on time. Error Messages. 2 Check the H-’Xport Harness connections. Does the error still occur? Yes Go to Step 15. Print a Test Print. Print a Test Print.Jam at A (H-X’port Entrance Sensor) Troubleshooting Procedure (Continued) Step 14 Actions and Questions Replace the H-’Xport Motor. Applicable Error Codes Jam at A . No Problem solved.

9 10 Go to Step 10. Does the motor rotate normally? Check the H-’Xport Motor connections. Replace the H’Xport Motor (page 3-113). Is the H-’Xport Motor correctly connected to the harness? Print a Test Print. 11 Check the H-’Xport Motor resistance. 1. Does the error still occur? Check the harness for continuity. 7 Replace the H’Xport PWB (page 3-247). 2. and P8372 on the H-’Xport PWB. Check for continuity at the following: P8372-7 <=> J8380-3 P8372-8 <=> J8380-2 P8372-9 <=> J8380-1 Are these conductive? Yes Go to Step 4. Go to Step 10. 6 Replace the H’Xport PWB (page 3-247). Repair the harness. Replace the H’Xport PWB (page 3-247). Does the voltage across J8372-8 <=> J8372-7 on the H-’Xport PWB change when the sensor actuator is operated? Test the H-’Xport Motor. Check for continuity at the following: P8372-13 <=> J8379-6 P8372-12 <=> J8379-4 P8372-11 <=> J8379-1 P8372-10 <=> J8379-3 P8372-15 <=> J8379-2 P8372-3 <=> J8379-5 Are these conductive? Go to Step 6. 2. 3-90 Phaser 5500 Printer Service Manual . Problem solved. Run the Service Diagnostics H-’Xport Motor test. 8 Connect and go to Step 9. No Problem solved.Jam at A or F (H-X’port Entrance Sensor) Troubleshooting Procedure (Continued) Step 3 4 Actions and Questions Print a Test Print. Replace the sensor (page 3-117). Does the error still occur? Check the H-’Xport Harness continuity. 5 Check for +5 V to the Entrance Sensor. Go to Step 11. Is there some amount of resistance across P8379-2/5(COM) and P8379-1/3/ 4/6? Go to Step 12. Go to Step 5. Is there +5 V across J8372-9 <=> J83727 on the H-’Xport PWB? Check the H-’Xport Entrance Sensor signal. Disconnect the H-’Xport Entrance Sensor (J8380) and P8372 on the H’Xport PWB. 1. Disconnect P/J8379 of the H-’Xport Motor. Go to Step 8. Repair the harness.

Print a Test Print. Jam at A or F .14 Finisher Electrical (page 4-70) Jam at A or F (H-X’port Exit Sensor) Troubleshooting Procedure Step 1 Actions and Questions Check the paper path.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual Horizontal Transport P/J Locator (page 5-29) Horizontal Transport Wiring (page 5-39) Finisher Main PWB P/J Locator (page 5-35) PL25. and Procedures 3-91 . 13 Replace the H’Xport PWB (page 3-247). Is there +24 V across J8372-15 <=> J8372-7. and correctly installed? Yes Go to Step 2. Does the error still occur? Yes Go to Step 13. Are the Belts and Pinch Rollers clean. operate freely.F4-n H-X’port Exit SNR ON Paper activated the Horizontal Transport Entrance Sensor but did not reach the Horizontal Transport Exit Sensor on time. and J8372-14 <=> J8372-7 on the H-’Xport PWB? Replace the H-’Xport Motor. No Replace the H’Xport PWB (page 3-247). Problem solved.F4-24 H-X’port Exit SNR ON Jam C Jam at A or F (H-X’port Exit Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ ■ H-X’port Belts H-X’port Pinch Rollers H-X’port Motor H-X’port Harness H-X’port Exit Sensor Finisher H-X’port PWB Finisher Main PWB Engine Logic Board Print Engine P/J Engine Logic Board (page 10-13) PL8.F4-23 H-X’port Exit SNR ON Jam B Jam at F . Open Door F. Applicable Error Codes Jam at A .Jam at A or F (H-X’port Entrance Sensor) Troubleshooting Procedure (Continued) Step 12 Actions and Questions Check for +24 V to the H-’Xport Motor.2 Horizontal Transport (1/2) (page 4-46) PL25. No Clean or replace affected components. Error Messages.F4-22 H-X’port Exit SNR ON Jam A Jam at F .3 Horizontal Transport (2/2) (page 4-48) PL25. Codes.

Run the Service Diagnostics H-’Xport Motor test. 2. Is the harness connected to the Exit Sensor and Finisher correctly? Print a Test Print. 3-92 Phaser 5500 Printer Service Manual . 6 Check for +5 V to the Exit Sensor. 7 Replace the H’Xport PWB (page 3-247). Does the voltage across J8372-5 <=> J8372-4 on the H-’Xport PWB change when the sensor actuator is operated? Test the H-’Xport Motor. Problem solved. Problem solved.Jam at A or F (H-X’port Exit Sensor) Troubleshooting Procedure (Continued) Step 2 Actions and Questions Test the H-’Xport Exit Sensor. Does the motor rotate normally? Check the H-’Xport Motor connections. Check for continuity at the following: P8372-4 <=> J8381-3 P8372-5 <=> J8381-2 P8372-6 <=> J8381-1 Are these conductive? Go to Step 5. Go to Step 11. Does the error still occur? Check the H-’Xport Harness continuity. 10 Go to Step 11. Repair the harness. No Go to Step 3. Reconnect and go to Step 4. Go to Step 6. 8 9 Connect and go to Step 10. Does the sensor change state? Yes Go to Step 8. Disconnect the Exit Sensor (J8381) and P8372 on the H-’Xport PWB. Replace the sensor (page 3-118). Run the Service Diagnostic H-’Xport Exit Sensor test. Does the error still occur? Go to Step 7. 1. Is the H-’Xport Motor correctly connected to the harness? Print a Test Print. 1. Open Door F. 4 5 Go to Step 5. 3 Check the H-’Xport Harness connections. 2. Replace the H’Xport PWB (page 3-247). Replace the H’Xport PWB (page 3-247). Is there +5 V across J8372-6 <=> J83724 on the H-’Xport PWB? Check the Exit Sensor signal. Go to Step 9.

Problem solved. 13 Go to Step 14. and J8372-14 <=> J8372-7 on the H-’Xport PWB? Replace the H-’Xport Motor. No Repair the harness. Problem solved. Is there +24 V across J8372-15 <=> J8372-7. Is there some amount of resistance across P8379-2/5(COM) and P8379-1/3/ 4/6? Check for +24 V to the H-’Xport Motor.3 Horizontal Transport (2/2) (page 4-48) PL25.14 Finisher Electrical (page 4-70) Error Messages. Does the error still occur? Go to Step 13. Does the error still occur? Replace the H-’Xport PWB.F4-26 H-X’port Exit SNR Static Remaining paper is detected by the Horizontal Transport Exit Sensor. Print a Test Print. Print a Test Print. Disconnect P/J8379 of the H-’Xport Motor. 15 Replace the Finisher Main PWB (page 3-248). Applicable Error Code Jam at F . 1.F4-26 H-X’port Exit SNR Static Jam at F (H-X’port Exit Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ H-X’port Motor H-X’port Harness H-X’port Exit Sensor Finisher H-X’port PWB Phaser 5500 Printer Options Service Manual Horizontal Transport P/J Locator (page 5-29) Horizontal Transport Wiring (page 5-39) Finisher Main PWB P/J Locator (page 5-35) PL25. 14 Go to Step 15. Check for continuity at the following: P8372-13 <=> J8379-6 P8372-12 <=> J8379-4 P8372-11 <=> J8379-1 P8372-10 <=> J8379-3 P8372-15 <=> J8379-2 P8372-3 <=> J8379-5 Are these conductive? Yes Go to Step 12. and Procedures 3-93 . Replace the H’Xport Motor (page 3-113). 12 Check the H-’Xport Motor resistance. Codes. 2. Replace the H’Xport PWB (page 3-247). and P8372 on the H-’Xport PWB.Jam at A or F (H-X’port Exit Sensor) Troubleshooting Procedure (Continued) Step 11 Actions and Questions Check the harness for continuity. Jam at F .

Run the Service Diagnostic H-’Xport Exit Sensor test. Does the error still occur? Check the H-’Xport Harness continuity. Is the harness connected to the Exit Sensor and Finisher correctly? Print a Test Print.Jam at F (H-X’port Exit Sensor) Troubleshooting Procedure Step 1 Actions and Questions Test the H-’Xport Exit Sensor. Problem solved. Is there +5 V across J8372-6 <=> J83724 on the H-’Xport PWB? Check the H-’Xport Exit Sensor signal. Run the Service Diagnostics H-’Xport Motor test. 1. 9 Go to Step 10. 5 Check for +5 V to the H-’Xport Exit Sensor. Does the voltage across J8372-5 <=> J8372-4 on the H-’Xport PWB change when the sensor actuator is operated? Check the H-’Xport Motor. 3 4 Go to Step 4. 2 Check the H-’Xport Harness connections. 3-94 Phaser 5500 Printer Service Manual . Does the sensor change state? Yes Go to Step 7. Replace the H’Xport PWB (page 3-247). Is the H-’Xport Motor correctly connected to the harness? Print a Test Print. 2. Go to Step 10. 2. 6 Replace the H’Xport PWB (page 3-247). Open Door F. Does the error still occur? Go to Step 6. Problem solved. No Go to Step 2. Does the motor rotate normally? Test the H-’Xport Motor connections. Reconnect and go to Step 3. Go to Step 5. Check for continuity at the following: P8372-4 <=> J8381-3 P8372-5 <=> J8381-2 P8372-6 <=> J8381-1 Are these conductive? Go to Step 4. Replace the H’Xport PWB (page 3-247). 1. Repair the harness. Disconnect the Exit Sensor (J8381) and P8372 on the H-’Xport PWB. Replace the H’Xport Exit Sensor (page 3-118). 7 8 Connect and go to Step 9. Go to Step 8.

1. 13 Replace the H’Xport PWB (page 3-247). Disconnect P/J8379 of the H-’Xport Motor. SNR ON Error Messages.Jam at F (H-X’port Exit Sensor) Troubleshooting Procedure (Continued) Step 10 Actions and Questions Check the harness for continuity. Is there +24 V across J8372-15 <=> J8372-7. No Repair the harness. Does the error still occur? Go to Step 12. Replace the H’Xport PWB (page 3-247). Jam at F . 12 Go to Step 13.F4-32 X’port Ent. Is there some amount of resistance across P8379-2/5(COM) and P8379-1/3/ 4/6? Check for +24 V to the H-’Xport Motor. SNR ON Paper does not reach the Finisher’s Transport Entrance Sensor following the paper’s leading edge activating the Horizontal Transport Exit Sensor. Check for continuity at the following: P8372-13 <=> J8379-6 P8372-12 <=> J8379-4 P8372-11 <=> J8379-1 P8372-10 <=> J8379-3 P8372-15 <=> J8379-2 P8372-3 <=> J8379-5 Are these conductive? Yes Go to Step 11. Problem solved. 11 Check the H-’Xport Motor resistance.F4-32 X’port Ent. Replace the H’Xport Motor (page 3-113). and J8372-14 <=> J8372-7 on the H-’Xport PWB? Replace the H-’Xport Motor. Applicable Error Code Jam at F . and Procedures 3-95 . and P8372 on the H-’Xport PWB. Codes. 2. Print a Test Print.

Jam at F (Transport Entrance Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ H-X’port Belts H-X’port Pinch Rollers H-X’port Motor H-X’port Harness H-X’port Exit Sensor Finisher Entrance Sensor Harness Main SNR Harness Ent. 1. 3-96 Phaser 5500 Printer Service Manual . Is there +5 V across J8372-6 <=> J83724 on the H-’Xport PWB? Go to Step 7. and correctly installed? Test the H-’Xport Exit Sensor. Repair the harness. Does the error still occur? Check the H-’Xport Harness continuity. Go to Step 3. Disconnect the Exit Sensor (J8381) and P8372 on the H-’Xport PWB. 2 Go to Step 8. 2. Open Door F.12 Finisher Transport (1/2) (page 4-66) PL25. 4 5 Go to Step 5. Sensor Finisher H-X’port PWB Finisher Main PWB Phaser 5500 Printer Options Service Manual Horizontal Transport P/J Locator (page 5-29) Horizontal Transport Wiring (page 5-39) Finisher Main PWB P/J Locator (page 5-35) Finisher Sensors (1/2) Wiring (page 5-40) PL25. Is the harness connected to the Exit Sensor and Finisher correctly? Print a Test Print. 6 Check for +5 V to the H-’Xport Exit Sensor. No Clean or replace affected components. Replace the H’Xport PWB (page 3-247). 3 Check the H-’Xport Harness connections. Reconnect and go to Step 4. Check for continuity at the following: P8372-4 <=> J8381-3 P8372-5 <=> J8381-2 P8372-6 <=> J8381-1 Are these conductive? Go to Step 5.15 Finisher Harness (page 4-72) Jam at F (Transport Entrance Sensor) Troubleshooting Procedure Step 1 Actions and Questions Check the paper path. Go to Step 6. operate freely. Does the sensor change state? Yes Go to Step 2. Problem solved. Run the Service Diagnostic H-’Xport Exit Sensor test.14 Finisher Electrical (page 4-70) PL25. 2.2 Horizontal Transport (1/2) (page 4-46) PL25. Open Door F.3 Horizontal Transport (2/2) (page 4-48) PL25. 1. Are the Belts and Pinch Rollers clean.

and J8372-14 <=> J8372-7 on the H-’Xport PWB? Replace the H-’Xport Motor. Go to Step 12. Problem solved. Does the voltage across J8372-5 <=> J8372-4 on the H-’Xport PWB change when the sensor actuator is operated? Test the H-’Xport Motor. Check for continuity at the following: P8372-13 <=> J8379-6 P8372-12 <=> J8379-4 P8372-11 <=> J8379-1 P8372-10 <=> J8379-3 P8372-15 <=> J8379-2 P8372-3 <=> J8379-5 Are these conductive? Yes Replace the H’Xport PWB (page 3-247). 10 11 Go to Step 11. No Replace the H’Xport Exit Sensor (page 3-118). 15 Go to Step 16. Run the Service Diagnostics H-’Xport Motor test. Error Messages. Run the Service Diagnostics Finisher Transport Entrance Sensor test. Replace the H’Xport PWB (page 3-247). 14 Go to Step 15. and P8372 on the H-’Xport PWB. Codes. Does the error still occur? Check the harness for continuity. Connect and go to Step 10. Does the sensor state change? Go to Step 13. Problem solved. Print a Test Print. Replace the H’Xport Motor (page 3-113). Disconnect P/J8379 of the H-’Xport Motor. 16 Replace the Finisher Main PWB (page 3-248). 1. Go to Step 9. 13 Go to Step 14. Is there +24 V across J8372-15 <=> J8372-7. Is there some amount of resistance across P8379-2/5(COM) and P8379-1/3/ 4/6? Check for +24 V to the H-’Xport Motor. Problem solved.Jam at F (Transport Entrance Sensor) Troubleshooting Procedure (Continued) Step 7 Actions and Questions Check the H-’Xport Exit Sensor signal. Does the error still occur? Test the X'port Entrance Sensor. Does the motor rotate normally? Check the H-’Xport Motor connections. and Procedures 3-97 . 8 9 Go to Step 11. 12 Check the H-’Xport Motor resistance. Does the error still occur? Replace the H-’Xport PWB. 2. Go to Step 17. Print a Test Print. Is the H-’Xport Motor correctly connected to the harness? Print a Test Print. Repair the harness. Go to Step 16.

18 19 Go to Step 19. Repair the X’port Entrance Sensor Harness. Applicable Error Code Jam at F . Repair the Main Sensor Harness. SNR Static Remaining paper is detected in the Finisher Transport Entrance Sensor. 22 Replace the Finisher Main PWB (page 3-248). SNR Static 3-98 Phaser 5500 Printer Service Manual . Check for continuity at the following: J8303A-3 <=> J8302A-1 J8303A-2 <=> J8302A-2 J8303A-1 <=> J8302A-3 Are these conductive? Check for +5 V to the X’port Entrance Sensor Is there +5 V across J8302A-3 <=> J8302A-1 on the Finisher Main PWB? Check the X’port Entrance Sensor signal.Jam at F (Transport Entrance Sensor) Troubleshooting Procedure (Continued) Step 17 Actions and Questions Check the harness connections. No Reconnect and go to Step 18.F4-36 X’port Ent. 2. Replace the Finisher Main PWB (page 3-248). 1. Are P/J8319 and P/J8303 of the X’port Entrance Sensor. Go to Step 20. Disconnect P/J8303 on the Main Sensor Harness. and P/J8302A on the Main SNR harness connected? Print a Test Print. and P/J8302A on the Finisher Main PWB.F4-36 X’port Ent. Jam at F . Replace X’port Entrance Sensor (page 3-117). Does the voltage across P8302A-2 <=> P8302A-1 on the Finisher Main PWB change when the sensor is blocked? Go to Step 21. Does the error still occur? Check the sensor harness continuity. Check for continuity at the following: J8319-3 <=> J8303B-1 J8319-2 <=> J8303B-2 J8319-1 <=> J8303B-3 Are these conductive? Yes Go to Step 19. 21 Go to Step 22. Problem solved. Disconnect P/J8319 and P/J8303B on the X’port Entrance Sensor Harness. 20 Check Main Sensor Harness continuity.

5 Check Main Sensor Harness continuity. Check for continuity at the following: J8319-3 <=> J8303B-1 J8319-2 <=> J8303B-2 J8319-1 <=> J8303B-3 Are these conductive? Go to Step 4. Connect and go to Step 3. 6 Check for +5 V to the Entrance Sensor. 1. Go to Step 5. 1.15 Finisher Harness (page 4-72) Static Jam at F (Transport Entrance Sensor) Troubleshooting Procedure Step 1 Actions and Questions Test the H-’Xport Entrance Sensor.14 Finisher Electrical (page 4-70) PL25. Repair the Sensor Harness. 3 4 Go to Step 4. 2. Repair the Main Sensor Harness. and P/J8302A on the Finisher Main PWB. Is there +5 V across J8302A-3 <=> J8302A-1 on the Finisher Main PWB? Go to Step 7. and Procedures 3-99 . Open Door F. No Go to Step 2. Error Messages. Does the sensor change state? Yes Go to Step 8. Disconnect P/J8303A on the harness. Replace the Finisher Main PWB (page 3-248). Does the error still occur? Check Sensor Harness continuity. Problem solved. Disconnect P/J8319 and P/J8303B. 2 Check the Sensor Harness connections. Run the Service Diagnostic H-’Xport Entrance Sensor test. 1. Codes. 2.Static Jam at F (Transport Entrance Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ X’port Entrance Sensor Harness Main SNR Harness Ent. Is the harness connected to the sensor and Finisher correctly? Print a Test Print.12 Finisher Transport (1/2) (page 4-66) PL25. 2. Check for continuity at the following: J8303A-3 <=> J8302A-1 J8303A-2 <=> J8302A-2 J8303A-1 <=> J8302A-3 Are these conductive? Go to Step 6. Sensor Harness Main Drive Finisher Main PWB Transport Motor Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Sensors (1/2) Wiring (page 5-40) Finisher Motors Wiring (page 5-42) PL25.

Static Jam at F (Transport Entrance Sensor) Troubleshooting Procedure (Continued)
Step 7 Actions and Questions
Check Entrance Sensor signal. Does the voltage across P8302A-2 <=> P8302A-1 on the Finisher Main PWB change when the sensor is blocked? Check the Transport Motor. Run the Service Diagnostics Transport Motor test. Does the motor rotate normally? Test Entrance Roller drive. Run the Service Diagnostics Transport Motor test. Do the Entrance Rollers rotate? Check Main Drive Harness connections. Are P/J8342 and P/J8304 connected? Print a Test Print. Does the error still occur? Check Main Drive Harness continuity. 1. Disconnect P/J8342 and P/J8304. 2. Check for continuity at the following: J8342-1 <=> J8304-23 J8342-2 <=> J8304-16 J8342-3 <=> J8304-25 J8342-4 <=> J8304-27 J8342-5 <=> J8304-18 J8342-6 <=> J8304-29 Are these conductive?

Yes
Replace the Finisher Main PWB (page 3-248). Go to Step 9.

No
Replace the Entrance Sensor (page 3-217). Go to Step 10.

8

9

Replace the Finisher Main PWB (page 3-248). Go to Step 12. Go to Step 12. Go to Step 13.

Restore Roller operation.

10 11 12

Connect and go to Step 11. Problem solved. Repair the Main Drive Harness.

13

Check Transport Motor resistance. Is there some amount of resistance across P8342-2/5(COM) and P8342-1/3/ 4/6? Check for +24 V to the Transport Motor. Is there +24 V across J8304-16 <=> ground, and J8304-18 <=> ground on the Finisher Main PWB? Replace the Transport Motor. Print a Test Print. Does the error still occur?

Go to Step 14.

Replace the Transport Motor (page 3-222). Replace the Finisher Main PWB (page 3-248). Problem solved.

14

Go to Step 15.

15

Replace the Finisher Main PWB (page 3-248).

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Phaser 5500 Printer Service Manual

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

Applicable Error Codes
Jam at G - F4-42 Buffer Path SNR ON Jam A Jam at G - F4-43 Buffer Path SNR ON Jam B Jam at G (Buffer Path Sensor ON) Troubleshooting Reference
Applicable Parts
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

References
■ ■ ■ ■ ■ ■ ■ ■ ■

Entrance Roller Entrance Pinch Roller Buffer Roller Pinch Roller Entrance Sensor Harness Main Sensor Harness Finisher Main PWB X’port Entrance Sensor Main Drive Harness Transport Motor X’port Gate Sensor Sensor Harness Buffer Gate Solenoid Registration Motor Buffer Sensor Harness Buffer Path Sensor

Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Sensors (1/2) Wiring (page 5-40) Finisher Motors Wiring (page 5-42) Finisher Clutch and Solenoids (page 5-43) PL25.12 Finisher Transport (1/2) (page 4-66) PL25.13 Finisher Transport (2/2) (page 4-68) PL25.14 Finisher Electrical (page 4-70) PL25.15 Finisher Harness (page 4-72)

Jam at G (Buffer Path Sensor ON) Troubleshooting Procedure
Step 1 Actions and Questions
Check the paper path. 1. Open Door G. 2. Remove the Top Cover. 3. Remove the Top L/H Cover. 4. Open the Upper Entrance Chute. Are the Rollers attached to the Chute clean, roll freely, and correctly installed?

Yes
Go to Step 2.

No
Clean or replace the appropriate roller.

Error Messages, Codes, and Procedures

3-101

Jam at G (Buffer Path Sensor ON) Troubleshooting Procedure (Continued)
Step 2 Actions and Questions
Check the paper path. 1. Open Door G. 2. Remove the Top Cover. 3. Remove the Top L/H Cover. 4. Open the Upper Exit Chute. Are the Buffer and Pinch Rollers clean, roll freely, and installed correctly?

Yes
Go to Step 3.

No
Clean or replace the appropriate roller.

3

Test the X'port Entrance Sensor. Run the Service Diagnostics Finisher Transport Entrance Sensor test. Does the state change when white paper is placed over the sensing area? Check the harness connections. Are P/J8319 and P/J8303B of the X’port Entrance Sensor, and P/J8302A on the Main SNR harness connected? Print a Test Print. Does the error still occur? Check the sensor harness continuity. 1. Disconnect P/J8319 and P/J8303B on the X’port Entrance Sensor Harness. 2. Check for continuity at the following: J8319-3 <=> J8303B-1 J8319-2 <=> J8303B-2 J8319-1 <=> J8303B-3 Are these conductive?

Go to Step 10.

Go to Step 4.

4

Go to Step 6.

Reconnect and go to Step 5.

5 6

Go to Step 6. Go to Step 7.

Problem solved. Repair the X’port Entrance Sensor Harness.

7

Check Main Sensor Harness continuity. Disconnect P/J8303A on the Main Sensor Harness, and P/J8302A on the Finisher Main PWB. Check for continuity at the following: J8303A-3 <=> J8302A-1 J8303A-2 <=> J8302A-2 J8303A-1 <=> J8302A-3 Are these conductive? Check for +5 V to the Entrance Sensor. Is there +5 V across J8302A-3 <=> J8302A-1 on the Finisher Main PWB? Check the Entrance Sensor signal. Does the voltage across P8302A-2 <=> P8302A-1 on the Finisher Main PWB change when the sensor is blocked?

Go to Step 8.

Repair the Main Sensor Harness.

8

Go to Step 9.

Replace the Finisher Main PWB (page 3-248). Replace X’port Entrance Sensor (page 3-217).

9

Replace the Finisher Main PWB (page 3-248).

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Jam at G (Buffer Path Sensor ON) Troubleshooting Procedure (Continued)
Step 10 Actions and Questions
Test the Finisher Transport Motor. Run the Service Diagnostics Finisher Transport Motor Test. Does the motor rotate normally? Test the Entrance Roller drive. Run the Service Diagnostics Finisher Transport Motor Test. Does the Entrance Roller rotate? Print a Test Print. Does the error still occur? Check the Main Drive Harness. Are P/J8342 and P/J8304 connected? Print a Test Print. Does the error still occur? Check Main Drive Harness continuity. 1. Disconnect P/J8342 and P/J8304. 2. Check for continuity at the following: J8342-1 <=> J8304-23 J8342-2 <=> J8304-16 J8342-3 <=> J8304-25 J8342-4 <=> J8304-27 J8342-5 <=> J8304-18 J8342-6 <=> J8304-29 Are these conductive?

Yes
Go to Step 11.

No
Go to Step 13.

11

Go to Step 19.

After restoring operation, go to Step 12. Problem solved. Connect and go to Step 14. Problem solved. Repair the Main Drive Harness.

12 13 14 15

Go to Step 19. Go to Step 15. Go to Step 15. Go to Step 16.

16

Check the Transport Motor resistance. Is there some amount of resistance across P8342-2/5(COM) and P8342-1/3/ 4/6? Check for +24 V to the Transport Motor. Is there +24 V across J8304-16 <=> ground and J8304-18 <=> ground on the Finisher Main PWB? Replace the Transport Motor. Run the Service Diagnostics Finisher Transport Motor Test. Does the error still occur? Test the Gate Sensor. Run the Service Diagnostics Gate Sensor test. Does the state change when the sensor is blocked? Check the Sensor Harness connections. Is the Sensor Harness connected correctly?

Go to Step 17.

Replace the Transport Motor (page 3-222). Replace the Finisher Main PWB (page 3-248). Problem solved.

17

Go to Step 18.

18

Replace the Finisher Main PWB (page 3-248). Go to Step 25.

19

Go to Step 20.

20

Go to Step 22.

Connect and go to Step 21.

Error Messages, Codes, and Procedures

3-103

Jam at G (Buffer Path Sensor ON) Troubleshooting Procedure (Continued)
Step 21 22 Actions and Questions
Print a Test Print. Does the error still occur? Check the Sensor Harness continuity. 1. Disconnect P/J8432 and P/J8376. 2. Check for continuity at the following: J8432-3 <=> J8376-1 J8432-2 <=> J8376-2 J8432-1 <=> J8376-3 Are these conductive?

Yes
Go to Step 22. Go to Step 23.

No
Problem solved. Repair the Sensor Harness.

23

Check +5 V to the Gate Sensor. Is there +5 V across P8376-3 <=> P83761 on the Finisher Main PWB? Check the Gate Sensor. Does the voltage across P8376-2 <=> P8376-1 on the Finisher Main PWB change when the sensor is blocked? Test the Buffer Gate Solenoid. Run both Service Diagnostics Buffer Gate tests. Does the Buffer Gate operate? Check Main Drive Harness connections. Are P/J8394 and P/J8304 connected? Print a Test Print. Does the error still occur? Check Main Drive Harness continuity. 1. Disconnect P/J8394 and P/J8304. 2. Check for continuity at the following: J8394-1 <=> J8304-35 J8394-2 <=> J8304-34 J8394-3 <=> J8304-36 Are these conductive?

Go to Step 24.

Replace the Finisher Main PWB (page 3-248). Replace the Gate Sensor (page 3-236). Go to Step 26.

24

Replace the Finisher Main PWB (page 3-248). Go to Step 31.

25

26 27 28

Go to Step 28. Go to Step 28. Go to Step 29.

Connect and go to Step 27. Problem solved. Repair the Main Drive Harness.

29

Check for +24 V to the Buffer Gate Solenoid. Is there +24 V across J8304-34 <=> J8304-36 on the Finisher Main PWB? Replace the Buffer Gate Solenoid. Print a Test Print. Does the error still occur? Test the Registration Motor. Run the Service Diagnostics Finisher Registration Motor Test. Does the motor rotate normally?

Go to Step 30.

Replace the Finisher Main PWB (page 3-248). Problem solved.

30

Replace the Finisher Main PWB (page 3-248). Go to Step 32.

31

Go to Step 34.

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Phaser 5500 Printer Service Manual

Jam at G (Buffer Path Sensor ON) Troubleshooting Procedure (Continued)
Step 32 Actions and Questions
Test the Buffer Roller Drive. Run the Service Diagnostics Finisher Registration Motor CCW test. Does the Buffer Roller rotate? Print a Test Print. Does the error still occur? Check Main Drive harness connections. Are P/J8335 and P/J8304 connected? Print a Test Print. Does the error still occur? Check Main Drive Harness continuity. 1. Disconnect P/J8335 and P/J8304. 2. Check for continuity at the following: J8335-1 <=> J8304-7 J8335-2 <=> J8304-8 J8335-3 <=> J8304-9 J8335-4 <=> J8304-11 J8335-5 <=> J8304-10 J8335-6 <=> J8304-13 Are these conductive?

Yes
Go to Step 40.

No
Restore operation and go to Step 33. Problem solved. Connect and go to Step 35. Problem solved. Repair the Main Drive Harness.

33 34 35 36

Go to Step 40. Go to Step 36. Go to Step 36. Go to Step 37.

37

Check Registration Motor resistance. Is there some amount of resistance across P8335-2/5(COM) and P8335-1/3/ 4/6? Check for +24 V to the Registration Motor. Is there +24 V across J8304-8 <=> ground and J8304-10 <=> ground on the Finisher Main PWB? Replace the Registration Motor. Print a Test Print. Does the error still occur? Test the Buffer Path Sensor. Run the Service Diagnostics Buffer Path Sensor test. Does the sensor state change? Check the Buffer Path Sensor connection. Are P/J8392 and P/J8318B connected? Print a Test Print. Does the error still occur? Check Main Sensor Harness connections. Are P/J8318B and P/J8302A connected?

Go to Step 38.

Replace the Registration Motor (page 3-245). Replace the Finisher Main PWB (page 3-248). Problem solved.

38

Go to Step 39.

39

Replace the Finisher Main PWB (page 3-248). Replace the Finisher Main PWB (page 3-248). Go to Step 43. Go to Step 43. Go to Step 45.

40

Go to Step 41.

41 42 43

Connect and go to Step 42. Problem solved. Connect and go to Step 44.

Error Messages, Codes, and Procedures

3-105

Jam at G (Buffer Path Sensor ON) Troubleshooting Procedure (Continued)
Step 44 45 Actions and Questions
Print a Test Print. Does the error still occur? Check Buffer Sensor Harness continuity. 1. Disconnect P/J8392 and P/J8318B. 2. Check for continuity at the following: J8392-3 <=> J8318B-1 J8392-2 <=> J8318B-2 J8392-1 <=> J8318B-3 Are these conductive?

Yes
Go to Step 45. Go to Step 46.

No
Problem solved. Repair the Buffer Sensor Harness.

46

Check Main Sensor Harness continuity. 1. Disconnect P/J8318A from the harness, and P/J8302A on the Finisher Main PWB. 2. Check for continuity at the following: J8318A-3 <=> J8302A-13 J8318A-2 <=> J8302A-14 J8318A-1 <=> J8302A-15 Are these conductive?

Go to Step 47.

Repair the Main Sensor Harness.

47

Check for +5 V to the Buffer Path Sensor. Is there +5 V across J8302A-15 <=> J8302A-13 on the Finisher Main PWB? Check Buffer Path Sensor signal. Does the voltage across P8302A-14 <=> P8302A-13 on the Finisher Main PWB change when the actuator is operated?

Go to Step 48.

Replace the Finisher Main PWB (page 3-248). Replace the Buffer Path Sensor (page 3-207).

48

Replace the Finisher Main PWB (page 3-248).

Jam at G - F4-4n Buffer Path SNR Static
Remaining paper is detected in the Buffer Path by the Buffer Path Sensor.

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

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Phaser 5500 Printer Service Manual

Jam at G (Buffer Path Sensor Static) Troubleshooting Reference
Applicable Parts
■ ■ ■ ■ ■ ■

References
■ ■ ■ ■ ■ ■ ■ ■

Buffer Path Sensor Buffer Sensor Harness Main Sensor Harness Finisher Main PWB Main Drive Harness Registration Motor

Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Sensors (1/2) Wiring (page 5-40) Finisher Motors Wiring (page 5-42) PL25.12 Finisher Transport (1/2) (page 4-66) PL25.13 Finisher Transport (2/2) (page 4-68) PL25.14 Finisher Electrical (page 4-70) PL25.15 Finisher Harness (page 4-72)

Jam at G (Buffer Path Sensor Static) Troubleshooting Procedure
Step 1 Actions and Questions
Test the Buffer Path Sensor. Run the Service Diagnostics Buffer Path Sensor test. Does the sensor state change? Check the Buffer Path Sensor connection. Are P/J8392 and P/J8318 connected? Print a Test Print. Does the error still occur? Check Main Sensor Harness connections. Are P/J8318A and P/J8302 connected? Print a Test Print. Does the error still occur? Check Buffer Sensor Harness continuity. 1. Disconnect P/J8392 and P/J8318. 2. Check for continuity at the following: P/J8392-3 <=> J8318B-1 P/J8392-2 <=> J8318B-2 P/J8392-1 <=> J8318B-3 Are these conductive?

Yes
Go to Step 10.

No
Go to Step 2.

2 3 4 5 6

Go to Step 4. Go to Step 4. Go to Step 6. Go to Step 6. Go to Step 7.

Connect and go to Step 3. Problem solved. Connect and go to Step 5. Problem solved. Repair the Buffer Sensor Harness.

7

Check Main Sensor Harness continuity. 1. Disconnect P/J8318 from the harness, and P/J8302A on the Finisher Main PWB. 2. Check for continuity at the following: J8318A-3 <=> P/J8302A-13 J8318A-2 <=> P/J8302A-14 J8318A-1 <=> P/J8302A-15 Are these conductive?

Go to Step 8.

Repair the Main Sensor Harness.

Error Messages, Codes, and Procedures

3-107

Jam at G (Buffer Path Sensor Static) Troubleshooting Procedure (Continued)
Step 8 Actions and Questions
Check for +5 V to the Buffer Path Sensor. Is there +5 V across J8302A-15 <=> J8302A-13 on the Finisher Main PWB? Check Buffer Path Sensor signal. Does the voltage across P8302A-14 <=> P8302A-13 on the Finisher Main PWB change when the actuator is operated? Test the Registration Motor. Run the Service Diagnostics Finisher Registration Motor Test. Does the motor rotate normally? Test the Buffer Roller Drive. Run the Service Diagnostics Finisher Registration Motor CCW test. Does the Buffer Roller rotate? Print a Test Print. Does the error still occur? Check Main Drive harness connections. Are P/J8335 and P/J8304 connected? Print a Test Print. Does the error still occur? Check Main Drive Harness continuity. 1. Disconnect P/J8335 and P/J8304. 2. Check for continuity at the following: P/J8335-1 <=> P/J8304-7 P/J8335-2 <=> P/J8304-8 P/J8335-3 <=> P/J8304-9 P/J8335-4 <=> P/J8304-11 P/J8335-5 <=> P/J8304-10 P/J8335-6 <=> P/J8304-13 Are these conductive?

Yes
Go to Step 9.

No
Replace the Finisher Main PWB (page 3-248). Replace the Buffer Path Sensor (page 3-207). Go to Step 11.

9

Replace the Finisher Main PWB (page 3-248). Replace the Finisher Main PWB (page 3-248). Go to Step 13.

10

11

Restore operation and go to Step 12. Problem solved. Connect and go to Step 14. Problem solved. Repair the Main Drive Harness.

12 13 14 15

Go to Step 13. Go to Step 15. Go to Step 15. Go to Step 16.

16

Check Registration Motor resistance. Is there some amount of resistance across P8335-2/5(COM) and P8335-1/3/ 4/6? Check for +24 V to the Registration Motor. Is there +24 V across J8304-8 <=> ground and J8304-10 <=> ground on the Finisher Main PWB? Replace the Registration Motor. Print a Test Print. Does the error still occur?

Go to Step 17.

Replace the Registration Motor (page 3-245). Replace the Finisher Main PWB (page 3-248). Problem solved.

17

Go to Step 18.

18

Replace the Finisher Main PWB (page 3-248).

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Phaser 5500 Printer Service Manual

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

Applicable Error Codes
Jam at F - F4-51 Compile Exit SNR OFF Jam A Jam at F - F4-55 Compile Exit SNR OFF Jam B Jam at F or H (Compile Exit Sensor OFF) Troubleshooting Reference
Applicable Parts
■ ■ ■ ■ ■ ■ ■

References
■ ■ ■ ■ ■ ■ ■ ■ ■

Lower Exit Roller Compile Exit Sensor Compiler Harness Main Sensor Harness Finisher Main PWB Main Drive Harness Exit Motor

Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Sensors (1/2) Wiring (page 5-40) Finisher Motors Wiring (page 5-42) PL25.10 Finisher Eject (2/3) (page 4-62) PL25.11 Finisher Eject (3/3) page 4-64) PL25.13 Finisher Transport (2/2) (page 4-68) PL25.14 Finisher Electrical (page 4-70) PL25.15 Finisher Harness (page 4-72)

Jam at F (Compile Exit Sensor OFF) Troubleshooting Procedure
Step 1 Actions and Questions
Check the paper path. Open Door G. Is the Lower Exit Roller clean, installed correctly and roll freely? Test the Compile Exit Sensor. Run the Service Diagnostics Compile Exit Sensor test. Does the sensor state change? Check the Compile Exit Sensor connection. Are P/J8320 and P/J8391 connected? Print a Test Print. Does the error still occur? Check Main Sensor Harness connections. Are P/J8391 and P/J8302A connected? Print a Test Print. Does the error still occur?

Yes
Go to Step 2.

No
Clean or replace the Lower Exit Roller. Go to Step 2.

2

Go to Step 11.

3

Go to Step 5.

Connect and go to Step 4. Problem solved. Connect and go to Step 6. Problem solved.

4 5 6

Go to Step 5. Go to Step 7. Go to Step 7.

Error Messages, Codes, and Procedures

3-109

Jam at F (Compile Exit Sensor OFF) Troubleshooting Procedure (Continued)
Step 7 Actions and Questions
Check Compiler Harness continuity. 1. Disconnect P/J8320 and P/J8391. 2. Check for continuity at the following: P/J8320-3 <=> J8391B-1 P/J8320-2 <=> J8391B-2 P/J8320-1 <=> J8391B-3 Are these conductive?

Yes
Go to Step 8.

No
Repair the Compiler Harness.

8

Check Main Sensor Harness continuity. 1. Disconnect P/J8391 from the harness, and P/J8302A on the Finisher Main PWB. 2. Check for continuity at the following: J8391A-3 <=> J8302A-4 J8391A-2 <=> J8302A-5 J8391A-1 <=> J8302A-6 Are these conductive?

Go to Step 9.

Repair the Main Sensor Harness.

9

Check for +5 V to the Compile Exit Sensor. Is there +5 V across J8302A-6 <=> J8302A-4 on the Finisher Main PWB? Check Compile Exit Sensor signal. Does the voltage across P8302A-5 <=> P8302A-4 on the Finisher Main PWB change when the actuator is operated? Test the Exit Motor. Run the Service Diagnostics Finisher Exit Motor Test. Does the motor rotate normally? Test the Lower Exit Roller Drive. Run the Service Diagnostics Finisher Exit Motor CCW test. Do the Exit Rollers rotate? Print a Test Print. Does the error still occur? Check Exit Motor harness connections. Are P/J8334 and P/J8304 connected? Print a Test Print. Does the error still occur?

Go to Step 10.

Replace the Finisher Main PWB (page 3-248). Replace the Compile Exit Sensor (page 3-189). Go to Step 12.

10

Replace the Finisher Main PWB (page 3-248). Replace the Finisher Main PWB (page 3-248). Go to Step 14.

11

12

Restore operation and go to Step 13. Problem solved. Connect and go to Step 15. Problem solved.

13 14 15

Go to Step 14. Go to Step 16. Go to Step 16.

3-110

Phaser 5500 Printer Service Manual

Jam at F (Compile Exit Sensor OFF) Troubleshooting Procedure (Continued)
Step 16 Actions and Questions
Check Exit Motor Harness continuity. 1. Disconnect P/J8334 and P/J8304. 2. Check for continuity at the following: P/J8334-1 <=> P/J8304-2 P/J8334-2 <=> P/J8304-4 P/J8334-3 <=> P/J8304-1 P/J8334-4 <=> P/J8304-3 P/J8334-5 <=> P/J8304-6 P/J8334-6 <=> P/J8304-5 Are these conductive?

Yes
Go to Step 17.

No
Repair the Main Drive Harness.

17

Check Exit Motor resistance. Is there some amount of resistance across P8334-2/5(COM) and P8334-1/3/ 4/6? Check for +24 V to the Exit Motor. Is there +24 V across J8304-4 <=> ground and J8304-6 <=> ground on the Finisher Main PWB? Replace the Exit Motor. Print a Test Print. Does the error still occur?

Go to Step 18.

Replace the Exit Motor (page 3-243). Replace the Finisher Main PWB (page 3-248). Problem solved.

18

Go to Step 19.

19

Replace the Finisher Main PWB (page 3-248).

Error Messages, Codes, and Procedures

3-111

10 Finisher Eject (2/3) (page 4-62) PL25.Jam at F or G . roll freely. Problem solved. 3.13 Finisher Transport (2/2) (page 4-68) PL25. Connect and go to Step 4.F4-52 Compile Exit SNR ON Jam A Jam at G . 3 4 5 Go to Step 5.11 Finisher Eject (3/3) page 4-64) PL25. Does the error still occur? Check Main Sensor Harness connections. Run the Service Diagnostics Buffer Path Sensor test. 3-112 Phaser 5500 Printer Service Manual . Are P/J8392 and P/J8318 connected? Print a Test Print. Go to Step 3.F4-5n Compile Exit SNR ON Paper does not reach the Compile Exit Sensor on time. Connect and go to Step 5. Are the Buffer and Pinch Rollers attached to the chutes clean. Applicable Error Codes Jam at F . No Clean or replace the appropriate roller.12 Finisher Transport (1/2) (page 4-66) PL25. Go to Step 7.F4-53 Compile Exit SNR ON Jam B Jam at G . 2 Test the Buffer Path Sensor. 2. Open the Bottom Buffer Chute (3).15 Finisher Harness (page 4-72) Jam at F or G (Compile Exit Sensor ON) Troubleshooting Procedure Step 1 Actions and Questions Check the paper path. Are P/J8318 and P/J8302A connected? Go to Step 11. Open the Upper Exit Chute (2A).F4-54 Compile Exit SNR ON Jam C Jam at F or G (Compile Exit Sensor ON) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ Buffer Roller Pinch Roller Exit Pinch Roller Buffer Sensor Harness Main Sensor Harness Finisher Main PWB Buffer Path Sensor Main Drive Harness Registration Motor Compiler Harness Compile Exit Sensor Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Sensors (1/2) Wiring (page 5-40) Finisher Motors Wiring (page 5-42) PL25. Open Door G.14 Finisher Electrical (page 4-70) PL25. Does the sensor state change? Check the Buffer Path Sensor connection. and correctly installed? Yes Go to Step 3. Go to Step 5. 1.

Run the Service Diagnostics Registration Motor CCW Test. Restore operation and go to Step 13. Problem solved. 2. Does the Buffer Roller rotate? Print a Test Print. Replace the Buffer Path Sensor (page 3-207). 8 Check Main Sensor Harness continuity. Repair the Main Sensor Harness. Error Messages. 15 Go to Step 16. Repair the Buffer Sensor Harness. Problem solved. Connect and go to Step 15. Check for continuity at the following: J8318A-3 <=> P/J8302A-13 J8318A-2 <=> P/J8302A-14 J8318A-1 <=> P/J8302A-15 Are these conductive? Go to Step 9. Is there +5 V across J8302A-15 <=> J8302A-13 on the Finisher Main PWB? Check the Buffer Path Sensor signal. 13 14 Go to Step 14. 1. 10 Replace the Finisher Main PWB (page 3-248). Disconnect P/J8392 and P/J8318. Does the error still occur? Check the Registration Motor harness connections. 11 12 Go to Step 14. Does the error still occur? Check Buffer Sensor Harness continuity. Are P/J8335 and P/J8304 connected? Print a Test Print. Does the motor rotate normally? Test the Buffer Roller Drive. Run the Service Diagnostics Registration Motor CCW test. Disconnect P/J8318 from the harness. No Problem solved. Check for continuity at the following: P/J8392-3 <=> J8318B-1 P/J8392-2 <=> J8318B-2 P/J8392-1 <=> J8318B-3 Are these conductive? Yes Go to Step 7. and Procedures 3-113 . 2. Replace the Finisher Main PWB (page 3-248). Does the error still occur? Go to Step 10. Go to Step 12.Jam at F or G (Compile Exit Sensor ON) Troubleshooting Procedure (Continued) Step 6 7 Actions and Questions Print a Test Print. 1. Codes. Does the voltage across P8302A-14 <=> P8302A-13 on the Finisher Main PWB change when the actuator is operated? Test the Registration Motor. 9 Check for +5 V to the Buffer Path Sensor. Go to Step 8. and P/J8302A on the Finisher Main PWB. Go to Step 16. Go to Step 20.

21 Connect and go to Step 22. 19 Replace the Finisher Main PWB (page 3-248). 2. Go to Step 25. Replace the Finisher Main PWB (page 3-248). Does the error still occur? Test the Compile Exit Sensor. Disconnect P/J8335 and P/J8304. 1. Problem solved. Check for continuity at the following: P/J8335-1 <=> P/J8304-7 P/J8335-2 <=> P/J8304-8 P/J8335-3 <=> P/J8304-9 P/J8335-4 <=> P/J8304-11 P/J8335-5 <=> P/J8304-10 P/J8335-6 <=> P/J8304-13 Are these conductive? Yes Go to Step 17. No Repair the Main Drive Harness. Check for continuity at the following: P/J8320-3 <=> J8391B-1 P/J8320-2 <=> J8391B-2 P/J8320-1 <=> J8391B-3 Are these conductive? Go to Step 18. Does the sensor state change? Check the Compile Exit Sensor connection. 3-114 Phaser 5500 Printer Service Manual . 2. Go to Step 26. Replace the Registration Motor (page 3-245). Disconnect P/J8320 and P/J8391. Are P/J8320 and P/J8391 connected? Print a Test Print. Print a Test Print.Jam at F or G (Compile Exit Sensor ON) Troubleshooting Procedure (Continued) Step 16 Actions and Questions Check Main Drive Harness continuity. 18 Go to Step 19. Is there some amount of resistance across P8335-2/5(COM) and P8335-1/3/ 4/6? Check for +24 V to the Registration Motor. Does the error still occur? Check Compiler Harness continuity. Go to Step 25. Problem solved. Connect and go to Step 24. 22 23 24 25 Go to Step 23. Are P/J8391 and P/J8302A connected? Print a Test Print. 20 Go to Step 21. Run the Service Diagnostics Compile Exit Sensor test. Replace the Finisher Main PWB (page 3-248). Go to Step 23. Is there +24 V across J8304-8 <=> ground and J8304-10 <=> ground on the Finisher Main PWB? Replace the Registration Motor. Problem solved. 1. Repair the Compiler Harness. 17 Check Registration Motor resistance. Does the error still occur? Check Main Sensor Harness connections.

10 Finisher Eject (2/3) (page 4-62) PL25.13 Finisher Transport (2/2) (page 4-68) PL25.F4-56 Compile Exit SNR Static Remaining paper is detected by the Compile Exit Sensor. Is there +5 V across J8302A-6 <=> J8302A-4 on the Finisher Main PWB? Check Compile Exit Sensor signal. Codes. Does the voltage across P8302A-5 <=> P8302A-4 on the Finisher Main PWB change when the actuator is operated? Go to Step 10. Replace the Compile Exit Sensor (page 3-189). Jam at H .Jam at F or G (Compile Exit Sensor ON) Troubleshooting Procedure (Continued) Step 26 Actions and Questions Check Main Sensor Harness continuity. 27 Check for +5 V to the Compile Exit Sensor. 2. No Repair the Main Sensor Harness.11 Finisher Eject (3/3) page 4-64) PL25.14 Finisher Electrical (page 4-70) PL25.15 Finisher Harness (page 4-72) Error Messages. 28 Replace the Finisher Main PWB (page 3-248). and Procedures 3-115 . Replace the Finisher Main PWB (page 3-248). Disconnect P/J8391 from the harness. 1. Check for continuity at the following: J8391A-3 <=> P/J8302A-4 J8391A-2 <=> P/J8302A-5 J8391A-1 <=> P/J8302A-6 Are these conductive? Yes Go to Step 9.F4-56 Compile Exit SNR Static Static Jam at H (Compile Exit Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ ■ Compile Exit Sensor Compiler Harness Main Sensor Harness Finisher Main PWB Main Drive Harness Exit Motor Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Sensors (1/2) Wiring (page 5-40) Finisher Motors Wiring (page 5-42) PL25. and P/J8302A on the Finisher Main PWB. Applicable Error Codes Jam at H .

Check for continuity at the following: P/J8320A-3 <=> J8391B-1 P/J8320A-2 <=> J8391B-2 P/J8320A-1 <=> J8391B-3 Are these conductive? Yes Go to Step 10. 10 3-116 Phaser 5500 Printer Service Manual . Does the motor rotate normally? Go to Step 9. 1. Connect and go to Step 3. Run the Service Diagnostics Finisher Exit Motor Test. Replace the Finisher Main PWB (page 3-248). No Go to Step 2. 8 Check for +5 V to the Compile Exit Sensor. Check for continuity at the following: J8391A-3 <=> P/J8302A-4 J8391A-2 <=> P/J8302A-5 J8391A-1 <=> P/J8302A-6 Are these conductive? Go to Step 8. Repair the Main Sensor Harness. Repair the Compiler Harness. Does the error still occur? Check Compiler Harness continuity. Go to Step 11. Are P/J8391 and P/J8302A connected? Print a Test Print. Replace the Finisher Main PWB (page 3-248). Go to Step 6. Go to Step 7. Connect and go to Step 5. 2. 2 Go to Step 4. Go to Step 6. Problem solved. and P/J8302A on the Finisher Main PWB. Does the sensor state change? Check the Compile Exit Sensor connection. 3 4 5 6 Go to Step 4. 1. Disconnect P/J8391 from the harness. Run the Service Diagnostics Compile Exit Sensor test. 2. Replace the Buffer Path Sensor (page 3-207). Is there +5 V across J8302A-6 <=> J8302A-4 on the Finisher Main PWB? Check Compile Exit Sensor signal. Disconnect P/J8320 and P/J8391. 9 Replace the Finisher Main PWB (page 3-248). 7 Check Main Sensor Harness continuity. Are P/J8320 and P/J8391 connected? Print a Test Print.Static Jam at H (Compile Exit Sensor) Troubleshooting Procedure Step 1 Actions and Questions Test the Compile Exit Sensor. Does the error still occur? Check Main Sensor Harness connections. Problem solved. Does the voltage across P8302A-5 <=> P8302A-4 on the Finisher Main PWB change when the actuator is operated? Test the Exit Motor.

12 13 Go to Step 13. Go to Step 16. Disconnect P/J8334 and P/J8304. Problem solved. Connect and go to Step 14. Do the Exit Rollers rotate? Print a Test Print. Problem solved. 18 Replace the Finisher Main PWB (page 3-248). Is there some amount of resistance across P8334-2/5(COM) and P8334-1/3/ 4/6? Check for +24 V to the Exit Motor. Replace the Finisher Main PWB (page 3-248). Go to Step 15. Repair the Main Drive Harness. Error Messages. 17 Go to Step 18. Does the error still occur? Check Exit Motor Main Drive harness connections. 14 15 Go to Step 15. Replace the Exit Motor (page 3-243). Check for continuity at the following: P/J8334-1 <=> P/J8304-2 P/J8334-2 <=> P/J8304-4 P/J8334-3 <=> P/J8304-1 P/J8334-4 <=> P/J8304-3 P/J8334-5 <=> P/J8304-6 P/J8334-6 <=> P/J8304-5 Are these conductive? Yes Go to Step 13. 1. Are P/J8334 and P/J8304 connected? Print a Test Print. and Procedures 3-117 . Does the error still occur? Check Main Drive Harness continuity. Codes. Is there +24 V across J8304-4 <=> ground and J8304-6 <=> ground on the Finisher Main PWB? Replace the Exit Motor. Does the error still occur? Go to Step 17. Run the Service Diagnostics Finisher Exit Motor CCW test.Static Jam at H (Compile Exit Sensor) Troubleshooting Procedure (Continued) Step 11 Actions and Questions Test the Lower Exit Roller Drive. 16 Check Exit Motor resistance. 2. Print a Test Print. No Restore operation and go to Step 12. Problem solved.

Check for continuity at the following: J8339-1 <=> J8304-33 J8339-2 <=> J8304-31 Are these conductive? Yes Go to Step 2. 2. Go to Step 5. Is the Eject Roller clean. Does the error still occur? Replace the Finisher Main PWB (page 3-248).F4-61 Set Eject Jam Paper failed to clear the Compile Tray No Paper Sensor on time.14 Finisher Electrical (page 4-70) PL25.15 Finisher Harness (page 4-72) Jam at H (Compile Tray No Paper Sensor) Troubleshooting Procedure Step 1 Actions and Questions Check the paper path. Go to Step 6. Are P/J8339 and P/J 8304 connected? Print a Test Print. Print a Test Print. Disconnect P/J8339 and P/J 8304. rotate smoothly. 6 Replace the Eject Clamp Motor. Connect and go to Step 4. 3 4 5 Go to Step 5.Jam at H . Set Eject failed. Does the motor rotate properly? Check Main Drive Harness connections. 2 Go to Step 7. Does the error still occur? Check Main Drive Harness continuity. 1. Run the Service Diagnostics Eject Clamp Motor Up and Down tests. Problem solved. Applicable Error Codes Jam a H . No Clean or replace the Eject Roller.9 Finisher Eject (1/3) (page 4-60) PL25. and installed correctly? Test the Eject Clamp Motor. Problem solved.11 Finisher Eject (3/3) page 4-64) PL25.10 Finisher Eject (2/3) (page 4-62) PL25. 3-118 Phaser 5500 Printer Service Manual . Repair the Main Drive Harness.F4-61 Set Eject Jam Jam at H (Compile Tray No Paper Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ Eject Roller Shaft Main Drive Harness Eject Clamp Motor Eject Motor Finisher Main PWB Compiler Harness Main Sensor Harness Compile Exit Sensor Compile No Paper Sensor Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Sensors (1/2) Wiring (page 5-40) Finisher Motors Wiring (page 5-42) Finisher Clutch and Solenoids (page 5-43) Finisher Compiler Tray Wiring (page 5-44) PL25. Go to Step 3.

Connect and go to Step 16. Connect and go to Step 9. Connect and go to Step 18. Go to Step 18. Go to Step 23. Go to Step 11. Go to Step 19. Error Messages. Does the Eject Motor rotate properly? Check Main Drive Harness connections. 13 Replace the Finisher Main PWB (page 3-248). Is there some amount of resistance across P8336-2/5(COM) <=> P8336-1/3/ 4/6? Check for +24 V to the Eject Motor. Are P/J8391 and P/J8302A connected? Print a Test Print. Codes. Does the error still occur? Check Eject Motor Main Drive Harness continuity. Problem solved. Does the error still occur? Test the Compile Exit Sensor. 12 Go to Step 13. Run the Service Diagnostics Eject Motor Low Speed Forward and Reverse tests. Problem solved. Does the sensor state change? Check the Compile Exit Sensor connection. Run the Service Diagnostics Compile Exit Sensor test. 11 Check Eject Motor resistance.Jam at H (Compile Tray No Paper Sensor) Troubleshooting Procedure (Continued) Step 7 Actions and Questions Test the Eject Motor. 2. Check for continuity at the following: P/J8336-1 <=> P/J8304-15 P/J8336-2 <=> P/J8304-12 P/J8336-3 <=> P/J8304-17 P/J8336-4 <=> P/J8304-19 P/J8336-5 <=> P/J8304-14 P/J8336-6 <=> P/J8304-21 Are these conductive? Yes Go to Step 14. Go to Step 10. 15 Go to Step 17. and Procedures 3-119 . No Go to Step 8. 16 17 18 Go to Step 17. Problem solved. Are P/J8336 and P/J 8304 connected? Print a Test Print. Replace the Finisher Main PWB (page 3-248). 14 Go to Step 15. Repair the Main Drive Harness. Are P/J8320 and P/J8391 connected? Print a Test Print. Disconnect P/J8336 and P/J 8304. Replace the Eject Bracket Assembly (page 3-187). Print a Test Print. and P/J8304-14 <=> ground on the Finisher Main PWB? Replace the Eject Bracket Assembly. Does the error still occur? Go to Step 12. 8 9 10 Go to Step 10. 1. Does the error still occur? Check Main Sensor Harness connections. Problem solved. Is there +24 V across P/J8304-12 <=> ground.

Check for continuity at the following: P/J8359-3 <=>P/J8309-1 P/J8359-2 <=> P/J8309-2 P/J8359-1 <=> P/J8309-3 Are these conductive? Go to Step 22. Replace the Compile Exit Sensor (page 3-189). Go to Step 27. Disconnect P/J8359 and P/J8309. Are P/J8359 and P/J8309 connected? Print a Test Print. Check for continuity at the following: P/J8320-3 <=> J8391B-1 P/J8320-2 <=> J8391B-2 P/J8320-1 <=> J8391B-3 Are these conductive? Yes Go to Step 20. Problem solved. Replace the Finisher Main PWB (page 3-248). Does the sensor’s state change? Check the Compiler Harness connection. 1. 2. Replace the Finisher Main PWB (page 3-248). 1. and P/J8302A on the Finisher Main PWB. Repair the Compiler Harness. Check for continuity at the following: J8391A-3 <=> P/J8302A-4 J8391A-2 <=> P/J8302A-5 J8391A-1 <=> P/J8302A-6 Are these conductive? Go to Step 21. Disconnect P/J8320 and P/J8391. Is there +5 V across J8302A-6 <=> J8302A-4 on the Finisher Main PWB? Check the Compile Exit Sensor signal. 2. No Repair the Compiler Harness. Does the error still occur? Check Compiler Harness continuity. Replace the Finisher Main PWB (page 3-248). 23 24 25 26 Connect and go to Step 25. 1.Jam at H (Compile Tray No Paper Sensor) Troubleshooting Procedure (Continued) Step 19 Actions and Questions Check the Compiler Harness continuity. Does the voltage across P8302A-5 <=> P8302A-4 on the Finisher Main PWB change when the actuator is operated? Test the Compile Tray No Paper Sensor. 22 Replace the Finisher Main PWB (page 3-248). Is there +5 V across J8309-3 <=> J83091 on the Finisher Main PWB? Go to Step 28. 21 Check for +5 V to the Compile Exit Sensor. Go to Step 24. 27 Check for +5 V to the No Paper Sensor. Disconnect P/J8391 on the harness. Repair the Main Sensor Harness. Run the Service Diagnostics Compile Tray No Paper Sensor test. 2. 20 Check Main Sensor Harness continuity. Go to Step 26. 3-120 Phaser 5500 Printer Service Manual . Go to Step 26.

14 Finisher Electrical (page 4-70) PL25.10 Finisher Eject (2/3) (page 4-62) PL25.F4-66 Compile Paper SNR Static Paper is detected by the Compile Tray No Paper Sensor following an eject operation. Error Messages. Applicable Error Codes Jam at H . Codes. and Procedures 3-121 . Does the voltage across P8309-2 <=> P8309-1 on the Finisher Main PWB change when the actuator is moved? Yes Replace the Finisher Main PWB (page 3-248). Are P/J8339 and P/J8304 connected? Print a Test Print. No Replace the Compile Tray No Paper Sensor (page 3-182). No Go to Step 2. Problem solved. Jam at H . 2 Go to Step 4. Run the Service Diagnostics Eject Clamp Motor Up and Down tests. Does the motor rotate properly? Check Eject Clamp Motor Main Drive Harness connections.15 Finisher Harness (page 4-72) Static Jam at H (No Paper Sensor) Troubleshooting Procedure Step 1 Actions and Questions Test the Eject Clamp Motor. 3 Go to Step 4. Connect and go to Step 3.9 Finisher Eject (1/3) (page 4-60) PL25.Jam at H (Compile Tray No Paper Sensor) Troubleshooting Procedure (Continued) Step 28 Actions and Questions Check the No Paper Sensor signal.F4-66 Compile Paper SNR Static Static Jam at H (No Paper Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ ■ Eject Clamp Motor Main Drive Harness Eject Motor Finisher Main PWB No Paper Sensor Compiler Harness Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Motors Wiring (page 5-42) Finisher Clutch and Solenoids (page 5-43) Finisher Compiler Tray Wiring (page 5-44) PL25. Does the error still occur? Yes Go to Step 6.

Print a Test Print. Replace the Eject Bracket Assembly (page 3-187). Check for continuity at the following: P/J8339-1 <=> P/J8304-33 P/J8339-2 <=> P/J8304-31 Are these conductive? Yes Go to Step 5. 3-122 Phaser 5500 Printer Service Manual . 2. 1. 1. and J8304-14 <=> ground on the Finisher Main PWB? Replace the Eject Motor. Does the Eject Motor rotate forward? Check Eject Motor Main Drive Harness connections. Are P/J8336 and P/J8304 connected? Print a Test Print.Static Jam at H (No Paper Sensor) Troubleshooting Procedure (Continued) Step 4 Actions and Questions Check Eject Clamp Motor Main Drive Harness continuity. 12 Replace the Finisher Main PWB (page 3-248). Does the error still occur? Go to Step 11. Check for continuity at the following: P/J8336-1 <=> P/J8304-15 P/J8336-2 <=> P/J8304-12 P/J8336-3 <=> P/J8304-17 P/J8336-4 <=> P/J8304-19 P/J8336-5 <=> P/J8304-14 P/J8336-6 <=> P/J8304-21 Are these conductive? Replace the Finisher Main PWB (page 3-248). Run the Service Diagnostics Eject Motor Low Speed Forward test. Problem solved. 11 Go to Step 12. 6 Go to Step 7. 2. No Repair the Main Drive Harness. Connect and go to Step 8. Repair the Main Drive Harness. Problem solved. 5 Replace the Eject Clamp Motor. Problem solved. 7 Go to Step 9. Is there +24 V across J8304-12 <=> ground. Go to Step 13. 10 Check Eject Motor resistance. Disconnect P/J8336 and P/J8304. Go to Step 10. 8 9 Go to Step 9. Print a Test Print. Replace the Finisher Main PWB (page 3-248). Does the error still occur? Test the Eject Motor. Disconnect P/J8339 and P/J8304. Does the error still occur? Check Eject Motor Main Drive Harness continuity. Is there some amount of resistance across P8336-2/5(COM) <=> P8336-1/3/ 4/6? Check for +24 V to the Eject Motor.

Does the voltage across P8309-2 <=> P8309-1 on the Finisher Main PWB change when the sensor actuator is moved? Go to Step 18. 1. Jam at F or G . 18 Replace the Finisher Main PWB (page 3-248). Run the Service Diagnostics Compile Tray No Paper Sensor test. Does the error still occur? Check Compiler Harness continuity. Does the sensor’s state change? Check the Compiler Harness connection. Problem solved. Repair the Compiler Harness.Static Jam at H (No Paper Sensor) Troubleshooting Procedure (Continued) Step 13 Actions and Questions Test the Compile Tray No Paper Sensor. 14 15 16 Connect and go to Step 15. Applicable Error Codes Jam at F .F4-71 Top Tray Exit SNR ON Jam A Jam at G .F4-7n Top Tray Exit SNR ON Paper does not reach the Stacker Upper Tray Exit Sensor on time. Go to Step 17. Replace the Compile Tray No Paper Sensor (page 3-182).F4-74 Top Tray Exit SNR ON Jam C Error Messages. Are P/J8359 and P/J8309 connected? Print a Test Print. and Procedures 3-123 . Check for continuity at the following: P/J8359-3 <=> P/J8309-1 P/J8359-2 <=> P/J8309-2 P/J8359-1 <=> P/J8309-3 Are these conductive? Yes Replace the Finisher Main PWB (page 3-248). Replace the Finisher Main PWB (page 3-248). Go to Step 16. 17 Check for +5 V to the Compile Tray No Paper Sensor.F4-73 Top Tray Exit SNR ON Jam B Jam at G . 2. Codes. Is there +5 V across J8309-3 <=> J83091 on the Finisher Main PWB? Check the Compile Tray No Paper Sensor) signal. No Go to Step 14. Go to Step 16. Disconnect P/J8359 and P/J8309.

Does the Entrance and Transport Rollers rotate? Check the Transport Motor Main Drive Harness. roll freely. Run the Service Diagnostics Finisher Transport Motor Test. 3 Go to Step 4.14 Finisher Electrical (page 4-70) PL25. Are P/J8342 and P/J8304 connected? Print a Test Print.13 Finisher Transport (2/2) (page 4-68 PL25. No Clean or replace the appropriate roller. Go to Step 5. Does the error still occur? Go to Step 3. 3-124 Phaser 5500 Printer Service Manual . and correctly installed? Test the Finisher Transport Motor. Does the motor rotate normally? Test Entrance and Transport Roller drive. 5 Go to Step 7. Clean or replace the appropriate roller. Open Door G. 3. Remove the Top Cover. and correctly installed? Yes Go to Step 2. Open the Lower Top Exit Chute (2b). 1. Remove the Knob and open the Upper Entrance Chute. Restore operation. 2 Check the paper path. 2. 4.15 Finisher Harness (page 4-72) Jam at F or G (Stacker Upper Tray Exit Sensor ON) Troubleshooting Procedure Step 1 Actions and Questions Check the paper path. Are the Pinch Rollers attached to the chute and the two Transport Rollers clean. 4 Go to Step 11. Problem solved.Jam at F or G (Stacker Upper Tray Exit Sensor ON) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ Entrance Roller Entrance Pinch Roller Transport Roller Pinch Roller Transport Motor Main Drive Harness Finisher Main PWB Top Exit Sensor Harness Main Sensor Harness Top Exit Sensor Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Sensors (1/2) Wiring (page 5-40) Finisher Motors Wiring (page 5-42) PL25. Connect and go to Step 6. Run the Service Diagnostics Finisher Transport Motor Test. roll freely. 6 Go to Step 7.12 Finisher Transport (1/2) (page 4-66) PL25. Are the Rollers attached to the chute clean. Remove the Top L/H Cover.

