Phaser 5500/5550 Service Documentation

Transcription

1 Phaser 5500/5550 Service Documentation 705P01216 March 2008

2 About this Manual... Organization... How to Use this Documentation... Power Safety Precautions... Service Safety Summary... Electrostatic Discharge Precautions... Service Terms... Symbology and Nomenclature... Regulatory Specifications... Phaser 5500/5550 Printer Overview... Phaser 5500/5550 Printer Configurations... Parts of the Printer... Printer Options... Consumables and Routine Maintenance Items... Printer Specifications... Phaser 5500/5550 Printer Menu Map... iii iii iv vi vii viii ix x xiii xiv xiv xv xvi xviii xix xxi Introduction Initial Issue Phaser 5500/5550 Printer March 2008 i Introduction

3 Service Call Procedures Servicing Instructions Service Call Procedures Initial Issue Phaser 5500/5550 Printer March Service Call Procedures

4 Overview Messages, Codes, and Procedures Entry Level Fault Isolation Procedure Main Motor Failure Drum Motor Failure - U1-4 Drum Motor Failure Laser Unit Failure - U3-3 Laser Power Laser Motor Failure - U3-5 Polygon Motor Rotation Fuser Failure - U4-1 On Time Fuser Failure - U4-n Over Heat / Thermistor Fuser Failure - U4-7 Cold Sagging Fan Failure - U4-9 Fan Defect Toner Motor Failure - U5-1 Motor Rotation Fan Failure - U5-9 Fan Failure Engine Control Board Failure - U6-2, 3, 4, 5, 6, Paper Size Jam - E1-1 Regi Area Jam Jam at A - E1-2 Regi Area Jam Jam at A - E1-6 Regi Area Jam Jam at A - Fuser Area Jam Jam at A - E3-6 Fuser Area Jam Jam at A - E4-1 Exit 2 Area Jam Jam at E - E4-3 Exit 2 Area Jam Jam at E - E4-6 Exit 2 Area Jam Jam at E - E8-2 Duplex Area Jam Jam at D and A - C6-1 Duplex Area Jam Jam at D and A - C6-2 Duplex Area Jam Jam at Tray n - Pre-Feed Jam at Tray n - Registration Jam at Tray n - Feed Out # Jam at Tray n - Feed Out # Jam at Tray 5 - C4-0 Tray Jam at Tray 6 - C5-1 Tray Jam at Tray 6 - C5-2 Tray Jam at B - C5-3 Tray Jam at B - C8-2 F/03 SNR Static Jam Jam at C - C8-3 F/04 SNR Static Jam Jam at C - C8-4 F/05 SNR Static Jam Jam at Tray 6 - C8-5 HCF F/0 Sensor Static Jam Jam at D - C8-6 Duplex Jam at Tray 1/MPT - C9-3 Tray 1/MPT Jam at A - F4-12 H-Transport Entrance Sensor ON Jam at A or F - F4-n H-Transport Entrance Sensor Static Jam at A or F - F4-n H-Transport Exit Sensor ON Jam at F - F4-26 H-Transport Exit Sensor Static Jam at F - F4-32 Transport Entrance Sensor ON Jam at F - F4-36 Transport Entrance Sensor Static Jam at G - F4-4n Buffer Path Sensor ON Jam at G - F4-4n Buffer Path Sensor Static Status Indicator RAPs Jam at F or H - F4-5n Compile Exit Sensor OFF Jam at F or G - F4-5n Compile Exit Sensor ON Jam at H - F4-56 Compile Exit Sensor Static Jam at H - F4-61 Set Eject Jam Jam at H - F4-66 Compile Paper Sensor Static Jam at F or G - F4-7n Top Tray Exit Sensor ON Jam at F or Stacker Upper Tray - F4-7n Top Tray Sensor OFF Jam at F or G - F4-7n Top Tray Exit Sensor Static Jam at F - F4-82 Gate Sensor ON Jam at F or G - Gate Sensor Static Jam (Upper Tray) Jam at F or G - Gate Sensor 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/ Tray Paper Guide Does Not Match Size Menu -H4-3/ 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 Lower Tray Limit Stacker Lower Tray Failure - H5-2n Front Home Sensor Stacker Lower Tray Failure - H5-2n Rear Home Sensor Punch Failure - H5-3n Sensor Punch Failure - H5-3n Home Sensor Stacker Lower Tray Failure - H5-8n Eject Clamp Sensor Stacker Lower Tray Failure - H5-8n Set Clamp Sensor Stacker Lower Tray Failure - H5-86 Side Regi Sensor OFF Stapler Failure - H5-91 Staple Fail Stapler Failure - H5-9n Move Sensor Tray 6 Control Board Failure - H6-4 NVM R/W Error Tray 6 Control Board Failure - H6-7 HFC Comm Failure Tray 4-5 Control Board Failure - NVM Tray 4-5 Control Board Failure - H7-7 Comm Failure Incorrect Tray 4-5 Installed - H7-8 Type Error Tray N Failure - H8-1, Tray 2-3 Size Sensor Broken Tray N Failure - H8-3, 4-5 Tray Size Sensor Broken Toner Empty - J1-2 Toner Empty No Drum Cartridge - J3-1 Drum Not Installed Drum Cartridge Failure - J4-1 ATC Sensor Detect 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 Type Mismatch Toner Cartridge Failure - J8-n Toner Comm/Read/Write Replace Incorrect Toner Cartridge - J8-3 Toner Cartridge Type Mismatch Initial Issue Phaser 5500/5550 Printer March Status Indicator RAPs

