Documente Academic
Documente Profesional
Documente Cultură
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
do so.
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 Unpublished rights reserved under the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
Servicesare 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.
1 General Information
Printer Introduction and Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Printer Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Available Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Hard Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Additional Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Exit 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Networking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1000-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Stacker / Finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
2000-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Envelope Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Consumables and Routine Maintenance Items. . . . . . . . . . . . . . . . . . . . . 1-8
Option Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Option Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Physical Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Tray and Media Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
2 Theory of Operation
Phaser 5500 Options Operational Overview . . . . . . . . . . . . . . . . . . . . . . . 2-2
Exit 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Exit 2 Paper Path Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Exit 2 Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Exit 2 Drive and Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Duplex Paper Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Duplex Unit Paper Path Components . . . . . . . . . . . . . . . . . . . . . . 2-8
Duplex Unit Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Duplex Unit Drive and Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Contents iii
1000-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
1000-Sheet Feeder Paper Path Components . . . . . . . . . . . . . . . 2-11
1000-Sheet Feeder Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
1000-Sheet Feeder Drive and Electrical . . . . . . . . . . . . . . . . . . . 2-16
Finisher/Stacker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Finisher Paper Path Components. . . . . . . . . . . . . . . . . . . . . . . . 2-19
Finisher Paper Path Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Punch Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Compiler Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Stapler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Stacker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
2000-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Tray 6 Paper Path Components . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Tray 6 Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Tray Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
2000-Sheet Feeder Drive and Electrical . . . . . . . . . . . . . . . . . . . 2-49
3 FRU Disassembly
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Standard Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
General Notes on Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Notations in the Disassembly Text . . . . . . . . . . . . . . . . . . . . . . . . 3-3
1000-Sheet Feeder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Foot Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Casters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Paper Size Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Tray Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Feed/Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Tray 4 and 5 No Paper Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Tray 4 and 5 Level Sensor Actuator . . . . . . . . . . . . . . . . . . . . . . 3-15
Tray 4 and 5 Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Tray 4 and 5 Pre-Feed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Feed Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Retard Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Nudger Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Tray 4 Feed Out Sensor #4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Tray 5 Feed Out Sensor #5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Upper Take Away Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Lower Take Away Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Upper Pinch Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Lower Pinch Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Pinch Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
iv Phaser 5500 Printer Options Service Manual
Door C Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Tray 4-5 PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Take Away Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Take Away Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
2000-Sheet Feeder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Docking the 2000-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Tray 6 Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Tray 6 Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Tray 6 Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Tray 6 Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Tray 6 Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Door J. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Tray Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Tray 6 Casters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Tray 6 Tray In Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Tray 6 Paper Size Sensors A/B . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Tray 6 End Guide Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Tray 6 Gear Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Tray 6 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Tray 6 Feeder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Tray 6 Feed/Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Tray 6 Drive Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Tray 6 Nudger Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Tray 6 Pre-Feed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Tray 6 No Paper Sensor Actuator . . . . . . . . . . . . . . . . . . . . . . . . 3-53
Tray 6 No Paper Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
Tray 6 Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Tray 6 Nudger Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Tray 6 Feeder Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
Tray 6 Feed Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
Tray 6 Retard Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
Tray 6 Lower Feeder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
Tray 6 Retard Clutch, Bracket or Spring . . . . . . . . . . . . . . . . . . . 3-60
Door J Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
Tray 6 Feed Out Sensor #6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
Tray 6 Take Away Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
Take Away Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
Docking Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
Tray 6 PWB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
Contents v
Duplex Unit Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
Duplex Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
Duplex Unit Chutes and Cover . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
Door D Latch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
Door D Interlock Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
Wait Sensor Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
Duplex Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76
Duplex Unit PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77
Duplex Wait Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78
Exit 2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
Exit 2 Transport Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
Face-Up Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
Invert Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
Exit 2 Tray Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86
Stack Full Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
Offset Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
OCT (Offset) Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
Exit 2 Pinch Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91
Exit Sensor Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92
Exit 2 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93
Door E Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-95
Face-Up Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
Exit Gate Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98
Offset Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100
Exit Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-102
OCT Home Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103
Exit 2 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-104
Full Stack Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105
Finisher/Stacker Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106
Horizontal Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106
Horizontal Transport Rear Cover . . . . . . . . . . . . . . . . . . . . . . . 3-107
Door F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108
Horizontal Transport Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . 3-109
Horizontal Transport Right Shaft . . . . . . . . . . . . . . . . . . . . . . . 3-110
Horizontal Transport Left Shaft . . . . . . . . . . . . . . . . . . . . . . . . 3-111
Horizontal Transport Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . 3-112
Horizontal Transport Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113
Horizontal Transport Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113
Horizontal Transport Top Cover . . . . . . . . . . . . . . . . . . . . . . . . 3-115
Door F Interlock Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-116
Horizontal Transport Entrance Sensor . . . . . . . . . . . . . . . . . . . 3-117
Horizontal Transport Exit Sensor . . . . . . . . . . . . . . . . . . . . . . . 3-118
Finisher Docking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-119
Finisher Upper Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-120
Finisher Lower Rear Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121
Finisher Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-122
Contents vii
Compile Exit Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-189
Lower Exit Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-191
Lower Exit Chute R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-196
Paddle Shaft/Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-200
Exit Pinch Rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-201
Lower Exit Chute (2b) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-202
Lower Exit Chute Pinch Rollers . . . . . . . . . . . . . . . . . . . . . . . . 3-204
Transfer Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-204
Buffer Gate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-206
Buffer Path Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-207
Buffer Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-208
Bottom Buffer Chute (3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-211
Exit Pinch Rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-213
Upper Entrance Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-214
Upper Entrance Chute Pinch Rollers . . . . . . . . . . . . . . . . . . . . 3-216
Transport Entrance Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-217
Entrance Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-218
Finisher Transport Motor and Belt . . . . . . . . . . . . . . . . . . . . . . 3-222
Transfer Gate Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-223
Buffer Gate Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-225
Stacker Upper Tray Exit Sensor . . . . . . . . . . . . . . . . . . . . . . . . 3-226
Top Exit Pinch Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-227
Top Exit Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-227
Stacker Upper Tray Full Stack Sensor . . . . . . . . . . . . . . . . . . . 3-233
Upper Exit Chute (2a). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-234
Upper Exit Chute Pinch Rollers . . . . . . . . . . . . . . . . . . . . . . . . 3-236
Gate Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-236
Transport Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-238
Finisher Exit Motor and Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-243
Finisher Registration Motor and Belt . . . . . . . . . . . . . . . . . . . . 3-245
Horizontal Transport PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-247
Finisher Main PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-248
Low Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-250
4 Parts Lists
Phaser 5500 Printer Option Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Using the Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
1000-Sheet Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
2000-Sheet Feeder (Tray 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Exit 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Finisher/Stacker Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Contents ix
Finisher Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
General Wiring (1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
General Wiring (2/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Horizontal Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Sensors (1/2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Sensors (2/2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Clutch and Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Compiler Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Stapler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
Punch (1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Punch (2/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Index
Manual Terms
Various terms are used throughout this manual to either provide additional
information on a specific topic or to warn of possible danger present during a
procedure or action. Be aware of all symbols and terms when they are used, and
always read NOTE, CAUTION, and WARNING statements.
Consumable: Ink, toner, or DrumCartridge that is consumed. Customer is expected
to replace once consumed.
Routine Maintenance Item: Supply item or kit that has a limited life. Customer
is expected to replace at end-of-life.
Accessory: A single component or assembly that may be added to a printer;
however, it is NOT an option to the product.
Common Acronyms:
FRU: Field Replaceable Unit
PL: Corresponds to the FRU Parts List.
CRU: Customer Replaceable Unit
ESD: Electrostatic Discharge
Note
A note indicates an operating or maintenance procedure, practice or condition
that is necessary to efficiently accomplish a task.
A note can provide additional information related to a specific subject or add a
comment on the results achieved through a previous action.
Caution
A caution statement indicates an operating or maintenance procedure, practice or
condition that, if not strictly observed, results in damage to, or destruction of,
equipment.
Warning
A warning statement indicates an operating or maintenance procedure, practice
or condition that, if not strictly observed, results in injury or loss of life.
Safety xi
Product Terms
Caution: A personal injury hazard exists that may not be apparent. For example, a
panel may cover the hazardous area.
Danger: A personal injury hazard exists in the area where you see the sign.
The surface is hot while the printer is running. After turning off
the power, wait 40 minutes.
00:40
Power Source
For 110 VAC printers, do not apply more than 135 volts RMS between the supply
conductors or between either supply conductor and ground. For 220 VAC printers, do
not apply more than 254 volts RMS between the supply conductors or between either
supply conductor and ground. Use only the specified power cord. This manual
assumes that the reader is a Xerox-certified service technician.
Plug the three-wire power cord (with grounding prong) into a grounded AC outlet
only. If necessary, contact a licensed electrician to install a properly grounded outlet.
If the product loses its ground connection, contact with conductive parts may cause an
electrical shock.
Disconnecting Power
Turning the power off using the On/Off switch does not completely de-energize the
printer. You must also disconnect the printer power cord from the AC outlet. Position
the power cord so that it is easily accessible during servicing so that you may power
down the printer during an emergency.
Disconnect the power plug by pulling the plug, not the cord.
Safety xiii
Electrostatic Discharge (ESD) Precautions
Some semiconductor components, and the respective sub-assemblies that contain
them, are vulnerable to damage by Electrostatic discharge (ESD). These components
include Integrated Circuits (ICs), Large-Scale Integrated circuits (LSIs), field-effect
transistors and other semiconductor chip components. The following techniques will
reduce the occurrence of component damage caused by static electricity.
Be sure the power is off to the chassis or circuit board, and observe all other safety
precautions.
After removing a static sensitive assembly from its anti-static bag, place it on a
grounded conductive surface. If the anti-static bag is conductive, you may ground
the bag and use it as a conductive surface.
General Guidelines
For Xerox-certified service personnel only: Refer also to the preceding Power
Safety Precautions.
Avoid servicing alone: Do not perform internal service or adjustment of this
product unless another person capable of rendering first aid or resuscitation is present.
Use care when servicing with power: Dangerous voltages may exist at several
points in this product. To avoid personal injury, do not touch exposed connections and
components while power is on. Disconnect power before removing the power supply
shield or replacing components.
Do not wear jewelry: Remove jewelry prior to servicing. Rings, necklaces and
other metallic objects could come into contact with dangerous voltages and currents.
Power source: This product is intended to operate from a power source that will
not apply more then 254 volts RMS for a 220 volt AC outlet or 135 volts RMS for a
110 volt AC outlet between the supply conductors or between either supply conductor
and ground. A protective ground connection by way of the grounding conductor in the
power cord is essential for safe operation.
Warning Labels
Read and obey all posted warning labels. Throughout the printer, warning labels are
displayed on potentially dangerous components. As you service the printer, check to
make certain that all warning labels remain in place.
Safety Interlocks
Make sure all covers and the printers front panel are in place and all interlock
switches are functioning correctly after you have completed a printer service call. If
you bypass an interlock switch during a service call, use extreme caution when
working on or around the printer.
Safety xv
Servicing Electrical Components
Before starting any service procedure, switch off the printer power and unplug the
power cord from the wall outlet. If you must service the printer with power applied,
be aware of the potential for electrical shock.
Warning
Turning the power off by using the On/Off switch does not completely de-
energize the printer. You must also disconnect the printer power cord from the
AC outlet. Position the power cord so that it is easily accessible during servicing.
Warning
Do not touch any electrical component unless you are instructed to do so by a
service procedure.
S7300-02
Warning
Do not try to manually rotate or manually stop the drive assemblies while any
printer motor is running.
S7300-03
Connect the printer into an outlet on a circuit different from that which the
receiver is connected.
Route the interface cables on the printer away from the receiver
Consult the dealer, Xerox service, or an experienced radio/television technician
for help.
Changes or modifications not expressly approved by Xerox can affect the emission
and immunity compliance and could void the user's authority to operate this product.
To ensure compliance, use shielded interface cables. A shielded parallel cable can be
purchased directly from Xerox at www.xerox.com/office/5500supplies.
Xerox has tested this product to internationally accepted electromagnetic emission
and immunity standards. These standards are designed to mitigate interference caused
or received by this product in a normal office environment. This product is also
suitable for use in a residential environment based on the levels tested.
In the United States this product complies with the requirements of an unintentional
radiator in part 15 of the FCC rules. Operation is subject to the following two
conditions: (1) this device may not cause harmful interference; (2) this device must
accept any interference received, including interference that may cause undesired
operation.
This digital apparatus does not exceed the Class B limits for radio noise emissions
from digital apparatus set out in the Radio Interference Regulations of the Canadian
Department of Communications, ICES-003.
Le prsent appareil numrique n'met pas de bruits radiolectrique dpassant les
limits applicables aux appareils numriques de la classe B prescrites dans le
Rglement sur le brouillage radiolectrique dict par le ministere des
Communications du Canada, NMB-003.
Safety xvii
Declaration of Conformity
Xerox Corporation, declares, under our sole responsibility that the printer to which
this declaration relates, is in conformity with the following standards and other
normative documents:
This product, if used properly in accordance with the user's instructions is neither
dangerous for the consumer nor for the environment. A signed copy of the
Declaration of Conformity for this product can be obtained from Xerox.
Book 2 - Options
Use Book 2 as a reference when servicing printer options. Book 2 includes
information important for the repair or replacement of option components. Use the
troubleshooting procedures in Book 1 to diagnose and isolated the problem.
Book 2 contains these sections:
Introductory, Safety, and Regulatory Information: This section contains
important safety information, regulatory requirements, and information about this
manual.
Chapter 1 - General Information: This section contains an overview of the
options available, configuration, specifications, and consumables.
Chapter 2 - Theory of Operation: This section contains functional information
on each option.
Chapter 3 - FRU Disassembly: This section contains removal procedures for
parts listed in the options Field Replaceable Units (FRUs) Parts List. A replacement
procedure is included when necessary.
Chapter 4 - Parts Lists: This section contains exploded views of the option FRUs
as well as FRU part numbers.
Chapter 5 - Wiring Diagrams: This section contains option plug/jack locations
and wiring diagrams.
Safety xix
Book 1 - Print Engine
Use Book 1 as your primary resource for understanding the operational characteristics
of the print engine. Book 1 describes printer specifications, theory and includes
information important to the diagnosis and repair of problems occurring in the print
engine and attached options. Book 1 also provides detailed print engine FRU
replacement procudures, FRU parts lists and wiring diagrams of print engine
components.
Book 1 contains these sections:
Introductory, Safety and Regulatory Information: This section contains
important safety information, regulatory requirements, and information about this
manual.
Chapter 1 - General Information: This section contains an overview of the
printers operation, configuration, specifications, and consumables.
Chapter 2 - Theory of Operation: This section contains detailed functional
information on print engine components.
Chapter 3 - Error Codes and Messages: This section describes the resident
diagnostics available to assist the troubleshooting process. These diagnostics include
Power On Self Test (POST), Service Diagnostics error messages, and Service Usage
Profile data stored in the printer. This section provides complete troubleshooting
information for the print engine and all its options.
Chapter 4 - General Troubleshooting: This section provides troubleshooting
methods for situations where no error indicator is available.
Chapter 5 - Print-Quality Troubleshooting: This section focuses on techniques
to correct image quality problems associated with printer output.
Chapter 6 - Adjustments and Calibrations: This section provides procedures
for the adjustment of print engine components.
Chapter 7 - Cleaning and Maintenance: This section provides periodic
cleaning procedures for the printer.
Chapter 8 - FRU Disassembly: This section contains removal procedures for
parts listed in the print engines Field Replaceable Units (FRUs) Parts List. A
replacement procedure is included when necessary.
Chapter 9 - Parts Lists: This section contains exploded views of the print engine
FRUs as well as part numbers for items available as FRUs. Part numbers for printer
options and accessories are also included.