2. Does the error still occur? Test the Upper Tray Exit Sensor. Error Messages. Disconnect P/J8321 and P/J8312. 13 14 Go to Step 14. 9 Go to Step 10. 1. Does the error still occur? Check Exit Sensor Harness continuity. Is there some amount of resistance across P8342-2/5(COM) and P8342-1/3/ 4/6? Check for +24 V to the Transport Motor.Jam at F or G (Stacker Upper Tray Exit Sensor ON) Troubleshooting Procedure Step 7 Actions and Questions Check Main Drive Harness continuity. Does the sensor state change? Check the Sensor Harness connections. Disconnect P/J8342 and P/J8304. Replace the Transport Motor (page 3-222). No Repair the Main Drive Harness. Check for continuity at the following: P/J8342-1 <=> P/J8304-23 P/J8342-2 <=> P/J8304-16 P/J8342-3 <=> P/J8304-25 P/J8342-4 <=> P/J8304-27 P/J8342-5 <=> P/J8304-18 P/J8342-6 <=> P/J8304-29 Are these conductive? Yes Go to Step 8. Are P/J8321 and P/J8312 on the sensor harness. Codes. 12 Connect and go to Step 13. 8 Check the Transport Motor resistance. Is there +24 V across J8304-16 <=> ground and J8304-18 <=> ground on the Finisher Main PWB? Replace the Transport Motor. Problem solved. Replace the Finisher Main PWB (page 3-248). Problem solved. 2. Go to Step 14. and Procedures 3-125 . Check for continuity at the following: P/J8321-3 <=> J8312B-1 P/J8321-2 <=> J8312B-2 P/J8321-1 <=> J8312B-3 Are these conductive? Go to Step 9. 10 Replace the Finisher Main PWB (page 3-248). Run the Service Diagnostics Finisher Transport Motor Test. 1. Repair the Upper Tray Exit Sensor Harness. Go to Step 15. Run the Service Diagnostics Upper Tray Exit Sensor test. 11 Go to Step 12. and P/J8312 and P/J8302 on the Main Sensor Harness connected? Print a Test Print. Replace the Finisher Main PWB (page 3-248).

14 Finisher Electrical (page 4-70) PL25. Check for continuity at the following: J8312A-3 <=> P/J8302A-7 J8312A-2 <=> P/J8302A-8 J8312A-1 <=> P/J8302A-9 Are these conductive? Yes Go to Step 16. No Repair the Main Sensor Harness. 17 Replace the Finisher Main PWB (page 3-248).F4-75 Top Tray Exit SNR OFF Jam B Jam at F or Upper Tray (Exit Sensor OFF) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ Transport Roller Pinch Roller Transport Motor Main Drive Harness Finisher Main PWB Top Exit Sensor Harness Main Sensor Harness Top Exit Sensor Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Sensors (1/2) Wiring (page 5-40) Finisher Motors Wiring (page 5-42) PL25. and P/J8302A on the Finisher Main PWB.F4-7nTop Tray SNR OFF Paper does not leave the Stacker Upper Tray Exit Sensor on time. Applicable Error Codes Jam at F . Disconnect P/J8312 from the harness. 1.F4-72 Top Tray Exit SNR OFF Jam A Jam at Stacker Upper Tray .13 Finisher Transport (2/2) (page 4-68 PL25. 16 Check for +5 V to the Upper Tray Exit Sensor. Is there +5 V across J8302A-9 <=> J8302A-7 on the Finisher Main PWB? Check the Upper Tray Exit Sensor signal. Replace the Finisher Main PWB (page 3-248). Does the voltage across P8302A-8 <=> P8302A-7 on the Finisher Main PWB change when sensor is actuated? Go to Step 48.12 Finisher Transport (1/2) (page 4-66) PL25.15 Finisher Harness (page 4-72) 3-126 Phaser 5500 Printer Service Manual . Jam at F or Stacker Upper Tray .Jam at F or G (Stacker Upper Tray Exit Sensor ON) Troubleshooting Procedure Step 15 Actions and Questions Check Main Sensor Harness continuity. Replace the Upper Tray Exit Sensor (page 3-226). 2.

Replace the Finisher Main PWB (page 3-248). 5 6 Go to Step 6. Run the Service Diagnostics Finisher Transport Motor Test. 1. Open the Lower Top Exit Chute (2a). Disconnect P/J8342 and P/J8304. Replace the Transport Motor (page 3-222). 8 Go to Step 9. Does the motor rotate normally? Test Entrance and Transport Roller drive. Do the Entrance and Transport Rollers rotate? Check the Transport Motor Main Drive Harness. Does the error still occur? Check Transport Motor Main Drive Harness continuity. Error Messages. Does the error still occur? Go to Step 8. Go to Step 7.Jam at F or Upper Tray (Exit Sensor OFF) Troubleshooting Procedure Step 1 Actions and Questions Check the paper path. Is there some amount of resistance across P8342-2/5(COM) and P8342-1/3/ 4/6? Check for +24 V to the Transport Motor. Is there +24 V across J8304-16 <=> ground and J8304-18 <=> ground on the Finisher Main PWB? Replace the Transport Motor. Problem solved. 7 Check the Transport Motor resistance. Go to Step 4. Check for continuity at the following: P/J8342-1 <=> P/J8304-23 P/J8342-2 <=> P/J8304-16 P/J8342-3 <=> P/J8304-25 P/J8342-4 <=> P/J8304-27 P/J8342-5 <=> P/J8304-18 P/J8342-6 <=> P/J8304-29 Are these conductive? Yes Go to Step 2. and correctly installed? Test the Finisher Transport Motor. 2. 9 Replace the Finisher Main PWB (page 3-248). Problem solved. No Clean or replace the appropriate roller. Repair the Main Drive Harness. Are the Pinch Rollers attached to the chute and the two Transport Rollers clean. Run the Service Diagnostics Finisher Transport Motor Test. Connect and go to Step 5. 4 Go to Step 6. Restore roller operation. 2 Go to Step 3. roll freely. 3 Go to Step 10. and Procedures 3-127 . Are P/J8342 and P/J8304 connected? Print a Test Print. Run the Service Diagnostics Finisher Transport Motor Test. Codes.

and P/J8312 and P/J8302 on the Main Sensor Harness connected? Print a Test Print. Are P/J8321 and P/J8312 on the sensor harness. 3-128 Phaser 5500 Printer Service Manual . 14 Check Main Exit Sensor Harness continuity. No Go to Step 11. Repair the Main Sensor Harness. Run the Service Diagnostics Upper Tray Exit Sensor test. Check for continuity at the following: J8312A-3 <=> P/J8302A-7 J8312A-2 <=> P/J8302A-8 J8312A-1 <=> P/J8302A-9 Are these conductive? Go to Step 15. Disconnect P/J8321 and P/J8312. Does the sensor state change? Check the Upper Tray Exit Sensor Harness connections. Go to Step 13. 1. Does the error still occur? Check Exit Sensor Harness continuity. 2. Replace the Finisher Main PWB (page 3-248). 1. Repair the Upper Tray Exit Sensor Harness. 12 13 Go to Step 13. Does the voltage across P8302A-8 <=> P8302A-7 on the Finisher Main PWB change when the sensor is actuated? Go to Step 16. 11 Connect and go to Step 12. 2. 15 Check for +5 V to the Upper Tray Exit Sensor. and P/J8302A on the Finisher Main PWB. 16 Replace the Finisher Main PWB (page 3-248). Disconnect P/J8312 from the harness. Check for continuity at the following: P/J8321-3 <=> J8312B-1 P/J8321-2 <=> J8312B-2 P/J8321-1 <=> J8312B-3 Are these conductive? Yes Replace the Finisher Main PWB (page 3-248). Go to Step 14. Problem solved. Is there +5 V across J8302A-9 <=> J8302A-7 on the Finisher Main PWB? Check the Upper Tray Exit Sensor signal.Jam at F or Upper Tray (Exit Sensor OFF) Troubleshooting Procedure (Continued) Step 10 Actions and Questions Test the Upper Tray Exit Sensor. Replace the Upper Tray Exit Sensor (page 3-226).

Are P/J8321 and P/J8312 on the sensor harness. 2.15 Finisher Harness (page 4-72) Static Jam at F or G (Stacker Upper Tray Exit Sensor) Troubleshooting Procedure Step 1 Actions and Questions Test the Upper Tray Exit Sensor. and Procedures 3-129 .Jam at F or G . No Go to Step 2.F4-7n Top Tray Exit SNR Static Paper is detected by the Stacker Upper Tray Exit Sensor.F4-78 Top Tray Exit SNR Static Static Jam at F or G (Stacker Upper Tray Exit Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ Transport Motor Main Drive Harness Finisher Main PWB Top Exit Sensor Harness Main Sensor Harness Upper Tray Exit Sensor Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Sensors (1/2) Wiring (page 5-40) Finisher Motors Wiring (page 5-42) PL25. 1.13 Finisher Transport (2/2) (page 4-68 PL25. Check for continuity at the following: P/J8321-3 <=> J8312B-1 P/J8321-2 <=> J8312B-2 P/J8321-1 <=> J8312B-3 Are these conductive? Yes Go to Step 8. and P/J8312 and P/J8302 on the Main Sensor Harness connected? Print a Test Print. 2 Go to Step 4. Disconnect P/J8321 and P/J8312.F4-76 Top Tray Exit SNR Static Jam at G . Connect and go to Step 3.F4-77 Top Tray Exit SNR Static Jam at G . Applicable Error Codes Jam at F . Error Messages. Repair the Top Tray Exit Sensor Harness. Does the error still occur? Check Upper Tray Exit Sensor Harness continuity. Go to Step 5. Run the Service Diagnostics Upper Tray Exit Sensor test. 3 4 Go to Step 4.14 Finisher Electrical (page 4-70) PL25. Does the sensor state change? Check the Upper Tray Exit Sensor Harness connections.12 Finisher Transport (1/2) (page 4-66) PL25. Problem solved. Codes.

Check for continuity at the following: P/J8342-1 <=> P/J8304-23 P/J8342-2 <=> P/J8304-16 P/J8342-3 <=> P/J8304-25 P/J8342-4 <=> P/J8304-27 P/J8342-5 <=> P/J8304-18 P/J8342-6 <=> P/J8304-29 Are these conductive? Go to Step 7. Go to Step 13. Run the Service Diagnostics Finisher Transport Motor Test. Run the Service Diagnostics Finisher Transport Motor Test. Go to Step 12. 1. Does the voltage across P8302A-8 <=> P8302A-7 on the Finisher Main PWB change when the sensor is actuated? Test the Finisher Transport Motor. 6 Check for +5 V to the Upper Tray Exit Sensor. No Repair the Main Sensor Harness. Problem solved. Go to Step 10. Check for continuity at the following: J8312A-3 <=> P/J8302A-7 J8312A-2 <=> P/J8302A-8 J8312A-1 <=> P/J8302A-9 Are these conductive? Yes Go to Step 6. 1. Repair the Main Drive Harness. 2. 7 Replace the Finisher Main PWB (page 3-248). Go to Step 9. Does the error still occur? Check Main Drive Harness continuity. 2. Replace the Finisher Main PWB (page 3-248). Is there +5 V across J8302A-9 <=> J8302A-7 on the Finisher Main PWB? Check the Upper Tray Exit Sensor signal. Disconnect P/J8342 and P/J8304. Are P/J8342 and P/J8304 connected? Print a Test Print. 3-130 Phaser 5500 Printer Service Manual . Replace the Upper Tray Exit Sensor (page 3-226).Static Jam at F or G (Stacker Upper Tray Exit Sensor) Troubleshooting Procedure Step 5 Actions and Questions Check Main Upper Exit Sensor Harness continuity. Does the motor rotate normally? Test Entrance and Transport Roller drive. Disconnect P/J8312 from the harness. and P/J8302A on the Finisher Main PWB. 8 9 Replace the Finisher Main PWB (page 3-248). Restore operation. 10 Connect and go to Step 11. Do the Entrance and Transport Rollers rotate? Check the Finisher Transport Motor Main Drive Harness. 11 12 Go to Step 12.

14 Finisher Electrical (page 4-70) PL25. 15 Replace the Finisher Main PWB (page 3-248).15 Finisher Harness (page 4-72) Error Messages. No Replace the Transport Motor (page 3-222). and Procedures 3-131 .2 Horizontal Transport (1/2) (page 4-46) PL25. Problem solved.F4-82 Gate SNR ON Jam at F (Transport Gate Sensor ON) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ H-X’port Belts H-X’port Pinch Rollers Entrance Rollers H-X’port Exit Sensor H-X’port Harness Finisher H-X’port PWB Finisher Entrance Sensor Main Sensor Harness Finisher Main PWB Transport Motor Main Drive Harness Transport Gate Sensor Gate Sensor Harness Phaser 5500 Printer Options Service Manual Horizontal Transport P/J Locator (page 5-29) Horizontal Transport Wiring (page 5-39) Finisher Main PWB P/J Locator (page 5-35) Finisher Sensors (1/2) Wiring (page 5-40) Finisher Motors Wiring (page 5-42) PL25. 14 Go to Step 15.Static Jam at F or G (Stacker Upper Tray Exit Sensor) Troubleshooting Procedure Step 13 Actions and Questions Check the Transport Motor resistance. Does the error still occur? Yes Go to Step 14.3 Horizontal Transport (2/2) (page 4-48) PL25. Print a Test Print. Is there +24 V across J8304-16 <=> ground and J8304-18 <=> ground on the Finisher Main PWB? Replace the Transport Motor. Replace the Finisher Main PWB (page 3-248).F4-82 Gate SNR ON Paper does not reach the Gate Sensor within the specified time. Is there some amount of resistance across P8342-2/5(COM) and P8342-1/3/ 4/6? Check for +24 V to the Transport Motor. Codes. Jam at F .13 Finisher Transport (2/2) (page 4-68 PL25. Applicable Error Code Jam at F .12 Finisher Transport (1/2) (page 4-66) PL25.

Replace the HX’port PWB (page 3-247). 5 6 Go to Step 6. Remove the Top and Top L/H Covers. Disconnect J8381 on the Exit Sensor. and operate freely? Yes Go to Step 2. 7 Check for +5 V to the H-X’port Exit Sensor. and P/J8372 on the H-X’port PWB. 3 Test the H-X'port Exit Sensor. 2 Go to Step 3. Is the H-X’port Exit Sensor Harness connected to the Exit Sensor and HX’port PWB? Print a Test Print. No Clean or replace the affected parts. and installed correctly? Check the paper path. Are the Belts and Pinch Rollers clean. Repair the HX’port Harness. Replace the HX’port Exit Sensor (page 3-118). 3. Open Door F. 4 Go to Step 6. 3-132 Phaser 5500 Printer Service Manual . 1. 1. 2. 2. Clean or replace the affected parts. Connect and go to Step 5.Jam at F (Transport Gate Sensor ON) Troubleshooting Procedure Step 1 Actions and Questions Check the paper path. Problem solved. Go to Step 7. Is there +5 V across J8372-6 <=> J83724 on the H-X’port PWB? Check H-X’port Exit Sensor signal. Does the voltage across J8372-5 <=> J8372-4 on the H-X’port PWB change when the actuator is operated? Go to Step 8. 8 Replace the HX’port PWB (page 3-247). Check for continuity at the following: P/J8372-4 <=> P/J8381-3 P/J8372-5 <=> P/J8381-2 P/J8372-6 <=> P/J8381-1 Are these conductive? Go to Step 9. Are the Pinch Rollers and Entrance Roller clean. Run the Service Diagnostics H-X’port Exit Sensor test. Go to Step 4. Remove the Knob and open the Upper Entrance Chute. installed correctly. roll freely. Does the error still occur? Check the H-X’port Exit Sensor Harness continuity. Does the sensor change state? Check the H-X’port Exit Sensor Harness connections. Open Door G.

2. Are P/J8319 and P/J8303 on the Entrance Sensor Harness and P/J8302A on the Main Sensor Harness connected? Print a Test Print. 14 Check for +5 V to X'port Entrance Sensor. Does the sensor change state when the sensor is blocked? Check harness connections. Does the error still occur? Check X’port Entrance Sensor Harness continuity. Go to Step 13. 13 Check Main X’port Entrance Sensor Harness continuity. 2. Disconnect P/J8303 on the harness.Jam at F (Transport Gate Sensor ON) Troubleshooting Procedure (Continued) Step 9 Actions and Questions Test the X'port Entrance Sensor. Codes. Check for continuity at the following: P/J8319-3 <=> J8303B-1 P/J8319-2 <=> J8303B-2 P/J8319-1 <=> J8303B-3 Are these conductive? Yes Go to Step 16. Does the voltage across P8302A-2 <=> P8302A-1 on the Finisher Main PWB change. Connect and go to Step 11. Check for continuity at the following: J8303A-3 <=> P/J8302A-1 J8303A-2 <=> P/J8302A-2 J8303A-1 <=> P/J8302A-3 Are these conductive? Go to Step 14. Disconnect P/J8319 and P/J8303. and Procedures 3-133 . 16 Error Messages. 1. when the sensor is blocked? Check the Finisher Transport Motor. Does the motor rotate normally? Go to Step 15. Run the Service Diagnostics Finisher Transport Motor Test. 10 Go to Step 12. Run the Service Diagnostics Transport Entrance Sensor test. and P/J8302A on the Finisher Main PWB. Repair the Main Sensor Harness. Replace the Finisher Main PWB (page 3-248). Go to Step 25. 1. Go to Step 17. 11 12 Go to Step 12. Replace the Entrance Sensor (page 3-217). 15 Replace the Finisher Main PWB (page 3-248). Repair the Entrance Sensor Harness. Is there +5 V across J8302A-3 <=> J8302A-1 on the Finisher Main PWB? Check the X'port Entrance Sensor signal. Problem solved. No Go to Step 10.

Problem solved. Check for continuity at the following: P/J8342-1 <=> P/J8304-23 P/J8342-2 <=> P/J8304-16 P/J8342-3 <=> P/J8304-25 P/J8342-4 <=> P/J8304-27 P/J8342-5 <=> P/J8304-18 P/J8342-6 <=> P/J8304-29 Are these conductive? Yes Go to Step 19. Disconnect P/J8342 and P/J8304. 26 27 Connect and go to Step 27. Repair the Main Drive Harness. Does the error still occur? Go to Step 23. Are P/J8342 and P/J8304 connected? Print a Test Print. 1. Is there some amount of resistance across P8342-2/5(COM) and P8342-1/3/ 4/6? Check for +24 V to the Transport Motor.Jam at F (Transport Gate Sensor ON) Troubleshooting Procedure (Continued) Step 17 Actions and Questions Test Entrance and Transport Roller drive. Is there +24 V across J8304-16 <=> ground and J8304-18 <=> ground on the Finisher Main PWB? Replace the Transport Motor. Go to Step 28. Connect and go to Step 20. Go to Step 21. 24 Replace the Finisher Main PWB (page 3-248). Do the Entrance and Transport Rollers rotate? Print a Test Print. Problem solved. 23 Go to Step 24. Problem solved. 3-134 Phaser 5500 Printer Service Manual . Print a Test Print. Does the sensor state change when the sensor is blocked? Check the Gate Sensor Harness. Is the harness connected? Print a Test Print. 18 19 20 21 Go to Step 19. Replace the Finisher Main PWB (page 3-248). Does the error still occur? Check Main Drive Harness continuity. Go to Step 28. 25 Go to Step 26. Problem solved. Replace the Transport Motor (page 3-222). 22 Check the Transport Motor resistance. Go to Step 22. Run the Service Diagnostics Finisher Transport Motor Test. Does the error still occur? Check the Main Drive Harness. No Restore operation and go to Step 18. 2. Go to Step 21. Replace the Finisher Main PWB (page 3-248). Does the error still occur? Test the Gate Sensor. Run the Service Diagnostics Gate Sensor test.

Gate SNR Static Jam (Upper Tray) Paper remains at the Gate Sensor with Finisher in the Stacker Upper Tray exit mode. Does the voltage across P8376-2 <=> P8376-1 on the Finisher Main PWB change when the sensor is blocked? Yes Go to Step 29.12 Finisher Transport (1/2) (page 4-66) PL25.15 Finisher Harness (page 4-72) Error Messages. and Procedures 3-135 .F4-83 Gate SNR Static Jam A Jam at G .14 Finisher Electrical (page 4-70) PL25. Disconnect P/J8432 and P/J8376. Applicable Error Codes Jam at F . 29 Go to Step 30. Codes. Is there +5 V acrossP8376-3 <=> P83761 on the Finisher Main PWB? Check Gate Sensor signal.F4-84 Gate SNR Static Jam B Jam at G . Check for continuity at the following: J8432-3 <=> J8376-1 J8432-2 <=> J8376-2 J8432-1 <=> J8376-3 Are these conductive? Check for +5 V to the Gate Sensor. Jam at F or G .F4-85 Gate SNR Static Jam C Static Jam at F or G (Gate Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ Transport Motor Main Drive Harness Finisher Main PWB Top Exit Sensor Harness Gate Sensor Gate Sensor Harness Transport Gate Solenoid Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Motors Wiring (page 5-42) Finisher Clutch and Solenoids (page 5-43) PL25.13 Finisher Transport (2/2) (page 4-68) PL25. 30 Replace the Finisher Main PWB (page 3-248). No Repair the Gate Sensor Harness. Replace the Gate Sensor (page 3-236). Replace the Finisher Main PWB (page 3-248).Jam at F (Transport Gate Sensor ON) Troubleshooting Procedure (Continued) Step 28 Actions and Questions Check Gate Sensor Harness continuity.

Does the sensor state change when the sensor is blocked? Check the Gate Sensor Harness. No Go to Step 3. Problem solved.Static Jam at F or G (Gate Sensor) Troubleshooting Procedure Step 1 Actions and Questions Test the Finisher Transport Motor. Are P/J8432 and P/J8376 connected? Go to Step 7. Disconnect P/J8342 and P/J8304. Run the Service Diagnostics Gate Sensor test. 2. Repair the Transport Motor Main Drive Harness. Print a Test Print. 2 Go to Step 9. 3 Go to Step 5. 7 Go to Step 8. Problem solved. Does the error still occur? Check Transport Motor Main Drive Harness continuity. Connect and go to Step 11. 10 Go to Step 12. Does the motor rotate normally? Test Entrance and Transport Roller drive. Replace the Finisher Main PWB (page 3-248). Do the Entrance and Transport Rollers rotate? Check the Transport Motor Main Drive Harness. 8 Replace the Finisher Main PWB (page 3-248). Run the Service Diagnostics Finisher Transport Motor Test. 6 Check the Transport Motor resistance. Are P/J8342 and P/J8304 connected? Print a Test Print. Connect and go to Step 4. Does the error still occur? Test the Gate Sensor. 4 5 Go to Step 5. Go to Step 15. Restore operation and go to Step 4. Run the Service Diagnostics Finisher Transport Motor Test. Go to Step 6. Check for continuity at the following: P/J8342-1 <=> P/J8304-23 P/J8342-2 <=> P/J8304-16 P/J8342-3 <=> P/J8304-25 P/J8342-4 <=> P/J8304-27 P/J8342-5 <=> P/J8304-18 P/J8342-6 <=> P/J8304-29 Are these conductive? Yes Go to Step 2. Replace the Transport Motor (page 3-222). Is there some amount of resistance across P8342-2/5(COM) and P8342-1/3/ 4/6? Check for +24 V to the Transport Motor. 3-136 Phaser 5500 Printer Service Manual . Is there +24 V across J8304-16 <=> ground and J8304-18 <=> ground on the Finisher Main PWB? Replace the Transport Motor. 1. 9 Go to Step 10.

2. 17 18 Go to Step 18. Disconnect P/J8432 and P/J8376. Error Messages. Does the Buffer Gate open for Path-in and close for Path-out? Check Buffer Gate Solenoid Harness connections. Repair the Buffer Gate Solenoid Harness. 1.Static Jam at F or G (Gate Sensor) Troubleshooting Procedure (Continued) Step 11 12 Actions and Questions Print a Test Print. Replace the Finisher Main PWB (page 3-248). Disconnect P/J8394 and P/J8304. Go to Step 13. Check for continuity at the following: P/J8394-1 <=> P/J8304-35 P/J8394-2 <=> P/J8304-34 P/J8394-3 <=> P/J8304-36 Are these conductive? Yes Go to Step 12. 15 16 Connect and go to Step 17. Run both Service Diagnostics Buffer Gate Solenoid tests. Repair the Gate Sensor Harness. Is there +5 V across P8376-3 <=> P83761 on the Finisher Main PWB? Check the Gate Sensor signal. Does the error still occur? Check Buffer Gate Solenoid Harness continuity. Does the voltage across P8376-2 <=> P8376-1 on the Finisher Main PWB change when the sensor is blocked? Test the Buffer Gate Solenoid. 20 Replace the Finisher Main PWB (page 3-248). Go to Step 16. Check for continuity at the following: P/J8432-3 <=> P/J8376-1 P/J8432-2 <=> P/J8376-2 P/J8432-1 <=> P/J8376-3 Are these conductive? Check for +5 V to the Gate Sensor. Replace the Gate Sensor (page 3-236). 19 Check for +24 V to the Buffer Gate Solenoid. Codes. Does the error still occur? Go to Step 20. 13 Go to Step 14. Is there +24 V across J8304-34 <=> J8304-36 on the Finisher Main PWB? Replace the Buffer Gate Solenoid. No Problem solved. Go to Step 18. Problem solved. Go to Step 19. Does the error still occur? Check Gate Sensor Harness continuity. Replace the Finisher Main PWB (page 3-248). Are P/J8394 and P/J8304 connected? Print a Test Print. Problem solved. 14 Replace the Finisher Main PWB (page 3-248). and Procedures 3-137 . Replace the Finisher Main PWB (page 3-248). Print a Test Print.

No Go to Step 3.F4-86 Gate SNR Static Jam A Jam at G .Jam at F or G . Do the Entrance and Transport Rollers rotate? Check the Transport Motor Drive Harness. 2 Go to Step 9. Are P/J8342 and P/J8304 connected? Print a Test Print.14 Finisher Electrical (page 4-70) PL25. Does the error still occur? Yes Go to Step 2. Problem solved.F4-88 Gate SNR Static Jam C Static Jam at F or G (Gate Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ Transport Motor Main Drive Harness Finisher Main PWB Top Exit Sensor Harness Gate Sensor Gate Sensor Harness Transport Gate Solenoid Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Motors Wiring (page 5-42) Finisher Clutch and Solenoids (page 5-43) PL25.15 Finisher Harness (page 4-72) Static Jam at F or G (Gate Sensor) Troubleshooting Procedure Step 1 Actions and Questions Test the Finisher Transport Motor.F4-87 Gate SNR Static Jam B Jam at G . Run the Service Diagnostics Finisher Transport Motor Test. Go to Step 5. Connect and go to Step 4. Restore operation and go to Step 4.13 Finisher Transport (2/2) (page 4-68) PL25. Applicable Error Codes Jam at F . 3-138 Phaser 5500 Printer Service Manual . 3 4 Go to Step 5.12 Finisher Transport (1/2) (page 4-66) PL25. Does the motor rotate normally? Test Entrance and Transport Roller drive.Gate SNR Static Jam (Lower Tray) Paper remains at the Gate Sensor when the Finisher is in the Stacker Lower Tray exit mode. Run the Service Diagnostics Finisher Transport Motor Test.

Disconnect P/J8342 and P/J8304. 8 Replace the Finisher Main PWB (page 3-248). 6 Check the Transport Motor resistance. 7 Go to Step 8. Check for continuity at the following: P/J8342-1 <=> P/J8304-23 P/J8342-2 <=> P/J8304-16 P/J8342-3 <=> P/J8304-25 P/J8342-4 <=> P/J8304-27 P/J8342-5 <=> P/J8304-18 P/J8342-6 <=> P/J8304-29 Are these conductive? Yes Go to Step 6. 9 Go to Step 10. 10 11 12 Go to Step 12. Codes. 1. Is there +5 V across P8376-3 <=> P83761 on the Finisher Main PWB? Go to Step 7. Go to Step 13. Replace the Finisher Main PWB (page 3-248). Does the sensor state change when the sensor is blocked? Check the Gate Sensor Harness. 2. Error Messages. Run the Service Diagnostics Gate Sensor test. Replace the Finisher Main PWB (page 3-248). Does the error still occur? Test the Gate Sensor. Are P/J8432 and P/J8376 connected? Print a Test Print. Replace the Transport Motor (page 3-222). No Repair the Transport Motor Drive Harness. Go to Step 15. 13 Go to Step 14. Does the error still occur? Check Gate Sensor Harness continuity. Print a Test Print. Problem solved. Is there +24 V across J8304-16 <=> ground and J8304-18 <=> ground on the Finisher Main PWB? Replace the Transport Motor. Problem solved. Is there some amount of resistance across P8342-2/5(COM) and P8342-1/3/ 4/6? Check for +24 V to the Transport Motor. and Procedures 3-139 .Static Jam at F or G (Gate Sensor) Troubleshooting Procedure (Continued) Step 5 Actions and Questions Check Transport Motor Drive Harness continuity. Connect and go to Step 11. Disconnect P/J8432 and P/J8376. Check for continuity at the following: P/J8432-3 <=> P/J8376-1 P/J8432-2 <=> P/J8376-2 P/J8432-1 <=> P/J8376-3 Are these conductive? Check for +5 V to the Gate Sensor. Go to Step 12. Repair the Gate Sensor Harness.

Run both Service Diagnostics Buffer Gate Solenoid tests. Is there +24 V across J8304-34 <=> J8304-36 on the Finisher Main PWB? Replace the Buffer Gate Solenoid. 15 16 Connect and go to Step 17. 17 18 Go to Step 18. 19 Check for +24 V to the Buffer Gate Solenoid. Replace the Finisher Main PWB (page 3-248). 1. Problem solved. Does the error still occur? Check Buffer Gate Solenoid Harness continuity. Go to Step 16. Repair the Main Drive Harness. No Replace the Gate Sensor (page 3-236). Go to Step 19. Are P/J8394 and P/J8304 connected? Print a Test Print. Problem solved. 20 Replace the Finisher Main PWB (page 3-248). Disconnect P/J8394 and P/J8304. Print a Test Print. Does the error still occur? Go to Step 20. Does the voltage across P8376-2 <=> P8376-1 on the Finisher Main PWB change when the sensor is blocked? Test the Buffer Gate Solenoid. Does the Buffer Gate open for Path-in and close for Path-out? Check Buffer Gate Solenoid Harness connections. Replace the Finisher Main PWB (page 3-248). 3-140 Phaser 5500 Printer Service Manual . Check for continuity at the following: P/J8394-1 <=> P/J8304-35 P/J8394-2 <=> P/J8304-34 P/J8394-3 <=> P/J8304-36 Are these conductive? Yes Replace the Finisher Main PWB (page 3-248). 2. Go to Step 18.Static Jam at F or G (Gate Sensor) Troubleshooting Procedure (Continued) Step 14 Actions and Questions Check the Gate Sensor signal.

Paper size detection inoperative.6 Tray 4-5 Drive and Electrical (page 4-16) Universal Tray Failure Troubleshooting Procedure Step 1 2 Actions and Questions Check paper supply. No Load paper and go to Step 2. Codes.H1-1 Tray 2 Fail Tray 3 Failure .3 Tray 4-5 Tray (2/2) (page 4-8) PL20. Does the motor operate properly? Yes Go to Step 2.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual 1000-Sheet Feeder P/J Locator (page 5-5) 1000-Sheet Feeder Tray 4 & 5 Wiring (page 5-9) PL20. 4 Go to Step 9. Is paper loaded in the affected tray? Check the tray.3 Feeder (2/2) (page 9-12) PL8. Applicable Error Codes Tray 2 Failure .2 Tray (2/2) (page 9-10) PL2. 3 Replace the tray. and Procedures 3-141 .4 Tray 4-5 Feeder (2/2) (page 4-10) PL20.1 Tray (1/2) and Feeder (1/2) (page 9-8) PL2. Go to Step 3. Replace the tray with one from another position. Error Messages.H1-2 Tray 3 Fail Tray 4 Failure .Tray n Failure .H1-3 Tray 4 Fail Tray 5 Failure . Does the replaced tray lift? Check lift components. Print Engine P/J Tray 2 & 3 Feeders (page 10-11) Print Engine P/J Engine Logic Board (page 10-13) Print Engine Tray 2 & 3 Wiring (page 10-26) PL2. Is the Sector Gear or surrounding parts damaged? Test the Feed/Lift Motor.H1-4 Tray 5 Fail Universal Tray Failure Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ Tray Feeder Feed/Lift Motor Level Sensor Paper Size Switch Tray 4-5 PWB Engine Logic Board.H1 -1/2/3/4 Tray n Fail Detected lift failure. Go to Step 4.2 Tray 4-5 Tray (1/2) Feeder (1/2) (page 4-6) PL20. Go to Step 4. Run the Service Diagnostics Lift Motor test for the affected tray. Go to Step 5.

Repair the wiring. Is the affected Feed/Lift motor properly connected to the harness? Test the Feed/Lift Motor. No Connect the motor. 8 Replace the motor. 10 Go to Step 11. 12 Replace the sensor. Go to Step 10. go to Step 11. If error continues. 1. 11 Check harness continuity between the Level Sensor and Engine Logic Board. 3-142 Phaser 5500 Printer Service Manual . Exchange the Feed/Lift Motor with one from an operational feeder. 7 Check for continuity on the connections. go to Step 6. If the error persists replace Tray 4-5 PWB (page 3-29). Is there +5 V across Pin-3 (+) <=> ground? Go to Step 12. Is there +24 V across the motor connector’s Pin 4(+) <=> ground? Go to Step 8. Replace the Engine Logic Board. Run the Service Diagnostics Level Sensor test for the affected tray. Does the motor operate properly? Yes Go to Step 6. If error persists. Go to Step 7. If the error persists replace Tray 4-5 PWB (page 3-29). Is there continuity on each wire between P/J409 (Trays 2-3) or P/J549 (Trays 4-5) and the Feeder Harness? Check for +24 V to the affected Feed/Lift Motor. Is there continuity on each wire between the Level Sensor <=> P/J409 (Trays 2-3) or P/J549 (Trays 4-5)? Check for +5 V to the affected Level Sensor. Connect the sensor. Does the sensor state change? Check the Level Sensor connection.Universal Tray Failure Troubleshooting Procedure (Continued) Step 5 Actions and Questions Check the Feed/Lift Motor connections. Replace the Engine Logic Board (page 8-89). 2. Repair the wiring. 6 Replace the Feed/ Lift motor. Is the sensor connected to the harness? Go to Step 13. Run the Service Diagnostics Lift Motor test on the replacement motor. Reinstall the motors in the original feeders. 9 Test the affected Level Sensor.

Is the paper size detected correctly when the tray. Error Messages.Universal Tray Failure Troubleshooting Procedure (Continued) Step 13 Actions and Questions Test the affected Paper Size Switch. If the error persists replace Tray 4-5 PWB (page 3-29). Yes Replace the Engine Logic Board. 16 Replace the switch.3 V to the Paper Size Switch Is there +5 V across P/J412-1 (+) <=> ground? for Tray 2-3 or 3. Repair the wiring.3 V across P/ J548-1 for Tray 4-5. No Go to Step 14. Replace the Engine Logic Board. Is there continuity on each wire between the switch <=> P/J412 (Tray 23) or P/J548 (Tray 4-5)? Check for +3. 15 Go to Step 16. and Procedures 3-143 . Go to Step 15. Codes. 14 Connect the switch. is moved in and out? Check the affected Paper Size Switch connection. Run the Service Diagnostics Paper Size Sensor test for the affected tray. If the error persists replace Tray 4-5 PWB (page 3-29). If problem persists. Is the switch connected to the harness? Check continuity between the Paper Size Switch and the Engine Logic Board (Tray 23) or Tray 4-5 PWB (Tray 4-5). loaded with paper. go to Step 15.

Print Engine P/J Engine Logic Board (page 10-13) PL2.1 Tray (1/2) and Feeder (1/2) (page 9-8) PL2.H1-5 Tray 6 Fail Tray 6 Failure Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ Tray In Sensor Tray 6 Main Harness Tray 6 Feeder Harness Tray 6 PWB Lift Cables Feed/Lift Motor Nudger Solenoid Level Sensor Engine Logic Board. 5 Go to Step 7. Go to Step 10.H1-5 Tray 6 Fail Detected lift failure or paper size detection inoperative. Go to Step 4. or is it deformed or damaged? Check the Tray installation. Correct and go to Step 3.1 Tray 6 Covers (page 4-18) PL23. Problem solved.3 Tray (2/2) (page 4-20) PL22. Run the Service Diagnostics Tray In Sensor test.5 Tray 6 Feeder (2/3) (page 4-26) PL22. Does the actuator enter the sensing area of the Tray Set Sensor. Connect and go to Step 6. Is the Tray installed correctly? Check the repairs. Go to Step 5.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual 2000-Sheet Tray 6 Feeder P/J Locator (page 5-20) 2000-Sheet Tray 6 Drive P/J Locator (page 5-21) 2000-Sheet Tray 6 Sensors Wiring (page 5-24) 2000-Sheet Tray 6 Drive Wiring (page 5-25) PL22. 3-144 Phaser 5500 Printer Service Manual .3 Feeder (2/2) (page 9-12) PL8. Does the error reoccur? Test the Tray In Sensor. Pull the Tray out. Are PF53 and JF01 connected? Yes Go to Step 2.8 Tray 6 Electrical (page 4-32) Tray 6 Failure Troubleshooting Procedure Step 1 Actions and Questions Check Tray In Sensor alignment. Applicable Error Code Tray 6 Failure . Does the sensor status change when the tray is moved in and out? Check the Tray In Sensor Main Harness connection. No Repair the damage and go to Step 2.Tray 6 Failure .4 Tray 6 Feeder (1/3) (page 4-24) PL22.2 Tray (2/2) (page 9-10) PL2. 2 3 4 Go to Step 3.

Repair the Tray 6 Feeder Harness. Are PF56B and JF02 connected? Check the repair. Go to Step 8. 1. Codes. 14 15 Go to Step 15. 1. Problem solved. 2. Replace the Tray 6 PWB (page 3-67). Go to Step 12. Is there +5 V across PF01-6 <=> PF04-2 on the Tray 6 PWB? Check Tray In Sensor signal. Connect and go to Step 13. 9 Go to Step 36.Tray 6 Failure Troubleshooting Procedure (Continued) Step 6 7 Actions and Questions Check the repairs. 11 Go to Step 19. Error Messages. Run the Service Diagnostics Tray 6 Level Sensor test. Check for continuity at the following: PF62-1 <=> JF56B-6 PF62-2 <=> JF56B-5 PF62-3 <=> JF56B-4 Are these conductive? Go to Step 9. Repair the Tray 6 Tray Set Sensor harness. Connect and go to Step 14. No Problem solved. Does the error reoccur? Check Tray In Sensor Main Harness continuity. Remove the Tray from the HCF. Does the voltage across JF01-5 <=> PF04-2 on the Tray 6 PWB change when the sensor is blocked? Check the Tray cables. Are the two cables installed correctly? Test the Level Sensor. Go to Step 16. Correct and go to Step 11. and Procedures 3-145 . Does the sensor state change? Check the Level Sensor Harness connections. Replace the sensor (page 3-41). Check for continuity at the following: PF53-1 <=> JF01-6 PF53-2 <=> JF01-5 PF53-3 <=> JF01-4 Are these conductive? Yes Go to Step 7. Disconnect PF53 and JF01. 10 Go to Step 11. 12 Go to Step 13. Does the error still occur? Check Level Sensor Harness continuity. Disconnect PF62 and JF56B. Are PF62 and PF56B connected? Check the Level Sensor Harness connections. 2. 13 Go to Step 15. 8 Check for +5 V to the Tray In Sensor.

Disconnect PF56B and JF02. Go to Step 20. 2. Disconnect PF59 and JF56A. and JF06 on the Tray 6 PWB connected? Check the repair. 21 22 Go to Step 22. Is there some amount of resistance across PF59-1 and PF59-2? Go to Step 25. 18 Go to Step 36. Open Door J. 1. Does the voltage across PF02-2 <=> PF04-2 on the Tray 6 PWB change when the sensor is blocked? Go to Step 18. 1. Replace the Tray 6 PWB (page 3-67). 19 Test the Nudger Solenoid. Replace the Level Sensor (page 3-55). 17 Check for +5 V to the Level Sensor. 2.Tray 6 Failure Troubleshooting Procedure (Continued) Step 16 Actions and Questions Check Main Harness continuity. Connect and go to Step 21. Repair the Feeder Harness. 20 Go to Step 22. Is there +5 V across PF02-3 <=> P/JF042 on the Tray 6 PWB? Check Level Sensor signal. 24 Check Nudger Solenoid resistance. Are PF59 and PF56 on the Feeder and Main Harnesses. Check for continuity at the following: JF56B-1 <=> JF02-3 JF56B-2 <=> JF02-2 JF56B-3 <=> JF02-1 Are these conductive? Yes Go to Step 17. Check for continuity at the following: PF59-2 <=> JF56A-1 PF59-1 <=> JF56A-2 Are these conductive? Go to Step 28. Run the Service Diagnostics Tray 6 Nudger Solenoid test. 1. Replace the Solenoid (page 3-50). 1. Disconnect PF56A and P/JF06. 2. Does the error still occur? Check Nudger Solenoid Harness continuity. Problem solved. 3-146 Phaser 5500 Printer Service Manual . 23 Check Nudger Solenoid Main Harness continuity. Check for continuity at the following: PF56A-6 <=> P/JF06-13 PF56A-5 <=> P/JF06-14 Are these conductive? Go to Step 24. Repair the Nudger Solenoid Main Harness. Open the Upper Feeder Assembly. No Repair the Tray 6 Main Harness. Go to Step 23. 2. Does the solenoid activate? Check Nudger Solenoid harness connections.

Error Messages. Run the Service Diagnostics Nudger Solenoid Low Power test. Repair the Feeder Harness. Problem solved. No Replace the Tray 6 PWB (page 3-67). Replace the Tray 6 PWB (page 3-67). 30 31 Go to Step 31. 26 Go to Step 27. Check for continuity at the following: PF58-1 <=> JF56-1 PF58-2 <=> JF56-2 PF58-3 <=> JF56-3 PF58-4 <=> JF56-4 PF58-5 <=> JF56-5 PF58-6 <=> JF56-6 Are these conductive? Yes Go to Step 26.5 V to the Nudger Solenoid. Run the Service Diagnostics Tray 6 Lift Motor test. 2. 27 28 Go to Step 36. Disconnect PF56 and JF06. and Procedures 3-147 . Does the Tray raise? Check the harness connections. 1. Problem solved.7V across PF06-13 <=> P/ JF04-2 on the Tray 6 PWB? Replace the Nudger Solenoid. Are PF58 and PF56 on the Feeder and Main Harness. Is there +14. Does the error still occur? Test the Feed/Lift Motor. Repair the Main Harness.5 V across PF06-13 <=> P/ JF04-2 on the Tray 6 PWB? Test for +14. Disconnect PF58 and JF56. Go to Step 32. 32 Check Main Harness continuity. Go to Step 36. Does the error still occur? Check Feeder Harness continuity.Tray 6 Failure Troubleshooting Procedure (Continued) Step 25 Actions and Questions Test for +24.7 V Nudger Solenoid. 2. Connect and go to Step 30. Codes. Check for continuity at the following: PF56-1 <=> JF06-1 PF56-2 <=> JF06-3 PF56-3 <=> JF06-2 PF56-4 <=> JF06-6 PF56-5 <=> JF06-4 PF56-6 <=> JF06-5 Are these conductive? Go to Step 33. Go to Step 29. Run the Service Diagnostics Nudger Solenoid High Power test. and JF06 on the Tray 6 PWB connected? Check the repair. 1. Is there +24. 29 Go to Step 31.

2 Go to Step 3. Applicable Error Code Duplex Unit Failure . Problem solved. Are the voltages across PF06-3 <=> PF04-3.Tray 6 Failure Troubleshooting Procedure (Continued) Step 33 Actions and Questions Check Feed/Lift Motor resistance. No Replace the Feed/Lift Motor (page 3-49). Connect P/J540 and P/J417.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual Duplex Unit Plug/Jack Locator (page 5-12) Duplex Unit Wiring (page 5-13) PL23. Reinstall the Duplex Unit.1 Duplex Unit (page 4-34) Duplex Comm Failure Troubleshooting Procedure Step 1 Actions and Questions Check Duplex Unit installation. Replace the Tray 6 PWB (page 3-67). Does the error still occur? Check the Duplex PWB connection. Problem solved. Is there some amount of resistance across PF58-2/5(COM) and PF58-1/3/4/ 6? Check for +24 V to the Feed/Lift Motor. Are P/J540 and P/J417 connected? Yes Go to Step 2. Does the error still occur? Replace the Tray 6 PWB. No Problem solved. Print a Test Print. 36 Replace the Engine Logic Board (page 8-89). and PF06-4 <=> PF04-3 on the Tray 6 PWB +24 V? Replace the Feed/Lift Motor. 3-148 Phaser 5500 Printer Service Manual .H2-7 Duplex Comm Failure Communications failure between the Engine Logic Board and the Duplex Unit. 35 Go to Step 36. Does the error still occur? Yes Go to Step 34.H2-7 Duplex Comm Failure Duplex Comm Failure Troubleshooting Reference Applicable Parts ■ ■ References ■ ■ ■ ■ ■ ■ Duplex Unit PWB Engine Logic Board Print Engine P/J Engine Logic Board (page 10-13) PL8. Duplex Unit Failure . 34 Go to Step 35.

Check for continuity at the following: P/J540-1 <=> P/J417-A1 P/J540-2 <=> P/J417-B1 P/J540-3 <=> P/J417-A2 P/J540-4 <=> P/J417-B2 P/J540-5 <=> P/J417-A3 P/J540-6 <=> P/J417-B3 P/J540-7 <=> P/J417-A4 P/J540-8 <=> P/J417-B4 Are these conductive? Yes Go to Step 4.Duplex Comm Failure Troubleshooting Procedure (Continued) Step 3 Actions and Questions Check Duplex Harness continuity between the Duplex PWB and the Engine Logic Board. 2. Incorrect Duplex Unit Installed . No Problem solved.H2-8 Duplex Type Error Incorrect Duplex Unit installed. Codes. 1. and Procedures 3-149 . Disconnect P/J540 and P/J417. Replace the Engine Logic Board (page 8-89).H2-8 Duplex Type Error Incorrect Duplex Unit Installed Troubleshooting Reference Applicable Parts ■ ■ References ■ ■ ■ ■ ■ ■ Duplex Unit PWB Engine Logic Board Print Engine P/J Engine Logic Board (page 10-13) PL8. Is there +24 V across P/J540-2 (+) <=> ground? Replace the Duplex PWB (page 3-77). 4 Check for +24 V to the Duplex PWB. Does the error still occur? Yes Go to Step 2.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual Duplex Unit Plug/Jack Locator (page 5-12) Duplex Unit Wiring (page 5-13) PL23. Reinstall the Duplex Unit. Applicable Error Code Duplex Unit Failure . No Repair the wiring.1 Duplex Unit (page 4-34) Incorrect Duplex Unit Installed Troubleshooting Procedure Step 1 Actions and Questions Check Duplex Unit installation. Error Messages.

Run the Service Diagnostics Exit 1 or 2 Offset Home Position Sensor test. 2 Go to Step 3. Exit Unit Failure . Connect the sensor. No Go to Step 2.H3-n Offset Error Failure to establish Offset Home Position on Exit1 (H3-1) or Exit 2 (H3-2). Is P/J117 (Exit 1) or P/J111 (Exit 2) connected? Check continuity between the affected OCT Position Sensor and the Exit PWB P/ J111 <=> P/J434 and SJ1 (Exit2) P/J117 <=> P/J423 (Exit 1). Does the sensor state change? Check the sensor connection.H3-2 Offset Error Exit Offset Error (OCT Position Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ ■ OCT Position Sensor Offset Motor Exit PWB LVPS Engine Logic Board Print Engine P/J Engine Logic Board (page 10-13) Print Engine P/J Laser and Exit PWB (page 10-7) Print Engine LVPS Wiring (page 10-21) Print Engine Exit 1 Wiring (page 10-30) PL8. No Replace the Engine Logic Board (page 8-89). Is there continuity on each wire? Yes Go to Step 10.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual Exit 2 Plug/Jack Locator (page 5-15) Exit 2 General Wiring (page 5-7) PL24. Repair the wiring. Is there +24 V across P/J540-2 (+) <=> ground? Yes Replace the Duplex PWB (page 3-77). 3 Go to Step 4.Incorrect Duplex Unit Installed Troubleshooting Procedure (Continued) Step 2 Actions and Questions Check for +24 V to the Duplex PWB. 3-150 Phaser 5500 Printer Service Manual .H3-1 Offset Error Exit Unit Failure .2 Exit 2 Tray Guide Assembly (page 4-40) Exit Offset Error (OCT Position Sensor) Troubleshooting Procedure Step 1 Actions and Questions Test the affected OCT Position Sensor. Applicable Error Codes Exit Unit Failure .

Error Messages. Check for continuity at the following: P/J431-1 <=> P/J421-8 P/J431-2 <=> P/J421-7 P/J431-3 <=> P/J421-6 P/J431-4 <=> P/J421-5 P/J431-5 <=> P/J421-4 P/J431-6 <=> P/J421-3 P/J431-7 <=> P/J421-2 P/J431-8 <=> P/J421-1 Are these conductive? Yes Replace the affected OCT Position Sensor. 1. Is there +5 V across P/J434-1 (Exit 2) or P/J432-1 (Exit 1) (+) <=> ground? Check the connection between the Exit PWB and the Engine Logic Board. Are P/J430 and P/J526 connected? Check continuity between the Exit PWB and the LVPS. replace the Engine Logic Board (page 8-89). If problem persists. Run the Service Diagnostics Offset Output Motor tests for the appropriate Exit. 6 Go to Step 7. Codes. Go to Step 6. 10 11 Check the affected Offset Motor connection. 7 Check the connection between the Exit PWB and the LVPS. and Procedures 3-151 . Is there +24 V across P/J430-1 (+) <=> ground? Test the Offset Motor. Replace the Exit PWB (page 8-88). No Go to Step 5. 8 Go to Step 9. go to Step 6. Go to Step 11. Are P/J431 and P/J421 connected? Check continuity between the Exit PWB and the Engine Logic Board. Disconnect P/J430 and P/J526. Repair the wiring. 2. If problem persists go to Step 12. Disconnect P/J431 and P/J421. Is the motor connected? Connect the motor. Check for continuity at the following: P/J430-3 <=> P/J526-6 P/J430-4 <=> P/J526-5 P/J430-1 <=> P/J526-8 P/J430-2 <=> P/J526-7 Are these conductive? Go to Step 8. Exit 1 P/J432 <=> J206 or Exit 2 P/J433 <=> J207.Exit Offset Error (OCT Position Sensor) Troubleshooting Procedure (Continued) Step 4 Actions and Questions Check for +5 V to the OCT Position Sensor. Repair the wiring. 1. 9 Check for +24 V to the Exit PWB. Connect P/J430 and P/J526. Go to Step 12. 5 Connect P/J431 and P/J421. Does the Offset Motor operate properly? Replace the Exit PWB (page 8-88). If problem persists. 2. Replace the LVPS (page 8-92). If problem persists. go to Step 8.

Exit Offset Error (OCT Position Sensor) Troubleshooting Procedure (Continued) Step 12 Actions and Questions Check continuity between the affected Offset Motor and Exit PWB.H3-7 Exit Board Comm Failure Exit Comm Failure Troubleshooting Reference Applicable Parts ■ ■ ■ References ■ ■ ■ ■ ■ Exit PWB LVPS Engine Logic Board Print Engine P/J Engine Logic Board (page 10-13) Print Engine P/J Laser and Exit PWB (page 10-7) Print Engine LVPS Wiring (page 10-21) Print Engine Exit 1 Wiring (page 10-30) PL8. Check for continuity at the following: P/J432-7 <=> J206-1 P/J432-8 <=> J206-2 P/J432-9 <=> J206-3 P/J432-10 <=> J206-4 P/J432-11 <=> J206-5 For Exit 2: 1. Check for continuity at the following: P/J433-1 <=> J207-1 P/J433-2 <=> J207-2 P/J433-3 <=> J207-3 P/J433-4 <=> J207-4 P/J433-5 <=> J207-5 Is there continuity on each wire? Yes Go to Step 13.1 Print Engine Electrical 3-152 Phaser 5500 Printer Service Manual . No Repair the wiring. Exit Unit Failure . Replace the Exit PWB (page 8-88). Disconnect P/J433 and J207. Disconnect P/J432 and J206. Applicable Error Code Exit Unit Failure .H3-7 Exit Board Comm Failure Communications failure between the Engine Logic Board and Exit PWB. 2. For Exit 1: 1. 13 Check for +24 V to the affected Offset Motor. 2. Is there +24 V across (Exit 2) P/J433-1 or (Exit 1) P/J432-7(+) <=> ground? Replace the Offset Motor.

Error Messages. 2. Disconnect P/J430 and P/J526. Repair the wiring. Check for continuity at the following: P/J430-3 <=> P/J526-6 P/J430-4 <=> P/J526-5 P/J430-1 <=> P/J526-8 P/J430-2 <=> P/J526-7 Are these conductive? Go to Step 4. Are P/J431 and P/J421 connected? Check continuity between the Exit PWB and the Engine Logic Board. 5 Check for +24 V to the Exit PWB. Are P/J430 and P/J526 connected? Check continuity between the Exit PWB and the LVPS.Exit Comm Failure Troubleshooting Procedure Step 1 2 Actions and Questions Check the Exit PWB connection. Codes. 1. and Procedures 3-153 . Repair the wiring. 4 Go to Step 5. 3 Check the connection between the Exit PWB and the LVPS. Is there +24 V across P/J430-1 (+) <=> ground? Replace the Exit PWB (page 8-88). 2. Go to Step 3. Connect P/J430 and P/J526. Check for continuity at the following: P/J431-1 <=> P/J421-8 P/J431-2 <=> P/J421-7 P/J431-3 <=> P/J421-6 P/J431-4 <=> P/J421-5 P/J431-5 <=> P/J421-4 P/J431-6 <=> P/J421-3 P/J431-7 <=> P/J421-2 P/J431-8 <=> P/J421-1 Are these conductive? Yes Go to Step 2. No Connect P/J431 and P/J421. Replace the LVPS (page 8-92). 1. Disconnect P/J431 and P/J421.

3 Tray 1/MPT Assembly (page 9-20) PL8. 1. Check for continuity at the following: J107-1 <=> J411-1 J107-2 <=> J411-2 J107-3 <=> J411-3 Are these conductive? Yes Go to Step 2. Is there +5 V across J107-1 (+) <=> ground? Replace the Tray 1/MPT Assembly (page 8-32). 5 Go to Step 6. Tray 1/MPT Paper Guides (Paper Size Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ References ■ ■ ■ ■ ■ Paper Size Sensor Paper Guides Size Sensor Harness Engine Logic Board Print Engine Tray 1/MPT P/J Locator (page 10-9) Print Engine Tray 1/MPT Wiring (page 10-28) Print Engine P/J Locator Electrical (page 10-12) PL3. P/J609. \Disconnect J107 and J411. Go to Step 5. 4 Connect the Paper Size Sensor. Does the size displayed change as the size guides are moved in and out? Check the Paper Size Switch connection. Run the Service Diagnostics Tray 1 Size Sensor test.Tray 1/MPT Paper Guide Does Not Match Size Menu The Tray 1/MPT paper guides do no match the paper size stored in NVRAM for Tray 1/MPT. Go to Step 3.1 Print Engine Electrical (page 9-40) Tray 1/MPT Paper Guides (Paper Size Sensor) Troubleshooting Procedure Step 1 2 3 Actions and Questions Check the paper in Tray 1/MPT. Go to Step 4. Reset the guides. 6 Check for +5 V to the Paper Size Sensor. Are the paper guides set correctly? Test the Paper Size Sensor for Tray 1/MPT. P/J605 and J411 connected? Check continuity between the Tray 1/MPT Paper Size Sensor and the Engine Logic Board. 3-154 Phaser 5500 Printer Service Manual . Replace the Engine Logic Board (page 8-89). Repair the wiring. 2. No Reload the paper. Are J107. Is paper loaded in the tray properly? Check the paper guides. Replace the Engine Logic Board (page 8-89).

No Reload the paper. Reset the guides.1 Print Engine Electrical (page 9-40) Paper Size Failure (Tray 2-3 Paper Size Switch) Troubleshooting Procedure Step 1 2 3 Actions and Questions Check the paper in the affected tray. Codes. Connect the Paper Size Switch. Is paper loaded in the tray properly? Check the tray paper guides. For Tray 2: Are P/J109 and P/J412 connected? For Tray 3: Are P/J110 and P/J412 connected? Yes Go to Step 2. Go to Step 5.H4-2 Tray 3 Paper Size Error Paper Size Failure (Tray 2-3 Paper Size Switch) Troubleshooting Reference Applicable Parts ■ ■ ■ References ■ ■ ■ ■ Paper Size Switch Tray Paper Guides Engine Logic Board Print Engine P/J Engine Logic Board (page 10-13) Print Engine P/J Locator Electrical (page 10-12) PL2. Run the Service Diagnostics Size Sensor test for the affected tray. and Procedures 3-155 . Error Messages. 5 Go to Step 6. Go to Step 3. Correct the installation. Go to Step 4.1 Tray (1/2) Feeder (1/2) (page 9-8) PL8.Tray Paper Guide Does Not Match Size Menu -H4-1/2 Applicable Error Codes Tray Paper Guide Does Not Match Size Menu. 4 Reconnect the connector of the Engine Logic Board.H4-1 Tray 2 Paper Size Error Tray Paper Guide Does Not Match Size Menu. Is the switch installed correctly? Test the Paper Size Switch for the affected tray. Are the paper guides set correctly? Check the Paper Size Switch for the affected tray. Does the sensor state change each time the loaded tray is moved in or out? Check the Paper Size Switch connection.

Check for continuity at the following: P/J110-1 <=> P/J412-9 P/J110-2 <=> P/J412-8 P/J110-3 <=> P/J412-7 P/J110-4 <=> P/J412-6 Are these conductive? Yes Go to Step 7. 2. No Repair the wiring. For Tray 2: 1.Paper Size Failure (Tray 2-3 Paper Size Switch) Troubleshooting Procedure Step 6 Actions and Questions Check continuity between the affected Paper Size Switch and the Engine Logic Board. For Tray 2: Is there +5 V across J109-1 (+) <=> ground? For Tray 3: Is there +5 V across J110-1 (+) <=> ground? Replace the paper Size Switch for the affected tray. Disconnect P/J109 and P/J412. 2. Check for continuity at the following: P/J109-1 <=> P/J412-4 P/J109-2 <=> P/J412-3 P/J109-3 <=> P/J412-2 P/J109-4 <=> P/J412-1 For Tray 3: 1. 3-156 Phaser 5500 Printer Service Manual . Replace the Engine Logic Board (page 8-89). 7 Check for +5 V to the Paper Size Switch. Disconnect P/J110 and P/J412.

5 Go to Step 6. Is paper loaded in the tray properly? Check the tray paper guides. Set the guides properly.6 Tray 4-5 Drive and Electrical (page 4-16) Paper Size Failure (Tray 4-5 Paper Size Switch) Troubleshooting Procedure Step 1 2 3 Actions and Questions Check the Paper in the affected tray.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual 1000-Sheet Feeder P/J Locator (page 5-5) 1000-Sheet Feeder P/J Electrical (page 5-6) 1000-Sheet Tray 4 & 5 Wiring (page 5-9) PL20. 4 Reconnect the connector of the Engine Logic Board. Does the sensor state change each time the loaded tray is moved in or out? Check the Paper Size Switch connection. Error Messages. Go to Step 4. and Procedures 3-157 .2 Tray (1/2) Feeder (1/2) (page 4-6) PL20.H4-3 Tray 4 Paper Size Error Tray Paper Guide Does Not Match Size Menu. Correct the installation. Run the Service Diagnostics Size Sensor test for the affected tray. Is the switch installed correctly? Test the Paper Size Switch for the affected tray. Are the paper guides set correctly? Check the Paper Size Switch for the affected tray. Codes.Tray Paper Guide Does Not Match Size Menu -H4-3/4 Applicable Error Codes Tray Paper Guide Does Not Match Size Menu.H4-4 Tray 5 Paper Size Error Paper Size Failure (Tray 4-5 Paper Size Switch) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ Paper Size Switch Tray Paper Guides Tray 4-5 PWB Engine Logic Board Print Engine P/J Engine Logic Board (page 10-13) PL8. Go to Step 5. No Reload the paper. Connect the Paper Size Switch. Go to Step 3. For Tray 4: Are P/J820 and P/J548 connected? For Tray 5: Are P/J824 and P/J548 connected? Yes Go to Step 2.

2. Check for continuity at the following: P/J824-1 <=> P/J548-7 P/J824-2 <=> P/J548-6 P/J824-3 <=> P/J548-5 P/J824-4 <=> P/J548-4 Are these conductive? Yes Go to Step 7. Replace the Engine Logic Board (page 8-89). Repair the wiring.3 V across P/J824-1 (+) <=> ground? Check the Tray 4-5 PWB connection. Are P/J413 and P/J541 connected? Check continuity between the Tray 4-5 PWB and the Engine Logic Board.3 V across P/J820-1 (+) <=> ground? For Tray 5: Is there +3. 2. 3-158 Phaser 5500 Printer Service Manual .Paper Size Failure (Tray 4-5 Paper Size Switch) Troubleshooting Procedure Step 6 Actions and Questions Check continuity between the affected Paper Size Switch and the Engine Logic Board. 7 Check for +3. Disconnect P/J820 and P/J548.3 V to the Paper Size Switch. Connect P/J413 and P/541. No Repair the wiring. Go to Step 10. 8 9 Go to Step 9. Check for continuity at the following: P/J820-1 <=> P/J548-14 P/J820-2 <=> P/J548-13 P/J820-3 <=> P/J548-12 P/J820-4 <=> P/J548-11 For Tray 5: 1. Disconnect P/J541 and P/J413. For Tray 4: 1. Check for continuity at the following: P/J541-1 <=> P/J413-A1 P/J541-2 <=> P/J413-A2 P/J541-3 <=> P/J413-A3 P/J541-4 <=> P/J413-A4 P/J541-5 <=> P/J413-A5 P/J541-6 <=> P/J413-A6 P/J541-7 <=> P/J413-B1 P/J541-8 <=> P/J413-B2 P/J541-9 <=> P/J413-B3 P/J541-10 <=> P/J413-B4 P/J541-11 <=> P/J413-B5 P/J541-12 <=> P/J413-B6 Are these conductive? Replace the Paper Size Switch for the affected tray. Disconnect P/J824 and P/J548. 2. For Tray 4: Is there +3. 1.

H5-8 Finisher Type Error Finisher Board Error (NVRAM R/W Error) Troubleshooting Reference Applicable Parts ■ ■ References ■ ■ ■ ■ ■ Finisher Main PWB Engine Logic Board Print Engine P/J Engine Logic Board (page 10-13) PL8.Paper Size Failure (Tray 4-5 Paper Size Switch) Troubleshooting Procedure Step 10 Actions and Questions Check for +5 V to the Tray 4-5 PWB Is there +5 V across P/J413-A5 (+) <=> ground? Yes Replace the Tray 4-5 PWB (page 3-29). Codes. Connect all connectors.H5-7 MCU-Finisher Comm Error Incorrect Finisher Installed . Are the interface cables connected correctly? Does the error occur when the power is cycled? Check Finisher Main PWB connections. Error Messages. No Replace the Engine Logic Board (page 8-89).H5-4 NVM R/W Error Finisher Failure . Finisher Board Failure . and Procedures 3-159 . No Reconnect the cables and got to Step 2.H5-4. 8 NVM/Comm/Type Error Applicable Error Codes Finisher Board Failure . Are P/J8300 and P416 connected? Yes Go to Step 2.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) PL25. Go to Step 3.14 Finisher Electrical (page 4-70) Finisher Board Error (NVRAM R/W Error) Troubleshooting Procedure Step 1 Actions and Questions Check the Finisher installation. Problem solved. 7. 2 3 Go to Step 2. Go to Step 3.

5 Check for +24 V to the Finisher Main PWB. Stacker Lower Tray Failure .H5-11 Low Tray Fail The Lower Tray No Paper Sensor is not turned Off or On within the specified time following the Stacker Tray beginning to move. Is there +24 V across J416-6 (+) <=> ground? Replace the Finisher Main PWB (page 3-248).H5-11 Low Tray Fail Stacker Lower Tray Failure (Stack Height Sensors) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ ■ Lower Tray No Paper Sensor Upper Limit Actuator Finisher Main PWB Main Sensor Harness Elevator Motor Engine Logic Board Print Engine P/J Engine Logic Board (page 10-13) PL8. 1.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Sensors (2/2) Wiring (page 5-41) Finisher Clutch and Solenoids (page 5-43) PL25. 2. Replace the Engine Logic Board (page 8-89). Disconnect P/J8300 and P/J416.15 Finisher Harness (page 4-72) 3-160 Phaser 5500 Printer Service Manual .Finisher Board Error (NVRAM R/W Error) Troubleshooting Procedure (Continued) Step 4 Actions and Questions Check continuity between the Finisher Main PWB and the Engine Logic Board. No Repair the wiring. Applicable Error Code Stacker Lower Tray Failure .6 Finisher Stack (page 4-54) PL25. Check for continuity at the following: P/J8300-11 <=> P/J416-1 P/J8300-10 <=> P/J416-2 P/J8300-9 <=> P/J416-3 P/J8300-8 <=> P/J416-4 P/J8300-7 <=> P/J416-5 P/J8300-6 <=> P/J416-6 P/J8300-4 <=> P/J416-7 P/J8300-3 <=> P/J416-8 P/J8300-2 <=> P/J416-9 P/J8300-1 <=> P/J416-10 P/J8300-4 <=> P/J416-11 Are these conductive? Yes Go to Step 4.14 Finisher Electrical (page 4-70) PL25.

Go to Step 12. Repair the Actuator. 2. Connect and go to Step 5. Replace the Finisher Main PWB (page 3-248). Go to Step 10. 2 Go to Step 3. If problem persists. No Go to Step 2. Does the Actuator enter the Upper Limit sensor sensing area? Test the Lower Tray No Paper Sensor. Does the Elevator Motor operate? Check the Elevator Motor connection. Replace the Lower Tray No Paper Sensor (page 3-143). Go to Step 7. Repair the Lower Tray No Paper Sensor Harness. 5 6 Go to Step 6. go to Step 7. 7 Check for +5 V to the Lower Tray No Paper Sensor. Does the sensor state change when the sensor is blocked? Check the Lower Tray No Paper Sensor Harness connection. Problem solved. and Procedures 3-161 . Is P/J8305 connected to the Finisher Main PWB? Go to Step 8. Are there obstacles or belt wear in the vertical transport mechanism? Check the Actuator installation. Disconnect P/J8326 on the Lower Tray No Paper Sensor Harness. Run the Service Diagnostics Stacker Motor Up and Down tests alternately. 3 Go to Step 9. 4 Go to Step 6. Does the error still occur? Check the Lower Tray No Paper Sensor Harness continuity. Are P/J8326 and P/J8302B connected? Print a Test Print. Error Messages. Codes. Run the Service Diagnostics Lower Tray No Paper Sensor test. and P/ J8302B on the Finisher Main PWB.Stacker Lower Tray Failure (Stack Height Sensors) Troubleshooting Procedure Step 1 Actions and Questions Check the Stacker Lower Tray vertical transport and belts for obstacles and deformation. Check for continuity at the following: P/J8326-3 <=> P/J8302B-15 P/J8326-2 <=> P/J8302B-16 P/J8326-1 <=> P/J8302B-17 Are these conductive? Yes Remove obstacles/replace deformed part. 9 10 Connect and go to Step 11. 1. 8 Replace the Finisher Main PWB (page 3-248). Replace the Finisher Main PWB (page 3-248). Go to Step 4. Is there +5 V across J8302B-17 <=> J8302B-15 on the Finisher Main PWB? Check Stacker Lower Tray No Paper Sensor. Does the voltage across P8302B-16 <=> P8302B-15 on the Finisher Main PWB change when the sensor is blocked? Test the Elevator Motor.

Stacker Lower Tray Failure (Stack Height Sensors) Troubleshooting Procedure Step 11 12 Actions and Questions Print a Test Print. Does the error still occur? Yes Go to Step 12. Stacker Lower Tray Failure .H5-12 Low Tray Upper Limit Stacker Lower Tray Failure (Upper Limit Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ ■ Lower Tray No Paper Sensor Lower Tray Upper Limit Sensor Upper Limit Actuator Finisher Main PWB Main Sensor Harness Elevator Motor Engine Logic Board Print Engine P/J Engine Logic Board (page 10-13) PL8. Are there obstacles or belt wear in the vertical transport mechanism? Yes Remove any obstacles. Problem solved. Does the error still occur? Replace the Finisher Main PWB. Does the error still occur? Replace the Elevator Motor.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Sensors (2/2) Wiring (page 5-41) Finisher Clutch and Solenoids (page 5-43) PL25.H5-12 Low Tray Upper Limit The Stacker Lower Tray rose beyond the upper limit position.15 Finisher Harness (page 4-72) Stacker Lower Tray Failure (Upper Limit Sensor) Troubleshooting Procedure Step 1 Actions and Questions Check the Stacker Lower Tray vertical transport and belts for obstacles and deformation. No Problem solved. Problem solved. Go to Step 13.14 Finisher Electrical (page 4-70) PL25.6 Finisher Stack (page 4-54) PL25. 13 Replace the Engine Logic Board (page 8-89). 3-162 Phaser 5500 Printer Service Manual . Applicable Error Codes Stacker Lower Tray Failure . No Go to Step 2. Print a Test Print.