5 Toner Is Low - Toner Low Drum Cartridge Near End of Life - DRUM Life Near End Tray Empty - No Paper in Tray 2 or Tray Empty - No Paper in Tray 4 or Tray Empty - No Paper in Tray Paper Size Jam - Paper Size in Tray 2 or Paper Size Jam - Paper Size in Tray 4 or Paper Size Jam - Paper Size in Tray Drum Cartridge Failure - Drum ATC Value Out of Range Temp/Humidity Sensor Failure - Value Out of Range Face Down Tray Paper Full - Face Down Tray Full Stacker Upper Tray Full - Finisher Tray Paper Full Stacker Lower Tray Full - Finisher Mix Full Stack Stapler is Empty - Staple Pin Warning Staple Cartridge is Low or Missing - Staple Pin Misfeed Stapler Failure - Staple Failure Staple Set Over Count Stacker Lower Tray Failure Punch Waste Box is Missing Punch Waste Box is Full Printer Front Door is Open - Front Cover is Open Slide In Tray 6 Feeder - Tray 6 Undocked Close Door A - Door A is Open Close Door B - Door B is Open Close Door C - Door C is Open Close Door D - Door D is Open Close Door E - Door E is Open Close Door F - Door F is Open Close Door G - Door G is Open Close Door H - Door H is Open Close Door J - Door J is Open Replace Maintenance Kit Invalid or Missing Configuration Card Duplicate IP Address Detected Status Indicator RAPs March Initial Issue

6 Print-Quality Problems Overview Analyzing Test Prints Image Quality RAPs IQ1 Deletions (Line, Band, Spots) IQ2 Unfused Image IQ3 Resolution IQ4 Registration IQ5 Registration (Side to Side) IQ6 Skips and Smears IQ7 Spots IQ8 Skewed Image IQ9 Light (Undertoned) Print IQ10 Blank Print (No Image) IQ11 Black Prints IQ12 Process Deletions IQ13 Scan Deletions IQ14 Process Streaks IQ15 Scan Streaks IQ16 Damaged Print IQ17 Spot Deletions IQ18 Repeating Defects IQ19 Residual Image IQ20 Background IQ21 Uneven Density Image Quality Initial Issue Phaser 5500/5550 Printer March Image Quality