Chapter 10 - Wiring Diagrams: This section contains the plug/jack locations and
the wiring diagrams for the print engine.
Appendix A - Menu Maps: This section provides an illustration of the front-panel
menu as well as a listing of the Service Diagnostics tests available.
Chapter
1
Printer Introduction and Overview
The Xerox Phaser 5500 Laser Printer Service Manual is the primary document used
to repair, maintain, and troubleshoot this printer. For manual updates, Service
Bulletins, knowledge base, etc., see www.xerox.com/office/partners. For further
technical support, contact your assigned Xerox Technical Support for this product.
To ensure complete understanding of this product, participation in Xerox Phaser 5500
Printer Service Training is strongly recommended. To service this product, Xerox
certification for this product is required.
s5500-006
The Phaser 5500 printer combines a single-pass, monochrome laser print engine with
an image processor supporting Adobes PostScript 3 description language. The
PCL5e, PCL6 and Oak PCL 5.0 printer languages are also supported. Print speed is
50 pages per minute at either 600 x 600 or True 1200 x 1200 dpi in 1-sided or 2-sided
modes. The printer features a bi-directional parallel interface and a USB port. The
Phaser 5500 printer provides a 100-sheet Tray 1/MPT from which specialty media,
card stock, larger format paper, and envelopes are fed. Tray 1/MPT also supports
manual feeding. Two additional trays, Tray 2 and 3, each provide another 500 sheets
of capacity. The Standard Output Tray holds 500 sheets facedown.
Phaser 5500 printer options add memory, paper capacity and functionality. For
models not originally equipped, an internal Hard Drive is available for font storage,
storing print files, job collation, proof print, personal print, and secure print support.
A selection of RAM memory upgrades are available to raise the installed quantity to
the 512 MB maximum. A 1000-Sheet Feeder is available with two, 500-sheet
universal media trays (Trays 4 and 5). A 2000-sheet Feeder (Tray 6) brings the
maximum input capacity to 4,100 sheets. An Envelope Tray, replacing Tray 2, holds
up to 35 envelopes. On the output side, a 3,500-sheet, high-capacity stapler/punch/
stacker is available raising the output total to 4000 sheets. A Configuration Card adds
100baseT Ethernet networking for host communication.
The Phaser 5500 printer is marketed in five configurations.
Printer Configurations
Features
5500B 5500N 5500DN 5500DT 5500DX
Hard Drive
A 20 GB hard drive is available to enable the Job Collation, Saved Jobs, Proof,
Persoanl, and Secure Print options. The hard drive installs on the Image Processor
Board with stand-offs and connects to the board with a single data/power connector.
Additional Memory
Options provide additional RAM in 128 MB and 256 MB increments. Also available
is 16 MB of Flash Memory for fonts, forms, and macros. Both RAM and NVRAM
options install to the Image Processing board. The Startup Page and Configuration
Page list the amount of installed RAM.
Exit 2
Exit 2 is required when either the Duplex Unit or Stacker/Finisher is installed. When
used in conjunction with the Duplex Unit, Exit 2 performs as a paper inverter. With
the Stacker/Finisher, Exit 2 serves as the replacement face-down exit to the top tray.
Exit 2 mounts directly above Exit 1 with spring loaded latches and guide pins.
Networking
A Configuration Card is used to enable or disable networking capabilities. This option
provides a replacement card to enable Ethernet on the base model (Phaser 5500B
printer).
1-4 Phaser 5500 Printer Options Service Manual
1000-Sheet Feeder
The 1000-Sheet Feeder forms a base for the printer and adds two, 500-sheet trays
(Tray 4 and Tray 5). Control signals reach the sheet feeder by a single connection.
The sheet feeder is secured to the print engine with two screws located under the front
edge of Tray 3.
s5500-012
Duplex Unit
The Duplex Unit , combined with Exit 2, adds two-sided printing. The Duplex Unit
attaches to the left side above Tray 1 using two twist locks. Exit 2 connects above the
printers Exit 1 to switch the Exit gate and reverse each sheet back into the Duplex
Unit. Electrical connection to the printer is made by an interface cable.
A
D
s5500-008
2
1
s5500-009
s5500-013
Envelope Tray
The Envelope Tray replaces Tray 2 to handle up to 35 envelopes.
s5500-014
2 s5500-010
Consumables
Physical Dimensions
Duplex Unit 211 mm (8.3 in.) 64 mm (2.52 in.) 458 mm (18.0 in.) 1.8 kg (4 lbs.)
1000-Sheet 280 mm (11.0 in.) 540 mm (21.2 in.) 520 mm (21.1 in.) 23 kg (50 lbs.)
Feeder
Stacker/ 1050mm (41.3 in.) 740mm (29.1 in.) 650mm (25.6 in.) 49kg (108 lbs.)
Finisher
Exit 2 142 mm (5.6 in.) 130 mm (5.1 in.) 460 mm (18.1 in.) 2 kg (4.4 lbs.)
Envelope Tray 76 mm (3.0 in.) 538 mm (21.2 in.) 521 mm (20.5 in.) 3.2 kg (7 lbs.)
2000-Sheet 363 mm (14.3 in.) 385.5 mm 600 mm (23.6 in.) 50 kg (110 lbs.)
Feeder (15.1 in.)
Environmental Specifications
Characteristic Specification
Temperature:
Operating 5 to 32 C (41 to 95 F)
Transportation -20 to 40 C (-4 to 104 F)
Humidity (%RH)
Operating 15 to 85
Transportation 5 to 85
Altitude
Operating 0 to 2,500 meters (8,200) feet)
Transportation* 0 to 15,000 meters (49,200 feet)
Acoustic Noise
LWA(B) Engine only With options
Idle 4.00 B
Printing 6.80 B 7.00 B
Tray Specifications
Supported Media Tray 1,3,4,5,6 60-216 g/m2 (16 lb. bond to 133 lb. card stock)
Weights Tray 2
60-105 g/m2 (16 to 28 lb. bond)
Duplex
60-163 g/m2
Section
2
Phaser 5500 Options Operational Overview
The Phaser 5500 printer options add memory, paper capacity, and functionality. For
models not originally equipped, a 20 GB Hard Drive is available. A selection of
memory upgrades can raise the installed quantity to the 512 MB maximum. A
optional 1000-Sheet Feeder is available that adds two (Trays 4 and 5), 500-sheet
universal media trays. A high-capacity 2000-Sheet Feeder (Tray 6) brings the
maximum paper storage capacity to 4,100 sheets. An Envelope Tray, replacing Tray
2, holds up to 35 envelopes. On the output side, stapler/punch/stacker is available
increasing output capacity by 3,500 sheets.
This section describes in detail the paper path, sensors, major system assemblies, and
operational characteristics for each Phaser 5500 printer option.
Face Up Roller
Invert Roller Exit Pinch Rollers
Exit 2
Tray 2
Pinch Roller
Tray 5
Take Away Rollers
Feed Rollers
Retard Rollers s5500-233
Direct through Exit 1, the Horizontal Transport to the Stacker Upper or Lower
Trays.
Direct through Exit 2 to the Standard Output Tray on the Horizontal Transport
Cover (facedown).
Through Exit 2 back into the Duplex Unit then out Exit 2 to the Horizontal
Transport Cover (facedown).
Through Exit 2 back into the Duplex Unit then out Exit 1 to the Horizontal
Transport then either the Stacker Upper or Lower Tray.
Shown below is the paper path for the Standard Output Tray, the Horizontal
Transport, and Finisher/Stacker.
Stacker Upper
Tray
Exit 1
Compiler Tray
Stapler
s5500-024
Exit 2
s5500-235
Exit Roller
This roller drives the printed paper from the Fuser, to the Standard Output Tray.
Face-up Solenoid
The Solenoid FU directs paper to the Face-Up Tray (Not used in the Phaser
5500.).
FU Solenoid
Full Stack Sensor
OCT Position Sensor Exit 2 Exit Sensor
OCT Roller
Door E Interlock
Exit PWB
FU Roller
Invert Roller
Offset Motor
Rear
Exit Motor Exit Gate Solenoid s5500-236
Exit 2 Motor
Gear-19Z Gear-19Z
Gear-19Z Gear-19Z
s5500-237
Offset Motor
The Offset Motor is a stepping motor that uses the Offset Gear to move the OCT
Roller frontward or rearward providing paper offset capability. Forward rotation
of this motor moves the OCT Roller to the front side. Reverse rotation of this
motor moves it to the rear side.
Offset Motor
Gear-Offset2
OCT Chute
OCT Roller
s5500-238
Exit PWB
The Exit PWB controls paper feeding and reports sensor/switch information back
to the Engine Logic Board.
Exit 2 Fan
The Exit 2 Fan cools the Exit 2 motors and solenoids during normal operations.
2-6 Phaser 5500 Printer Options Service Manual
Duplex Unit
If 2-sided printing is selected, paper is directed partially out Exit 2. The Exit 2 Motor
reverses direction and loads the paper into the Duplex Unit. The paper pauses briefly,
then continues through the Duplex Unit to the Registration Roller for printing on the
opposite side. Rollers and solenoid-activated gates drive and direct the paper along
the duplex path. The purpose of the Duplex Unit is to accept a printed sheet of paper
from the Fuser exit area, effectively flipping the sheet over, wait a period of time for
the second side to develop, then reinsert the sheet back into the printer registration
area to receive an image on the reverse side. The Duplex Unit provides 2-sided
printing for paper fed from all available paper trays except envelopes.
Wait Sensor
Registration Sensor
Duplex Roller
Drives the paper through the Duplex Unit.
Pinch Rollers
Both Chutes have multiple Pinch Rollers to maintain pressure on the paper.
Wait Sensor
Duplex PWB
Duplex Roller
Duplex PWB
The Duplex PWB responds to commands, controls paper feed, and reports
sensor/switch status to the Engine Logic Board.
Duplex Motor
Gear Idle 33
Gear Roll 28
Tray 4 Tray 5
Registration Roller
Transfer Roller
Drum
Drum Cartridge
Heat Roller
Pressure Roller
Fuser
OCT Roller
Exit Pinch Roller
Pressure Roller
Heat Roller
Fuser Transfer Roller
Drum Cartridge Drum
Pinch Roller
Registration Roller
Tray 2
Tray 4
Pinch Roller 1000 Sheet Feeder
Tray 5
Take Away Roller
Feed Roller
Retard Roller s5500-242
When the optional 1000-Sheet Feeder is installed under the printer, two additional
500-sheet universal trays are available. These two trays are identical to the 500-sheet
trays standard with the printer. The Feeder Assemblies are also identical to those used
in the printer.
End Guide
Bottom Plate
Front Side Guide
s5500-033
Lift Up Shaft
Gear
13T/60T s5500-034
Feed/Lift Motor
Level Sensor
No Paper Sensor
Feeder Assembly
Paper Size Switch
Front
s5500-245
Front
s5500-2
Levers in the bottom of the tray are positioned by the trays end guide. Actuators
on the side of the tray close or open the switches in a pattern that correspond to
one of the pre-defined paper sizes.
No Paper Sensor
This sensor, located on the Feeder, uses an actuator to determine whether the tray
is empty. When the actuator lowers, the sensor state changes to High and signals
the Engine Logic Board.
Level Sensor
This sensor, located on the Feeder, uses an actuator to determine whether paper in
the tray is lifted. When the flag of the actuator leaves the sensing area, the sensor
detects that the paper has been lifted.
Pre-Feed Sensor
This sensor, located on the Feeder, detects a paper jam in the tray by the paper
position and sensor transition time.
Left
s5500-247
Gear (22T/40T)
Stacker
Upper Tray
Compiler Tray
Stapler
s5500-249
Compiler Trays function is to neatly stack the paper by using Cyclone Paddles
and tampers.
Exit section delivers or transfers paper to and from the Compiler Tray and out to
the Finisher trays.
What follows is an overview of the way each of these sections operate and the
components involved. Following this overview, detailed descriptions of the Punch,
Stapler, Compiler Tray and Stacker provides additional information. The Finisher
paper path begins at the Printers Exit 1.
Paper directed to the Finisher is fed out Exit 1 into the Horizontal Transport. The
Horizontal Transport motor, activated by the Printers registration timing going High,
drives the two Transport Belts that move the paper towards the Finisher entrance.
To Finisher
From Exit 1
Belt
Entrance Sensor Exit Sensor
s5500-025
As the paper enters the Finisher it is detected by the Transport Entrance Sensor
activating the Entrance Roller driven by the Finisher Transport Motor. The papers
path inside the Finisher is determined by the Transfer Gate.
The Transfer Gate switches the paper path between the Stacker Lower Tray below or
upwards to the Stacker Upper Tray. Transfer Gate position is under control of the
Printers Engine Logic Board and is switched using the Transfer Gate Solenoid. The
Transfer Gate Solenoid, when energized, positions the Transfer Gate to direct paper
upward. The following illustrates the action and position of the Transfer Gate.
Paper
From H-X'Port
Entrance Rollers
(Driven by Finisher
Transport Motor)
Buffer Roller
(Driven by Regi Motor)
s5500-251
Depending on the position of the Transfer Gate, the paper is further transported into
the Finisher by either the Transfer Rollers or the Buffer Roller. The Gate Sensor
monitors the arrival of paper to the Transfer Gate. The Transfer Rollers or the Buffer
Roller are driven by the Finishers Registration Motor.
This diagram represents the Finisher input as viewed from the front, left-hand corner.
The flow arrows indicate the paper entering from below, encountering the Transfer
Gate and being directed either up or down. The motors, drive belts, Transfer Gate
Solenoid, and Transfer Gate all appear in their actual positions relative to each other.
Registration Motor
Punch
Transfer Gate
Entrance Sensor
Finisher Transport Motor Entrance Roller Buffer Roller
s5500-252
Transfer Gate
Solenoid
Transfer
Rollers
Transfer Gate
Front
s5500-600
Sub Paddle
(Driven by Finisher Transport Motor)
Eject Clamp
(Driven by Eject Clamp Motor)
The Buffer Path is a timing mechanism used to compensate for the time required to
compile and eject a set to the Stacker Lower Tray and still maintain full-speed
processing. The Buffer Path is used when printing multiple sets. As the first set is
being compiled and ejected, the first sheet of the next set is redirected to the Buffer
Path instead of colliding with the first set in the Compiler Tray.
To accomplish this, the printers Engine Logic Board activates the Buffer Gate
Solenoid moving the Buffer Gate to direct the paper to the Buffer Roller. The paper
then travels the circumference of the Buffer Roller and pauses temporarily while the
second sheet of the set enters the Finisher.
The Transport Entrance Sensor signals the Engine Logic Board that the second sheet
has entered the Finisher and the Buffer Gate Solenoid is deactivated allowing the
second sheet to pass over the Buffer Roller. At this point, the first sheet, in the Buffer
path, is aligned with the second and both are driven to the Compiler Tray. Subsequent
sheets of the same set are fed directly to the Compiler Tray. This process repeats for
each set. The ability to store a sheet in line and move two sheets to the Compiler Tray
compensates for the time required to compile and eject the set.
Paper enters the Compiler Tray driven by the Buffer and Lower Exit Rollers. The
Buffer Roller is driven by the Registration Motor, while the Lower Exit Roller is
driven by the Exit Motor. As the first sheet passes over the Compiler Tray, the Eject
Clamp Motor is activated to lower the Eject Clamp to clamp the paper against the
Eject Rollers holding it in the Eject Chute at the Finisher exit. As the end of the sheet
passes through the Compile Exit Sensor, the Eject Motor reverses direction raising the
Eject Clamp and energizing the Sub Paddle Solenoid that engages the Paddles that
feed the paper into the Compiler Tray. Paper is aligned against the back of the
Compiler Tray by the rotation of the Cyclone Paddles driven by the Finisher Transport
Motor.