Are P/J8326 and P/J8302B connected? Print a Test Print. Go to Step 4. 3 Go to Step 9. Go to Step 7. 7 Check for +5 V to the Lower Tray No Paper Sensor. 5 6 Go to Step 6. Replace the Finisher Main PWB (page 3-248). Does the Actuator enter the Upper Limit sensor sensing area? Test the Lower Tray No Paper Sensor. Run the Service Diagnostics Lower Tray No Paper Sensor test. Connect and go to Step 11. Does the sensor state change when the sensor is blocked? Check Lower Tray Upper Limit Sensor Harness connection. Codes. Disconnect P/J8326 on the Main Sensor Harness. No Replace the Actuator. Go to Step 15. and Procedures 3-163 . 9 10 Go to Step 12.Stacker Lower Tray Failure (Upper Limit Sensor) Troubleshooting Procedure Step 2 Actions and Questions Check the Actuator installation. Replace the Lower Tray No Paper Sensor (page 3-143). Does the error still occur? Check Main Sensor Harness continuity. 4 Go to Step 6. Are P/J8327 and P/J8302B connected? Print a Test Print. Problem solved. and P/J8302B on the Finisher Main PWB. Connect and go to Step 5. 8 Replace the Finisher Main PWB (page 3-248). Error Messages. Does the sensor state change when the sensor is blocked? Check the Lower Tray No Paper Sensor Harness connection. Go to Step 10. 2. Problem solved. Does the voltage across P8302B-16 <=> P8302B-15 on the Finisher Main PWB change when the sensor is blocked? Test the Lower Tray Upper Limit Sensor. Is there +5 V across J8302B-17 <=> J8302B-15 on the Finisher Main PWB? Check the Lower Tray No Paper Sensor. Run the Service Diagnostics Lower Tray Upper Limit Sensor test. Check for continuity at the following: P/J8326-3 <=> P/J8302B-15 P/J8326-2 <=> P/J8302B-16 P/J8326-1 <=>P/J8302B-17 Are these conductive? Yes Go to Step 3. Repair the Main Sensor Harness. 1. Does the error still occur? Go to Step 8. 11 Go to Step 12.

Replace the Finisher Main PWB (page 3-248). 14 Replace the Finisher Main PWB (page 3-248). Go to Step 18. Does the Elevator Motor operate? Check the Elevator Motor connection. Is there +5 V across J8302B-20 <=> J8302B-18 on the Finisher Main PWB? Check Lower Tray Upper Limit Sensor signal. Replace the Lower Tray Upper Limit Sensor (page 3-143). Run the Service Diagnostics Stacker Motor Up and Down tests alternately. Problem solved. Does the error still occur? Replace the Elevator Motor. Is P/J8305 connected to the Finisher Main PWB? Print a Test Print. 15 16 Connect and go to Step 17. Go to Step 19. 2. Go to Step 16. Does the error still occur? Replace the Finisher Main PWB. 17 18 Go to Step 18. Print a Test Print. and P/J8302B on the Finisher Main PWB. Problem solved. Check for continuity at the following: P/J8327-3 <=> P/J8302B-18 P/J8327-2 <=> P/J8302B-19 P/J8327-1 <=> P/J8302B-20 Are these conductive? Yes Go to Step 13. Problem solved. 19 Replace the Engine Logic Board (page 8-89). Does the error still occur? Go to Step 14. Replace the Finisher Main PWB (page 3-248). Disconnect P/J8327 on the harness. 13 Check for +5 Vto the Lower Tray Upper Limit Sensor. 3-164 Phaser 5500 Printer Service Manual . 1. Does the voltage across P8302B-19 <=> P8302B-18 on the Finisher Main PWB change when the sensor is blocked? Test the Elevator Motor. No Repair the Lower Tray Upper Limit Sensor Harness.Stacker Lower Tray Failure (Upper Limit Sensor) Troubleshooting Procedure Step 12 Actions and Questions Check Lower Tray Upper Limit Sensor Sensor Harness continuity.

Codes. Run the Service Diagnostics Stack Height 1 test.15 Finisher Harness (page 4-72) Stacker Lower Trail Failure (Stacker Encoder Sensor) Troubleshooting Procedure Step 1 Actions and Questions Check the Stacker Lower Tray vertical transport and belts for obstacles and deformation. Does the sensor state change when the sensor is blocked? NOTE: Sensor requires a 10 second timeout between sensing events.Stacker Lower Tray Failure . 4 Go to Step 5. Connect and go to Step 4.H5-13 Low Tray Lower Limit The Stacker Lower Tray descends beyond the specified lower limit position.14 Finisher Electrical (page 4-70) PL25.6 Finisher Stack (page 4-54) PL25. Does the error still occur? Go to Step 5. Problem solved. Are P/J8331 and P/J8302B connected? Print a Test Print. Go to Step 3.H5-13 Low Tray Lower Limit Stacker Lower Trail Failure (Stacker Encoder Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ Stack Height Sensor 1 Stack Height Sensor 2 Stacker Encoder Sensor Finisher Main PWB Main Sensor Harness Elevator Motor Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Sensors (2/2) Wiring (page 5-41) Finisher Clutch and Solenoids (page 5-43) PL25. Error Messages. No Go to Step 2. and Procedures 3-165 . 3 Check Stack Height Sensor 1 Sensor Harness connection. Are there obstacles or belt wear in the vertical transport mechanism? Test the Stack Height Sensor 1 (top). 2 Go to Step 8. Applicable Error Code Stacker Lower Tray Failure . Yes Remove any obstacles.

NOTE: Sensor requires a 10 second timeout between sensing events. and P/J8302B on the Finisher Main PWB.Stacker Lower Trail Failure (Stacker Encoder Sensor) Troubleshooting Procedure Step 5 Actions and Questions Check Stack Height Sensor 1 Sensor Harness continuity. Go to Step 12. Does the voltage across P8302B-2 <=> P8302B-1 on the Finisher Main PWB change when the sensor is blocked? Test the Stack Height Sensor 2 (bottom). Go to Step 9. Check for continuity at the following: P/J8331-5 <=> P/J8302B-1 P/J8331-4 <=> P/J8302B-2 P/J8331-3 <=> P/J8302B-3 P/J8331-2 <=> P/J8302B-4 P/J8331-1 <=> P/J8302B-5 Are these conductive? Yes Go to Step 6. No Repair the Stack Height Sensor 1 Sensor Harness. 1. 6 Check for +5 V to Stack Height Sensor 1. Check for continuity at the following: P/J8330-5 <=> P/J8302A-16 P/J8330-4 <=> P/J8302A-17 P/J8330-3 <=> P/J8302A-18 P/J8330-2 <=> P/J8302A-19 P/J8330-1 <=> P/J8302A-20 Are these conductive? Go to Step 11. Replace the Finisher Main PWB (page 3-248). Are P/J8330 and P/J8302A connected? Print a Test Print. Disconnect P/J8331 on the Main Sensor Harness. Replace Stack Height Sensor 1 (page 3-140). 10 11 Go to Step 11. Problem solved. 3-166 Phaser 5500 Printer Service Manual . Disconnect P/J8330 on the harness. Run the Service Diagnostics Stack Height Sensor 2 test. Connect and go to Step 10. Repair the Stack Height Sensor 2 Harness. 7 Replace the Finisher Main PWB (page 3-248). and P/J8302A on the Finisher Main PWB. 8 9 Check Stack Height Sensor 2 Sensor Harness connections. Does the sensor state change when the sensor is blocked? Go to Step 7. 2. 2. 1. Is there +5 V across J8302B-3 <=> J8302B-1 on the Finisher Main PWB? Check Stack Height Sensor 1 signal. Go to Step 14. Does the error still occur? Check Stack Height Sensor 2 Sensor Harness continuity.

Replace the Finisher Main PWB (page 3-248). Replace the Finisher Main PWB (page 3-248). Go to Step 15. Does the sensor state change when the Elevator Motor Belt is moved by hand rotating the Encoder Wheel? Check Stacker Encoder Sensor Harness connections. No Replace the Finisher Main PWB (page 3-248). Go to Step 18. Replace Stacker Encoder Sensor (page 3-142). Is the voltage across J8302B-14 <=> J8302B-12 on the Finisher Main PWB? Check Stacker Encoder Sensor signal. Is P/J8305 connected to the Finisher Main PWB? Go to Step 19. Replace Stack Height Sensor 2 (page 3-141). 13 Replace the Finisher Main PWB (page 3-248). Error Messages. Is there +5 V across J8302A-18 <=> J8302A-16 on the Finisher Main PWB? Check Stack Height Sensor 2 signal. Run the Service Diagnostics Stacker Motor Up and Down tests alternately. Codes. Are P/J8328 and P/J8302B connected? Print a Test Print. and P/J8302B on the Finisher Main PWB. 1. Repair the Stacker Encoder Sensor Harness. 18 Check for +5 V to Stacker Encoder Sensor. Does the voltage across P8302B-13 and P8302B-12 on the Finisher Main PWB change when the sensor is blocked? Test the Elevator Motor. 16 17 Go to Step 17. Go to Step 20. 2. 14 15 Go to Step 17. Check for continuity at the following: P/J8328-3 <=> P/J8302B-12 P/J8328-2 <=> P/J8302B-13 P/J8328-1 <=> P/J8302B-14 Are these conductive? Yes Go to Step 13. Problem solved. Does the voltage across P8302A-17 <=> P8302A-16 on the Finisher Main PWB change when the sensor is blocked? Test the Stacker Encoder Sensor. 20 21 Connect and go to Step 22. Run the Service Diagnostics Stacker Encoder Sensor test. Go to Step 21. Disconnect P/J8328 on the harness. 19 Replace the Finisher Main PWB (page 3-248). Go to Step 22. Does the error still occur? Check Stacker Encoder Sensor Harness continuity.Stacker Lower Trail Failure (Stacker Encoder Sensor) Troubleshooting Procedure Step 12 Actions and Questions Check for +5 V to Stack Height Sensor 2. Does the Elevator Motor operate? Check the Elevator Motor connection. and Procedures 3-167 . Connect and go to Step 16.

the Front Tamper Home Sensor is not turned On within 800 ms following the Front Tamper beginning to move to the Front Tamper Home position. or the Front Tamper Home Sensor is turned On again after the Front Tamper Home Sensor is turned Off and the Front Tamper stops moving. No Repair or replace the Compiler Tray (page 3-177). Problem solved. Replace the Finisher Main PWB (page 3-248).Stacker Lower Trail Failure (Stacker Encoder Sensor) Troubleshooting Procedure Step 22 23 Actions and Questions Print a Test Print. the Front Tamper Home Sensor is not turned Off in the time specified following the Front Tamper leaving the home position. Does the error still occur? Replace the Elevator Motor. 3-168 Phaser 5500 Printer Service Manual . Print a Test Print.H5-21 Front Home SNR ON Stacker Lower Tray Failure . Stacker Lower Tray Failure .H5-23 Front Home SNR OFF Tamper (Front Tamper Home Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ Front Tamper Home Sensor Compiler Tray Assembly Compiler Harness Finisher Main PWB Front Tamper Motor Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Compiler P/J Locator (page 5-33) Finisher Compiler Tray Wiring (page 5-44) PL25.H5-2n Front Home SNR For H5-21. Does the error still occur? Yes Go to Step 23. Applicable Error Codes Stacker Lower Tray Failure . Move the Front Tamper mechanism. Does the Tamper mechanism operate smoothly? Yes Go to Step 2.10 Finisher Eject (2/3) (page 4-62) PL25.14 Finisher Electrical (page 4-70) Tamper (Front Tamper Home Sensor) Troubleshooting Procedure Step 1 Actions and Questions Check the Tamper mechanism. No Problem solved. For H5-23.

Replace the Finisher Main PWB (page 3-248). Repair the Compiler Front Tamper Harness. Replace the Finisher Main PWB (page 3-248). Does the error still occur? Go to Step 7. 7 Replace the Finisher Main PWB (page 3-248). 6 Check for +5 V to the Front Tamper Home Sensor. Connect and go to Step 4. 8 9 Go to Step 11. Problem solved. Error Messages. 3 4 5 Go to Step 5. Go to Step 6. Check for continuity at the following: P/J8360-3 <=> P/J8309-4 P/J8360-2 <=> P/J8309-5 P/J8360-1 <=> P/J8309-6 Are these conductive? Yes Go to Step 8. Are P/J8363B and P/J8309 connected? Print a Test Print. Problem solved. Run the Service Diagnostics Front Tamper Home Sensor test. and Procedures 3-169 . and the Tamper move front to rear? Check Compiler Front Tamper Motor Harness connections. Is there +5 V across J8309-6 <=> J83094 on the Finisher Main PWB? Check Front Tamper Home Sensor signal. Does the Front Tamper Motor rotate. 2. Connect and go to Step 10. Replace the Front Tamper Home Sensor (page 3-180). Does the voltage across P8309-5 <=> P8309-4 on the Finisher Main PWB change when the sensor is blocked? Test the Front Tamper Motor. Are P/J8360 and P/J8309 connected? Print a Test Print. Codes. Does the error still occur? Check Compiler Front Tamper Harness continuity. Does the sensor state change when the sensor is blocked? Check the Compiler harness connections.Tamper (Front Tamper Home Sensor) Troubleshooting Procedure (Continued) Step 2 Actions and Questions Test the Front Tamper Home Sensor. Disconnect P/J8360 on the harness and P/J8309 on the Finisher Main PWB. 10 Go to Step 11. Go to Step 9. Go to Step 5. 1. No Go to Step 3. Run the Service Diagnostics Front Tamper Motor Low Speed Inboard and Outboard tests alternately.

Disconnect P/J8363B and P/J8309. Applicable Error Codes Stacker Lower Tray Failure . No Repair the Compiler Front Tamper Motor Harness.14 Finisher Electrical (page 4-70) 3-170 Phaser 5500 Printer Service Manual . Is there +24 V across J8309-11 <=> ground on the Finisher Main PWB? Replace the Front Tamper Motor. Does the error still occur? Go to Step 13.10 Finisher Eject (2/3) (page 4-62) PL25. Print a Test Print.H5-22 Rear Home SNR ON Stacker Lower Tray Failure .Tamper (Front Tamper Home Sensor) Troubleshooting Procedure (Continued) Step 11 Actions and Questions Check Compiler Front Tamper Motor Harness continuity. the Rear Tamper Home Sensor is not turned On within 800 ms following the Rear Tamper beginning to move to the Rear Tamper Home position. 13 Replace the Finisher Main PWB (page 3-248). 2. Replace the Finisher Main PWB (page 3-248). Stacker Lower Tray Failure . Problem solved.H5-24 Rear Home SNR OFF Tamper (Rear Tamper Home Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ Rear Tamper Home Sensor Compiler Tray Assembly Compiler Harness Finisher Main PWB Rear Tamper Motor Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Compiler P/J Locator (page 5-33) Finisher Compiler Tray Wiring (page 5-44) PL25.H5-2n Rear Home SNR For H-22. For H5-24. the Rear Tamper Home Sensor is not turned Off in the time specified following the Rear Tamper leaving the home position. Check for continuity at the following: P/J8363B-6 <=> P/J8309-10 P/J8363B-5 <=> P/J8309-11 P/J8363B-4 <=> P/J8309-12 P/J8363B-3 <=> P/J8309-13 P/J8363B-2 <=> No connection P/J8363B-1 <=> P/J8309-14 Are these conductive? Yes Go to Step 12. 12 Check for +24 V to the Front Tamper Motor. 1. or the Rear Tamper Home Sensor is turned On again after the Rear Tamper Home Sensor is turned Off and the Rear Tamper stops moving.

Disconnect P/J8361 on the harness and P/J8309 on the Finisher Main PWB. Are P/J8362 and P/J8309 connected? Print a Test Print. Are P/J8361 and P/J8309 connected? Print a Test Print. Go to Step 3. 7 Replace the Finisher Main PWB (page 3-248). Replace the Finisher Main PWB (page 3-248). 2 Go to Step 8. 8 9 Go to Step 11. Does the error still occur? Go to Step 7. Go to Step 5. 6 Check for +5 V to the Rear Tamper Home Sensor.Tamper (Rear Tamper Home Sensor) Troubleshooting Procedure Step 1 Actions and Questions Check the Tamper mechanism. Problem solved. 3 4 5 Go to Step 5. Does the error still occur? Check Compiler Rear Tamper Harness continuity. Run the Service Diagnostics Rear Tamper Home Sensor test. and the Tamper move front to rear? Check Compiler Rear Tamper Motor Harness connections. Move the Rear Tamper mechanism. Repair the Compiler Rear Tamper Harness. Does the Rear Tamper Motor rotate. Check for continuity at the following: P/J8361-3 <=> P/J8309-7 P/J8361-2 <=> P/J8309-8 P/J8361-1 <=> P/J8309-9 Are these conductive? Yes Go to Step 2. and Procedures 3-171 . 2. Go to Step 6. Does the Tamper mechanism operate smoothly? Test the Rear Tamper Home Sensor. No Repair or replace the Compiler Tray (page 3-177). Problem solved. 10 Go to Step 11. Codes. Replace the Finisher Main PWB (page 3-248). Run the Service Diagnostics Rear Tamper Motor Low Speed Inboard and Outboard tests alternately. Does the voltage across P8309-8 <=> P8309-7 on the Finisher Main PWB change when the sensor is blocked? Test the Rear Tamper Motor. Connect and go to Step 4. Connect and go to Step 10. Replace the Rear Tamper Home Sensor (page 3-180). Error Messages. Go to Step 9. Does the sensor state change when the sensor is blocked? Check the Compiler harness connections. Is there +5 V across J8309-9 <=> J83097 on the Finisher Main PWB? Check Rear Tamper Home Sensor signal. 1.

No Repair the Compiler Harness. Applicable Error Codes Punch Failure . Is there +24 V across J8309-16 <=> ground on the Finisher Main PWB? Replace the Front Tamper Motor. Problem solved.H5-32 SNR OFF Punch Failure (Punch Home Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ Punch Home Sensor Punch Harness Punch Sensor Harness Finisher Main PWB Punch Motor Punch Drive Harness Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Punch P/J Locator (page 5-31) Finisher Punch (2/2) Wiring (page 5-47) PL25. Check for continuity at the following: J8362B-6 <=> P/J8309-15 J8362B-5 <=> P/J8309-16 J8362B-4 <=> P/J8309-17 J8362B-3 <=> P/J8309-18 J8362B-2 <=> Non connection J8362B-1 <=> P/J8309-19 Are these conductive? Yes Go to Step 12. 1.7 Finisher Punch (page 4-56) PL25.H5-3n SNR The Punch Home Sensor is not turned On (H5-31) or Off (H5-32) within the specified time after Punch Motor activation. 13 Replace the Finisher Main PWB (page 3-248). Replace the Finisher Main PWB (page 3-248).Tamper (Rear Tamper Home Sensor) Troubleshooting Procedure (Continued) Step 11 Actions and Questions Check Compiler Rear Tamper Motor Harness continuity. Print a Test Print. Punch Failure . 12 Check for +24 V to the Rear Tamper Motor.H5-31 SNR ON Punch Failure . Disconnect P/J8362 and P/J8309.14 Finisher Electrical (page 4-70) PL25.15 Finisher Harness (page 4-72) 3-172 Phaser 5500 Printer Service Manual . 2. Does the error still occur? Go to Step 13.

3 Go to Step 5. Does the sensor change state when the sensor is blocked? Check Punch Home Sensor harness connections. Connect and go to Step 4. Does the error still occur? Check Punch Home Sensor Harness continuity. Go to Step 9. Disconnect P/J8333 and P/J8307. Run the Service Diagnostics Punch Unit Motor Front and Rear tests. Problem solved. Codes. Disconnect P/J8348 and P/J8333. Does the voltage across P8307-B4 <=> P8307-B5 on the Finisher Main PWB change when the sensor is blocked? Test the Punch Motor. Does the punch move smoothly? Test the Punch Home Sensor. 2. Are P/J8348 and P/J8333 on the Punch Harness. 7 Check for +5 V to the Punch Home Sensor. 4 5 Go to Step 5. 1. No Correct the installation. Does the Punch Motor rotate? Go to Step 8. Replace the Finisher Main PWB (page 3-248). 1. Go to Step 6. Run the Service Diagnostics Punch Home Sensor test. Replace the Finisher Main PWB (page 3-248). Is there +5 V across J8307-B6 <=> J8307-B5 on the Finisher Main PWB? Check the Punch Home Sensor signal. 6 Check Punch Home Sensor Harness continuity. and Procedures 3-173 . Repair the Punch Home Sensor Harness. 9 Error Messages. 2. and P/J8333 and P/J8307 on the Punch Sensor Harness connected? Print a Test Print. Check for continuity at the following: P/J8333-7 <=> P/J8307-B6 P/J8333-8 <=> P/J8307-B5 P/J8333-9 <=> P/J8307-B4 Are these conductive? Go to Step 7. Check for continuity at the following: P/J8348-3 <=> P/J8333-7 P/J8348-2 <=> P/J8333-8 P/J8348-1 <=> P/J8333-9 Are these conductive? Yes Go to Step 2. Replace the Punch Home Sensor (page 3-151).Punch Failure (Punch Home Sensor) Troubleshooting Procedure Step 1 2 Actions and Questions Check the Punch operation. Repair the Punch Home Sensor Harness. Go to Step 10. 8 Replace the Finisher Main PWB (page 3-248). Go to Step 3.

Does the error still occur? Check Punch Motor Harness continuity. Problem solved. 13 Check Punch Motor Drive Harness continuity.H5-33 Home SNR ON Punch Failure . Disconnect P/J8345 and P/J8332. Repair the Punch Motor Drive Harness. Check for continuity at the following: P/J8332-2 <=> P/J8306-8 P/J8332-1 <=> P/J8306-7 Are these conductive? Go to Step 14. 14 Replace the Punch Motor. Punch Failure . and P/J8332 and P/J8306 on the Punch Drive Harness connected? Print a Test Print. Repair the Punch Harness. 1. 11 12 Go to Step 12. Are P/J8345 and P/J8332 on the Punch Harness. 2. Check for continuity at the following: P/J8345-2 <=> P/J8332-2 P/J8345-1 <=> P/J8332-1 Are these conductive? Yes Go to Step 12. 2.H5-34 Home SNR OFF 3-174 Phaser 5500 Printer Service Manual . Problem solved. Applicable Error Codes Punch Failure .H5-3n Home SNR The Punch Unit Move Home Sensor does not change state within the specified time following activation of the Punch Move Motor or the Move Home sensor changes state after the Punch Move Motor has stopped. No Connect and go to Step 11.Punch Failure (Punch Home Sensor) Troubleshooting Procedure (Continued) Step 10 Actions and Questions Check the harness connections. Disconnect P/J8332 and P/J8306. Punch a Test Print. 1. Does the error still occur? Replace the Finisher Main PWB (page 3-248). Go to Step 13.

Error Messages.15 Finisher Harness (page 4-72) Punch Failure (Punch Move Home Sensor) Troubleshooting Procedure Step 1 Actions and Questions Check the Punch Unit operation.14 Finisher Electrical (page 4-70) PL25. Problem solved. 4 5 Go to Step 5. Go to Step 6. 7 Replace the Finisher Main PWB (page 3-248). Codes. Replace the Punch Unit Move Home Sensor (page 3-153). Connect and go to Step 4. Repair the Punch Unit Move Home Sensor Harness. Disconnect P/J8352 and P/J8307. Replace the Finisher Main PWB (page 3-248). Does the voltage across P8307-A5 <=> P8307-A6 on the Finisher Main PWB change when the sensor is blocked? Go to Step 7. Slide the Punch Unit in and out. 2. Go to Step 3. Check for continuity at the following: P/J8352-3 <=> P/J8307-A6 P/J8352-2 <=> P/J8307-A5 P/J8352-1 <=> P/J8307-A4 Are these conductive? Yes Go to Step 2.7 Finisher Punch (page 4-56) PL25. 6 Check for +5 V to the Punch Unit Move Home Sensor. 3 Go to Step 5. Does the Punch Unit move smoothly? Test the Punch Unit Move Home Sensor. Are P/J8352 and P/J8307 connected? Print a Test Print. No Correct the installation. Does the sensor state when the sensor is blocked? Check Punch Unit Move Home Sensor Harness connection. 1.Punch Failure (Punch Move Home Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ Punch Unit Move Home Sensor Punch Sensor Harness Finisher Main PWB Punch Motor Bracket Punch Drive Harness Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Punch P/J Locator (page 5-31) Finisher Punch (1/2) Wiring (page 5-46) PL25. 2 Go to Step 8. Does the error still occur? Check Punch Unit Move Home Sensor Harness continuity. Is there +5 V across J8307-A4 <=> J8307-A6 on the Finisher Main PWB? Check the Punch Home Sensor signal. Run the Service Diagnostics Punch Unit Move Home Sensor test. and Procedures 3-175 .

2.H5-8n Eject Clamp SNR The Eject Clamp Home Sensor does not change state within the time interval specified following the activation of the Eject Clamp. Does the Punch Move Motor rotate and the Punch frame move? Check Punch Motor Harness connections. Problem solved. Run the Service Diagnostics Front and Rear Punch Move Motor tests.Punch Failure (Punch Move Home Sensor) Troubleshooting Procedure (Continued) Step 8 Actions and Questions Test the Punch Move Motor. Check for continuity at the following: P/J8344-1 <=> P/J8306-7 P/J8344-2 <=> P/J8306-3 P/J8344-3 <=> P/J8306-6 P/J8344-4 <=> P/J8306-5 P/J8344-5 <=> P/J8306-2 P/J8344-6 <=> P/J8306-1 Are these conductive? Yes Replace the Finisher Main PWB (page 3-248). Problem solved. 12 Replace the Punch Move Motor.H5-82 Eject Clamp SNR OFF 3-176 Phaser 5500 Printer Service Manual . No Go to Step 9. Go to Step 11. Go to Step 11. Are P/J8344 and P/J8306 connected? Print a Test Print. 1. Does the error still occur? Replace the Finisher Main PWB. Disconnect P/J8344 and P/J8306. 9 10 11 Connect and go to Step 10. Stacker Lower Tray Failure .H5-81 Eject Clamp SNR ON Stacker Lower Tray Failure . 13 Replace the Finisher Main PWB (page 3-248). Problem solved. Applicable Error Codes Stacker Lower Tray Failure . Repair the Punch Motor Harness. Go to Step 12. Does the error still occur? Go to Step 13. Punch a Test Print. Does the error still occur? Check Punch Motor Harness continuity.

Codes. Replace the Eject Clamp Home Sensor (page 3-175). Does the error still occur? Check Eject Clamp Sensor Harness continuity. Problem solved. 1. 3 Go to Step 5. Disconnect P/J8324 and P/J8302B.Eject Clamp Failure (Eject Clamp Home Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ Eject Clamp Home Sensor Eject Clamp Sensor Harness Finisher Main PWB Eject Clamp Motor Eject Clamp Motor Harness Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Input Drive P/J Locator (page 5-32) Finisher Sensors (2/2) Wiring (page 5-41) Finisher Clutch and Solenoids Wiring (page 5-43) PL25. Does the voltage across P8302B-7 <=> P8302B-6 on the Finisher Main PWB change when the sensor is blocked? Go to Step 7.9 Finisher Eject (1/3) (page 4-60) PL25. Does the sensor change state? Check Eject Clamp Sensor Harness connection. Rotate the Eject Clamp Motor. No Correct the installation. 2. Is there +5 V across J8302B-8 <=> J8302B-6 on the Finisher Main PWB? Check the Eject Clamp Home Sensor signal. Check for continuity at the following: P/J8324-3 <=> P/J8302B-6 P/J8324-2 <=> P/J8302B-7 P/J8324-1 <=> P/J8302B-8 Are these conductive? Yes Go to Step 2. 6 Check for +5 V to the Eject Clamp Home Sensor. Go to Step 3. 4 5 Go to Step 5. Repair the Eject Clamp Sensor Harness. Are P/J8324 and P/J8302B connected? Print a Test Print. 7 Replace the Finisher Main PWB (page 3-248). 2 Go to Step 8. Run the Service Diagnostics Eject Clamp Home Sensor test. Does the Eject Clamp move smoothly? Test the Eject Clamp Home Sensor.14 Finisher Electrical (page 4-70) PL25.15 Finisher Harness (page 4-72) Eject Clamp Failure (Eject Clamp Home Sensor) Troubleshooting Procedure Step 1 Actions and Questions Check the Eject Clamp operation. Replace the Finisher Main PWB (page 3-248). Go to Step 6. and Procedures 3-177 . Connect and go to Step 4. Error Messages.

H5-83 Set Clamp SNR ON Stacker Lower Tray Failure . Go to Step 11. 9 Connect and go to Step 10. Repair the Eject Clamp Motor Harness. Problem solved. Problem solved. Does the error still occur? Check Eject Clamp Motor Harness continuity. Print a Test Print. Does the error still occur? Go to Step 13. Are P/J8339 and P/J8304 connected? Print a Test Print.H5-8n Set Clamp SNR The Set Clamp Home Sensor does not change state within the time interval specified following the start or stop of the Set Clamp. Check for continuity at the following: P/J8339-1 <=> P/J8304-33 P/J8339-2 <=> P/J8304-31 Are these conductive? Yes Replace the Finisher Main PWB (page 3-248). Go to Step 12. Run the Service Diagnostics Up and Down Eject Clamp Motor tests. Does the Eject Clamp Motor rotate normally? Check Eject Clamp Motor Harness connections. 2.H5-84 Set Clamp SNR OFF 3-178 Phaser 5500 Printer Service Manual . Disconnect P/J8339 and P/J8304. 10 11 Go to Step 11. 13 Replace the Finisher Main PWB (page 3-248). No Go to Step 9. 12 Check Eject Clamp Motor voltage. Applicable Error Codes Stacker Lower Tray Failure . 1. Replace the Finisher Main PWB (page 3-248). Is there +24 V across P/J8304-31 and -33 <=> P/J8302A-1? Replace the Eject Clamp Motor. Stacker Lower Tray Failure .Eject Clamp Failure (Eject Clamp Home Sensor) Troubleshooting Procedure Step 8 Actions and Questions Test the Eject Clamp Motor.

Is there +5 V across J8302B-11 <=> J8302B-9 on the Finisher Main PWB for H5-83? Is there +5 V across J8302B-4 <=> J8302B-9 on the Finisher Main PWB for H5-84? Go to Step 7. 4 5 Go to Step 5. 2 Go to Step 8. Codes. Check for continuity at the following: P/J8325-3 <=> P/J8302B-4 P/J8325-2 <=> P/J8302B-9 P/J8325-1 <=> P/J8302B-11 Are these conductive? Yes Go to Step 2. Rotate the Eject Clamp Motor. No Correct the installation. Does the error still occur? Check the Set Clamp Home Sensor Harness continuity. Error Messages.10 Finisher Eject (2/3) (page 4-62) PL25.15 Finisher Harness (page 4-72) Eject Clamp (Set Clamp Home Sensor) Troubleshooting Procedure Step 1 Actions and Questions Check the Eject Clamp operation. 1. 2.Eject Clamp (Set Clamp Home Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ Set Clamp Home Sensor Main Sensor Harness Finisher Main PWB Eject Bracket Assembly Main Drive Harness Set Clamp Clutch Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Compiler P/J Locator (page 5-33) Finisher Sensors (2/2) Wiring (page 5-41) Finisher Clutch and Solenoids Wiring (page 5-43) PL25. Replace the Finisher Main PWB (page 3-248). Disconnect P/J8325 and P/J8302B. Go to Step 3. Does the sensor change state? Check the Set Clamp Home Sensor Harness connection. Repair the Set Clamp Home Sensor Harness. Problem solved. and Procedures 3-179 . Run the Service Diagnostics Set Clamp Home Sensor test. Go to Step 6. Does the Eject Clamp move smoothly? Test the Set Clamp Home Sensor.14 Finisher Electrical (page 4-70) PL25. 3 Go to Step 5. 6 Check for +5 V to the Set Clamp Home Sensor. Are P/J8325 and P/J8302B connected? Print a Test Print. Connect and go to Step 4.

2. Does the error still occur? Test the Set Clamp Clutch (Clutch Z34). Repair the Eject Motor Harness. Does the error still occur? Go to Step 13. Problem solved. Problem solved. Does the Set Clamp Clutch operate? Check the Set Clamp Clutch Harness connection. 13 Go to Step 14. Is there resistance across P8336-2/ 5(COM) and P8336-1/3/4/6? Check for +24 V to the Eject Motor. 17 Go to Step 18. Are P/J8336 and P/J8304 connected? Print a Test Print. 12 Check Eject Motor resistance. 14 Replace the Finisher Main PWB (page 3-248). Print a Test Print. 16 Connect and go to Step 17. Check for continuity at the following: P/J8336-1 <=> P/J8304-15 P/J8336-2 <=> P/J8304-12 P/J8336-3 <=> P/J8304-17 P/J8336-4 <=> P/J8304-19 P/J8336-5 <=> P/J8304-14 P/J8336-6 <=> P/J8304-21 Are these conductive? Yes Replace the Finisher Main PWB (page 3-248). 1. Run the Service Diagnostics Set Clamp Clutch test. 15 Go to Step 16. Connect and go to Step 10. Go to Step 12. Does the Eject Motor rotate normally? Check Eject Motor Harness connections. No Replace the Set Clamp Home Sensor (page 3-188). Disconnect P/J8336 and P/J8304. Run the Service Diagnostics Low Speed Forward and Reverse Eject Motor tests. Does the error still occur? Check Eject Motor Harness continuity. Replace the Finisher Main PWB (page 3-248). Problem solved. Replace the Finisher Main PWB (page 3-248). Does the voltage across P8302B-11<=> P8302B-9 on the Finisher Main PWB change when the sensor is blocked? Test the Eject Motor. 3-180 Phaser 5500 Printer Service Manual . Replace the Eject Bracket Assembly (page 3-187). Go to Step 18. Go to Step 15. Go to Step 9. Go to Step 11. Is there +24 V across J8304-12 <=> ground. and J8304-14 <=> ground on the Finisher Main PWB? Replace the Eject Clamp Motor. 8 9 10 11 Go to Step 11. Are P/J8338B and P/J8304 connected? Print a test Print.Eject Clamp (Set Clamp Home Sensor) Troubleshooting Procedure (Continued) Step 7 Actions and Questions Check the Set Clamp Home Sensor signal.

Replace the Finisher Main PWB (page 3-248).14 Finisher Electrical (page 4-70) PL25. Print a Test Print. Check for continuity at the following: J8338B-1 <=> P/J8304-20 J8338B-2 <=> P/J8304-22 Are these conductive? Yes Go to Step 19. Problem solved. 20 Replace the Finisher Main PWB (page 3-248). Does the error still occur? Go to Step 20. Codes.7 Finisher Punch (page 4-56) PL25. No Repair the Set Clamp Clutch Harness.15 Finisher Harness (page 4-72) Error Messages. 1.1 Print Engine Electrical (page 9-40) PL25. Applicable Error Code Stacker Lower Tray Failure .H5-86 Side Regi SNR OFF Punch Failure (Side Registration Sensors) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ ■ Punch Move Motor Punch Drive Harness Finisher Main PWB Engine Logic Board Side Registration Sensors Punch Sensor Harness Punch Unit Harness Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Punch P/J Locator (page 5-31) Finisher Punch (1/2) Wiring (page 5-46) Finisher Punch (2/2) Wiring (page 5-47) PL8. 2. Is there +24 V across J8304-22 <=> ground on the Finisher Main PWB? Replace the Set Clamp Clutch. 19 Check for +24 V to the Set Clamp Clutch. Disconnect P/J8338B and P/J8304. Stacker Lower Tray Failure . and Procedures 3-181 .Eject Clamp (Set Clamp Home Sensor) Troubleshooting Procedure (Continued) Step 18 Actions and Questions Check Set Clamp Clutch Harness continuity.H5-86 Side Regi SNR OFF Either or both Side Registration Sensors do not transition within the time interval specified (500 ms) following activation of the Punch Move Motor or the state changes to On after the Punch Move Motor stops.

Print a Test Print. No Correct the installation. 4 5 Go to Step 5. Check for continuity at the following: P/J8344-1 <=> P/J8306-7 P/J8344-2 <=> P/J8306-3 P/J8344-3 <=> P/J8306-6 P/J8344-4 <=> P/J8306-5 P/J8344-5 <=> P/J8306-2 P/J8344-6 <=> P/J8306-1 Are these conductive? Yes Go to Step 2. Punch.Punch Failure (Side Registration Sensors) Troubleshooting Procedure Step 1 Actions and Questions Check the Punch operation. 1. Does the Punch Move Motor rotate and the Punch frame move? Check Punch Move Motor Harness connections. Does the state change when the sensor is blocked? Test the Side Regi Sensor 2. Replace the Finisher Main PWB (page 3-248). Disconnect P/J8344 and P/J8306. 3 Go to Step 5. 9 Go to Step 10. Does the state change when the senor is blocked? Go to Step 9. Does the error still occur? Go to Step 7. Problem solved. Run the Service Diagnostics Side Registration Sensor 2 test. 2 Go to Step 8. 3-182 Phaser 5500 Printer Service Manual . Go to Step 3. 2. Repair the Punch Move Motor Harness. Run the Service Diagnostics Front and Rear Punch Move Motor tests. Go to Step 6. Are P/J8344 and P/J8306 connected? Print a Test Print. Does the error still occur? Check Punch Move Motor Harness continuity. Does the punch move smoothly? Test the Punch Move Motor. 6 Replace the Bracket Assy-Motor. 7 Replace the Finisher Main PWB (page 3-248). Problem solved. Run the Service Diagnostics Side Registration Sensor 1 test. Connect and go to Step 4. Problem solved. Move the Punch Unit in and out. Does the error still occur? Replace the Finisher Main PWB. 8 Test the Side Regi Sensor 1. Replace the Finisher Main PWB (page 3-248).

and P/J8351 (Side Regi Sensor 2). Does the error still occur? Check Main Punch Sensor continuity. Problem solved. P/J8333 and P/J8350 (for Side Regi Sensor 1). Codes. Print a Test Print. Go to Step 13. Does the error still occur? Replace the Finisher Main PWB. Does the error still occur? Go to Step 16 Go to Step 18 15 Go to Step 17 Go to Step 18. Check for continuity at the following: P/J8333-13 <=> P/J8350-3 P8333-14 <=> P/J8350-2 P8333-15 <=> P/J8350-1 P8333-16 <=>P/J8351-3 P8333-17 <=> P/J8351-2 P8333-18 <=> P/J8351-1 Are these conductive? Yes Go to Step 12. Disconnect P/J8333. Are P/J8307. Repair the Punch Unit Harness.Punch Failure (Side Registration Sensors) Troubleshooting Procedure (Continued) Step 10 Actions and Questions Check the harness connections. 16 Go to Step 18. Disconnect P/J8307 and P/J8333. and P/J8351 (for Side Regi Sensor 2) connected? Print a Test Print. 2. 17 Go to Step 18. Is there continuity on each wire between J8307 <=> J8333? Check Side Regi Sensor continuity. 1. Error Messages. Print a Test Print. Problem solved. 18 Replace the Engine Logic Board (page 8-89). 14 Check for +5 V at Side Regi Sensor 1 Is there +5 V between P/J8307-A10 <=> P/J8307-A12? Check for +5 V at Side Regi Sensor 2 Is there +5 V between P/J8307-A7 <=> P/ J8307-A9? Replace the Side Registration Sensor 1. P/J8350 (Side Regi Sensor 1). 13 Go to Step 14. Repair the Main Punch Sensor Harness. Does the error still occur? Replace the Side Registration Sensor 2. Problem solved. No Connect and go to Step 11. Problem solved. and Procedures 3-183 . 11 12 Go to Step 12.

No Go to Step 2.H5-91 Staple Fail The Stapler Home Sensor state is not detected within the specified time after a Stapler Move Motor forward operation. 2. Go to Step 6. Does the sensor state change when the staple gear is rotated? Replace the Finisher Main PWB (page 3-248). Problem solved. Applicable Error Code Stapling Failure . 2 Go to Step 4. Check for continuity at the following: P/J8357-1 <=> P/J8308-10 P/J8357-2 <=> P/J8308-9 P/J8357-3 <=> P/J8308-8 P/J8357-4 <=> P/J8308-7 Are these conductive? Yes Go to Step 5. 5 Test the Staple Head Home Sensor. 3 4 Go to Step 4. Connect and go to Step 3. Run the Service Diagnostics Staple Head Home Sensor test. Does the error still occur? Check the Staple Motor Harness continuity 1. Go to Step 9.1 Print Engine Electrical (page 9-40) PL25.Stapler Failure . Does the Stapler Motor rotate normally? Check the Staple Motor Harness connections. 3-184 Phaser 5500 Printer Service Manual . Repair the Staple Motor Harness.14 Finisher Electrical (page 4-70) Stapler Failure (Stapler Home Sensor) Troubleshooting Procedure Step 1 Actions and Questions Test the Stapler Assembly. Disconnect P/J8357 and P/J8308.8 Finisher Staple (page 4-58) PL25. or the Stapler Home Sensor is not turned ON within the specified time following a Stapler Move Motor reverse operation. Run the Service Diagnostics Staple Motor Forward and Reverse tests.H5-91 Staple Fail Stapler Failure (Stapler Home Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ Stapler Assembly Staple Home Position Sensor Staple Motor Stapler Harness Finisher Main PWB Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Staple P/J Locator (page 5-30) Finisher Stapler Wiring (page 5-45) PL8. Are P/J8357 and P/J8308 connected? Print a Test Print.

Problem solved. 10 Replace the Engine Logic Board (page 8-89). Are P/J8356 and P/J8308 connected? Staple a Test Print.H5-9n Move SNR The Staple Move Position Sensor does not change state in the specified time interval after the Stapler Head starts moving toward or reaching the staple position.Stapler Failure (Stapler Home Sensor) Troubleshooting Procedure (Continued) Step 6 7 8 Actions and Questions Check the Staple Harness connections. Codes. 2. Problem solved. Disconnect P/J8356 and P/J8308. Does the error still occur? Go to Step 10. Repair the Staple Harness. Does the error still occur? Replace the Finisher Main PWB. 9 Replace the Stapler Assembly.H5-95 Move SNR ON Stapling Failure . Stapler Failure . Go to Step 8. Applicable Error Codes Stapling Failure .8 Finisher Staple (page 4-58) PL25. and Procedures 3-185 .H5-96 Move SNR OFF Stapler Failure (Staple Move Position Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ Stapler Lower Carriage Move Home Position Sensor Stapler Harness Finisher Main PWB Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Staple P/J Locator (page 5-30) Finisher Stapler Wiring (page 5-45) PL25. This error also occurs if the Stapler Move Position Sensor is turned OFF again after being ON and the Stapler Head is stopped. Check for continuity at the following: P/J8356-1 <=> P/J8308-15 P/J8356-2 <=> P/J8308-14 P/J8356-3 <=> P/J8308-13 P/J8356-4 <=> P/J8308-12 P/J8356-5 <=> P/J8308-11 Are these conductive? Yes Go to Step 8. Staple a Test Print. 1. Go to Step 9. No Connect and go to Step 7. Problem solved. Does the error still occur? Check Staple Harness continuity.14 Finisher Electrical (page 4-70) Error Messages.

Problem solved. 9 Go to Step 10. Problem solved. No Remove obstacles or repair motion. Problem solved. Run the Service Diagnostics Staple Move Position Sensor test. Does the Staple Head move smoothly? Test the Staple Move Motor. Are P/J8358 and P/J8308 connected? Staple a Test Print. 3-186 Phaser 5500 Printer Service Manual . 3 Go to Step 5. Does the Staple Head Jog? Check the Staple Move Motor Harness connections. Staple a Test Print. 1. Connect and go to Step 4. Go to Step 6. Does the error still occur? Replace the Finisher Main PWB (page 3-248). Are P/J8354 and P/J8308 connected? Staple a Test Print.Stapler Failure (Staple Move Position Sensor) Troubleshooting Procedure Step 1 Actions and Questions Check Staple Head motion. Does the error still occur? Check Staple Move Motor Harness continuity. Repair the Staple Move Motor Harness. Disconnect P/J8358 and P/J8308. Go to Step 3. 8 Connect and go to Step 9. Does the sensor state change? Check the Staple Move Position Sensor Harness connections. Go to Step 10. 7 Go to Step 8. Slide the Staple Head across the rails. Replace the Finisher Main PWB (page 3-248). 2 Go to Step 7. 6 Replace the Stapler Lower Carriage. Run the Service Diagnostics Staple Move Motor mid speed Front and Rear tests. 2. Does the error still occur? Test the Staple Move Position Sensor. Check for continuity at the following: P/J8358-1 <=> P/J8308-3 P/J8358-2 <=> P/J8308-6 P/J8358-3 <=> P/J8308-5 P/J8358-4 <=> P/J8308-1 P/J8358-5 <=> P/J8308-4 P/J8358-6 <=> P/J8308-2 Are these conductive? Yes Go to Step 2. 4 5 Go to Step 5.

No Problem solved. Replace the Finisher Main PWB (page 3-248). Replace the Staple Move Position Sensor (page 3-162) 12 Replace the Finisher Main PWB (page 3-248). Is there +5 V across J8308-18 <=> J8308-16 on the Finisher Main PWB? Check the Stapler Move Home Position Sensor signal.Stapler Failure (Staple Move Position Sensor) Troubleshooting Procedure Step 10 Actions and Questions Check Staple Move Position Sensor Harness continuity. 1. Does the error still occur? Yes Go to Step 2. Codes. Tray 6 Logic Board Failure . No Repair the Staple Move Position Sensor Harness. Does the voltage across J8308-17 <=> J8308-16 on the Finisher Main PWB change when the sensor is blocked by moving the Stapler Head. Error Messages.8 Tray 6 Electrical (page 4-32) Tray 6 Comm Error Troubleshooting Procedure Step 1 Actions and Questions Cycle printer power. 11 Check for +5 V to the Stapler Move Position Sensor. Applicable Error Code Tray 6 Logic Board Failure . Check for continuity at the following: P/J8354-1 <=> P/J8308-18 P/J8354-2 <=> P/J8308-17 P/J8354-3 <=> P/J8308-16 Are these conductive? Yes Go to Step 11.H6-4 NVM R/W Error A read/write error has occurred in the NVRAM located on the Tray 6 PWB. Go to Step 12. 2. and Procedures 3-187 . DisconnectP/J8354 and P/J8308.H6-4 NVM R/W Error Tray 6 NVRAM Error Troubleshooting Reference Applicable Parts ■ References ■ ■ ■ ■ Tray 6 PWB Phaser 5500 Printer Options Service Manual 2000-Sheet Tray 6 Drive P/J Locator (page 5-21) 2000-Sheet Tray 6 Drive Wiring (page 5-25) PL22.

Does the error still occur? Yes Go to Step 4. If problem persists. P/J800 and P/ J414 connected? Go to Step 3. No Connect and go to Step 3. Applicable Error Code Tray 6 Logic Board Failure . Connect and go to Step 4. Go to Step 4. Tray 6 Logic Board Failure . Are P/J800A. Problem solved. 3-188 Phaser 5500 Printer Service Manual . go to Step 2. Does the error still occur? Disconnect all the connectors connected to the Tray 6 PWB and reconnect them. Problem solved. Does the error still occur? Check the Tray 6 PWB connections.Tray 6 Comm Error Troubleshooting Procedure (Continued) Step 2 Actions and Questions Check the Tray 6 PWB connections. 3 4 Go to Step 4.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual 2000-Sheet Tray 6 Drive P/J Locator (page 5-21) 2000-Sheet Tray 6 Drive Wiring (page 5-25) PL22.8 Tray 6 Electrical (page 4-32) Tray 6 NVRAM Error Troubleshooting Procedure Step 1 Actions and Questions Check the Tray 6 installation. Replace the Tray 6 PWB (page 3-67). Problem solved.H6-7 HCF Comm Failure Tray 6 Comm Error Troubleshooting Reference Applicable Parts ■ ■ References ■ ■ ■ ■ ■ ■ Tray 6 PWB Engine Logic Board Print Engine P/J Engine Logic Board (page 10-13) PL8. Is Tray 6 installed correctly? Yes Go to Step 2.H6-7 HCF Comm Failure A communications error occurred between Tray 6 and the Engine Logic Board. No Correct the installation. Cycle printer power. P/J800B. 2 3 Cycle printer power. Are the connectors connected to the PWB? Cycle printer power.

No Problem solved. No Repair the wiring. Replace the Engine Logic Board (page 8-89). and Procedures 3-189 . Applicable Error Codes Tray 4-5 Logic Board Failure .6 Tray 4-5 Drive and Electrical (page 4-16) Tray 4-5 NVRAM Error Troubleshooting Procedure Step 1 2 Actions and Questions Cycle the printer power. Go to Step 3. Tray 4-5 Logic Board Failure .NVM A read/write error has occurred in the NVRAM located on the Tray 4-5 PWB. Codes. 5 Replace the Tray 6 PWB (page 3-67).H7-4 NVM R/W Error Tray 4-5 NVRAM Error Troubleshooting Reference Applicable Parts ■ ■ References ■ ■ ■ ■ ■ ■ Tray 4-5 PWB Engine Logic Board Print Engine P/J Engine Logic Board (page 10-13) PL8. Error Messages. Are P/J413 and P/J541 connected? Yes Go to Step 3. Connect P/J413 and P/541. Cycle printer power. Does the error still occur? Yes Go to Step 5.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual 1000-Sheet Electrical P/J Locator (page 5-6) 1000-Sheet Drive Wiring (page 5-8) PL20.Tray 6 NVRAM Error Troubleshooting Procedure (Continued) Step 4 Actions and Questions Check continuity between the Tray 6 PWB and Engine Logic Board. Check for continuity at the following: P/J800A <=> P/J415 P/J800B <=> P/J415 P/J800 <=> P/J414 Are these conductive? Disconnect all the connectors connected to the Tray 6 PWB and reconnect them.H7-3 NVM out-of-order Tray 4-5 Logic Board Failure . Does the error reoccur? Check the Tray 4-5 PWB connection.

Tray 4-5 Logic Board Failure . Is there +5 V across P/J413-A5 (+) <=> ground? Replace the Tray 4-5 PWB (page 3-29). Replace the Engine Logic Board (page 8-89). DisconnectP/J413 and P/J541. No Repair the wiring.6 Tray 4-5 Drive and Electrical (page 4-16) 3-190 Phaser 5500 Printer Service Manual . 4 Check for +5 V to the Tray 4-5 PWB. Check for continuity at the following: P/J413-A1 <=> P/J541-1 P/J413-A2<=> P/J541-2 P/J413-A3 <=> P/J541-3 P/J413-A4 <=> P/J541-4 P/J413-A5 <=> P/J541-5 P/J413-A6 <=> P/J541-6 P/J413-B1 <=> P/J541-7 P/J413-B2 <=> P/J541-8 P/J413-B3 <=> P/J541-9 P/J413-B4 <=> P/J541-10 P/J413-B5 <=> P/J541-11 P/J413-B6 <=> P/J541-12 Are these conductive? Yes Go to Step 4.H7-7 Comm Failure Tray 4-5 Comm Failure Troubleshooting Reference Applicable Parts ■ ■ References ■ ■ ■ ■ ■ ■ Tray 4-5 PWB Engine Logic Board Print Engine P/J Engine Logic Board (page 10-13) PL8.H7-7 Comm Failure Communications error between 1000-Sheet Feeder and the Engine Logic Board. 1. Applicable Error Code Tray 4-5 Logic Board Failure .1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual 1000-Sheet Electrical P/J Locator (page 5-6) 1000-Sheet Drive Wiring (page 5-8) PL20.Tray 4-5 NVRAM Error Troubleshooting Procedure (Continued) Step 3 Actions and Questions Check continuity between the Tray 4-5 PWB and the Engine Logic Board. 2.

Is P/J541 connected? Check continuity between the Tray 4-5 PWB and the Engine Logic Board. Replace the Engine Logic Board (page 8-89). Codes. Applicable Error Code Incorrect Tray 4-5 Installed . Is there +5 V across P/J541-5 (+) <=> ground? Replace the Tray 4-5 PWB (page 3-29). 2 3 Go to Step 3. Disconnect P/J413 from the Printer and reconnect it. No Go to Step 2. 1. Repair the wiring. 4 Check for +5 V to the Tray 4-5 PWB. and Procedures 3-191 .H7-8 Type Error The 1000-Sheet Feeder is not recognized as the proper type for the printer. Does the 1000-Sheet Feeder operate? Check the Tray 4-5 PWB connection. Go to Step 4. 2. Check for continuity at the following: P/J413-A1 <=> P/J541-1 P/J413-A2<=> P/J541-2 P/J413-A3 <=> P/J541-3 P/J413-A4 <=> P/J541-4 P/J413-A5 <=> P/J541-5 P/J413-A6 <=> P/J541-6 P/J413-B1 <=> P/J541-7 P/J413-B2 <=> P/J541-8 P/J413-B3 <=> P/J541-9 P/J413-B4 <=> P/J541-10 P/J413-B5 <=> P/J541-11 P/J413-B6 <=> P/J541-12 Are these conductive? Yes Problem solved. Incorrect Tray 4-5 Installed . Connect P/J413. DisconnectP/J413 and P/J541.Tray 4-5 Comm Failure Troubleshooting Procedure Step 1 Actions and Questions Check the 1000-Sheet Feeder installation.H7-8 Type Error Error Messages.

SW1-1 is in the Left position SW1-2 is in the Right position SW1-3 is in the Right position SW1-4 is in the Left position Are the switches set correctly? Check Tray 4-5 PWB connections. If problem persists. Repair the wiring. 5 Check for +5 V to the Tray 4-5 PWB. 3-192 Phaser 5500 Printer Service Manual . 3 4 Go to Step 4. Check for continuity at the following: P/J413-A1 <=> P/J541-1 P/J413-A2<=> P/J541-2 P/J413-A3 <=> P/J541-3 P/J413-A4 <=> P/J541-4 P/J413-A5 <=> P/J541-5 P/J413-A6 <=> P/J541-6 P/J413-B1 <=> P/J541-7 P/J413-B2 <=> P/J541-8 P/J413-B3 <=> P/J541-9 P/J413-B4 <=> P/J541-10 P/J413-B5 <=> P/J541-11 P/J413-B6 <=> P/J541-12 Are these conductive? Yes Go to Step 2. go to Step 3. 2.Incorrect Tray 4-5 Troubleshooting Reference Applicable Parts ■ ■ References ■ ■ ■ ■ ■ ■ Tray 4-5 PWB Engine Logic Board Print Engine P/J Engine Logic Board (page 10-13) PL8. 1. Does the error still occur? Check the settings of the Dip Switch SW1 on the Tray 4-5 PWB.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual 1000-Sheet Electrical P/J Locator (page 5-6) 1000-Sheet Drive Wiring (page 5-8) PL20. Disconnect the 1000-Sheet Feeder from the Printer and reconnect it. Is there +5 V across P/J541-5 (+) <=> ground? Replace the Tray 4-5 PWB (page 3-29). Disconnect P/J413 and P/J541. Replace the Engine Logic Board (page 8-89). 2 Go to Step 3. Connect P/J541.6 Tray 4-5 Drive and Electrical (page 4-16) Incorrect Tray 4-5 Troubleshooting Procedure Step 1 Actions and Questions Check the Tray 4-5 installation. Is P/J541 connected? Check continuity between the Tray 4-5 PWB and the Engine Logic Board. Correct the Switch settings. Go to Step 5. No Problem solved.

Connect the Paper Size Switch.1 Tray (1/2) Feeder (1/2) (page 9-8) PL8.H8-1.H8-1 Tray 2 Size Sensor Broken Tray 3 Failure . Go to Step 4. Does the sensor state change each time the loaded tray is moved in or out? Check the Paper Size Switch connection. Applicable Error Codes Tray 2 Failure . Go to Step 3. 2 Tray Size Sensor Broken Paper size detection has failed in Tray 2 or Tray 3. 4 Go to Step 5. 3 Reconnect the connector of the Engine Logic Board. Error Messages.Tray N Failure . Codes.1 Print Engine Electrical (page 9-40) Tray Failure (Tray 2-3 Paper Size Switch) Troubleshooting Procedure Step 1 2 Actions and Questions Check the Paper in the affected tray. Run the Service Diagnostics Size Sensor test for the affected tray. Correct the installation. and Procedures 3-193 . Is the switch installed correctly? Test the Paper Size Switch for the affected tray. No Reload the paper. Is paper loaded in the tray properly? Check the Paper Size Switch for the affected tray. For Tray 2: Are P/J109 and P/J412 connected? For Tray 3: Are P/J110 and P/J412 connected? Yes Go to Step 2.H8-2 Tray 3 Size Sensor Broken Tray Failure (Tray 2-3 Paper Size Switch) Troubleshooting Reference Applicable Parts ■ ■ References ■ ■ ■ ■ Paper Size Switch Engine Logic Board Print Engine P/J Engine Logic Board (page 10-13) Print Engine P/J Locator Electrical (page 10-12) PL2.

Disconnect P/J109 and P/J412. 6 Check for +5 V to the Paper Size Switch. No Repair the wiring. 2. Disconnect P/J110 and P/J412.H8-3 Tray 4 Size Sensor Broken Tray 5 Failure . Check for continuity at the following: P/J110-1 <=> P/J412-9 P/J110-2 <=> P/J412-8 P/J110-3 <=> P/J412-7 P/J110-4 <=> P/J412-6 Are these conductive? Yes Go to Step 6. Applicable Error Codes Tray 4 Failure . 2.H8-4 Tray 5 Size Sensor Broken 3-194 Phaser 5500 Printer Service Manual . 4 Tray Size Sensor Broken Paper size detection has failed in Tray 4 or Tray 5. Check for continuity at the following: P/J109-1 <=> P/J412-4 P/J109-2 <=> P/J412-3 P/J109-3 <=> P/J412-2 P/J109-4 <=> P/J412-1 For Tray 3: 1. For Tray 2: 1.Tray Failure (Tray 2-3 Paper Size Switch) Troubleshooting Procedure (Continued) Step 5 Actions and Questions Check continuity between the affected Paper Size Switch and the Engine Logic Board. Replace the Engine Logic Board (page 8-89). Tray N Failure . For Tray 2: Is there +5 V across J109-1 (+) <=> ground? For Tray 3: Is there +5 V across J110-1 (+) <=> ground? Replace the Paper Size Switch for the affected tray (page 8-19).H8-3.

Codes. No Reload the paper.6 Tray 4-5 Drive and Electrical (page 4-16) Tray Failure (Tray 4-5 Paper Size Switch) Troubleshooting Procedure Step 1 2 Actions and Questions Check the Paper in the affected tray. For Tray 4: Are P/J820 and P/J548 connected? For Tray 5: Are P/J824 and P/J548 connected? Yes Go to Step 2. Error Messages.2 Tray (1/2) Feeder (1/2) (page 4-6) PL20. Is paper loaded in the tray properly? Check the Paper Size Switch for the affected tray. Go to Step 4.Tray Failure (Tray 4-5 Paper Size Switch) Troubleshooting Reference Applicable Parts ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ Paper Size Switch Tray 4-5 PWB Engine Logic Board Print Engine P/J Engine Logic Board (page 10-13) PL8. Is the switch installed correctly? Test the Paper Size Switch for the affected tray. Go to Step 3. and Procedures 3-195 .1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual 1000-Sheet Feeder P/J Locator (page 5-5) 1000-Sheet Feeder P/J Electrical (page 5-6) 1000-Sheet Tray 4 & 5 Wiring (page 5-9) PL20. Connect the Paper Size Switch. Run the Service Diagnostics Size Sensor test for the affected tray. Does the sensor state change each time the loaded tray is moved in or out? Check the Paper Size Switch connection. 4 Go to Step 6. 3 Reconnect the connector of the Engine Logic Board. Correct the installation.

Tray Failure (Tray 4-5 Paper Size Switch) Troubleshooting Procedure (Continued) Step 5 Actions and Questions Check continuity between the affected Paper Size Switch and the Engine Logic Board. Disconnect P/J824 and P/J548. No Repair the wiring. Connect P/J413 and P/541. 1. 3-196 Phaser 5500 Printer Service Manual . 7 8 Go to Step 9. 2. Go to Step 10.3 V across P/J820-1 (+) <=> ground? For Tray 5: Is there +3. 6 Check for +3. For Tray 4: Is there +3. Disconnect P/J820 and P/J548. Disconnect P/J541 and P/J413. Replace the Engine Logic Board (page 8-89). Check for continuity at the following: P/J541-1 <=> P/J413-A1 P/J541-2 <=> P/J413-A2 P/J541-3 <=> P/J413-A3 P/J541-4 <=> P/J413-A4 P/J541-5 <=> P/J413-A5 P/J541-6 <=> P/J413-A6 P/J541-7 <=> P/J413-B1 P/J541-8 <=> P/J413-B2 P/J541-9 <=> P/J413-B3 P/J541-10 <=> P/J413-B4 P/J541-11 <=> P/J413-B5 P/J541-12 <=> P/J413-B6 Are these conductive? Replace the Paper Size Switch for the affected tray. Are P/J413 and P/J541 connected? Check continuity between the Tray 4-5 PWB and the Engine Logic Board. For Tray 4: 1. 2.3 V to the Paper Size Switch. Check for continuity at the following: P/J824-1 <=> P/J548-7 P/J824-2 <=> P/J548-6 P/J824-3 <=> P/J548-5 P/J824-4 <=> P/J548-4 Are these conductive? Yes Go to Step 7. 2. Repair the wiring. Check for continuity at the following: P/J820-1 <=> P/J548-14 P/J820-2 <=> P/J548-13 P/J820-3 <=> P/J548-12 P/J820-4 <=> P/J548-11 For Tray 5: 1.3 V across P/J824-1 (+) <=> ground? Check the Tray 4-5 PWB connection.

CRU and Toner Dispense (page 9-32) PL8.Tray Failure (Tray 4-5 Paper Size Switch) Troubleshooting Procedure (Continued) Step 9 Actions and Questions Check for +5 V to the Tray 4-5 PWB Is there +5 V across P/J413-A5 (+) <=> ground? Check the Paper Size Switch connection. For Tray 4: Are P/J820 and P/J548 connected? For Tray 5: Are P/J824 and P/J548 connected? Yes Replace the Tray 4-5 PWB (page 3-29). Restore proper operation.J1-2 Toner Empty The Toner Cartridge is empty. Go to Step 6. Error Messages. 10 Toner Empty. Does it operate properly? Check the gear of the Toner Dispense Assembly. No Replace the Toner Cartridge. Does the Toner Cartridge contain sufficient toner? Check the Toner Cartridge installation. and Procedures 3-197 .1 Print Engine Electrical (page 9-40) Toner Empty Troubleshooting Procedure Step 1 Actions and Questions Check remaining toner. No Replace the Engine Logic Board (page 8-89).J1-2 Toner Empty Toner Empty Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ Toner Cartridge Toner Dispense Assembly Toner Dispense Motor Toner CRUM PWB Engine Logic Board Print Engine P/J Drum and Toner (page 10-6) Print Engine P/J Engine Logic Board (page 10-13) Print Engine Xerographics Wiring (page 10-24) Print Engine Drive/CRUM Wiring (page 10-25) PL5. 2 Problem solved. Applicable Error Code Toner Empty . Remove the Toner Cartridge and reinstall. 3 Go to Step 4. Connect the Paper Size Switch. Go to Step 3.1 Laser. Does the gear of the Toner Dispense Assembly rotate smoothly? Yes Go to Step 2. Codes.

Repair the wiring. Go to Step 11. Check for continuity at the following: P127-6 <=> P/J419-6 P127-5 <=> P/J419-7 P127-4 <=> P/J419-8 P127-3 <=> P/J419-9 P127-2 <=> P/J419-10 P127-1 <=> Not connected Are these conductive? Yes Clean the tube. Are P127 and P/J419 connected? Check continuity between the Toner CRUM PWB and Engine Logic Board. 8 Check for +5 V to the Toner CRUM PWB. Does the motor rotate? Check Toner Dispense Motor connections. Replace the Engine Logic Board (page 8-89). Is the tube located at the lower part of the Toner Dispense Assembly clogged? Check the Toner CRUM PWB installation.Toner Empty Troubleshooting Procedure (Continued) Step 4 Actions and Questions Check the Toner Dispense Assembly for clogging. 10 11 Connect P/J216 and P/J420. Run the Service Diagnostics Toner Dispense Motor test. Go to Step 10. No Go to Step 5. 1. Go to Step 12. Replace the Engine Logic Board (page 8-89). Check for continuity at the following: P/J420-1 <=> P/J216-2 P/J420-2 <=> P/J216-1 Are these conductive? Go to Step 9. 2. Repair the wiring. Go to Step 8. 6 7 Go to Step 7. Connect P127 and P/J419. Disconnect P/J420 and P/J216. 1. Disconnect P/127 and P/J419. Is the Toner CRUM PWB installed correctly? Check the Toner CRUM PWB connections. 2. 5 Go to Step 6. 3-198 Phaser 5500 Printer Service Manual . 12 Check for +24 V to the Toner Dispense Motor Is there +24 V across P/J216-1 (+) <=> ground? Replace the Toner Dispense Motor (page 8-73). Correct the installation. Is there +5 V across P127-6 (+) <=> ground? Test the Toner Dispense Motor. Are P/J216 and P/J420 connected? Check continuity between the Toner Dispense Motor and Engine Logic Board. 9 Replace the Engine Logic Board (page 8-89).

Does the switch status change when the Drum Cartridge is moved in and out? Check the Drum Cartridge Detect Switch connection.1 Print Engine Electrical (page 9-40) Drum Cartridge (Drum Cartridge Detect SW) Troubleshooting Procedure Step 1 Actions and Questions Check the Drum Cartridge installation. If the error persists. Is there +5 V across P/J404-3 (+) <=> ground? Replace the Engine Logic Board (page 8-89). No Replace the Drum Cartridge. Connect P/J404. Is P/J404 connected? Check Drum Cartridge Detect Switch continuity. Repair the wiring. Run the Service Diagnostics Detect DRUM Cartridge Switch test. 3 Go to Step 4. Applicable Error Code DRUM not installed . Error Messages.1 Laser. 5 Replace the Drum Cartridge Detect Switch (page 8-60). 4 Go to Step 5. 2 Test the Drum Cartridge Detect Switch.J3-1 Drum Not Installed The Drum Cartridge is not detected by the Drum Cartridge Detect Switch. Go to Step 3. Replace the Engine Logic Board (page 8-89). and Procedures 3-199 . Was the Drum Cartridge replaced? Yes Go to Step 2. CRU and Toner Dispense (page 9-32) PL8.J3-1 Drum Cartridge (Drum Cartridge Detect SW) Troubleshooting Reference Applicable Parts ■ ■ ■ References ■ ■ ■ ■ ■ ■ Drum Cartridge Drum Cartridge Detect Switch Engine Logic Board Print Engine P/J Drum and Toner (page 10-6) Print Engine P/J Engine Logic Board (page 10-13) Print Engine LVPS Wiring (page 10-21) Print Engine Drive/CRUM Wiring (page 10-25) PL5. Codes. go to Step 2.No Drum Cartridge . Is there continuity between P/J404-1 <=> P/J404-3 when the Drum Cartridge is installed? Check for +5 V to the Drum Cartridge Detect Switch.