7 4 Repairs and Adjustments Disassembly Overview Overview General Notes on Disassembly Covers REP 1.1 Front Left Cover REP 1.2 Top Rear Cover REP 1.3 Top Cover REP 1.4 Front Door REP 1.5 Inner Main Cover REP 1.6 Front Door Interlock Switch REP 1.7 Upper Right Cover REP 1.8 Rear Panel Cover REP 1.9 Lower Right Cover REP 1.10 I/P Board Cover REP 1.11 Upper Rear Cover REP 1.12 Tray 1/MPT Rear Cover REP 1.13 Lower Rear Cover REP 1.14 Option Interface Cover REP 1.15 Exit 1 Top Cover REP 1.16 Control Panel Upper Transportation and Registration REP 2.1 Paper Size Switches REP 2.2 Tray 2 Feeder REP 2.3 Tray 3 Feeder REP 2.4 Feed/Lift Motor REP 2.5 Tray 2 and 3 No Paper Sensor REP 2.6 Tray 2 and 3 Level Sensor Actuator REP 2.7 Tray 2 and 3 Level Sensor REP 2.8 Tray 2 and 3 Pre-Feed Sensor REP 2.9 Feed Roller REP 2.10 Retard Roller REP 2.11 Nudger Roller Tray 1 Disassembly REP 3.1 Tray 1 Feeder REP 3.2 Tray 1/MPT No Paper Sensor Actuator REP 3.3 Tray 1/MPT No Paper Sensor REP 3.4 Pick Up Gear REP 3.5 Pick Up Solenoid REP 3.6 Cam Gear Spring REP 3.7 Feed Roller Assembly REP 3.8 Retard Pad Lower Transportation and Registration REP 4.1 Take Away Bracket REP 4.2 Door B Interlock Switch REP 4.3 Take Away Roller Assembly REP 4.4 Door B REP 4.5 Transfer Roller REP 4.6 Door A Interlock Switch REP 4.7 Door A REP 4.8 Registration Roller REP 4.9 Registration Transport Assembly REP 4.10 Registration Clutch REP 4.11 Registration Sensor REP 4.12 Take Away Clutch REP 4.13 Feed Out Sensor Xerographics REP 5.1 Drum Cartridge Fan Intake Duct REP 5.2 Drum Cartridge Fan REP 5.3 Fuser Fan REP 5.4 Drum Cartridge Detect Switch REP 5.5 Environmental Sensor PWB REP 5.6 Drum Cartridge CRUM PWB REP 5.7 Toner Cartridge CRUM PWB REP 5.8 Toner Dispense Assembly REP 5.9 Toner Dispense Motor REP 5.10 Laser Assembly Fuser and Exit 1 REP 6.1 Fuser Assembly REP 6.2 Fuser Exit Sensor REP 6.3 Exit Transport Assembly REP 6.4 Exit 1 Offset Motor REP 6.5 Offset Home Position Sensor REP 6.6 Full Stack Sensor REP 7.1 Main Drive Belt REP 7.2 Motor Assembly REP 8.1 High Voltage Power Supply REP 8.2 Power Switch REP 8.3 Exit PWB REP 8.4 Engine Control Board REP 8.5 Image Processor Board REP 8.6 Low Voltage Power Supply REP 8.7 AC Accessory Panel REP 8.8 GFI Breaker Sheet Feeder Assembly 1000-Sheet Feeder Assembly REP 20.1 Top Cover REP 20.2 Right Cover REP 20.3 Foot Cover REP 20.4 Left Cover Initial Issue Phaser 5500/5550 Printer March Repairs and Adjustments

8 Parts List Overview Using the Parts List Serial Number Format Parts List Covers PL 1.1 Covers (1/2) PL 1.2 Covers (2/2) Trays PL 2.1 Tray (1/2) and Feeder (1/2) PL 2.2 Tray (2/2) Feeder PL 2.3 Feeder (2/2) PL 2.3 Feeder (2/2) (Continued) Tray 1/MPT PL 3.1 Tray 1/MPT Assembly PL 3.2 Tray 1/MPT Lower Frame Assembly PL 3.3 Tray 1/MPT Assembly Development PL 4.1 Transportation and Registration L/H Lower PL 4.2 L/H Upper Assembly PL 4.3 L/H Chute Assembly PL 4.4 L/H Cover Assembly PL 4.5 Registration Xerographics PL 5.1 Laser, CRU and Toner Dispense Fuser and Exit PL 6.1 Fuser and Exit Exit 1 PL 6.2 Exit Drive PL 7.1 Drive Electrical PL 8.1 Electrical PL 8.2 Harness Sheet Feeder PL Sheet Feeder (Tray 4 & 5) PL 20.2 Tray (1/2) and Feeder (1/2) (Trays 4 and 5) PL 20.3 Tray (2/2) PL 20.4 Feeder (2/2) Parts List PL 20.4 Feeder (2/2) (Continued) PL 20.5 Transportation (Trays 4 & 5) PL 20.6 Drive and Electrical (Trays 4 & 5) Sheet Feeder (Tray 6) PL 22.1 Tray 6 (HCF) Covers PL 22.2 Tray (1/2) PL 22.3 Tray (2/2) PL 22.4 Tray 6 Feeder (1/3) PL 22.5 Tray 6 Feeder (2/3) PL 22.6 Tray 6 Feeder (3/3) PL 22.7 Tray 6 Drive and Transportation PL 22.8 Tray 6 Electrical Duplex Unit PL 23.1 Duplex Unit PL 23.2 Inner Chute Assembly Duplex Module Exit 2 PL 24.1 Exit 2 L/H Upper Chute Assembly PL 24.2 Exit 2 Tray Guide Assembly PL 24.2 Exit 2 Tray Guide Assembly (Continued) Finisher/Stacker Parts PL 25.1 Finisher/Stacker Unit PL 25.2 Horizontal Transport Assembly (1/2) PL 25.3 Horizontal Transport Assembly (2/2) PL 25.4 Finisher/Stacker Covers (1/2) PL 25.5 Finisher/Stacker Covers (2/2) PL 25.6 Finisher Stack PL 25.7 Finisher Punch PL 25.8 Finisher Staple PL 25.9 Finisher Eject (1/3) PL Finisher Eject (2/3) PL Finisher Eject (3/3) PL Finisher Transport (1/2) PL Finisher Transport (2/2) PL Finisher Electrical PL Finisher Harness Xerox Supplies and Accessories Initial Issue Phaser 5500/5550 Printer March 2008 Parts List