Sub Paddle
(Driven by Finisher Transport Motor)
Eject Clamp
(Driven by Eject Clamp Motor)
Stapled or aligned sets on the Compile Tray are held between the Eject Clamp and the
Eject Roller Shaft. The Clamp Paddles attached to the Eject Roller Shaft, driven by
the Eject Motor, transfer the compiled sets from the Compiler Tray to the Stacker
Lower Tray.
Gate Sensor
A reflective photo-sensor to detect the front end of paper as it arrives at the
Transfer Gate. The Gate Sensor signal goes Low when paper reaches the sensing
area.
Punch Unit
Two types of Punch Units are available: a 2-/4-hole version and a 3-hole version. Both
types have similar construction and operate essentially the same. For punch
operations, following the Transport Entrance Sensor signal going High, indicating the
presence of paper, a timing delay related to the paper size passes and the Registration
Motor reverses rotation to back the sheet of paper into the Punch Guide for hole
punching. The stopper in the Punch Guide drops while the Registration Motor runs in
the forward direction letting paper pass through, but rises when the Registration
Motor reverses to stop the paper at the punch position. This position is a fixed
distance from the sheets feed edge.
Punch position in relation to the papers width is determined for each sheet by the
following method.
1. Activate the Punch Move Motor and move the Punch to the front until the Punch
Unit Move Home Sensor signal goes Low.
2. Reverse the motor and move the Punch to the rear until the Punch Unit Move
Home Sensor signal goes High to determine the home position.
3. Move the Punch forward again until the Side Regi Sensor 1 or Side Regi Sensor 2
detects the paper edge.
Punch Unit
Home Sensor
Punch Motor Punch Motor
Sensor
Side Registration Sensor 1 s5500-256
4. Activate the Punch Motor to move the Cam Plate. The movement of the Cam
Plate lowers the pins along the guide holes to punch the paper. The Cam Plate can
lower the pins in either direction of travel.
The following shows the action of the Cam Plate, Pins, and Punch Motor for a 3-hole
punch operation.
Pin Position
Punch Hole Select Sensor
Punch Front Sensor Pin Cam Plate
Punch Unit Home Sensor
Home Position
Punch Motor
3 Hole Position
s5500-257
Note
When the sensor detects that the box is removed for four seconds, the Punch
Box Full count is reset to zero.
Punch Motor
A DC motor to move the Cam Plate that lowers the punching pins. Forward
rotation of the motor moves the Cam Plate to the front, and reverse rotation
moves it to the rear.
Compiler Tray
The Compiler Tray assembles sets and aligns the paper edges for stapling.When paper
is fed onto the Compiler Tray, a tamping operation is performed to align the paper
edge along the papers width. The Compiler Tray also offsets stapled sets when
ejecting to the Stacker Lower Tray.
Rear Tamper
Front Tamper
Rear Tamper
Home Sensor
Paper capacity depends on whether the paper is being stapled or not, as well as paper
size. If the number of sheets of one stapled set exceeds the Compiler Tray limit set in
NVRAM, the sheets exceeding this setting are ejected to the Stacker Lower Tray. This
avoids damage to the Staple assembly. The default capacity value is 50 sheets.
When two or more paper sizes are used and their widths are identical, (example: A4L
and A3S), all the sheets are compiled and stapled as a set on the Compiler Tray, and
then ejected to the Stacker Lower Tray. If different widths of paper are used, stapling
is stopped and the paper is ejected to the Stacker Lower Tray.
Front Tamping
Tampering by the Rear Tamper with the Front Tamper fixed at the home position
in either non-staple mode or when executing front corner stapling.
Front Rear
s5500-261
Tamper (center) home position is determined by the Compile Exit Sensor signal going
High and both tamper motors activated and moving. The Front Tamper home position
is determined when the Front Tamper enters the Front Tamper Home Sensor sensing
area. The Rear Tamper home position is determined when the Rear Tamper enters the
Rear Tamper Home Sensor sensing area. Center tamping occurs after a preset time
following the Compile Tray No Paper Sensor signal going High indicating paper on
the Compiler Tray.
Offset
Offset shifts the paper position as each set is ejected to the Stacker Lower Tray to
avoid ejection jams due to the stacking of multiple stapled sets. Offset occurs for
these staple positions.
For straight-stapled paper with a width of less than 8.5 inches (216 mm), the
Front Tamper offsets the set by .35 inch (9 mm) to the rear side before ejecting
them to the tray.
Dual Stapling
Dual-stapled sheets are offset by .35 inch (9 mm) using the Front Tamper to the
rear side before ejecting them to the tray.
s5500-262
Staple Head
Stapling operation is executed by closing the Staple Head. The Staple Head,
containing the Staple Motor, the Staple Head Home Sensor, the Staple Head Self
Priming Sensor, and the Low Staple Sensor, is activated by the Staple Motor. Forward
(clockwise) rotation of the Staple Motor drives the Staple Head to staple a set of
sheets (closed), and returns the Staple Head to the home (open) position. If stapling
fails, the Staple Motor rotates reversely (counterclockwise) to return the Stapler Head
to the home position.
Staple Head
Low Staple Sensor
Staple Position
Sheets of paper are tamped on the Compile Tray, and then stapled at specified
positions. These are the four stapling positions.
Dual staple
The Stapler staples a set of paper at fixed positions (front/rear sides) in parallel
with the paper edge, after the Front Tamper aligns the paper to the specified
position for each paper size.
Front Front
Rear Rear
Front Front
s5500-264
The number of sheets to be stapled is limited to prevent damage to the Stapler. If the
number of sheets per set exceeds the Compile Tray limit set in NVRAM, the sheets
exceeding the limit are ejected to the tray without being stapled. A single sheet set is
also ejected without being stapled. The upper limit of Compile Tray paper capacity
when stapling is set by default to 50 sheets.
When sheets with different sizes and same width (example: A4L and A3S) are present
on the Compile Tray, all the sheets are stapled, and then ejected to the Stacker Lower
Tray. If sheets with different widths are present on the Compile Tray, stapling is
stopped when a different width is detected. These different-width sheets are ejected to
the Stacker Lower Tray.
Stapler Sensors/Motors
Staple Move Position Sensor
A photo-interrupter to detect the Stapler home position, Rear Staple (Corner)
position, and Rear Staple (Straight) position. The Stapler Move Home Position
Sensor signal goes High when the Stapler reaches the home position.
Staple Motor
A DC motor in the Staple Head to activate the Staple Head for stapling.
Clockwise rotation of this motor staples, while counterclockwise rotation opens
the Staple Head.
Stacker
s5500-265
A sheet of paper of less than 11 inches in length is stacked in the Stacker Lower
Tray with the staple mode changed. As the stacking position shifts due to staple
position, sheets are stacked on the rear side of the tray irrespective of offset in the
rear staple mode.
One or more sheets are added when no paper remains in the tray. The size and
condition of paper stacked is unknown to the Engine Logic Board.
Paper was present in the Stacker Lower Tray when power was turned On. The
size and condition of paper is unknown to the Engine Logic Board.
The Finisher entered Sleep Mode with mix stacking and has exited Sleep
Mode.The size and condition of paper is unknown to the Engine Logic Board
Eject Motor
Set Clamp
Home Sensor
Elevator Motor
A DC motor to raise or lower the Stacker Lower Tray. Clockwise rotation
elevates the tray, counterclockwise rotation lowers the tray.
Eject Motor
A DC motor to eject stapled or non-stapled paper to the Stacker Lower Tray.
Clockwise rotation ejects paper to the tray, counterclockwise rotation reverses the
Eject Roller to feed paper to the Compiler Tray.
Exit Motor
Gate Solenoid
Eject Motor
Buffer Gate
Solenoid
Finisher
Transport Motor
Horizontal
Elevator Motor Transport PWB
Finisher Interlock
The Finisher is equipped with the following interlock switches.
Door G Interlock
Door F Interlock
s5500-267
Nudger Roller
Feed Roller
Retard Roller
The Nudger, Feed, and Retard Rollers are driven by the Feed/Lift Motor. The paper
fed by the Feed and Retard Rollers passes through the Pre-Feed Sensor. The Pre-Feed
Sensor detects the presence of paper fed from the tray and detects paper jams. The
Pre-Feed Sensor controls the Feed/Lift Motor speed, and the Nudger Solenoid. The
Take Away Roller, located inside Door J, is driven by the Take Away Motor. Paper fed
by the Take Away Roller passes through the Tray 6 Feed Out Sensor #6 and into the
printer. The Feed Out Sensor #6 signal indicates when the Feed/Lift Motor should
stop and the Take Away Motors speed. The Feed Out Sensor #6 signal is also used to
detect jams.
The following diagram illustrates these components.
Feed/Lift Motor
Take Away
Feed Roller
Motor
Nudger Roller
Paper
Retard Roller Nudger Solenoid
Take Away
Motor
Paper
The feed start signal also starts the delayed activation the Take Away Motor at a high
speed after a preset time has passed. The Take Away Motor drives the Take Away
Roller, and the paper is transferred to the printer paper path.
When the Feed Out Sensor #6 signal goes High, the Take Away Motor slows to low
speed after a preset time has passed. When the printers Registration Sensor signal
goes High, the Take Away Motor stops. If the next feed start signal is received before
the Take Away Motor is turned off, the Take Away Motor continues to rotate at low
speed.When the paper is transferred to the printer and the Feed Out Sensor #6 signal
goes High, the Nudger Solenoid is re-activated for a preset time. The following
illustrates the timing relationships between the paper path components.
Feed Motor
Pre-Feed Sensor
Feed Out Sensor
Tray 6 Sensors
Door J Interlock
When Open printing operation is stopped, and the 24 V supply to the Feed/Lift
and Take Away Motors is shut off.
Door J Interlock
Docking Interlock
s5500-271
No Paper Sensor
An actuator is raised by the lifting of paper in the tray. If paper runs out while the
tray is at the feeding position, the actuator falls inside the sensing area indicating
No Paper. If the Bottom Plate is down, the actuator remains in the sensing area
indicating No Paper regardless of the presence of paper in the tray.
Actuator
No Paper Sensor
s5500-272
Polling of the No Paper Sensor occurs every 10 ms after the paper lifting
operation has finished. Paper transfer from the tray is inhibited if the No Paper
Sensor has detected an empty tray.
Level Sensor
This sensor, located on the Feeder, uses an actuator to determine whether paper in
the tray is lifted to feeding position.
Pre-Feed Sensor
The Pre-Feed Sensor detects whether paper has been fed from the Tray and
controls the Feed/Lift Motor speed. The sensor also serves as a trigger to
deactivate the Nudger Solenoid.
Paper Lift
The Paper lift operation starts automatically when the tray is closed. Tray lifting is
accomplished by the Feed/Lift Motor acting on a gear assembly that drives a cable/
pulley combination at each end of the tray. The Bottom Plate lifts the paper and stops
at the feeding position. At the same time, detection of no paper and remaining paper
volume is made. The Feed/Lift Motor is attached to the frame behind the Rear Cover.
The remainder of the lifting mechanism is attached to the tray.
Feed/Lift Motor
Gear Assembly
Cables
Cables
Bottom Plate
s5500-273
These steps describe the lift operation when power is turned On or when the tray is
inserted.
1. Activate the Nudger Solenoid.
2. Check the Level Sensor status 500 ms after the Nudger Solenoid is activated.
If the Level Sensor signal is Low, reverse the Feed/Lift Motor to lift the tray.
When the Level Sensor signal is High, stop the Feed/Lift Motor after 90 ms to
stop tray lift. If the Level Sensor signal is High at power On, the tray is already at
the feed position.
These steps describe the lift operation while paper is being transferred to the printer.
1. The Level Sensor is Off while the Nudger Solenoid is deactivated during paper
feeding.
Rear Size
Guide
s5500-274
Detectable paper size and sensor logic level patterns are as follows:
B5/Executive
0 0
7.25 x 10.5
8.5 x 11 0 1
A4 1 0
Paper Volume
This function determines the quantity of paper remaining by using the Feed/Lift
Motor rotation time and the Level Sensor timing during the tray lift.
Feed/Lift Motor
Front
s5500-275
FULL 0 - 3337
If the remaining paper volume becomes zero before No-Paper is detected, the
indication remains at 25%. When the No Paper Sensor detects No-Paper, the
indication becomes zero.
When a fault occurs, remaining paper volume is calculated as follows:
1. When the Interlock opens during a lifting operation:
Remaining paper volume is based on the total time until Interlock open and the
time from the Feed Motor forward/reverse rotation until the Level Sensor goes
High.
2. When the power is cycled during a lifting operation:
Remaining paper volume is determined by the lifting time after power On.
3. When the power is cycled while the tray is at the feeding position:
If the Level Sensor signal is High when the power is turned On, the remaining
paper volume before the previous power Off is regarded as the remaining paper.
If the Level Sensor signal is Low when the power is turned On, it is assumed that
the tray has been removed, and the remaining paper volume is based on the time
from the Feed Motor forward/reverse rotation until the Level Sensor signal goes
High.
Feed/Lift Motor
The Feed Motor is a stepping motor that drives the Nudger and Feed Rollers to
feed paper from the tray to the Take Away Roller. When run in reverse, The Feed
Motor lifts the tray.
Nudger Solenoid
The Nudger Solenoid raises or lowers the Nudger Roller. The solenoid remains
activated from the beginning of paper feed until the Pre-Feed Sensor signal goes
High. The solenoid is also activated when the tray is inserted and the power is
turned On to check for the presence of paper in the tray.
Tray 6 PWB
PF06
PF08
PF01
PF05
PF04 PF02
PF03
Rear
s5500-331
Tray In Sensor
When the tray is opened, the Tray In sensor inhibits feeding from Tray 6.
Section
3
Overview
This section contains the removal and replacement procedures for selected parts of the
printer according to the Field Replaceable Units (FRUs) Parts List. Replacement
procedures are not provided for most of the FRUs because in most cases, re-installing
a part only requires reversing the removal procedure. Where the replacement process
is not a simple reversal of the removal, a replacement procedure is included.
Replacement Notes provide tips and suggestions that can aid in reassembling the part.
Standard Orientation
Locations given in the repairs, such as left, right, front, or rear, assume you are facing
the printer front panel.
When needed the orientation of the option is called out in the procedure for locating
printer parts. Refer to the option orientation graphic for locating the right, left, front,
and back sides of the printer.
Rear
Right
Left
Front
s5500-075
Preparation
Before you begin any Removal Procedure:
1. Switch Off the printer power and disconnect the power cord from the wall outlet.
2. Remove the Drum and Toner 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.
Disconnect all computer interface cables from the printer.
3. Wear an electrostatic discharge wrist strap to help prevent damage to the sensitive
electronics of the printer circuit boards.
4. Remove the Fuser. 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.
Caution
Many parts are secured by plastic tabs. DO NOT over Flex or force these parts.
Do not over torque the screws threaded into plastic parts.
Note
Part names that appear in the disassembly procedures do not match the names
that appear in the Parts List. For example, a part called the Registration Chute
Assembly may appear on the Parts List as ASSY, CHUTE REGI.
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.
Warning
Unplug the AC power cord from the wall outlet before removing any printer part.
Covers
Casters
Trays
Feeders
Sensors
Rollers
Most repair procedures are possible with the 1000-Sheet Feeder docked to the print
engine. However, if separation is necessary, remove the interface cable, Tray 3 and the
two large screws securing the 1000-Sheet Feeder to the Print Engine.
Warning
Two people are required to remove the Print Engine from atop the 1000-Sheet
Feeder. Remove the trays and use the lift points provided on the left and right-
hand sides of the Print Engine to lift it from the 1000-Sheet Feeder.