Is P/J404 connected? Check DRUM Cartridge Detect Switch continuity.J4-1 ATC SNR Defect The ATC Sensor is defective.1 Print Engine Electrical (page 9-40) Drum Cartridge Failure (ATC Sensor) Troubleshooting Procedure Step 1 2 Actions and Questions Replace the Drum Cartridge. 3 Go to Step 4.1 Laser. Is there +5 V across P/J404-3 (+) <=> ground? Yes Go to Step 2. Connect P/J404. Go to Step 3. Does the error reoccur? Test the Front Harness A. No Problem solved. Replace the Engine Logic Board (page 8-89). Replace Drum Cartridge . Does the switch status change when the Drum Cartridge is moved in and out? Check the DRUM Cartridge Detect Switch connection. Repair the wiring. 5 Replace the Drum Cartridge Detect Switch (page 8-60). Applicable Error Code Drum Cartridge Failure .J6-1 DRUM End of Life The Drum Cartridge has reached its end of life count. Replace the Engine Logic Board (page 8-89). Run the Service Diagnostics DRUM Cartridge Detect Switch test. CRU and Toner Dispense (page 9-32) PL8. 4 Go to Step 5. 3-200 Phaser 5500 Printer Service Manual .Drum Cartridge Failure . Is there continuity between P/J404-1 <=> P/J404-3 when the Drum Cartridge is installed? Check for +5 V to the DRUM Cartridge Detect Switch.J4-1 ATC SNR Defect Drum Cartridge Failure (ATC Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ Drum Cartridge Front Harness A Drum Cartridge Detect Switch Engine Logic Board Print Engine P/J Drum and Toner (page 10-6) Print Engine P/J Engine Logic Board (page 10-13) Print Engine LVPS Wiring (page 10-21) Print Engine Drive/CRUM Wiring (page 10-25) PL5.

No Replace the Drum Cartridge. Codes. 4 Go to Step 5.J6-1 Drum Cartridge End of Life (CRUM PWB) Troubleshooting Reference Applicable Parts ■ ■ ■ References ■ ■ ■ ■ ■ Drum Cartridge Drum Cartridge CRUM PWB Engine Logic Board Print Engine P/J Drum and Toner (page 10-6) Print Engine P/J Engine Logic Board (page 10-13) Print Engine Drive/CRUM Wiring (page 10-25) PL5.J7-n Comm/NVRAM/Type Error The Drum Cartridge CRUM failed to communicate with the Engine Logic Board. Replace the Engine Logic Board (page 8-89). CRU and Toner Dispense (page 9-32) PL8. Connect P/126 and P/J419. 1. Disconnect P/126 and P/J419. 5 Check +5 V to the Drum Cartridge CRUM PWB. 3 Go to Step 4. go to Step 2. Was the Drum Cartridge replaced? Yes Go to Step 2. Correct the installation.Applicable Error Code DRUM end of life . If the error persists. Repair the wiring. Error Messages. Is the Drum Cartridge CRUM PWB installed correctly? Check the Drum Cartridge CRUM PWB connection.1 Laser. Is there +5 V across P126-6 (+) <=> ground? Replace the Drum Cartridge CRUM PWB (page 8-70). Drum Cartridge Failure . Are P126 and P/J419 connected? Check continuity between the Drum Cartridge CRUM PWB and Engine Logic Board.1 Print Engine Electrical (page 9-40) Drum Cartridge End of Life (CRUM PWB) Troubleshooting Procedure Step 1 Actions and Questions Check the Drum Cartridge installation. 2 Check the Drum Cartridge CRUM PWB installation. Check for continuity at the following: P126-6 <=> P/J419-1 P126-5 <=> P/J419-2 P126-4 <=> P/J419-3 P126-3 <=> P/J419-4 P126-2 <=> P/J419-5 Are these conductive? Go to Step 3. and Procedures 3-201 . 2.

go to Step 2. 3-202 Phaser 5500 Printer Service Manual . 5 Check +5 V to Drum Cartridge CRUM PWB.J7-1 DRUM Comm Error Drum Cartridge Failure .1 Print Engine Electrical (page 9-40) Drum Cartridge Comm Failure Troubleshooting Procedure Step 1 Actions and Questions Check the Drum Cartridge installation. Check for continuity at the following: P126-6 <=> P/J419-1 P126-5 <=> P/J419-2 P126-4 <=> P/J419-3 P126-3 <=> P/J419-4 P126-2 <=> P/J419-5 Are these conductive? Go to Step 3. Was the Drum Cartridge replaced? Yes Go to Step 2. Repair the wiring. Is there +5 V across P126-6 (+) <=> ground? Replace the Drum Cartridge CRUM PWB (page 8-70).J7-2 DRUM NVRAM Error Drum Cartridge Comm Failure Troubleshooting Reference Applicable Parts ■ ■ ■ References ■ ■ ■ ■ ■ Drum Cartridge Drum Cartridge CRUM PWB Engine Logic Board Print Engine P/J Drum and Toner (page 10-6) Print Engine P/J Engine Logic Board (page 10-13) Print Engine Drive/CRUM Wiring (page 10-25) PL5. 2. No Replace the Drum Cartridge.Applicable Error Codes Drum Cartridge Failure . 2 Check the Drum Cartridge CRUM PWB. Correct the installation. Disconnect P/126 and P/J419. 3 Go to Step 4. 4 Go to Step 5. Is the Drum Cartridge CRUM PWB installed correctly? Check the Drum Cartridge CRUM PWB connection. 1. Replace the Engine Logic Board (page 8-89). CRU and Toner Dispense (page 9-32) PL8.1 Laser. Connect P/126 and P/J419. Are P126 and P/J419 connected? Check continuity between the Drum Cartridge CRUM PWB and Engine Logic Board. If the error persists.

Replace the Engine Logic Board (page 8-89). Is the Drum Cartridge CRUM PWB installed correctly? Check the Drum Cartridge CRUM PWB connection. Correct the installation. 4 Go to Step 5.1 Laser. Was the Drum Cartridge replaced? Yes Go to Step 2. and Procedures 3-203 .J7-3 DRUM Type Mismatch Non-Xerox Drum Cartridge (CRUM PWB) Troubleshooting Reference Applicable Parts ■ ■ ■ References ■ ■ ■ ■ ■ Drum Cartridge Drum CRUM PWB Engine Logic Board Print Engine P/J Drum and Toner (page 10-6) Print Engine P/J Engine Logic Board (page 10-13) Print Engine Drive/CRUM Wiring (page 10-25) PL5. If the error persists. 2 Check the Drum Cartridge CRUM PWB. go to Step 2. 1. 5 Check +5 V to the Drum Cartridge CRUM PWB. Codes. Is there +5 V across P126-6 (+) <=> ground? Replace the Drum Cartridge CRUM PWB (page 8-70). No Replace the Drum Cartridge. Applicable Error Code Non-Xerox Drum Cartridge . Error Messages. CRU and Toner Dispense (page 9-32) PL8.J7-3 DRUM Type Mismatch The Drum Cartridge CRUM PWB indicates a non-Xerox Drum Cartridge is installed. Disconnect P/126 and P/J419. Check for continuity at the following: P126-6 <=> P/J419-1 P126-5 <=> P/J419-2 P126-4 <=> P/J419-3 P126-3 <=> P/J419-4 P126-2 <=> P/J419-5 Are these conductive? Go to Step 3. Connect P/126 and P/J419.1 Print Engine Electrical (page 9-40) Non-Xerox Drum Cartridge (CRUM PWB) Troubleshooting Procedure Step 1 Actions and Questions Check the Drum Cartridge installation. Are P126 and P/J419 connected? Check continuity between the Drum Cartridge CRUM and Engine Logic Board. Repair the wiring. 2. 3 Go to Step 4.Replace Incorrect Drum Cartridge .

read/write error Toner Cartridge Comm Failure Troubleshooting Reference Applicable Parts ■ ■ ■ References ■ ■ ■ ■ ■ Toner Cartridge Toner Cartridge CRUM PWB Engine Logic Board Print Engine P/J Drum and Toner (page 10-6) Print Engine P/J Engine Logic Board (page 10-13) Print Engine Drive/CRUM Wiring (page 10-25) PL5. Connect P127 and P/J419.J8-2 Toner Cart. 2 Check the Toner Cartridge CRUM PWB.J8-1 Toner Comm Error .J8-n Toner Comm/Read/Write The Toner CRUM PWB failed to communicate with the Engine Logic Board. Applicable Error Codes Toner Cartridge Failure . Check for continuity at the following: P127-6 <=> P/J419-6 P127-5 <=> P/J419-7 P127-4 <=> P/J419-8 P127-3 <=> P/J419-9 P127-2 <=> P/J419-10 Are these conductive? Go to Step 3. 3 Go to Step 4. Are P127 and P/J419 connected? Check continuity between the Toner CRUM PWB and Engine Logic Board. CRU and Toner Dispense (page 9-32) PL8. No Replace the Toner Cartridge. Repair the wiring. Was the Toner Cartridge replaced? Yes Go to Step 2. 5 Check +5 V to the Toner Cartridge CRUM PWB. 2. go to Step 2. If the error persists.1 Print Engine Electrical (page 9-40) Toner Cartridge Comm Failure Troubleshooting Procedure Step 1 Actions and Questions Check the Toner Cartridge installation.1 Laser. Disconnect P127 and P/J419. Correct the installation. Is the Toner Cartridge CRUM PWB installed correctly? Check the Toner Cartridge CRUM PWB connection. 4 Go to Step 5. Is there +5 V across P127-6 (+) <=> ground? Replace the Toner Cartridge CRUM PWB (page 8-71).Toner Cartridge Failure . Replace the Engine Logic Board (page 8-89). 1. 3-204 Phaser 5500 Printer Service Manual .J8-1 Toner Cartridge Failure .

Type Mismatch Applicable Error Codes Replace Incorrect Toner Cartridge . Connect P127 and P/J419.J8-3 Toner Cart. No Replace with a Xerox Toner Cartridge.1 Laser. CRU and Toner Dispense (page 9-32) PL8. 3 Go to Step 4. Disconnect P127 and P/J419. Are P127 and P/J419 connected? Check continuity between the Toner CRUM PWB and Engine Logic Board. Was a Xerox Toner Cartridge replaced? Yes Go to Step 2. 2 Check the Toner Cartridge CRUM PWB installation. go to Step 2.Replace Incorrect Toner Cartridge . type mismatch Non-Xerox Toner Cartridge Non-Xerox Toner Cartridge Troubleshooting Reference Applicable Parts ■ ■ ■ References ■ ■ ■ ■ ■ Toner Cartridge Toner Cartridge CRUM PWB Engine Logic Board Print Engine P/J Drum and Toner (page 10-6) Print Engine P/J Engine Logic Board (page 10-13) Print Engine Drive/CRUM Wiring (page 10-25) PL5. 2. 4 Go to Step 5. Check for continuity at the following: P127-6 <=> P/J419-6 P127-5 <=> P/J419-7 P127-4 <=> P/J419-8 P127-3 <=> P/J419-9 P127-2 <=> P/J419-10 Are these conductive? Go to Step 3. Repair the wiring. Codes. If the error persists. 1. Is the Toner Cartridge CRUM PWB installed correctly? Check the Toner Cartridge CRUM PWB connection. and Procedures 3-205 . Correct the installation.1 Print Engine Electrical (page 9-40) Non-Xerox Toner Cartridge Troubleshooting Procedure Step 1 Actions and Questions Check the Toner Cartridge installation. Error Messages.J8-3 Toner Cart.

Does the motor rotate? Problem solved. Run the Service Diagnostics Toner Dispense Motor test.Toner Low The Toner CRUM PWB indicates a Low Toner condition. go to Step 2. Is there +5 V across P127-6 (+) <=> ground? Yes Replace the Toner Cartridge CRUM PWB (page 8-71). Does it operate properly? Check the gear of the Toner Dispense Assembly. No Replace the Engine Logic Board (page 8-89).1 Print Engine Electrical (page 9-40) Low Toner Troubleshooting Procedure Step 1 Actions and Questions Check the Toner Cartridge installation. 4 Go to Step 5.Non-Xerox Toner Cartridge Troubleshooting Procedure (Continued) Step 5 Actions and Questions Check +5 V to the Toner Cartridge CRUM PWB. Low Toner Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ Toner Cartridge Toner Dispense Assembly Toner Dispense Motor Toner CRUM PWB Engine Logic Board Print Engine P/J Drum and Toner (page 10-6) Print Engine P/J Engine Logic Board (page 10-13) Print Engine Xerographics Wiring (page 10-24) Print Engine Drive/CRUM Wiring (page 10-25) PL5. Remove the Toner Cartridge and reinstall. Toner Is Low . If the error persists. CRU and Toner Dispense (page 9-32) PL8. 3-206 Phaser 5500 Printer Service Manual . 5 Replace the Engine Logic Board (page 8-89). Clean the tube.1 Laser. 3 Go to Step 4. Does the gear located on the Toner Dispense Assembly rotate smoothly? Check the Toner Dispense Assembly Tube for clogging. Go to Step 3. Restore proper operation. No Replace the Toner Cartridge. Is the tube located at the lower part of the Toner Dispense Assembly clogged? Test the Toner Dispense Motor. 2 Check the Toner Cartridge installation. Go to Step 6. Was the Toner Cartridge replaced? Yes Go to Step 2.

Replace Engine Logic Board (page 8-89).1 Laser. Is there continuity on each wire between P/J216 <=> P/J420? Check for +24 V to Toner Dispense Motor Is there +24 V across P/J420-2 (+) <=> ground? Yes Go to Step 7.1 Print Engine Electrical (page 9-40) Drum End of Life (Drum CRUM) Troubleshooting Procedure Step 1 Actions and Questions Check the Drum Cartridge installation. CRU and Toner Dispense (page 9-32) PL8. Drum Cartridge Near End of Life . If the error persists. Is the Drum Cartridge CRUM PWB installed correctly? Check the Drum Cartridge CRUM PWB connection. Drum End of Life (Drum CRUM) Troubleshooting Reference Applicable Parts ■ ■ ■ References ■ ■ ■ ■ ■ Drum Cartridge Drum Cartridge CRUM PWB Engine Logic Board Print Engine P/J Drum and Toner (page 10-6) Print Engine P/J Engine Logic Board (page 10-13) Print Engine Drive/CRUM Wiring (page 10-25) PL5. 3 Go to Step 4. Are P126 and P/J419 connected? Go to Step 3. 2 Check the Drum Cartridge CRUM PWB installation. Correct the installation. Repair the wiring. Was the Drum Cartridge replaced? Yes Go to Step 2.Low Toner Troubleshooting Procedure (Continued) Step 6 7 Actions and Questions Check Toner Dispense Motor connections. Are P/J216 and P/J420 connected? Check continuity between the Toner Dispense Motor and Engine Logic Board. Go to Step 8. No Connect P/J216 and P/J420. Error Messages. and Procedures 3-207 . 8 Replace the Toner Dispense Motor (page 8-73). Codes. No Replace the Drum Cartridge. go to Step 2. Connect P126 and P/J419.DRUM Life Near End The Drum Cartridge is near its end of life count or the Drum Cartridge CRUM PWB has failed to communicate with the Engine Logic Board.

No Paper in Tray 2 or 3 No paper is detected in either Tray 2 or 3. Does the sensor state change when the sensor is blocked? Yes Go to Step 2. Disconnect P126 and P/J419. Go to Step 3. Tray Empty . No Load paper. 1. Replace the Engine Logic Board (page 8-89). No Paper in Tray 2 or 3 (No Paper Sensor) Troubleshooting Reference Applicable Parts ■ ■ References ■ ■ ■ ■ No Paper Sensor Engine Logic Board Print Engine P/J Engine Logic Board (page 10-13) Print Engine Tray 2 & 3 Wiring (page 10-26) PL2. Is paper loaded in the selected tray? Test the No Paper Sensor.1 Print Engine Electrical (page 9-40) No Paper in Tray 2 or 3 (No Paper Sensor) Troubleshooting Procedure Step 1 2 Actions and Questions Check for paper. Run the Service Diagnostics No Paper Sensor test for the affected tray. Is there +5 V across P126-6 (+) <=> ground? Replace the Drum Cartridge CRUM PWB (page 8-70). 3-208 Phaser 5500 Printer Service Manual . Check for continuity at the following: P126-6 <=> P/J419-1 P126-5 <=> P/J419-2 P126-4 <=> P/J419-3 P126-3 <=> P/J419-4 P126-2 <=> P/J419-5 Are these conductive? Yes Go to Step 5. Replace the Engine Logic Board (page 8-89). 2. No Repair the wiring. 5 Check +5 V to the Drum Cartridge CRUM PWB.Drum End of Life (Drum CRUM) Troubleshooting Procedure (Continued) Step 4 Actions and Questions Check continuity between the Drum Cartridge CRUM PWB and Engine Logic Board.3 Feeder (2/2) (page 9-12) PL8.

No Paper in Tray 4 or 5 (No Paper Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ No Paper Sensor Tray 4-5 PWB Engine Logic Board Print Engine P/J Engine Logic Board (page 10-13) PL8. 2. For Tray 2: 1.4 Tray 4-5 Feeders (page 4-10) PL20. Replace the Engine Logic Board (page 8-89). Disconnect P/J103 and P/J409. Repair the wiring. 5 Check for +5 V to the No Paper Sensor.6 Tray 4-5 Drive and Electrical (page 4-16) Error Messages. Codes. Tray Empty . 4 Go to Step 5. No Connect the sensor. For Tray 2: Is there +5 V across P/J101-3 (+) <=> ground? For Tray 3: Is there +5 V across P/J103-3 (+) <=> ground? Replace the No Paper Sensor (page 8-24). and Procedures 3-209 .1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual 1000-Sheet P/J Tray 4 & 5 Feeders (page 5-5) 1000-Sheet P/J Tray 4 & 5 Electrical (page 5-6) 1000-Sheet Tray 4 Wiring (page 5-9) PL20. Disconnect P/J101 and P/J409. Check for continuity at the following: P/J101-3 <=> P/J409-A10 P/J101-2 <=> P/J409-A11 P/J101-1 <=> P/J409-A12 For Tray 3: 1. For Tray 2: Are P/J101 and P/J409 connected? For Tray 3: Are P/J103 and P/J409 connected? Check continuity between the No Paper Sensor and Engine Logic Board.No Paper in Tray 2 or 3 (No Paper Sensor) Troubleshooting Procedure (Continued) Step 3 Actions and Questions Check the No Paper Sensor connection.No Paper in Tray 4 or 5 No paper is detected in either Tray 4 or 5. Check for continuity at the following: P/J103-3 <=> P/J409-B10 P/J103-2 <=> P/J409-B11 P/J103-1 <=> P/J409-B12 Are these conductive? Yes Go to Step 4. 2.

2. 6 Go to Step 7. Are P/J413 and P/J541 connected? Replace the No Paper Sensor. Run the Service Diagnostics No Paper Sensor test for the selected tray. For Tray 4: Are P/J102B. 3-210 Phaser 5500 Printer Service Manual . Is paper loaded in the selected tray? Test the No Paper Sensor. For Tray 4: 1. Disconnect P/J103 and P/J409. Go to Step 4. No Load paper. 4 Go to Step 5. 5 Check for +5 V to the No Paper Sensor. Check for continuity at the following: P/J102B-3 <=> P/J549-B10 P/J102B-2 <=> P/J549-B11 P/J102B-1 <=> P/J549-B12 For Tray 5: 1. Replace the Engine Logic Board (page 8-89).No Paper in Tray 4 or 5 (No Paper Sensor) Troubleshooting Procedure Step 1 2 Actions and Questions Check for paper. Repair the wiring. P/J661A and P/J549 connected? Check continuity between the No Paper Sensor and Engine Logic Board. For Tray 4: Is there +5 V across P/J102B-3 (+) <=> ground? For Tray 5: Is there +5 V across P/J102A-3 (+) <=> ground? Check the Tray 4-5 PWB connections. Go to Step 3. P/J661B and P/J549 connected? For Tray 5: Are P/J102A. Disconnect P/J101 and P/J409. 2. Does the sensor state change when the sensor is blocked? Check the No Paper Sensor connection. 3 Connect the sensor. Connect P/J413 and P/541. Check for continuity at the following: P/J102A-3 <=> P/J549-A10 P/J102A-2 <=> P/J549-A11 P/J102A-1 <=> P/J549-A12 Are these conductive? Yes Go to Step 2. Go to Step 6.

No Paper in Tray 6 The Tray 6 No Paper Sensor indicates that the tray is empty. 8 Check for +5 V to the Tray 4-5 PWB.8 Tray 6 Electrical (page 4-32) No Paper in Tray 6 (No Paper Sensor) Troubleshooting Procedure Step 1 Actions and Questions Check Tray 6 harness connections. go to Step 2. Check for continuity at the following: P/J541-1 <=> P/J413-A1 P/J541-2 <=> P/J413-A2 P/J541-3 <=> P/J413-A3 P/J541-4 <=> P/J413-A4 P/J541-5 <=> P/J413-A5 P/J541-6 <=> P/J413-A6 P/J541-7 <=> P/J413-B1 P/J541-8 <=> P/J413-B2 P/J541-9 <=> P/J413-B3 P/J541-10 <=> P/J413-B4 P/J541-11 <=> P/J413-B5 P/J541-12 <=> P/J413-B6 Are these conductive? Yes Go to Step 8. JF56A. Codes. Is there +5 V across P/J541-5 (+) <=> ground? Replace the Tray 4-5 PWB (page 3-29). Error Messages. Tray Empty . and Procedures 3-211 . PF56A. and P/JF02 connected? Yes Go to Step 2.5 Tray 6 Feeder (2/3) (page 4-26) PL22. 1. No Paper in Tray 6 (No Paper Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ References ■ ■ ■ ■ ■ No Paper Sensor Tray 6 PWB Engine Logic Board Phaser 5500 Printer Options Service Manual 2000-Sheet Tray 6 Feeder P/J Locator (page 5-20) 2000-Sheet Tray 6 Drive Wiring (page 5-25) PL22. No Repair the wiring. Are P/JF60. 2. No Connect and if error persists. Disconnect P/J541 and P/J413. Replace the Engine Logic Board (page 8-89).No Paper in Tray 4 or 5 (No Paper Sensor) Troubleshooting Procedure (Continued) Step 7 Actions and Questions Check continuity between the Tray 4-5 PWB and the Engine Logic Board.

3-212 Phaser 5500 Printer Service Manual . Paper Size Jam . 3 Check the Tray 6 No Paper Sensor harness continuity. 1. Replace the No Paper Sensor (page 3-54). Is paper loaded in the selected tray? Yes Go to Step 2. PF56A. 4 Go to Step 5. Paper Size Mismatch in Tray 2 or 3 Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ Paper Size Switch Front Size Guide Rear Side Guide End Size Guide Engine Logic Board Print Engine P/J Engine Logic Board (page 10-13) Print Engine Tray 2 & 3 Wiring (page 10-26) PL2. Open Door J 2.Paper Size in Tray 2 or 3 Paper size mismatch in either Tray 2 or 3. JF56A. Does the voltage across P/JF02-8 <=> P/ JF02-7? change when the sensor is blocked Go to Step 4.3 Feeder (2/2) (page 9-10) PL8. Replace the Tray 6 PWB(page 3-67). Note Custom size papers loaded in the tray must match the custom size paper selected at the Front Panel or from the print driver. No Go to Step 3. No Load paper. Is there +5 V across P/JF02-9 <=> P/ JF02-7? Check the Tray 6 No Paper Sensor signal.1 Tray (1/2) and Feeder (1/2) (page 9-8) PL2.No Paper in Tray 6 (No Paper Sensor) Troubleshooting Procedure (Continued) Step 2 Actions and Questions Test the No Paper Sensor. Is there continuity between P/JF60.1 Print Engine Electrical (page 9-40) Paper Size Mismatch in Tray 2 or 3 Troubleshooting Procedure Step 1 Actions and Questions Check for paper. 5 Replace the Tray 6 PWB(page 3-67). Does the sensor state change when the actuator moves and blocks the sensor? Yes Replace the Tray 6 PWB(page 3-67). Run the Service Diagnostics No Paper Sensor test for the selected tray. Repair the wiring. and P/JF02? Check for +5 V to the No Paper Sensor.

4 Replace the Engine Logic Board (page 8-89). No Set the guides properly. Are the tray’s paper size guides set correctly? Check Paper Size Switch installation. 3 Go to Step 4. Disconnect P/J110 and P/J412. and Procedures 3-213 . Go to Step 5. For Tray 2: Is there +5 V across P/J109-1 (+) <=> ground? For Tray 3: Is there +5 V across P/J110-1 (+) <=> ground? Replace the Paper Size Switch (page 8-19). 7 Check for +5 V to the Paper Size Switch. Codes. Error Messages. 2. Run the Service Diagnostics Paper Size Switch test for the affected tray. Disconnect P/J109 and P/J412.Paper Size Mismatch in Tray 2 or 3 Troubleshooting Procedure (Continued) Step 2 Actions and Questions Check the tray’s paper size guides. Go to Step 6. 2. Repair the wiring. Check for continuity at the following: P/J110-1 <=> P/J412-9 P/J110-2 <=> P/J412-8 P/J110-3 <=> P/J412-7 P/J110-4 <=> P/J412-6 Are these conductive? Yes Go to Step 3. Check for continuity at the following: P/J109-1 <=> P/J412-4 P/J109-2 <=> P/J412-3 P/J109-3 <=> P/J412-2 P/J109-4 <=> P/J412-1 For Tray 3: 1. For Tray 2: 1. For Tray 2: Are P/J109 and P/J412 connected? For Tray 3: Are P/J110 and P/J412 connected? Check continuity between the Paper Size Switch and Engine Logic Board. Is the Paper Size Switch installed correctly? Test the Paper Size Switch. Replace the Engine Logic Board (page 8-89). Correct the installation. 6 Go to Step 7. Does the paper size displayed match the paper size in the tray? Check the Paper Size Switch connections. 5 Connect the switch.

Does the paper size displayed match the paper size in the tray? Check the Paper Size Switch connections. 3-214 Phaser 5500 Printer Service Manual . Connect the switch. Run the Service Diagnostics Paper Size Switch test for the affected tray. Are the paper size guides set correctly? Check Paper Size Switch installation. Go to Step 3. For Tray 3: Are P/J820 and P/J548 connected? For Tray 4: Are P/J824 and P/J548 connected? Yes Go to Step 2.Paper Size in Tray 4 or 5 Paper size mismatch in either Tray 4 or 5. Note Custom size papers loaded in the tray must match the custom size paper selected at the Front Panel or from the print driver.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual 1000-Sheet P/J Tray 4 & 5 Electrical (page 5-6) PL20. Correct the installation. Paper Size Mismatch in Tray 4 or 5 Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ Paper Size Switch Front Size Guide Rear Side Guide Registration Sensor Registration Clutch Tray 4-5 PWB Engine Logic Board Print Engine P/J Engine Logic Board (page 10-13) Print Engine P/J Registration Transport (page 10-10) Print Engine Registration Transport Wiring (page 10-13) PL8. No Load paper.6 Tray 4-5 Drive and Electrical (page 4-16) Paper Size Mismatch in Tray 4 or 5 Troubleshooting Procedure Step 1 2 3 Actions and Questions Check for paper.Paper Size Jam . Go to Step 4. Set the guides properly. 4 Go to Step 11. Is the Paper Size Switch installed correctly? Test the Paper Size Switch. Go to Step 5. Is paper loaded in the selected tray? Check the tray’s paper size guides. 5 Go to Step 6.

Check for continuity at the following: P/J824-1 <=> P/J548-7 P/J824-2 <=> P/J548-6 P/J824-3 <=> P/J548-5 P/J824-4 <=> P/J548-4 Are these conductive? Yes Go to Step 7. Disconnect P/J820 and P/J548. 2. Is there +5 V across P/J541-5 (+) <=> ground? Replace the Tray 4-5 PWB (page 3-29).3 V to the Paper Size Switch.3 V across P/J824-1 (+) <=> ground? Check the Tray 4-5 PWB connections.3 V across P/J820-1 (+) <=> ground? For Tray 5: Is there +3. 2. Check for continuity at the following: P/J541-1 <=> P/J413-A1 P/J541-2 <=> P/J413-A2 P/J541-3 <=> P/J413-A3 P/J541-4 <=> P/J413-A4 P/J541-5 <=> P/J413-A5 P/J541-6 <=> P/J413-A6 P/J541-7 <=> P/J413-B1 P/J541-8 <=> P/J413-B2 P/J541-9 <=> P/J413-B3 P/J541-10 <=> P/J413-B4 P/J541-11 <=> P/J413-B5 P/J541-12 <=> P/J413-B6 Are these conductive? Replace the Paper Size Switch (page 3-10). For Tray 4: Is there +3. Repair the wiring. For Tray 4: 1. Connect P/J413 and P/541. 10 Check for +5 V to the Tray 4-5 PWB. 1. Are P/J413 and P/J541 connected? Check continuity between the Tray 4-5 PWB and Engine Logic Board. Codes. 2. Check for continuity at the following: P/J820-1 <=> P/J548-14 P/J820-2 <=> P/J548-13 P/J820-3 <=> P/J548-12 P/J820-4 <=> P/J548-11 For Tray 5: 1. Disconnect P/J824 and P/J548. Error Messages. No Repair the wiring. 7 Check for +3.Paper Size Mismatch in Tray 4 or 5 Troubleshooting Procedure (Continued) Step 6 Actions and Questions Check continuity between the Paper Size Switch and Tray 4-5 PWB. Go to Step 8. and Procedures 3-215 . Go to Step 10. Disconnect P/J541 and P/J413. Replace the Engine Logic Board (page 8-89). 8 9 Go to Step 9.

16 17 Check the Registration Sensor connection. Go to Step 22.Paper Size Mismatch in Tray 4 or 5 Troubleshooting Procedure (Continued) Step 11 Actions and Questions Check the tray’s rollers. Are P215 and P/J403 connected? Check continuity between the Registration Clutch and Engine Logic Board. Open Door A. Does the Registration Clutch operate? Check Registration Clutch connections. Repair the wiring. 18 Replace the Registration Sensor (page 8-52). Repair the wiring. No Clean or replace the affected roller. 2. Is there continuity on each wire between P215 <=> P/J403? Go to Step 17. Replace the Engine Logic Board (page 8-89). Is there continuity on each wire between J104 <=> J403? Check for +5 V to the Registration Sensor. Retard or Nudger Roller worn or contaminated? Check paper jam position. Does the sensor status change when the actuator is moved? Yes Go to Step 12. Connect J104 and J403. 14 Go to Step 15. 19 20 21 Connect P215 and P/J403. Go to Step 18. Run the Service Diagnostics Registration Clutch test. Open Door A. Does the paper touch the Registration Sensor? Check the Take Away Roller. Go to Step 14. Is the Feed. Open Door A. Is there +5 V across J403-B13 (+) <=> ground? Test the Registration Clutch. 12 Remove the paper and go to Step 15. Replace the Engine Logic Board (page 8-89). Go to Step 20. Run the Service Diagnostics Registration Sensor test. Remove the tray. Is the Take Away Roller worn or contaminated? Check the Registration Roller. 3-216 Phaser 5500 Printer Service Manual . 13 Clean or replace the Take Away Roller. Clean or replace the rolls. Go to Step 13. 15 Go to Step 19. Go to Step 16. Open Door C. Are J104 and J403B connected? Check continuity between the Registration Sensor and Engine Logic Board. 1. Is the Registration Roller worn or contaminated? Test the Registration Sensor. Go to Step 21.

Paper Size in Tray 6 Paper size mismatch in Tray 6. Run the Service Diagnostics Paper Size Sensor tests for sensors A and B.1 Tray 6 Covers (page 4-18) PL22. 3 Go to Step 4. For Paper Size Sensor A: Are P/JF01 and P/JF52 connected? For Paper Size Sensor B: Are P/JF01 and P/JF53 connected? Yes Go to Step 2. Paper Size Jam . 23 Replace the Engine Logic Board (page 8-89). Paper Size Jam in Tray 6 (Paper Size Sensors) Troubleshooting Reference Applicable Parts ■ ■ ■ References ■ ■ ■ ■ ■ Paper Size Sensors A and B Rear Size Guide Tray 6 PWB Phaser 5500 Printer Options Service Manual 2000-Sheet Tray 6 Feeder P/J Locator (page 5-20) 2000-Sheet Tray 6 Sensors Wiring (page 5-24) PL22. No Correct the installation. Are the Paper Size Sensors installed correctly? Test the Tray 6 Paper Size Sensors. Connect the sensor. and Procedures 3-217 . 2 Replace the Tray 6 PWB (page 3-67). Does the displayed state change when the sensors are blocked? Check the Paper Size Switch connections.8 Tray 6 Electrical (page 4-32) Paper Size Jam in Tray 6 (Paper Size Sensors) Troubleshooting Procedure Step 1 Actions and Questions Check the installation of Tray 6 Paper Size Sensors. Is the resistance across J215-1 and J215-2 approximately 240 ohm? Yes Go to Step 23. Is there +24 V across P/J403-B9 (+) <=> ground? Check the Registration Clutch resistance. Error Messages. Codes. go to Step 2 Go to Step 4. If the error persists. No Replace the Engine Logic Board (page 8-89). Replace the Registration Clutch (page 8-51). Remove the Rear and Top Covers.Paper Size Mismatch in Tray 4 or 5 Troubleshooting Procedure (Continued) Step 22 Actions and Questions Check for +24 V to the Registration Clutch.

Drum ATC Value Out of Range The ATC Sensor in the Drum Cartridge has failed. 2.1 Laser. 5 Check for +5 V to the Paper Size Sensors. Replace the Tray 6 PWB (page 3-67). For Paper Size Sensor A: 1. Disconnect P/JF01 and P/JF53. go to Step 2. Check for continuity at the following: P/JF01-12 <=> PF53-1 P/JF01-11 <=> PF53-2 P/JF01-10 <=> PF53-3 Are these conductive? Yes Go to Step 5. Disconnect P/JF01 and P/JF52. Drum Cartridge Failure . No Replace the Drum Cartridge. Check for continuity at the following: P/JF01-9 <=> PF52-1 P/JF01-8 <=> PF52-2 P/JF01-7 <=> PF52-3 For Paper Size Sensor B: 1.1 Print Engine Electrical (page 9-40) Temperature Sensor Failure (ATC Sensor) Troubleshooting Procedure Step 1 Actions and Questions Check the Drum Cartridge installation.Paper Size Jam in Tray 6 (Paper Size Sensors) Troubleshooting Procedure Step 4 Actions and Questions Check continuity between the Paper Size Sensors and the Tray 6 PWB. Temperature Sensor Failure (ATC Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ References ■ ■ ■ ■ ■ Drum Cartridge Front Harness A Drum Cartridge Detect Engine Logic Board Print Engine P/J Drum and Toner (page 10-6) Print Engine P/J Engine Logic Board (page 10-13) Print Engine LVPS Wiring (page 10-21) PL5. If the error persists. 3-218 Phaser 5500 Printer Service Manual . 2. Was the Drum Cartridge replaced? Yes Go to Step 2. No Repair the wiring. CRU and Toner Dispense (page 9-32) PL8. For Paper Size Sensor A: Is there +5 V across PF52-1 (+) <=> ground? For Paper Size Sensor B: Is there +5 V across PF53-1 (+) <=> ground? Replace the Paper Size Sensors (page 3-42).

4 Go to Step 5. Does the switch status change when the Drum Cartridge is moved in and out? Check the Drum Cartridge Detect Switch connection. Is there +5 V across P/J404-3 (+) <=> ground? Yes Replace the Engine Logic Board (page 8-89). No Go to Step 3. go to Step 2.Value Out of Range The Temperature Sensor or Humidity Sensor has failed. Are P/J403 and P/J150 connected? Yes Go to Step 2. and Procedures 3-219 . Replace the Engine Logic Board (page 8-89). 3 Go to Step 4. No Connect P/J403 and P/J150. Connect P/J404. CRU. If the error persists. Temp/Humidity Sensor Failure (Environmental PWB) Troubleshooting Reference Applicable Parts ■ ■ References ■ ■ ■ ■ ■ Environmental Sensor PWB Engine Logic Board Print Engine P/J Registration Transport (page 10-10) Print Engine P/J Engine Logic Board (page 10-13) Print Engine Xerographics Wiring (page 10-24) PL5. and Toner Dispense (page 9-32) PL8. Is P/J404 connected? Check the Drum Cartridge Detect Switch continuity. Is there continuity between P/J404-1 <=> P/J404-3 when the Drum Cartridge is installed? Check for +5 V to the Drum Cartridge Detect Switch. Temp/Humidity Sensor Failure . 5 Replace the Drum Cartridge Detect Switch (page 8-60). Repair the wiring. Codes.Temperature Sensor Failure (ATC Sensor) Troubleshooting Procedure (Continued) Step 2 Actions and Questions Test the Front Harness A.1 Laser. Run the Service Diagnostics DRUM Detect Cartridge Switch test.1 Print Engine Electrical (page 9-40) Temp/Humidity Sensor Failure (Environmental PWB) Troubleshooting Procedure Step 1 Actions and Questions Check the harness connections. Error Messages.

No Repair the wiring.2 Exit 2 (page 4-40) Standard Output Tray Full (Exit Full Stack Sensor) Troubleshooting Procedure Step 1 Actions and Questions Check the actuator installation on the affected Exit.2 Exit 1 (page 9-36) PL8. 2. Replace the Engine Logic Board (page 8-89).Face Down Tray Full The Full Stack Sensor on Exit 1 or Exit 2 indicates a Stack Full condition for the Standard Output Tray.. 3-220 Phaser 5500 Printer Service Manual .Temp/Humidity Sensor Failure (Environmental PWB) Troubleshooting Procedure Step 2 Actions and Questions Check continuity between the sensor and the Engine Logic Board. Is there +5 V across P/J403-15 <=> and P/J403-4? Replace the Environmental PWB (page 8-64) If the error persists. 1. Does the Actuator move normally and pass through the sensing area? Yes Go to Step 2. Face Down Tray Paper Full . Check for continuity at the following: P/J403-B15 <=> P/J150-1 P/J403-B7 <=> P/J150-2 P/J403-B4 <=> P/J150-3 P/J403-B6 <=> P/J150-4 Are these conductive? Yes Go to Step 3. Disconnect P/J403 and P/J150. 3 Check for +5 V to the sensor. Standard Output Tray Full (Exit Full Stack Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ ■ Exit PWB Engine Logic Board Full Stack Actuator Link Full Stack Actuator Full Stack Sensor Print Engine P/J Laser and Exit PWB (page 10-7) Print Engine P/J Engine Logic Board (page 10-13) Print Engine Exit 1 Wiring (page 10-30) PL6. No Correct the installation. replace the Engine Logic Board (page 8-89).1 Print Engine Electrical (1/2) Phaser 5500 Printer Options Service Manual Exit 2 P/J Locator (page 5-15) Exit 2 Sensor/Fan Wiring (page 5-18) PL24.

For Exit 1: Is there +5 V across P/J118-3 (+) <=> ground? For Exit 2: Is there +5 V across P/J113-3 (+) <=> ground? Check the Exit PWB connections. Does the sensor state change when the actuator is moved and sensor is blocked? Check the Stack Full Sensor connections. 8 Check for +5 V to the Exit PWB. For Exit 1: Are P/J118. Error Messages. Go to Step 8. and Procedures 3-221 . Codes.Standard Output Tray Full (Exit Full Stack Sensor) Troubleshooting Procedure Step 2 Actions and Questions Test the Stack Full Sensor. Are P/J421 and P/J431 connected? Check continuity between the Exit PWB and Engine Logic Board. P/J606B and P/J434 connected? Check continuity between the Stack Full Sensor and the Exit PWB. 1. 2. Run the Service Diagnostics Output Tray Full test for the appropriate Exit. For Exit 1: Is there continuity on each wire between P/J118 <=> P/J432? For Exit 2: Is there continuity on each wire between P/J113 <=> P/J434? Check for +5 V to the Stack Full Sensor. Connect P/J421 and P/J431. Is there +5 V across P/J421-3 (+) <=> ground? Replace the Exit PWB (page 8-88). Go to Step 6. 4 Go to Step 5. Disconnect P/J431 and P/J421. 6 7 Go to Step 7. Check for continuity at the following: P/J431-1 <=> P/J421-8 P/J431-2 <=> P/J421-7 P/J431-3 <=> P/J421-6 P/J431-4 <=> P/J421-5 P/J431-5 <=> P/J421-4 P/J431-6 <=> P/J421-3 P/J431-7 <=> P/J421-2 P/J431-8 <=> P/J421-1 Are these conductive? Yes Replace the Engine Logic Board (page 8-89). 3 Go to Step 4. P/J613 and P/J432 connected? For Exit 2: Are P/J113. Repair the wiring. Repair the wiring. No Go to Step 3. 5 Replace the Full Stack Sensor. Replace the Engine Logic Board (page 8-89). Connect the sensor.

Repair the Top Tray Sensor Harness. Disconnect P/J8393 and P/J8302A. 2. Upper Tray Full (Upper Tray Full Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ Finisher Main PWB Top Sensor Harness Main Sensor Harness Full Stack Sensor Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Sensors (1/2) Wiring (page 5-40) PL25. 3 4 Go to Step 4. Disconnect P/J8322 and P/J8393. 1. P/J8393 and P/J8302A of the Top Tray Sensor Harness connected? Print a Test Print. Are P/J8322. 5 Check Top Tray Sensor Harness continuity.13 Finisher Transport (2/2) (page 4-68) PL25. Check for continuity at the following: P/J8322-3 <=> J8393B-1 P/J8322-2 <=> J8393B-2 P/J8322-1 <=> J8393B-3 Are these conductive? Yes Replace the Finisher Main PWB (page 3-248). Go to Step 4. Does the sensor state change when the sensor area is covered? Check the Top Tray Sensor and Main Sensor Harness connections.Finisher Tray Paper Full The Full Stack Sensor on the Stacker Upper Tray indicates a Stack Full condition.14 Finisher Electrical (page 4-70) PL25. Problem solved. 2 Connect and go to Step 3. No Go to Step 2. 3-222 Phaser 5500 Printer Service Manual . Check for continuity at the following: J8393A-3 <=> P/J8302A-10 J8393A-2 <=> P/J8302A-11 J8393A-1 <=> P/J8302A-12 Are these conductive? Go to Step 6.15 Finisher Harness (page 4-72) Upper Tray Full (Upper Tray Full Sensor) Troubleshooting Procedure Step 1 Actions and Questions Test the Upper Tray Full Sensor. 1.Stacker Upper Tray Full . Go to Step 5. Repair the Top Sensor Harness. 2. Does the error still occur? Check Top Sensor Harness continuity. Run the Service Diagnostics Upper Tray Full Sensor test.

14 Finisher Electrical (page 4-70) PL25. Stacker Lower Tray Full .Upper Tray Full (Upper Tray Full Sensor) Troubleshooting Procedure (Continued) Step 6 Actions and Questions Check for +5 V to the Top Tray Full Sensor.Finisher Mix Full Stack The Stacker Encoder Sensor for the Stacker Lower Tray indicates a Stack Full condition. Is there +5 V across J8302A-12 <=> J8302A-10 on the Finisher Main PWB? Check the Top Tray Full Sensor signal.15 Finisher Harness (page 4-72) Lower Tray Full (Stack Encoder Sensor) Troubleshooting Procedure Step 1 Actions and Questions Check the Stacker Lower Tray for obstructions. Are there any obstacles in the path of the Stacker Lower Tray? Check the Encoder wheel installation. No Replace the Finisher Main PWB (page 3-248). Replace the Upper Tray Full sensor (page 3-233). Go to Step 4. 2 Go to Step 3. 7 Replace the Finisher Main PWB (page 3-248). Does the sensor state change when the Elevator Motor Belt is moved by hand rotating the Encoder Wheel? Yes Remove the obstacles. Error Messages. 3 Go to Step 9. Does the voltage across P8302A-11 <=> P8302A-10 on the Finisher Main PWB change when the sensor is covered? Yes Go to Step 7. Run the Service Diagnostics Stacker Encode Sensor test. Codes. Does the Encoder rotate and enter the sensing area of the Stacker Encode Sensor? Test the Stacker Encoder Sensor.6 Finisher Stack (page 4-54) PL25. Lower Tray Full (Stack Encoder Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ Finisher Main PWB Main Sensor Harness Stacker Encoder Sensor Elevator Motor Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Sensors (2/2) Wiring (page 5-41) Finisher Clutch and Solenoids Wiring (page 5-43) PL25. Correct and go to Step 3. No Go to Step 2. and Procedures 3-223 .

Disconnect the sensor P/J8328. Problem solved. Does the voltage across P8302B-13 and P8302B-12 on the Finisher Main PWB change when the sensing area is blocked or opened? Check the Elevator Motor. Go to Step 7. 11 12 Go to Step 12. Print a Test Print. 7 Check for +5 V to the Stacker Encode Sensor. Does the error still occur? Replace the Elevator Motor. Run the Service Diagnostics Stacker Motor Up and Down tests alternately. Are P/J8328 and P/J8302B connected? Print a Test Print. Replace the Finisher Main PWB (page 3-248). Check for continuity at the following: P/J8328-3 <=> P/J8302B-12 P/J8328-2 <=> P/J8302B-13 P/J8328-1 <=> P/ J8302B-14 Are these conductive? Yes Go to Step 6. 3-224 Phaser 5500 Printer Service Manual . Problem solved. and P/ J8302B on the Finisher Main PWB. Replace Stacker Encode Sensor (page 3-142). Replace the Finisher Main PWB (page 3-248). Problem solved. No Connect and go to Step 5. Does the error still occur? Check Stacker Encoder Sensor Harness continuity. Replace the Finisher Main PWB (page 3-248). 1.Lower Tray Full (Stack Encoder Sensor) Troubleshooting Procedure (Continued) Step 4 Actions and Questions Check Stacker Encoder Sensor Harness connections. Does the Elevator Motor operate? Check the Elevator Motor connection. 9 Go to Step 10. Go to Step 12. Does the error still occur? Go to Step 8. Is the voltage across J8302B-14 <=> J8302B-12 on the Finisher Main PWB? Check Stacker Encode Sensor signal. 5 6 Go to Step 6. 2. Is P/J8305 connected to the Finisher Main PWB? Print a Test Print. 10 Connect and go to Step 11. Repair the Stacker Encoder Sensor Harness. 8 Replace the Finisher Main PWB (page 3-248).

Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Staple P/J Locator (page 5-30) Finisher Stapler Wiring (page 5-45) PL25. Go to Step 6. Codes. Go to Step 3. 2 Replace faulty parts or clean as needed.8 Finisher Staple (page 4-58) PL25. Are P/J8356 and P/J8308 connected? Cycle the printer power. Go to Step 5. Go to Step 5. Error Messages. Is there +5 V across J8308-11 <=> J8308-15 on the Finisher Main PWB? Go to Step 7. Repair the Staple Harness. No Go to Step 2. Does the error still occur? Check Staple Harness continuity. 2. Stapler is Empty (Low Staple Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ Finisher Main PWB Staple Harness Stapler Assembly Engine Logic Board. and Procedures 3-225 .Stapler is Empty . 6 Check for +5 V to the Low Staple Sensor.Staple Pin Warning The Low Staple Sensor in the Staple Cartridge indicates no staples remain. Check for continuity at the following: P/J8356-1 <=> P/J8308-15 P/J8356-2 <=> P/J8308-14 P/J8356-3 <=> P/J8308-13 P/J8356-4 <=> P/J8308-12 P/J8356-5 <=> P/J8308-11 Are these conductive? Yes Go to Step 9. Does the sensor state change when the Staple Cartridge is removed or replaced? Check the Staple Cartridge for faulty parts and foreign particles. Replace the Finisher Main PWB (page 3-248).14 Finisher Electrical (page 4-70) Stapler is Empty (Low Staple Sensor) Troubleshooting Procedure Step 1 Actions and Questions Test the Low Staple Sensor. 3 4 5 Connect and go to Step 4. 1. Run the Service Diagnostics Staple Head Low Staple Sensor test. Problem solved. Are there damaged parts or foreign particles? Check the Staple Harness connections. Disconnect P/J8356 and P/J8308.

go to Step 3.Stapler is Empty (Low Staple Sensor) Troubleshooting Procedure (Continued) Step 7 Actions and Questions Check the Low Staple Sensor signal.14 Finisher Electrical (page 4-70) Staple Cartridge Low or Missing (Self-Priming Senor) Troubleshooting Procedure Step 1 Actions and Questions Test the Self Priming Sensor. Does the error still occur? Yes Go to Step 8. Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Staple P/J Locator (page 5-30) Finisher Stapler Wiring (page 5-45) PL25. 8 9 Go to Step 9. Go to Step 4. Does the error still occur? Replace the Finisher Main PWB. Staple Cartridge is Low or Missing .8 Finisher Staple (page 4-58) PL25. Go to Step 4. Does the sensor state change when the Staple Cartridge is removed or replaced? Check the Staple Cartridge for a staple jam. No Go to Step 2. Does the error still occur? Yes Go to Step 11. Does the voltage across P8308-14 <=> P8308-15 on the Finisher Main PWB change when the Staple Cartridge is removed or replaced? Replace the Stapler Assembly. Problem solved. Is there a staple jam? Cycle the printer power. Run the Service Diagnostics Staple Head Self Priming Sensor test. 3 Problem solved. Replace the Engine Logic Board (page 8-89). 3-226 Phaser 5500 Printer Service Manual . Problem solved. No Replace the Finisher Main PWB (page 3-248). Staple Cartridge Low or Missing (Self-Priming Senor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ Finisher Main PWB Staple Harness Stapler Assembly Engine Logic Board. 2 After removal.Staple Pin Misfeed The Self Priming Sensor in the Staple Cartridge indicates not ready.

Problem solved. 8 Check for +5 V to the Self Priming Sensor. Does the error still occur? Go to Step 9.Staple Cartridge Low or Missing (Self-Priming Senor) Troubleshooting Procedure Step 4 Actions and Questions Check the Staple Cartridge for faulty parts and foreign particles. Codes. No Go to Step 5. Check for continuity at the following: P/J8356-1 <=> P/J8308-15 P/J8356-2 <=> P/J8308-14 P/J8356-3 <=> P/J8308-13 P/J8356-4 <=> P/J8308-12 P/J8356-5 <=> P/J8308-11 Are these conductive? Yes Replace faulty parts or clean as needed. 10 11 Go to Step 11. 9 Go to Step 10. Go to Step 7. 1. Problem solved. Does the error still occur? Check Staple Harness continuity. Does the voltage across P8308-14 <=> P8308-15 on the Finisher Main PWB change when the Staple Cartridge is removed or replaced? Replace the Stapler Assembly. Go to Step 7. Replace the Finisher Main PWB (page 3-248). Are P/J8356 and P/J8308 connected? Cycle the printer power. Replace the Engine Logic Board (page 8-89). 5 6 7 Connect and go to Step 6. Error Messages. Does the error still occur? Replace the Finisher Main PWB. and Procedures 3-227 . Are there damaged parts or foreign particles? Check the Staple Harness connections. Problem solved. Is there +5 V across J8308-11 <=> J8308-15 on the Finisher Main PWB? Check the Self Priming Sensor signal. Repair the Staple Harness. Go to Step 8. Disconnect P/J8356 and P/J8308. 2. Replace the Finisher Main PWB (page 3-248).

Connect and go to Step 4. Go to Step 6. Does the Staple Motor operate? Check the Staple Motor Harness connections. 4 5 Go to Step 5. Stapler Failure (Staple Head Home Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ Finisher Main PWB Staple Harness Stapler Assembly Engine Logic Board. Go to Step 11. 1.14 Finisher Electrical (page 4-70) Stapler Failure (Staple Head Home Sensor) Troubleshooting Procedure Step 1 Actions and Questions Check the Compiler Tray for obstructions. 3-228 Phaser 5500 Printer Service Manual . Run the Service Diagnostics Staple Motor Forward and Reverse tests alternately. 3 Go to Step 5. Run the Service Diagnostics Staple Head Home Sensor test. Are there any obstructions in the Compiler Tray? Test the Staple Motor in the Staple Head. Are P/J8357 and P/J8308 connected? Cycle the printer power. No Go to Step 2. Does the error still occur? Check Staple Motor Harness continuity. 2. Problem solved. 2 Go to Step 3.Staple Failure The status of the Staple Home Sensor is not determined within the time specified following a Stapler Move Motor forward operation. Go to Step 7. Disconnect P/J8357 and P/J8308. Repair the Staple Harness. Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Staple P/J Locator (page 5-30) Finisher Stapler Wiring (page 5-45) PL25. the Staple Home Sensor is not turned On in the time specified.8 Finisher Staple (page 4-58) PL25. Check for continuity at the following: J8357-1 <=> J8308-10 J8357-2 <=> J8308-9 J8357-3 <=> J8308-8 J8357-4 <=> J8308-7 Are these conductive? Yes Remove the obstacles. Does the sensor state change when the Staple gear is rotated? Go to Step 12. 6 Test the Staple Head Home Sensor. For Staple Move Motor reverse.Stapler Failure .

Does the error still occur? Replace the Finisher Main PWB. Are all the connectors connected to the Finisher Main PWB? Yes Go to Step 3. Problem solved. Repair the Staple Harness. Go to Step 9. No Connect and go to Step 2.Stapler Failure (Staple Head Home Sensor) Troubleshooting Procedure (Continued) Step 7 8 9 Actions and Questions Check Staple Harness connections.14 Finisher Electrical (page 4-70) Staple Set Over Count Troubleshooting Procedure Step 1 Actions and Questions Check the Finisher Main PWB. Is there +5 V across J8308-11 <=> J8308-15 on the Finisher Main PWB? Replace the Stapler Assembly. Problem solved. Does the error still occur? Check Staple Harness continuity. No Connect and go to Step 8. Are P/J8356 and P/J8308 connected? Cycle the printer power. and Procedures 3-229 . Does the error still occur? Go to Step 11. 2. 10 Check for +5 V to the Staple Assembly.1 Print Engine Electrical (page 9-40) PL25. 1. Go to Step 10. Check for continuity at the following: P/J8356-1 <=> P/J8308-15 P/J8356-2 <=> P/J8308-14 P/J8356-3 <=> P/J8308-13 P/J8356-4 <=> P/J8308-12 P/J8356-5 <=> P/J8308-11 Are these conductive? Yes Go to Step 9. Problem solved. Replace the Finisher Main PWB (page 3-248). Staple Set Over Count Troubleshooting Reference Applicable Parts ■ ■ References ■ ■ ■ Finisher Main PWB Engine Logic Board Finisher Main PWB P/J Locator (page 5-35) PL8. Codes. Replace the Engine Logic Board (page 8-89). Staple Set Over Count The Stacker Lower Tray set count has reached its limit. Error Messages. 11 12 Go to Step 12. Disconnect P/J8356 and P/J8308.

Replace the Engine Logic Board (page 8-89). 3 Go to Step 4. Does the sensor state change when the sensor is blocked? Yes Remove any obstacles. Go to Step 9. Are there any obstacles on the lower part of the Stacker Tray? Check the Actuator installation. Does the Actuator enter the Upper Limit sensor sensing area? Check the Stacker No Paper Sensor. 3-230 Phaser 5500 Printer Service Manual . Does the error still occur? Yes Go to Step 3. Go to Step 3. Run the Service Diagnostics Stacker No Paper Sensor test.14 Finisher Electrical (page 4-70) PL25. 2 Repair the Actuator. Does the error still occur? Replace the Finisher Main PWB.Staple Set Over Count Troubleshooting Procedure (Continued) Step 2 3 Actions and Questions Cycle the printer power. No Problem solved.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Sensors (2/2) Wiring (page 5-41) Finisher Clutch and Solenoids (page 5-43) PL25. Lower Tray Failure (No Paper Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ ■ Finisher Main PWB Sensor Actuator Stacker No Paper Sensor Main Sensor Harness Elevator Motor Engine Logic Board. No Go to Step 2.6 Finisher Stack (page 4-54) PL25. Print Engine P/J Engine Logic Board (page 10-13) PL8. Stacker Lower Tray Failure The Stacker No Paper Sensor does not change state within the time specified following the Stacker Lower Tray beginning to lower.15 Finisher Harness (page 4-72) Lower Tray Failure (No Paper Sensor) Troubleshooting Procedure Step 1 Actions and Questions Check the lower part of the Stacker for obstacles. Problem solved.

Lower Tray Failure (No Paper Sensor) Troubleshooting Procedure (Continued) Step 4 Actions and Questions Check No Paper Sensor Harness connection. Does the error still occur? Go to Step 8. 9 10 Go to Step 12. Are P/J8326 and P/J8302B connected? Print a Test Print. Problem solved. Problem solved. Error Messages. 7 Check for +5 V to the Stacker No Paper Sensor. Go to Step 13. Does the error still occur? Replace the Finisher Main PWB. Does the error still occur? Replace the Elevator Motor. Go to Step 10. Go to Step 13. Go to Step 7. 2. Problem solved. Replace the sensor (page 3-143). 13 Replace the Engine Logic Board (page 8-89). Is P/J8305 connected to the Finisher Main PWB? Print a Test Print. 8 Replace the Finisher Main PWB (page 3-248). Is there +5 V across P/J8302B-17 <=> P/ J8302B-15 on the Finisher Main PWB? Check the Stacker No Paper Sensor signal. Codes. Connect and go to Step 11. Replace the Finisher Main PWB (page 3-248). 11 12 Go to Step 12. Repair the Main Sensor Harness. Does the Elevator Motor operate? Check the Elevator Motor connection. Run the Service Diagnostics Stacker Motor Up and Down tests alternately. Check for continuity at the following: P/J8326-3 <=> P/J8302B-15 P/J8326-2 <=> P/J8302B-16 P/J8326-1 <=> P/J8302B-17 Are these conductive? Yes Go to Step 6. Print a Test Print. Does the voltage across P8302B-16 <=> P8302B-15 on the Finisher Main PWB change when the sensor is blocked? Test the Elevator Motor. Problem solved. No Connect and go to Step 5. Does the error still occur? Check No Paper Sensor Harness continuity. and Procedures 3-231 . 5 6 Go to Step 6. Disconnect P/J8326 and P/J8302B on the Finisher Main PWB. 1.

2. Go to Step 5.7 Finisher Punch (page 4-56) PL25. and P/J8355 and P/J8307 of the Punch Sensor Harness connected? Cycle the printer power. 3-232 Phaser 5500 Printer Service Manual . Disconnect P/J8353 and P/J8355.1 Print Engine Electrical (page 9-40) PL25. 1. 3 4 Go to Step 4. 2 Check the harness connections. Problem solved. Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Punch P/J Locator (page 5-31) Finisher Punch (1/2) Wiring (page 5-46) PL8. Does the sensor state change when the Punch Box is removed and replaced? Yes Go to Step 8. Does the error still occur? Check Punch Box Sensor Harness continuity.14 Finisher Electrical (page 4-70) PL25.Punch Waste Box is Missing The Punch Box Set Sensor indicates the Punch Box is not installed in the Finisher. 3. Connect and go to Step 3. Run the Service Diagnostics Punch Box Set Sensor test. Open Door G.15 Finisher Harness (page 4-72) Punch Box Missing (Punch Box Set Sensor) Troubleshooting Procedure Step 1 Actions and Questions Test the Punch Box Set Sensor. Repair the wiring. Remove the Punch Box. Punch Box Missing (Punch Box Set Sensor) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ Punch Box Set Sensor Punch Box Sensor Harness Punch Sensor Harness Finisher Main PWB Engine Logic Board. 1. Are P/J8353 and P/J8355 of the Punch Box Sensor Harness. 2. Check for continuity at the following: J8353-3 <=> P8355-3 J8353-2 <=> P8355-2 J8353-1 <=> P8355-1 Are these conductive? Go to Step 4. No Go to Step 2.

Codes. 2.15 Finisher Harness (page 4-72) Error Messages.7 Finisher Punch (page 4-56) PL25. 8 Replace the Engine Logic Board (page 8-89). Replace the Punch Box Set Sensor (page 3-154). Punch Waste Box is Full The Punch Box counter has reached its maximum count. Punch Box Full (Punch Box Counter) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ Punch Box Set Sensor Punch Box Sensor Harness Punch Sensor Harness Finisher Main PWB Engine Logic Board.Punch Box Missing (Punch Box Set Sensor) Troubleshooting Procedure (Continued) Step 5 Actions and Questions Check Punch Sensor Harness continuity.14 Finisher Electrical (page 4-70) PL25. Does the voltage across P/J8307-A2 <=> P/J8307-A3 on the Finisher Main PWB change when the Punch Box is removed or replaced? Replace the Finisher Main PWB. Phaser 5500 Printer Options Service Manual Finisher Main PWB P/J Locator (page 5-35) Finisher Punch P/J Locator (page 5-31) Finisher Punch (1/2) Wiring (page 5-46) PL8.1 Print Engine Electrical (page 9-40) PL25. Disconnect P/J8355 and P/J8307. 1. and Procedures 3-233 . 7 Go to Step 8. No Repair the Punch Sensor Harness. 6 Check for +5 V to the Punch Box Set Sensor Is there +5 V across J8307-A1 <=> J8307-A3 on the Finisher Main PWB? Check the Punch Box Set Sensor signal. Check for continuity at the following: J8355-3 <=> J8307-A3 J8355-2 <=> J8307-A2 J8355-1 <=> J8307-A1 Are these conductive? Yes Go to Step 6. Does the error still occur? Go to Step 7. Replace the Finisher Main PWB (page 3-248). Problem solved.

Repair the Punch Sensor Harness. Does the error still occur? Yes Go to Step 2. No Problem solved. Go to Step 6. Replace the Finisher Main PWB (page 3-248). and P/J8355 and P/J8307 of the Punch Sensor Harness connected? Cycle the printer power. 7 Check for +5 V to the Punch Box Set Sensor Is there +5 V across J8307-A1 <=> J8307-A3 on the Finisher Main PWB? Go to Step 8. Close Door G.Punch Box Full (Punch Box Counter) Troubleshooting Procedure Step 1 Actions and Questions Reset the Punch Box Full Counter. Check for continuity at the following: J8355-3 <=> J8307-A3 J8355-2 <=> J8307-A2 J8355-1 <=> J8307-A1 Are these conductive? Go to Step 7. Does the sensor state change when the Punch Box is removed and replaced? Go to Step 8. Connect and go to Step 4. 1. 2. 1. Disconnect P/J8353 and P/J8355. Open Door G. Check for continuity at the following: J8353-3 <=> P8355-3 J8353-2 <=> P8355-2 J8353-1 <=> P8355-1 Are these conductive? Go to Step 5. Go to Step 3. 1. then replace the Punch Box. 3. 1. 3. 2. 4 5 Go to Step 5. Problem solved. Are P/J8353 and P/J8355 of the Punch Box Sensor Harness. Disconnect P/J8355 and P/J8307. 6 Check Punch Sensor Harness continuity. Open Door G. 3-234 Phaser 5500 Printer Service Manual . Remove the Punch Box. Repair the wiring. Remove the Punch Box for a minimum of four seconds. Run the Service Diagnostics Punch Box Set Sensor test. 3 Check the harness connections. 2 Test the Punch Box Set Sensor. Does the error still occur? Check Punch Box Sensor Harness continuity. 2. 2.

Does the sensor status change when the Front Door is opened and closed? Check the switch connections. No Correct the installation. Does the voltage across P/J8307-A2 <=> P/J8307-A3 on the Finisher Main PWB change when the Punch Box is removed or replaced? Replace the Finisher Main PWB.Punch Box Full (Punch Box Counter) Troubleshooting Procedure (Continued) Step 8 Actions and Questions Check the Punch Box Set Sensor signal. Connect P/J121 and P/J405. Are P/J121 and P/J405 connected? Check continuity between the switch and the Engine Logic Board.1 Print Engine Electrical (page 9-40) Front Door Open (Front Door Interlock) Troubleshooting Procedure Step 1 Actions and Questions Check Front Door operation. Does the error still occur? Yes Go to Step 9. Go to Step 3. Codes. Does the Front Door open and close normally? Test the Front Door Interlock Switch. 9 Replace the Engine Logic Board (page 8-89). No Replace the Punch Box Set Sensor (page 3-154). Go to Step 5. 3 4 Go to Step 4. 2 Replace the Engine Logic Board.Front Cover is Open The Printer’s Front Door Interlock Switch indicates that the Front Door is open. Print Engine P/J Engine Logic Board (page 10-13) Print Engine P/J Locator LVPS (page 10-16) Print Engine LVPS Wiring (page 10-21) PL1. Is there continuity on each wire between P/J121 <=> P/J405? Yes Go to Step 2. Problem solved. Error Messages. Printer Front Door is Open . Front Door Open (Front Door Interlock) Troubleshooting Reference Applicable Parts ■ ■ References ■ ■ ■ ■ ■ Front Cover Interlock Switch Engine Logic Board.1 Covers (2/2) (page 9-6) PL8. and Procedures 3-235 . Run the Service Diagnostics Front Cover Switch test. Repair the wiring.

Does the error still occur? Go to Step 6. No Correct and go to Step 2. Connect and go to Step 5. 2.Tray 6 Undocked The Tray 6 Docking Switch indicates that Tray 6 is separated from the printer. 1. Does the sensor status change when the switch plunger is repeatedly pushed? Yes Go to Step 2.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual 2000-Sheet Feeder P/J Locator (page 5-20) 2000-Sheet Feeder Interface Wiring (page 5-23) PL22. Tray 6 Undocked (Docking Interlock Switch) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ Tray 6 PWB Tray 6 Main Harness Tray 6 Docking Switch Engine Logic Board Print Engine P/J Engine Logic Board (page 10-13) PL8. Slide In Tray 6 Feeder . Problem solved. Is the Docking Switch damaged? Test the Docking Switch. Are FS003. FS004 and P/JF08 connected? Cycle printer power. 5 Go to Step 6.Front Door Open (Front Door Interlock) Troubleshooting Procedure (Continued) Step 5 Actions and Questions Check for +24 V to the switch.8 Tray 6 Electrical (page 4-32) Tray 6 Undocked (Docking Interlock Switch) Troubleshooting Procedure Step 1 2 Actions and Questions Check the Tray 6 installation. 3-236 Phaser 5500 Printer Service Manual . Is there +24 V across P/J121-B1 (+) <=> ground? Yes Replace the Switch No Replace the Engine Logic Board. 3 Go to Step 4. Pull Tray 6 away from the printer. Run the Service Diagnostics Tray 6 Interlock Switch test. 4 Check Tray 6 Docking Switch Harness connections. Go to Step 3. Go to Step 10. Is Tray 6 installed correctly? Check the Docking Switch condition.7 Tray 6 Drive and Transportation (page 4-30) PL22. Replace the Docking Switch (page 3-66).

FS004 and P/JF08.2 L/H Upper Assembly (page 9-24) PL8. Is there +5 V across P/JF08-2 <=> P/ JF04-2 on the Tray 6 PWB? Check the Docking Switch signal. Replace the Tray 6 PWB (page 3-67). 2.Door A is Open The Door A Interlock Switch indicates that Door A is open. 1. Run the Service Diagnostics Door A Interlock Switch test.1 Print Engine Electrical (page 9-40) Door A Open (Door A Interlock Switch) Troubleshooting Procedure Step 1 2 Actions and Questions Check Door A operation. Replace the Engine Logic Board (page 8-89). and Procedures 3-237 . Close Door A . Check for continuity at the following: FS003 <=> P/JF08-1 FS004 <=> P/JF08-2 Are these conductive? Yes Go to Step 7. Print Engine P/J Locator Electrical (page 10-12) Print Engine P/J Engine Logic Board (page 10-13) Print Engine LVPS Wiring (page 10-21) PL4. Door A Open (Door A Interlock Switch) Troubleshooting Reference Applicable Parts ■ ■ References ■ ■ ■ ■ ■ Door A Interlock Switch Engine Logic Board. Does the voltage across P/JF08-1 <=> P/ JF04-3 on the Tray 6 PWB change when the switch plunger is pushed? Replace the Tray 6 PWB.Tray 6 Undocked (Docking Interlock Switch) Troubleshooting Procedure (Continued) Step 6 Actions and Questions Check Tray 6 Docking Switch Harness continuity. Replace the Docking Switch (page 3-66). No Correct the installation. Disconnect FS003. Does the sensor status change when Door A is opened and closed? Yes Go to Step 2. No Repair the Tray 6 Docking Switch Harness. Codes. Does Door A open and close normally? Test the Door A Interlock Switch. 7 Check for +5 V to the Docking Switch. Does the error still occur? Go to Step 8. 9 Replace the Engine Logic Board (page 8-89). Go to Step 3. Error Messages. Problem solved. 8 Go to Step 9.

