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Phaser 5500
Fuji Xerox Phaser 5500 User Manual
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P
arts Lists
9-29
Parts List 4.4
L/H Cover Assembly
No.
Name/Descripti
on
Pa
r
t N
u
m
be
r
1
COVER ASSY
-L/H (wit
h 2~10) (Door A)
802K58260
2
HA
NDLE L/
H
003E59832
3
ROD CRU SHUTTER
024E03250
4
CHUTE
LHCO
V
5
-
6
CHUTE
ASSY
-DUP
054K24060
7
F
RAME ASSY
LH
8
COVER-LH
9
S
PRING COMP LH
809E42460
10
SUPP
OR
T
- LH CO
VER (D
oor A Stopper)
849E
13981
532
534
Table of Contents
Default Chapter
3
Service Manual
3
Table of Contents
5
Service Terms
15
Product Terms
16
Symbols Marked on the Product
16
Power Safety Precautions
17
Power Source
17
Electrostatic Discharge (ESD) Precautions
18
Service Safety Summary
19
General Guidelines
19
Warning Labels
19
Safety Interlocks
19
Servicing Electrical Components
20
Servicing Mechanical Components
20
Regulatory Specifications
21
Declaration of Conformity
22
In the European Union
22
Manual Organization
23
1 General Information
25
Printer Introduction and Overview
26
Printer Configurations
27
Parts of the Printer
28
Front View
28
Rear View
28
Front Panel
29
Printer Options
30
Hard Drive
30
Additional Memory
30
Exit 2
30
Networking
30
1000-Sheet Feeder
31
Duplex Unit
31
Stacker / Finisher
32
2000-Sheet Feeder
33
Envelope Tray
33
Consumables and Routine Maintenance Items
34
Supply Life Counters
34
Printer Specifications
35
Physical Dimensions
35
Memory Specifications
35
Operational Clearances
35
Functional Specifications
37
Electrical Specifications
37
Environmental Specifications
38
Tray and Media Specifications
38
2 Theory of Operation
41
Phaser 5500 Operational Overview
42
Summary of the Printing Process
42
Paper Handling
44
Main Motor
44
Drum Motor
44
Input Paper Path
45
Output Paper Path
47
Duplex Path
50
Sensors
51
Sensor Types
51
Sensors in the Paper Path
53
Paper Feed Sensors
54
Paper Size Sensing
54
Xerographics
55
Drum Cartridge
55
Transfer Roller
56
Toner Dispense Assembly
57
Toner Dispense Motor
58
Laser Assembly
58
Fuser
61
Major Assemblies and Functions
66
Trays
66
Exit 1 Assembly
70
Printer Drive and Electrical
72
3 Error Messages, Codes, and Procedures
79
Introduction
80
Servicing Instructions
80
System Startup
81
Power on Self Test (POST)
82
POST Soft Fault Messages
83
POST Hard Fault Messages
84
Service Usage Profile
85
Accessing Fault Histories
85
Interpreting Fault History Error Codes
85
Jam Errors
87
Service Diagnostics
89
Using Service Diagnostics
90
Starting Service Diagnostics
90
Service Diagnostics Controls
91
Messages, Codes, and Procedures
92
Error Message Abbreviations
92
Error Message Summary
93
Using the Troubleshooting Procedures
98
Measurement Techniques
99
Entry Level Fault Isolation Procedure
100
Main Motor Failure
101
Drum Motor Failure - U1-4 Drum Motor Rotation
102
Laser Unit Failure - U3-3 Laser Power
103
Laser Motor Failure - U3-5 Polygon Motor Rotation
104
Fuser Failure - U4-1 on Time
105
Fuser Failure - U4-N over Heat / Thermistor
107
Fuser Failure - U4-7 Cold Sagging
108
Fan Failure - U4-9 Fan Defect
110
Toner Motor Failure - U5-1 Motor Rotation
111
Fan Failure - U5-9 Fan Failure
112
Engine Logic Board Failure - U6-2, 3, 4, 5, 7
113
Paper Size Jam - E1-1 Regi Area Jam
113
Jam at a - E1-2 Regi Area Jam
115
Jam at a - E1-6 Regi Area Jam
116
Jam at a - Fuser Area Jam
117
Jam at a - E3-6 Fuser Area Jam
119
Jam at a - E4-1 Exit 2 Area Jam
120
Jam at E - E4-3 Exit 2 Area Jam
122
Jam at E - E4-6 Exit 2 Area Jam
125
Jam at E - E8-2 Duplex Area Jam
127
Jam at D and a - C6-1 Duplex Area Jam
129