As most parts are common among all four universal trays and feeders, many of the
procedures presented here describe the process for Tray 4 but apply equally to Tray 5.
Top Cover
Front
s5500-276
2. Remove the one screw securing the Top Cover to the frame.
3. Slide to the left and remove the Top Cover.
Rear
Right Cover
s5500-277
1. Remove the three screws securing the Right Cover to the frame.
2. Move the Right Cover in the direction of the arrow to remove.
Replacement Note
Put the three hooks on the lower part of the Right Cover into the holes on the
frame.
Foot Cover
1. Remove the Tray 5.
2. Remove the Right Cover (page 3-6).
Front
Foot Cover
s5500-278
3. Remove the two screws securing the Foot Cover to the frame.
4. Remove the Foot Cover by sliding the cover downward.
Left Cover
PL20.1.4
Left
Replacement Note
Put the three hooks on the lower part of the Left Cover into the holes on the
frame.
Rear Cover
PL20.1.5
Rear
Rear Cover
s5500-280
1. Remove the four screws securing the Rear Cover to the frame.
2. Remove the Rear Cover.
Front
Caster (Stopper)
s5500-281
Front
s5500-246
2. Disconnect the defective Paper Size Switch from the wire harness.
3. Remove the screw securing the switch to the frame.
4. Remove the switch.
Replacement Note
When installing the Paper Size Switch, fit the boss on the frame into the hole
on the switch.
Support
Left
s5500-282
Bracket
Tray 4 Feeder
Left
s5500-283
6. Remove the screw securing the bracket to the frame and remove the bracket.
7. Release the harness from the clamp.
8. Disconnect the connector from the feeder.
9. Remove the two screws securing the feeder to the frame.
10. Move the feeder in the direction of the arrow to remove.
Replacement Note
When installing the feeder, fit the two bosses on the frame into the two holes
on the feeder.
PL2.3.2
Feeder Assembly
Feed/Lift Up
Motor
Connector
s5500-104
PL2.3.14
Feeder
No Paper Sensor
Harness
Hooks
Upper Frame
s5500-109
2. Release the hooks securing the Sensor to the Upper Frame as shown in the figure.
3. Disconnect the connector from the No Paper Sensor.
4. Remove the No Paper Sensor.
PL2.3.13
Feeder
Upper Frame
Bosses Actuator
s5500-108
2. Release the two bosses on the Actuator securing the Actuator to the Upper
Frame.
3. Remove the Actuator.
Note
As an alternate procedure, remove Trays 4 and 5, then reach in and release the
actuator bosses from the feeder assembly.
PL2.3.14
Feeder
Harness
Level Sensor
Hook
Upper Frame
Hooks
s5500-110
2. Release the hooks securing the Level Sensor to the Upper Frame as shown in the
figure.
3. Disconnect the connector from the Level Sensor and remove the sensor.
PL2.3.15
Feeder
2. Remove the Pre-Feed Sensor from the Front Chute as shown in the figure.
3. Disconnect the connector from the Pre-Feed Sensor.
PL2.3.20
Shaft
Oneway Clutch
Feed Roll
Front Chute
s5500-114
PL2.3.28
Front Chute
Support Assembly
Retard Roller
s5500-117
2. Release the hook securing the Retard Roller to the shaft as shown in the figure.
3. Remove the Retard Roller.
PL2.3.32
Support Assembly
Nudger Roller
Front Chute
s5500-120
Chute
Bottom View
Hooks
Left
s5500-284
Replacement Note
Put the Actuator attached to the Feed Out Sensor #4 into the hole on the
Chute.
Bottom View
Support Hooks
Chute
Left
s5500-285
2. Remove the screw securing the Support on the front to the frame.
3. Remove the two screws securing the Chute to the frame.
4. Disconnect the Feed Out Sensor #5 from the harness.
5. Release the hooks securing the Feed Out Sensor #5 to the Chute as shown in the
figure.
Replacement Note
Be sure to put the Feed Out Sensor #5 actuator into the hole on the Chute.
E-Ring Gear
Bearing Upper Take Away Roller
E-Ring
EL-Clip
Chute
Left
s5500-286
Chute
Gear
E-Ring
EL Clip
Bearing
Replacement Note
Install the gear by aligning it with the D-shaped shaft end. Also, be careful
not to install the bearing in a wrong direction.
Upper Pinch
Roller Chute Left
s5500-288
2. Remove the four screws securing the Chute to the door and remove the Chute.
3. Remove the two screws securing the Upper Pinch Roller Assembly to the door.
4. Remove the Upper Pinch Roller Assembly.
Lower Pinch
Roller
Left
s5500-289
2. Remove the two screws securing the Lower Pinch Roller Assembly to the door.
3. Remove the Lower Pinch Roller Assembly.
Spring
Pinch Roller
Left
Bracket
s5500-290
Replacement Note
Install the bearings to the center shaft of the Pinch Roller in the direction
shown in the figure, secure them with the three springs.
Bracket
Rear
s5500-292
Bracket
Rear
s5500-293
Bearing
Washer
Bearing
Bracket
Shaft
Gear (38T)
Clutch
E-Ring
Rear
s5500-294
Replacement Note
Fit the Gear 38T to the D-shaped end of the Shaft. Install the Bracket with its
boss fit into the notch on the Clutch. Also, verify that the Clutch harness
does not contact the gears.
Take Away
Motor
Rear
s5500-295
Pins
Latch
s5500-612
Replacement Note
Align the pins on the docking bracket with the holes in the feeder frame and
push the two together. The latch is self-locking.
3-32 Phaser 5500 Printer Options Service Manual
Tray 6 Rear Cover
1. Slide the Tray Module away from the printer.
PL22.1.14
2. Remove the four screws securing the Rear Cover to the frame.
3. Remove the interface cable from the cover.
4. Remove the Rear Cover.
Tray
s5500-297
4. Remove the two screws on each end securing the Top Cover to the frame.
5. Remove the Top Cover.
Right Cover
s5500-298
2. Remove the four screws securing the Right Cover to the frame.
3. Remove the Right Cover.
Left Cover
s5500-299
5. Remove the four screws securing the Left Cover to the frame.
6. Remove the Left Cover.
Indicator
Bottom Plate
Front Cover
Tray
s5500-300
2. Remove the screws, two on the upper portion, one on the right side, and two on
the left side, securing the Front Cover to the tray.
3. Remove the Front Cover.
Replacement Note
Make sure that the Front Cover indicator moves up-and-down smoothly
when the Bottom Plate is raised by rotating the Lift Shaft by hand.
Door J
1. Slide the Tray Module out from the printer.
2. Remove the Rear Cover (page 3-37).
3. Remove the Top Cover (page 3-33).
4. Open Door J.
Torsion Spring R
Door J
Torsion
Door J
Spring R
Top Pivot
Shaft
Torsion
Spring L
D-Cut Longitudinal
Hole
D-Shaped Hole
Door J
Torsion Spring L
Rear Hinge
Bracket
s5500-301
5. Remove the two screws securing the Rear Hinge Bracket to the frame.
6. Remove the Rear Hinge Bracket leaving the Top Pivot Shaft and the Torsion
Spring R attached to Door J.
Replacement Note
Install the captured side of the Top Pivot Shaft so that its D-cut is positioned
at the front side of Door J first. Make sure the cover properly rests against the
stop before replacing the Rear hinge Bracket.
Tray Removal
1. Slide the Tray Module out from the printer.
2. Unload the contents of the tray.
3. Insert the tip of a screwdriver, perpendicular to the drawer track, into the round
hole located at the end of each track to release the drawer rails from the tracks.
4. Pull the drawer out evenly from the frame.
s5500-611
Caster
s5500-303
2. Place the Tray Module on its left side being careful not to damage the cover.
3. Remove the three screws securing the Caster to the frame.
4. Remove the Caster.
Front
Tray In Sensor
s5500-304
Replacement Note
Push the tray into the Tray Module to check that the sensor properly aligns
with the tray shutter.
JF51
Front
s5500-305
5. Disconnect the connector (JF51 for B) or (JF52 for A) from the defective sensor.
6. Release the hooks securing the sensor to the bracket and remove the Paper Size
Sensor.
Replacement Note
Push the tray into the Tray Module to check that the Rear Size Guide
properly aligns with the Paper Size Sensors.
E-Ring
Tray
End Guide s5500-306
Note
To lift the End Guide from the shafts, position the guide close to its closed
position.
3. Lift the End Guide upward to release the shafts on the top and bottom of the tray
from the holes on the End Guide.
Gear Assembly
Tray
s5500-308
Replacement Note
When installing the Gear Assembly, engage the gears with the tray.
E-Ring Pulley
(1)
Guide Wire Ss
Pulley Ss
Cables
Guide Wire L
Pulley L
Cable
4. Remove the E-ring securing the Powered Bearing to the Lift Shaft at the rear,
right side of the tray.
5. Move the Powered Bearing in the direction of arrow (1) to remove it from the
frame.
6. Move the Lift Shaft in the direction of arrow (2) to remove it from the frame.
7. Move the Pulley in the direction of arrow (3).
Pulley Pulley
(6)
(5)
(4)
Lift Shaft
Cables
Powered Bearing
Pulley Ss
Guide Wire Ss
Wire Guide L
Pulley L
Bottom Plate Cables
s5500-310
9. Remove the two E-rings securing the two Pulley Ss to remove the two Wire
Guides and two Pulleys.
10. Remove the E-ring securing the Pulley L and remove the Wire Guide L and
Pulley L.
11. Remove the two Cables from the Bottom Plate.
12. Remove the E-ring securing the Powered Bearing to the Lift Shaft at the front,
right side of the tray.
13. Move the Powered Bearing in the direction of arrow (4) to remove it from the
frame.
14. Move the Lift Shaft in the direction of arrow (5) to remove it from the frame.
15. Move the Pulley in the direction of the arrow (6).
16. Detach the two Cables from the Lift Shaft.
Replacement Note
When replacing the Cables, use the Tray Cable Kit (604K19980) to replace
all cables. Begin with the Cable on the front of the Tray.
1. Orient the Bottom Plate so the arrow points in the direction shown in the figure.
2. Fit the tips of the two Cables into the holes on the front of the Bottom Plate.
3. Hang the Cable onto the Pulley S, and install the Pulley S and the Guide Wire S
to the upper shaft. Fix them with two E-rings.
4. Hang the Cable onto the Pulley L and install the Pulley L and the Guide Wire L
to the lower shaft. Fix them with E-ring.
5. Fit the tips of the two Cables into the two holes on the Lift Shaft.
6. Press the Pulley in the opposite direction of the arrow (6) so that the tips of the
Cables are not detached from the Lift Shaft.
7. Fix the Pulley to the Lift Shaft using the E-ring.
8. Move the Lift Shaft in the opposite direction of the arrow (5) to fit it to the notch
on the frame.
9. Move the Powered Bearing in the opposite direction of the arrow (4) to install it
to the frame.
10. Fix the Powered Bearing to the Lift Shaft using the E-ring.
11. Fit the tips of the two Cables into the holes at the rear of the Bottom Plate.
12. Hang the Cable onto the Pulley S, and install the Pulley S and the Wire Guide S
to the upper shaft. Fix them with the two E-rings.
13. Hang the Cable onto the Pulley L, and install the Pulley L and the Wire Guide L
to the lower shaft. Fix them with the E-ring.
14. Fit the tips of the two Cables into the two holes on the Lift Shaft.
15. Press the Pulley in the opposite direction of the arrow (3) so that the tips of the
Cables are not detached from the Lift Shaft.
16. Move the Lift Shaft in the opposite direction of the arrow (2) to fit it to the notch
on the frame.
17. Move the Powered Bearing in the opposite direction of the arrow (1) to install it
to the frame.
Feeder
JF56
Front
Guide Pin
s5500-312
6. Remove the front two screws securing the Feeder to the frame.
7. Push the Feeder from the rear to the front until it slides out of the machine.
Replacement Note
Align the feeder guides with the feeder track and rear guide pins.
Feeder
(PF58)
s5500-313
Feeder
s5500-314
9. Remove the three screws securing the Drive Frame to the Feeder.
Pin
Nudger Solenoid
Feeder
s5500-315
Replacement Note
When installing the solenoid, engage the solenoid with the Link on the Rear
Frame.
Upper Chute
PF61
Upper Feeder
Assembly
s5500-316
4. Remove the three screws securing the Upper Chute to the Upper Feeder.
5. Remove the Upper Chute.
6. Remove the Feeder harness connector (PF61) from the Pre-Feed Sensor.
7. Remove the one screw securing the Pre-Feed Sensor to the Upper Feeder.
8. Remove the Pre-Feed Sensor.
E-Ring
No Paper Sensor
Upper Feeder
Assembly
s5500-317
Replacement Note
The Actuator must fall smoothly into the recess on the No Paper Sensor.
No Paper Sensor
PF60
Actuator
Upper Feeder
Assembly
Front
s5500-318
4. Disconnect the No Paper Sensor from the Upper Feeder harness connector
(P/JF60).
5. Release the hooks securing the No Paper Sensor to the Upper Feeder to remove
the sensor.
Replacement Note
After installing the No Paper Sensor, make sure that the actuator falls
smoothly into the recess of the sensor.
s5500-590
4. Release the hooks securing the Level Sensor to the Upper Feeder to remove the
Level Sensor.
5. Disconnect the Level Sensor connector (P/JF62) from the harness of the Upper
Feeder.
Replacement Note
After installing the Level Sensor, make sure that the actuator on the Nudger
Roller falls smoothly into the recess of the Level Sensor.
Nudger Roller
4. Remove the Nudger Roller by compressing the ends of the shaft with your
fingers.
Bearing
E-Ring Bearings
Feeder Shaft
Upper Feeder
Assembly
Front s5500-321
5. Remove the E-ring securing the Feeder Shaft to the Upper Feeder.
Replacement Note
Note the orientation of the torsion spring on the Feeder Shaft. The anchor
point of the spring is the hole in the plate.
Feed Roller
Front
s5500-322
4. Remove the Feed Roller by compressing the shaft ends with your fingers.
Retard Roller
Front
s5500-323
3. Remove the Retard Roller from the Lower Feeder by compressing the shaft ends
with your fingers.
Lower Frame
Bearing-6
Retard Shaft
s5500-325
9. Remove the four self-tapping screws securing the Lower Chute to the Lower
Frame.
10. Remove the Lower Chute.
11. Remove the two E-clips securing the two bearings.
12. Remove the Bearings from the two brackets on the Lower Frame.
Note
The Retard Spring is compressed and is not a captured spring. Use care not to
lose or damage the Retard Spring while removing the Retard Shaft.
Switch
Bracket Switch
s5500-326
Lower Chute
Bracket s5500-327
4. Remove the two screws securing the Feed Out Sensor Bracket to the frame.
5. Disconnect the connector from the Feed Out Sensor #6.
6. Release the hooks securing the sensor to the bracket and remove the sensor.
Replacement Note
When installing the Feed Out Sensor Bracket, put the actuator into the slot of
the Lower Chute.
Harness Clamp
PF57 s5500-328
Replacement Note
When installing the Take Away Motor, remove the motor from the bracket (2
screws) and install the bracket on the frame. Next, install the motor on the
bracket.
s5500-329
Replacement Note
When installing the Take Away Motor, remove the motor from the bracket
(2 screws) and install the bracket on the frame. Next, install the motor on the
bracket.
Hook
N.O.
FS004
Front COM
Docking
Interlock Switch
s5500-330
Replacement Note
Connect the FS004 connectors to the COM and N.O. terminals on the
switch.
Tray 6 PWB
PF06
PF08
PF01
PF05
PF04 PF02
PF03
Rear
s5500-331
Clamp
Clamp
1. Move the Cover Cap in the direction of the arrow to remove it from the Lower
Rear Cover.