Replace the Engine Logic Board (page 8-89). Door B Open (Door B Interlock Switch) Troubleshooting Reference Applicable Parts ■ ■ References ■ ■ ■ ■ ■ Door B Interlock Switch Engine Logic Board. Are P/J106 and P/J410 connected? Check continuity between the switch and the Engine Logic Board. Is there +24 V across P/J120-B1 (+) <=> ground? Yes Go to Step 4. Are P/J120 and P/J405 connected? Check continuity between the switch and the Engine Logic Board. Does the sensor status change when Door B is opened and closed? Check the switch connections.1 Print Engine Electrical (page 9-40) Door B Open (Door B Interlock Switch) Troubleshooting Procedure Step 1 2 Actions and Questions Check Door B operation. Go to Step 5. Replace the Engine Logic Board (page 8-89). Close Door B .Door B is Open The Door B Interlock Switch indicates that Door B is open. Repair the wiring. Repair the wiring. Does Door B open and close normally? Test the Door B Interlock Switch. Go to Step 4. Is there continuity on each wire between P/J106 <=> P/J410? Yes Go to Step 2. Go to Step 5. 3 4 Connect P/J106 and P/J410.Door A Open (Door A Interlock Switch) Troubleshooting Procedure (Continued) Step 3 4 Actions and Questions Check the switch connections. Go to Step 3.1 L/H Upper Assembly (page 9-22) PL8. Run the Service Diagnostics Door B Interlock Switch test. No Correct the installation. 5 Replace the Door A Interlock Switch (page 8-45). No Connect P/J120 and P/J405. 3-238 Phaser 5500 Printer Service Manual . Print Engine P/J Tray 2 & 3 Feeder (page 10-11) Print Engine P/J Engine Logic Board (page 10-13) Print Engine Registration Transport Wiring (page 10-23) PL4. Is there continuity on each wire between P/J120 <=> P/J405? Check for +24 V to the switch.

Go to Step 6. Run the Service Diagnostics Door C Interlock Switch test. and Procedures 3-239 . 4 Go to Step 5. 5 Replace the switch (page 3-28). FS813 and P/ J554. No Replace the Engine Logic Board (page 8-89). Error Messages. Go to Step 4. Does Door C open and close normally? Test the Door C Interlock Switch. Repair the wiring. Door C Open (Door C Interlock Switch) Troubleshooting Reference Applicable Parts ■ ■ References ■ ■ ■ ■ ■ ■ Door C Interlock Switch Engine Logic Board. Go to Step 3. Print Engine P/J Engine Logic Board (page 10-13) PL8. Is there continuity on each wire between FS812 <=> P/J554? Is there continuity on each wire between FS813 <=> P/J554? Check for +24 V to the switch. Is there +5 V across P/J106-2 (+) <=> ground? Yes Replace the Switch (page 8-41).5 Transportation (page 4-14) Door C Open (Door C Interlock Switch) Troubleshooting Procedure Step 1 2 Actions and Questions Check Door C operation.Door B Open (Door B Interlock Switch) Troubleshooting Procedure (Continued) Step 5 Actions and Questions Check for +5 V to the switch. FS813 and P/J554 connected? Check continuity between the switch and the Tray 4-5 PWB. Is there +24 V across FS813 <=> ground? Yes Go to Step 2. No Correct the installation. Are FS812. Does the sensor state change each time the switch is pressed? Check the switch connections.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual 1000-Sheet Feeder P/J Tray 4 & 5 Feeders (page 5-5) 1000-Sheet Feeder Drive Wiring (page 5-8) PL20. 3 Connect FS812. Close Door C . Replace the Engine Logic Board (page 8-89).Door C is Open The Door C Interlock Switch on the 1000-Sheet Feeder indicates that Door C is open. Codes.

Replace the Engine Logic Board (page 8-89).1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual Duplex Unit P/J Locator (page 5-12) Duplex Unit Wiring (page 5-13) PL23. Door D Open (Door D Interlock Switch) Troubleshooting Reference Applicable Parts ■ ■ ■ References ■ ■ ■ ■ ■ ■ Door D Interlock SW Duplex PWB Engine Logic Board. Repair the wiring. 3-240 Phaser 5500 Printer Service Manual .Door C Open (Door C Interlock Switch) Troubleshooting Procedure (Continued) Step 6 7 Actions and Questions Check the Tray 4-5 PWB connection. Disconnect P/J541 and P/J413. No Correct the installation. Check for continuity at the following: P/J541-1 <=> P/J413-A1 P/J541-2 <=> P/J413-A2 P/J541-3 <=> P/J413-A3 P/J541-4 <=> P/J413-A4 P/J541-5 <=> P/J413-A5 P/J541-6 <=> P/J413-A6 P/J541-7 <=> P/J413-B1 P/J541-8 <=> P/J413-B2 P/J541-9 <=> P/J413-B3 P/J541-10 <=> P/J413-B4 P/J541-11 <=> P/J413-B5 P/J541-12 <=> P/J413-B6 Are these conductive? Yes Go to Step 7. 8 Check for +24 V to the Tray 4-5 PWB. Is there +24 V across P/J541-7 (+) <=> ground? Replace the Tray 4-5 PWB (page 3-29).1 Transportation (page 4-34) Door D Open (Door D Interlock Switch) Troubleshooting Procedure Step 1 Actions and Questions Check Door D operation. Are P/J541 and P/J413 connected? Check continuity between the Tray 4-5 PWB and the Engine Logic Board. Print Engine P/J Engine Logic Board (page 10-13) PL8.Door D is Open The Door D Interlock Switch in the Duplex Unit indicates that Door D is open. Does Door D open and close normally? Yes Go to Step 2. Close Door D . 2. No Connect P/J541 and P/J413. 1. Go to Step 8.

Does the sensor state change each time the switch is pressed? Check the switch connections. Error Messages. Disconnect P/J540 and P/J417. Go to Step 4. Go to Step 6. Codes. 1. Go to Step 7. Is there continuity on each wire between J124 <=> P/J541? Check for +5 V to the switch. and Procedures 3-241 . Replace the Engine Logic Board (page 8-89). Check for continuity at the following: P/J540-1 <=> P/J417-A1 P/J540-2 <=> P/J417-B1 P/J540-3 <=> P/J417-A2 P/J540-4 <=> P/J417-B2 P/J540-5 <=> P/J417-A3 P/J540-6 <=> P/J417-B3 P/J540-7 <=> P/J417-A4 P/J540-8 <=> P/J417-B4 Are these conductive? Yes Replace the Engine Logic Board (page 8-89). No Go to Step 3. Is there +5 V across P/J540-1 (+) <=> ground? Replace the Duplex PWB (page 3-77). 5 Replace the switch (page 3-74). Repair the wiring. Go to Step 5. 6 7 Connect P/J540 and P/J417.Door D Open (Door D Interlock Switch) Troubleshooting Procedure (Continued) Step 2 Actions and Questions Test the Door D Interlock Switch. Is there +5 V across J124-2 <=> ground? Check the Duplex PWB connection. 3 4 Connect P/J124 and P/J541. Repair the wiring. Run the Service Diagnostics Door D Interlock Switch test. Go to Step 8. 8 Check for +5 V to the Duplex PWB. Are J124 and P/J541 connected? Check continuity between the switch and the Duplex PWB. 2. Are P/J540 and P/J417 connected? Check continuity between the Duplex PWB and the Engine Logic Board.

Are P/J116.2 Exit 2 Tray Guide Assembly (page 4-40) Door E Open (Door E Interlock Switch) Troubleshooting Procedure Step 1 2 Actions and Questions Check Door E operation. P/J606B and P/ J434. 3-242 Phaser 5500 Printer Service Manual . Replace the Exit PWB (page 8-88). Is there +5 V across P/J116-2 (+)<=> ground? Yes Go to Step 2. Connect P/J116. Door E Open (Door E Interlock Switch) Troubleshooting Reference Applicable Parts ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ Door E Interlock Switch Exit PWB Engine Logic Board. Does Door E open and close normally? Test the Door E Interlock Switch. Is there continuity on each wire between P/J116 and P/J434? Check for +5 V to the switch.Close Door E . Print Engine P/J Laser and Exit PWB (page 10-7) Print Engine P/J Engine Logic Board (page 10-13) PL8.Door E is Open The Door E Interlock Switch in Exit 2 indicates that Door E is open. Reconnect the Engine Logic Board connector. 3 Go to Step 4.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual Exit 2 P/J Locator (page 5-15) Exit 2 Sensor/Fan Wiring (page 5-18) PL24. P/J606B and P/J434 connected? Check continuity between the switch and the Exit PWB. Repair the wiring. No Correct the installation. 5 Replace the Door E Interlock switch (page 3-95). Go to Step 3. Run the Service Diagnostics Door E Interlock Switch test. Does the sensor state change each time the switch is pressed? Check the switch connections. 4 Go to Step 5.

2 Horizontal Transport (1/2) (page 4-46) PL25. Does the error still occur? Yes Go to Step 2. Go to Step 4. 6 Go to Step 7.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual Horizontal Transport P/J Locator (page 5-29) Finisher Main PWB P/J Locator (page 5-35) Horizontal Transport Wiring (page 5-39) PL25. and Procedures 3-243 . Is the sensor installed correctly? Test the sensor.3 Horizontal Transport (2/2) (page 4-48) PL25. 4 Go to Step 11. Does the sensor state change when Door F is opened and closed? Check the Door F Interlock Sensor Harness connections.Close Door F . 5 Go to Step 7. 3 Correct the installation. Problem solved.14 Finisher Electrical (1/2) (page 4-70) Door F Open (Door F Interlock Sensor) Troubleshooting Procedure Step 1 2 Actions and Questions Check Door F operation. Run the Service Diagnostics Door F Interlock Sensor test. No Correct the installation. Error Messages. Door F Open (Door F Interlock Switch) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ ■ H-X’port Top Cover Door F Interlock Sensor H-X’port Harness H-X’port PWB Finisher Main PWB Engine Logic Board. and P/ J8372 on the H-X’port PWB connected? Cycle printer power. Go to Step 3. Print Engine P/J Engine Logic Board (page 10-13) PL8.Door F is Open The Door F Interlock Sensor in the Horizontal Transport indicates Door F is open. Does Door F open and close smoothly? Check the Door F Interlock Sensor Actuator. Go to Step 5. Codes. Are P/J8382 of the harness. Replace the Top Cover (page 3-108). Connect and go to Step 6. Is the actuator damaged? Check the Door F Interlock Sensor installation.

Check for continuity at the following: P/J8382-3 <=> P/J8372-1 P/J8382-2 <=> P/J8372-2 P/J8382-1 <=> P/J8372-3 Are these conductive? Yes Go to Step 8. Problem solved. 2. 9 Go to Step 10. 11 Replace the Engine Logic Board (page 8-89).Door F Open (Door F Interlock Sensor) Troubleshooting Procedure (Continued) Step 7 Actions and Questions Check H-X’port Interlock Harness continuity. 8 Check for +5 V to the Door F Interlock sensor. 1. Replace the Door F Interlock Sensor (page 3-116). Does the error still occur? Go to Step 9. Does the error still occur? Replace the Finisher Main PWB. 10 Go to Step 11. and P/J8372 on the H-X’port PWB. Does the voltage across P/J8372-3 <=> P/J8372-1 on the H-X’port PWB change when the sensor is blocked? Replace the Door F Interlock Sensor. Disconnect P/J8382 on the harness. No Repair the HX’port Harness. Cycle the printer power. Is there +5 V across P/J8372-3 <=> P/ J8372-1 on the H-X’port PWB? Check the Door F Interlock Sensor signal. Problem solved. Cycle the printer power. Replace the Finisher Main PWB (page 3-248). 3-244 Phaser 5500 Printer Service Manual .

4 Go to Step 6. Is the sensor installed correctly? Test the Door G Interlock Switch. Door G Open (Door G Interlock Switch) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ Finisher Front Cover Door G Interlock Switch Interlock Harness Eject Cover Sensor Finisher Main PWB Engine Logic Board. Run the Service Diagnostics Door G Interlock Switch test. and Procedures 3-245 . and J8388 and J8314 on the Finisher Main PWB connected? Cycle printer power.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual Finisher P/J Locator Door G Interlock (page 5-30) Finisher Main PWB P/J Locator (page 5-35) Finisher Power Wiring (page 5-38) PL25. Are J8365 on the harness. 3 Go to Step 9. Correct the installation.9 Finisher Eject (1/3) (page 4-60) PL25. 5 Go to Step 6. J8364 on the Eject Cover SW.5 Finisher Covers (2/2) (page 4-52) PL25. Does Door G open and close smoothly? Check the Door G Interlock Switch installation. Problem solved. Error Messages. Go to Step 4. Does the error still occur? Yes Go to Step 2. Print Engine P/J Engine Logic Board (page 10-13) PL8.Door G is Open The Door G Interlock Switch behind the Finisher Front Door indicates Door G is open. Codes. No Correct the installation. Go to Step 3. Does the sensor state change when Door G is opened and closed? Check the Door G Interlock Harness connections.14 Finisher Electrical (1/2) (page 4-70) PL25. Connect and go to Step 5.15 Finisher Electrical (2/2) (page 4-72) Door G Open (Door G Interlock Switch) Troubleshooting Procedure Step 1 2 Actions and Questions Check Door G operation.Close Door G .

Disconnect J8365 on the harness. Go to Step 10. 7 Check +5/+24 V to the Door G Interlock Switch. Replace the Finisher Main PWB (page 3-248). 2. Does the error still occur? Go to Step 8. Replace the Door H Interlock Switch (page 3-176). 3-246 Phaser 5500 Printer Service Manual . 1. Problem solved. 9 10 Go to Step 11.Door G Open (Door G Interlock Switch) Troubleshooting Procedure (Continued) Step 6 Actions and Questions Check Door G Interlock Harness continuity. Does the voltage across J8314-2 <=> J8314-3 on the Finisher Main PWB change when the switch is pressed? Check the Eject Cover Switch. 11 Replace the Engine Logic Board (page 8-89). and J8388 and J8314 on the Finisher Main PWB. J8364 on the Eject Cover SW. Does the voltage across J8388-2 <=> ground on the Finisher Main PWB change when the Eject Cover SW and Door G Interlock Switch are actuated simultaneously? Replace the Finisher Main PWB. Is there +5 V across J8314-2 <=> ground on the Finisher Main PWB? Is there +24 V across J8388-1 <=> ground on the Finisher Main PWB? Check the Door G Interlock Switch signal. Cycle printer power. Replace the Switch (page 3-127). 8 Replace the Finisher Main PWB (page 3-248). Does the voltage across J8365-1B <=> ground on the Door G Interlock Harness change when the Eject Cover Switch is actuated? Check the Door G Interlock signal. Check for continuity at the following: J8365-1A <=> J8388-2 J8365-1B <=> J8364-2 J8365-2A <=> J8314-3 J8365-2B <=> J8314-2 J8364-1 <=> J8388-1 J8364-3 <=> J8314-1 Are these conductive? Yes Go to Step 7. Replace the Door G Interlock Switch. No Repair the Interlock Harness.

Is the sensor installed correctly? Check the Door H Interlock Harness connections. J8364 on the Eject Cover SW. Repair the Interlock Harness.Door H is Open The Door H (Finisher Eject Cover) Interlock Switch indicates Door H is open. Problem solved. Does the error still occur? Check Door H Interlock Harness continuity.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual Finisher P/J Locator Door G Interlock (page 5-30) Finisher P/J Locator Input Drive (page 5-30) Finisher Main PWB P/J Locator (page 5-35) Finisher Power Wiring (page 5-38) PL25. No Correct the installation. Disconnect J8365 on the harness. Go to Step 3.14 Finisher Electrical (1/2) (page 4-70) PL25. Correct the installation.9 Finisher Eject (1/3) (page 4-60) PL25. Check for continuity at the following: J8365-1A <=> J8388-2 J8365-1B <=> J8364-2 J8365-2A <=> J8314-3 J8365-2B <=> J8314-2 J8364-1 <=> J8388-1 J8364-3 <=> J8314-1 Are these conductive? Yes Go to Step 2. 1. 2. Error Messages. and J8388 and J8314 on the Finisher Main PWB connected? Cycle printer power. 3 Go to Step 5. Go to Step 6. Does Door G open nd close correctly? Check the Door H Interlock Sensor installation. Print Engine P/J Engine Logic Board (page 10-13) PL8.5 Finisher Covers (2/2) (page 4-52) PL25. J8364 on the Eject Cover SW.15 Finisher Electrical (2/2) (page 4-72) Door H Open (Door H Interlock Switch) Troubleshooting Procedure Step 1 2 Actions and Questions Check Door G operation. Codes. and Procedures 3-247 . and J8388 and J8314 on the Finisher Main PWB.Close Door H . 4 5 Go to Step 5. Are J8365 on the harness. Connect and go to Step 5. Door H Open (Door H Interlock Switch) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ Finisher Front Cover Door G Interlock Switch Door H Interlock Switch Interlock Harness Finisher Main PWB Engine Logic Board.

Does the voltage across J8388-2 <=> ground on the Finisher Main PWB change when the Eject Cover SW and Door G Interlock Switch are actuated simultaneously? Replace the Finisher Main PWB. Problem solved.8 Tray 6 Electrical (page 4-32) 3-248 Phaser 5500 Printer Service Manual . Print Engine P/J Engine Logic Board (page 10-13) PL8. Does the voltage across J8314-2 <=> J8314-3 on the Finisher Main PWB change when the switch is pressed? Check the Door H Interlock Sensor.Door J is Open The Door J Interlock Switch on the 2000-Sheet Feeder indicates that Door J is open. Cycle printer power.7 Tray 6 Drive and Transportation (page 4-30) PL22. Does the error still occur? Yes Go to Step 7. Is there +5 V across J8314-2 <=> ground on the Finisher Main PWB? Is there +24 V across J8388-1 <=> ground on the Finisher Main PWB? Check the Door G Interlock signal. Close Door J . Replace the Door H Interlock Sensor (page 3-176). 9 Go to Step 10. 7 Go to Step 8. Replace the Door G Interlock Switch (page 3-127). Door J Open (Door J Interlock Switch) Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ References ■ ■ ■ ■ ■ ■ ■ Tray 6 PWB Door J Interlock Switch Tray 6 Main Harness Door J Engine Logic Board. No Replace the Finisher Main PWB (page 3-248). 8 Go to Step 9.1 Print Engine Electrical (page 9-40) Phaser 5500 Printer Options Service Manual 2000-Sheet Feeder P/J Locator (page 5-20) 2000-Sheet Feeder Interface Wiring (page 5-23) PL22.Door H Open (Door H Interlock Switch) Troubleshooting Procedure (Continued) Step 6 Actions and Questions Check +5/+24 V to the Door G switch. Replace the Door G Interlock Switch (page 3-127). Does the voltage across J8365-1B <=> ground on the Door H Interlock Harness change when the Eject Cover Switch is actuated? Check the Door G Interlock signal. 10 Replace the Engine Logic Board (page 8-89).

and Procedures 3-249 . Run the Service Diagnostics Door J Interlock Switch test. FS002 and P/JF05. 6 Check for +24 V to the Door J Interlock Switch. Does the error still occur? Replace the Tray 6 PWB. Codes. Repair the Door J Interlock Harness. Error Messages. Are FS001. Check for continuity at the following: FS002 <=> P/JF05-2 FS001 <=> P/JF05-1 Are these conductive? Yes Replace Door J. Problem solved. No Go to Step 2. 4 5 Go to Step 5. Is there +24 V across PF05-2 <=> PF04-3 on the Tray 6 PWB? Check the Door J Interlock Switch signal. Problem solved. Does the error still occur? Check Door J Interlock Harness continuity. Replace the Tray 6 PWB (page 3-67). Replace the Engine Logic Board (page 8-89). Disconnect FS001. Replace the Door J Interlock Switch (page 3-62). 3 Go to Step 5. 2. 7 Go to Step 8. Go to Step 3. Connect and go to Step 4. FS002 and P/JF05 connected? Cycle the printer power. Does the error still occur? Go to Step 7. 8 9 Go to Step 9. Does the voltage across PF05-1 <=> PF04-3 on the Tray 6 PWB change when Door J is opened and closed? Cycle printer power. Problem solved. 2 Go to Step 9. Is the Door J Interlock Switch actuator damaged? Test the Door J Interlock Switch. Go to Step 6.Door J Open (Door J Interlock Switch) Troubleshooting Procedure Step 1 Actions and Questions Check the condition of Door J. Does the sensor state change when Door J is opened and closed? Check Door J Interlock Harness connections. 1.

No Problem solved. 2.1 Print Engine Electrical (page 9-40) Upgrade Kits and Options (page 9-45) Invalid or Missing Configuration Card Troubleshooting Procedure Step 1 Actions and Questions Check the Configuration Card installation. Does the error still occur? Yes Replace the Engine Logic Board (page 8-89). Reset the Fuser Life counter (page 6-9). Does the error still occur? Yes Replace the Configuration Card.Replace Maintenance Kit The Fuser Life Counter has reached its maximum count. Replace Maintenance Kit Troubleshooting Reference Applicable Parts ■ References ■ ■ ■ Fuser PL6. Invalid or Missing Configuration Card The printer’s Configuration Card is missing or defective. No Problem solved. 1. If the problem persists.1 Fuser and Exit 1 Unit (page 9-34) PL8.1 Print Engine Electrical (page 9-40) Routine Maintenane Items (page 9-45) Replace Maintenance Kit Troubleshooting Procedure Step 1 Actions and Questions Warning: Allow the Fuser to cool. replace the I/P Board (page 8-91). Install a new Maintenance Kit. 3-250 Phaser 5500 Printer Service Manual . Remove and reinsert the Configuration Card. Invalid or Missing Configuration Card Troubleshooting Reference Applicable Parts ■ ■ References ■ ■ Configuration Card I/P Board PL8. The printer operates as a base model (non-networking) until a valid Configuration Card is detected.

1 Print Engine Electrical (page 9-40) Duplicate IP Address Detected Troubleshooting Procedure Step 1 Actions and Questions Check the TCP/IP Address stored in the printer’s NVRAM. Is the address correct for the printer? Yes Advise the customer of the address conflict. No Enter the correct IP address. Codes.Duplicate IP Address Detected Another device on the network is using the IP address assigned to this printer. Duplicate IP Address Detected Troubleshooting Reference Applicable Parts ■ References ■ ■ I/P Board Resetting Connection Setup Values (6-10) PL8. and Procedures 3-251 . Error Messages.

3-252 Phaser 5500 Printer Service Manual .

■ ■ ■ ■ ■ ■ ■ Introduction Network Problems Operating System and Application Problems Front Panel Troubleshooting Low Voltage Power Supply Troubleshooting AC Power Supply Troubleshooting Print Engine Troubleshooting Chapter 4 .General Troubleshooting In this chapter...

xerox. From the main menu. NetWare.Introduction With the exclusion of POST RAM errors. but will not print or returns to“Ready” mode without printing. Make sure the correct Phaser 5500 printer is selected in the Chooser. 3. The logs list events chronologically. then select Network Log Pages. switch background printing off. To Print an Event Log or Runtime Log: 1. and a network reset available for troubleshooting Network problems. The logs are stored on the Hard Drive so only new data is stored each time the printer’s power is cycled. the procedures in this chapter troubleshoot problems that are not associated with an error code or Front Panel error message. The logs can also be accessed remotely via CentreWare Internet Services. The page should now print. select the Troubleshooting Menu. Try again. Try again. 3. and AppleTalk initialization events. Configuration Page. In the Chooser or print dialog. The most likely cause is a printer PostScript error. Macintosh Printing Problems Image Never Prints Printer acts as if it is receiving data. Operating System and Application Problems More troubleshooting tips and information are available on the Xerox web site at: www. 2. 1. There is a Connection Setup Page.com/office/support. 4-2 Phaser 5500 Printer Service Manual . 2. Highlight the appropriate menu item from the list and select the OK button. The log is limited in length. The logs contain TCP/IP. when the log is full the printer stops recording data to the log. Power cycle the printer and try printing again. Network Problems The Phaser 5500 printer maintains six logs in memory detailing network functions.

Windows Printing Problems Image Never Prints 1. ensure the selected paper size is correct. or CentreWare IS and print the document again. If the error returns. Image Rotated 90 Degrees In the application's Page Setup. Take note of the information on the error page that just printed. turn on the PostScript error handler through the Front Panel PostScript Error Info in the Support menu. Try printing from another computer. Select the appropriate Phaser 5500 PPD with the LaserWriter Driver or application. Also. If the PostScript error does not occur. Not selecting the appropriate PPD can cause PostScript errors. 3. Try to print a different document from the application. turn on the PostScript error handler through the Front Panel PostScript Error Info in the Support menu. make sure that the image is selected to print in portrait or landscape orientation to match the document. General Troubleshooting 4-3 . 4. If the error persists. 2. 5. or CentreWare IS and print the document again. Try printing a test page from the printer driver’s properties dialog box. then the original document may be causing the problem. Try printing to another printer.4. Try printing from another application. 6. 5. Take note of the information on the error page that just printed.

Front Panel Troubleshooting Reference Applicable Parts ■ ■ ■ ■ References ■ ■ ■ Front Panel Front Panel Harness Image Processor Board LVPS Image Processor Board P/J Locator (page 10-14) Image Processor Board (1/2) Wiring (page 10-32) PL1. J150-5 <=> Ground = +5 V J150-6< => Ground = +3. Repair or replace the wiring.8 V J150-10 <=> Ground = +5 V Are the voltages within specification? Check Continuity between the Image Processor Board and the Front Panel. 3 Problem solved. No Replace the Image Processor Board (page 8-91). Replace the Image Processor Board (page 8-91).8V J150-7 <=> Ground = +5 V J150-8 <=> Ground = +3. 4-4 Phaser 5500 Printer Service Manual .Front Panel Display Error/Inoperable Buttons The Front Panel either fails to illuminate or the buttons fail to operate after the power switch is turned On.1 Covers (1/2) (page 9-4) Front Panel Troubleshooting Procedure Step 1 Actions and Questions Check the Front Panel input DC voltages: On the Image Processor Board measure the voltages at the following test points. 2 Go to Step 3. Is there continuity on each wire between J150 and the Front Panel connector? Replace the Front Panel. Is the problem resolved? Yes Go to Step 2.8V J150-9 <=> Ground = +3.

3. verify the wire harness to the I/P Board. Verify that the GFI Breaker is not tripped.6 <=> ground +3. General Troubleshooting 4-5 . Turn the printer power On. If the wiring checks out.Low Voltage Power Supply Troubleshooting Print Engine LVPS Print Engine LVPS Troubleshooting Reference Applicable Parts ■ ■ ■ ■ References ■ ■ ■ ■ ■ LVPS Engine Logic Board Image Processor Board Power Switch Engine Logic Board Plug/Jack locator (page 10-13) Image Processor Board Plug/Jack Locator (page 10-14) Print Engine LVPS Plug/Jack locator (page 10-16) Print Engine LVPS Wiring Diagram (page 10-21) PL8. 3.3 V P/J 521. Turn the printer power On.1 <=> ground +3. Remove the Upper Right Cover. 2.3 V P/J 521. Verify the power cord is in good condition and plugged into the Printer and AC outlet. 1. Measure AC voltage at the following test points on the LVPS: P/J1-1 <=> P/J1.3 <=> ground +5. Measure the voltage at these points: P/J 521. Replace the LVPS (page 8-92). Remove the Upper Right Cover.1 Print Engine Electrical (page 9-40) Print Engine LVPS Troubleshooting Procedure Step 1 Actions and Questions Check AC supply voltage to the LVPS. Verify correct operation of the printer power switch and AC harness. If the problem persists.0 V Are the voltage levels correct? Go to Step 3. No Verify correct power from the AC outlet. 2 Check DC supply voltage to the I/P Board: 1. replace the I/P Board (page 8-91). 2. Yes Go to Step 2.4 Is the voltage across pins 1 and 4 equal to 120V or 220V (line voltage).

Remove the I/P Board Cover. Measure AC voltage at the following test points on the LVPS: J2.0V Are the voltage levels correct? All voltages are present and problem persists. if problem continues verify the wire harness to the Exit PWB.3 <=> J2. 1. verify the wire harness to the Engine Logic board. 2.4 220 V (220 Volt Printer) Are the voltages within specification? Yes Go to Step 2. and Lower Rear Covers. replace the Exit PWB (page 8-88).4 120 V (120 Volt Printer) J2. If the wiring checks out. Measure the voltage at these points: P/J526. 3.14 Finisher Electrical (page 4-70) Finisher LVPS Troubleshooting Procedure Step 1 Actions and Questions Check AC supply voltage to the LVPS. 4-6 Phaser 5500 Printer Service Manual .0 V Are the voltage levels correct? Yes Go to Step 4. No Replace the LVPS (page 8-92). 4 Check DC supply voltage to the Exit PWB: 1.4 <=> ground +24. If the wiring checks out.6 < = > ground +5. Upper. Measure the voltage at these points: P/J526. Turn the printer power On. Remove the Top Cover. Check that the Finisher power cord is connected to the printer’s AC Accessory Panel and turn the printer power On.3 <=> J2. Replace the LVPS. replace the LVPS (page 8-92). Turn the printer power On. 2. Finisher LVPS Finisher LVPS Troubleshooting Reference Applicable Parts ■ ■ ■ References ■ ■ ■ ■ LVPS Power Cord Printer AC Accessory Panel Phaser 5500 Printer Options Service Manual Finisher LVPS Plug/Jack Locator (page 5-35) Finisher Power Wiring Diagram (page 5-38) PL25. 3.Print Engine LVPS Troubleshooting Procedure (Continued) Step 3 Actions and Questions Check DC supply voltage to the Engine Logic Board: 1.0 V P/J526. No Verify the printer’s AC Accessory Panel is delivering power. If the problem persists.2 <=> ground +5. 3. Remove the Bottom Cover.0V P/J526.8 < = > ground +24. 2. replace the Engine Logic Board (page 8-89).

Do not attempt to correct the wiring yourself.2 <=> ground +24V Are the voltage levels correct? Yes Go to Step 3. the cause must be corrected. Measure the voltage at these points: P/J502. Caution If any of the voltage measurements are not as specified in the following steps. Warning Improper connection of the grounding conductor can result in the risk of electrical shock. AC Power Supply Troubleshooting There is a possible problem with AC power.4 <=> ground +2.Finisher LVPS Troubleshooting Procedure (Continued) Step 2 Actions and Questions Check DC voltages on the LVPS harness. 3. replace the LVPS (page 3-250). Never remove any covers that are fastened with screws. General Troubleshooting 4-7 . Never use a ground adapter plug to connect the machine to a power source. No Replace the Finisher LVPS (page 3-250).8V P/J505. Caution the customer NOT to connect the machine to the wall outlet. Replace the Finisher LVPS (page 3-250). Never attempt any maintenance function that is not specifically called out in the service procedures.1 <=> ground +24V P/J502. Advise the customer that a licensed electrician must correct the wiring.3 <=> ground +2. 2. If intermittent operation is suspected. The following must be observed: 1. Measure the voltage at these points: P/J505. 3 Finisher LVPS is producing the correct voltages.8V Are the voltage levels correct? Check DC voltages on the LVPS harness. unless so instructed in the service procedures.

AC Neutral AC Line s4400-285 2. The voltage between Line and Neutral and between Line and Earth/Ground should range from 198 to 254 VAC and the voltage between Neutral and Ground should be less than 3 VAC. and between Neutral and Earth/Ground. No Inform customer of insufficient voltage or improper wiring. between AC Line and Earth/Ground.1 Print Engine Electrical (page 9-40) AC Power Troubleshooting Procedure Step 1 Actions and Questions For 115 V: 1. and between AC Neutral and Ground. Is the AC voltage within specification? For 220V: 1. Disconnect the AC power cord from the wall outlet. Yes Go to Step 2. Inform customer of insufficient voltage or improper wiring. Go to Step 2. The voltage between Line and Neutral and between Line and Ground should range from 99 to 135 VAC and the voltage between Neutral and Ground should be less than 3 VAC. 3.Verifying AC Power AC Power Troubleshooting Reference Applicable Parts ■ ■ ■ References ■ ■ ■ Power Cord AC Accessory Panel Wall Outlet Print Engine Electrical Specifications (page 1-13) AC Accessory Panel Plug/Jack Locator (page 10-15) PL8. Measure the AC voltage between AC Line and Neutral. Disconnect the AC power cord from the wall outlet. Is the AC line voltage within specification? 4-8 Phaser 5500 Printer Service Manual . between AC Line and Ground. Measure the AC voltage between Line and Neutral. 3. Earth/GND Neutral Line Neutral Earth/GND Line s4400-286 2.

3. No Inform customer of insufficient voltage or improper wiring. The voltage between Line and Neutral and between Line and Earth/Ground should range from 198 to 254 VAC and the voltage between Neutral and Ground should be less than 3 VAC.AC Power Troubleshooting Procedure (Continued) Step 1 Actions and Questions For 220V: 1. Disconnect the AC power cord from the wall outlet. General Troubleshooting 4-9 . Yes Go to Step 2. The measurement should be less than 10 ohms for each connection. Earth Supply Pins Earth s4400-287 2. between AC Line and Earth/Ground. Measure the AC voltage between Line and Neutral. 2. Is the AC line voltage within specification? 2 1. and between Neutral and Earth/Ground. Check the continuity through all connections of the power cord. Does continuity test per specification? Test the Print Engine LVPS (page 4-5) Replace the power cord.

T 11 –1 <=>T 12 –1 + 120V or 220 V Are the voltages within specification? Yes Go to Step 2. Is there approximately 110V (or 220V if a 220V model) at the AC outlet? Check the AC input Voltage to the LVPS 1. Measure AC voltage at the following test points on the LVPS. Power the printer On. No Plug in the AC Power Cord or reset the GFI Breaker Notify customer that the power is out of specification. 3.1 Print Engine Electrical (page 9-40) Inoperative Printer Troubleshooting Procedure Step 1 Actions and Questions Check the AC Power Cord. Go to Step 5. 2000-Sheet Feeder. 1. Initial Actions Eliminate the possibility that an installed option is the cause of the problem. 2. 2 Go to Step 3. Power Printer Off. If the printer remains inoperative. 4-10 Phaser 5500 Printer Service Manual . 2.Print Engine Troubleshooting Inoperative Printer No response from printer when the main power is switched on. Unplug all installed options (Finisher. If printer powers up normally. 1000-Sheet Feeder. use the following procedure to locate the problem. 3. Remove the Upper Right Cover. plug in the options one at a time until the defective option is isolated. 3 Go to Step 4. Is the AC Power Cord plugged into the printer and the AC outlet? Is the GFI breaker operational? Check the voltage at the AC outlet. Power the Printer on. Duplex and Exit 2. Inoperative Printer Troubleshooting Reference Applicable Parts ■ ■ ■ ■ References ■ ■ ■ Power Cord GFI Breaker AC Accessory Panel Wall Outlet Print Engine Electrical Specifications (page 1-13) AC Accessory Panel Plug/Jack Locator (page 10-15) PL8.

Verify the GFI breaker is not tripped and is operational. 5 Check AC input continuity. 1. General Troubleshooting 4-11 . If necessary. Remove the Upper Right Cover. repair the AC inlet connector wiring.Inoperative Printer Troubleshooting Procedure (Continued) Step 4 Actions and Questions Check AC supply voltage to the LVPS. replace Power Switch (page 8-86).4 Is the voltage across pins 1 and 4 equal to 120V or 220V (line voltage). Measure AC voltage at the following test points on the LVPS P/J 1 – 3 < = > P/J 1 – 6 + 120V or 220 V Are the voltages measured within specification? Verify or repair the wiring from the LVPS to the Power Switch. Measure AC voltage at the following test points on the LVPS: P/J1-1 <=> P/J1. 1. 2. Power the Printer off. 2. If necessary. 3. If necessary. 6 Check the AC Voltage from the LVPS to the Power Switch. replace the cord. If problem persists. Replace the LVPS (page 8-92). replace the GFI Breaker (page 8-94). Turn the printer power On. Check for continuity between the printer AC power inlet connector and T 11 <=>T12 Are these conductive? Verify the Power Cord is in good condition and is the correct cord. No Go to Step 6. Yes Go to LVPS Procedure (page 4-5).

Verify that the GFI breaker is not tripped. Turn the printer power On. 3. Check for continuity at the following: P/J526-2 <=> P/J400-3 P/J526-1 <=> P/J400-4 P/J526-4 <=> P/J400-1 P/J526-3 <=> P/J400-2 Are these conductive? Replace the LVPS (page 8-92). Measure the voltage at these points: P/J400-3 <=> ground +5. 2.Engine Logic Board Engine Logic Board Troubleshooting Reference Applicable Parts ■ ■ Wiring and Plug/Jack Map References ■ ■ ■ ■ Engine Logic Board LVPS Engine Logic Board Plug/Jack locator (page 10-13) Print Engine LVPS Plug/Jack locator (page 10-16) Print Engine LVPS Wiring Diagram (page 10-21) PL8. Disconnect P/J526 from the LVPS and P/J400 from the Engine Logic Board. Verify correct operation of the printer power switch and AC harness. 1. Remove the I/P Board Cover. Repair the wiring. 2. 3 Check the Engine Logic Board harness continuity: 1. No Verify the power cord is in good condition and plugged into the Printer and AC outlet. 2.0 V P/J400-1 <=> ground +24. Remove the Upper Right Cover. Go to Step 3. 2 Check DC supply voltage to the Engine Logic Board: 1.1 Print Engine Electrical (page 9-40) Engine Logic Board Troubleshooting Procedure Step 1 Actions and Questions Check AC supply voltage to the LVPS. replace the LVPS. and Lower Rear Covers. 4-12 Phaser 5500 Printer Service Manual . 3. Upper. Yes Go to Step 2. Verify correct power from the AC outlet.0 V Are the voltage levels correct? Replace the Engine Logic Board (page 8-89). Turn the printer power On. and if necessary. the Engine Logic Board (page 8-89). If the problem persists. Measure AC voltage at the following test points on the LVPS: P/J1-1 <=> P/J1-4 Is the voltage across pins 1 and 4 equal to 120V or 220V (line voltage).

Remove all on-board options (Hard Drive. Disconnect all cables connected to the Rear Panel. Re-install one of the removed options or cables. etc. Replace the option or cable just installed.) from the Image Processor Board.Image Processor Board Isolation This procedure is used to isolate the Image Processor Board. NOTE: If no on-board options are installed (Hard Drive. etc. 2 1. 3 Isolate the faulty on-board option. Does the printer boot correctly and is Ready displayed on the Front Panel? Problem solved. Switch the printer power Off. Switch the printer power Off. No Go to Step 2. 2. go on to Step 2. or one of its on-board options as the root cause of the failure. 3. Does the printer boot correctly and is Ready displayed on the Front Panel? Repeat the last Step with the next option or cable until the problem is found. 2. Image Processor Board Isolation Troubleshooting Reference Applicable Parts ■ ■ References ■ ■ ■ Image Processor Board Options Image Processor Board P/J Locator (page 10-14) Image Processor Board (1/2) Wiring (page 10-32) PL8. Does the printer boot correctly and is Ready displayed on the Front Panel? Yes Go to Step 3. Switch the printer power On. 3.1 Print Engine Electrical (page 9-40) Image Processor Board Isolation Troubleshooting Procedure Step Actions and Questions 1 Check option installation. 3. Remove then re-install the cable between P/J590 on the Image Processor Board and P/J402 on the Engine Logic Board. Switch the printer power On. 4. 1. Go to "Image Processor Board" on (page 4-14). Switch the printer power Off. 1.). General Troubleshooting 4-13 . 2. Switch the printer power On.

4-14 Phaser 5500 Printer Service Manual . Measure voltages across these points: P120-1 <=> ground 3. Disconnect P/J120 on the Image Processor Board. 1. 2. If the LVPS is operating correctly.3 V Are the voltages correct? Yes Replace the I/P Board (page 8-91).3 V P120-12 <=> ground 3. No Go to Print Engine LVPS (page 4-5) and verify LVPS operation.1 Print Engine Electrical (page 9-40) Image Processor Board Troubleshooting Procedure Step 1 Actions and Questions Check the DC power suppled from the LVPS. Repair the wiring connecting the LVPS and I/P Board.3 V P120-4 <=> ground 5 V P120-6 <=> ground 3.Image Processor Board Image Processor Board Troubleshooting Reference Applicable Parts ■ ■ References ■ ■ ■ Image Processor Board LVPS Image Processor Board P/J Locator (page 10-14) Image Processor Board (1/2) Wiring (page 10-32) PL8.

No Go to Step 2. A minimum of 128 MB of RAM must be installed for proper printer operation.1 Print Engine Electrical (page 9-40) Initial Actions: Check that the RAM devices aremaking positive contact with their connectors. Is RAM ERROR displayed on the Front Panel? Is POWER ON SELF TEST ERROR 4: MEMORY displayed on the Front Panel? Yes Go to Step 5. See "Memory Specifications" on page 1-11. 1. Go to Step 3. Power off the printer. Remove and re-install the RAM memory after verifying it meets the Xerox specifications. or 256 MB in combinations to a total of 512 MB. 2 Go to Step 5. The Phaser 5500 supports PC133 SDRAM in 144-pin SO-DIMM form. POST RAM Memory Failure Troubleshooting Procedures Step 1 Actions and Questions Power on the printer. The printer accepts modules of 128.RAM Memory Fault Isolation Image Processor Board RAM memory has failed or is not installed. 2. If the problem persists. Applicable POST Error Codes Hardware Failure: RAM Memory Slot 1 Checksum Hardware Failure:RAM Memory Slot 2 Checksum Hardware Failure:RAM Memory Slot 1 Rejected Hardware Failure:RAM Memory Slot 2 Rejected Power On Self Test Error 4:Memory Power On Self Test Error 15:RAM DIMM Power On Self Test Error RAM ERROR POST RAM Memory Failure Troubleshooting Reference Applicable Parts ■ ■ References ■ ■ SDRAM Memory Image Processor Board Image Processor Board P/J Locator (page 10-14) PL8. General Troubleshooting 4-15 . use the following procedure to correct it.

Is a memory fault message displayed? Go to Step 4. Go to Step 5. 8 1. Problem Solved. Does the DIMM fail in the new location? Replace the DIMM and go to Step 9. 2. Power on the printer. Install the second DIMM and power on the printer. Go to Step 7. 2. 9 Install all of the DIMMs and power on the printer. 7 1. Does the Startup Page identify a failed memory DIMM? Are there two DIMMs installed in the printer? 1. Go to Step 9. Problem Solved. Power off the printer and move the suspected defective DIMM to the other memory socket. 4-16 Phaser 5500 Printer Service Manual . Is a memory fault message displayed? Replace the I/P board (page 8-92). Go to Step 8. 4 Replace the DIMM and go to Step 9. Replace the I/P board (page 8-92). 5 6 Go to Step 6. Go to Step 8. Is a memory fault message displayed? Go to Step 8. Power on the printer. 2. Power off the printer and remove one of the DIMMs.POST RAM Memory Failure Troubleshooting Procedures (Continued) 3 Is POWER ON SELF TEST ERROR 15: RAM DIMM displayed on the Front Panel? Print a Startup Page and review the contents. Power off the printer and remove the first DIMM.

■ ■ ■ Print-Quality Problems Overview Analyzing Test Prints Print-Quality Troubleshooting Chapter 5 ..Print-Quality Troubleshooting In this chapter..

Temperature and humidity extremes can adversely affect the Xerographic and fusing characteristics of the printer. located under the PCL Setup menu. external software applications. From the Main menu. These pages contain detailed explanations of print-quality and image-quality problems along with possible causes and solutions for the problems. software applications. media. otherwise. is set to Off before printing the test print. Insure that Edge-to-Edge Printing. Compare this to the environmental specifications for the printer found in "Environmental Specifications" on page 1-14 of this manual. then press the OK button. 5-2 Phaser 5500 Printer Service Manual .Print-Quality Problems Overview Print-quality defects can be attributed to printer components. consumables. To print the Print Quality test print: 1. Scroll to Test Prints. and environmental conditions. The visible surfaces of all rollers should be inspected for obvious defects. The Print Quality test print shown on page 5-4 is used to evaluate that the printed image meets specifications. Further assistance in evaluating image-quality problems is available in the Troubleshooting Print Quality Page in the Print-Quality Problems section of the Troubleshooting menu. To successfully troubleshoot print-quality problems. Note The printer prints the test print using the job defaults established in the Printer Setup menu. and environmental conditions need to be researched. then media. are the most difficult to diagnose. Print a Configuration Page to determine the temperature and humidity under which the printer has been operating. When analyzing a print-quality defect. If the print-quality defect is still present after printing on approved media from an unopened ream of paper. Continuous defects in the process direction. The first step is to generate test prints using information pages embedded in the printer on laser paper from the approved media list. first determine if the defect is repeating or random. 2. eliminate as many variables as possible. scroll to Troubleshooting. internal software. The paper should be from an unopened ream that has been acclimated to room temperature. Scroll to Print Quality Problems. such as voids and lines. 3. then press the OK button. Analyzing Test Prints The Test Print analysis procedures explain each of the areas and the print-quality parameters. then press the OK button. the image will be shifted left.

spots. their definition. The text/line darkness and solid area density image varies across the print. Defect Light Prints Blank Prints Black Prints Vertical Deletions Definition The overall image density is too light. Part of or all of the image is unfused. in the process or scan direction. excessive curl. Recurring marks. from its intended position on the print. or voids. Prints with no visible image. These areas run vertically along the page in the direction of paper movement. lines. Uniform toner contamination in non image areas.Print-Quality Defect Definitions The following table lists the print-quality defect corrective procedures. There are spots of toner on the page. Displacement of the image. Smear . Extraneous dark lines/bands in the process direction. These areas run horizontally across the page in the direction of scanning. See the Background specification. Angular displacement of the image from its intended position on the print.The distortion of the image in bands across the process direction that appears to be blurred or compressed. Extraneous dark lines/bands in the direction of scan. Refer to the specification. Skip . Solid areas are marked with irregular white areas. The print is completely covered with toner with no visible image. See the specification. Go To: page 5-14 page 5-16 page 5-19 page 5-21 Horizontal Deletions Vertical Streaks Horizontal Streaks Spots Unfused Image Damaged Prints Resolution Spot Deletions Repeating Defects Residual Image Background Uneven Density Skewed Image Registration Skip/Smears page 5-23 page 5-25 page 5-27 page 5-11 page 5-30 page 5-33 page 5-7 page 5-35 page 5-37 page 5-38 page 5-40 page 5-42 page 5-44 page 5-45 page 5-47 Print-Quality Troubleshooting 5-3 . the two pixel lines and halftone patches cannot be reproduced clearly on the print. folds or embossed marks. Creases. The image from a previous print appears on the current print. At 600 dpi. cuts. wrinkles. There are areas of the image that are extremely light or missing entirely.Loss or stretching of the image in bands across the process direction. and the page where each procedure is presented. There are areas of the image that are extremely light or missing entirely.

5x11 (LEF Only) LEAD EDGE s5500-619 5-4 Phaser 5500 Printer Service Manual .Print Quality Test Print Test Print Phaser5500-040302-2-L 8.

Go to Horizontal Deletions on page 5-23. Band. Are there deletions on the test prints? Are there vertical (in process direction) Line/ Band deletions present? Yes Go to Step 2. Fusing performance varies according to the environment. Band. Go to Step 3. Spots) s5500-048 Line.Deletions (Line. 2 Go to "Vertical Deletions" on page 5-21. or Spot Deletions Line.5 mm visible on test prints. Go to "Spot Deletions" on page 5-35. Note The specified operating environment for the printer ranges from 41 degrees F (5 degrees C) at 15% relative humidity to 95 degrees F (32 degrees C) at 85% relative humidity. Print-Quality Troubleshooting 5-5 . 3 Are there Horizontal (in direction of scanning) Line/Band Deletions present? Go to Step 4. Band or Spot Deletions Troubleshooting Procedure Step 1 Actions and Questions Inspect the test print for the presence of deletions (missing image). No Go to "Fusing" on page 5-6. There should be no deletions with a diameter larger than 0. 4 Are there Spot Deletions present? Go to "Fusing" on page 5-6.

The image should not lift off of the surface. No Go to "Unfused Image" on page 5-30.5x11 (LEF Only) LEAD EDGE s5500-049 ■ A cold environment affects the warm-up time. The paper weight or composition or transparency affects the fusing of prints.Fusing Test Print Phaser5500-040302-2-L 8. while high humidity has an adverse effect on the fusing of prints. ■ Fusing Errors Troubleshooting Procedure Actions and Questions Rub the image three times at the marked check points with a soft cloth or tissue. Does the fusing quality of the image appear acceptable? Yes Go to "Resolution" on page 5-7. 5-6 Phaser 5500 Printer Service Manual .

and diagonal lines should be clear and continuous.Resolution Test Print Phaser5500-040302-2-L 8. ■ Arrow 2: The text paragraphs should be roughly equal in density. Print-Quality Troubleshooting 5-7 . and 3) within specification? ■ Yes The printed test patterns meet the Resolution Specification . Go to page 5-8. No Go to "Resolution" on page 5-34. ■ Arrow 3: The half-tone patches adjacent to the solid blocks in the corners should be uniform in appearance. Check the image resolution in each of these areas: Arrow 1: The two pixel vertical. The diagonal lines might appear to be narrower than the others. Are the check points (arrows 1.5x11 (LEF Only) LEAD EDGE s5500-050 Resolution Troubleshooting Procedure Actions and Questions Observe the three resolution check points on several test prints. horizontal. 2.

Go to "Registration (Side to Side)" on page 5-9. Fold the paper in half (leading edge to trailing edge).5 mm of the target cross hairs (each line on the target is 1 mm). No Go to "Registration" on page 5-45. Yes The test prints meet the Leading Edge to Trailing Edge Registration Specification. Observe the fold line of the paper with reference to the cross hairs of the target.2. 5-8 Phaser 5500 Printer Service Manual . Is the fold within +/.Registration s5500-051 Leading Edge to Trailing Edge (Process) Registration Troubleshooting Procedure Actions and Questions Measure the registration on two consecutive test prints.

Observe the fold line of the paper with reference to the cross hairs of the target. 2. Yes The printed test patterns meet the Side to Side Registration Specification. Print-Quality Troubleshooting 5-9 . Go to "Skewed Image" on page 5-44. Is the fold within +/. No Go to "Registration" on page 5-45. Fold the paper in half (side to side).Registration (Side to Side) s5500-052 Side to Side (Scan Direction) Registration Troubleshooting Procedure Actions and Questions Measure the registration on two consecutive test prints: 1.0 mm of the target cross hairs (each line on the target is 1 mm).2.

Is the pattern free from skips and smears? Yes Go to "Spots" on page 5-11. 5-10 Phaser 5500 Printer Service Manual . No Go to "Skips and Smears" on page 5-47.5x11 (LEF Only) LEAD EDGE Skip Smear s5500-053 Skips or Smears Troubleshooting Procedure Actions and Questions Inspect the ladder chart test pattern as shown in the figure.Skips/Smears Test Print Phaser5500-040302-2-L 8.

Within a 289 X 95 mm square: There should be no spots larger than or equal to 0. From the Main Menu.Spots s5500-054 Spots Troubleshooting Procedure Actions and Questions 1.4 mm visible on the print. 3. 4. ■ There should be no more than 1 spot measuring between 0.5 mm visible on the print. Are the prints free of spots or the spots that are visible fall within the acceptable range? ■ Yes Go to "Light (Undertoned) Print" on page 5-14. 2. then press the OK button. Inspect the print for spots. select Information.25 mm and 0.4 mm and 0.5 mm visible on the prints. ■ Any spot measuring less than 0. Scroll to Information Pages. Print-Quality Troubleshooting 5-11 . No Go to "Spots" on page 5-29. then press the OK button. then press the OK button. Scroll to Configuration Page. ■ There should be no more than 16 spots measuring between 0.25 mm is acceptable.

2. Select Test Prints. Scroll to Print Quality Problems.Skew Test Print Phaser5500-040302-2-L 8. then press the OK button. Measure the dimensions ‘A’ and ‘B’ on two consecutive test patterns. 3. then press the OK button. Go to "Skips and Smears" on page 5-47. No Go to "Skewed Image" on page 5-44.25 mm or less? Yes The printed test patterns meet the Skew specifications. Select Troubleshooting. Is the difference between ‘A’ and ‘B’ 1. 5-12 Phaser 5500 Printer Service Manual .5x11 (LEF Only) Lead Edge of Paper s5500-055 LEAD EDGE Skew Troubleshooting Procedure Actions and Questions 1. then press the OK 4.

Print-Quality Troubleshooting 5-13 . 2 Are there dark streaks present on the test prints? Go to Step 3. Are the test prints free of defects? Yes Return to "Analyzing Test Prints" on page 5-2.? Problem solved. Go to "Damaged Print" on page 5-33. No Go to Step 2. Go to"Residual Image" on page 5-38. tears. 3 Is there a residual image (ghost) on the test print? Go to Step 4.Other Print Defects Other Print Defects Troubleshooting Procedure Step 1 Actions and Questions Inspect the Test Patterns for other Print Defects. etc. Go to "Vertical Streaks" on page 5-25 or "Horizontal Streaks" on page 5-27. 4 Is the paper damage: wrinkles. creases.

No Go to Step 2. Initial Actions ■ ■ ■ ■ ■ Inspect the paper path for items. and paper scraps. paper clips. such as staples. dry recommended paper. Light Print Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ Example Print Durm Cartridge Toner Cartridge Transfer Roller High-Voltage Power Supply Image Processor Board Engine Logic Board s5500-056 Light Print Troubleshooting Procedure Step 1 Actions and Questions Checking paper condition Load new.Print-Quality Troubleshooting Light (Undertoned) Print The overall image density is too light. Check the installation of the Drum Cartridge. Check that the Drum Cartridge ground contact points are clean. Ensure that there are no obstructions in the Laser path. Is the image density normal? Yes Problem solved. and perform Test Print. 5-14 Phaser 5500 Printer Service Manual . Ensure that draft mode is turned off.

2. Remove the Drum Cartridge and check the Earth Plate located behind the Drum Cartridge. 2. Print a Test Print. right after the Transfer Roller. Clean High-Voltage Contacts. 5 Correct and clean Earth Plate or replace the Drum Cartridge. Print-Quality Troubleshooting 5-15 . 7 Check image transfer. Check the image formed on the drum. 2. Replace the Engine Logic Board (page 8-89). 1. Print a Test Print. 8 Problem solved. Install a new Drum Cartridge. 6 Go to Step 7. Replace the I/P Board (page 8-91). Remove the Transfer Roller. Go to Step 9.Light Print Troubleshooting Procedure (Continued) Step 2 Actions and Questions Check the Drum Cartridge. Is the image completely transferred on the paper? Check the HVPS. 1. black. Check for contamination or wear. Go to Step 6. Go to Step 8. 1. Is the Earth Plate contaminated or deformed? Check image development. Is the Test Print normal? Go to Step 9. Carefully remove the Drum Cartridge and check the image formed on the drum right before the Transfer Roller. Print a Test Print. Go to Step 4. Remove the Drum Cartridge and check the Drum Cartridge HighVoltage contacts. 4 Check Drum Cartridge installation. Is there any contamination or wear on the Transfer Roller? Replace the Transfer Roller (page 8-44). and easy to read? Go to Step 5. Check the Drum Cartridge ground. 1. 3. Go to Step 9. 9 Check the Engine Logic Board. Is the image density normal? Yes Problem solved. Is the image completely formed on the drum? Is it clear. Print a Test Print. Is the Test Print normal? Problem solved. 1. 2. Turn off the power while printing. 2. No Go to Step 3. Replace the HVPS (page 8-86). 3 Checking the Transfer Roller. Are the contacts clean?.

Print the Configuration Page. Is the Configuration Page normal? Check the Customer’s Print Job. Ensure the blank prints are not the result of multi-sheet feeds. Initial Actions ■ ■ ■ ■ ■ Inspect the paper path for items.Blank Print (No image) No visible image anywhere on the output print as shown here. and paper scraps. If problem persists. No Go to Step 4. Ensure there are no obstructions in the Laser path. Is the Test Print Normal? Check Confirguration Page. 5-16 Phaser 5500 Printer Service Manual . Replace the I/P Board (page 8-91). Blank Print Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ Example Print Laser Assembly Drum Cartridge Transfer Roller High-Voltage Power Supply Image Processor Board Engine Logic Board s5500-057 Blank Print Troubleshooting Procedure Step 1 Actions and Questions Check the Print Engine. Is the Customer’s Print Job blank? Yes Print a Configuration Page. Check that the Drum Cartridge ground contact points are clean. Check the installation of the Drum Cartridge. 2 Go to Step 4. Verify printer connections. paper clips. 3 Go to Step 4. Verfiy the Customer’s print job. such as staples. Go to Step 3. Go to Step 2. Print a Test Print.

Is the image density normal? Yes Problem solved. P/ J140. P/J160. P/J406. Is the Earth Plate contaminated or deformed? Check laser beam path. Install a new Drum Cartridge. 2. No Go to Step 5. Remove the Drum Cartridge and check the Earth Plate located behind the Drum Cartridge. P/ J170. Is there any contamination or wear on the Transfer Roller? Replace the Transfer Roller (page 8-44). Is the Laser Assembly installed securely with four screws? Check Laser Assembly installation. Check for contamination or wear. Are P/J130. and P/J620 connected? CAUTION: Excessive force applied to the board can cause a Laser misalignment. Print-Quality Troubleshooting 5-17 . 7 Correct and clean the Earth Plate or replace the Drum Cartridge.Blank Print Troubleshooting Procedure (Continued) Step 4 Actions and Questions Check the Drum Cartridge. 2. P/J140. Check the Laser Assembly window for contamination. 11 Check Laser Assembly connections. P/J160. Go to Step 5. Remove the Transfer Roller. and P/J620. 1. Go to Step 9. Check that there are no obstacles between the Laser Assembly and Drum. 1. 10 Problem solved. Go to Step 11. Print a Test Print. 2. Remove the Drum Cartridge and check the Drum Cartridge High Voltage contacts. Go to Step 12. Is the trouble rectified? Go to Step 11. Go to Step 6. Are the contacts clean? Check the Drum Cartridge ground. Run a Test Print. Go to Step 10. 6 Check Drum Cartridge installation. 1. 9 Check Laser Assembly installation. Install the Laser Assembly. Clean the contacts. Connect P/J130. Is there any obstacle in the laser beam path or in the window? Go to Step 7. 2. 5 Checking the Transfer Roller. P/J170 P/J406. 8 Remove obstacles or clean the Laser Assembly window. 1.

1. Is the Test Print normal? Go to Step 14. Go to Step 15. black. Print a Test Print. Is the Test Print normal? Problem solved. 2. Carefully remove the Drum Cartridge and check the image formed on the drum right before the Transfer Roller. Replace the I/P Board (page 8-91). right after the Transfer Roller. Is the image completely formed on the drum? Is it clear. and easy to read? Yes Go to Step 13. 13 Check image transfer. No Go to Step 14. Check the image formed on the drum. 2. 14 Problem solved. 2. 15 Check the Engine Logic Board. Print a Test Print. Print a Test Print. Go to Step 15. Replace the Engine Logic Board (page 8-89). 5-18 Phaser 5500 Printer Service Manual . Turn off the power while printing. 1. Replace the HVPS (page 8-86).Blank Print Troubleshooting Procedure (Continued) Step 12 Actions and Questions Check image development. 1. Is the image completely transferred on the paper? Check the HVPS. 3.

Print-Quality Troubleshooting 5-19 . Go to Step 2. Black Print Troubleshooting Reference Applicable Parts ■ ■ ■ ■ Example Print Drum Cartridge High-Voltage Power Supply Image Processor Board Engine Logic Board s5500-058 Black Print Troubleshooting Procedures Step 1 Actions and Questions Check the Print Engine. Ensure the covers are in place and no outside light enters the printer. Check the installation of the Drum Cartridge.Black Prints A totally black output print. Print a Test Print. There is toner on the paper with no visible image. Is the Test Print Normal? Check Confirguration Page. paper clips. Go to Step 3. 2 Go to Step 4. Initial Actions ■ ■ ■ ■ Inspect the paper path for items. Verfiy the Customer’s print job. such as staples. Is the Configuration Page normal? Yes Print a Configuration Page. No Go to Step 4. and paper scraps. Print the Configuration Page. Check that the Drum Cartridge ground contacts are clean.

Go to Step 6. 1. 2. 6 Check the Engine Logic Board. Problem solved. Is the image density normal? Go to Step 5. 2. Print a Test Print. replace the I/P Board (page 8-91). 1. 5-20 Phaser 5500 Printer Service Manual . Replace the HVPS (page 8-86). Go to Step 4. Run a Test Print. Replace the I/P Board (page 8-91). Print a Test Print. 4 Check the Drum Cartridge. Is the Test Print normal? Problem solved. 1. Replace the Engine Logic Board (page 8-89). If the problem persists. 5 Check the HVPS.Black Print Troubleshooting Procedures (Continued) 3 Check the Customer’s Print Job. 2. Is the Customer’s Print Job blank? Verify printer connections. Is the Test Print normal? Problem solved. Install a new Drum Cartridge.

Print-Quality Troubleshooting 5-21 . Inspect the paper path for items. Vertical Deletions Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ Example Print Drum Cartridge Transfer Roller Laser Assembly Fuser Image Processor Board Engine Logic Board s5500-059 Vertical Deletions Troubleshooting Procedure Step 1 Actions and Questions Check paper condition. Is the paper path clear? Go to Step 3.Vertical Deletions A vertical band in the scan direction where the image is missing or extremely light. Check Transfer Roller for wear or contamination. Check installation of the Drum Cartridge. 1. Check that the Drum Cartridge ground contacts are clean. dry paper. 2 Check the paper path. Remove obstacles or contamination. Check that rollers and other paper path components are clean and unobstructed. paper clips. and paper scraps. Load new. Print a Test Print. such as staples. Ensure there are no obstructions in the laser path. 2. Initial Actions ■ ■ ■ ■ ■ ■ ■ Check that the paper supply is dry and meets specifications. No Problem solved. Does the problem still occur? Yes Go to Step 2.

Are P/J130. 2. Go to Step 5. Print a Test Print. Go to Step 7. Go to Step 8. Print a Test Print. 1. 1. P/J160. Install a new Drum Cartridge. Go to Step 6. 1. 2. P/J160. Replace the I/P Board (page 8-91). 9 Check the Engine Logic Board. 2. Is the Laser Assembly installed securely with four screws? Check Laser Assembly installation.Vertical Deletions Troubleshooting Procedure (Continued) Step 3 Actions and Questions Check laser beam path. P/J170. P/J620 and P/J406 connected? CAUTION: Excessive force applied to the board can cause a Laser misalignment. Check that there are no obstacles between the Laser Assembly and Drum. P/J140. Is there contamination or defects on the Heat or Pressure Roller? Replace the Fuser (page 8-76). 8 Check the Heat and Pressure Rollers. Is there any contamination or wear on the Transfer Roller? Replace the Transfer Roller (page 8-44). P/J170 P/J620. Remove the Fuser. Print a Test Print. 5 Problem solved. 6 Check the Drum Cartridge. Is there obstacles in the laser beam path or window? Yes Go to Step 4. No Remove obstacles or clean the Laser Assembly window. P/ J140. Go to Step 9. Install the Laser Assembly. Check the Laser Assembly window for contamination. 7 Checking the Transfer Roller. Remove the Transfer Roller. Go to Step 10. Is the Test Print normal? Go to Step 6. Replace the Engine Logic Board (page 8-89). and P/J406 . WARNING: Allow the Fuser to cool before removing it. 5-22 Phaser 5500 Printer Service Manual . 2. 1. Is the Test Print normal? Problem solved. 4 Check Laser Assembly installation. Connect P/J130. Check for contamination or wear. 1. 10 Check Laser Assembly connections. Is the image density normal? Problem solved. 2.

2. Check the Transfer Roller for contamination or wear. dry paper. Load new. paper clips. Is the paper path clear? Go to Step 3. Print-Quality Troubleshooting 5-23 . Remove obstacles or contamination.Horizontal Deletions A deletion is an area of the print where the image is missing or extremely light. Inspect the paper path for items. such as staples. Horizontal Deletions Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ Example Print Drum Cartridge Transfer Roller Laser Assembly Fuser Image Processor Board Engine Logic Board s5500-060 Horizontal Deletions Troubleshooting Procedure Step 1 Actions and Questions Check paper condition. 2 Check the paper path. Check that rollers and other paper path components are clean and unobstructed. No Problem solved. Does the problem still occur? Yes Go to Step 2. Horizontal deletions extend across the page. Check that the Drum Cartridge ground contacts are clean. and paper scraps. 1. Print a Test Print. Check the installation of the Drum Cartridge. Initial Actions ■ ■ ■ ■ ■ ■ Check that the paper supply is dry and meets specifications.

Go to Step 8. Go to Step 5. Is the image completely transferred on the paper? Check the HVPS. Go to Step 8. 3. 5-24 Phaser 5500 Printer Service Manual . Is there any contamination or crack on Heat or Pressure Roller? Replace the Fuser (page 8-76). 2. WARNING: Allow the Fuser to cool before attempting to remove it. Print a Test Print. 8 Problem solved. black. Go to Step 6. 9 Check the Engine Logic Board.Horizontal Deletions Troubleshooting Procedure (Continued) Step 3 Actions and Questions Check the Drum Cartridge. Turn off the power while printing. Is the image completely formed on the drum? Is it clear. Is there any contamination or wear on the Transfer Roller? Replace the Transfer Roller (page 8-44). Replace the HVPS (page 8-86). Print a Test Print. 1. Print a Test Print. Is the Test Print normal? Problem solved. 7 Check image transfer. 1. 5 Check the Heat and Pressure Roller. Check the Transfer Roller for contamination and wear. 1. Is the Test Print normal? Go to Step 9. 4 Check the Transfer Roller. 1. 2. 2. Remove the Transfer Roller. Print a Test Print. Go to Step 9. 1. Install a new Drum Cartridge. 6 Check image development. Remove the Fuser. Replace the Engine Logic Board (page 8-89). right after the Transfer Roller. Is the image density normal? Yes Problem solved. 2. Replace the I/P Board (page 8-91). Check the image formed on the drum. and easy to read? Go to Step 7. 2. No Go to Step 4. Carefully remove the Drum Cartridge and check the image formed on the drum right before the Transfer Roller.

No Problem solved. Check that the Drum Cartridge ground contacts are clean. Print-Quality Troubleshooting 5-25 . Does the problem still occur? Yes Go to Step 2. Initial Actions ■ ■ ■ ■ ■ Check that the paper supply is dry and meets specifications. and paper scraps. Check the installation of the Drum Cartridge. Print a Test Print. 2. Vertical Streaks Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ Example Print Drum Cartridge Transfer Roller Laser Assembly Fuser Image Processor Board Engine Logic Board s5500-061 Vertical Streaks Troubleshooting Procedure Step 1 Actions and Questions Check paper condition. dry paper. Is the paper path clear? Go to Step 3. 1. Load new. Inspect the paper path for contamination or obstructions. paper clips. Inspect the paper path for items.Vertical Streaks Extraneous dark lines/bands in the scan direction. 2 Check the paper path. Remove obstacles or contamination. such as staples.

Go to Step 5. 5-26 Phaser 5500 Printer Service Manual . WARNING: Allow the Fuser to cool before removing it. 2. Clean the contacts. 2. Go to Step 7. 1. Is the Test print normal? Problem solved. 4 Checking the Transfer Roller. Go to Step 9. No Go to Step 4. 1. Go to Step 8. 1. Install a new Drum Cartridge. 7 Remove obstacles or clean the Laser Assembly window. 1. 2. 5 Check Drum Cartridge installation. Remove the Transfer Roller. Print a Test Print.Vertical Streaks Troubleshooting Procedure (Continued) Step 3 Actions and Questions Check the Drum Cartridge. 2. Check the Drum Cartridge ground. Remove the Fuser. Check the Transfer Roller for contamination and wear. 9 Check the Engine Logic Board. Check the Laser Assembly window for contamination. Is the image density normal? Yes Problem solved. Is there obstacles in the laser beam path or window? Go to Step 6. Remove the Drum Cartridge and check the Drum Cartridge HighVoltage contacts. Remove the Drum Cartridge and check the Earth Plate located behind the Drum Cartridge. Print a Test Print. Replace the I/P Board (page 8-91). 6 Correct and clean Earth Plate or replace the Drum Cartridge. Is the Earth Plate contaminated or deformed? Check laser beam path. Check that there are no obstacles between the Laser Assembly and Drum. Is there contamination or defects on the Heat or Pressure Roller? Replace the Fuser (page 8-76). 8 Check the Heat and Pressure Roller. Are the contacts clean?. Is there any contamination or wear on the Transfer Roller? Replace the Transfer Roller (page 8-44). Replace the Engine Logic Board (page 8-89).