Jam at D and a - C6-2 Duplex Area Jam
131
Jam at Tray N - Pre-Feed
134
Jam at Tray N - Registration
137
Jam at Tray N - Feed out #3
139
Jam at Tray N - Feed out #4
141
Jam at Tray 5 - C4-0 Tray 5
143
Jam at Tray 6 - C5-1 Tray 6
146
Jam at Tray 6 - C5-2 Tray 6
149
Jam at B - C5-3 Tray 6
151
Jam at B - C8-2 F/O3 SNR Static Jam
154
Jam at C - C8-3 F/O4 SNR Static Jam
155
Jam at C - C8-4 F/O5 SNR Static Jam
156
Jam at Tray 6 - C8-5 HCF F/O SNR Static Jam
157
Jam at D - C8-6 Duplex
161
Jam at Tray 1/MPT - C9-3 Tray 1/MPT
162
Jam at a - F4-12 H-X'port Ent. SNR on
165
Jam at a or F - F4-N H-X'port Ent. SNR Static
167
Jam at a or F - F4-N H-X'port Exit SNR on
169
Jam at F - F4-26 H-X'port Exit SNR Static
171
Jam at F - F4-32 X'port Ent. SNR on
173
Jam at F - F4-36 X'port Ent. SNR Static
176
Jam at G - F4-4N Buffer Path SNR on
179
Jam at G - F4-4N Buffer Path SNR Static
184
Jam at F or H - F4-5N Compile Exit SNR off
187
Jam at F or G - F4-5N Compile Exit SNR on
190
Jam at H - F4-56 Compile Exit SNR Static
193
Jam at H - F4-61 Set Eject Jam
196
Jam at H - F4-66 Compile Paper SNR Static
199
Jam at F or G - F4-7N Top Tray Exit SNR on
201
Jam at F or Stacker Upper Tray - F4-7Ntop Tray SNR off
204
Jam at F or G - F4-7N Top Tray Exit SNR Static
207
Jam at F - F4-82 Gate SNR on
209
Jam at F or G - Gate SNR Static Jam (Upper Tray)
213
Jam at F or G - Gate SNR Static Jam (Lower Tray)
216
Tray N Failure - H1 -1/2/3/4 Tray N Fail
219
Tray 6 Failure - H1-5 Tray 6 Fail
222
Duplex Unit Failure - H2-7 Duplex Comm Failure
226
Incorrect Duplex Unit Installed - H2-8 Duplex Type Error
227
Exit Unit Failure - H3-N Offset Error
228
Exit Unit Failure - H3-7 Exit Board Comm Failure
230
Tray 1/MPT Paper Guide Does Not Match Size Menu
232
Tray Paper Guide Does Not Match Size Menu -H4-1/2
233
Tray Paper Guide Does Not Match Size Menu -H4-3/4
235
Finisher Board Failure - H5-4, 7, 8 Nvm/Comm/Type Error
237
Stacker Lower Tray Failure - H5-11 Low Tray Fail
238
Stacker Lower Tray Failure - H5-12 Low Tray Upper Limit
240
Stacker Lower Tray Failure - H5-13 Low Tray Lower Limit
243
Stacker Lower Tray Failure - H5-2N Front Home SNR
246
Stacker Lower Tray Failure - H5-2N Rear Home SNR
248
Punch Failure - H5-3N SNR
250
Punch Failure - H5-3N Home SNR
252
Stacker Lower Tray Failure - H5-8N Eject Clamp SNR
254
Stacker Lower Tray Failure - H5-8N Set Clamp SNR
256
Stacker Lower Tray Failure - H5-86 Side Regi SNR off
259
Stapler Failure - H5-91 Staple Fail
262
Stapler Failure - H5-9N Move SNR
263
Tray 6 Logic Board Failure - H6-4 NVM R/W Error
265
Tray 6 Logic Board Failure - H6-7 HCF Comm Failure
266
Tray 4-5 Logic Board Failure - NVM
267
Tray 4-5 Logic Board Failure - H7-7 Comm Failure
268
Incorrect Tray 4-5 Installed - H7-8 Type Error
269
Tray N Failure - H8-1, 2 Tray Size Sensor Broken
271
Tray N Failure - H8-3, 4 Tray Size Sensor Broken
272
Toner Empty- J1-2 Toner Empty
275
No Drum Cartridge - J3-1 Drum Not Installed
277
Drum Cartridge Failure - J4-1 ATC SNR Defect
278
Replace Drum Cartridge - J6-1 DRUM End of Life
278
Drum Cartridge Failure - J7-N Comm/Nvram/Type Error
279
Toner Cartridge Failure - J8-N Toner Comm/Read/Write
282
Toner Is Low - Toner Low
284
Drum Cartridge Near End of Life - DRUM Life Near End
285
Tray Empty - no Paper in Tray 2 or 3
286
Tray Empty - no Paper in Tray 4 or 5
287
Tray Empty - no Paper in Tray 6
289
Paper Size Jam - Paper Size in Tray 2 or 3
290
Paper Size Jam - Paper Size in Tray 4 or 5
292
Paper Size Jam - Paper Size in Tray 6
295
Drum Cartridge Failure - Drum ATC Value out of Range
296
Temp/Humidity Sensor Failure - Value out of Range