2. Disconnect the Duplex Unit connector (left).
3. Release the clamp from the frame by pinching the sides of the clamp and pulling
the clamp straight out.
Lock
Door D
Front
s5500-333
4. Open Door D.
5. Turn the two locks on the Outer Chute 90 degrees as shown in the figure to
release the Duplex Unit from the printer.
Replacement Note
Rotate the locks until they click while holding the Duplex Unit.
Lower Chute
2. Remove the two screws securing the Lower Chute to the Outer Chute.
Hook
Inner Chute
Outer Chute
Stopper
Cable Cutout
Replacement Note
Use care when installing the cover to the chutes. Make sure the cable is in
the cable cutout in the cover and the wiring remains within the unit.
FRU Disassembly 3-71
Door D Latch Lever
1. Remove the Duplex Unit (page 3-68).
2. Remove the Duplex Unit Chutes and Cover (page 3-70).
Rear
Outer Chute
PL23.1.7
Notch
Index Tab
s5500-633
9. Slide the Front and Rear Latch Levers off the latch shaft.
Door D
Interlock Switch
Hooks
Motor Bracket
Rear
Actuator Spring
Left
Outer Chute
s5500-341
3. Remove the spring from the actuator and the Outer Chute as shown in the figure.
4. Turn the actuator 180 degrees and move it in the direction of the arrow to remove.
Outer Chute
Left
Duplex Motor
s5500-342
Duplex PWB
Outer Chute
Right
s5500-343
Outer Chute
Left
Outer Chute
s5500-344
Exit 2
s5500-347
2. While lifting the levers on both lower sides of the Exit 2 Unit, move it in the
direction of the arrow to remove it.
Replacement Note
Align the Exit 2 Unit with the guides. Also, be sure that the connector
located on the rear side of Exit 2 securely engages the printer.
Stopper
Push
Lower Chute
E-Ring
Front
Boss
s5500-348
Upper Chute-FU
s5500-349
9. Remove the two screws securing the L/H Chute High to the Upper Chute-FU to
remove the L/H Chute High and the Door E latch.
Gear 19Z
Bearing E-Ring
Rear
Gear Cover s5500-350
10. Remove the two screws securing the Gear Cover to the L/H Chute High to
remove the Gear Cover.
11. Remove the E-ring securing the Gear-19Z to the shaft to remove the Gear-19Z.
12. Release the hook of the bearing securing the Face-Up Roller to the L/H Chute
High as shown in the figure. The bearing hook is easily damaged, use care when
removing it.
13. Move the Face-Up Roller in the direction of the arrow to remove.
Replacement Note
Install the Face-Up Roller shaft by rotating the Gear Cover as shown in the
figure.
Stopper
Push
Lower Chute
E-Ring
Front
Boss
s5500-348
Upper Chute-FU
s5500-349
9. Remove the two screws securing the L/H Chute High to the Upper Chute-FU to
remove the L/H Chute High.
Rear
Gear-52Z
Gear Cover
Gear-19Z
Rear
s5500-351
10. Remove the two screws securing the Gear Cover to the L/H Chute High to
remove Gear-52Z and Gear-19Z.
11. Remove the E-ring securing the Invert Roller to the L/H Chute High.
12. Release the hook of the Bearing securing the Invert Roller to the L/H Chute High.
13. Move the Invert Roller in the direction of the arrow to remove.
Stopper
Push
Lower Chute
E-Ring
Front
Boss
s5500-348
Lower Chute
Rear Cover
Tray Guide
Rear
Hook
Square Hole Hook
s5500-352
10. Release the hook securing the Rear Cover to the Lower Chute, as shown in the
figure.
11. Move the Rear Cover in the direction of the arrow to remove.
12. Remove the four screws securing the Tray Guide to the Lower Chute.
13. Release the left and right (front/rear) hooks of the Tray Guide that secure it to the
Lower Chute.
Lower Chute
Rear Cover
Tray Guide
Hooks Hook
Square Hole
Spring
Hook
Hook
Slit
Paper Weight-A
s5500-353
Offset Gear
Offset Gear
Lower Chute
s5500-354
6. Move the Offset Gear in the direction of the arrow to remove it from the shaft of
the Lower Chute.
7. Remove the hook on the shaft end of the Offset Gear from the hole on the OCT
Chute to remove the Offset Gear.
E-Ring
E-Ring
OCT Roller
Rear
s5500-355
5. Release the Gear-19Z hook securing the OCT Roller to the Lower Chute as
shown in the figure. Remove the Gear.
6. Remove the two E-rings securing the OCT Roller to the OCT Chute.
7. Release the bearing hook on the left side securing the OCT Roller to the Lower
Chute. Remove the bearing.
8. Move the OCT Roller in the direction of the arrow (to the front) to remove.
Spring
Exit Pinch Roller
Release
E-Ring
OCT Chute
Roller Bearing Hook
Hook
E-Ring
5. Release the hook securing the Exit Pinch Roller to the OCT Chute.
6. Move the Exit Pinch Roller in the direction of the arrow to remove it.
Lower Chute
Front
s5500-357
Replacement Note
Install the actuator spring in the direction shown and check that the actuator
goes into the gap (sensing area) of the Exit Sensor correctly.
Exit 2 Fan
1. Open Door A.
2. Remove Exit 2 (page 3-79).
3. Open Exit 2.
4. Remove the Tray Guide (page 3-86).
Front
s5500-630
5. Release the harness secured to the guide on the backside of the Lower Chute.
6. Disconnect the Fan from the harness.
PL24.2.39
Lower Chute
Exit Fan
Marker
Hole
Cover
Rear
s5500-631
8. Feed the connector through to the Lower Chute and remove the Fan.
Replacement Note
Install the Exit 2 Fan with the Label facing downward and the marker facing
to the rear.
PL24.2.18
Door E Interlock
Switch
Front
s5500-358
5. Release the harness secured to the guide on the backside of the Lower Chute.
s5500-359
Replacement Note
Return the harness to the guides.
Face-Up Solenoid
1. Open Door A.
2. Remove Exit 2 (page 3-79).
3. Open Exit 2.
4. Remove the Tray Guide (page 3-86).
Positioning Boss
Link Rear
Front
Solenoid Harness s5500-360
Replacement Note
Fit the iron core of the Face-Up Solenoid to the Rear Latch Spring as shown.
Also, fit the boss on the Lower Chute into the hole on the solenoid.
Exit Gate
Solenoid
Front
Link Clamp
5. Release the harness of the solenoid from the guide on the Lower Chute.
6. Release harness from the clamp.
7. Disconnect the solenoid from the junction connector.
8. Remove the screw securing the solenoid to the Lower Chute.
9. Remove the iron core of the solenoid from the Link.
FRU Disassembly 3-99
10. Remove the solenoid.
Replacement Note
Fit the Exit Gate Solenoid to the Link as shown in the figure. Also, fit the
boss on the Lower Chute into the hole on the solenoid.
Offset Motor
1. Open Door A.
2. Remove Exit 2 (page 3-79).
3. Open Exit 2.
4. Remove the Tray Guide (page 3-86).
5. Remove the Face-Up Solenoid (page 3-96).
Offset Motor
Rear
Lower Chute
Rear
Offset Motor Harness
s5500-362
Exit Sensor
Hook
Front
Actuator
Lower Chute s5500-363
Lower Chute
Hooks
Offset Gear
LOW CHUTE
Rear
s5500-364
Rear
Connector
Rear Plate
Connector s5500-365
Hook
Lower Chute
Front
s5500-366
Horizontal Transport
1. Press at point A to remove the Connector Cover from the Finisher.
PL25.1.2
A
Converter Cover
Right
Rear s5500-368
Horizontal Transport
Screw
Screw
s5500-369
2. Disconnect the cable between the Horizontal Transport and the Finisher.
3. Disengage the Finisher from the printer (page 3-119).
3-106 Phaser 5500 Printer Options Service Manual
4. Remove the two screws securing the Horizontal Transport to the printer.
5. Remove the Horizontal Transport from the printer.
Hinge
4. Remove the six screws securing the left and right hinges to the Drive Bracket on
the Lower Chute.
5. Remove Door F in the direction of the arrow.
Motor
Drive Belt
Note
Mark the pulley to indicate the outward facing side.
Replacement Note
Install the Pulley on the shaft in the direction shown. Hold the other end of
the shaft while pressing the pulley back on.
Rear
Right Shaft
Drive Bracket Bearing
E-Ring
Lower Chute
Belts
Front
3. Remove the screw securing the Bearing Bracket on the front of the Left Shaft.
4. Remove the screw securing the Bearing Bracket on the rear of the Left Shaft.
5. Remove the Left Shaft from the two belts.
Note
Use caution when removing rollers and bearings as these parts are small and
easily lost.
PL25.3.13
Right Shaft
Roller
Belt
Bearing
Lower Chute
Flat
Bearing s5500-376
2. Lift the Roller up in the direction of the arrow to remove it from the Lower
Chute.
3. Remove the Bearings from the both ends of the Roller.
Replacement Note
Install the Roller to the Lower Chute so that the flat surface of the Bearing
faces the direction shown in the figure.
Lower Chute
s5500-377
Motor Clamp
Connector
Rear s5500-378
4. Open Door F.
5. Remove the two screws securing the Motor Cover and remove the Cover.
6. Disconnect the Motor connector from the harness.
7. Release the Motor harness from the clamp.
Drive Bracket
Horizontal Transport
Motor
Motor Cover
s5500-379
8. Remove the two screws securing the Motor to the Drive Bracket, and remove the
Motor in the direction of the arrow.
Top Cover
Lower Chute
s5500-380
3. Remove the two screws securing the Top Cover to the Lower Chute and remove
the Top Cover.
Bracket
Lower Chute
s5500-381
3. Remove the one screw securing the bracket to the Lower Chute and remove the
bracket.
4. Disconnect the connector from the sensor.
5. Release the hooks securing the sensor to the bracket to remove the sensor.
Entrance Sensor
Bracket
Lower Chute
s5500-601
Bracket
Exit Sensor
Lower Chute
s5500-602
Door G
Docking Plate
s5500-382
1. Move the Finisher to the right while pulling the Docking Plate toward you.
2. Close Door G.
A
Connector Cover
Upper Rear Cover s5500-384
3. Remove the four screws securing the Upper Rear Cover to the Finisher and
remove the cover.
3-120 Phaser 5500 Printer Options Service Manual
Finisher Lower Rear Cover
1. Remove the Upper Rear Cover (page 3-120).
PL25.4.9
s5500-385
2. Remove the four screws securing the Lower Rear Cover to the Finisher and
remove the cover.
Door G
s5500-386
4. Remove the two screws on the front and rear securing the Top Cover to the
Finisher and remove the cover.
Power Cord
Notch
Bottom Cover
s5500-387
1. Remove the two screws securing the Bottom Cover to the Finisher.
2. Remove the cover.
Replacement Note
When installing the Bottom Cover, be sure to put the power cord into the
notch on the Bottom Cover.
Door G
Magnet
Rib
Magnet
Inner Cover
Door G
Interlock Switch
s5500-388
2. Remove the three screws securing the Inner Cover and remove the Door.
Replacement Note
Make sure that the rib of Door G engages the Interlock Switch. Also, verify
that the two magnets on Door G contact the Finisher.
Inner Cover
Door G s5500-389
2. Remove the four screws securing the inner Cover to Door G and remove the Inner
Cover.
s5500-390
4. Remove the two screws securing the Top Front Cover to the Finisher and remove
the cover.
Replacement Note
Make sure that after replacing the Top Front Cover, the Stacker Top Tray
moves smoothly when pushed down once and then released by hand.
Connector
2. Pull the Punch Box toward the front to remove it from the Finisher.
3. Remove the three screws on the front side and one screw on the rear securing the
Dust Box Chute to the Finisher and remove the chute.
4. Disconnect the connector from the Door G Interlock Switch.
5. Release the hooks of the switch by using two fingers to press down the two hooks
on either side or the switch and push the switch towards the front to remove it
from the frame.
Door G
2. Remove the two screws securing the L/H Front Cover to the Finisher and remove
the cover.
s5500-392
4. Remove the two screws securing the Top L/H Cover to the Finisher.
5. Move the Top L/H Cover to the front to release the tabs from the frame.
Right
s5500-393
1. Remove the two screws securing the Stacker Upper Tray to the Finisher.
2. While compressing the tray to collapse the springs, lift the tray in the direction of
the arrow to remove it from the Finisher.
Replacement Note
After installation, make sure that the tray moves up and down smoothly.
Eject Cover
Right
4. Remove the two screws securing the Eject Cover to the Finisher.
5. Remove the Eject Cover.
Hooks
1. Release the hooks left and right on the lower part of the Stacker Lower Tray by
gently pulling the tabs and lifting the tray.
2. Lift the Stacker Lower Tray up to remove it from the Tray Carriage.
Replacement Note
Make sure that the two hooks on the Stacker Lower engage the square holes
on the Tray Carriage.
Rear
Rear
3. Loosen the four screws securing the Finisher Main PWB Cover and remove it in
the direction of the arrow.
Stacker Encoder
Sensor
J8328
Bracket
Clamp
Clamp s5500-398
P8305
Stacker Bracket
Encoder
s5500-400
Rear
3. Without touching the Encoder, slide the Gear in the direction of the arrow and
away from the Pulley Doc Clutch. Move the Stacker Lower Tray to its lowest
position.
Belt Clamp
Tray Carriage
Front
Left Carriage
Spring
Pulley T18 s5500-401
Replacement Note
Put the boss on the back of the Belt Clamp into the hole on the Carriage.
Also check that the Stacker Lower Tray moves smoothly up and down.
Rear
3. Without touching the Encoder, slide the Gear in the direction of the arrow and
away from the Pulley Doc Clutch. Move the Stacker Lower Tray to its lowest
position.
Belt Clamp
Tray Carriage
Rear
Right Carriage
Spring
Pulley T16 s5500-402
Replacement Note
Put the boss on the back of the Belt Clamp into the hole on the Carriage.
Also check that the Stacker Lower Tray moves smoothly up and down.
J8331
Front
2. Remove the one screw securing the Stack Height Sensor 1 and remove the
Sensor.
3. Disconnect the connector (J8331) from the Stack Height Sensor 1.
Replacement Note
Put the two bosses on the Stack Height Sensor 1 into the two holes on the
Finisher frame.
Rear
J8330
2. Remove the one screw securing the Stack Height Sensor 2 and remove the
Sensor.
3. Disconnect the connector (J8330) from the Stack Height Sensor 2.
Replacement Note
Put the two bosses on the Stack Height Sensor 2 into the two holes on the
Finisher frame.
Stacker Encoder
Sensor
Bracket
J8328
Harness Clamp
Rear
2. Remove the one screw securing the sensor bracket to remove it from the Stacker
Bracket.
3. Release the harness from the harness clamp.
4. Disconnect the connector (J8328) from the Stacker Encoder Sensor.
5. Release the hooks of the sensor to remove it from the sensor bracket.
Rear
Stacker No Paper
Sensor
J8327 (Yellow)
J8326
3. Disconnect the connector (J8327 or J8326) from the Upper Limit Sensor or No
Paper Sensor.
4. Release the hooks of the Sensor to remove.
Replacement Note
Connect the yellow connector (J8327) to the Lower Tray Upper Limit
Sensor.
Rear
4. Remove the two screws securing the Elevator Motor to the Stacker Bracket.
PL25.6.26
Pulley T60
Belt
Elevator Motor
5. Remove the Elevator Motor in the direction of the arrow while removing the Belt.
Sensor Bracket
Rear Punch
Bracket
J8352
Punch Frame
J8346
Rear
s5500-408
Front
11. Remove the three screws securing the Front Punch Bracket and remove it from
the frame.