9 PL 1.1 Covers (1/2) Item Part Description 1 802K74110 Cover Left FR, E55372 Cover-FRS FR, PR (Front Left Cover) 3 802E55362 Cover-Top RR, PR (Top Rear Cover) 4 Bracket ILSW 5 110E94770 Switch (Front Door Interlock Switch) 6 802E64160 Control Panel, K63680 Control Panel, K24041 Harn Assy Console Panel 8 802K74170 Cover Assy Top PR (Top Cover) 9 802K74080 Cover Assy Front (with 10~12) (Front Door) K16200 Cover Assy Front (with 10~12) (Front Door) Magnet Catch (P/O PL 1.1 Item 9) 11 Cover-Front (P/O PL 1.1 Item 9) E55351 Strip (Stopper) (P/O PL 1.1 Item 9) K58180 Cover Assy Inner, Main (Inner Main Cover) 14 Foot Front 15 Plate Ser Initial Issue March 2008 Parts List Phaser 5500/5550 Printer

10 Introduction Space Requirements Power On Self Test (POST) Service Usage Profile Service Diagnostics Network Problems Operating System and Application Problems Control Panel Display Error/ Inoperable Buttons Low Voltage Power Supply Troubleshooting AC Power Supply Troubleshooting Print Engine Troubleshooting Service Diagnostics Menu Map Service Diagnostic Tests and Utilities General Troubleshooting Initial Issue Phaser 5500/5550 Printer March General Troubleshooting

11 How to Use Plug/Jack Locations Print Engine Plug/Jack Locations Sheet Feeder Plug/Jack Locations Duplex Unit Plug/Jack Locations Exit 2 Plug/Jack Locations Tray 6 Plug/Jack Locations Finisher Plug/Jack Locations Print Engine Wiring Diagrams Sheet Feeder Wiring Diagrams Duplex Unit Wiring Diagrams Exit 2 Wiring Diagrams Tray 6 Wiring Diagrams Finisher Wiring Diagrams Wiring Data Initial Issue Phaser 5500/5550 Printer March Wiring Data

12 Phaser 5500/5550 Operational Overview Paper Handling Sensors Xerographics Major Assemblies and Functions Phaser 5500/5550 Options Operational Overview Exit Duplex Unit Sheet Feeder Sheet Feeder Finisher/Stacker Theory of Operation Initial Issue Phaser 5500/5550 Printer March Theory of Operation

13 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 d

14 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 Printer Configurations Parts of the Printer Front View Rear View Front Panel Printer Options Hard Drive Additional Memory Exit Networking Sheet Feeder Duplex Unit Stacker / Finisher Sheet Feeder Envelope Tray Consumables and Routine Maintenance Items Supply Life Counters Printer Specifications Physical Dimensions Memory Specifications Operational Clearances Functional Specifications Electrical Specifications Environmental Specifications Tray and Media Specifications Contents iii