297
Face down Tray Paper Full - Face down Tray Full
298
Stacker Upper Tray Full - Finisher Tray Paper Full
300
Stacker Lower Tray Full - Finisher MIX Full Stack
301
Stapler Is Empty - Staple Pin Warning
303
Staple Cartridge Is Low or Missing - Staple Pin Misfeed
304
Stapler Failure - Staple Failure
306
Staple Set over Count
307
Stacker Lower Tray Failure
308
Punch Waste Box Is Missing
310
Punch Waste Box Is Full
311
Printer Front Door Is Open - Front Cover Is Open
313
Slide in Tray 6 Feeder - Tray 6 Undocked
314
Close Door a - Door a Is Open
315
Close Door B - Door B Is Open
316
Close Door C - Door C Is Open
317
Close Door D - Door D Is Open
318
Close Door E - Door E Is Open
320
Close Door F - Door F Is Open
321
Close Door G - Door G Is Open
323
Close Door H - Door H Is Open
325
Close Door J - Door J Is Open
326
Replace Maintenance Kit
328
Invalid or Missing Configuration Card
328
Duplicate IP Address Detected
329
4 General Troubleshooting
331
Introduction
332
Network Problems
332
Operating System and Application Problems
332
Macintosh Printing Problems
332
Windows Printing Problems
333
Front Panel Display Error/Inoperable Buttons
334
Low Voltage Power Supply Troubleshooting
335
Print Engine LVPS
335
Finisher LVPS
336
AC Power Supply Troubleshooting
337
Verifying AC Power
338
Print Engine Troubleshooting
340
Inoperative Printer
340
Engine Logic Board
342
Image Processor Board Isolation
343
Image Processor Board
344
RAM Memory Fault Isolation
345
5 Print-Quality Troubleshooting
347
Print-Quality Problems Overview
348
Analyzing Test Prints
348
Print-Quality Defect Definitions
349
Deletions (Line, Band, Spots)
351
Fusing
352
Resolution
353
Registration
354
Registration (Side to Side)
355
Skips/Smears
356
Spots
357
Skew
358
Other Print Defects
359
Print-Quality Troubleshooting
360
Light (Undertoned) Print
360
Blank Print (no Image)
362
Black Prints
365
Vertical Deletions
367
Horizontal Deletions
369
Vertical Streaks
371
Horizontal Streaks
373
Spots
375
Unfused Image
376
Damaged Print
379
Resolution
380
Spot Deletions
381
Repeating Defects
383
Residual Image
384
Background
386
Uneven Density
388
Skewed Image
390
Registration
391
Skips and Smears
393
6 Adjustments and Calibrations
395
Service Test Prints
396
Print Quality Test Print
396
Adjustments
398
Checking Registration
398
Adjusting Simplex Registration
400
Adjusting Duplex Registration
401
Adjusting Fuser Temperature
402
Resetting Fuser Life
403
Resetting the Printer to Default Values
403
Resetting Connection Setup Values
404
Resetting Paper Handling Setup Values
404
Resetting Postscript Setup Values
404
Resetting PCL Setup Values
405
Resetting General Setup Values
405
Resetting Front Panel Setup Values
405
Resetting Printer Controls Setup Values
405
Resetting File Security Setup Values
406
Resetting Printer Default Settings (Postscript NVRAM)
406
7 Cleaning and Maintenance
409
Service Preventive Maintenance Procedure
410
Recommended Tools
410
Cleaning
410
8 FRU Disassembly
411
Overview
412
Standard Orientation of the Printer
412
General Notes on Disassembly
413
Preparation
413
Notations in the Disassembly Text
414
Print Engine Covers
415
Front Left Cover
415
Top Rear Cover
416
Top Cover
417
Front Door
418
Inner Main Cover
419
Front Door Interlock Switch
420
Upper Right Cover
421
Rear Panel Cover
422
Lower Right Cover
423
I/P Board Cover
424
Upper Rear Cover
425
Tray 1/MPT Rear Cover
426
Lower Rear Cover
426
Option Interface Cover
427
Exit 1 Top Cover
428
Upper Transportation and Registration
429
Paper Size Switches
429
Tray 2 Feeder
430
Tray 3 Feeder