Go to Step 4. Check that the Drum Cartridge ground contacts are clean. Horizontal Streaks Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ ■ Example Print Drum Cartridge Transfer Roller Laser Assembly Fuser Image Processor Board Engine Logic Board s5500-062 Horizontal Streaks Troubleshooting Procedure Step 1 Actions and Questions Check paper condition.Horizontal Streaks There are black lines running horizontally across the page in the process direction. No Problem solved. 1. 2 3 Check the paper path. Print a Test Print. paper clips. Check the Drum Cartridge Drum surface for scratches. Does the problem still occur? Yes Go to Step 2. Is the image density normal? Go to Step 3. Initial Actions ■ ■ ■ ■ ■ Check that the paper supply is dry and meets specifications. Check the installation of the Drum Cartridge. 2. dry paper. Remove obstacles or contamination. Print-Quality Troubleshooting 5-27 . Print a Test Print. Problem solved. 1. 2. Load new. and paper scraps. Install a new Drum Cartridge. Inspect the paper path for items. Is the paper path clear? Check the Drum Cartridge. such as staples.

8 Problem solved. WARNING: Allow the Fuser to cool before removing it. Is there any contamination or crack on Heat or Pressure Roller? Replace the Fuser (page 8-76). 5-28 Phaser 5500 Printer Service Manual . 2. Go to Step 8. right after the Transfer Roller. 10 Check Laser Assembly connections. 7 Check image transfer. Is the Test Print normal? Problem solved. No Go to Step 5. 1. black. Go to Step 9. Replace the Engine Logic Board (page 8-89). 6 Check image development. Remove the Transfer Roller. 2. P/J140. Go to Step 8. and easy to read? Go to Step 7. Are P/J130. Check the image formed on the drum. P/J170 P/J620 and P/J406 connected? CAUTION: Excessive force applied to the board can cause a Laser misalignment. Is there any contamination or wear on the Transfer Roller? Yes Replace the Transfer Roller (page 8-44). 1. Print a Test Print. Is the image completely transferred on the paper? Check the HVPS. 2. Print a Test Print. 3. Remove the Fuser. P/J170 P/J620 and P/J406 . Connect P/J130.Horizontal Streaks Troubleshooting Procedure (Continued) Step 4 Actions and Questions Checking the Transfer Roller. Is the Test Print normal? Go to Step 9. Carefully remove the Drum Cartridge and check the image formed on the drum right before the Transfer Roller. Turn off the power while printing. P/J160. 5 Check the Heat and Pressure Roller. Go to Step 10. Go to Step 6. Replace the I/P Board (page 8-91). Is the image completely formed on the drum? Is it clear. 1. Replace the HVPS (page 8-86). 2. 1. P/J160. Print a Test Print. P/ J140. 9 Check the Engine Logic Board. Check the Transfer Roller for contamination and wear.

Is the paper path clear? Go to Step 3. Print a Test Print. 1. dry. and meets specifications. Check the installation of the Drum Cartridge. Inspect the paper path for items. 2. Check Drum surface for spots or contamination. Print-Quality Troubleshooting 5-29 . 2 Check the paper path. dry paper. If using recycled paper. Spots Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ Example Print Drum Cartridge Transfer Roller Fuser Image Processor Board Engine Logic Board s5500-063 Spots Troubleshooting Procedure Step 1 Actions and Questions Check paper condition. Does the problem still occur? Yes Go to Step 2. Check the Fuser for wear or contamination. Remove obstacles or contamination. Initial Actions ■ ■ ■ ■ ■ ■ ■ Check that the paper is clean. Load new.Spots There are spots of toner randomly scattered on the page. Check that the Drum Cartridge ground contacts are clean. paper clips. and paper scraps. No Problem solved. such as staples. it may have spots.

No Go to Step 4. 2. Replace the Transfer Roller (page 8-44). 6 Replace the Engine Logic Board (page 8-89). Is the image density normal? Yes Problem solved.Spots Troubleshooting Procedure (Continued) Step 3 Actions and Questions Check the Drum Cartridge. ■ ■ ■ 5-30 Phaser 5500 Printer Service Manual . Remove the Transfer Roller. Remove the Fuser. A location that’s too cold or too humid reduces fusing performance. Is the Test Print normal? Problem solved. paper clips. such as staples. and paper scraps. Verify that the paper type is set correctly for the Fuser temperature configuration. Is there contamination or defects on Heat or Pressure Roller? Replace the Fuser (page 8-76). Check to ensure that the paper is dry and within specifications. 1. 1. Inspect the paper path for items. The image rubs off easily. WARNING: Allow the Fuser to cool before removing it. Initial Actions ■ Check to ensure that the printer installation meets environmental specifications. Install a new Drum Cartridge. 2. Is there contamination or wear? Go to Step 5. Replace the I/P Board (page 8-91). Unfused Image The printed image is not fully fused to the paper. Print a Test Print. 4 Check the Transfer Roller. Print a Test Print. Go to Step 6. 5 Check the Heat and Pressure Roller. Check for contamination or wear.

Print a Test Print.Fuser Temperature Defaults Paper Type Plain Letterhead Transparency Labels Colored Paper Card Stock Envelope Special Fuser Temperature Setting Medium Medium Low High Medium High High Medium Unfused Image Troubleshooting Reference Applicable Parts ■ ■ ■ ■ Example Print Fuser High-Voltage Power Supply Image Processor Board Engine Logic Board s5500-064 Unfused Image Troubleshooting Procedure Step 1 Actions and Questions 1. 2. Print-Quality Troubleshooting 5-31 . dry paper from an unopened ream. Replace the paper with new. No Go to Step 2. Is the Test Print Normal? Yes Problem solved.

Print a Test Print. Replace the Engine Logic Board (page 8-89). Print a Test Print. Is there contamination or cracks on Heat or Pressure Roller? Replace the Fuser (page 8-76). Go to Step 4. black. Check that the thumbscrews on on the Fuser Assembly are tight. 2. 2. 1. 4 Check image development. 1. Is the image completely formed on the drum? Is it clear. 7 Check the Engine Logic Board. Go to Step 7. Print a Test Print. Replace the HVPS (page 8-86). Is the image completely transferred on the paper? Check the HVPS. Remove the Fuser. Turn off the power while printing. Print a Test Print. right after the Transfer Roller. Go to Step 7. Yes Problem solved. Go to Step 7.Unfused Image Troubleshooting Procedure (Continued) Step 2 Actions and Questions 1. Is the Test Print normal? Go to Step 6. Is the Test Print Normal? 3 Check the Heat and Pressure Roller. Handle E Knob s5500-065 2. WARNING: Allow the Fuser to cool before removing it. 6 Problem solved. 5-32 Phaser 5500 Printer Service Manual . 1. 5 Check image transfer. Replace the I/P Board (page 8-91). No Go to Step 3. Carefully remove the Drum Cartridge and check the image formed on the drum right before the Transfer Roller. Is the tTest print normal? Problem solved. 2. Check the image formed on the drum. 3. and easy to read? Go to Step 5.

Damaged Print The page comes out of the Standard Output Tray either wrinkled. No Correct the installation. go to Step 2. Is the installation adaquate? Yes Go to Step 2. Check that the printer is level. has its feet. If the problem persists. determine the location where the damage occurs an correct as necessary to eliminate the problem. and is in alignment. Inspect the paper path for items. and paper scraps. or torn. Check that rollers and other paper path components are clean and unobstructed. Check that the paper supply is dry and meets specifications. Print-Quality Troubleshooting 5-33 . Initial Actions ■ ■ ■ ■ Verify that the Drum Shutter operates properly when Door A is opened or closed. such as staples. Damaged Print Troubleshooting Reference Applicable Parts ■ ■ ■ Example Print Fuser Feed Rollers Tray s5500-066 Damaged Print Troubleshooting Procedure Step 1 Actions and Questions Check the installation location. Note If paper damage occurs within an installed option. creased. paper clips.

1. Problem solved. 3. Go to Step 7. Is the paper path clear? Check rollers in the paper path. Check whether pinch rollers rotate freely and spring pressure is applied evenly. Reload paper in the tray. wear. 5-34 Phaser 5500 Printer Service Manual . 4 5 Check the paper path. Remove obstacles or contamination. in order. Print a Test Print. Does the problem still occur? Yes Go to Step 3. which is 4. Check Feed and paper path rollers for contamination. Does the problem still occur? Go to Step 4. 2. 1. wear or damage to the rollers? Go to Step 5. Load new. Remove the Fuser. Is there contamination or defects on the Heat or Pressure Roller? Replace the Fuser (page 8-76).Damaged Print Troubleshooting Procedure (Continued) Step 2 Actions and Questions Check paper feeding. or damage. Go to Step 6. ■ ■ ■ ■ Paper Feed Rollers Fuser (page 8-76) Transfer Roller (page 8-44) Exit Assembly (page 8-78) Resolution The two pixel lines and halftone patches cannot be reproduced clearly on the test print. Is there any contamination. 1. No Problem solved. Remove the source Tray. until the defective component is found. 6 Check the Heat and Pressure Roller. 7 Replace the following. 2. 3 Check paper condition. WARNING: Allow the Fuser to cool before removing it. Replace defective rollers. Initial Actions Ensure the NVRAM Laser Power adjustment is set to the default. dry paper. Print a Test Print. 2.

Print a Test Print. 2 Replace the following. and paper scraps. such as staples. Is the test print output resolution good? Yes Problem solved. 2. Check that the Drum Cartridge ground contacts are clean. s5500-067 Print-Quality Troubleshooting 5-35 . in order until the defective component is found: ■ ■ Laser Assembly (page 8-74) Engine Logic Board (page 8-89) Spot Deletions Solid areas are marked with irregular white areas. Check the installation of the Drum Cartridge. dry. Inspect the paper path for items. and meets specifications.Resolution Troubleshooting Procedure Step 1 Actions and Questions 1. No Go to Step 2. Install a new Drum Cartridge. Spot Deletions Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ Example Print Drum Cartridge Transfer Roller Fuser Engine Logic Board Image Processor Board. paper clips. Initial Actions ■ ■ ■ ■ Check that the paper is clean.

Remove the Fuser. Go to Step 4. Is the image density normal? Go to Step 3. Install a new Drum Cartridge. 4 Checking the Transfer Roller. 1. Print a Test Print. 6 Check the Engine Logic Board. Replace the Engine Logic Board (page 8-89). Does the problem still occur? Yes Go to Step 2. Load fresh. 2. Is there contamination or defects on the Heat or Pressure Roller? Replace the Fuser (page 8-76). Remove the Transfer Roller. Is the paper path clear? Check the Drum Cartridge. Is the trouble rectified? Problem solved. 2. Check the paper path for contamination or obstacles. 2. Replace the I/P Board (page 8-91). 5-36 Phaser 5500 Printer Service Manual . WARNING: Allow the Fuser to cool before removing it. 2. dry paper. 5 Check the Heat and Pressure Roller. Check the Transfer Roller for contamination and wear. Go to Step 6. Re-print the defective image. Is there any contamination or wear on the Transfer Roller? Replace the Transfer Roller (page 8-44). 1. 2 Check the paper path. 1. Print a Test Print.Spot Deletions Troubleshooting Procedure Step 1 Actions and Questions Check paper condition. 3 Problem solved. Remove obstacles or contamination. 1. No Problem solved. Go to Step 5.

) Print-Quality Troubleshooting 5-37 .Repeating Defects Recurring marks.2 in.) 94.) 56. Check that the Drum Cartridge ground contacts are clean. Print a test print. dry.) 56.)? Do the defects occur every: 78. Replace paper with new paper.) 78. Check the installation of the Drum Cartridge.2 mm (3. Go to Step 3. 2.) 94.0 mm (1. Do the repeating defects still appear? Yes Go to Step 2. Refer to these measurements when diagnosing a repeating print-quality problem. such as staples.) Install a new Drum Cartridge. and paper scraps.1 in.7 in.5 mm (3. and meets specifications.5 mm (2. Replace the Fuser (page 8-76).2 in. Inspect the paper path for items.7 mm (2. Initial Actions ■ ■ ■ ■ Check that the paper is clean. lines.7 in. Go to Step 4. 4 Xerographic Component Specifications The following table lists measurements of critical printer components.1 in. Repeating Defects Troubleshooting Procedure Step 1 Actions and Questions 1.5 mm (2.) 58.5 mm (3. or voids.7 in. No Problem solved. 3 Do the defects occur every 58. Component Charge Roller (Drum Cartridge) Developer Roller (Drum Cartridge) Photoreceptor (Drum Cartridge) Transfer Roller (Door A) Fuser Heat Roller (Fuser) Circumference 44.7 in. 2 Do the defects occur every: ■ ■ ■ 44 mm (1.)? Replace the Transfer Roller (page 8-44).3 in. spots. paper clips.7 mm (2.2 mm (3.3 in.

Residual Image Troubleshooting Reference Applicable Parts ■ ■ ■ ■ Example Print Fuser Engine Logic Board Image Processor Board.Residual Image The image from a previous print appears on the current print. paper clips. Check the installation of the Drum Cartridge. No Go to Step 3. and paper scraps. Initial Actions ■ ■ ■ ■ Inspect the paper path for items. HVPS s5500-068 Residual Image Troubleshooting Procedure Step 1 Actions and Questions Check image quality. such as staples. Print 30 Test Prints. Problem solved. dry paper. Does the residual image appear? Check paper condition. Verify the paper is within the specifications on the Paper Tips Page. Load new. Does the problem still occur? Yes Go to Step 2. Check that the Drum Cartridge ground contact points are clean. 5-38 Phaser 5500 Printer Service Manual . 1. Print 30 customer prints and go to Step 3. Is the customer printing the same image in large quantity? Print 30 Test Prints. 2 3 Go to Step 3. 2. Go to Step 4.

Replace the Engine Logic Board (page 8-89). Go to Step 8. Problem solved. 2. Install a new Drum Cartridge. Does the residual image appear? Yes Go to Step 5. Is the Earth Plate contaminated or deformed? Check the Drum Cartridge. 6 Go to Step 7. 8 Check that the HVPS is installed correctly? Is the HVPS installed correctly? Check the Engine Logic Board. 5 Correct and clean the Earth Plate or replace the Drum Cartridge. 7 Check the Heat and Pressure Roller. WARNING: Allow the Fuser to cool before attempting to remove it. Print a Test Print. 1. 1. No Clean the contacts. Go to Step 6. Remove the Drum Cartridge and check the Drum Cartridge High Voltage contacts. Replace the I/P Board (page 8-91). Remove the Drum Cartridge and check the Earth Plate located behind the Drum Cartridge. 9 Problem solved. Print 30 Test Prints. Check the Drum Cartridge ground.Residual Image Troubleshooting Procedure (Continued) Step 4 Actions and Questions Check Drum Cartridge installation. Are the contacts clean?. 2. Go to Step 9. Is there any contamination or defects on Heat or Pressure Roller? Replace the Fuser (page 8-76). Is the trouble rectified? Replace the HVPS. Remove the Fuser. Print-Quality Troubleshooting 5-39 .

Check the installation of the Drum Cartridge. The contamination appears as a very light gray dusting. If a non-Xerox Toner Cartridge is being used. and paper scraps. Check that the Drum Cartridge ground contacts are clean. Inspect the paper path for items. Background Troubleshooting Reference Applicable Parts ■ ■ ■ ■ ■ Example Print Drum Cartridge Transfer Roller High-Voltage Power Supply Engine Logic Board Image Processor Board. 1. paper clips.Background There is toner contamination on all or part of the page. No Problem solved. such as staples. Load new. Initial Actions ■ ■ ■ ■ ■ ■ ■ Check that the paper is clean. 5-40 Phaser 5500 Printer Service Manual . dry. dry paper. Verify the Toner Cartridge is a Xerox manufactured part. this could be the problem. 2. Ensure the covers are in place and no outside light enters the printer. and meets specifications. Print a Test Print. s5500-069 Background Troubleshooting Procedure Step 1 Actions and Questions Check paper condition. Does the problem still occur? Yes Go to Step 2. Check that the Laser Window is clean.

2. Go to Step 7. 6 Check image transfer. Check the Transfer Roller for contamination and wear. Install a new Drum Cartridge. Go to Step 5. Problem solved. Replace the HVPS (page 8-86). and easy to read? Go to Step 6. 1. 7 Problem solved. Print a Test Print. Turn off the power while printing. Is the paper path clear? Check the Drum Cartridge. Go to Step 4. 1. 2. 5 Check image development. Go to Step 8. No Remove obstacles or contamination. 2. Print a Test Print. Is the image density normal? Yes Go to Step 3. Is the image completely formed on the drum? Is it clear. 1. 4 Checking the Transfer Roller. Replace the I/P Board (page 8-91). black.Background Troubleshooting Procedure (Continued) Step 2 3 Actions and Questions Check the paper path. Remove the Transfer Roller. Replace the Engine Logic Board (page 8-89). Re-print the defective image. Print a Test Print. 1. 1. Print-Quality Troubleshooting 5-41 . Carefully remove the Drum Cartridge and check the image formed on the drum right before the Transfer Roller. Is the trouble rectified? Go to Step 8. 8 Check the Engine Logic Board. 3. Go to Step 7. right after the Transfer Roller. Is the trouble rectified? Problem solved. Is there any contamination or wear on the Transfer Roller? Replace the Transfer Roller (page 8-44). 2. Is the image completely transferred on the paper? Check the HVPS. 2. Check the image formed on the drum.

No Problem solved.Uneven Density Image density varies across the page in either direction. Uneven Density Troubleshooting Reference Applicable Parts ■ ■ ■ Example Print Drum Cartridge Transfer Roller Fuser s5500-070 Uneven Density Troubleshooting Procedure Step 1 Actions and Questions 1. Install a new Drum Cartridge. contamination. or obstructions. Does the test print output image contain uneven print? Yes Go to Step 2. 2. Check that the Toner Cartridge is properly installed and not empty. dry paper that meets specifications. Ensure that the printer is reasonably level. Initial Actions: ■ ■ ■ ■ ■ Load new. 5-42 Phaser 5500 Printer Service Manual . Remove the Drum Cartridge and check for wear. Print a test print. Check to make sure the Laser path is clean and unobstructed.

Check the image formed on the drum. Is the image completely formed on the drum? Is it clear. Does the print on the paper have even density? Go to Step 4. right after the Transfer Roller. Replace the Transfer Roller (page 8-44). 4 Replace the Fuser Assembly (page 8-76). 1. No Repair or replace the Transfer Roller (page 8-44). Is the image completely transferred on the paper? Look at the print on the paper before the Fuser. Repair or replace the Transfer Roller (page 8-44). Print-Quality Troubleshooting 5-43 . black. 3. and easy to read? Yes Go to Step 3. 2. Carefully remove the Drum Cartridge and check the image formed on the drum right before the Transfer Roller. 3 Check image transfer. Print a Test Print. Turn off the power while printing.Uneven Density Troubleshooting Procedure Step 2 Actions and Questions Check image development.

or debris. Problem solved. Does the problem still occur? Yes Go to Step 2. If problem persists. Load new. Is the printer insalled on a level surface? Check the paper. Remove obstacles or contamination. damage. 2. 1. go to Step 2. Check the rollers in the paper path for any obstructions. No Correct the installation. Initial Actions ■ ■ ■ ■ Check that the paper guides are set correctly. Ensure the Drum Cartridge is properly installed. dry paper that meets specifications. Print a Test Print. 3 Check the paper path.Skewed Image The image is not parallel to the edges of the print sheet. Skewed Image Troubleshooting Reference Applicable Parts ■ ■ ■ ■ Example Print Drum Cartridge Engine Logic Board Image Processor Board Tray s5500-071 Skewed Image Troubleshooting Procedure Step 1 Actions and Questions Check the installation site. Reload new. 2 Go to Step 3. Is the paper path clear? Go to Step 4. 5-44 Phaser 5500 Printer Service Manual . dry paper in the source tray.

replace in sequence as necessary: Feed. Check the rollers in the paper path for contamination. Check that the paper supply is new. Retard Rollers ■ Take Away Clutch ■ Feeder Assembly ■ Registration Transport Assembly. replace in sequence as necessary: ■ ■ ■ ■ ■ Example Print s5500-072 Laser Assembly Image Processor Board Drum Cartridge Tray Print-Quality Troubleshooting 5-45 . wear or damage to the rollers? Yes Replace defective rollers. dry. Check whether pinch rollers rotate freely and spring pressure is applied evenly. From all trays in the process direction. In the scan direction. replace the Registration Transport Assembly. and loaded correctly. Check that the paper tray guides are set correctly. Is there any contamination. wear. No Go to Step 5. From a specific tray in the process direction. 1. Registration The image is positioned incorrectly in either the process or scan direction. 2. Nudger. or damage.Skewed Image Troubleshooting Procedure (Continued) Step 4 Actions and Questions Check rollers in the paper path. replace Duplex Unit. Registration Troubleshooting Reference Applicable Parts If Duplex only. Check that components in the paper path are clean and unobstructed. Initial Actions: ■ ■ ■ ■ Check to ensure that the paper is within specification.

Print duplex prints if a duplex option is installed. Problem may be application related. Are the customer’s prints correctly registered? Problem solved. Have the customer contact Xerox Customer Support. replace the I/P Board (page 8-91). No Go to Step 2. 3 Have the customer run a print job. If the problem persists. Is the image registration correct after the adjustment? Yes Go to Step 3. Is the image registration within specifications? Perform the registration adjustment procedure. 2 Problem solved.Registration Troubleshooting Procedure Step 1 Actions and Questions Print Test Prints from all paper trays. Replace the Engine Logic Board (page 8-89). 5-46 Phaser 5500 Printer Service Manual .

Check that the paper supply is new. Does the printed image still have skips/smears? Replace the Transfer Roller. Check the paper path for any obstructions or debris. Problem solved.Skips and Smears Initial Actions: ■ ■ ■ Check to ensure that the paper is within specification. Problem solved. 2 Go to Step 3. and loaded correctly. Does the printed image still have skip/smears? Replace in sequence as necessary: ■ ■ ■ Yes Go to Step 2. No Problem solved. Skips/Smears Troubleshooting Reference Applicable Parts ■ ■ ■ Example Print Drum Cartridge Transfer Roller Fuser XEROX XEROX XEROX Skips/Smears Troubleshooting Procedure Step 1 Actions and Questions Replace the Drum Cartridge. dry. 3 Go to Step 4. Does the printed image still have skips/smears? Replace the Fuser. 4 Registration Transport Assembly (page 8-49) Main Motor (page 8-84) Take Away Bracket (page 8-40) Print-Quality Troubleshooting 5-47 .

5-48 Phaser 5500 Printer Service Manual .

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

In the example. From the Main menu. then press the OK button. then press the OK button. select Edge-to-Edge Printing. The Print Quality test print aids in the evaluation of print quality and in making registration adjustments. and text. then press the OK button. Select Print Quality Problems. 2. the printer prints two images. then press the OK button. otherwise. the printer prints 10 pages when duplexing is off (in the Paper Handling Setup submenu) or five 2-sided prints when duplexing is on. Select the print parameter that you want to change. as shown in the sample on the following page. select Printer Setup.Laser off Print Quality Test Print The Print Quality test print contains blocks. The printer automatically doubles the image quality selected. 3. From the Main menu. lines. select Troubleshooting. Insure that Edge-to-Edge Printing. select the PCL Setup submenu. then press the OK button. For example. Select the submenu containing the print parameter that you want to change. 6-2 Phaser 5500 Printer Service Manual . is set to Off before printing the test print. located under the PCL Setup menu. Note The printer prints the test print using the job defaults established in the Printer Setup menu.Service Test Prints There are five test prints stored in the printer that are primarily intended for service use: ■ ■ Print Quality Test Print Engine Test Prints (from Service Diagnostics) ■ ■ ■ ■ Grid Pattern Stripe pattern Dark pattern Blank . patterns. to change Edge-to-Edge Printing. if one page is selected. 3. Select Test Prints. see page 5-2. To print a Print Quality Test Print: 1. the image is shifted left. As an example. To set or change the job defaults: 1. For more details about analyzing Test Prints. 2. If the default Print Quantity (in the General Setup submenu) is 5. then press the OK button.

When you have finished setting all the parameters. In most cases. then press the OK button.4. In other cases. Print Quality Test Print Test Print Phaser5500-040302-2-L 8.5x11 (LEF Only) LEAD EDGE s5500-619 Adjustments and Calibrations 6-3 . 5. you press the OK button to toggle the setting between On and Off. you make a choice from several alternatives. select Exit and press the OK button to return the printer to the Ready state.

If any registration measurement does not meet the specification. perform registration testing on all input trays in both simplex and duplex modes. then press the OK button. select Troubleshooting. Once set to factory defaults. Start the registration adjustment procedure by verifying that the current settings in NVRAM are at the factory defaults of 50 for the scan direction and 33 for the process direction. 4. Select Test Prints. use the Printer NVRAM Adjustments utilities found in Service Diagnostics to make the necessary registration adjustments. Use the job defaults to change the supply tray and mode to generate Print Quality test prints from each source. For the scan direction. From the Main menu. 1. then press the OK button. Select Print Quality Problems. 3.Adjustments Checking Registration This procedure checks the printer registration in the horizontal (scan) direction and the vertical (process) direction for both simplex and duplex printing. fold the test print like this: s5500-052 6-4 Phaser 5500 Printer Service Manual . then press the OK button. side-to-side. Depending on your job settings. 2. two or more Print Quality Test prints should print.

s5500-051 6.5 mm in either direction.5. Maximum deflection from the centerline is 2. Check the point where the fold line intersects the target. Adjustments and Calibrations 6-5 . increments. fold the test print as shown below. For the Process direction. The target lines are graduated in 1 mm. leading to trailing edge. If the fold line falls more than 2.5 mm from the target. use the following procedure to realign the image on the paper.

254 mm change in the image position. increasing the value moves the image toward the trail edge and decreasing the value moves the image towards the lead edge. 6-6 Phaser 5500 Printer Service Manual . In general. 2. Note In the scan direction. Exit Service Diagnostics and reprint the Print Quality test print.363mm closer or further from the edge of the paper. For the process direction the factory default is 33. 7. The maximum is 66 and the minimum is zero (0). check that duplex registration remains within specification. In the process direction. 3. Fold as before to verify your adjustments. each variable is set at the factory to a value of 50. Select Printer NVRAM Adjustments. 5. Enter Service Diagnostics. 6. Registration changes are made by increasing or decreasing the stored value that controls the image position on the page. then press the OK button. adjustment changes are automatically replicated for duplex prints. Repeat Steps 1 through 8 until simplex registration is corrected. 1. The maximum for scan direction adjustments is 99 with a minimum of 1. Press the OK button to save the setting. it is best to make registration adjustments for individual trays. or for all trays in the process direction.Adjusting Simplex Registration Note When making scan direction adjustments. 9. 4. Press the Back button. Use the Up Arrow and Down Arrow buttons to set the new value based on measurements taken from the target area. Changes to the current value for process direction variables by one (1) moves the leading edge of the image . Limit use of the All Trays utilities to only those instances when testing indicates a general misalignment condition exists. Increasing or decreasing a scan direction value by one (1) results in a . Following a scan or all tray process direction adjustment. For scan direction adjustments. increasing the value moves the image down and decreasing the value moves the image up. then press the OK button. 8. Select either the process adjustment (Tray [#] Proc Dir) or scan adjustment (Tray [#] Scan Dir) for the desired tray.

1. If deflection of the fold line in either direction exceeds 2. 6. 5. Exit Service Diagnostics and reprint the Print Quality test print.5 mm. 9. Repeat Steps 1 through 8 until duplex registration is corrected. then press the OK button. 4. Use the job defaults under the Printer Setup menu to print multiple copies of the Print Quality Test print in two-sided (duplex) mode. Fold these prints as before and measure deflection of the fold line on the target. Adjustments and Calibrations 6-7 . use the following procedure to make the necessary duplex registration adjustments. Press the OK button to save the setting. 2.Adjusting Duplex Registration Duplex registration adjustment follows a similar procedure to simplex adjustments. 8. Select Printer NVRAM Adjustments. Enter Service Diagnostics. then press the OK button. Fold as before to verify your adjustments. 7. 3. Press the Back button. Select either the duplex process adjustment (Duplex Proc Dir) or scan adjustment (Duplex Scan Dir). Use the Up Arrow and Down Arrow buttons to set the new value based on measurements taken from the target area.

then press the OK button. 6. then press the OK button. select Printer Setup. 3. The default fuser temperature setting for each paper type is also noted. Colored. Letterhead. 2. Envelopes Prepunched To change the Fuser setting for a particular paper type: 1. Select Temperature for [paper type].Adjusting Fuser Temperature Four temperature settings. Special Transparency Plain Paper Mode 1 Medium Plain Paper Mode 1 (Default) High Thick Paper Mode 1 Extra High Thick Paper Mode 2 Transparency Paper Mode (Default) Plain Paper Mode 1 Plain Paper Mode 2 Plain Paper Mode 2 Plain Paper Mode 2 Thick Paper Mode 1 Plain Paper Mode 1 Plain Paper Mode 1 and (Default) Plain Paper Mode 1 Thick Paper Mode 4 (Default) Thick Paper Mode 1 (Default) Thick Paper Mode 1 Thick Paper Mode 1 Thick Paper Mode 2 Thick Paper Mode 2 Thick Paper Mode 2 Labels Card Stock. then press the OK button to place a check mark by that setting. Front Panel Fuser Temperature Modes by Paper Type Temperature Paper Type Low Plain. 6-8 Phaser 5500 Printer Service Manual . See "Fuser" on page 2-21 for additional information on Fuser temperature settings. listed in the following table. then press the OK button. From the Main menu. then press the OK button. Select Exit. 4. Note You must scroll up to see the Extra High setting. Select Fuser Configuration. Select a temperature setting from the four available. 5. are available for each paper type supported by the printer. then press the OK button. Select Paper Handling Setup.

Select Reset Fuser Life. 4. select Information. Select Reset Fuser Life NOW. Resetting the Printer to Default Values You can reset printer values on the following menus to the factory default settings: ■ ■ ■ ■ ■ ■ ■ ■ Connection Setup Paper Handling Setup PostScript Setup PCL Setup General Setup Front Panel Setup Printer Controls File Security (available if the printer has a hard drive) You can reset all of the Image Processor Board NVRAM-stored parameters to their factory default values by resetting the PostScript NVRAM. Select Supplies Info. Perform this procedure after you install a new Maintenance Kit.Resetting Fuser Life This procedure restarts the counter that tracks Fuser life. From the Main menu. Instructions for resetting PostScript NVRAM are in "Resetting Printer Default Settings (PostScript NVRAM)" on page 6-12. then press the OK button to reset the fuser life. Adjustments and Calibrations 6-9 . then press the OK button. 3. Note Resetting the Fuser Life counter also resets the Transfer Roller counter and all Tray Page counters to zero. Note There is no single reset for the Print Engine NVRAM. then press the OK button. To reset the Fuser: 1. 2. then press the OK button.

broadcast. etc. tray setup (default paper type/size). job offset. From the Main menu. 4. 6-10 Phaser 5500 Printer Service Manual . 3. fuser temperature configuration. and Edge-to-Edge Printing settings. 2. Caution Before resetting the connection setup values to factory default values. Select Reset Connection Setup. then press the OK button. EtherTalk. 2-sided printing. then press the OK button. Select PostScript Setup.). 2. select Printer Setup. Resetting Paper Handling Setup Values Resetting the paper handling setup values resets the default paper source. then press the OK button. 1. default paper destination. From the Main menu. Select Connection Setup. then press the OK button. Select Reset PostScript Setup. and Ethernet speed to their default values. Select Reset Paper Handling Setup. Resetting PostScript Setup Values Resetting the PostScript setup values resets the PostScript Error Info. then press the OK button. 4. Select Reset Connection Setup NOW. then press the OK button. Select Paper Handling Setup. make note of the current network settings or print a Configuration Page to record the printer’s current network settings. 3. then press the OK button. tray prompt. IPP. set IPX frame type.Resetting Connection Setup Values Resetting the connection setup values resets the Printer Name. 2. select Printer Setup. then press the OK button. Select Reset Paper Handling Setup NOW. output tray switch. then press the OK button. TCP/IP address. Image Smoothing. NetWare. select Printer Setup. 4. custom size paper units. TCP/ IP address menu settings (gateway. then press the OK button. 3. then press the OK button. tray sequence. load paper timeout. 1. Select Reset PostScript Setup NOW. 1. then press the OK button. From the Main menu. CentreWare IS. and reprint jammed pages settings.

then press the OK button. Adjustments and Calibrations 6-11 . then press the OK button. 2. then press the OK button. 4. and Print with Low Toner settings. Select Printer Controls. select Printer Setup. Select Front Panel Setup. 4. 3. then press the OK button. Select PCL Setup. 1. Resetting Printer Controls Setup Values Resetting the Printer Controls values resets the Startup Page. then press the OK button. then press the OK button. and Edge-to-Edge Printing settings. Print Quantity. 3. 1. then press the OK button. then press the OK button. 2. 4. From the Main menu. Select Reset General Setup. Front Panel Contrast. Select Reset PCL Setup. Select Reset Front Panel Setup NOW. Resetting Front Panel Setup Values Resetting the Front Panel values resets the Front Panel Language. then press the OK button. Resetting General Setup Values Resetting the General setup values resets the Print-Quality Mode. Select General Setup. Select Reset Front Panel Setup. select Printer Setup. Select Reset General Setup NOW. symbol set. 3. Power Saver Timeout. pitch. and Power Saver settings. From the Main menu. then press the OK button.Resetting PCL Setup Values Resetting the PCL Setup values resets the default font number. line termination character. From the Main menu. 1. select Printer Setup. orientation. then press the OK button. then press the OK button. select Printer Setup. 4. point size. and Accessible Front Panel settings. Front Panel Brightness. form length. 3. Select Reset Printer Controls. 2. then press the OK button. 1. then press the OK button. From the Main menu. then press the OK button. Select Reset Printer Controls NOW. then press the OK button. Select Reset PCL Setup NOW. 2.

select Printer Setup. Select File Security Setup. then press the OK button. and margin) to their factory default values. You can reset the PostScript NVRAM by: ■ ■ ■ Using the Main menu Using the Service Diagnostics menu Using the Front Panel Shortcut Using the Main Menu 1. 4. make note of the current network settings or print a Configuration Page to record the customer’s current network settings. 4. job defaults. The print counts and the Adobe firmware serial number are not affected by this reset. then press the OK button. 3. then press the OK button. From the Main menu. select Troubleshooting. Resetting the File Security values resets the settings that control making files deleted from the hard drive unrecoverable and control when old Proof and Secure Job Print files are removed from the hard drive. then press the OK button. then press the OK button to reset all the settings to their factory default values.Resetting File Security Setup Values The File Security settings are only available when the printer has a hard drive. then press the OK button. Caution Before resetting the printer default settings to factory default values. press the OK button. 2. Select Reset NVRAM. Select Reset File Security. 2. Select Reset File Security NOW. then press the OK button. 6-12 Phaser 5500 Printer Service Manual . From the Main menu. Select Reset NVRAM and Reset Printer NOW. Select Service Tools. 1. 3. Resetting Printer Default Settings (PostScript NVRAM) Resetting the PostScript NVRAM restores all printer values stored in the Image Processor Board (including network. printer setup.

4. press and hold the Up Arrow + Down Arrow buttons together within 2 seconds. Select IP NVRAM Access. then press the OK button. 3. While booting. The printer then exits Service Diagnostics and reboots. Adjustments and Calibrations 6-13 . 2. press the Back + OK buttons together. When Resetting NVRAM! Are you sure? is displayed. highlight Yes and press the OK button. At power-on. Using the Front Panel Shortcut 1. 2. press the OK button. When Password appears. With PostScript NVRAM Reset highlighted.Using the Service Diagnostics Menu 1. NVRAM is reset. Enter Service Diagnostics.

6-14 Phaser 5500 Printer Service Manual .

.Cleaning and Maintenance In this chapter.. ■ ■ ■ Service Preventive Maintenance Procedure Recommended Tools Cleaning Chapter 7 .

dry. Clean feed rollers with a lint-free cloth lightly dampened with water. 3. Fuser. and paper path. and damaged or obviously worn parts.5 mm hex-head Nut Driver Toner vacuum cleaner Clean water Clean. Recommended Tools ■ ■ ■ ■ ■ 5. or repair a printer. place it in a light protective bag.Service Preventive Maintenance Procedure Perform the following procedures whenever you check. assures proper operation of the printer and reduces the probability of having to service the printer in the future. 9. Vacuum out any loose toner with a Type II toner vacuum only. The frequency of use and the type of paper a customer prints on determines how critical and how often cleaning is necessary. Cleaning the printer. Remove the I/P Board and Upper Rear covers and clean the Fuser Fan with a brush or dry cloth to remove excess dust and toner. 8. lint-free cloth Black. Print to all output trays and staple or punch if Finisher is installed. 6. 2. 5. Note Never use a damp cloth to clean up toner. 7. Remove any debris or foreign objects from the Transfer Roller. replace with a new one. 10. loose connections. Laser Assembly. as outlined in the following steps. 4. 7-2 Phaser 5500 Printer Service Manual . Turn off the printer and disconnect the Power Cord. service. toner leakage. If you remove the Drum Cartridge. Inspect the interior of the printer for damaged wires. Print several sheets of paper to check for problems or defects. Remove and clean all paper trays. Record number of sheets printed. light protective bag Cleaning Caution Never apply alcohol to any parts in the printer. 1. If the Drum or Toner Cartridges appear damaged.

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

Overview This section contains the removal and replacement procedures for spared parts according to the Field Replaceable Units (FRUs) Parts List. front. or rear. left. assume you are facing the printer Front Panel. front and back sides of the printer Rear Right Left Front s5500-075 8-2 Phaser 5500 Printer Service Manual . Replacement Notes provide tips and suggestions that can aid in reassembling the part. such as left. re-installing a part only requires reversing the removal procedure. Replacement procedures are not provided for most of the FRUs because in most cases. right. Where the replacement process is not a simple reversal of the removal. When needed the orientation of the printer is called out in the procedure for locating printer parts. refer to the printer orientation graphic for locating the right. Standard Orientation of the Printer Locations given in the repairs. a replacement procedure is included.

General Notes on Disassembly Removal and replacement procedures are organized in eight major categories. a part called the Registration Chute Assembly may appear on the Parts List as Assembly. For example. Remove the Fuser Assembly or wait at least 5 minutes after you have switched Off printer power for the Fuser to cool before you work on or around the Fuser. Disconnect all computer interface cables from the printer. observe their assembling condition before starting the service. Wear an electrostatic discharge wrist strap to help prevent damage to the sensitive electronics of the printer circuit boards. ■ ■ ■ ■ ■ ■ ■ ■ ■ Print Engine Covers Upper Transportation and Registration Trays and Feeders Tray 1 Lower Transportation and Registration Xerographics Fuser and Exit 1 Drive Electrical Parts are controlled as spare parts. Switch Off the printer power and disconnect the power cord from the wall outlet. Preparation Before you begin any Removal and Replacement Procedure: 1. DO NOT over Flex or force these parts. Do not over torque the screws threaded into plastic parts. Caution Many parts are secured by plastic tabs or hooks. 3. Note Names of parts that appear in the disassembly procedures may not be exactly the same as the names that appear in the Parts List. Chute REGI. 4. these categories roughly correspond to classification of FRU parts list in Chapter 10. FRU Disassembly 8-3 . When servicing for parts for which no procedures are described. 2. Remove the Drum Cartridge and protect it from exposure to light by covering it with a light proof bag or by placing it in a light-tight container.

Caution Always use the correct type and size screw. Using the wrong screw can damage tapped holes. Do not use excessive force to either remove or install either a screw or a printer part. Caution Do not remove red screws. Frame mis-alignment will result. Warning Unplug the AC power cord from the wall outlet before removing any printer part.

Notations in the Disassembly Text

The notation “PLX.X.X” at the top of each Figure references the FRU parts list containing this part or assembly. Page number references are given in-line for procedural steps previously described. Bold arrows in an illustration show direction of movement when removing or replacing a component. Numbered arrows indicate manipulation steps for removal of the part.

8-4

Phaser 5500 Printer Service Manual

Print Engine Covers
Front Left Cover
1. Open the Front Door. PL1.1.2

Front Left Cover
2. Remove the one screw securing the Front Left Cover. 3. Remove the Front Left Cover.

s5500-076

FRU Disassembly

8-5

Top Rear Cover
PL1.1.3

Top Rear Cover

Upper Rear Cover
s5500-077

1. Remove the Rear Panel Cover (page 8-12). 2. Remove the Upper Rear Cover (page 8-15). 3. Remove the screw securing the Top Rear Cover. 4. Remove the Top Rear Cover by sliding it left then lifting as shown.

8-6

Phaser 5500 Printer Service Manual

Top Cover
Caution Use care not to catch the the Stack Full sensor flag while removing the cover. 1. Open the Front Door. 2. Remove the Front Left Cover (page 8-5). PL1.1.8

Top Cover

Connector

s5500-078

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

FRU Disassembly

8-7

Front Door
1. Open the Front Door. PL1.1.9

B

Front Cover A

s5500-079

2. Release the Stopper from the Inner Main Cover. 3. Open Tray 2 halfway. 4. Lower the Front Door perpendicular to the printer and slide the Front Door to the right to release the lower right holder from the boss on the right of the printer. 5. With the lower right holder released, hold the cover at a slight angle to the printer and slide it to the left to release the lower left holder from the boss.

8-8

Phaser 5500 Printer Service Manual

Inner Main Cover
1. Remove the Top Cover (page 8-7). 2. Remove the Front Door (page 8-8). 3. Remove the Left Front Cover (page 8-5). PL1.1.13

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

FRU Disassembly

8-9

Front Door Interlock Switch
1. Remove the Top Cover (page 8-7). 2. Remove the Front Door (page 8-8). 3. Remove the Front Left Cover (page 8-5). 4. Remove the Inner Main Cover (page 8-9). PL1.1.5

Bracket Switch
s5500-082

5. Remove the screw securing the Interlock Switch Bracket. 6. Remove the switch together with the bracket. 7. Disconnect the connector from the switch. 8. Release the switch by pressing the hooks. 9. Remove the switch.

8-10

Phaser 5500 Printer Service Manual

Upper Right Cover
PL1.2.1

Upper Right Cover

Lower Right Cover
s5500-083

1. Remove the two screws securing the Upper Right Cover. 2. Lower the Upper Right Cover to release the upper rib. 3. Remove the Upper Right Cover. Replacement Note Be sure to secure the lower rib on the Upper Right Cover to the upper part of the Lower Right Cover.

FRU Disassembly

8-11

Rear Panel Cover
PL1.2.4

Rear Panel Cover
1. Open the Rear Panel Cover.

s5500-084

2. Remove the lower boss securing the Rear Panel Cover to the printer. It is easier to remove by pushing down the retainer of the boss.

8-12

Phaser 5500 Printer Service Manual

Lower Right Cover
1. Remove the Upper Right Cover (page 8-11). 2. Pull out Trays 2 and 3 at least partially. PL1.2.2

Lower Right Cover

s5500-

3. Remove the Lower Right Cover by lifting upwards to release the hooks, then outward.

FRU Disassembly

8-13

I/P Board Cover
PL8.1.20

I/P Board Cover

s5500-087

1. Loosen the two captive thumbscrews securing the I/P Board Cover. 2. Remove the I/P Board Cover by moving it in the direction of the arrow.

8-14

Phaser 5500 Printer Service Manual

Upper Rear Cover
1. Remove the I/P Board Cover (page 8-14). PL1.2.5

Upper Rear Cover

s5500-088

2. Remove the two screws securing the Upper Rear Cover to the printer. 3. Remove the Upper Rear Cover by moving it in the direction of the arrow.

FRU Disassembly

8-15

1.2. Lower Rear Cover 1. Remove the Upper Rear Cover (page 8-15). PL1.Tray 1/MPT Rear Cover PL3.6 Rear Lower Rear Cover s5500-627 8-16 Phaser 5500 Printer Service Manual . Remove the one screw securing the Tray 1/MPT Rear Cover to the frame.14) Tray 1/MPT Cover s5500-089 1. Remove the I/P Board Cover (page 8-14). 2.

Option Interface Cover PL1. Remove the two screws securing the Lower Rear Cover to the frame.3. Replacement Note Attach the four lower hooks on the Lower Rear Cover to the bracket on the printer. Remove the Lower Rear Cover by tilting the top outwards slightly then lifting the cover up and out.7 Option Interface Cover s5500-090 1. 4. FRU Disassembly 8-17 . Remove the Option Interface Cover from the Lower Rear Cover by moving the Option Interface Cover in the direction of the arrow.2.

Exit 1 Top Cover PL6. 8-18 Phaser 5500 Printer Service Manual . Remove the Exit 1 Top Cover by moving it in the direction of the arrow.22 Exit 1 Top Cover s5500-091 1.2.

3. remove the Engine Logic Board (page 8-89). PL2. Use this procedure to replace either the Tray 2 or Tray 3 Paper Size switches. 1. Remove the Lower Rear Cover (page 8-16).Upper Transportation and Registration Paper Size Switches Both paper size sensing switch arrays are located behind the AC Accessory Panel. Note To remove the Tray 2 switch. Remove the Upper Rear Cover (page 8-15). Remove the three screws securing the AC Accessory Panel. and loosen the Engine Logic Board Bracket. 2. s5500-092 FRU Disassembly 8-19 . Remove the I/P Board Cover (page 8-14).1.4 AC Accessory Panel Paper Size Switch Switch Bracket 4.

Remove the switch together with the bracket. 7. Disconnect the connector from the switch. Disconnect the connector. 8-20 Phaser 5500 Printer Service Manual . Tray 2 Feeder 1. 8. Remove the two screws securing the Feeder to the frame. Remove the one screw securing the switch to the bracket. 8. Release the harness from the two clamps on the frame. Remove the Tray 1/MPT Rear Cover (page 8-16) 2. Replacement Note When installing the Feeder. Remove Door A (page 8-46). Clamp Harness Connector Tray 2 Feeder s5500-094 7. 6. and transfer the Feed Out Chute to the new Feeder. fit the two bosses on the frame into the holes on the Feeder. Remove the Take Away Bracket (page 8-40). 9. Release the harness clamps on the AC Accessory Panel. Remove Tray 2. Remove the Feeder by moving it in the direction of the arrow. 6. 4. Remove the two screws securing the switch bracket. 9.5. 5. 3. Remove the Tray 1/MPT Feeder (page 8-32).

Release the boss on the both ends on the Feed Out Chute securing it to the frame. Remove the two screws securing the Take Away Chute to the frame. Remove the Take Away Bracket (page 8-40). Pull out Tray 3. PL2.1. 4. Release these latches before attempting to remove the Take Away Chute. Open Door B. 5. Remove the Tray 1/MPT Rear Cover (page 8-16). 3. 6. FRU Disassembly 8-21 . Release the right side first and remove the chute. 2. 8. Remove the Tray 1/MPT Feeder (page 8-32). Caution The Take Away Chute is easily damaged if the latches located on the backside of the chute are not released before attempting to remove the chute from the frame. Remove Door A (page 8-46).Tray 3 Feeder 1.7 Boss Boss Feed Out Chute Door B s5500-095 7.

9. Take Away Chute Bearing Gear-18T Take Away Roller E-Ring Bearing Sleeve s5500-096 8-22 Phaser 5500 Printer Service Manual . Reach in and release the latch at the center of the Take Away Chute from behind and remove the chute.

Remove the Tray 1/MPT Rear Cover (page 8-16). Release the harness from the two clamps on the frame. When installing the Take Away Chute. Replacement Note When installing the Feeder. Remove Door A (page 8-46). Remove the Tray 1/MPT Feeder (page 8-32). FRU Disassembly 8-23 . 14. Remove the Take Away Roller assembly (page 8-41). 2. fit the bosses on the Take Away Chute into the holes on the frame. Harness Connector Tray 3 Feeder s5500-097 11. Remove the Take Away Bracket (page 8-40). 12. 3. fit the two bosses on the frame into the holes on the Feeder. Remove the Feeder by moving it in the direction of the arrow. Remove the two screws securing the Feeder to the frame.10. Disconnect the connector. 4. 13. Feed/Lift Motor 1.

8. 8-24 Phaser 5500 Printer Service Manual .3. Remove Door A (page 8-46). 3. Remove the Tray 2 Feeder (page 8-20) or Tray 3 Feeder (page 8-21). Remove the Take Away Bracket (page 8-40). Remove the Feed/Lift Motor. Remove the two Phillips screws securing the Feed/Lift Motor to the Feeder. Disconnect the connector from the Feed/Lift Motor. 2. Remove the Tray 1/MPT Rear Cover (page 8-16).2 Feeder Assembly Feed/Lift Up Motor Connector s5500-104 6. Tray 2 and 3 No Paper Sensor 1. 7. 4. Remove the Tray 1/MPT Feeder (page 8-32).5. PL2.

Remove the Tray 2 Feeder (page 8-20) or Tray 3 Feeder (page 8-21). Disconnect the connector from the No Paper Sensor. PL2. 8. 7.5. Tray 2 and 3 Level Sensor Actuator 1.14 Feeder No Paper Sensor Harness Hooks Upper Frame s5500-109 6. Release the hooks securing the Sensor to the Upper Frame as shown in the figure. Remove Door A (page 8-46). Remove the Take Away Bracket (page 8-40). 4. Remove the No Paper Sensor. Remove the Tray 1/MPT Feeder (page 8-32).3. 2. FRU Disassembly 8-25 . Remove the Tray 1/MPT Rear Cover (page 8-16). 3.

then reach in and release the actuator bosses from the feeder assembly. Release the two bosses on the Actuator securing the Actuator to the Upper Frame. 7.5. Remove the Actuator. 8-26 Phaser 5500 Printer Service Manual . PL2. Remove the Tray 2 Feeder (page 8-20) or Tray 3 Feeder (page 8-21). Note As an alternate procedure.13 Feeder Bosses Actuator Upper Frame s5500-108 6.3. remove Trays 2 and 3.

14 Feeder Harness Level Sensor Hook Upper Frame Hooks s5500-110 7. 6. FRU Disassembly 8-27 . Remove the Level Sensor Actuator (page 8-25). Remove the Tray 1/MPT Feeder (page 8-32). 8. 5. 2. 3. PL2. Remove the Tray 2 Feeder (page 8-20) or Tray 3 Feeder (page 8-21). Remove Door A (page 8-46). Remove the Take Away Bracket (page 8-40). Release the hooks securing the Level Sensor to the Upper Frame as shown in the figure.Tray 2 and 3 Level Sensor 1. 4. Disconnect the connector from the Level Sensor and remove the sensor. Remove the Tray 1/MPT Rear Cover (page 8-16).3.

Remove Door A (page 8-46). Remove the Tray 1/MPT Feeder (page 8-32).3. Disconnect the connector from the Pre-Feed Sensor.Tray 2 and 3 Pre-Feed Sensor 1. 3. Remove the Tray 2 Feeder (page 8-20) or Tray 3 Feeder (page 8-21). Remove the Tray 1/MPT Rear Cover (page 8-16). Remove the Pre-Feed Sensor from the Front Chute as shown in the figure. 8-28 Phaser 5500 Printer Service Manual . Remove the Take Away Bracket (page 8-40).15 Feeder Pre Feed Sensor s5500-111 6. 7. PL2. 4. 5. 2.

Move the Front Chute in the direction of the arrow. 3. Release the hook securing the Feed Roller to the Shaft and remove the Feed Roller. Remove the tray.3.Feed Roller 1. FRU Disassembly 8-29 .20 Shaft Oneway Gear (22T) Oneway Clutch Feed Roll Front Chute s5500-114 2. PL2.

Release the hook securing the Retard Roller to the Shaft as shown in the figure.Retard Roller 1.3. Remove the Retard Roller. 3. 8-30 Phaser 5500 Printer Service Manual .28 Front Chute Support Assembly Retard Roller s5500-117 2. PL2. Remove the tray.

FRU Disassembly 8-31 .3. Release the hook securing the Nudger Roller to the Shaft as shown in the figure. Remove the tray. 4. Remove the Nudger Roller. 3. PL2.32 Support Assembly Nudger Roller Front Chute s5500-120 2. Move the Front Chute in the direction of the arrow.Nudger Roller 1.

1.1 Tray 1 Feeder s5500-124 2. Disconnect the connector from the printer. 5. 4. Release the harness from the clamp. Remove the two screws securing the Tray 1/MPT Feeder to the frame. Remove the Tray 1 Feeder. 3. Replacement Note Place the harness along the slot on the left of the Feeder to avoid pinching the harness between the Feeder and the Frame 8-32 Phaser 5500 Printer Service Manual .Tray 1 Disassembly Tray 1 Feeder 1. PL3. Remove the Tray 1/MPT Rear Cover (page 8-16).

2. then pull it out of the hole in the upper frame. 4. 5. Remove the two hooks securing the upper frame to the printer. Remove the upper frame by moving it in the direction of the arrow. PL3.1. Pull the right side of the Actuator toward you. FRU Disassembly 8-33 . press on both sides of the actuator pivot point to avoid breaking the part. Remove the Tray 1/MPT Rear Cover (page 8-16).3 Upper Frame Hook (Upper Frame) Slot Actuator s5500-125 3. Replacement Note When installing the actuator into the Upper Frame. Remove the Tray 1/MPT Feeder (page 8-32).Tray 1/MPT No Paper Sensor Actuator 1.

Disconnect the connector from the sensor. 5. Remove the Tray 1/MPT Feeder (page 8-32).1. PL3. and move the Upper Frame in the direction of the arrow to remove. 8-34 Phaser 5500 Printer Service Manual . Remove the Tray 1/MPT Rear Cover (page 8-16). 4. Release the two hooks securing the Upper Frame to the Tray 1 Feeder.Tray 1/MPT No Paper Sensor 1. Remove the sensor. 6. Release the hooks securing the sensor to the Tray 1 upper frame.4) Upper Frame Connector Hook (Upper Frame) Slot No Paper Sensor s5500-126 3. 2.

Remove the Tray 1/MPT Rear Cover (page 8-16). 2. FRU Disassembly 8-35 .2. Replacement Note Slide the Pick Up Gear until it locks on the Stopper Lever. Remove the Tray 1/MPT Feeder (page 8-32).Pick Up Gear Spring 1. PL3. Remove the Spring from the Gear Bracket and Pick Up Gear.6 Tray 1 Feeder Pick Up Gear Pick Up Gear Spring Hook Pick Up Shaft Gear Bracket s5500-129 3.

Remove the Feed Roller (page 8-38). Remove the Tray 1 Feeder (page 8-32). 3. Cam Gear Spring 1. 2. 4. Remove the Pick Up Gear (page 8-35). 3. Remove the Tray 1/MPT Rear Cover (page 8-16). 5.2. Remove the Cam Gear and Spring (page 8-36). Disconnect the connector from the Pick Up Solenoid. Remove the three screws securing the Gear Bracket to the Tray 1 Feeder to remove the Gear Bracket. 4.15 Gear Lever Pick Up Solenoid Lower Frame s5500-131 5. Leave the other end of the Spring connected to the Pick Up Gear. Remove the one screw securing the Pick Up Solenoid to the Gear Bracket. Remove the three screws securing the Gear Bracket to the Tray 1 Lower Frame. 7.Tray 1 Pick Up Solenoid 1. 8. Remove the Spring from the Gear Bracket. Remove the Tray 1/MPT Feeder (page 8-32). Remove the Tray 1/MPT Rear Cover (page 8-16). 2. 6. PL3. 8-36 Phaser 5500 Printer Service Manual . Lower the Gear Lever in the direction of the arrow and remove the Pick Up Solenoid.

16 Cam Gear Stopper Lever Hook Spring Pick Up Shaft Bearing 8 Cam Gear Pick Up Gear Pick Up Cam E-Ring E-Ring Bearing 8 Lower Frame Gear Bracket s5500-132 FRU Disassembly 8-37 .6.2. remove the Pick Up Gear together with the Spring. 7. Cam Gear and Stopper Lever. While releasing the hooks securing the Pick Up Gear to the Pick Up Shaft. Remove the Cam Gear Spring securing the Pick Up Gear to the Cam Gear. PL3.

and slide the Feed Roller outward. Remove the Feed Roller from the Pick Up Shaft by moving it in the direction of the arrow (to the front). Remove the Tray 1/MPT Feeder (page 8-32). PL3. 5. 4.2. Note the orientation of the roller and remove the Pinch Chute. 2. While releasing the two hooks of the Roller Core left and right securing the Feed Roller to the Pick Up Shaft as shown in the figure. Remove the Tray 1/MPT Rear Cover (page 8-16).20) Pinch Chute Feed Roller Hook Roller Core Hook Pick Up Shaft Pin Lower Frame Roller Core s5500-133 3. 8-38 Phaser 5500 Printer Service Manual .Feed Roller Assembly 1. Remove the two screws securing the Pinch Chute to the Tray 1/MPT Lower Frame.

3. FRU Disassembly 8-39 . Remove the Retard Pad and the Retard Shaft by moving it in the direction of the arrow.2. Remove two Pad Springs under the Retard Pad. Grip each spring firmly when removing them. The Retard Pad is held down by the force of the Feed Roller. Remove the Feed Roller (page 8-38). PL3. 5.Retard Pad 1.12 Retard Pad Pad Spring Retard Shaft Lower Frame Retard Shaft s5500-134 Caution The Retard pad springs are easily lost. Remove the Tray 1/MPT Rear Cover (page 8-16). from the backside. 2. Remove the Tray 1/MPT Feeder (page 8-32). 4.

1 Take Away Bracket Door B s5500-139 5. Remove the Tray 1/MPT Feeder (page 8-32). Remove the two screws securing the Take Away Bracket to the printer. Remove the Tray 1/MPT Rear Cover (page 8-16).1. Open Door B. PL4. 4. Remove Door A (page 8-46). Disconnect the Door B Interlock Switch from the harness and remove the Take Away Bracket. 8-40 Phaser 5500 Printer Service Manual . 7. 6.Lower Transportation and Registration Take Away Bracket 1. 2. Disconnect the harness and release the harness from the clamp on the Take Away Bracket. 3.

3 Take Away Bracket Door B Interlock Switch Door B s5500-140 2. Remove the Tray 1/MPT Rear Cover (page 8-16). Take Away Roller Assembly 1. PL4. 3. 2. Release the hooks securing the switch to the Take Away Bracket. Remove the Door B Interlock Switch. Disconnect the connector from the switch. Remove Door A (page 8-46).Door B Interlock Switch 1. 3. FRU Disassembly 8-41 .1. 4. Remove the Tray 1/MPT Feeder (page 8-32). Open Door B.

4. 7. Remove the Take Away Roller by moving it in the direction of the arrow. Remove the K-clip on the right side.8 Take Away Chute Bearing Gear-18T Take Away Roller E-Ring Bearing Sleeve s5500-096 Caution The Take Away Chute is easily damaged if the latches located on the backside of the chute are not released before attempting to remove the chute from the frame. 6. Release these latches before attempting to remove the Take Away Chute. PL4. Caution The Take Away Bearing and Gear 18T are not captive on the shaft. securing the Take Away Roller to the frame. Remove the two screws securing the Take Away Chute to the frame. 8-42 Phaser 5500 Printer Service Manual . 5. 8. Use care to capture these parts as you remove the shaft. Open Door B. Reach in and release the latch at the center of the Take Away Chute from behind and remove the chute.1.

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

PL4. Pinch the hooks at each end of the Transfer Roller and lift to remove the Transfer Roller from the chute.1 Transfer Roller Hook Hook Left s5500-598 2. Open Door A.Transfer Roller 1. 8-44 Phaser 5500 Printer Service Manual .2.

Door A Interlock Switch 1. 4. Remove the I/P Board Cover (page 8-14). 2. Remove the Upper Rear Cover (page 8-15). Remove the switch from the bracket by compressing the hooks. 5. FRU Disassembly 8-45 . Remove the single screw securing the Door A Interlock Switch to the frame. Door A Interlock Switch Bracket Rear s5500-623 3. Disconnect the switch from the harness and remove the switch and bracket from the Printer.

Door A 1. 8-46 Phaser 5500 Printer Service Manual .8 Door A s5500-144 2. Remove Door A by moving it in the direction of the arrow. Remove the screw securing the Stopper to the Door.2. Remove the Door A (page 8-46). 3. PL4. Registration Roller 1. Open Door A.

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

3 Bearing Transfer Roller Registration Pinch Roller L/H Chute Door A Hooks s5500-146 5. Remove the hooks of the two Pinch Out Bearings on the left and right securing the Registration Rollers to the Chute as shown in the figure. PL4.4.3. 8-48 Phaser 5500 Printer Service Manual . Move the Registration Rollers in the direction of the arrow to remove.

FRU Disassembly 8-49 .1 Registration Transport Assembly Chute-R Registration Transport Assembly Pinch Roller Pinch Roller Boss Feed Out Chute Boss Connector Clamp Connector Left View s5500-147 4. Remove the Tray 1/MPT Feeder (page 8-32). 2. Release the bosses on each end of the Feed Out Chute starting with the right end and remove the Feed Out Chute. Remove Door A (page 8-46). 3. Remove the Tray 1/MPT Rear Cover (page 8-16).5.Registration Transport Assembly 1. PL4.

Extract the Registration Transport Assembly from the frame by moving it in the direction of the arrow. Release the harness from the clamp. Using a small screwdriver. 8. 10. 8-50 Phaser 5500 Printer Service Manual . Remove the Pinch Roller in the center of the Registration Transport Assembly to provide access to the locking retaining tab behind the Registration Transport Assembly. or something similar. Replacement Note Make sure the retaining tab fits over the frame rather than under it.5. 7. push on the retaining tab to unlock it from the notch in the frame while pushing the Registration Transport Assembly to the left. 11. Remove the two screws securing the Registration Transport Assembly to the frame. Remove the two tapping screws securing the Chute-R to the Registration Transport Assembly to remove the Chute-R. 9. Disconnect the connector from the printer. and lifting the center upward to release the retaining tab from the frame. Use care to avoid damage to the wiring connected on the back. 6. Disconnect the connector from the Registration Trans Assembly. Note It could require significant force to flex the Registration Transport Assembly to clear the retaining tab and remove it from the frame.

Avoid pinching the harness. FRU Disassembly 8-51 . Remove the Tray 1/MPT Rear Cover (page 8-16). Remove the Registration Transport Assembly (page 8-49). 3. Remove Door A (page 8-46). 6. Remove the Tray 1/MPT Feeder (page 8-32). Replacement Note Route the harness through the hole as shown. Remove the Registration Clutch together with the harness.5. 4. PL4. Remove the E-ring securing the Registration Clutch to the Registration Roller. 2.Registration Clutch 1.2 Registration Clutch E-Ring Boss Registration Transport Assembly s5500-148 5.

8-52 Phaser 5500 Printer Service Manual .5. Remove Door A (page 8-46). Release the three hooks securing the sensor to the Registration Transport Assembly and remove. 4. Remove the Tray 1/MPT Feeder (page 8-32).7 Hook Registration Sensor Registration Transport Assembly Registration Sensor Hooks s5500-150 5. Remove the Tray 1/MPT Rear Cover (page 8-16). 3.Registration Sensor 1. 2. Remove the Registration Transport Assembly (page 8-49). PL4.

PL4. 4. 2. Remove the screws securing the Take Away Clutch Bracket to the frame and Motor Assembly and remove the bracket. Remove the I/P Board Cover (page 8-14). Replacement Note Make sure the notch in the clutch fits over the protrusion. Disconnect the Take Away Clutch connector from the harness.14 Notch Rear E-Ring Protrusion Take Away Bracket s5500-599 Take Away Clutch 3. FRU Disassembly 8-53 . Remove the E-clip securing the Take Away Clutch and remove the Clutch. Remove the Upper Rear Cover (page 8-15). 5.Take Away Clutch 1.5.

Remove Door A (page 8-46). 3. Open Door B. 8-54 Phaser 5500 Printer Service Manual .5. Release these latches before attempting to remove the Take Away Chute. 2.Feed Out Sensor 3 1. Remove the Tray 1 Feeder (page 8-32). PL4.18 Take Away Chute Feed Out Sensor 3 Take Away Chute Hook s5500-152 Caution The Take Away Chute is easily damaged if the latches located on the backside of the chute are not released before attempting to remove the chute from the frame.

6. fit the bosses on the Take Away Chute into the holes on the frame. Replacement Note When installing. 8. FRU Disassembly 8-55 . Disconnect the connector from the Feed Out Sensor.5. Reach in and release the latch at the center of the Take Away Chute from behind and remove the chute. Remove the two screws securing the Take Away Chute to the frame. 7. Release the hook securing the sensor to the Take Away Chute and remove.

Xerographics Drum Cartridge Fan Intake Duct 1. Disconnect the harness from the junction connector on the Intake Duct.1. Remove the Top Cover (page 8-7). PL5. 2.117 Connector Hooks Junction Connector Intake Duct Holes Front Clamps Connector s5500-624 8-56 Phaser 5500 Printer Service Manual .

Hook Toner Dispense Assembly Intake Duct Front Intake Duct Toner Dispense Assembly Hook Front View s5500-625 4. FRU Disassembly 8-57 . Move the Intake Duct in the direction of the arrow while lifting the left side.3. Release the hook holding the Intke Duct to the Toner Dispense Assembly.

Release the two hooks holding the fan to the Intake Duct and remove the fan.18 Junction Connector Intake Duct Hooks Front Drum Cartridge Fan Connector s5500-626 4. Remove the Top Cover (page 8-7).Drum Cartridge Fan 1. PL5. 8-58 Phaser 5500 Printer Service Manual . Remove the Drum Cartridge Fan Intake Duct (page 8-56). 2.1. Disconnect the Drum Cartridge Fan from the junction connector. 3.

FRU Disassembly 8-59 . 4. PL5.1. Release the hooks left and right securing the Fan to the duct as shown and remove the Fan. Replacement Note Install the Fan with the label facing outward.Fuser Fan 1. Remove the Upper Rear Cover (page 8-15). Remove the I/P Board Cover (page 8-14). Disconnect the Fan connector from the Motor Assembly.13 Hooks Fuser Fan Label CN102 CN102 Motor Assembly s5500-163 3. Also. 2. route the Fan harness in the slot as shown in the figure.

Remove the Toner Dispense Assembly (page 8-71). 3. Disconnect the two connectors (P403 and P404) from the Engine Logic Board. Remove the Toner Cartridge. 10. 2. 6. Remove the Drum Cartridge Fan Intake Duct (page 8-56). 8. Be sure this part is defective before begining this procedure. Remove the Front Left Cover (page 8-5).1. 1. 9. 8-60 Phaser 5500 Printer Service Manual . 5.Drum Cartridge Detect Switch Note Replacing this part requires major disassembly of the printer. PL5. Remove the Drum Cartridge. Remove the HVPS (page 8-86). Remove the Inner Main Cover (page 8-9).4 P404 P403 Engine Logic Board s5500-153 11. Remove the Top Cover (page 8-7). Remove the Lower Rear Cover (page 8-16). Remove the Front Door (page 8-8). 4. 7.

Laser C Connector Clamps Toner Dispense Assembly s5500-154 13. 14.12. Release the harness from the clamp on the Laser C. Remove the two screws securing the Laser C to the frame. Remove the Registration Transport Assembly (page 8-49). FRU Disassembly 8-61 .