15 2 Theory of Operation Phaser 5500 Operational Overview Summary of the Printing Process Paper Handling Main Motor Drum Motor Input Paper Path Output Paper Path Duplex Path Sensors Sensor Types Sensors in the Paper Path Xerographics Drum Cartridge Transfer Roller Toner Dispense Assembly Toner Dispense Motor Laser Assembly Fuser Major Assemblies and Functions Trays Exit 1 Assembly Printer Drive and Electrical iv 3 Error Messages, Codes, and Procedures Introduction Servicing Instructions System Startup Power On Self Test (POST) POST Soft Fault Messages POST Hard Fault Messages Service Usage Profile Accessing Fault Histories Interpreting Fault History Error Codes Service Diagnostics Using Service Diagnostics Starting Service Diagnostics Service Diagnostics Controls Messages, Codes, and Procedures Error Message Abbreviations Error Message Summary Using the Troubleshooting Procedures Measurement Techniques Entry Level Fault Isolation Procedure Main Motor Failure Drum Motor Failure - U1-4 Drum Motor Rotation Phaser 5500 Printer Service Manual

16 Laser Unit Failure - U3-3 Laser Power Laser Motor Failure - U3-5 Polygon Motor Rotation Fuser Failure - U4-1 On Time Fuser Failure - U4-n Over Heat / Thermistor Fuser Failure - U4-7 Cold Sagging Fan Failure - U4-9 Fan Defect Toner Motor Failure - U5-1 Motor Rotation Fan Failure - U5-9 Fan Failure Engine Logic Board Failure - U6-2, 3, 4, 5, Paper Size Jam - E1-1 Regi Area Jam Jam at A - E1-2 Regi Area Jam Jam at A - E1-6 Regi Area Jam Jam at A - Fuser Area Jam Jam at A - E3-6 Fuser Area Jam Jam at A - E4-1 Exit 2 Area Jam Jam at E - E4-3 Exit 2 Area Jam Jam at E - E4-6 Exit 2 Area Jam Jam at E - E8-2 Duplex Area Jam Jam at D and A - C6-1 Duplex Area Jam Jam at D and A - C6-2 Duplex Area Jam Jam at Tray n - Pre-Feed Jam at Tray n - Registration Jam at Tray n - Feed Out # Jam at Tray n - Feed Out # Jam at Tray 5 - C4-0 Tray Jam at Tray 6 - C5-1 Tray Jam at Tray 6 - C5-2 Tray Jam at B - C5-3 Tray Jam at B - C8-2 F/O3 SNR Static Jam Jam at C - C8-3 F/O4 SNR Static Jam Jam at C - C8-4 F/O5 SNR Static Jam Jam at Tray 6 - C8-5 HCF F/O SNR Static Jam Jam at D - C8-6 Duplex Jam at Tray 1/MPT - C9-3 Tray 1/MPT Jam at A - F4-12 H-X port Ent. SNR ON Jam at A or F - F4-n H-X port Ent. SNR Static Jam at A or F - F4-n H-X port Exit SNR ON Jam at F - F4-26 H-X port Exit SNR Static Jam at F - F4-32 X port Ent SNR ON c Jam at F or H - F4-5n Compile Exit SNR OFF Jam at F or G - F4-5n Compile Exit SNR ON Jam at H - F4-56 Compile Exit SNR Static Jam at H - F4-61 Set Eject Jam Contents v

17 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/ Tray Paper Guide Does Not Match Size Menu -H4-3/ 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 vi Phaser 5500 Printer Service Manual

18 Tray Empty - No Paper in Tray 2 or Tray Empty - No Paper in Tray 4 or Tray Empty - No Paper in Tray Paper Size Jam - Paper Size in Tray 2 or Paper Size Jam - Paper Size in Tray 4 or Paper Size Jam - Paper Size in Tray Drum Cartridge Failure - Drum ATC Value Out of Range Temp/Humidity Sensor Failure - Value Out of Range Face Down Tray Paper Full - Face Down Tray Full Stacker Upper Tray Full - Finisher Tray Paper Full Stacker Lower Tray Full - Finisher Mix Full Stack Stapler is Empty - Staple Pin Warning Staple Cartridge is Low or Missing - Staple Pin Misfeed Stapler Failure - Staple Failure Staple Set Over Count Stacker Lower Tray Failure Punch Waste Box is Missing Punch Waste Box is Full Printer Front Door is Open - Front Cover is Open Slide In Tray 6 Feeder - Tray 6 Undocked Close Door A - Door A is Open Close Door B - Door B is Open Close Door C - Door C is Open Close Door D - Door D is Open Close Door E - Door E is Open Close Door F - Door F is Open Close Door G - Door G is Open Close Door H - Door H is Open Close Door J - Door J is Open Replace Maintenance Kit Invalid or Missing Configuration Card Duplicate IP Address Detected General Troubleshooting Introduction Network Problems Operating System and Application Problems Macintosh Printing Problems Wi d Printing Problems ay Error/Inoperable Buttons er Supply Troubleshooting ne LVPS Finisher LVPS AC Power Supply Troubleshooting Verifying AC Power Contents vii