431
Feed/Lift Motor
433
Tray 2 and 3 no Paper Sensor
434
Tray 2 and 3 Level Sensor Actuator
435
Tray 2 and 3 Level Sensor
437
Tray 2 and 3 Pre-Feed Sensor
438
Feed Roller
439
Retard Roller
440
Nudger Roller
441
Tray 1 Disassembly
442
Tray 1 Feeder
442
Tray 1/MPT no Paper Sensor Actuator
443
Tray 1/MPT no Paper Sensor
444
Pick up Gear Spring
445
Tray 1 Pick up Solenoid
446
Cam Gear Spring
446
Feed Roller Assembly
448
Retard Pad
449
Lower Transportation and Registration
450
Take Away Bracket
450
Door B Interlock Switch
451
Take Away Roller Assembly
451
Door B
453
Transfer Roller
454
Door a Interlock Switch
455
Door a
456
Registration Roller
456
Registration Transport Assembly
459
Registration Clutch
461
Registration Sensor
462
Take Away Clutch
463
Feed out Sensor 3
464
Xerographics
466
Drum Cartridge Fan Intake Duct
466
Drum Cartridge Fan
468
Fuser Fan
469
Drum Cartridge Detect Switch
470
Environmental Sensor PWB
474
Drum Cartridge CRUM PWB
480
Toner Cartridge CRUM PWB
481
Toner Dispense Assembly
481
Toner Dispense Motor
483
Laser Assembly
484
Fuser Assembly
486
Fuser and Exit 1
486
Fuser Exit Sensor
487
Exit Transport Assembly
488
Exit 1 Offset Motor
490
Offset Home Position Sensor
491
Full Stack Sensor
492
Drive
493
Main Drive Belt
493
Motor Assembly
494
Print Engine Electrical
496
High Voltage Power Supply
496
Power Switch
496
Exit PWB
498
Engine Logic Board
499
Front Panel
500
Image Processor Board
501
Low Voltage Power Supply
502
AC Accessory Panel
503
GFI Breaker
504
9 Parts Lists
505
Serial Number Format
506
Using the Parts List
507
Print Engine Parts
508
Xerox Supplies and Accessories
548
10 Wiring Diagrams
551
Print Engine Plug/Jack Designators
552
Plug/Jack Locator Diagrams
556
Drum and Toner Cartridge
556
Laser Assembly and Exit PWB
557
Fuser and Exit 1
558
Tray 1/MPT
559
Registration Transport Assembly
560
Tray 2 & 3 Feeder Assemblies
561
Print Engine Electrical
562
Engine Logic Board
563
Image Processor Board
564
AC Accessory Panel
565
Lvps
566
Print Engine Wiring Diagrams
567
Notations Used in Wiring Diagrams
567
Print Engine General Wiring (1/2)
569
Print Engine General Wiring (2/2)
570
Lvps
571
Fuser
572
Registration Transport
573
Xerographics
574
Drive/Crum
575
Tray 2
576
Tray 3
577
Tray 1/MPT
578
Laser Assembly
579
Exit 1
580
Engine Logic and Image Processor Board Interface
581
Image Processor Board (1/2)
582
Image Processor Board (2/2)
583
Phaser 5500 Laser Printer Menu Map
585
Service Diagnostics Menu Map
585
Service Diagnostic Tests and Utilities
593
General Status Menu
593
Test Print Menu
594
Printer NVRAM Adjustments Menu
594
Print Engine Motors/Fan Test Menu
596
Duplex Unit Motor Tests Menu
596
Exit 2 Motor Tests Menu
597
Trays 4 & 5 Motor Tests Menu
597
Tray 6 Motor Tests Menu
597
Finisher Motor Tests Menu
598
Print Engine Sensor/Switch Tests Menu
599
Duplex Unit Sensor/Switch Tests Menu
600
Exit 2 Sensor/Switch Tests Menu
601
Tray 4 & 5 Sensor/Switch Tests Menu
601
Tray 6 Sensor/Switch Tests Menu
602
Finisher Sensor/Switch Tests Menu
603
Print Engine Solenoid/Clutch Tests Menu
604
Exit 2 Solenoid/Clutch Test Menu
605
Tray 4 & 5 Solenoid/Clutch Test Menu
605
Tray 6 Solenoid/Clutch Test Menu
605
Finisher Solenoid/Clutch Tests Menu
605
Controller NVRAM Access Menu
606
Engine Logic Board Replacement Menu
606
Finisher Board Setup Menu
607
Exit
607
Mode Select Port
608
4
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Fuji Xerox Phaser 5500 Specifications
General
Brand
Fuji Xerox
Model
Phaser 5500
Category
Printer
Language
English
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