Disconnect the connector from the Laser C. s5500-155 17. Remove the four screws securing the SUB Guide Assembly to the frame. Connector Sub Guide Assembly Junction Connector Screws 16. Remove the Laser C by moving it in the direction of the arrow. 8-62 Phaser 5500 Printer Service Manual .15.

lift the left side of the SUB Guide Assembly upward. 22. FRU Disassembly 8-63 . Remove the two hooks securing the Contact Cover to the frame. lower the left side (left) of the SUB Guide Assembly. Slide the SUB Guide Assembly toward the left side and disconnect the connector from the Front Harness A. 20. While pressing the Drum Motor gear located on the rear side of the Motor Assembly. 21. Release the harness from the clamp on the rear side of the SUB Guide Assembly. While pressing the Drum Motor gear located on the rear side of Motor Assembly.18. Drum Motor Gear Hook Hook Sub Guide Assembly Contact Cover s5500-156 19.

4. 8-64 Phaser 5500 Printer Service Manual . Remove the HVPS (page 8-86). Remove the Toner Cartridge. 5. 2. Remove the Toner Dispense Assembly (page 8-71). 9. Remove the Top Cover (page 8-7). 7. Remove the Front Door (page 8-8).23. Lift the right side of the SUB Guide Assembly. Remove the Inner Main Cover (page 8-9). Remove the screw securing the Drum Cartridge Detect Switch and the Switch Plate to the SUB Guide Assembly. 3. 8. Connector Sub Guide Assembly Drum Cartridge Detect Switch Screw s5500-157 24. Remove the Drum Cartridge Detect Switch together with the Switch Plate. Remove the Drum Cartridge. 6. Remove the Drum Cartridge Fan Intake Duct (page 8-56). Environmental Sensor PWB 1. 25. Remove the Front Left Cover (page 8-5).

FRU Disassembly 8-65 . Open Door A. Remove the Lower Rear Cover (page 8-16).1. Release the harness from the clamp on the printer.5 P404 P403 Engine Logic Board s5500-153 11.10. PL5. 12. 13. Disconnect the two connectors (P403 and P404) from the Engine Logic Board.

14. Remove the two screws securing the Laser C to the frame. Laser C Connector Clamps Toner Dispense Assembly s5500-154 15. 8-66 Phaser 5500 Printer Service Manual . Remove the Registration Trans Assembly (page 8-49).

Remove the Laser C by moving it in the direction of the arrow. s5500-155 18. Release the harness from the clamp on the Laser C. Remove the four screws securing the SUB Guide Assembly to the frame. FRU Disassembly 8-67 .16. Connector Sub Guide Assembly Junction Connector Screws 17.

Drum Motor Gear Hook Hook Sub Guide Assembly Contact Cover s5500-156 20. 8-68 Phaser 5500 Printer Service Manual .19. Slide the SUB Guide Assembly toward the left side and disconnect the connector from the Front Harness A. Remove the two hooks securing the Contact Cover to the frame.

Disconnect the connector from the Environmental Sensor PWB. While pressing the Drum Motor gear located on the rear side of the Motor Assembly. Sub Guide Assembly Connector Humidity And Temperature Sensor s5500-159 22.21. 24. Remove the screw securing the Environmental Sensor PWB to the SUB Guide Assembly. lift the left side of the SUB Guide Assembly upward. 23. FRU Disassembly 8-69 . Remove the Environmental Sensor PWB.

Drum Cartridge CRUM PWB 1. PL5. Remove the Drum Cartridge CRUM PWB by moving it in the direction of the arrow.8 Drum Cartridge CRUM PWB Toner Dispense Assembly s5500-158 2. Remove the Top Cover (page 8-7).1. 8-70 Phaser 5500 Printer Service Manual . 3. Disconnect the connector from the Drum Cartridge CRUM PWB.

Remove Door A (page 8-46). 8. Move the Toner Cartridge CRUM PWB in the direction of the arrow to remove. Remove the Top Cover (page 8-7). 2. Toner Dispense Assembly 1. 3. Remove the Duplex Unit if present. Remove the Front Door (page 8-8). Remove the Front Left Cover (page 8-5). Remove the Drum Cartridge Fan Intake Duct (page 8-56).1. 5. PL5. Remove the Top Cover (page 8-7).8 Toner Cartridge CRUM PWB s5500-589 2. Disconnect the connector from the Toner Cartridge CRUM PWB. FRU Disassembly 8-71 . 7.Toner Cartridge CRUM PWB 1. 3. 4. Remove the Drum Cartridge. Remove the Toner Cartridge. 6.

9. 8-72 Phaser 5500 Printer Service Manual . 11. 12. Remove the two screws securing the Toner Dispense Assembly to the frame.1. PL5.10 Toner Dispense Assembly Harness Clamps Screw Toner Dispense Motor Toner Dispense Assembly Shaft s5500-161 10. Disconnect the harness Toner Cartridge CRUM PWB on the right side. Remove the Inner Main Cover (page 8-9). Release the harness from the clamps on the left side of the Toner Dispense Assembly.

2. 5. Remove the Top Cover (page 8-7). Remove the Inner Main Cover (page 8-9). fit the shaft into the hole on the Toner Dispense Motor. Remove the Drum Cartridge.13. Remove the Front Door (page 8-8). Remove the Front Left Cover (page 8-5). 6. Remove the Toner Cartridge. Toner Dispense Motor 1. Remove the Drum Cartridge Fan Intake Duct ( FRU Disassembly 8-73 . reach in from the Left end and remove the screw securing the Dispense Tube to the frame. Also. 3. 4. 7. While pushing the Toner Dispense Assembly toward the left side. Dispense Tube Toner Dispense Assembly s5500-594 Replacement Note Fit the hole on the Toner Dispense Assembly to the Toner Dispense Motor.

PL5. Remove the Toner Dispense Assembly (page 8-71).11 Toner Dispense Motor Connector s5500-162 9. Remove the Inner Main Cover (page 8-9). Remove the Top Cover (page 8-7). 2. Remove the Front Door (page 8-8). Remove the four screws securing the Toner Dispense Motor to the frame and remove. Remove the Toner Cartridge. 3. Disconnect the connector from the Toner Dispense Motor. Laser Assembly 1.1. 4. 10. 5. Remove the Drum Cartridge. 8-74 Phaser 5500 Printer Service Manual .8.

8. 9.6. Lift the Laser Assembly from the frame. Remove the four screws securing the Laser Assembly to the frame. FRU Disassembly 8-75 . PL5. 10. Disconnect the connector from the junction connector. Remove the Toner Dispense Assembly (page 8-71).14 Laser Assembly s5500-164 7.1. Disconnect the three connectors from the Laser Assembly.

3. 8-76 Phaser 5500 Printer Service Manual .7 Fuser Handle Knob s5500-165 2.Fuser and Exit 1 Fuser Assembly 1. Open Door A. Pull the Fuser toward you by holding the two handles. PL6. Loosen the two knobs securing the Fuser to the frame.1.

4. FRU Disassembly 8-77 . 5.4 Fuser Exit Sensor Hook Sensor Bracket s5500-166 3. Open Door A. Disconnect the connector from the sensor. Remove the screw securing the bracket to the frame. PL6. 2. Release the three hooks securing the sensor to the bracket. Remove the Fuser (page 8-76).Fuser Exit Sensor 1.1.

1 Exit Bracket Upper Rear Cover Door A s5500-167 7. Remove the Front Left Cover (page 8-5). PL6. 4. Remove the Exit 1 Top Cover (page 8-18). 2. 8-78 Phaser 5500 Printer Service Manual . Remove the two screws securing the Exit Bracket to the frame.Exit Transport Assembly 1. 6. Remove the Upper Rear Cover (page 8-15). Remove the Top Rear Cover (page 8-6). Open Door A. Open the Front Door. 5. 3. Remove the Exit bracket. Replacement Note Make sure the Stack Full Actuator rotates freely.2. 8.

11. Disconnect the connector from the Offset Motor. Disconnect the two connectors from the two sensors. Remove the two screws securing the Exit Transport Assembly to the frame. Harness Connectors Exit Transport Assembly s5500-168 10.9. FRU Disassembly 8-79 . 13. Remove the Main Drive Belt (page 8-83). 12. Remove the Exit Transport Assembly by lifting upward.

Exit 1 Offset Motor
1. Remove the Upper Rear Cover (page 8-15). 2. Remove the Top Rear Cover (page 8-6). 3. Open Door A. 4. Remove the Exit 1 Top Cover (page 8-18). 5. Open the Front Door. 6. Remove the Front Left Cover (page 8-5). 7. Remove the Exit Transport Assembly (page 8-78). PL6.2.3

Connector

Clamps

Offset Motor

Exit Transport Assembly
s5500-169

8. Disconnect the connector from the Offset Motor. 9. Remove the two standard, Phillips-head screws securing the Offset Motor to the Exit.

8-80

Phaser 5500 Printer Service Manual

Offset Home Position Sensor
1. Remove the Upper Rear Cover (page 8-15). 2. Remove the Top Rear Cover (page 8-6). 3. Open Door A. 4. Remove the Exit 1 Top Cover (page 8-18). 5. Open the Front Door. 6. Remove the Front Left Cover (page 8-5). 7. Remove the Exit Transport Assembly (page 8-78). PL6.2.5

Exit Transport Assembly

Offset Home Position Sensor

Hooks

Hook

Sensor Bracket
s5500-170

8. Remove the Exit 1 Offset Motor. 9. Remove the two screws securing the sensor bracket to the Exit Transport Assembly. 10. Release the three hooks securing the Offset Home Position Sensor to the sensor bracket. 11. Remove the Offset Home Position Sensor.

FRU Disassembly

8-81

Full Stack Sensor
1. Remove the Upper Rear Cover (page 8-15). 2. Remove the Top Rear Cover (page 8-6). 3. Open Door A. 4. Remove the Exit 1 Top Cover (page 8-18). 5. Open the Front Door. 6. Remove the Front Left Cover (page 8-5). 7. Remove the two screws securing the Exit Bracket to the frame. 8. Remove the Exit Bracket. PL6.2.5

Exit Transport Assembly

Hook

Hooks

Full Stack Sensor
s5500-171

9. Remove the two screws securing the bracket to the Exit Transport Assembly. 10. Release the three hooks securing the sensor to the bracket. 11. Remove the sensor.

8-82

Phaser 5500 Printer Service Manual

Drive
Main Drive Belt
1. Remove the I/P Board Cover (page 8-14). 2. Remove the Upper Rear Cover (page 8-15). 3. Remove the Exit 1 Top Cover (page 8-18). PL7.1.5

Main Drive Belt

Exit Flange

Rear
s5500-176

4. Release the hook on the Exit Flange securing the belt to the Motor Assembly to remove the Exit Flange.

FRU Disassembly

8-83

5. Remove the Belt from the Pulley 25T and Exit Gear. Replacement Note It’s easier to install the Belt if the Motor is rotated slowly by hand. Fit the flange to the D-shaped shaft and install the flange until the hook locks.

Motor Assembly
1. Remove the I/P Board Cover (page 8-14). 2. Remove the Upper Rear Cover (page 8-15). 3. Remove the Exit 1 Top Cover (page 8-18). 4. Open the Front Door. 5. Pull out the Drum Cartridge.

Main Drive Belt

s5500-177

8-84

Phaser 5500 Printer Service Manual

6. Remove the Main Drive Belt (page 8-83). PL7.1.7

Main Drive Belt

Motor Assembly

CN102

Exit Flange

CN101

Take Away Clutch Bracket
7. Disconnect the two connectors from the Motor Assembly.

s5500-178

8. Remove the two screws securing the Take Away Clutch bracket to the frame and to the Motor Assembly to remove the bracket. 9. Remove the four screws securing the Motor Assembly to the frame. Replacement Note Install the Motor Assembly by pushing the Gear on the upper part of the Motor in the direction of the arrow.

FRU Disassembly

8-85

Print Engine Electrical
High Voltage Power Supply
1. Remove the Front Left Cover (page 8-5). 2. Remove the Top Cover (page 8-7). 3. Pull out the Drum Cartridge. 4. Remove the Front Door (page 8-8). 5. Remove the Inner Main Cover (page 8-9). PL8.1.1

Clamp

HVPS

Clamp
6. Disconnect the connector from the HVPS. 7. Release the harness from the clamps. 8. Remove the two screws securing the HVPS to the frame.

s5500-179

9. Carefully remove the HVPS by moving it in the direction of the arrow. Replacement Note Insert the board into the guides on both sides.

Power Switch
1. Remove the Top Cover .(page 8-7). 2. Open the Front Door.

8-86

Phaser 5500 Printer Service Manual

3. Remove the Upper Right Cover (page 8-11). PL8.1.2

Power Switch Hook Hook

Notch Switch Bracket Connector

s5500-180

4. Remove the screw securing the bracket to the frame. 5. Remove the bracket and switch to the left to remove from the frame. 6. Disconnect the four connectors from the Power Switch. 7. Release the hooks securing the Power Switch to the bracket as shown. Replacement Note Fit the notch on the Power Switch to the boss on the frame.

FRU Disassembly

8-87

Exit PWB
1. Remove the Top Cover (page 8-7). PL8.1.4

Connectors

Supports

Exit PWB Lower Bracket
s5500-181

2. Disconnect all connectors from the Exit PWB. Connector P/J403 has a hook. Disconnect it by pushing the hook. 3. Remove the two screws securing the Lower Bracket to the frame. 4. Release the locks of the supports holding the Exit PWB to the frame as shown in the figure. 5. Remove the Exit PWB together with Lower Bracket from the frame. 6. Remove the two screws securing the Exit PWB to the Lower Bracket. 7. Remove the Exit PWB. Replacement Note Fit the tips of the supports into the holes on the Exit PWB.

8-88

Phaser 5500 Printer Service Manual

Engine Logic Board
1. Remove the I/P Board Cover (page 8-14). 2. Remove the Upper Rear Cover (page 8-15). 3. Remove the Lower Rear Cover (page 8-16). PL8.1.5

Connectors

Engine Logic Board

s5500-184

4. Mark and disconnect all connectors from the Engine Logic Board. Connectors P/ J400, P/J401, and TTM/2TM have a hook. Disconnect by pushing the hook. 5. Remove the six screws securing the Engine Logic Board to the frame. 6. Remove the Engine Logic Board.

FRU Disassembly

8-89

Front Panel
1. Remove the Top Cover (page 8-7). PL1.1.6

Front Panel

Top Cover Hooks

Hooks

Hooks Hooks

Bottom View
s5500-185

2. Place the Top Cover up side down, and remove the Front Panel Cover by releasing the four hooks securing the Cover to the Top Cover. 3. Move the Front Panel Cover in the arrow direction (right side) to remove.

8-90

Phaser 5500 Printer Service Manual

Image Processor Board
1. Remove the I/P Board Cover (page 8-14). 2. Disconnect all external interface connections. PL8.1.5

Screws

Screw Image Processor Board
3. Disconnect the four connectors from the I/P Board.

s5500-613

4. Remove the three 5.5mm, hex-head screws securing the I/P Board to the frame. 5. Remove the I/P Board and its carrier using the knob provided on the rear panel. Replacement Note Tighten the back panel screw before tightening the board mounting screws. If installing a new I/P Board, be sure to transfer NVRAM, Configuration Card, and if installed, the Flash Memory and Hard Drive to the new board.

FRU Disassembly

8-91

Disconnect by pushing the hook.Low Voltage Power Supply 1. 4. P6.1. Replacement Note Fit the holes on the board to the two bosses on the frame. Remove the Upper Right Cover (page 8-11). Mark and disconnect all connectors from the LVPS. J12 (White wire) are interchangeable. Use the designators printed on the board to identify the proper connection. P7 is unused. Connectors P1. Remove the LVPS.8 LVPS s5500-186 2. P2. Remove the nine screws securing the LVPS to the frame. Caution J11 (Black wire). 3. P521 and P526 have a hook. 8-92 Phaser 5500 Printer Service Manual . PL8.

Remove the Top Cover (page 8-7). Remove the Upper Rear Cover (page 8-15). 4. Remove the Lower Rear Cover (page 8-16). 2.1. Remove the I/P Board Cover (page 8-14). Remove the Upper Right Cover (page 8-11). PL8.10 RIGHT VIEW Connectors Harness Clamps s5500-187 FRU Disassembly 8-93 . 5. 3.AC Accessory Panel 1.

10. 5. 7. 3.1. 9. GFI Breaker 1. Remove the I/P Board Cover (page 8-14). 8.13 GFI Breaker s5500-188 4. Remove the three screws securing the AC Accessory Panel to the frame. Remove the three screws securing the AC Accessory Panel to the printer. Remove the Lower Rear Cover (page 8-16). Remove the two screws securing the GFI Breaker to the AC Accessory Panel. 8-94 Phaser 5500 Printer Service Manual . 2. Release the harness from the clamp. Release the four harnesses from the three clamps. J11 (Black wire). 6. PL8. Remove the Upper Rear Cover (page 8-15).6. Disconnect the three connectors (P2. J12 (White wire) from the LVPS. Disconnect the two connectors from the GFI Breaker. Remove the AC Accessory Panel.

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

as shown in the following table. a printer having RET219638 as its Serial Number: ■ ■ Is a 110 V Phaser 5500 Printer Has a 219638 serial number 9-2 Phaser 5500 Printer Service Manual .Serial Number Format Changes to Xerox products are made to accommodate improved components as they become available. Network Phaser 5500. Base Phaser 5500. 110 V. 110V. Product Code RET RET REU REU Product 5500/B 5500/N 5500V/B 5500V/N Configuration Phaser 5500. Base Phaser 5500. 220V. It is important when ordering parts to include the following information: ■ ■ ■ Component's part number Product type or model number Serial number of the printer The serial number is found on a label located on the rear frame of the printer just inside Door A. Network SSSSSS = Numeric serial number. 220V. The nine-digit serial number has the following format: PPP-SSSSSS PPP = product code. Open Door A to see it. For example.

made up of the individual parts called out in parentheses. Abbreviations Abbreviation C E KL S Meaning C-ring E-ring K-clip Screw Parts Lists 9-3 .1. Part Number: The material part number used to order that specific part. A black triangle preceding a number followed by a parenthetical statement in an illustrated parts list means the item is a parent assembly. PL3.#.#. Parts identified throughout this manual are referenced PL#.10 means the part is item 10 of Parts List 3. For example. An asterisk (*) following a part name indicates the page contains a note about this part. The notation “with X~Y” following a part name indicates an assembly that is made up of components X through Y. Parts not showing part numbers are only available as part of a parent assembly. part 3. Name/Description: The name of the part to be ordered. “1 (with 2~4)” means part 1 consists of part 2.Using the Parts List ■ ■ No. ■ ■ ■ ■ ■ Note Only parts showing part numbers are available for ordering by support. For example.: The callout number from the exploded part diagram. and the number of parts supplied per order. appearing in UPPERCASE letters. and part 4.1.

Print Engine Parts Parts List 1.1 Covers 1/2 6 4 3 S S 5 7 15 9 (with 10-12) 10 S S 8 11 12 14 1 S S 14 S S 2 13 Lef t Front s5500-190 9-4 Phaser 5500 Printer Service Manual .

PR (Front Left Cover) COVER-TOP RR. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Name/Description COVER LEFT FR COVER-FRS FR.MAIN (Inner Main Cover) FOOT FRONT PLATE SER Part Number 802K74110 802E55371 802E55361 110E94770 802E64160 962K24041 802K74170 802K74080 802E55351 802K58180 Parts Lists 9-5 .Parts List 1.1 Covers 1/2 No. PR (Top Rear Cover) BRACKET ILSW SWITCH (Front Door Interlock Switch) CONSOLE PANEL (Front Panel) HARN ASSY CONPANEL COVER ASSY TOP PR (Top Cover) COVER ASSY FRONT (with 10~12) (Front Door) MAGNET CATCH COVER-FRONT STRIP (Stopper) COVER ASSY INNER.

2 Covers 2/2 S S 5 1 9 8 S S 3 2 4 S 6 Rig ht Rear s5500-191 7 9-6 Phaser 5500 Printer Service Manual .Parts List 1.

Parts List 1.2 Covers 2/2 No.PR (Rear Panel Cover) COVER REAR UPR (Upper Rear Cover) COVER REAR LOW PR (Lower Rear Cover 110V) COVER REAR LOW PR (Lower Rear Cover 220V) COVER-CAP MCU (Option Interface Cover) FOOT FRONT FOOT REAR LEFT Part Number 802E55230 802E55241 802E55260 802E55381 802E55271 802K74120 802K74130 802E55292 Parts Lists 9-7 . 1 2 3 4 5 6 7 8 9 Name/Description COVER RIGHT UPR (Upper Right Cover) COVER RIGHT LOW] (Lower Right Cover) COVER ESS RH COVER-CAP ESS.

14) 99 (with 3. 12.2.2. PL20. PL20.Parts List 2.2.3) 7 10 11 Lef t Front s5500-192 9-8 Phaser 5500 Printer Service Manual .1 Tray 1/2 and Feeder 1/2 S 5 4 S S 15 6 7 12 S 2 1 2 S 3 15 14 13 14 9 (with 13.

1 2 3 4 5 6 7 9 10 11 12 13 14 15 97 98 99 Name/Description STOPPER-TRAY SPACER TRAY G TRAY ASSY (PL 2.1) CHUTE FEED OUT (with 13. TRAY NO1 (included with 97) LABEL.3) TRAY. TRAY NO2 (included with 97) LABEL INST.Parts List 2.2. ENVELOPE (as option. 14) LABEL.2. PL20. PL20.2.1 Tray 1/2 and Feeder 1/2 No.2. included with 99) SWITCH ASSY P S (Paper Size Switch) BRACKET-SW CHUTE ASSY FEEDER FEEDER ASSY (PL2.2. 11.3.M/N CHUTE FEED OUT PAD ASSY LH LOW COVER SENSOR KIT LABEL (with 10. not shown) 500 TRAY Part Number 003E58700 014E44710 110K11680 054K24091 059K26934 054K27550 604K23370 604K24320 109R00733 Parts Lists 9-9 .

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

2 Tray 2/2 No.Parts List 2. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 99 Name/Description TRAY ASSEMBLY (with 2~26) TRAY COVER LABEL (MAX) BOTTOM PAD FRONT SIDE GUIDE TRAY PAD REAR SIDE GUIDE BOTTOM PLATE TRAY SIDE GUIDE ACTUATOR GUIDE ACTUATOR SPRING PINION GEAR END GUIDE SPRING END GUIDE ACTUATOR LINK COUPLING GEAR (13T) GEAR (13T/60T) SECTOR GEAR (60T) BRACKET LIFT UP SHAFT STOPPER SEAL KIT. LABEL Part Number 109R00733 Parts Lists 9-11 .

3 Feeder 2/2 1 (with 2-50) 15 Sensor Pre Feed 43 C 44 2 S S 3 42 40 14 Level Sensor S 45 45 S 17 14 A 18 10 6 5 E No Paper Sensor S B 9 11 36 A S 39 13 21 20 38 33 20 31 22 12 E 39 19 30 23 48 S C 4 B 8 46 35 7 34 50 37 16 27 99 (with 20x3Pcs.Parts List 2.) 29 20 26 Front Right s5500-194 49 S 47 S 24 25 9-12 Phaser 5500 Printer Service Manual .

Parts List 2.3 Feeder 2/2 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Name/Description FEEDER ASSEMBLY (with 2~50) TRAY FEED LIFT UP MOTOR BRACKET SPACER GEAR (31T) SPRING ONEWAY CLUTCH ONEWAY GEAR GEAR (13T) BEARING SHAFT FRONT CHUTE ACTUATOR (No Paper Sensor Actuator) SENSOR (No Paper or Level Sensor) SENSOR (Pre-Feed Sensor) WIRE HARNESS GEAR (28T/21T) GEAR (29T) SPRING ROLLER ASSY--Periodic replacement part per 300k prints (included with 99) (Feed Roller) ONEWAY CLUTCH ONEWAY GEAR (22T) SHAFT CHUTE SPRING FRICTION CLUTH SHAFT-RETARD -- Part Number 059K26934 127K38170 120E22481 930W00113 930W00211 809E51070 21 22 23 24 25 26 27 28 Parts Lists 9-13 .

3 Feeder 2/2 No. 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 99 Name/Description SPACER GEAR (33T) SHAFT-NUDGER -GEAR (25T) LOWER FRAME BEARING GEAR (27T) LEVER BEARING WASHER UPPER FRAME HOLDER HARNESS CTR HOLDER HARNESS REAR HOLDER HARNESS UPPER HOLDER HARNESS PS1 (ALT) CLAMP MINI-SADDLE (ALT) RAIL SUPPORT RETARD SUPPORT NUDGER HOLDER SPRING KIT ROLLS (with 20 x 3 pcs.)Periodic replacement (per 300k print) Part Number 604K20530 9-14 Phaser 5500 Printer Service Manual .Parts List 2.

Parts Lists 9-15 .This page intentionally left blank.

1 Tray 1/MPT Assembly S 14 1 (with 2-12.2.1) 10 Lef S t Front s5500-195 9-16 Phaser 5500 Printer Service Manual .1) 11 (PL3.16-19) S S 8 13 4 5 S 16 6 7 17 18 9 9 19 17 18 12 (PL3.15-19) 2 20 20 3 15 (with 8.Parts List 3.9.3.

15~19) (Tray 1/MPT Feeder) FRAME UPPER ACTUATOR (No Paper Sensor Acutator) SENSOR-PHOTO IN (No Paper Sensor) HARNESS ASSY MSI SPRING MSI (Pick-Up Gear Spring) BRKT ASSY-GEAR CHUTE PINCH ROLL ASSY-PINCH CHUTE LOW FRAME ASSY LOWER (PL3.1 Tray 1/MPT Assembly No.2) TRAY ASSY-MSI (PL3. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Name/Description FEEDER ASSEMBLY MSI (with 2~12.3) COVER MSI FR (Tray 1/MPT Front Cover) COVER MSI RR (Tray 1/MPT Rear Cover) CHUTE ASSY PINCH GUIDE PINCH SPRING PINCH SPACER SPRING PINCH SHAFT PINCH WIRE SADDLE Part Number 059K31460 120E22230 930W00113 809E38160 802K74140 802E55211 Parts Lists 9-17 .Parts List 3.

Parts List 3.2 Tray 1/MPT Lower Frame Assembly 1 (with 2-28) 17 19 20 6 22 7 4 21 26 S E 14 16 19 13 18 3 9 12 5 15 8 23 2 25 10 24 24 25 E 21 28 Lef t Front 11 27 9 E s5500-196 9-18 Phaser 5500 Printer Service Manual .

Parts List 3. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Name/Description FRAME ASSY LOWER (with 2~28) FRAME LOWER MSI STOPPER LEVER COLLAR SHAFT-RETARD GEAR PICK UP GEAR 18T LEVER-GEAR BEARING 8 PAD BOTTOM PLATE BOTTOM PAD ASSY-RETARD GUIDE PAPER MSI ROLL ASSY-DRIVE SOLENOID PICK UP SHAFT ASSY PICK UP CAM PICK UP 2 CAM PICK UP FRONT ROLL CORE ROLLER ASSY-FEED (Feed Roller with installation instructions) BEARING SLEEVE GEAR CAM SPRING LEVER GE SPRING PAD (Retard Pad Spring) SPRING N F SPRING-GEAR CAM PLATE EARTH BOTTOM PLATE EARTH FRONT Part Number 019E56551 019K07085 121E92780 008E93831 008E94270 604K23380 809E27650 809E54530 Parts Lists 9-19 .2 Tray 1/MPT Lower Frame Assembly No.

3 Tray 1/MPT Assembly 1 (with 2-13) 7 13 6 5 4 8 10 S 12 2 3 11 9 S Lef t Front s5500-197 9-20 Phaser 5500 Printer Service Manual .Parts List 3.

1 2 3 4 5 6 7 8 9 10 11 12 13 Name/Description TRAY ASSY MSI (with 2~13)] GEAR-PINION RACK-FRONT RACK-REAR LINK-SENSOR GUIDE-SIDE FRONT GUIDE-SIDE REAR TRAY MSI TRAY EXT SENSOR ASSY-MSI (Paper Size Sensor) COVER TRAY SPRING-SENSOR HARNESS ASSY SIZE Part Number 050K49741 Parts Lists 9-21 .Parts List 3.3 Tray 1/MPT Assembly No.

3) S 3 2 Door B Interlock Switch 4 S 6 7 5 10 (with 11-22) 16 (with 17-22) S 8 E 9 19 21 17 18 20 22 12 13 19 21 11 14 Lef t Front 15 s5500-198 9-22 Phaser 5500 Printer Service Manual .Parts List 4.1 Transportation and Registration L/H Lower 1 (with 2.

1 Transportation and Registration L/H Lower No.18T ROLLER ASSY-TA (Take Away Roller) BEARING SLEEVE COVER ASSY LH LOW C (with 11~22) (Door B) CHUTE LH LOW C HANDLE LH LOW SPRING-COMP LH LOW COVER LH LOW C PLATE-EARTH BRKT ASSY LH LOW C (with 17~22) BRKT LH LOW ROLLER-TA PINCH BEARING-OUT BEARING-IN SPRING LH LOW SPRING Part Number 015K61010 110E11580 029E31600 013E26990 007E79270 059K26840 413W77559 802K58280 Parts Lists 9-23 . 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Name/Description BRKT ASSY TA (with 2. CAB (Door B Interlock Switch) RIVET CHUTE-LOWER BEARING TA GEAR .Parts List 4.3) (Take Away Bracket) BRACKET ASSY IDLER SWITCH-I/L.

2 L/H Upper Assembly Door A Interlock Switch 5 4 S 3 S 2 1 6 E 7 (PL4.4.3.1) Lef t Front s5500-199 9-24 Phaser 5500 Printer Service Manual .Parts List 4.1) 8 (PL4.

1) COVER ASSY-LH (PL4.2 L/H Upper Assembly No.Periodic replacement part (per 300k prints) (Transfer Roller) COVER ASSY-CONTACT LINK ASSY-SHUTTER SWITCH (Door A Interlock Switch) BRACKET ILSW STUD CHUTE ASSY LH (PL4.Parts List 4.4.3. 1 Name/Description HSG ASSY-BTR -.1) Part Number 802K56094 2 3 4 5 6 7 8 802K49240 012K94341 110E94770 826E08440 Parts Lists 9-25 .

Parts List 4.3 L/H Chute Assembly 1 (with 2-9) 2 3 4 2 5 5 6 6 7 7 5 7 S 5 6 8 6 Lef t Front 9 s5500-200 9-26 Phaser 5500 Printer Service Manual .

3 L/H Chute Assembly No.Parts List 4. 1 2 3 4 5 6 7 8 9 Name/Description CHUTE ASSY LH (with 2~9 BEARING-PINCH OUT ROLLER ASSY-REGI-P CHUTE-ASSY SPRING COMP FL GUIDE SPRING COMP PINCH PLATE-TIE PLATE-EARTH Part Number 054K24051 Parts Lists 9-27 .

4 L/H Cover Assembly 1 (with 2-10) 3 S 10 S 7 4 S 6 2 9 8 Lef t Front s5500-201 9-28 Phaser 5500 Printer Service Manual .Parts List 4.

LH COVER (Door A Stopper) Part Number 802K58260 003E59832 024E03250 054K24060 809E42460 849E13981 Parts Lists 9-29 . 1 2 3 4 5 6 7 8 9 10 Name/Description COVER ASSY-L/H (with 2~10) (Door A) HANDLE L/H ROD CRU SHUTTER CHUTE LHCOV CHUTE ASSY-DUP FRAME ASSY LH COVER-LH SPRING COMP LH SUPPORT .Parts List 4.4 L/H Cover Assembly No.

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

Parts List 4.5 Registration No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Name/Description TRANS ASSY REGI (with 2~8) (Registration Transport Assembly) CLUTCH ASSY REGI H (Registration Clutch) CHUTE-REGI ROLLER REGI IDLER ROLLER ASSY REGI BEARING REGI E SNR ASSY REGI (Registration Sensor) PLATE-EARTH F G CHUTE-TA CHUTE ASSY-R BEARING SHAFT TA GEAR-19T CLUTCH ASSY-TA (Take Away Clutch) BRACKET-TA BEARING CHUTE-TA (with 9. 18. 19) (Take Away Chute) SENSOR (Feed Out Sensor #3) HARNESS PUSH TIE Part Number 059K26820 121K32660 130K64270 054E23910 054K23940 013E26090 007E79320 121K31640 013E26060 930W00211 Parts Lists 9-31 .

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

1 Laser.Parts List 5. CRU and Toner Dispense No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 98 Name/Description BLOCK STOPPER CRU ] SCREW PLATE-SW-INTLK SWITCH ASSY XERO INTLK (Drum Cartridge Detect Switch) SENSOR HUM & TE (Environmental Sensor Temp/Humidity PWB) GUIDE ASSY SUB HSG ASSY LASER C PWBA CRUM CP1 (Drum Cartridge/Toner Cartridge CRUM) HARN ASSY FRONT A GUIDE ASSY CTG30 SUB (Toner Dispense Assembly) MOTOR ASSY-DISP 30K (Toner Dispense Motor) DUCT FUSER FAN FUSER ROS ASSY-12 (Laser Assembly) CRU DRUM CARTRIDGE TONER CARTRIDGE DUCT INTAKE CRU FAN (Drum Cartridge Fan DRUM CARTRIDGE CONN (Drum Cartridge Connector) Part Number 014E44733 815E05030 110K11810 130K87980 032K96910 802K73190 160K95830 032K96951 127K38040 127K37880 062K13614 113R00670 113R00668 927W00112 114E14880 Parts Lists 9-33 .

2) 99 S 6 4 E S 3 5 1 E 7 Lef t Front s5500-204 9-34 Phaser 5500 Printer Service Manual .Parts List 6.1 Fuser and Exit 1 Unit 8 (PL6.

Periodic replacement part (per 300k prints) FUSER ASSY 220V --.2) KIT EXIT SENSOR (with 3~6) (Fuser Exit Sensor Kit) Part Number 126K18300 126K18310 015K60900 Parts Lists 9-35 . EXIT (included with 99) FUSER ASSY 120V --.Parts List 6. 1 2 3 4 5 6 7 7 8 99 Name/Description SHAFT-ACTUATOR -ACTUATOR-EXIT (included with 99) SENSOR PHOTO (Fuser Exit Sensor included with 99) SPRING-ACTUATOR (included with 99) BRKT-SENSOR.Periodic replacement part (per 300k prints) TRANS ASSY EXIT (PL6.1 Fuser and Exit 1 No.

2 Exit 1 22 32 30 25 1 (with 2-21.34.Parts List 6.35) 2 26 27 33 3 S 28 23 31 29 24 19 34 35 S 18 17 5 16 5 4 6 7 8 9 E 20 15 14 13 E 10 11 12 Fron t Rig ht 21 10 s5500-205 9-36 Phaser 5500 Printer Service Manual .

2 Exit 1 No. 34. 35) (Exit Transport Assembly) HARN ASSY EXIT 1 C MOTOR ASSY-OFFSET (Offset Motor) PLATE-EARTH MOTOR SENSOR-PHOTO IN (Offset Home Position or Full Stack Sensor) BEARING GEAR-19T CAP GEAR-EXIT BEARING ROLL CHUTE-OCT1 SPRING-PINCH EXIT RLR-PINCH EXIT ROLL ASSTY OCT CHUTE-LOW BRACKET SENSOR GEAR-OFFSET SPRING-GATE GATE-EXIT 1 (Exit Gate) BEARING PLATE-EARTH COVER-TOP. EXIT 1 BRKT-EXIT 2 ELIMINATOR EXIT GUIDE-TRAY EXIT 1 ACTUATOR FULLSTACK ACTUATOR WEIGHT-ASSY PAPER PAD EXIT A PAD EXIT B PAD EXIT C LABEL EXIT 1 XC LABEL CAUTION XC SEAL A SEAL B Part Number 059K31550 127K37951 930W00113 809E42370 050E19802 802E55151 120E22171 120E24670 036K91600 Parts Lists 9-37 . 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Name/Description TRANS ASSY EXIT (with 2~21.Parts List 6.

1 Drive 6 (with 7.Parts List 7. 8) 7 PL6.4) 9 4 3 1 2 Rig ht Rear s5500-206 9-38 Phaser 5500 Printer Service Manual .2.9 5 8 S 99 (with 1 .

2. 4) Part Number 423W13155 007K88596 020E36600 005E17860 604K23270 Parts Lists 9-39 .1 Drive No. 3. 8number) (Motor Assembly) MOTOR ASSY 242 PULLEY 25T FLANGE EXIT KIT. GEAR (with 1.Parts List 7. 1 2 3 4 5 6 7 8 9 99 Name/Description COLLAR GEAR 21/21T MSI GEAR 18T MSI GEAR 28T TA BELT-SYNCHRONOUS BAN (Main Drive Belt) DRIVE ASSY 242 (with 7.

Parts List 8.1 Electrical 23 25 33 6 4 2 S S S 22 3 34 35 32 29 30. 31 1 S S 24 S 9 S 21 S 8 26 20 10 (with 11-16) 11 14 S S S 16 S 5 12 7 15 13 Rig ht Rear 27 28 s5500-207 9-40 Phaser 5500 Printer Service Manual .

1 Electrical No.Parts List 8. 1 2 3 4 5 6 7 8 Name/Description PSHV-Y2 High-Voltage Power Supply (HVPS) SWITCH-POWER BRACKET-SW CPR PWB A EXIT (Exit PWB) PWBA MCU F 110V/220V (Engine Logic Board) PWB SUPP EDGE BRACKET MCU POWER UNIT-C1(100/127) Low-Voltage Power Supply (LVPS) POWER UNIT C1H(200/240) Low-Voltage Power Supply (LVPS) Part Number 105E11420 110E11320 160K94216 960K06080 105E11390 115E11400 104E94080 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 CHOKE COIL (220/240) CHAS ASSY AC XC (with 11~16) (AC Accessory Panel) SCREW BRACKET-CONN AC BREAKER GFI INL (GFI Breaker) HARNESS ASSY F/G.E HARN ASSY AC US EU OUTLET MN 908W01201 COVER ASSY ESS (I/P Board Cover) PANEL ASSY CONN HCF BRKT GUIDE PRX CHASSIS ASSY ESS PRX BRKT-EXIT LOW IMAGE PROCESSOR BOARD (with NVRAM) PLATE ASSY LVPS PKG POWER CORD (110V) PKG POWER CORD (220V) NVRAM DEVICE (I/P Board NVRAM) BASE CONFIG CARD (Networking disabled) NETWORK CONFIG CARD (Networking enabled) HARD DRIVE FLASH RAM (Optional flash memory) 128 MB DIMM 256 MB DIMM 802K73070 650-4341-00 673K44480 673K55640 163-1459-00 163-1518-00 163-1519-00 650-4343-00 671-5338-0A 156-4860-00 156-4663-00 Parts Lists 9-41 .

2 Harness 1 2 3 4 5 6 9 10 11 7 8 13 12 Rig ht Rear s5500-2 9-42 Phaser 5500 Printer Service Manual .Parts List 8.

1 2 3 4 5 6 7 8 9 10 11 12 13 Name/Description HARN ASSY FEEDER C HARN ASSY MSI A HARN ASSY SIZE A HARN ASSY ESS C HARN ASSY ROS C HARN ASSY EXIT C HARN ASSY PH C HARN ASSY FUSER AC C HARN ASSY LV PWR C HARN ASSY INTLK A HARN ASSY MAIN SW C HARN ASSY DRIVE A WIRE HARNESS CRUM B Part Number 962K18991 Parts Lists 9-43 .2 Harness No.Parts List 8.

Xerox Supplies and Accessories User Documentation and Kit Instructions Description 1000-Sheet Feeder Instructions 2.000-Sheet Feeder Instructions Duplex Unit Instructions Maintenance Kit Instructions 3.500-Sheet Stacker/Finisher Printer Repacking Instructions Envelope Tray instructions User Guide (English only) User Documentation CD-ROM B to N Upgrade Instructions Tray 1/MPT Feed Roller Replacement Printer Installer and Utilities CD-ROM Adding Memory Instructions Flash Memory DIMM Instructions Hard Drive Instructions Toner Cartridge Instruction Sheet (on box) Drum Cartridge Instruction Sheet (on box) Staple Pack Instruction Sheet (on box) Part Number 075-0909-00 075-0910-00 075-0911-00 075-0906-00 075-0912-00 075-0918-00 075-0913-00 001-1581-00 063-3455-00 075-0917-00 075-0908-00 063-3456-00 075-0915-00 075-0916-00 075-9914-00 075-0904-00 075-0907-00 075-0905-00 9-44 Phaser 5500 Printer Service Manual .

interconnects) Part Number 109R00731 109R00732 113R00670 109R00733 600K65640 600K65630 604K23340 Parts Lists 9-45 . 220 V Drum Cartridge (60K) 500-Sheet Universal Replacement Tray Hardware Kit Common Clip Kit Electrical Kit (2 ea.500-Sheet Stacker 3. 110 V Maintenance Kit.500-Sheet Finisher (w/ 2 or 4-hole punch) 3.500-Sheet Finisher (w/ 3-hole punch) Envelope Tray (replaces Tray 2) Part Number 097S03123 097S03225 097S03125 097S03227 097S03222 097S03218 097S03219 097S03220 097S03221 097S03281 097S03282 097S03286 Routine Maintenance Items Description Maintenance Kit.Consumables Description Toner Cartridge (30K) Staple Pack Part Number 113R00668 008R12941 Upgrade Kits and Options Description 128 MB Memory Option 256 MB Memory Option 16 MB Flash Memory DIMM 20 GB Hard Drive Option B to N Upgrade Kit 1000-Sheet Feeder (Trays 4 & 5) 2000-Sheet Feeder (Tray 6) Duplex Unit 3.

9-46 Phaser 5500 Printer Service Manual .

. ■ ■ ■ ■ Print Engine Plug/Jack Designators Print Engine Plug/Jack Locator Diagrams Notations Used in Wiring Diagrams Print Engine Wiring Diagrams Chapter 10 .Wiring Diagrams In this chapter..

Connects the LVPS and Heater Harness. Connects the Tray 3 Level Sensor and Tray 3 Feeder Harness. Connects the Power Switch and Power Switch Harness. Connects the Finisher Outlet and LVPS. Connects the Finisher Outlet and LVPS. Connects the LVPS and Finisher Outlet. Print Engine Plug/Jack Designators P/J 1 2 3 6 7 11 12 20 21 22 50 56 57 68 69 72 73 74 75 100 101 102 Coordinates Remarks D-204 D-243 D-245 E-245 E-245 D-245 D-245 J-141 J-141 J-141 F-229 B-238 B-239 B-239 B-239 F-230 G-230 G-230 G-230 G-180 G-180 G-180 Connects the LVPS and Main Switch Harness. Connects the Power Switch and Power Switch Harness. Connects the Fuser Sub Lamp 1 and Fuser Harness. Connects the LVPS and GFI Breaker Connects the Fuser Main Lamp (Heat Rod) and Fuser Harness. A brief description of each connection is included in the remarks column. Connects the GFI Breaker and LVPS. Connects the Finisher Outlet and Ground (Earth). Connects the LVPS and Fuser AC Harness. Connects the GFI Breaker and Ground (Earth).Print Engine Plug/Jack Designators The Plug/Jack locators consist of the P/J Locator Tables and the P/J Locator Diagrams. Connects the Tray 2 No Paper Sensor and the Tray 2 Feeder Harness. Connects the Power Switch and Power Switch Harness. Connects the Power Switch and Power Switch Harness. Connects the Fuser Sub Lamp 2 and Fuser Harness. The table lists the plug/jack numbers in numerical order. The co-ordinates column lists the diagram coordinates for the location of the connector. Connects the Tray 2 Level Sensor and the Tray 2 Feeder Harness. 10-2 Phaser 5500 Printer Service Manual . Not Connected Connects the LVPS and GFI Breaker.

Connects the OCT Home 1 Sensor and OCT Harness. Connects the Tray 2 Feed/Lift Motor and Tray 2 Feeder Harness. Connects the I/P Board to the Front Panel. Connects the Tray 2 Size Sensor and Size Sensor Harness. 108 109 110 117 118 120 120 121 125 126 127 130 131 132 133 133 134 140 150 150 160 170 201 G-152 D-200 D-201 B-134 B-134 H-196 C-119 C-244 C-106 D-122 F-108 E-124 B-139 B-139 B-139 H-181 H-181 F-123 G-166 F-119 F-123 F-123 E-180 Wiring Diagrams 10-3 . Connects the 2nd STS and Fuser Outlet. Connects the Drum Cartridge and CRUM Harness. Connects the Rear STS and Fuser Outlet.Print Engine Plug/Jack Designators P/J 103 104 105 106 107 Coordinates Remarks G-180 F-167 F-186 D-183 D-153 Connects the Tray 3 No Paper Sensor and Tray 3 Feeder Harness. Connects the Laser Assembly and Laser Harness. Connects the Feed Out #3 Sensor and Feed Out #3 Sensor Harness. Connects the Full Stack Sensor and OCT Harness. Connects the Laser (Scanner) and Laser Harness. Connects the I/P Board to the LVPS. Connects the Laser Assembly and Laser Harness. Connects the Toner Cartridge and CRUM Harness. Connects the Tray 3 Size Sensor and Size Sensor Harness. Connects the Tray 3 Pre Feed Sensor and Tray 2 Feeder Harness. Connects the Hum & Temp (Environmental) Sensor and REGI Harness. Connects the Laser Assembly and Laser Harness. Connects the Center STS and Fuser Outlet. Connects the LHL Switch and the PH Harness. Connects the Tray 2 Pre Feed Sensor and Tray 2 Feeder Harness. Connects the Tray 1/MPT No Paper Sensor and Tray 1/MPT Harness. Connects the Front Door Interlock Switch and INTLK Harness. Connects the Tray 1/MPT Size Sensor and Tray 1/MPT Sensor Harness. Connects the Fuser Exit Sensor and PH Harness. Connects the Registration Sensor and Registration Harness. Connects the Door A Interlock Switch and Engine Logic Board.

Connects the Engine Logic Board and PH Harness. Connects the Engine Logic Board and Laser Harness. Connects the Registration Clutch and Registration Harness. Connects the Engine Logic Board and Duplex Unit Harness. Connects the Engine Logic Board and Drum Cartridge Fan. Connects the Engine Logic Board and Size Harness. Connects the Engine Logic Board and LV PWR Harness.Print Engine Plug/Jack Designators P/J 202 204 205 206 214 215 216 221 311 400 401 402 403 404 405 406 407 408 409 410 411 412 413 414 415 416 417 419 Coordinates Remarks E-180 H-199 D-151 G-196 G-198 E-166 H-106 E-107 B-242 C-214 C-214 D-212 F-211 E-212 G-212 D-212 C-212 G-211 G-213 G-212 G-214 C-213 D-214 F-214 F-214 D-214 E-214 D-212 Connects the Tray 3 Feed/Lift Motor and Tray 2 Feeder Harness. Connects the Engine Logic Board and Tray 1/MPT Harness. Connects the Drive Assembly and Drive Harness. Connects the Engine Logic Board and Feeder Harness. Connects the Tray 1/MPT Feed Solenoid and MSI Harness. Connects the Takeaway Clutch and PH Harness. Connects the Exit 1 Offset Motor and EXIT Harness. Connects the Engine Logic Board and LV PWR Harness. Connects the Engine Logic Board and Tray 6 Harness. Connects the Engine Logic Board and Xerographics Harness. Connects the Engine Logic Board and Tray 6 Harness. Connects the Engine Logic Board and Output Unit. Connects the Engine Logic Board and CRUM Harness. Connects the Toner Dispense Motor and LV PWR Harness. Connects the Engine Logic Board and Registration Harness. Connects the Engine Logic Board and Drive Harness. Connects the Engine Logic Board and Laser Harness. Connects the Front Panel and Front Panel Harness. Connects the Engine Logic Board and I/P Board Harness. 10-4 Phaser 5500 Printer Service Manual . Connects the Engine Logic Board and Interlink Harness. Connects the Engine Logic Board and Tray 4-5 Harness.

Connects the Exit PWB and EXIT Harness. Connects the Fuser Harness and PH Harness. Connects the Tray 1/MPT and Tray 1/MPT Harness. Connects the HVPS and Registration Harness. Connects the EXIT 2 Harness and EXIT Harness. Connects the Tray 1/MPT Sensor Harness and Tray 1/MPT Harness. Wiring Diagrams 10-5 . Connects the LVPS and LV PWR Harness.Print Engine Plug/Jack Designators P/J 420 421 430 431 432 433 434 490 500 521 525 526 540 590 600 600 601 602 605 606 607 608 609 610 613 830 831 890 Coordinates Remarks C-212 C-213 H-120 H-120 H-120 I-120 I-120 I-121 C-110 I-246 I-247 I-245 E-122 J-123 A-139 H-196 C-183 C-184 I-199 G-195 G-199 C-184 D-151 B-109 G-196 C-125 C-125 I-125 Connects the Engine Logic Board and LV PWR Harness. Connects the Tray 2 Feeder Harness and Feeder Harness. Connects the LVPS and LV PWR Harness. Connects the ATC Sensor and Registration Harness. Connects the Take Away Sensor Harness and PH Harness. Connects the RAM DIMM to the I/P Board. Connects the Exit PWB and LV PWR Harness. Connects the Fuser and Fuser AC Harness. Connects the Exit PWB and LV PWR Harness. Connects the RAM DIMM to the I/P Board. Connects the Exit PWB and EXIT Harness. Connects the Engine Logic Board and LV PWR Harness. Connects the Flash ROM device to the I/P Board. Connects the I/P Board and Engine Logic Board. Connects the Fuser and Fuser Harness. Connects the OCT Harness and EXIT Harness. Connects the Exit PWB and EXIT Harness. Connects the Hard Drive to the I/P Board. Connects the I/P Board to the Laser Assembly. Connects the LVPS and LV PWR Harness. Connects the Tray 3 Feeder Harness and Feeder Harness.

and 5. Drum and Toner Cartridge A B C D E F G H I J K L 101 102 103 104 125 221 127 105 106 107 108 109 216 110 111 610 500 112 113 114 115 s5500-209 10-6 Phaser 5500 Printer Service Manual . 4.Plug/Jack Locator Diagrams The Print Engine P/J Locator diagrams show the location of primary connections within the printer. Use these illustrations to locate connections called out in the troubleshooting procedures presented in Chapters 3.

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

Fuser and Exit 1 A B C D E F G H I J K L 131 132 117 133 118 Exit 1 134 135 136 137 600 138 131 132 133 139 140 20 21 22 141 Fuser Assembly 142 143 144 145 s5500-211 10-8 Phaser 5500 Printer Service Manual .

Tray 1/MPT
A B C D E F G H I J K L

146

147

148

149

150

205 609 108

151

152

153

154

107
155

156

157

158

159

160

s5500-212

Wiring Diagrams

10-9

Registration Transport Assembly
A B C D E F G H I J K L

161

162

163

164

215

150 104

165

166

167

168

169

170

171

172

173

174

175

s5500-213

10-10

Phaser 5500 Printer Service Manual

Tray 2 & 3 Feeder Assemblies
A B C D E F G H I J K L

176

177

178

Tray 2 : 201 Tray 3 : 202

179

180

Tray 2 : 100 Tray 3 : 102 Tray 2 : 101 Tray 3 : 103 Tray 2 : 133 Tray 3 : 134

181

182

601 106 602

183

184

185

608
186

187

105
188

189

190

s5500-214

Wiring Diagrams

10-11

Print Engine Electrical
A B C D E F G H I J K L

191

192

193

613 206

606 120

194

195

600
196

197

198

214
199

200

605

201

204
202

109
203

607

800

110

204

205

s5500-215

10-12

Phaser 5500 Printer Service Manual

Engine Logic Board
A B C D E F G H I J K L

206

207

208

209

210

407

406

402

404

403

408 405

211

419
212

410

420
213

409 421

214

412
215

411 415

401
216

414 413 417

400
217

416

218

219

220

s5500-216

Wiring Diagrams

10-13

Image Processor Board
A 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130
s5500-620

B

C

D

E

F

G

H

I

J

K

L

120

150

490

540 590

890

830

831

10-14

Phaser 5500 Printer Service Manual

AC Accessory Panel
A B C D E F G H I J K L

221

222

223

224

225

226

227

74

228

50

73

229

230

75

231

72
232

233

234

235

s5500-217

Wiring Diagrams

10-15

LVPS
A B C D E F G H I J K L

236

Power Switch
237

56

238

239

68
240

69 311

57

241

242

2 121 526 1 11

243

244

245

246

521
247

248

12 3 7 525 6

249

250

s5500-218

10-16

Phaser 5500 Printer Service Manual

Print Engine Wiring Diagrams
Notations Used in Wiring Diagrams
The symbols in the interconnection wiring diagram are described below. Note that the description of general symbols is omitted.

Symbol

Description
Represents an interconnection between parts using wiring harness or wire, and indicates its signal name/ contents. The arrow “>” or “<” on the line represents the direction of signal flow. Represents an interconnection between parts using wiring harness or wire, which differs according to the specifications, and indicates its signal name/contents. The arrow “>” or “<” on the line represents the direction of signal flow. Represents a connection between parts using a conductive member such as a plate spring, and indicates its signal name/contents. The arrow “>” or “<” on the line represents the direction of signal flow. Represents a function and a logical value (High (H) or Low (L)) of a signal when the function is activated. The voltage indicates a value when the signal is High. The arrow indicates the direction of signal flow. Represents a function and a logical value (High (H) or Low (L)) of a signal when the function is in a detectable state. The voltage indicates a value when the signal is High. The arrow indicates the direction of signal flow. Represents a connection between lead wires.

Represents a connection between parts by tightening of a screw. Represents a connection between “A” and “A”.

24 VDC

The DC voltage indicates an approximate value measured when the negative side is connected to a signal ground (SG). Indicates a signal ground (SG).

Wiring Diagrams

10-17

Symbol

Description
Indicates a frame ground (FG).

Indicates a return. RTN Represents a connector. The connector and PIN Nos. are shown at the upper and lower parts respectively. “P,-” indicates the plug side of the connector. “J,>” indicates the jack side of the connector.

Represents a connection terminal with a plate spring on the printed circuit board. The connector No. is indicated inside the box. Represents a connector directly connected to the printed circuit board. The connector No. is indicated inside the box.

Represents a part. “PL X.Y.Z” indicates the item “Z” of the plate (PL) “X.Y” described in Chapter 5 “Parts List”.

Represents a functional part within a part, and indicates the name of the functional part.

Indicates a reference item associated with the section.

10-18

Phaser 5500 Printer Service Manual

Print Engine General Wiring (1/2)
1 LVPS LVPS P/J526 P/J1 Power Switch P/J430 Exit PWB Exit 1 P/J431 P/J206 Offset Motor P/J118 Full Stack Sensor P/J432 P/J613 P/J117 OCT Home Sensor 10

P/J2

Outlet MN

P/J5

Choke Coil 11

Laser Assembly P/J160 P/J421 Laser Assembly P/J170 P/J140 P/J406 P/J620 P/J130 ROS Motor LD PWB P/J406 SOS Sensor

9

P/J302 I/P Board

P/J400 P/J521 P/J300 P/J301 P/J402

Drum Cartridge Detect Sw

P/J404

P/J411

P/J605

P/J609

P/J107 Tray 1 Paper Size

8

Front Door Interlock Switch Door A Interlock Switch 2 P/J525 P/J6

P/J120

P/J405 Tray 1

P/J205 Solenoid Pick Up

P/J121

P/J108 Tray 1 No Paper Sensor P/J401

Fuser

Fuser Assembly

P/J600

P/J607

Engine Logic P/J410 Board

Fuser Exit Sensor

P/J125

s5500-219

Wiring Diagrams

10-19

Print Engine General Wiring (2/2)
Engine Logic Board
P/J202 Tray 3 Feed Lift Up Motor

P/J409

P/J602

7

P/J102 Tray 3 Level Sensor

Tray 3

P/J103 Tray 3 No Paper Sensor

P/J134 Tray 3 Pre Feed Sensor 3 Feed Out #3 Sensor P/J105 P/J608 P/J412 Door B Interlock Switch P/J106 P/J409 P/J204 P/J601 P/J201 Tray 2 Feed Lift Up Motor 6 P/J110 Tray 3 Size Sensor

Take Away Clutch

Registration
Registration Sensor P/J104 P/J403

P/J100 Tray 2 Level Sensor

Tray 2
Registration Clutch P/J215

P/J101 Tray 2 No Paper Sensor

4

Chute-Assembly DTS Transfer Roller BTR Drum Cartridge DRUM BCR Mag Roll

P/J133 Tray 2 Pre Feed Sensor P/J500

HVPS

P/J412

P/J109 Tray 2 Size Sensor

5 P/J408 P/J214 Main Motor Drum Motor CN102 Fuser Fan

ATC Sensor P/J610

Environmental Sensor

P/J150

P/J419

P/J126 Drum Cartridge CRUM

Xerographics
Toner Dispense Motor P/J216 P/J420

Drive/CRUM
P/J417

P/J127 Toner Cartridge CRUM P/J221 CRU Fan

s5500-628

10-20

Phaser 5500 Printer Service Manual

3VDC +3.3VDC SG SG +5VDC SG P/J300 12 1 6 2 7 4 9 Exit PWB +5VDC SG +24VDC RTN Engine Logic Board Interlock +24VDC +24VDC Supply Door A Interlock Switch P/J405 P/J121 I/L +24VDC 4 B1 3 A1 P/J430 3 4 1 2 I/P Board ON/OFF +3.3VDC Supply +5VDC Supply P/J526 2 1 4 3 +5VDC SG +24VDC RTN P/J400 3 4 1 2 Front Door Interlock Switch P/J405 P/J120 2 B1 +24VDC 1 A1 Choke Coil P/J5 1 2 From XERO To ROS Outlet MN P/J2 1 5 P/J404 1 3 Drum Cartridge Detect Switch LD +5VDC Power Switch P/J1 1 6 4 3 NUT HOT Breaker GFI INL T11 1 1 T12 HOT NUT P/J50 1 2 s5500-220 2 1 3 4 Wiring Diagrams 10-21 .LVPS LVPS P/J521 5 1 6 2 7 3 8 P/J526 6 5 8 7 Main Power On +3.

Fuser Engine Logic Board LVPS Fuser P/J401 5 4 3 2 1 Main Lamp On(H)+5VDC Sub Lamp1 On(H)+5VDC Sub Lamp2 On(H)+5VDC Relay On(L)+24VDC Zero Cross P/J525 1 2 3 4 5 Heater Control P/J6 2 3 4 1 P/J600 1 4 7 11 P/J410 7 6 5 4 3 2 Center STS Signal SG 2ND STS Signal SG Rear STS Signal SG P607 1 2 3 4 5 6 6 5 4 3 2 1 J607 P/J600 2 3 P131 2 1 P132 5 6 P133 8 9 1 2 Rear STS 1 2 2nd STS Center STS +5VDC P/J410 8 9 10 +5VDC SG Fuser Exit Paper Sensed(L)+5VDC P/J125 3 2 1 Fuser Exit Sensor s5500-221 10-22 Phaser 5500 Printer Service Manual .

Registration Transport Engine Logic Board +24VDC P/J403 B9 B10 +24VDC Registration Clutch ON (L)+24VDC P215 2 1 1 2 Registration Clutch +5VDC J403 B13 B8 B3 +5VDC Registration Sensor Paper Sensed (L)+5VDC SG J104 1 2 3 Registration Sensor Door B Interlock Switch P/J410 12 11 +5VDC J410 15 14 15 +24VDC +5VDC F/O #3 Sensor Sensed (L)+5VDC SG P608 1 2 3 3 2 1 J608 J105 1 2 3 Feed out #3 Sensor Door B Open (H)+5VDC SG J106 1 2 P/J410 16 17 +24VDC Takeaway Clutch ON (L)+24VDC P204 2 1 1 2 Take Away Clutch s5500-222 Wiring Diagrams 10-23 .

Xerographics Engine Logic Board Interlock +24VDC P/J403 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 I/L +24VDC I/L +24VDC RTN RTN DTS ON BTR Monitor AGND BTR SEL BTR Remote BCR AC Clock BCR AC ON BCR DC Remote DEVE BIAS DC Remote DEVE BIAS DC ON P/J500 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 HVPS Chute-Assembly DTS Drum Cartridge BCR BTR Transfer Roller Drum Mag Roll +5VDC P/J403 B5 B11 B12 B2 To Power +5VDC P/J403 B15 B7 B4 B6 +5VDC Humidity Signal SG Temperature Signal P/J150 1 2 3 4 Toner Dispense Motor +24VDC P/J420 1 2 Dispense Motor On(L) +24VDC +24VDC P/J216 2 1 M Environmental Sensor B1 ATC Sensor Signal +5VDC +5VDC SG LD +5VDC P610 6 5 4 3 1 2 3 4 5 7 ATC Sensor J610 s5500-223 10-24 Phaser 5500 Printer Service Manual .

Drive/CRUM Engine Logic Board Motor Assembly P/J408 14 13 +5VDC 12 11 10 2 1 9 8 3 7 6 5 4 P/J214 1 2 3 4 5 13 14 6 7 12 8 9 10 11 M Drum Motor M Main Motor CN102 2 3 1 Fuser Fan Interlock +24VDC I/L +24VDC I/L +24VDC RTN RTN +5VDC Fuser Fan On Fuser Fan Fail M/C Clock Main Motor Ref Clock Main Motor On(L)+5VDC Drum Motor Fail(H)+5VDC Drum Motor Ref Clock Drum Motor On(L)+5VDC Drum Motor CW/CCW Drum Cartridge CRUM PWB +5VDC P/J419 1 2 3 4 5 +5VDC SG TX DATA MUTE CDET P126 6 5 4 3 2 1 1 2 3 4 5 6 Toner Cartridge CRUM PWB +5VDC P/J419 6 7 8 9 10 +5VDC SG TX DATA MUTE CDET P127 6 5 4 3 2 1 1 2 3 4 5 6 P/J417 RTN Drum Cartridge Fan On Drum Cartridge Fan Fail P221 J221 2 3 1 Drum Cartridge Fan s5500-224 Wiring Diagrams 10-25 .

Tray 2 Engine Logic Board +24VDC P/J409 A1 A2 A3 A4 A5 A6 +5VDC P/J409 A7 A8 A9 +5VDC SG Tray 2 Level Up(H)+5VDC P601 9 8 7 7 8 9 J601 P/J100 3 2 1 Tray 2 Level Sensor +5VDC P/J409 A10 A11 A12 +5VDC SG Tray 2 Paper Sensed(L)+5VDC P601 6 5 4 10 11 12 J601 P/J101 3 2 1 Tray 2 No Paper Sensor +5VDC P/J409 A13 A14 A15 SG Tray 2 Pre Feed Sensed(L)+5VDC +5VDC P601 3 2 1 13 14 15 J601 P/J133 3 2 1 Tray 2 Pre Feed Sensor +5VDC P/J412 4 3 2 1 +5VDC Tray 2 Size Switch Signal SG Tray 2 Size Switch S5 On(L)+5VDC P/J109 1 2 3 4 Tray 2 Size Sensor s5500-225 FMOT1 /B FMOT1 /A +24VDC +24VDC FMOT1 B FMOT1 A P601 15 14 13 12 11 10 1 2 3 4 5 6 J601 P/J201 6 5 4 3 2 1 M Tray 2 Feed/Lift Motor 10-26 Phaser 5500 Printer Service Manual .

Tray 3 Engine Logic Board +24VDC P/J409 B1 B2 B3 B4 B5 B6 +5VDC P/J409 B7 B8 B9 +5VDC SG Tray 3 Level Up(H)+5VDC P602 9 8 7 7 8 9 J602 P/J102 3 2 1 Tray 3 Level Sensor +5VDC P/J409 B10 B11 B12 +5VDC SG Tray 3 Paper Sensed(L)+5VDC P602 6 5 4 10 11 12 J602 P/J103 3 2 1 Tray 3 No Paper Sensor +5VDC P/J409 A13 A14 A15 SG Tray 3 Pre Feed Sensed(L)+5VDC +5VDC P602 3 2 1 13 14 15 J602 P/J134 3 2 1 Tray 3 Pre Feed Sensor +5VDC P/J412 9 8 7 6 +5VDC Tray 3 Size Switch Signal SG Tray 3 Size Switch S5 On(L)+5VDC P/J110 1 2 3 4 Tray 3 Size Sensor FMOT2 /B FMOT2 /A +24VDC +24VDC FMOT2 B FMOT2 A P602 15 14 13 12 11 10 1 2 3 4 5 6 J602 P/J202 6 5 4 3 2 1 Tray 3 Feed/Lift Motor M s5500-226 Wiring Diagrams 10-27 .

Tray 1/MPT Engine Logic Board +5VDC J411 P605 J605 P609 J609 +5VDC 1 8 1 3 1 SG 2 7 2 2 2 Tray 1/MPT Size Sensor Signal 3 6 3 1 3 J107 1 2 3 Tray 1/MPT Paper Size Sensor +24VDC P/J411 4 5 Pick Up Solenoid On(L)+24VDC +24VDC P605 5 4 4 5 J605 P205 2 1 1 2 Pick Up Solenoid +5VDC P/J411 6 7 8 +5VDC SG Tray 1/MPT Paper Sensed(L)+5VDC P605 3 6 2 7 1 8 J605 P/J108 3 2 1 Tray 1/MPT No Paper Sensor s5500-227 10-28 Phaser 5500 Printer Service Manual .

Laser Assembly Laser Assembly I/P Board LD PWB P/J890 2 1 4 3 Engine Logic Board From Power /VD01 VD01 /VD02 VD02 P/J160 2 1 P/J170 2 1 +24VDC P/J406 1 2 3 4 5 6 7 8 9 ROS Valid LD+5VDC SG SOS Signal Power Control1 On(L)+5VDC ROS VREF Out Signal ROS Monitor Power Control2 On(L)+5VDC LD Enable On(L)+5VDC P/J140 9 8 7 6 5 4 3 2 1 P/J406 1 3 2 SOS Sensor P/J406 P620 +24VDC 10 RTN 11 Scanner Motor On(L)+5VDC 12 Scanner Motor Clock 13 J620 4 3 2 1 1 2 3 4 P/J130 5 4 3 1 M Scanner Motor s5500-228 Wiring Diagrams 10-29 .

Exit 1 Exit PWB +5VDC P/J432 1 2 3 +5VDC SG OCT Home Sensed(L)+5VDC P613 6 5 4 1 2 3 J613 P/J117 3 2 1 OCT Home Sensor +5VDC P/J432 4 5 6 +5VDC SG Full Stack Sensed(L)+5VDC P613 3 2 1 4 5 6 J613 P/J118 3 2 1 Full Stack Sensor Offset Motor +24VDC P/J432 7 8 9 10 11 +24VDC Offset Motor A Offset Motor B Offset Motor /A Offset Motor /B P206 5 4 3 2 1 1 2 3 4 5 M J206 Engine Logic Board P/J431 1 2 3 4 5 6 7 8 SG Engine To Exit Exit To Engine SG Fuser Exit Paper Sensed(H)+5VDC Full Stack Sensed(L)+5VDC Registration Clutch On(L)+5VDC Exit Gate Solenoid On(H)+5VDC P/J421 8 7 6 5 4 3 2 1 s5500-229 10-30 Phaser 5500 Printer Service Manual .

Engine Logic and Image Processor Board Interface Engine Logic Board P/J402 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 SG SG SG Command (I/P To Engine) Status (Engine To I/P) Status Ready Command Ready SClock FWE P/J301 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 s5500-230 I/P Board TOP BD Start PRED Engine Ready I/P Ready Ready Wiring Diagrams 10-31 .

Image Processor Board (1/2) I/P Board P/J120 1 2 3 4 5 6 7 8 9 10 11 12 3.3 V GND GND GND GND No Connection 3.3 V GND No Connection 5V No Connection 3.3 V P/J521 LVPS P/J150 1 2 3 4 5 6 7 8 9 10 Front Panel GND TXD GND RXD GND /THRTL GND /RST VCC VCC J601 GND SW1 SW2 SW3 /Reset GND 1 2 3 4 5 6 Mode Select Port s5500-621 10-32 Phaser 5500 Printer Service Manual .