19 Print Engine Troubleshooting Inoperative Printer Engine Logic Board Image Processor Board Isolation Image Processor Board RAM Memory Fault Isolation Print-Quality Troubleshooting Print-Quality Problems Overview Analyzing Test Prints Print-Quality Defect Definitions Deletions (Line, Band, Spots) Fusing Resolution Registration Registration (Side to Side) Skips/Smears Spots Skew Other Print Defects Print-Quality Troubleshooting Light (Undertoned) Print Blank Print (No image) Black Prints Vertical Deletions Horizontal Deletions Vertical Streaks Horizontal Streaks Spots Unfused Image Damaged Print Resolution Spot Deletions Repeating Defects Residual Image Background Uneven Density Skewed Image Registration Skips and Smears viii Phaser 5500 Printer Service Manual

20 6 Adjustments and Calibrations Service Test Prints Print Quality Test Print Adjustments Checking Registration Adjusting Simplex Registration Adjusting Duplex Registration Adjusting Fuser Temperature Resetting Fuser Life Resetting the Printer to Default Values Resetting Connection Setup Values Resetting Paper Handling Setup Values Resetting PostScript Setup Values Resetting PCL Setup Values Resetting General Setup Values Resetting Front Panel Setup Values Resetting Printer Controls Setup Values Resetting File Security Setup Values Resetting Printer Default Settings (PostScript NVRAM) Cleaning and Maintenance Service Preventive Maintenance Procedure Recommended Tools Cleaning FRU Disassembly Overview Standard Orientation of the Printer General Notes on Disassembly Preparation Notations in the Disassembly Text Print Engine Covers Front Left Cover Top Rear Cover Top Cover Front Door Inner Main Cover Front Door Interlock Switch I/P Board Cover Upper Rear Cover Tray 1/MPT Rear Cover Lower Rear Cover Contents ix

21 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 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 x Phaser 5500 Printer Service Manual

22 Contents Toner Dispense Motor Laser Assembly Fuser and Exit Fuser Assembly Fuser Exit Sensor Exit Transport Assembly Exit 1 Offset Motor Offset Home Position Sensor Full Stack Sensor Drive Main Drive Belt Motor Assembly Print Engine Electrical High Voltage Power Supply Power Switch Exit PWB Engine Logic Board Front Panel Image Processor Board Low Voltage Power Supply AC Accessory Panel GFI Breaker Parts Lists Serial Number Format Using the Parts List Print Engine Parts Xerox Supplies and Accessories Wiring Diagrams Print Engine Plug/Jack Designators Plug/Jack Locator Diagrams Drum and Toner Cartridge Laser Assembly and Exit PWB Fuser and Exit Tray 1/MPT Registration Transport Assembly Tray 2 & 3 Feeder Assemblies AC Accessory Panel LVPS Print Engine Wiring Diagrams Notations Used in Wiring Diagrams Print Engine General Wiring (1/2) xi

23 Print Engine General Wiring (2/2) LVPS Fuser Registration Transport Xerographics Drive/CRUM Tray Tray Tray 1/MPT Laser Assembly Exit Engine Logic and Image Processor Board Interface Image Processor Board (1/2) Image Processor Board (2/2) 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 Fi i S l i /Cl T enu A A-22 t Menu A A-23 Exit A-23 Mode Select Port A-24 xii Index Phaser 5500 Printer Service Manual