12. Remove the two screws on the front side of the Finisher securing the Punch
Frame to the Finisher.
13. Remove the two screws on the rear side of the Finisher securing the Punch Frame
to the Finisher.
14. While pushing the Belt in the direction shown in the figure, remove the Punch
Frame to the rear.
J8344
Punch Frame
s5500-410
3. Remove the two screws securing the Punch Move Motor Cover to the Punch
Frame.
4. Remove the two screws securing the Punch Move Motor Bracket to the Punch
Frame to remove the Bracket.
J8350
J8351
s5500-411
Holder Frame
Punch Bracket
J8350/J8351
Sensor Bracket
Punch Motor
Encoder Sensor
Bracket
J8345
J8349
Punch Frame
s5500-414
4. Disconnect the connector (J8345) from the Punch Motor. Use care as two pins
are exposed when this connector is removed.
Replacement Note
Engage the gears of the motor to the Punch Frame.
Bracket
Punch Frame
s5500-416
J8347
Bracket
J8348
Punch Home Sensor
s5500-417
5. Disconnect the connector (J8346) from the Punch Hole Select Sensor, connector
(J8347) from the Puncher Front Sensor, or connector (J8348) from the Puncher
Home Sensor.
6. Release the hooks of the sensor to remove the sensor from the bracket.
Replacement Note
When installing the bracket, engage each notch of the bracket and the Punch
Frame. Then tighten the screw while pushing the bracket toward the set
screw.
Sensor Bracket
J8352
4. Remove the two screws securing the Rear Punch Bracket and remove the bracket.
5. Remove the one screw securing the Sensor Bracket.
6. Disconnect the connector (J8352) from the Punch Unit Move Home Sensor.
7. Release the hooks of the sensor to remove the sensor from the bracket.
Door G
J8353
Stapler Cartridge
Stapler Head
s5500-419
Ground Terminal
P8308
Rear
Main PWB
s5500-603
5. Loosen the four screws securing the Finisher Main PWB Cover and remove it in
the direction of the arrow.
6. Disconnect the connector (P8308) from the Finisher Main PWB.
7. Remove the one screw securing the ground wire of the Staple Harness.
J8327 (Yellow)
J8326
Stapler Unit
Rear
Hook
Square Hole
9. Disconnect the two connectors from the Upper Limit and No Paper Sensors.
10. Release the harness from the clamp on the underside of the Stapler Unit.
11. Remove the two screws each on the front and rear securing the Stapler Unit.
12. Move the Stapler in the direction of the arrow to disengage the hooks from the
frame and remove the Stapler from the front.
PL25.8.2
Stapler Head
Stapler Holder
Stapler Cover
Upper Carriage
J8354
Ground Terminal
Replacement Note
Make sure the harness is not pinched between the Carriage and Holder.
PL25.8.2
Stapler Assembly
Harness Clamps
Staple Harness
Stapler Frame
s5500-421
s5500-422
5. Remove the two screws securing the Lower Carriage. Since the harnesses are
connected to the Lower Carriage and the head of the Stapler, the Lower Carriage
cannot be detached from the Stapler.
Replacement Note
If the replacement Lower Carriage Assembly includes the harness bracket,
remove the bracket and use the existing bracket instead. Also, be sure the
holes in the Lower Carriage Assembly seat properly over the bosses on the
Rail Base.
Upper Rail
Rail Base
Stapler Frame
s5500-632
4. Remove the six screws securing the Upper Rail to the Rail Base.
Harness Guide
Stapler Move
Position Sensor
s5500-424
7. Release the hooks of the Stapler Move Position Sensor from the Stapler Harness
Guide to remove the Sensor.
J8340
Right
Sub Paddle Solenoid s5500-425
Screw
s5500-426
8. While pushing the Lever in the direction of the arrow, remove the screw securing
the Lever to the Eject Pinch Shaft to remove the Lever.
9. Remove the E-ring securing the Eject Pinch Shaft on the rear of the Finisher.
10. Remove the Bearing on the rear side.
Bearing
E-Ring
Front s5500-427
11. Remove the E-ring securing the Eject Pinch Shaft on the front of the Finisher.
12. Remove the Bearing on the front side.
Right
13. While pulling the Eject Chute toward you from the right side of the Finisher, tilt
it slightly to remove the front end of the Eject Pinch Shaft from the hole in the
front of the frame. Pull the Eject Pinch Shaft from the rear enough to allow the
Eject Chute to clear the frame.
14. Remove the Eject Chute from the Finisher.
15. Remove the Sub Paddle Solenoid (page 3-166).
Right
Actuator
Replacement Note
Make sure the Door H Interlock Switch actuator, pictured above, is placed
under the bracket on the Eject Chute.
Harness Clamp
J8340
Harness Clamp
Right
Sub Paddle Solenoid Bracket Eject Chute s5500-430
2. Disconnect the connector (J8340) of the Sub Paddle Solenoid from the Main
Drive harness.
3. Release the harness of the Sub Paddle Solenoid from the two harness clamps.
Solenoid Bracket
Pin
Link
Pin
4. Remove the three screws securing the Solenoid Bracket to the Eject Chute and
remove it in the direction of the arrow.
5. Remove the two screws securing the Solenoid to the Bracket.
Pulley T16
2. Remove the Cyclone Paddles from the Pulley T16 shaft on the Eject Chute by
hand.
Replacement Note
After installation, make sure that the Cyclone Paddles do not contact the
Eject Chute when rotated by using Knob 2C
Paddle Shaft
Bearing
E-Rings
Set Screw
Knob 2C
Front
s5500-433
Rear
Pulleys s5500-434
11. Loosen the two screws securing the Tension Bracket on the rear.
12. Move the Tension Bracket in the direction of the arrow so the Belt tension
decreases and remove the Belt from the pulleys.
Replacement Note
Belt tension is automatically adjusted by the force of the Tension Spring
attached to the Tension Bracket. When tightening the two screws, do not
move the Tension Bracket.
Bearing
Paddle Shaft
Gear Z23
s5500-435
13. Release the hook of Gear Z23attached to the Paddle Shaft and remove.
14. Remove the Bearing.
15. Move the Cyclone Paddle Drive Shaft to the rear to remove the front of the
Paddle Shaft from the hole in the frame, then remove the Cyclone Paddle Drive
Shaft from the Finisher.
Tie Plate
Right
3. Push down on the two Pinch Springs to remove them from the Eject Chute.
Gear-Cam Z70
J8339
J8324
Eject Clamp Home Sensor s5500-437
4. Disconnect the Eject Clamp Motor connector (J8339) from the harness.
5. Disconnect the Eject Clamp Home Sensor connector (J8324).
6. Remove the three screws securing the Eject Clamp Bracket to the Finisher. If
necessary, release the cable clamp from the frame to access the screws.
Replacement Note
When installing the Eject Clamp Bracket, rotate the Gear-Cam Z70 so the
actuator on the Eject Clamp Bracket is retracted from the recess of the Eject
Clamp Home Sensor.
s5500-438
4. Remove the two screws securing the Eject Clamp Motor to the Eject Clamp
Bracket and remove the motor.
Bracket
s5500-439
4. Release the hooks of the Eject Clamp Home Sensor to remove it from the Eject
Clamp Bracket.
Right
Bracket
Tie Plate
s5500-440
Actuator
Replacement Note
Install the Door H Interlock so the actuator is placed under the Interlock
Bracket on the Eject Chute.
Note
There is an inline connector in the Compiler Tray harness located inside the
Finisher at the rear. If you disconnect this connector, skip Steps 10 and 11.
Rear
Harness Clamp
P8309
Rear
Main PWB
s5500-442
10. Loosen the four screws securing the Finisher Main PWB Cover and remove it in
the direction of the arrow.
11. Disconnect the connector (P8309) on the Finisher Main PWB.
12. Release the Compiler harness from the clamp.
s5500-593
Compiler Tray
Right
Boss
Compiler Tray Boss Compiler Tray
s5500-443
Compiler Tray
Compiler Tray
J8360
11. Disconnect the Front Tamper Home Sensor connector (J8360). For the Rear
Tamper Home Sensor, disconnect connector (J8361).
12. Release the hooks of the Sensor to remove the Sensor from the Compiler Tray.
Compiler Tray
J8359
Compiler Tray
Actuator s5500-445
Bearing
E-Ring
Bearing Gear
Rear s5500-448
11. Release the hook of the Gear to remove it from the shaft.
12. Remove the Bearing.
13. Remove the E-ring on the rear.
14. Remove the Bearing.
E-Rings
Front Bearing
s5500-449
15. Remove the two E-rings on the front securing the Eject Roller Shaft.
16. Remove the two Bearings.
s5500-450
Eject Motor
J8336
Replacement Note
Fit the clutch stop into the notch of the Eject Bracket at the 12:00 position.
Eject Bracket
Rear
s5500-453
3. Remove, then disconnect the Rear Upper Limit Sensor and remove the harness
from the clamps on the Eject Bracket.
4. Remove the three screws securing the Eject Bracket.
Replacement Note
Fit the notch of the Set Clamp Clutch onto the Eject Bracket.
Rear
J8325
Rear
Pulleys s5500-434
13. Loosen the two screws securing the Exit Motor Belt Tension Bracket.
s5500-455
15. Remove the two screws each on the front and rear securing the Upper Exit Chute.
16. Disconnect the connector from the Compile Exit Sensor.
Sensor Bracket
s5500-456
Replacement Note
Belt tension is automatically adjusted by the force of the Tension Spring
attached to the Tension Bracket. When tightening the two screws, be careful
not to move the Tension Bracket.
Rear
Pulleys s5500-434
13. Loosen the two screws securing the Exit Motor Belt Tension Bracket.
14. Move the Belt Tension Bracket in the direction of the arrow to reduce belt tension
and remove the belt from each pulley.
15. Disconnect the Compile Exit Sensor.
Replacement Note
Belt tension is automatically adjusted by the force of the Tension Spring
attached to the Tension Bracket. When tightening the two screws, be careful
not to move the Tension Bracket.
s5500-455
16. Remove the two screws each on the front and rear securing the Upper Exit Chute.
17. Remove the Upper Exit Chute.
18. Release the hook of Pulley T20 attached to the Lower Exit Roller shaft and
remove the pulley.
19. Remove the Bearing.
E-Ring Bearing
Front
s5500-458
Rear
Lower Exit Roller s5500-459
20. Remove the E-ring securing the Lower Exit Roller shaft on the front.
21. Remove the Bearing.
22. Move the Lower Exit Roller shaft to the rear to remove the front end of the shaft
from the hole in the frame and remove it from the Finisher.
Rear
Pulleys s5500-434
12. Loosen the two screws securing the Exit Motor Belt Tension Bracket.
13. Move the Belt Tension Bracket in the direction of the arrow to reduce Belt
tension and remove the Belt from the pulleys.
Pulley T17
Bearing
Paddle Shaft
Drive Belt
14. Loosen the two screws securing the Finisher Transport Motor Belt Tension
Bracket.
15. Move the Tension Bracket in the direction of the arrow to reduce Belt tension and
remove the belt from the pulleys.
16. Release the hook of the Pulley T17 and remove the pulley from the Paddle Shaft.
This also frees the Paddle Shaft Drive Belt.
17. Remove the Paddle Shaft Drive Belt from the Paddle Shaft.
18. Remove the Paddle Shaft Bearing.
Paddle Shaft
Gear Z23L
Bearing Pulley T44/Z20
s5500-462
19. Release the hook of the Pulley T44/Z20 and remove from the Paddle Shaft.
20. Pull out the Paddle Shaft.
21. Remove the Bearing from the Paddle Shaft.
22. Remove the Gear Z23L.
s5500-463
23. Remove the two screws each on the front and rear securing the Lower Exit Chute
R to the Finisher.
24. While moving the Lower Exit Chute R to the front, move the rear side of the
Lower Exit Chute R downward to remove it from the Finisher frame.
Replacement Note
Belt tension is automatically adjusted by the force of the Tension Spring
attached to the Tension Bracket. When tightening the two screws, be careful
not to move the Tension Bracket.
Bearing
Paddle Shaft Drive Belt
Paddle Shaft
Bearing
Front
E-Ring
s5500-465
s5500-464
14. Remove the four screws securing the four Exit Pinch Rollers.
Replacement Note
Note the orientation of the Pinch Rollers.Align the Lower Exit Chute R
bosses to the slots on the Pinch Roller brackets.
3. Open the Lower Exit Chute to the right by hand (Arrow 1).
4. Remove the one screw on the front securing the Lower Exit Chute to the frame.
PL25.12.1
Buffer Gate
Solenoid
Rear s5500-467
5. Remove the screw on the rear securing the Lower Exit Chute to the frame.
6. Remove the Lower Exit Chute Open from the front (Arrow 2).
Spring 1.9N
Shaft
Pinch Roller
s5500-468
4. Remove the Spring 1.9N left and right and remove the Pinch Roller Shaft.
5. Remove the two Pinch Rollers from the Shaft.
Transfer Gate
1. Open Door G.
2. Remove the Upper Rear Cover (page 3-120).
Gate
Link
Rear s5500-470
Replacement Note
Install the Gate with the hole facing the rear.
Buffer Gate
1. Open Door G.
2. Remove the Upper Rear Cover (page 3-120).
PL25.12.7
Buffer Gate
Buffer Gate
Solenoid
Link
Rear s5500-471
3. Remove the Buffer Gate Solenoid Bracket on the rear (page 3-225).
4. Remove the Buffer Link.
Replacement Note
Install the Buffer Gate with the hole facing the rear.
Left
s5500-473
7. Disconnect the Buffer Path Sensor connector (J8392) from the harness.
8. Remove the one screw securing the Sensor Bracket to the Top Buffer Chute.
9. Remove the Sensor Bracket.
10. Release the four hooks securing the Buffer Path Sensor to the Sensor Bracket.
Replacement Note
When installing the Sensor Bracket, be sure to put the actuator of the Buffer
Path Sensor into the hole of the Top Buffer Chute. Put the boss on the Top
Buffer Chute into the hole of the Sensor Bracket.
Buffer Roller
1. Open Door G.
2. Remove the Upper Rear Cover (page 3-120).
3. Remove the Stapler Cartridge.
4. Move the Staple Head to the rear by hand as far as possible.
Front
E-Ring
8. Remove the E-ring securing the front of the Buffer Roller Shaft.
FRU Disassembly 3-209
9. Remove the Bearing.
10. Remove the Transport Gate Solenoid Bracket (page 3-223).
PL25.12.28
Pulley T53/Z23
E-Ring
11. Release the hook of the Gear Z46 and slide the shaft toward the front and out of
the gear.
12. Remove the Bearing.
Buffer Roller
Front s5500-478
13. Move the Buffer Roller Shaft to the rear and remove the front end from the
frame.
14. Move the Buffer Roller Shaft downward first, then remove it from the Finisher.
Replacement Note
Begin installing the Buffer Roller Shaft with the end having the flat surface
towards the rear. Feed the shaft through the rear frame, then slide the bearing
over the shaft and work into place. Install the front bearing, followed by the
Gear Z46 at the rear. Finish the replacement by installing the E-clip on the
front of the shaft.
Caution
When removing the Buffer Chute, ensure not to break the retaining tab off the
frame.
Retaining Tab
Hole On Rear Frame
Boss
5. Remove the screw securing the Exit Pinch Roller to the Bottom Buffer Chute.
Replacement Note
Put the Bottom Buffer Chute bosses into the two holes on the Exit Pinch
Roller.
J8319
Upper Entrance
Chute
Sensor Bracket
Left s5500-481
Entrance Sensor
Harness Bracket
s5500-482
7. Remove the two screws at the top and bottom of the harness bracket.
8. Release the harness from the clamp on top of the harness bracket and move the
bracket to allow access to the Upper Entrance Chute screws.