Image Processor Board (2/2) I/P Board P/J590 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 /RDY /CPRDY /PPRDY /PRFD /START /BD /TOP No Connection No Connection No Connection /CCLK /CBSY /SBSY /STA /CMD GND GND GND Engine Logic Board Laser Assembly P/J890 1 2 VDO1 /VDO1 P/J160 P/J890 3 4 VDO2 /VDO2 P/J170 VX_RXD N/C 3.3V VX_TXD GND J700 1 2 3 4 5 Serial Debug Port s5500-622 Wiring Diagrams 10-33 .

10-34 Phaser 5500 Printer Service Manual .

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

†† Supplies Usage Page Personal Print Jobs†† Secure Print Jobs†† Proof Print Jobs†† Saved Print Jobs†† Walk-Up Printing* Select for Installation* Toner Cartridge Life Drum Cartridge Life Staple Cartridge Life Fuser Life Reset Fuser Life Total Print Count Printer Setup Configuration Page Connection Setup Connection Setup Page Network Setup* Parallel Setup USB Setup Reset Connection Setup TCP/IP Setup NetWare Setup Ethernet Speed EtherTalk Parallel Port Wait Timeout Page Description Language = prints an information page. Information Walk-Up Features Printer Setup Troubleshooting Front Panel Buttons: Cancel Back Up Arrow OK Information Down Arrow Model Printer Name Help Guide Configuration Page Paper Tips Page Supplies Usage Page Connection Setup Page Startup Page Usage Profile PostScript Font List PCL Font List Disk Directory † Flash Directory ‡‡ Information Menu Map Printer Identification Information Pages Sample Pages Billing Meters Supplies Info Print Server* IP Address* Serial # Activation Date Serial # Total Impressions Black Impressions Large Black Impressions Office Demonstration 2-Sided Demonstration** Walk-Up Features*. Requires: * Networked printer ** Duplex Unit † Hard Drive †† Hard Drive with stored jobs present ‡ Optional Tray(s) ‡‡ Flash Memory § Stacker §§ Finisher USB Port Wait Timeout Page Description Language TCP/IP DHCP/BOOTP AutoIP TCP/IP Address TCP/IP Network Mask TCP/IP Gateway Port 9100 LPR IPP SLP SSDP CentreWare IS NetWare IPX Frame Type s5500-615 A-2 Phaser 5500 Printer Service Manual .Phaser 5500 Laser Printer Menu Map Main Menu: READY TO PRINT.

§§ Job Offset Stapling Options §§ Punch §§ Punch Holes || PostScript Error Info Image Smoothing Edge-to-Edge Printing Reset PostScript Setup Font Number Pitch Point Size Symbol Set Orientation Form Length Line Termination Edge-to-Edge Printing Reset PCL Setup Printer Setup (continued) Paper Handling Setup PostScript Setup PCL Setup General Setup Front Panel Setup Printer Controls File Security† Output Tray Switch §. Requires: * Networked printer ** Duplex Unit † Hard Drive †† Hard Drive with stored jobs present ‡ Optional Tray(s) ‡‡ Flash Memory § Stacker §§ Finisher || 220 V Finisher s5500-616 Reference A-3 . §§ Fuser Configuration Reprint Jammed Pages Reset Paper Handling Setup Print-Quality Mode Print Quantity Print with Low Toner Reset General Setup Front Panel Language Startup Page Overwrite Removals Remove Job Files Daily Removal Remove At HH:MM Reset File Security Power Saver Timeout Date and Time Metric Defaults Power Saver Reset Printer Controls Front Panel Brightness Front Panel Contrast Accessible Front Panel Reset Front Panel Setup Troubleshooting Help Guide Paper Jams Print Quality Problems Network Log Pages* Service Tools Engine Error History Jam History Hexadecimal Mode Service Usage Profile Email Service Report* Reset NVRAM NetWare Start Log NetWare Runtime Log TCP/IP Start Log TCP/IP Runtime Log AppleTalk Start Log AppleTalk Runtime Log Paper Tips Page Online Jam Prevention Guide Troubleshooting Print Quality Page Test Prints = prints an information page.Paper Source 2-Sided Printing** Tray 1 (MPT) Setup Tray 2 Setup Tray 3 Setup Tray 4 Setup‡ Tray 5 Setup‡ Tray 6 Setup‡ Load Paper Timeout Tray Sequence Tray Prompt MPT Prompt Custom Units Paper Destination §.

then select the Finisher. For example. Service Diagnostics Tests Print Service Menu Map General Status Provides current print engine and option firmware version and counter values. Printer Version Duplex Version Exit Version Trays 4 & 5 Feeder Version Finisher Version Tray 6 Feeder Version Total Print Count Transfer Roller Count Drum Cartridge Count Drum Cartridge Cycles Tray 1/MPT Feed Count Tray 2 Feed Count Tray 3 Feed Fount Tray 4 Feed Count Tray 5 Feed Count Tray 6 Feed Count Print Pattern Print Quantity Input Tray Output Tray Duplex Staple Selection Pages Per Set Punch Selection Select Pattern Scan Direction All Trays Scan Direction Tray 1/MPT Scan Direction Tray 2 Scan Direction Tray 3 Scan Direction Tray 4 Scan Direction Tray 5 Scan Direction Tray 6/HCF Scan Direction Duplex All Trays Scan Direction Duplex Tray 1/MPT Scan Direction Duplex Tray 2 Scan Direction Duplex Tray 3 Scan Direction Duplex Tray 4 Scan Direction Duplex Tray 5 Scan Direction Duplex Tray6/HCF Test Print Starts the Test Print. A-4 Phaser 5500 Printer Service Manual . to access the list of Finisher motor tests. Printer NVRAM Adjustments Perform NVRAM adjustment essential to the performance of the printer. Finisher). Exit 2. then the individual test. first select Motor/Fans. To access a test or utility. solenoid). the specific part (Duplex Unit. sensor.Service Diagnostics Menu Map The Service Diagnostic Menu Map lists all the tests and utilities available within Service Diagnostics. This prints a 3-page Service Diagnostics Menu Map. select the test type (motor.

Motor/Fans Tests Print Engine Motor Tests: Tests motor/fans functionality.4 hole Duplex Assembly Motor Test Exit 2 Assembly Motor Tests Trays 4 & 5 Motor Tests Tray 6 Motor Tests Finisher Motor Tests Reference A-5 .CCW Exit Motor-Fast-CW Exit Motor-Slow-CW Exit Motor-CCW Punch Unit Motor Front Punch Unit Motor Rear Punch Motor .2 hole Punch Motor . Process Direction All Trays Process Direction Tray 1/MPT Process Direction Tray 2 Process Direction Trays 3-6 Process Direction Duplex All Trays Printer Main Motor On Fuser Fan Motor High Drum Fan Motor Laser Scan Motor Tray 2 Lift Motor Tray 2 Feed Motor Tray 3 Lift Motor Tray 3 Feed Motor Drum Cartridge Motor On Offset Output Motor 1 Front Offset Output Motor 1 Rear Toner Dispense Motor Duplex Motor Offset Output Motor 2 Front Offset Output Motor 2 Rear Exit Output Motor 2 Forward Exit Output Motor 2 Reverse Exit 2 Fan Tray 4 Lift Motor Tray 4 Feed Motor Tray 5 Lift Motor Tray 5 Feed Motor Take Away Drive Motor Tray 6 Lift Motor Tray 6 Feed Motor Tray 6 Take Away Motor-Slow Tray 6 Take Away Motor-Fast Horizontal Transport Motor-Fast Horizontal Transport Motor-Slow Transport Motor Registration Motor-Fast-CW Registration Motor-Slow-CW Registration Motor.3 hole Punch Motor .Service Diagnostics Tests (Continued) Printer NVRAM Adjustments Perform NVRAM adjustment essential to the performance of the printer.

Up Stacker Motor .Service Diagnostics Tests (Continued) Finisher Motor Tests Front Tamper Motor Motor Low Speed Outboard Motor Mid Speed Outboard Motor High Speed Outboard Motor Low Speed Inboard Motor Mid Speed Inboard Motor High Speed Inboard Rear Tamper Motor Motor Low Speed Outboard Motor Mid Speed Outboard Motor High Speed Outboard Motor Low Speed Inboard Motor Mid Speed Inboard Motor High Speed Inboard Staple Head Move Motor Motor Low Speed Front Motor Medium Speed Front Motor High Speed Front Motor Low Speed Rear Motor Medium Speed Rear Motor High Speed Rear Stapler Motor Forward Stapler Motor Reverse Eject Clamp Motor .Up Eject Clamp Motor . Duplex Sensor/Switch Tests A-6 Phaser 5500 Printer Service Manual .Down Door A Interlock Switch Door B Interlock Switch Front Cover Interlock Switch Tray 1/MPT Size Sensor (displays paper size for tray) Tray 2 Size Sensor (displays paper size for tray) Tray 3 Size Sensor (displays paper size for tray) Tray 1/MPT No Paper Sensor Tray 2 No Paper Sensor Tray 3 No Paper Sensor Tray 2 Level Sensor Tray 3 Level Sensor Tray 2 Pre-Feed Sensor Tray 3 Pre-Feed Sensor Tray 3 Feed Out Sensor Registration Sensor Fuser Exit Sensor Standard Output Tray Full Sensor Exit Offset 1 Home Position Sensor Detect Drum Cartridge Switch Door D Interlock Switch Wait Sensor Printer Sensor/Switch Tests Print Engine Sensor/Switch Tests: Tests the function of sensors/ switches by manually toggling each sensor/switch.Down Eject Motor Motor Low Speed Forward Motor High Speed Forward Motor Low Speed Reverse Motor High Speed Reverse Stacker Motor .

Reference A-7 . punch and stapler.Service Diagnostics Tests (Continued) Exit 2 Sensor/Switch Tests Door E Interlock Switch Exit Sensor Exit 2 Full Stack Sensor Exit Offset 2 Home Position Sensor Door C Interlock Switch Tray 4 Size Sensor (displays paper size for tray) Tray 5 Size Sensor (displays paper size for tray) Tray 4 No Paper Sensor Tray 5 No Paper sensor Tray 4 Level Sensor Tray 5 Level Sensor Tray 4 Pre-Feed Sensor Tray 5 Pre-Feed Sensor Tray 4 Feed Out Sensor Tray 5 Feed Out Sensor Door J Interlock Switch Tray 6 Paper Size Sensor Tray 6 No Paper Sensor Tray 6 Level Sensor Tray 6 Pre-Feed Sensor Tray 6 Feed Out Sensor Tray 6 Interlock Switch Tray 6 Size Sensor A Tray 6 Size Sensor B Tray 6 Tray In Sensor Door F Interlock Sensor Door G Interlock Switch Door H Interlock Switch Horizontal Transport Entrance Sensor Horizontal Transport Exit Sensor Transport Entrance Sensor Gate Sensor Buffer Path Sensor Upper Tray Exit Sensor Lower Tray Full Sensor Compiler Exit Sensor Compiler Tray No Paper Sensor Side Registration Sensor 1 Side Registration Sensor 2 Eject Clamp Home Sensor Set Clamp Home Sensor Punch Unit Move Home Sensor Punch Home Sensor Punch Front Sensor Punch Hole Select Sensor Punch Motor Encoder Sensor Punch Box Set Sensor Tray 4 & 5 Sensor/Switch Tests Tray 6 Sensor/Switch Test Finisher Sensor/Switch Tests Test the sensors and switches for the Finisher/Stacker.

punch and stapler.High Power Tray 6 Nudger Solenoid . Exit Read Current Status Set 3-Hole Punch & Staple (Finisher) Set 2/4-Hole Punch & Staple (Finisher) Set No Punch & No Staple (Stacker Only) Reboots Printer out of Diagnostics. A-8 Phaser 5500 Printer Service Manual .Low Power Buffer Gate Solenoid (Path Out) Buffer Gate Solenoid (Path In) Transport Gate Solenoid (Upper Tray) Transport Gate Solenoid (Lower Tray) Sub Paddle Solenoid Set Clamp Clutch PostScript NVRAM Reset Factory NVRAM Reset Save from Engine Board Restore to Engine Board IP NVRAM Access: This menu lets you reset NVRAM locations. Exit 2 Solenoid/Clutch Test Tray 4 & 5 Clutch Test Tray 6 Solenoid Tests Finisher Solenoid/Clutch Tests Exit 2 Gate Solenoid Take Away Clutch Tray 6 Nudger Solenoid .Service Diagnostics Tests (Continued) Finisher Sensor/Switch Tests Test the sensors and switches for the Finisher/Stacker. Finisher Board Setup Sets the Finisher/Stacker board configuration. Engine Logic Board Replacement Saves/restores NVRAM locations from Engine Logic Board when replaced. Front Tamper Home Sensor Rear Tamper Home Sensor Staple Move Position Sensor Staple Head Low Staple Sensor Staple Head Self Priming Sensor Staple Head Home Sensor Lower Tray No Paper Sensor Lower Tray Upper Limit Sensor Stacker Encoder Sensor Stack Height Sensor 1 Stack Height Sensor 2 Registration Clutch Tray 1/MPT Feed Solenoid Take Away Clutch Solenoid/Clutch Tests Print Enegine Solenoid/ Clutch Test: Test the functionality of Solenoids and Clutches.

Displays the number of sheets fed since the last Fuser reset. Displays the total count through the Transfer Roller since last reset. conditions. Displays the total count of the Drum Cartridge. Displays the number of sheets fed since the last Fuser reset. General Status Utilities Utility Printer Version Duplex Version Exit Version Tray 4-5 Feeder Version Finisher Version Tray 6 Feeder Version Total Print Count Transfer Roller Count Drum Cartridge Count Drum Cartridge Cycles Tray 1/MPT Feed Count Tray 2 Feed Count Tray 3 Feed Count Tray 4 Feed Count Tray 5 Feed Count Tray 6 Feed Count Action/Requirement Displays code version and release data stored in the Print Engine.Service Diagnostic Tests and Utilities These descriptions cover each grouping listed in the Service Diagnostics menu. Reference A-9 . When attempting to test a device that is not installed the “Option Not Installed” message appears. Displays code version and release data stored in the Duplex Unit. Displays the number of sheets fed since the last Fuser reset. Displays the Drum Cartridge total cycle count (240.). Displays code version and release data stored in the Finisher. Displays code version and release data for the 2000-Sheet Feeder. Displays code version and release data for the 1000-Sheet Feeder. or other information necessary to successfully run individual tests or utilities and interpret the results. Displays the number of prints made since the printer’s activation. Displays the number of sheets fed since the last Fuser reset. Described within each group are special instructions. The "Service Diagnostics Menu Map" on page A-4 lists all the tests and utilities as they appear on the display. The value updates each 154 cycles. General Status Menu The General Status menu provides a number of status queries about the printer and any installed options. These values are read-only and cannot be changed. Similar tests or utilities are grouped together for convenience. Displays the number of sheets fed since the last Fuser reset. Displays code version and release data stored in the Exit 2 Module.000 max. Displays the number of sheets fed since the last Fuser reset.

If multiple faults/jams are detected. Select the number of test prints to run. Test prints fed from Tray 1/MPT do not Duplex as Tray 1/MPT is set to irregular size in Diagnostic mode. Sets punch on or off. Printing is disabled in Diagnostic mode if Tray 1/MPT is the selected input tray and the output is set anything other than the Standard Output Tray.Test Print Menu Use Test Print options to identify. Select the number of holes to be punched. similar registration adjustment utilities have been grouped together in the following table. Test prints fed from Tray 1/MPT output to the Standard Output Tray only. Turns Duplex printing on or off. Sets staple on or off and displays the currents staple position setting (Dual. Sets the output tray. The next message appears when the current fault is cleared. Service Diagnostics generates an error for failures that occur during these tests. When making adjustments for scan direction. all 19 adjustments appear on the Service Diagnostics Menu Map on page A-4. options and outputs. the quantity selected indicates the number of two-sided prints. See "Checking Registration" on page 6-4 for detailed instructions for using these utilities to adjust image registration. However. Dark Dusting or Blank. check that duplex registration remains within specification. Configure your test using the options provided. Sets the input tray. For convenience. or for all trays in the process direction. Sets the number of pages per stapled set. repair. Input Tray Output Tray Duplex Staple Selection Pages Per Set Punch Selection Select Pattern Printer NVRAM Adjustments Menu Registration variables are stored in NVRAM to manage image registration for the scan and process directions on paper supplied from each input tray for simplex or duplex operations. Test Print Utilities Utility Print Pattern Print Quantity Action/Requirement Print one of the stored Engine test pages: Grid. This allows for the correction of minor variations as a result of wear or mis-alignment. Start or Stop printing tests. A-10 Phaser 5500 Printer Service Manual . and validate the operability of xerographics and paper handling from all paper sources. or Rear). If Duplex is set to On. Front. only one error message appears at a time. Chart. Select a quantity of two or more when the Stacker Lower Tray is the selected output tray. Following a scan or all tray process direction adjustment. adjustment changes are automatically replicated for duplex prints.

Sets process direction image registration on Trays 3~6 for simplex prints only. See "Adjusting Simplex Registration" on page 6-6 for instructions on using the Print Quality test print to evaluate image registration performance. Sets process direction image registration on all trays for both simplex and duplex prints. For Scan direction adjustments. Use the Printer NVRAM Adjustment utilities in conjunction with the Print Quality test print. Sets scan direction image registration on the tray selected for both simplex and duplex prints. Sets process direction image registration for duplex prints for all trays.254 mm change in the image position. Changes are made by increasing or decreasing the stored value changing the image position on the page. For the process direction the factory default is 33. to modify the general (All Trays) or specific (Tray 1~6) values to realign the image. The maximum is 66 and the minimum is zero (0). The maximum for scan direction adjustments is 99 with a minimum of 1. each variable is set at the factory to a value of 50. Changes to the current value for process direction variables by one (1) moves the leading edge of the image .363 mm closer or further from the edge of the paper. Any change in the scan direction value by one (1) results in a . Reference A-11 . Sets scan direction image registration on all trays for duplex prints. These utilities access Engine Logic Board NVRAM to modify the stored value for each variable.Printer NVRAM Registration Adjustment Utilities Utility Scan Direction All Trays Scan Direction Tray 1~6 Scan Direction Duplex All Scan Direction Duplex Trays 1~6 Process Direction All Process Direction Tray 1 Process Direction Tray 2 Process Direction Tray 3~6 Process Direction Duplex All Trays Action/Requirement Sets scan direction image registration on all trays for both simplex and duplex prints. Sets process direction image registration on Tray 1 for simplex prints only. Sets scan direction image registration for duplex prints from the tray selected. Sets process direction image registration on Tray 2 for simplex prints only.

Runs the Feed/Lift motor in a counter clockwise direction for about 2 seconds. In some cases. Runs the Drum Cartridge Fan at high speed. In other cases. Press the Back button to halt the test. The test runs with covers open. Engine Motor and Fan Tests Test Printer Main Motor On Action / Requirement Runs the main motor. Runs the Front Output Motor shifting the shaft forward. Test will run with the Duplex Unit open. Press the Back button to halt the test. the sound of the motor running indicates that the item passed or failed. Press the Back button to halt the test. Duplex Unit Motor Tests Test Duplex Motor Action / Requirement Runs the Duplex Unit motor. Press the Back button to halt the test. Runs the fan at high speed. Runs the Feed/Lift motor in a clockwise direction. Most motor rotational tests run for two or three seconds then stop. Runs the laser scan motor. Runs the Feed/Lift motor in a clockwise direction.Print Engine Motors/Fan Test Menu Individually activate each motor or fan. Runs the Drum Cartridge Motor. A-12 Phaser 5500 Printer Service Manual . This test requires the printer’s covers closed and the Drum Cartridge installed. movement of the mechanism is the indicator. Fuser Fan Drum Fan Motor Laser Scan Motor Tray 2 Lift Motor Tray 3 Lift Motor Tray 2 Feed Motor Tray 3 Feed Motor Drum Cartridge Motor On Offset Output Motor 1 Front Offset Output Motor 1 Rear Toner Dispense Motor Duplex Unit Motor Tests Menu Run the Duplex Motor. Press the Back button to halt the test. Press the Back button to halt the test. Runs the Rear Output Motor shifting the shaft reward. Runs the Toner Dispense Motor. Runs the Feed/Lift motor in a counter clockwise direction for about 2 seconds.

open. Runs the Feed/Lift motor in the Feed direction for two seconds. Runs the Exit 2 Output Motor in reverse for two seconds. These tests run with the Exit. Runs the Feed/Lift motor in the Lift direction for two seconds. Tray 4 & 5 Motor Tests Test Tray 4 Lift Motor Tray 4 Feed Motor Tray 5 Lift Motor Tray 5 Feed Motor Take Away Drive Action / Requirement Runs the Feed/Lift motor in the Lift direction for two seconds.Exit 2 Motor Tests Menu Test the Exit and Offset Motors in the Exit 2 Module. Tray 6 Motor Tests Menu Test the Feed/Lift and Take Away motors in Tray 6.2 cover. Tray 6 Motor Tests Test Tray 6 Lift Motor Tray 6 Feed Motor Action / Requirement Runs the Feed/Lift motor in the Lift direction for two seconds. Runs the Feed/Lift motor in the Feed direction for two seconds. Runs the Exit 2 fan. Runs the Take Away Drive Motor for five seconds. Runs the Exit 2 Output Motor in the forward direction for two seconds. Reference A-13 . Runs the Exit 2 Offset motor shifting the OCT Roller shaft rearward. Door E. Trays 4 & 5 Motor Tests Menu Test the Feed and Take Away motors in each tray feeder assembly. Runs the Feed/Lift motor in the Feed direction for two seconds. Exit 2 Motor Tests Test Offset Output Motor 2 Front Offset Output Motor 2 Rear Exit Output Motor 2 Forward Exit Output Motor 2 Reverse Exit 2 Fan Action / Requirement Runs the Exit 2 Offset motor shifting the OCT Roller shaft forward.

Runs the Transport motor. Most motor rotational tests run for two or three seconds then stop. Runs the Exit motor at high speed in the clockwise direction.3 hole Punch Motor.Tray 6 Motor Tests (Continued) Test Tray 6 Take Away Motor -Slow Tray 6 Take Away Motor . Runs the Exit motor at slow speed in the clockwise direction. Moves the Punch to the rear. Performs a 2-hole punch. Performs a 4-hole punch. Performs a 3-hole punch.4 hole Front Tamper Motor Action / Requirement Runs the Horizontal Transport motor at high speed. Runs the Registration motor clockwise at slow speed. Runs the Take Away Motor at high speed for two seconds. Mid Speed Outboard. Runs the Horizontal Transport motor at low speed. Runs the Registration motor counter clockwise. Runs the Registration motor clockwise at high speed. High Speed Outboard.Fast Horizontal Transport Motor .Fast Action / Requirement Runs the Take Away Motor at low speed for two seconds. Runs the Exit motor in the counter clockwise direction. Provides a sub-directory that includes tests to run the Front Tamper motor at the speed and position selected (Low Speed Outboard.Slow Transport Motor Registration MotorFast-CW Registration MotorSlow-CW Registration MotorCCW Exit Motor-Fast-CW Exit Motor-Slow-CW Exit Motor-CCW Punch Unit Motor Front Punch Unit Motor Rear Punch Motor. High Speed Inboard). Moves the Punch forward. A-14 Phaser 5500 Printer Service Manual .2 hole Punch Motor. Finisher Motor Tests Test Horizontal Transport Motor . Finisher Motor Tests Menu Individually activate each Finisher motor. Low Speed Inboard. Mid Speed Inboard.

opening the clamp. Medium Speed Front. High Speed Front.Finisher Motor Tests (Continued) Test Rear Tamper Motor Action / Requirement Provides a sub-directory that includes tests to run the Rear Tamper motor at the speed and position selected (Low Speed Outboard. High Speed Inboard). Staple Head Move Motor Stapler Motor Forward Stapler Motor Reverse Eject Clamp Motor Up Eject Clamp Motor Down Eject Motor Stacker Motor . Low Speed Rear. To repeat the test. Open or Closed. Low Speed Inboard. High Speed Outboard. print a Configuration Page and check for the presence of Temperature and Humidity readings. High Speed Forward.Down Print Engine Sensor/Switch Tests Menu Tests the functionality of sensors and switches located in the print engine. Lifts the Stacker Lower Tray to its upper limit. Medium Speed Rear. Provides a sub-directory that includes tests to run the Staple Head motor at the speed and position selected (Low Speed Front. Sensor / Switch Tests Test Door A Interlock SW Door B Interlock SW Front Cover Interlock Tray 1/MPT Size Sensor Action / Requirement Displays the status. Mid Speed Outboard. High Speed Rear). Displays the paper size indicated by the guides. High Speed Reverse). Open or Closed. Runs the motor in forward. Closes the Eject Clamp. Lowers the Stacker Lower Tray to its lower limit.Up Stacker Motor . no movement occurs. Mid Speed Inboard. Place the staple head in its home position prior to testing. rotate the black gear on the Staple Head until the clamp is closed (down position). Open or Closed. Low Speed Reverse. of the Door B Switch. Provides a sub-directory that includes tests to run the Eject motor at the speed and direction selected (Low Speed Forward. of the Door A Switch. re-close the clamp. Displays the status. Opens the Eject Clamp. Displays the status. The clamp returns to the open position following the test. A loose staple is generated in the forward direction. If the clamp is already open. of the Front Door Switch. For the Environmental Sensor. Test each device by manually toggling the sensor or switch and viewing the results on the display. To close the clamp. Runs the Staple Motor in reverse. Reference A-15 .

Displays the status. and “With Paper” when lifted. Test the sensor by removing all but three or four sheets of paper from the tray and reinserting it. and “With Paper” when lifted.“ when actuated. and “Low” when lifted. Reports “Without Paper” in the resting position. “Installed“or “Not Installed“ when actuated. Reports “Not Low” in the resting position. when manually toggled. Reports “Not Low” in the resting position. Reports “Empty” when the actuator is in the resting position. Displays the status.“ of the Exit sensor. Displays. and “Full” when the actuator is raised. “With or “Without Paper“. and “With Paper” when lifted.Sensor / Switch Tests (Continued) Test Tray 2 Size Sensor Tray 3 Size Sensor Tray 1/MPT No Paper Sensor Tray 2 No Paper Sensor Tray 3 No Paper Sensor Tray 2 Level Sensor Action / Requirement Displays the paper size indicated by the guides. “With or “Without Paper. “Open” or “Closed”. “With or “Without Paper”. Reports “Without Paper” in the resting position. “With or “Without Paper”. Test the sensor by removing all paper from the tray and reinserting it. and “Low” when lifted. Displays the status. Duplex Unit Sensor/Switch Tests Test Door D Interlock Switch Action / Requirement Shows the status. A-16 Phaser 5500 Printer Service Manual . Displays the status. You can test the sensor by removing all paper from the cassette in that tray and reinserting it. Displays “Home“or “Not Home. Reports “Without Paper” in the resting position. Tray 3 Level Sensor Tray 2 Pre-Feed Sensor Tray 3 Pre-Feed Sensor Tray 3 Feed Out Registration Sensor Fuser Exit Sensor Standard Output Tray Full Sensor Exit Offset 1 Home Position Sensor Detect Drum Cartridge Switch Duplex Unit Sensor/Switch Tests Menu Test the Duplex Unit sensors by toggling each sensor while viewing the results. Displays the paper size indicated by the guides. “With“or “Without Paper”. Displays the status. You can test the sensor by removing all but three or four sheets of paper from the tray and reinserting it.

Reports “Up” in the resting position. Displays the size indicated by the guide position. “Home” or “Not Home” when toggled. Tray 4 & 5 Sensor/Switch Tests Test Door C Interlock Tray 4 Size Sensor Tray 5 Size Sensor Tray 4 No Paper Sensor Action / Requirement Displays the status. Displays “With Paper” or “Without Paper” when manually toggled. Another method is to reach into the tray cavity and operate the actuator manually. Test the sensor by removing all paper from the tray and reinserting it. Exit 2 Sensor/Switch Tests Menu Test the Exit 2 sensors by manually toggling each sensor while viewing the results. of the Door C Interlock Switch. Tray 4 & 5 Sensor/Switch Tests Menu Tests the functionality of the sensors and switches located in Trays 4 and 5 by displaying the current state while you manually toggle the selected device. “Open” or “Closed”. when manually toggled.Duplex Unit Sensor/Switch Tests (Continued) Test Wait Sensor Action / Requirement Displays “With Paper” or “Without Paper” when manually toggled. Displays the sensor status. Reports “Without Paper” in the resting position. Displays the status of the Full Stack sensor on the Standard Output Tray. Another method is to reach into the tray cavity and operate the actuator manually. Another method is to reach into the tray cavity and operate the actuator manually. Reports “Without Paper” in the resting position. Open or Closed. and “With Paper” when lifted. Tray 5 No Paper Sensor Tray 4 Level Sensor Reference A-17 . Displays the size indicated by the guide position. and “With Paper” when lifted. Exit 2 Sensor/Switch Tests Test Door E Interlock Switch Exit Sensor Exit 2 Full Stack Sensor Exit Offset 2 Home Position Sensor Action / Requirement Shows the status. Test the sensor by removing all paper from the tray and reinserting it. and “Down” when lifted. Test the sensor by removing all but three or four sheets of paper from the tray and reinserting it.

Displays the status. Displays “Guide is on a Sensor” or “Guide is off a sensor”. Another method is to reach into the tray cavity and operate the actuator manually. Displays the status. and “With Paper” when lifted. and “Down” when lifted. “With Paper” or “Without Paper” of the sensor. Reports “Without Paper” in the resting position. “With or “Without Paper“ when actuated. “With or “Without Paper“ when actuated. Display the status. and “Down” when lifted. “In” or “Out” of the Tray-in sensor. “With or “Without Paper“ when actuated. Displays the status. Test the sensor by removing all but three or four sheets of paper from the tray and reinserting it. “Docked” or “Undocked” of the Docking Switch. Tray 6 Sensor/Switch Tests Test Door J Interlock Switch Tray 6 Paper Size Sensor Tray 6 No Paper Sensor Tray 6 Level Sensor Tray 6 Pre Feed Tray 6 Feed Out Tray 6 Interlock Switch Tray 6 Paper Size Sensor A Tray 6 Paper Size Sensor B Tray 6 Tray In Sensor Action / Requirement Displays “Open” or “Closed” when actuated.Tray 4 & 5 Sensor/Switch Tests (Continued) Test Tray 5 Level Sensor Action / Requirement Reports “Up” in the resting position. Reports “Up” in the resting position. “With or “Without Paper“ when actuated. Displays the status. Tray 4 Pre Feed Sensor Tray 5 Pre Feed Sensor Tray 4 Feed Out Sensor Tray 5 Feed Out Sensor Tray 6 Sensor/Switch Tests Menu Tests the functionality of Tray 6 sensors and switches by displaying the current state while you manually toggle the selected device. Displays the paper size indicated by the guide position. Displays the status. “With Paper” or “Without Paper” of the sensor. Displays “Guide is on a Sensor” or “Guide is off a sensor.” Displays the status. Displays the status. A-18 Phaser 5500 Printer Service Manual .

Displays the status as. “Home” or “Not Home” when toggled. Displays the sensor status as. “With Paper” or “Without Paper”. Displays the sensor status as. Displays the sensor status. Displays the sensor status as. “With Paper” or “Without Paper” when toggled. Reference A-19 . Displays the sensor status as. Displays the sensor status as. Displays the sensor state as. Displays the sensor status as. Displays the status as “Open” or “Closed”. “With Paper” or “Without Paper”. Displays the status. Displays the status as. “With Paper” or “Without Paper”. “Home” or “Not Home” when toggled. Finisher Sensor / Switch Tests Test Door F Interlock Sensor Door G Interlock Switch Door H Interlock Switch Horizontal Transport Entrance Sensor Horizontal Transport Exit Sensor Transport Entrance Sensor Gate Sensor Buffer Path Sensor Upper Tray Exit Sensor Upper Tray Full Sensor Compiler Exit Sensor Compiler Tray No Paper Sensor Side Registration Sensor 1 Side Registration Sensor 2 Eject Clamp Home Sensor Set Clamp Home Sensor Punch Move Home Punch Unit Move Home Sensor Punch Home Sensor Punch Front Sensor Action / Requirement Displays the status as “Open” or “Closed”.Finisher Sensor/Switch Tests Menu Tests the functionality of Finisher sensors and switches by displaying the sensor’s current state while you manually toggle the device. “With Paper” or “Without Paper”. Displays the sensor state. “Empty” or “Full”. Displays the sensor status as. Displays the status as “Open” or “Closed”. “With Paper” or “Without Paper”. Displays the status. “With Paper” or “Without Paper”. “Home” or “Not Home” when toggled. “Home” or “Not Home” when toggled.” Displays status as. “With Paper” or “Without Paper. “Home” or “Not Home” when toggled. “Home” or “Not Home” when toggled. “With Paper” or “Without Paper”. Displays the Transport Entrance sensor status as. Displays the state. “With Paper” or “Without Paper”.

“Home” or “Not Home” when toggled. Displays the sensor status. Print Engine Solenoid/Clutch Tests Test Registration Clutch Tray 1/MPT Feed Solenoid Take Away Clutch Action / Requirement Energize The Registration Clutch to check activity.The clicking made by the clutch when energized is an indication of its condition. Displays the sensor state as “ready” or “Not Ready”. Displays the sensor state as “Low” or “Not Low”. A-20 Phaser 5500 Printer Service Manual . Energize the Take Away Clutch on Tray 1/MPT. Displays sensor output as “Pulse not past slit” or “Pulse past slit”. Displays sensor status as “Staple Position” or “Non Staple Position”. Displays the sensor status as. Displays the sensor status.Finisher Sensor / Switch Tests (Continued) Test Punch Hole Select Sensor Punch Motor Encoder Sensor Punch Box Set Sensor Front Tamper Home Sensor Rear Tamper Home Sensor Staple Move Position Sensor Staple Head Low Staple Sensor Staple Head Self Prime Sensor Staple Head Home Sensor Lower Tray No Paper Sensor Lower Tray Upper Limit Sensor Stacker Encoder Sensor Stack Height Sensor 1 Stack Height Sensor 2 Action / Requirement Displays the sensor status as “Selected” or “Not Selected”. Displays the sensor status as either “With Box” or “Without Box”. Displays the status. “With Paper” or “Without Paper”. Displays the sensor status. “With Paper” or “Without Paper”. “Home” or “Not Home” when toggled. “Home” or “Not Home” when toggled. Energize the Tray 1/MPT Feed Solenoid. “Pulse on slit” or “Pulse not on slit”. Displays the status. Display the sensor output as “At upper limit” or “Not at upper limit”. Print Engine Solenoid/Clutch Tests Menu Activates the selected clutch to test the drive. Displays the sensor output as “Blocked” or “Unblocked”.

The clicking made by the part when energized indicates its condition Finisher Solenoid/Clutch Tests Test Buffer Gate Solenoid (path out) Buffer Gate Solenoid (path-in) Action / Requirement Energize the Buffer Gate Solenoid moving the Buffer Gate to direct paper over the Buffer Roller. Energize the Nudger Solenoid at low power. Tray 6 Solenoid/Clutch Tests Test Nudger (High Power) Nudger (Low Power) Action / Requirement Energize the Nudger Solenoid at high power. This test runs with Door E open. The clicking made by the solenoid when energized indicates its condition. Tray 4 & 5 Solenoid/Clutch Test Menu Activates the Take Away Clutch. The clicking made by the clutch when energized indicates its condition. Reference A-21 . Tray 6 Solenoid/Clutch Test Menu Tests the functionality of the optional Tray 6 solenoid.Exit 2 Solenoid/Clutch Test Menu Activates the Exit 2 Gate Solenoid. Exit 2 Solenoid Test Test Exit Gate Solenoid Action / Requirement Energize the Exit Gate Solenoid. Tray 4 & 5 Clutch Test Test Take Away Clutch Action / Requirement Energize the Take Away Clutch on the optional tray module. Energize the Buffer Gate Solenoid moving the Buffer Gate to direct paper into the Buffer Path. Finisher Solenoid/Clutch Tests Menu Activates the selected clutch or solenoid.

Engine Logic Board Replacement Menu These commands transfer the contents of a defected Engine Logic Board’s NVRAM to the Image Processor Board and return it to the new Engine Logic board after installation. After you enter the password.Finisher Solenoid/Clutch Tests (Continued) Test Transfer Gate Solenoid (Path Out) Transfer Gate Solenoid (Path In) Sub Paddle Solenoid Set Clamp Clutch Action / Requirement Activate the Transfer Gate Solenoid moving the Transfer Gate to direct paper to the Stacker Upper Tray. The following provides instructions for using these utilities during an Engine Logic Board replacement. The password to access the reset functions is 4370. Use the Front Panel buttons to enter the password. Controller NVRAM Utilities Utility Reset PostScript NVM Factory Reset NVRAM Action / Requirement Resets the PS NVRAM. A-22 Phaser 5500 Printer Service Manual . Energize the Finisher Set Clamp Clutch. Reset NVRAM to factory defaults. Activate the Sub Paddle Solenoid. Activate the Transfer Gate Solenoid moving the Transfer Gate to direct paper to the Stacker Lower Tray. This utility is password protected. You are prompted to confirm your decision to perform a reset operation. you are prompted to confirm your decision to perform a reset. Writes the Engine Logic Board NVRAM data to the replacement board from the NVRAM of the Image Processor Board. Engine Logic Board Replacement Utilities Utility Save from Engine Board Restore to Engine Board Action / Requirement Saves the NVRAM contents of the Engine Logic Board to a reserved area of NVRAm on the Image Processor Board. Controller NVRAM Access Menu This menu allows you to reset the PostScript NVRAM locations to factory defaults.

Finisher Board Setup Menu This menu allows you to reset the Punch configuration of the Finisher/Stacker. Power the printer off and replace the Engine Logic Board Restoring Engine Logic Board NVRAM To restore the Engine Logic Board NVRAM to the new board: 1. 2. Exit Reboot the printer out of Service Diagnostics. Select Save from Engine Board from the Engine Logic Board Replacement menu and press OK. Sets the Finisher Main PWB to a Stacker configuration with no Punch or Stapler. Exit diagnostics. Select Restore to Engine Board from the Engine Logic Board Replacement menu and press OK. Sets the Finisher Main PWB to support a 3-hole Punch and Stapler. 2. Reference A-23 . Finisher Board Setup Utilities Utility Read Current Status Set 3-Hole Punch & Staple Set 2. During the process the front panel will display "Restoring NVRAM" once the routine is completed the front panel will display "Restore Complete" 3.Saving Engine Logic Board NVRAM To save the Engine Logic Board’s NVRAM contents to the I/P Board: 1. Enter Service Diagnostics./4-hole Punch and Stapler. Sets the Finisher Main PWB to support a 2. Data is transferred from the Engine Logic Board to a reserved location on the Image Processor Board./4-Hole Punch & Staple Set No Punch & Staple Action / Requirement Displays the current Punch setting of the Finisher Main PWB. During the process the Front Panel will display "Saving NVRAM" once the routine is completed the front panel will display "Save Complete" 3. Data is transferred from the reserved location on the Image Processor to the replaced Engine Logic board. Re-enter Service Diagnostics.

Mode Select Port Settings Mode Printer Reset Customer Service Disaster Recovery Developer Customer Debug ■ ■ 1 GND GND GND GND GND GND 2 3 4 5 GND 6 GND GND GND GND GND GND GND GND GND GND GND GND GND GND Reset is a hardware reset of the Image Processor Board. Grounding pin 5 for more than a few seconds could damage the processor. Not typically used for servicing procedures. See "Power On Self Test (POST)" on page 3-4. accessible from the Rear Panel. Disaster Recovery mode instructs the printer to load only its operating system bypassing the networking and PostScript code. Caution To reset the I/P Board. These modes are set by connecting one or more pins to ground.Mode Select Port The Mode Select Port. Pins 2 through 5. when grounded. momentarily ground pin 5. Service Mode inhibits printing of the Startup page and causes POST to treat all errors as Hard Faults. Developer mode inhibits the execution of POST and allows for the introduction of startup scripts. ■ ■ ■ ■ A-24 Phaser 5500 Printer Service Manual . Service mode also switches the Serial Debug Port from PostScript back channel information to the printer’s operating system console. The six pins are arranged in numeric order with Pin 1 at the top of the connector. then immediately re-open the connection. The Serial Debug Port is receiving PostScript back channel information. Customer Debug mode instructs the printer to boot normally but switches the Serial Debug Port from PostScript back channel information to the printer’s operating system console. Customer Mode is the normal mode for printing. is a 6-pin header used to place the printer in one of five operational modes or to reset the Image Processor Board. The Serial Debug Port is receiving PostScript back channel information. set the printer to the mode indicated in the following table. Pins 1 and 6 are tied to a common ground with the Rear Panel.

5-16 Boot Loader. 2-7 roller locations. 9-41 removal. A-17 Take Away Clutch test. A-10 duplex registration. 6-6 analyzing test prints. 2-14 interconnect location. 3-3 Buffer Gate. A-21 Buffer Path. 10-15 removal. 3-239 Feed Out Sensor #4. 2-13 testing. 2-14 sensor tests.Index Numerics 1000-Sheet Feeder. 2-14 Feed Out Sensor #5. 9-45 paper handling. 2-13 sensor tests. A-13 option part number. 5-2 AppleTalk event logging. 3-211 A abbreviations. 9-45 sensor locations. A-13 Nudger Solenoid testing. 2-6 sensor locations. 2-14 motor tests. 6-7 fuser temperature. 6-8 process direction. 5-19 blank prints. A-17 Door C open. 1-11 Docking Interlock location. A-18 Docking Interlock open. 2-13 testing. 2-13 testing. 3-248 Feed Out Sensor #6. 3-6 operational description. 4-2 B black prints. 2-9 Index Index-1 . 6-6 simplex registration. 1-9 dimensions. A-18 Door J open. 2-38 plug/jack locator. 3-14 AC Accessory Panel GFI Breaker part number. 2-9 testing. A-21 option part number. A-21 tray empty. 1-7 dimensions. 3-236 Door J Interlock location. 2-9 Buffer Gate Solenoid. 4-8 adjustment adjustment utilities. 3-209 2000-Sheet Feeder. 8-93 AC power supply troubleshooting. 1-4 motor tests. 2-9 Buffer Roller. A-18 tray empty. 4-7 AC power tests. 8-94 operational description. 1-11 Door C Interlock location. 6-6 scan direction.

2-7 sensor tests. 1-10 CPU interrupts error. 1-10 part number. 1-10 Toner Gauge. 3-242 location. 6-10 character settings. A-24 display. 3-239 location. 1-2 failure. 3-240 location. 2-16 Diagnostics. 2-13 testing. A-19 testing. 10-3 part number. 2-13 part number. 9-23 removal. 8-70 Toner Cartridge CRUM connector. 3-9 view count. A-17 Door F Interlock close Door F. 5-33 DC power supply testing. 10-23 Door C Interlock close Door C. 3-233 reset fuser life. 2-15 feed count. 3-14 Drum Cartridge CRUM connector. 1-10 Staple Pack. A-9 life cycle. A-16 Door designations. 1-12 Compiler Tray. A-19 Index-2 Phaser 5500 Printer Service Manual . 2-13 testing. 3-10 Door E Interlock close Door E. A-9 punch waste box. 1-10 location. 8-71 customer debug mode. 4-5 default character set. 1-10 total pages. A-15 wiring. 9-45 Toner Cartridge. 9-33 counters drum cycle count. 7-2 clearance requirements. 2-13 testing. 6-11 contrast. 6-11 cleaning. 9-45 connection setup. A-19 Door G Interlock close Door G. 1-4 operational description. See Service Diagnostics disaster recovery mode. 6-10 consumables. 9-25 removal. 3-245 testing. 3-250 location. 10-21 Door B Interlock close Door B. 8-45 testing. 9-33 removal. 1-5 brightness. 1-6 part number.C CentreWare setup. 4-4 Door A Interlock close Door A. 3-6 CRUM. A-24 customer mode. 10-3 part number. 2-13 part number. 6-11 testing. 2-9 location. 6-11 Detack Saw. 3-238 location. A-24 D damaged prints. 6-9 supply life. A-14 Configuration Card. 8-41 testing. A-17 Door D Interlock close Door D. 9-41 upgrade kit. 9-33 removal. 3-243 testing. A-9 page count. 6-11 language. A-15 wiring. 3-237 location.

2-3 ATC Sensor failure. 8-60 testing. 3-7 Engine Logic Board data transfer. 9-33 removal. 10-21 removal. 3-34 fan wiring.Door H Interlock close Door H. 8-64 testing. A-12 wiring diagram. 9-33 removal. 3-148 interconnect location. 10-3 failure. 9-45 paper path. 2-21 Duplex Unit. 9-33 plug/jack locator. 1-7 Door D open. 10-13 power supply wiring. 8-89 restore NVRAM. 2-15 CRUM. 7-2 print life. 10-6 precaution. 3-203 part number. A-15 wiring. 2-31. 2-10 option part number. 2-4 failure. 8-70 wiring. A-18 Drum Cartridge. 3-200 fan failure. 2-10 registration adjustment. 10-24 Drum Cartridge Detect Switch. A-12 Duplex Unit (cont. 9-33 removal. 3-149 Wait Sensor. 6-10 type error. 2-35 part number. 6-7 roller location. 3-218 circumference. 3-6 engine error log display. 10-24 error message summary. 2-33 part number. A-23 save NVRAM. 3-251 E EEPROM error. 3-7 error codes. 10-21 Drum Motor.) operational description. A-10 Envelope Tray. 10-25 end of life. 2-13 testing. A-16 set duplex printing default. 3-248 location. A-22 failure. 1-4 motor tests. 1-9 Environmental Sensor. 1-9 part number. 8-84 testing. 9-39 removal. 5-37 components. 3-6 engine command error. 3-240 Duplex PWB failure. 3-15 Index Index-3 . 3-14 connector. 3-201 part number. 9-9 precautions. 1-10 testing. 2-4 drive train. 3-35 I/P Board interface. 10-25 location. A-23 testing. 10-31 location. 4-12 engine test prints. A-15 wiring diagram. 2-12 part number. 2-10 duplicate IP address. A-19 Door J Interlock close Door J. 3-24 part number. 9-41 plug/jack locator. 2-12 location. 3-8 format. 3-247 testing. 1-10 non-Xerox cartridge. 2-6 sensor tests. A-12 Dual-beam Laser Diode. 2-33 operational description.

3-15 front panel. 2-30 Exit Gate. 2-6 sensor tests. 2-6 part number. A-13 operational description. 2-33 location. 2-8 part number. A-16 wiring. 10-22 F Fan. 3-7 accessing. 9-41 plug/jack locator. 2-10 Exit 2 (cont. 9-37 removal. A-18 Feed Out Sensor #6. 2-31 Offset Home Position Sensor. 10-23 Feed Out Sensor #4. 9-37 plug/jack locator. A-17 Exit PWB. 8-88 Exit Sensor. 4-2 printing. 8-80 wiring. 8-59 testing. 3-7 engine error codes. 2-10 fan testing. 10-3 function. 2-33 operational description. 3-6 location. 8-81 wiring. 3-7 Feed Out Sensor #3 connector designator. 2-7 motor tests. 2-10 testing. 2-12 wiring.) roller location. 1-4 settings. 2-7 part number. 9-14 Index-4 Phaser 5500 Printer Service Manual . 10-30 Paper Weight. 9-37 Full Stack Sensor. 9-33 removal Drum Cartridge Fan. 2-31 part number. 10-21 removal. 10-30 Offset Motor. 2-7 components. 6-10 EtherTalk setup. A-21 Exit Motor. A-18 Feed Out Sensor #5. 10-30 Exit 2. 2-14 testing. 3-15 Service Diagnostics. 2-14 testing. 3-242 Exit Gate Solenoid. 10-7 power supply wiring. 2-36 part number. 9-37 removal. A-13 location. 4-2 Exit 1. 6-10 event log. 9-37 removal. 3-152 location. 10-25 fault history. 2-30 operation. 2-31 part number. 3-7 interpreting. 2-6 wiring diagram. 2-14 testing. 1-2 failure. 10-8 removal. 2-33 part number. 2-31 failure. 2-31 part number. A-18 Feed Roller function. 1-6 Door E open. 2-31 part number. 10-30 Offset Gear. 2-28 location. 3-14 corrective actions. 3-15 Ethernet Port. 8-82 wiring. 8-54 testing. 3-15 list of errors. 8-78 roller location. 8-58 Fuser Fan. 9-31 removal.error messages abbreviations used. A-12 wiring diagram.

1-5 lockout. 6-11 LED indications. 2-21 print life. 2-28 part number. 2-9 punch box full. 8-90 service shortcuts. 2-22 wiring. 6-12 setup. 8-76 set temperature. 2-9 dimensions. 1-5 contrast. A-14 operational description. 1-11 Door F open. 3-233 punch box missing. 3-232 sensor and switch testing. 2-9 Transfer Gate Solenoid.) Index Index-5 . 8-24 testing. 9-35 performance evaluation. 4-4 Toner Gauge. 3-13 setup. 2-9 option part number. 2-9 Stacker Upper Tray. 2-21 control temperatures. 2-13 part number. A-21 Stacker Lower Tray. 9-5 language. 3-27 fan failure. 2-3 change setting. 4-6 firmware version information. 6-12 Finisher. A-15 wiring diagram. 1-10 removal. 3-15 harness part number. 10-26 file security. 2-23 operational description. 2-22 location. 2-25 default temperatures. 3-247 interconnect location. 9-13 plug/jack locator. 2-28 part number. 10-8 Pressure Roller. 6-11 part number. 6-11 buttons. 2-9 Transport Motor. 10-21 Front Panel brightness. 6-11 error messages. 9-13 removal. 10-22 failures. 2-21 Heater Rods. 3-243 Door G open. 3-245 Door H open. 8-10 wiring. 2-38 Buffer Gate. A-19 Set Clamp Clutch testing. 1-8 AC power connection. 1-10 wiring diagram. 3-235 removal. 2-23 harness part number. 1-4 major components. 3-32 fault conditions. 2-9 Compiler Tray. 9-43 Heat Roller. A-23 solenoid testing. 10-11 sensor locations. 6-8 Fuser (cont. 9-5 removal. 9-45 Punch. 2-9 Transfer Gate. 9-5 printer front door is open. 2-9 Finisher LVPS testing. 2-9 Buffer Path. 10-32 Fuser. A-12 Feeder operational description.Feed/lift Motor operational description. 2-7 motor tests. A-21 set punch configuration. 6-11 testing. A-9 Front Door Interlock location. 6-8 Exit Sensor. 6-8 components. 5-6 plug/jack locator. 1-10 operating modes. 2-21 part number. 2-28 testing.

2-34 log storage. 5-14 horizontal deletions. 2-24 regulation. 4-13 Front Panel connector. 9-41 removal.temperature adjusting. 5-14 registration. 5-44 skips and smears. A-19 Humidity Sensor part number. 1-8 motor testing. 5-19 blank prints. 5-30 vertical deletions. 8-94 reset location. 2-8 PWB. 5-40 black prints. 2-36 part number. 2-33 G GFI Breaker part number. 2-12 unfused image. 3-243 location. 2-22 Horizontal Transport. 5-38 resolution. 3-6 Engine Logic Board interface. 10-31 Ethernet Port failure. A-15 Index-6 Phaser 5500 Printer Service Manual . 2-21 Heater Rods. 5-45 repeating defects. 3-6 fault isolation. 9-33 removal. 10-29 image defects background contamination. 6-8 configuration. 3-3 Heat Roller. 2-23 sensing. 5-30 wiring diagram. A-11 process direction. 10-24 I I/O ASIC error. 8-64 testing. 10-21 H Hard Drive. 3-6 EEPROM error. 3-6 image data wiring. 6-6 image data wiring. 2-38 wiring. 6-8 modes. 1-8 Door F open. 2-8 sensor locations. A-11 factory defaults. 5-37 residual image. 10-15 removal. 8-86 wiring diagram. 5-35 spots. 6-6 registration. 3-6 engine command error. 5-25 Image Processor Board CPU interrupts error. 3-6 IDE disk error. 5-27 light prints. 5-34 skewed image. 3-5 image adjustment adjustment utilities. 5-23 horizontal streaks. 3-5 location. 9-41 plug/jack locator. 2-8 sensor tests. A-14 operational description. 4-2 part number. 10-14 Health LED. 10-29 location. 10-22 HVPS. 10-3 I/O ASIC error. 5-47 spot deletions. 6-6 scan direction. 6-12 IDE disk error. 6-10 defaults. 5-42 unfused image. 9-41 plug/jack locator. 5-21 vertical streaks. 5-29 uneven density. 1-6 file security setup.

3-23 gear kit. 9-33 plug/jack locator. 10-7 removal. 10-16 removal. 9-13 removal. 4-14 USB Port failure. 4-2 Main Drive Belt location. 3-3 Health LED. 2-37 finisher testing. 5-8 skew. 2-18 Index Index-7 . 8-74 Scanner Motor. 10-14 power supply wiring. 8-83 Main Motor. 2-3 components. 4-6 Fuser power. 6-10 Laser Assembly (cont. 2-19 failure. 5-9 line. 10-21 M Macintosh printing problems. 5-12 skips/smears. 5-11 image smoothing. 3-3 Level Sensor. 2-4 failure.) part number. 2-20 wiring diagram. 2-21 LED blink patterns. 6-10 J jam error log display format. 3-6 color definitions. 8-84 testing. 10-29 Laser Diode.Image Processor Board (cont. 3-6 NVRAM part number. 6-11 LVPS. 6-10 low toner printing. 3-9 format. 3-25 Laser Diode. 2-19 operational description. 1-5 Front Panel start-up. 9-39 removal. 2-34 part number. 5-5 resolution. 6-10 IPX frame type setup. 3-9 error codes. 2-12 part number. 2-21 laser diode assembly. 10-21 removal. 9-41 plug/jack locator. 5-6 lead edge-to-trail edge.) memory error. See Front Panel L Laser Assembly. 9-41 operational description. A-24 troubleshooting. band. or spot deletions. A-12 K Keypad. 8-92 testing. 5-10 spots. 8-27 load paper timeout. 3-7 jam location map. 2-4 drive train. 9-39 part number. 6-10 job default settings. 3-6 image quality analysis fusing. 9-39 removal. 6-2 job offset setup. 4-5 wiring diagram. 10-22 part number. 3-10 jammed page reprint. 2-30 part number. 9-41 plug/jack locator. 5-7 side-to-side registration. 8-91 reset.

6-10 IP setup. 9-33 Drum Cartridge print life. 8-83 description. 3-6 maximum. 10-25 N NetWare setup. 9-39 Motor Assembly (cont. 2-12 Nudger Roller function. 1-11 O Offset Motor drive train. 2-16 part number. 9-45 print life. 2-15 part number. 1-10 replacement message. A-22 PostScript. 8-44 Maintenance Kit contents. 7-2 Transfer Roller. 4-2 troubleshooting.maintenance. 8-76 Fuser print life. 1-10 Drum Cartridge. A-22 reset PostScript. A-24 wiring diagram. 3-21 Memory connectors. 1-6 ordering parts. A-23 save. 2-32 Drum Motor. 9-41 part number. 9-41 reset. A-22 restore. 6-10 logging. 9-41 password. 1-11 troubleshooting. 4-2 option part number. 4-15 menu map. 8-31 NVRAM option part number. 1-6 part number. 4-2 network setup. 6-12 reset factory defaults. 9-25 removal. 5-5 options. 1-4 operational description. 2-28 location. 6-10 network ethernet speed setting. 3-6 requirements. 1-10 preventive. 9-39 plug/jack locator. 10-32 Motor Assembly Belt part number. 1-10 counters. 2-11 Mode Select Port location. 1-10 Fuser part number.) Main Motor. 9-39 removal. 2-4 part number. 7-2 service procedures. 3-250 reset fuser life. 4-15 supported types. 3-2 tools. 1-11 minimum. 9-2 Index-8 Phaser 5500 Printer Service Manual . 6-9 measurement techniques. 2-6 part number. 2-4 gear kit. 8-84 wiring diagram. 6-10 No Paper Sensor. 1-10 part number. 10-12 removal. A-2 Microswitch. 2-31 part number. 10-30 operating environment. 9-37 removal. 8-80 wiring diagram. 9-35 removal. 9-41 RAM error. 10-14 errors. 9-14 removal. A-23 supported types. 1-11 options.

or spot deletions. 5-33 fusing. 3-4 error indications. A-9 Index Index-9 . 9-3 PCL setup. 6-12 PostScript NVRAM. 6-11 timeout. 3-4 power saver setup. 3-5 types. 6-11 Door A open. 5-3 print quality test print analysis. 8-86 wiring diagram. 6-10 supported types. 8-28 Pressure Roller. 3-6 error display. 5-2 print quantity setup. 1-11 display setup. 4-8 Power On Self Test (POST) bypass testing.P paper custom size setup. 6-11 Power Switch location. 6-10 Power Cord connector. 1-15 Paper Size Switch. 3-6 LED blink patterns. 5-5 repeating defects. 1-4 configurations. 10-26 paper types. 2-33 part number. 3-3 memory error correction. 5-12 skip/smears. 5-8 skew. 3-6 types. 1-13 environmental specifications. 9-3 conventions. 1-4 part number. 3-4 fault types. 9-41 plug/jack locator. 1-4 controls setup. 3-4 description. 4-15 soft faults. 6-10 set default destination. 1-4 parts list availability. 3-237 Door B open. 6-10 damage. 8-19 Tray 2-3 testing. 6-12 PostScript setup. 3-5 corrective actions. 2-15 Drum Motor. 5-10 spots. A-17 wiring diagram. 2-34 location. 10-12 removal. 6-8 loading timeout. A-15 Tray 4-5 testing. 6-11 Printer components. 1-3 connections. 3-10 Drum Cartridge. 3-238 door designations. 2-12 locations. 9-13 removal. 4-5 dimensions. 3-4 hard faults. 1-14 firmware versions. 9-41 testing. 9-9 plug/jack locator. 5-37 resolution. 5-33 fuser temperature settings. 5-11 types. 6-8 Parallel Port. 2-12 locations. 2-21 print defects. 2-14 part number. 10-16 removal. 5-7 side-to-side registration. 5-3 damaged print. 3-5 test descriptions. 3-5 Start Page format. 6-10 set default source. 5-6 lead edge-to-trail edge. 10-21 Pre-Feed Sensor. 6-11 DC power supply testing. 2-14 part number. 6-11 personal print setup. 3-6 Health LED. band. 2-4 electrical specifications. 5-9 line.

6-10 operational modes customer debug. 9-31 removal. A-22 resolution. 2-38 print process. 4-2 Windows. 6-4 Registration Clutch part number. 6-6 image deletions. 3-233 waste box missing. 6-10 factory defaults. 3-5 registration adjustment parameters. 5-45 verification. 10-23 Registration Transport Assembly part number. 2-7 sensor tests. A-24 customer mode. 6-5 registration verification. A-24 options. 5-27 measurement. 2-6 tray capacity. 6-7 factory defaults. A-20 wiring. A-11 image adjustment. A-2 motor tests. 5-23 image streaking. 2-18 Main Motor. A-11 adjustment utilities. A-24 developer mode. A-24 service mode. A-22 file security. 10-10 removal. 3-3 supported media. A-23 location. 6-2 network configuration. 6-9 general setup. 2-4 menu map. A-24 disaster recovery. 8-51 testing. 2-18 sensor types. 9-31 removal. 4-3 process direction. 1-6 paper outputs. A-19 testing. 1-13 installation clearance. 2-5 power connections. 5-8 proof print setup. 6-10 Index-10 Phaser 5500 Printer Service Manual . 9-31 plug/jack locator. 2-7 paper transport. 6-12 Punch. A-4 transport components. 6-12 default paper destination. A-11 simplex adjustment. A-15 start-up routine. 3-232 R RAM DIMM fault isolation. 6-6 troubleshooting. 2-2 reset factory defaults. 6-12 Front Panel setup. 1-14 printing problems Macintosh. 6-11 fuser life counter. 6-10 paper default source. 1-15 testing. 2-9 configuration settings. A-12 network setup. A-15 wiring. 6-4 factory default. 10-23 Registration Sensor. 2-14 part number.Printer (cont. 2-11 sensor/switch testing. 1-11 Laser Assembly. 3-235 functional specifications. 8-52 testing. A-14 waste box full.) Front Door open. 6-11 job defaults. A-10 duplex adjustment. 8-49 reset all printer defaults. 2-12 location. 4-15 real time clock errors.

) microswitch. 9-2 location. A-10 print menu map. A-4 button functions. 2-15 paper size detection. 6-10 setup values. 3-11 available tests. 2-11 Serial Debug Port location. 4-2 printing. 8-64 Exit 1 sensors. 3-15 main menu. 2-11 operational description. 1-13 troubleshooting. 5-12 Index Index-11 . 5-34 Retard Roller location.reset (cont. A-24 wiring diagram. 6-11 settings. 3-26 operating modes. 3-9 format. 1-4 operational description. 3-7 display format. 2-15 Sensor (cont. 5-9 Scanner Motor failure. 2-12 Tray 1/MPT sensors. 3-7 skew. 3-11 menu map. 3-9 print a profile. 9-2 Service Diagnostics. 3-13 engine test prints. 5-7 setting. 3-9 jam errors. 2-13 level sensing. 2-31 Feed Out. 10-33 serial number interpretation. 9-33 removal. 6-4 factory default. 6-6 image deletions. 3-7 description. 5-38 resolution operational description. 2-11 paper detection. 5-25 measurement. 2-12 interlocks. 2-14 photo-receptive. A-11 image adjustment. 3-7 engine error log. 3-219 part number. 3-12 test descriptions. A-10 starting. 5-21 image streaking. 4-2 S scan direction. 6-12 PostScript setup. 6-4 registration verification. 2-11 testing. 6-11 PostScript NVRAM. 3-12 registration adjustment. 3-7 display a log. 2-6 part number. 3-9 display format.) PCL setup. 2-7 functions. 3-8 jam error log. 9-14 runtime log. 3-8 fault codes. A-4 print job setup. A-24 Service Usage Profile browser access. 2-20 testing. 2-10 Environmental Sensor failure. 2-18 performance evaluation. 2-26 types. 6-11 residual image. A-9 using. A-15 thermistor. 6-12 Sensor ATC sensor failure. A-12 wiring diagram. A-10 error messages. 3-218 CRUM. 3-12 service mode. 2-12 Duplex Wait Sensor. 3-9 history codes. 2-11 photo-reflective. 10-29 secure job setup.

A-14 Stacker Upper Tray. 8-73 testing. 6-11 start-up routine. 3-226 Staple Pack part number. 9-33 removal. 9-33 plug/jack locator. 3-33 operational description. 1-14 functional. 5-25 supply voltage testing. 2-17 Dispense Tube. A-20 wiring. 9-33 removal. A-19 Staple Cartridge low. 2-18 part number. 2-9 Testing. 1-10 part number. A-10 Thermistor. 10-6 print life. 2-9 Transfer Gate Solenoid. 3-206 part number. 2-7 sensor tests. A-12 wiring diagram. 1-13 image registration. 1-13 environmental. 1-11 electrical. 5-2 print job setup. 3-220 Stapler location. A-14 Startup Page setting. 1-10 Toner Dispense Assembly. 6-5 memory. 1-5 Transfer Gate. 8-55 Take Away Clutch part number. 1-14 spots. 2-9 location. 3-225 testing. 5-11 Stack Full Sensor. 1-15 tray capacity. 3-204 low toner. 2-12 Stacker. 5-5 operational clearances. A-22 Index-12 Phaser 5500 Printer Service Manual . 3-3 streaking. 9-33 removal. 8-71 Toner Dispense Motor description. 8-53 testing. 6-2 analyzing. 6-11 Toner Cartridge. 6-10 power saver. 2-32 failure. 10-3 failure. 2-9 location. 4-15 operating environment. 2-3 CRUM. 9-31 precautions. 2-12 timeout loading paper. 9-31 removal. 8-64 test prints. 2-9 operation. 2-17 part number. 10-23 Take Away Roller. 8-71 wiring. A-19 testing. 8-21 removal. 1-8 option part number. 9-45 stapler is empty. 4-8 T Take Away Chute part number. 2-7 sensor tests. 3-14 connector. 2-7 part number. 9-45 Stacker Lower Tray. 2-8 stack full. 2-12 removal.specifications dimensions. 10-25 empty. 3-197 location. 2-7 Standard Output Tray. 9-23 Temperature Sensor. 10-24 Toner Gauge. 1-11 supported media.

2-28 Tray 4-5. 2-28 feed operation. 1-15 paper level detection. 2-8 supported envelopes. 2-6 Cam Gear Spring part number. 8-36 testing. 2-28 Level Sensor. 3-236 universal feeders. 8-20 sensors. 1-9 Tray 6 undocked. 2-28 removal. 1-14 Feeder plug/jack locator. 2-27 Tray 1/MPT. 8-24 Index Index-13 . 6-10 set default destination. 9-17 No Paper Sensor connector designator. 6-10 Standard Output. 2-6 part number. 8-35 Pick-up Solenoid. 2-7 universal trays. 2-16 part number.) operation description. 3-9 media specifications. 10-3 location. 5-37 location. 2-26 Feed Roller. 2-29 part number. 2-26 part number. 9-16 Pick Up Gear Spring part number. 2-6 location. 2-26 testing. 9-19 removal. 9-19 removal. 8-39 Retard Pad Spring part number. 9-17 removal. 1-7 Tray 6. 8-39 sensor tests. 2-26 part number. 1-14 Tray 2-3 Feeder. A-15 Tray part number. 6-10 jam errors. 8-44 Tray capacities. 10-28 Tray 2-3 Feed Out Sensor #3 part number. 8-27 No Paper Sensor. 9-13 removal. 9-25 removal. 9-19 removal. 2-28 part number. 9-17 removal. 9-9 sequencing. 1-14 supported paper weights. 2-29 part number. 2-28 Tray 2-3 sensors. 8-34 testing. 9-13 removal. 2-26 Drive Roller. 2-26 part number. 9-31 removal. A-20 plug/jack locator. 8-23 Feeder components. 8-54 Feed Roller removal. 2-14 part number (universal tray). 2-3 circumference. 8-38 Feeder. 9-13 removal. 2-15 paper size detection. 2-26 Paper Size Sensor. 1-10 operational description. 8-29 Feed/lift Motor location. A-15 parts. 9-19 removal. 2-28 universal tray paper handling. 9-21 wiring diagram. 8-32 Retard Pad part number.Transfer Roller. 8-36 components. 10-9 removal. 9-19 removal. 6-10 set default source. 10-11 Front Panel prompt. A-15 Tray 1/MPT (cont.

8-71 Toner Dispense Motor. 4-8 warm-up time. 4-7 Engine Logic Board. 10-17 X xerographics component dimensions. 9-13 removal. 2-18 part number. 9-33 removal. 2-10 testing. 1-13 voltage tolerances. 1-9 Docking Interlock location. 3-211 troubleshooting AC power supply. 1-13 Windows printing problems. A-9 voltage requirements. 9-33 wiring. 8-28 replacement rollers. 8-61 part numbers. 2-13 motor tests. 8-73 wiring. 8-74 wiring. 5-37 Drum Cartridge. 9-25 removal. 2-27 Paper Size Switch signals. 9-33 removal. 9-33 Toner Dispense Assembly. 2-17 part number. 10-24 Fuser. 8-44 U USB Port. 2-29 part number. 10-24 Transfer Roller. 8-31 paper guides. 4-12 Image Processor Board. 8-30 Tray 6 connection. 2-27 Pre-Feed Sensor. 1-4 V version status. 4-14 RAM DIMM. 9-33 removal. 4-3 wiring diagram conventions. 2-36 Toner Cartridge part number. 3-21 Index-14 Phaser 5500 Printer Service Manual . 2-18 image data wiring. 2-13 Door J Interlock location. 3-6 location. 2-21 part number. 2-34 error.Nudger Roller removal. 4-15 W Wait Sensor. 10-33 part number. A-13 Nudger Solenoid testing. A-16 wall outlet testing. 9-33 power supply. A-21 sensor tests. 10-29 Laser C part number. A-18 slide in Tray 6. 2-15 part number. 2-16 part number. 9-35 removal. 8-76 Laser Assembly. 9-14 Retard Roller removal. 3-236 tray empty. 9-33 removal.

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