24 Phaser 5500 Laser er Service Manual Book 2 - Options 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 d

25 Contents Service Terms Product Terms Power Safety Precautions Electrostatic Discharge (ESD) Precautions Service Safety Summary Regulatory Specifications Manual Organization xi xii xiii xiv xv xvii xix 1 General Information Printer Introduction and Overview Printer Configurations Available Options Hard Drive Additional Memory Exit Networking Sheet Feeder Duplex Unit Stacker / Finisher Sheet Feeder Envelope Tray Consumables and Routine Maintenance Items Option Part Numbers Option Specifications Physical Dimensions Environmental Specifications Tray and Media Specifications Theory of Operation Phaser 5500 Options Operational Overview Exit Exit 2 Paper Path Components Exit 2 Sensors Exit 2 Drive and Electrical ing Path Components Duplex Unit Sensors Duplex Unit Drive and Electrical Contents iii

26 iv 1000-Sheet Feeder Sheet Feeder Paper Path Compon Sheet Feeder Sensors Sheet Feeder Drive and Electrical Finisher/Stacker Finisher Paper Path Components Finisher Paper Path Sensors Punch Unit Compiler Tray Stapler Stacker Sheet Feeder Tray 6 Paper Path Components Tray 6 Sensors Tray Assembly Sheet Feeder Drive and Electrical FRU Disassembly Overview Standard Orientation General Notes on Disassembly Preparation Notations in the Disassembly Text Sheet Feeder Disassembly Top Cover Right Cover Foot Cover Left Cover Rear Cover Casters Paper Size Switch Tray Feeder Feed/Lift Motor Tray 4 and 5 No Paper Sensor Tray 4 and 5 Level Sensor Actuator Tray 4 and 5 Level Sensor Tray 4 and 5 Pre-Feed Sensor Feed Roller Retard Roller Nudger Roller Tray 4 Feed Out Sensor # Tray 5 Feed Out Sensor # Upper Take Away Roller Lower Take Away Roller Upper Pinch Roller Assembly Lower Pinch Roller Assembly Pinch Roller Phaser 5500 Printer Options Service Manual

27 Door C Interlock Switch Tray 4-5 PWB Take Away Clutch Take Away Motor Sheet Feeder Disassembly Docking the 2000-Sheet Feeder Tray 6 Rear Cover Tray 6 Top Cover Tray 6 Right Cover Tray 6 Left Cover Tray 6 Front Cover Door J Tray Removal Tray 6 Casters Tray 6 Tray In Sensor Tray 6 Paper Size Sensors A/B Tray 6 End Guide Assembly Tray 6 Gear Assembly Tray 6 Cables Tray 6 Feeder Assembly Tray 6 Feed/Lift Motor Tray 6 Drive Frame Assembly Tray 6 Nudger Solenoid Tray 6 Pre-Feed Sensor Tray 6 No Paper Sensor Actuator Tray 6 No Paper Sensor Tray 6 Level Sensor Tray 6 Nudger Roller Tray 6 Feeder Shaft Assembly Tray 6 Feed Roller Tray 6 Retard Roller Tray 6 Lower Feeder Assembly Tray 6 Retard Clutch, Bracket or Spring Door J Interlock Switch Tray 6 Feed Out Sensor # Tray 6 Take Away Motor Take Away Roller Assembly Docking Interlock Switch Tray 6 PWB Contents v

28 Duplex Unit Disassembly Duplex Unit Removal Duplex Unit Chutes and Cover Door D Latch Lever Door D Interlock Switch Wait Sensor Actuator Duplex Motor Duplex Unit PWB Duplex Wait Sensor Exit 2 Disassembly Exit 2 Transport Assembly Face-Up Roller Invert Roller Exit 2 Tray Guide Stack Full Actuator Offset Gear OCT (Offset) Roller Exit 2 Pinch Roller Exit Sensor Actuator Exit 2 Fan Door E Interlock Switch Face-Up Solenoid Exit Gate Solenoid Offset Motor Exit Sensor OCT Home Position Sensor Exit 2 Motor Full Stack Sensor Finisher/Stacker Disassembly Horizontal Transport Horizontal Transport Rear Cover Door F Horizontal Transport Drive Belt Horizontal Transport Right Shaft Horizontal Transport Left Shaft Horizontal Transport Rollers Horizontal Transport Belts Horizontal Transport Motor Horizontal Transport Top Cover Door F Interlock Sensor Horizontal Transport Entrance Sensor Horizontal Transport Exit Sensor Finisher Docking Finisher Upper Rear Cover Finisher Lower Rear Cover Finisher Top Cover vi Phaser 5500 Printer Options Service Manual