9. Remove the three screws securing the Upper Entrance Chute and remove the
hinge from the square hole on the rear frame.
10. Remove the Upper Entrance Chute from the front.
Left s5500-483
5. Remove the one screw securing the Pinch Roller to the Upper Entrance Chute.
Replacement Note
Put the Upper Entrance Chute bosses into the Pinch Roller bracket.
J8319
Sensor Bracket
Left
s5500-484
Replacement Note
Install the sensor in the direction shown in the figure.
Punch Frame
Upper
Entrance Chute
s5500-485
9. Loosen the two screws securing the Transport Motor Belt Tension Bracket.
10. Move the Tension Bracket in the direction of the arrow to reduce belt tension and
remove the belt from the pulleys. This is best accomplished by removing the Belt
from the stationary pulley first, then removing the Belt from the tension pulley.
Pulley T20
Gear Z23
Entrance Roller
Shaft
Rear
s5500-486
11. Release the hook of the Gear Z23 on the rear attached to the Entrance Roller
Shaft and remove the Gear Z23.
12. Remove the Pulley T20.
13. Remove the Bearing.
Replacement Note
Belt tension is automatically adjusted by the force of the Tension Spring
attached to the Tension Bracket. When tightening the two screws, be careful
not to move the Tension Bracket.
Bearing
E-Ring
Front
s5500-487
14. Remove the E-ring securing the Entrance Roller Shaft on the front.
15. Remove the Bearing.
16. Push the Entrance Roller Shaft to the rear to remove the front end of the Entrance
Roller Shaft from the frame first.
17. Move the Entrance Roller Shaft downward to remove it from the front.
Belt
Tension Bracket Finisher Transport Motor s5500-460
2. Loosen the two screws securing the Transport Motor Belt Tension Bracket.
3. Move the Tension Bracket in the direction of the arrow to reduce belt tension and
remove the Belt from each pulley.
PL25.12.21
Bracket
J8342
s5500-488
Replacement Note
Align the two holes on the Motor Bracket with the bosses on the Finisher
frame. Also note that belt tension is automatically adjusted by the force of
the Tension Spring attached to the Tension Bracket. When tightening the two
screws, be careful not to move the Tension Bracket.
Harness Bracket
Clamp
Link
J8341
Guide
Link
Pin s5500-489
Replacement Note
Reinsert the Solenoid Guide into the Link Notch. Be sure the Transfer Gate
pivot is in place at the front when reinstalling the solenoid.
Clamp
J8394
Link
Rear
When Assembling
Pin
Guide
Link
s5500-490
Upper Tray
J8321 Exit Sensor
Left s5500-491
Rear
Left
Rear
Top Exit Upper Chute
s5500-492
4. Remove the screw securing the Exit Pinch Roller to the Top Exit Upper Chute.
Replacement Note
Put the two bosses of the Top Exit Upper Chute into the holes on the Exit
Pinch Roller.
Upper Tray
Exit Sensor
J8321
Left
s5500-493
Top Exit Upper Chute
s5500-494
Front
s5500-495
7. Remove the two screws each on the front and rear securing the Top Exit Upper
Chute to the Finisher.
Rear s5500-496
Bearing
Gear
Rear
s5500-497
11. Release the hook to remove the Gear from the Top Exit Roller shaft.
12. Remove the Bearing.
E-Ring
Bearing
Front
s5500-498
13. Remove the E-ring securing the Top Exit Roller shaft on the front.
14. Remove the Bearing.
15. Move the Top Exit Roller shaft to the front and remove the rear of the shaft from
the hole in the Finisher frame.
Replacement Note
Install the Top Exit Roller shaft with its one end with the flat surface facing
the rear.
J8322
Rear s5500-499
Rear s5500-500
4. Remove the three screws securing the hinge of the Upper Exit Chute on the rear.
Front
s5500-501
5. Remove the Upper Exit Chute from the Finisher by removing the hinge from the
square hole on the rear frame.
Spring 1.5N
Shaft
Detailed View
Pinch Roller
Spring 1.5N
Pinch Roller
s5500-502
5. Remove the two Springs 1.5N and remove the Pinch Roller shaft.
6. Remove the two Pinch Rollers from the shaft.
Gate Sensor
1. Open Door G.
2. Remove the Upper Rear Cover (page 3-120).
3. Remove the Top Cover (page 3-122).
4. Remove the L/H Front Cover (page 3-128).
5. Remove the Top L/H Cover (page 3-129).
6. Remove the Punch (page 3-145).
Sensor Bracket
s5500-503
7. Remove the three screws securing the Gate Sensor Bracket to the Upper Top Exit
Chute L.
8. Disconnect the Gate Sensor connector.
9. Remove the screw securing the Gate Sensor to the bracket.
Front s5500-504
Front
s5500-505
8. Remove the two screws securing the Top Exit Upper Chute at the front.
Top Exit
Upper Chute
Rear
s5500-506
Harness Bracket
Tension Bracket
Belt
s5500-510
12. Loosen the two screws securing the Registration Motor Belt Tension Bracket.
13. Move the Tension Bracket in the direction of the arrow to reduce belt tension and
remove the Belt from the pulleys.
Replacement Note
Belt tension is automatically adjusted by the force of the Tension Spring
attached to the Tension Bracket. When tightening the two screws, be careful
not to move the Tension Bracket.
Gears
14. Remove the Gear attached to the Transport Roller shaft on the rear.
15. Remove the Bearing.
E-Ring
Bearings
Front
E-Ring
s5500-508
Rear
Pulleys s5500-434
2. Loosen the two screws securing the Exit Motor Belt Tension Bracket.
3. Move the Tension Bracket in the direction of the arrow to reduce belt tension and
remove the Belt from the pulleys.
Replacement Note
Belt tension is automatically adjusted by the force of the Tension Spring
attached to the Tension Bracket. When tightening the two screws, be careful
not to move the Tension Bracket.
Exit Motor
J8334
s5500-509
Replacement Note
Put the two bosses of chassis into the two holes on the Exit Motor Bracket.
Harness Bracket
Tension Bracket
Belt
s5500-510
2. Remove the two screws securing the Harness Bracket. Remove only the two
screws to facilitate removal of the gear. Do not to remove the Harness Bracket
from the Finisher.
3. Loosen the two screws securing the Registration Motor Belt Tension Bracket.
4. Move the Tension Bracket in the direction of the arrow reduce belt tension and
remove the Belt from the pulleys.
Registration Motor
J8335
s5500-511
Replacement Note
Put the two bosses into the two holes on the Motor Bracket. Also, belt
tension is automatically adjusted by the force of the Tension Spring attached
to the Tension Bracket. When tightening the two screws, be careful not to
move the Tension Bracket.
Horizontal Transport
Connector Plate
Rear
s5500-512
Rear
3. Loosen the four screws securing the Finisher Main PWB Cover.
4. Move the Finisher Main PWB Cover in the direction of the arrow to remove.
Main PWB
P8304 P8308 P8389
P8306
P8309 P8307
P8305
P8300
P8302 P8301
P8311 P8310
s5500-513
5. Mark and disconnect all the connectors on the Finisher Main PWB.
6. Remove the six screws securing the Finisher Main PWB.
Replacement Note
When replacing this board, reset the punch type using Service Diagnostics.
Failure to reset the punch type can result in improper Finisher performance.
FRU Disassembly 3-249
Low Voltage Power Supply
1. Remove the Bottom Cover (page 3-123).
PL25.14.9
Harness Clamps
LVPS
Rear s5500-514
Chapter
4
Phaser 5500 Printer Option Parts Lists
Serial Number
Changes to Xerox products are made to accommodate improved components as they
become available. 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 Finisher serial number is located on the lower frame behind Door G. The 2000-
Sheet Feeder serial number is located on the rear frame. Remove the 2000-Sheet
Feeder Rear Cover to view the serial number. The Duplex Unit, Exit 2, and 1000-
Sheet Feeder are not serialized.
Name/Description: The name of the part to be ordered and the number of parts
supplied per order.
Part Number: The material part number used to order that specific part.
Parts identified throughout this manual are referenced PL#.#.#; For example,
PL3.1.10 means the part is item 10 of Parts List 3.1.
The notation with X~Y following a part name indicates an assembly that is
made up of components X through Y. For example, 1 (with 2~4) means part 1
consists of part 2, part 3, and part 4.
An asterisk (*) following a part name indicates the page contains a note about
this part.
Note
Only parts showing part numbers are available for ordering by support. Parts
without numbers are available on the parent assembly.
Abbreviations
Abbreviation Meaning
C C-ring
E E-ring
KL K-clip
S Screw
S
1
10
6
S
S
S
8 S
7
7 8 S 2
6 S
4 Left Front
s5500-608
5 REAR COVER
7 CASTER 017K93121
8 FOOT ADJUSTER
9 BRACKET REAR RH 2T
10 BRACKET REAR LH 2T
6
S
5
7 (PL20.4.1) 14
10
S
12
13
9 (with 12,13)
13
S 2
11
8 (PL20.4.1) 1 (1/2Pcs.) (PL20.3)
3
10
S
12
13 9 (with 12,13)
Left Front
13
99 (with 2, 3, PL2.1.3, PL2.1.10, PL2.1.11, PL2.1.12)
s5500-609
2 LABEL (No. 4)
3 LABEL (No. 5)
10 COVER SENSOR
11 COVER FDR
1 (with 2-26)
4 17
A E 16
E
10
B
13
12
14 C
8
5
24
9
S 15 8
S
25 15
18
20 23 A
C
B
6
S
S
D 11
21
22
D
25 S 26
2 Left Front
S
19 s5500-193
2 TRAY COVER
3 -
4 LABEL (MAX)
5 BOTTOM PAD
7 -
8 TRAY PAD
10 BOTTOM PLATE
11 TRAY
13 GUIDE ACTUATOR
14 SPRING
15 PINION GEAR
16 END GUIDE
17 SPRING
19 LINK
21 GEAR (13T/60T)
23 BRACKET
24 LIFT UP SHAFT
25 STOPPER
26 SEAL
C S
3 45
40 45
42 14 Level Sensor
S
17 18
S
14 A 10
No Paper B 9
Sensor 39 11 6
S
39
13 5
19
E
36 4
12
46 22 23 35
21 E 30 S
20 C A B
S
38 48
33 8
20 31 7
34
49
50 S
37
16 47 24
27 S
25
99 (with 20x3Pcs.) 26
29 Front Right
20
s5500-194
3 BRACKET
4 SPACER
5 GEAR (31T)
6 SPRING
7 ONEWAY CLUTCH
8 ONEWAY GEAR
9 GEAR (13T)
10 BEARING
11 SHAFT
12 FRONT CHUTE
16 WIRE HARNESS
17 GEAR (28T/21T)
18 GEAR (29T)
19 SPRING 809E51070
21 ONEWAY CLUTCH
23 SHAFT
24 CHUTE
25 SPRING
26 FRICTION CLUTH
27 SHAFT-RETARD
28 --
29 SPACER
30 GEAR (33T)
31 SHAFT-NUDGER
32 --
33 GEAR (25T)
34 LOWER FRAME
35 BEARING
36 GEAR (27T)
37 LEVER
38 BEARING
39 WASHER
40 UPPER FRAME
41 -
46 RAIL
47 SUPPORT RETARD
48 SUPPORT NUDGER
49 HOLDER
50 SPRING
1 2
S
4 E
3 Feed Out S
E
Sensor #4
9
8 E
S
E
8
7 9
6 5 S
Feed Out
Sensor #5
27
26
12
S 13 S
25
161514
S
13 11 (with 12-16)
16 16
S
18 S
17
S
19 S 24
10
(with 11-23) 20 S
23
21
22 Left Front
s5500-517
1 CHUTE
2 COVER
5 CHUTE
9 BEARING
12 BRACKET
13 BEARING
14 BEARING
15 PINCH ROLL
16 SPRING
17 CHUTE
18 ACTUATOR
19 HOOK
20 LEFT COVER
21 SPRING
22 LATCH}
23 HANDLE
24 BRACKET
25 SUPPORT 830E45710
26 BRACKET ASSEMBLY
14
13
14
S 8 15
16
4
2
5
6
E 11
3
S
7 9 12 Rear Left
10 11
s5500-518
3 BRACKET
4 SHAFT
5 BEARING
6 GEAR (38T)
8 GEAR (22T/40T)
9 GEAR (126T)
10 GEAR (60T)
11 GEAR (37T)
12 GEAR (32T)
13 WIRE HARNESS
14 GASKET
15 BEARING
16 WASHER-PLAIN, NYN
S
1 2
S
14 S
S S
S S
S
S
S
S
Paper Size
4 Sensor B 16 15
S
S
4 Paper Size S
Sensor A
S
12 S 16
S
17
3
S 3
S
S 4 Tray In (PL22.4.1)
S
5 E
Sensor
6
S
S S
S S
S
11 S 7
S
S
S
9
8 8
8 8
S S S S
S
S S 9 S
S
S
S
S S
(PL22.2 & PL22.3)
10
Left Front
S 10 s5500-519
2 COVER RH HCF
5 SPRING 009E84690
9 FOOT ADJUSTER
12 BRKT-ASSY SENSOR
13
1
S
11
10 S
E
2
16 6 E
4
5
Left Front
S
S s5500-520
3 ---
6 SPRING 009E84690
7 --
9 PLATE END
10 SPRING COMP
11 WASHR
13 PIN GUIDE
16 WASHR WAVE
6
6
6
5 (with 3, 4) 6
3
4
14 13 9
E
E
E 10
19 15
14 13 E
E
11 12
E E
E
E
18 17
13 14 13 14
E
E E
E
15
16 E
17 18
S
S
S
4 PLATE BOTTOM
9 BEARING POWERD
10 SHAFT LIFT
11 BEARING POWERD
12 WASHER
13 PULLEY S 020E99571
15 PULLEY TRAY
17 PULLEY L 020E37630
19 GEAR LIFT
S E
S 4 (with 5)
S S
S
S S
S 5
9
(PL22.6) 16 17
E
15
18
6
S 6
S
7
S 8
S
(PL22.5) S
S
Left Front
s5500-521
6 HOLDER
7 BLOCK
9 GEAR-25T
10 BEARING
11 SHAFT ASSY
12 GEAR-25T
13 BEARING
14 GEAR-19T
15 BRACKET
16 GEAR-40T
17 SPRING SPACER
18 SPACER
2 3 1 (with 2-19)
4
S
S
5
2
E
7 8 Tray 6 Pre Feed
Sensor 9
6
E
A E
S
10
11 10
10 E
10
Tray 6
12 Level 16 16
Sensor Tray 6 No Paper
Sensor
13
S E
15
14 S
S
S
Detail A
17
19
18 E
18
20
Left Front
21 s5500-522
2 LATCH 003E59570
4 SHAFT LATCH
5 LEVER 011K97840
7 PIN DRIVE
10 CLAMP MINI-SADDLE
11 GUIDE
14 CHUTE UPPER
15 ACTUATOR 120E21900
17 BEARING
18 SPACER
2 1 (with 2-17)
4 E
E
5
3
S
S
S
S
S
8 (with 9-16)
9 6
10 7
11 12
E
E
13
E
14
15
16 Left Front
17
s5500-523
2 CHUTE LOWER
4 LEVER RETARD
6 SLIDE RETARD
9 GEAR 22T
10 COLLAR
12 BEARING
13 SHAFT ASSY-RET
14 BEARING-6
16 GEAR 15T
14
15
2 (with 3-8)
3 16
S S S
4 6 Feed Out # 6
13 Sensor
5 S S
7
8 8
8
8
S
9
S
S S S 10
S 17 KL
S
11
12
S
S
Left Front
s5500-524
4 BRACKET SWITCH
5 CHUTE LOW
7 BRACKET SENSOR TA
8 CLAMP
10 BEARING CONDUCTIVE
15 SPRING TOSION R
16 SPRING TOSION L
3
3 3
1 S
4
S
S 3
3 5
S 3
3
3
Left Front
s5500-525
3 CLAMP WS-2N
4 CLAMP
5 WS-1N
21 14
7
17
22
S
6
12
2 S
18
4
5 15
4
10
9 19 (PL23.2)
S
2
S
2
3 3
E
16
11 S
23
24
8 13
Rear eft
L
s5500-526
8 CHUTE LOWER
16 BRACKET MOTOR
23 FAN-DUP
24 DUCT-DUP
10 9
(1/4Pcs.) (1/4Pcs.)
2
6 10
(1/2Pcs.)
9
(1/2Pcs.)
4
7
8
2
10 (1/4Pcs.)
9
7 (1/4Pcs.) 3
4
3
3
3
1
5
Rear eft
3 L
3 s5500-527
2 LOCK DUP
3 BEARING DUP
4 PIN DUP
5 CHUTE OUTER
6 CHUTE INNER
9
13 10
S
25 17
6
11 12
7
8
9
17
16 A
18
22 21
19
S 2
E
16
5
20 4
23 24
A
15 3 Front ight
R
14 s5500-581
3 GATE-EXIT,2
4 SPRING-GATE 2 809E50480
5 CHUTE-UPPER,FU
7 COVER GEAR
8 GEAR-52Z
9 GEAR-19Z
10 PLATE-EARTH INV
12 PLATE-EARTH FU
13 ELIMINATOR EXIT
14 ROLL PINCH
15 SPRING-PINCH FUP
16 BEARING
17 BEARING
18 CHUTE LH HIGH
19 ROLL ASSY-FU
20 ROLL ASSY-INV
23 LINK-FU
S
36
39
25
99 24
35 (with 17, 32, 34)
S 25
26 12
32
22 17
34
37 21
18 A
S
23 9 30 20
8 38
33 S 19
15
35
14 3
27 27
S
B
S
31 28
E
29
1
7
13 4 2
12 A
10 C
E
41
5
4 16 C
B
40
42
11
Front ight
R
s5500-528
1 GUIDE-TRAY, 2
2 ELIMINATOR EXIT
3 BEARING
4 BEARING ROLL
5 CHUTE-OCT 2
8 BEARING
9 GEAR-19Z
12 LATCH 003E60171
14 PLATE ASSY-FRONT
15 PLATE-EARTH 2
16 PLATE EARTH 3
20 PLATE ASSY-REAR
22 LINK-SOL FU 012E11680
23 SOLENOID ASSY FU
24 GEAR-20Z
25 SHAFT-GEAR
26 GEAR-19Z/44Z
33 CHUTE LOW
38 SCREW
99 KIT ACTUATOR (with 17, 32, 34) (Exit Sensor Actuator Kit) 604K23310
3 (PL25.4 - PL25.15)
2 (PL25.2, PL25.3)
1
1
Lef
t Front
s5500-529
1 SCREW 026E93560
6 LABEL 893E41630
9 (with 1-8)
4
S 3 S
2
4 S
S 5
S 5
S 5
8
5
7
7 6
7
7 6
6 7 7 6 Lef
t Front
6
6
s5500-530
1 COVER TOP, C
4 BRACKET-MAGNET
5 SPRING-CHUTE
7 SPRING-PINCH 809E55330
8 UPPER CHUTE
1
S
27 (with 2-7, 10-26, 28-30)
14
12
28 13
17
2
E 3
4 5 28
E
29 13 11
30 10 28
S
S
17
16 15 S E
16 E
18
7 10
S
30
S
6
25 Door F
18 Interlock Sensor
23
30 19
S
S
24 Exit
9 21
S 22
8 Sensor
Entrance S 20
26
Sensor
9
Lef
t Front
s5500-531
1 REAR COVER
2 BELT-DRIVE 023E20480
3 PULLEY
4 BEARING
5 BRACKET-DRIVE
6 COVER-MOTOR
10 BEARING
11 BEARING
12 BELT 023E20020
13 ROLL
16 BRACKET-BEARING
17 COVER-BEARING
18 MAGNET 121E92720
20 BRACKET
22 BRACKET
24 BRACKET
25 LOWER CHUTE
26 WIRE HARNESS
29 BUSH SADDLE
30 CLAMP MINI-CLAMP
1
S
3
S
S
11 S
2
S
4
S 5
S S
10
S
S
S
S
S
S
S
S
6
9 S
12
7
12
7
8 Left Front
8
s5500-532
4 COVER EJECT
7 CASTER 017E97220
8 CASTER 017E97230
12 NUT M12X1.25
S
S
S
9 2 4
S S
S
12
E
S
S
S
S
S
S
8 4
11 6
S
Left Front
11
10
s5500-53
5 COVER INNER
6 PLATE DOCKING
7 SPRING 009E94910
11 SCREW 026E93560
12 BRACKET-COVER
1
S
S
S
Stacker Encoder
24 (with 25, 26) 8 (with 9-12)
Sensor S
17
23 3
25 7 2 (with 3-5)
4
S S
6
5 7 3
S
5
S
22 (with 17) S S
S
S S S S
26 S S 6
S
7
Stack Height 5 11 5
Sensor 2 13 7 12
S
21 20
19 18
E 15
13 Stack Height
E Sensor 1
S
27
17 14
Lower Tray
Upper Limit 15
Sensor 16
E
Lower Tray E
No Paper Sensor
16
E
16
E
Left Front
s5500-534
1 CARRIAGE TRAY
4 CARRIAGE ASSY L
6 SPRING 809E56850
7 BEARING CARRIAGE
9 BELT STACKER
11 CARRIAGE ASSY R
12 ACTUATOR
14 SHAFT-ELEV
15 BEARING
16 PULLEY T18
20 SPRING DOC.
21 WASHER
23 ENCODER 146E01770
27 BEARING 10X6
1 (with 2-18) S S
3
18 (with 17)
S S S
Punch Unit
Move Home 17
Sensor 4
S
S
S
S 5
S
2
Punch Hole
S 22
S
Select Sensor 16 S S
S
15
Side Regi
Punch Front 15 15 Sensor 2 6 (with 8)
Sensor T Punch Home
Sensor Side Regi Sensor 1
S
8 7
11 S
S S
S
14 (with 12, 13) 11 9 (with 2, 6, 11-16, 22, 23)
S 11
24 Punch Motor 13S S
S Encoder Sensor 12
S
S S
S 10
23 S
25
19 S
S
S S
S
S S
S
26 20
S S S
S
21
Punch Box
Set Sensor
Left Front
27
s5500-535
5 HOLDER-FRAME ASSY
7 COVER-FRONT, PUNCH
BRACKET ASSY PUNCH 2 & 4-HOLE (with 2, 6, 11~16, 22, 23) 030K76640
10 COVER-LEFT, PUNCH
11 GUIDE ASSY
23 GUIDE BOX
24 BRACKET-OPB PUNCH
25 BRACKET-OPB FRAME F
26 BRACKET
Stapler Only
14 (with 1-10) 7
2
S S
6
1
S
3 S S
S 4 S
S S 5
Staple Move 8
S Position Sensor
S
10 S S
9
S
S
S
S S
S
S
S 12
S S
13
S
11
Left Front
s5500-536
10 RAIL-UPPER 001E66640
1 (with 2) 2
S
6 4 S S
6 S
7 (with 6) S
10 (with 11-13)
3
11
8
S 9
S
S
S
12 20
S 26
19 21
21 25
13 18 21
Eject Clamp S
22 23
S
Home Sensor
E
S
14 S
15 16
17
S
E
E
15 17
24
Left Front
s5500-537
4 BRACKET SOLENOID
5 SPRING-PINCH
6 PADDLE-CYCLONE 033E92850
15 BEARING 413W77559
17 BEARING 413W11660
18 GEAR-CAM Z70
19 GEAR Z23L
20 GEAR Z68L/Z20L
21 CLAMP
22 BRACKET SWITCH
25 EDGE SADDLE
26 CLAMP
Rear Tamper 2
Home Sensor 1 (with 2-8)
2
Front Tamper
Home Sensor
8
3
Compiler Tray
4 No Paper Sensor
S
6
17 (with 18) 7 S
10 S
S 10 10
S
S 18 Set Clamp
Home Sensor 11
11
S 11
16
15 9 (with 10)
12 S
E 19
14 13
12
E
E
13
Left Front
s5500-538
4 ACTUATOR-PAPER
5 --
10 PADDLE-SET CLAMP
11 GUIDE-PADDLE
12 BEARING
13 BEARING
14 GEAR
19 PLATE
1 (with 2, 3)
S
S
2 S
3 4
Compile Exit
Sensor S
6
7 (with 8-13)
8
11 E
S
S 11
10 S 9
S 10
15
9 13
12
14
16 S
S
17
18 E
22
20
19 S
S
9
S
S
E
21 S
9 S
Left Front
s5500-539
4 ELIMINATOR 105E13100
9 BEARING
15 SHAFT-DRIVE PADDLE
16 PULLEY
17 BEARING
19 GEAR Z23L
22 GEAR Z23R
2 3 4
3 2 2
1 (with 2-5) 3 4
3 2
5
34
S 6
S S 30
S 7
S
S 8
33
32
23 28 9
31 29
27
24 8
E S 8
S
S 8
S E
S 26 24
25 S
S
E
S S 12
21 Buffer Path 11 E
S
22 Sensor 9
S S
Transport 10 (with 11, 12)
19
18 Entrance
17 17 Sensor
S
S S 17
S
S
17
13
S 8
16 (with 17-19)
35
S
14 (with 8, 15)
20 15 S
S
15 15 S
15 Left Front
s5500-540
3
S 3
S 3 3
S
1 (with 2, 3) S
2
Upper Tray
Exit Sensor
30 29
S
4
S
S
S
S
30 Upper Tray
5
S S
Full Sensor
28 7
29 22 S 24 23
S
25 26 9
S
E E S
22 24
S 21 20 6
S
S 8
E E S (with 7)
27 S
S
S
9
S
22 21
23 E 20 S E
S 9
19 S
E
S
18
E
S
9
18 11 12 13
12
12 11
11
S 12
13 11
17 10 (with 11-13)
S
S
14 (with 15-17)
16 Left Front
S
15 Gate Sensor
s5500-541
9 BEARING
12 SPRING 1.5N
13 SHAFT
16 HARNESS ASSY-SNR
17 BRACKET-SENSOR
19 PULLEY T53/Z23
20 BEARING
21 PULLEY 020E37690
22 PULLEY 020E37740
23 BRACKET ASSY-TENSION
24 SPRING-TENSION 809E56840
26 GEAR 807E04720
29 BRACKET MOTOR
11 11
11
11 S
S
17 12
14
14 10
12
11 14 14 18
12 12 13 1 17 S 13
12 18 2
13
17
S
S
11 16
3 4
12 16
S 13
S
S S
13 S
1113
S
11 13 13 S
5
S S
S S
S
S
16 6
S
S S
S
S
S
9 8 S 7
Left Front
s5500-542
1 BRACKET HARNESS
6 BRACKET-PWBA MAIN
9 LVPS-C 105K21080
10 EDGE SADDLE
11 CLAMP
12 CLAMP
13 CLAMP
14 EDGE SADDLE
15 -
16 EDGE SADDLE
17 CLAMP
18 CLAMP
Punch Only
8
10
11
Left Front
2
s5500-543
Chapter
5
Phaser 5500 Option Wiring
Symbol Description
Indicates a return.
RTN
Represents a part.
PL X.Y.Z indicates the item Z of the plate (PL) X.Y
described in Chapter 5 Parts List.
101A C-304 Connects the Tray 5 Level Sensor and Tray 5 Harness.
101B C-304 Connects the Tray 4 Level Sensor and Tray 4 Harness.
102A D-305 Connects the Tray 5 No Paper Sensor and Tray 5 Harness.
102B D-305 Connects the Tray 4 No Paper Sensor and Tray 4 Harness.
103A D-306 Connects the Tray 5 Pre Feed Sensor and Tray 5 Harness.
103B D-306 Connects the Tray 4 Pre Feed Sensor and Tray 4 Harness.
202A B-304 Connects the Tray 5 Feed/Lift Motor and Tray 5 Harness.
202B B-304 Connects the Tray 4 Feed/Lift Motor and Tray 4 Harness.
541 F-323 Connects the Tray 4-5 PWB and Tray Module Harness.
548 E-323 Connects the Tray 4-5 PWB and Size Switch Harness.
549A F-324 Connects the Tray 4-5 PWB and Feeder Harness.
549B F-324 Connects the Tray 4-5 PWB and Feeder Harness.
552 F-323 Connects the Tray 4-5 PWB and T/A Harness.
554 F-323 Connects the Tray 4-5 PWB and Interlock Switch Harness.
812 D-308 Connects the Door C Interlock Switch and Interlock Harness.
820 G-307 Connects Tray 5 Paper Size Switch and Size Switch Harness.
821 E-308 Connects Feed Out Sensor #4 and the Sensor Harness.
822 I-322 Connects the Take Away Clutch and Take Away Harness.
824 G-308 Connects Tray 5 Paper Size Switch and Size Switch Harness.
825 E-309 Connects Feed Out Sensor #5 and the Sensor Harness.
826 G-324 Connects the Take Away Motor and Take Away Harness.
841 I-320 Connects the Feed Out Sensor #4 Harness and the Size Switch
Harness.
842 D-308 Connects the Feed Out Sensor #5 Harness and the Size Switch
Harness.
A B C D E F G H I J K L
301
302
Tray 4 : 202B
303 Tray 5 : 202A Tray 4 : 101B
Tray 5 : 101A
304 Tray 4 : 102B
Tray 5 : 102A
305 Tray 4 : 103B
Tray 5 : 103A
306 820
824
812
307
842
308 661B
309 661A
310
821
311
825
312
Tray 4 Feeder Assembly
Tray 5 Feeder Assembly
313
314
315
s5500-544
A B C D E F G H I J K L
316
317
318
554
541 822
319
548 841
320
321
322
323
324
325
326
826
327 549A
552 549B
328
329
330
s5500-545
General Wiring
P/J826
Take Away Motor
P/J554 FS812
Door C Interlock Switch
FS813
Tray 4
P/J101B
Level Sensor
P/J102B
No Paper Sensor
P/J103B
Pre Feed Sensor
P/J548 P/J820
Paper Size Switch
P/J841 P/J821
Feed Out Sensor #4
P/J102A
No Paper Sensor
P/J103A
Pre Feed Sensor
P/J548 P/J824
Paper Size Switch
P/J842 P/J825
Feed Out Sensor #5
s5500-546
+24VDC
P/J522 P822
Take Away Clutch On(L)+24VDC
9 1 2
+24VDC
8 2 1
P/J522 P/J826
+24VDC
7 1
+5VDC RTN
6 2
Take Away Motor On(L)+5VDC
5 3
+5VDC
4 4 M
SG
3 5
Main Motor Clock
2 6
M/C Clock
1 7
Door C
Interlock Switch
P/J554 FS812
Left Cover Open(H)+5VDC
2 1
FS813
SG
1 1
Engine Logic
Board
P/J541 P/J413
Engine To 2TM
1 A1
2TM To Engine
2 A2
Tray 4 Feed/Lift Motor On(H)+5VDC
3 A3
Tray 5 Feed/Lift Motor On(H)+5VDC
4 A4
+5VDC
5 A5
SG
6 A6
+24VDC
7 B1
RTN
8 B2
Feed Ready
9 B3
Tray 4 Feed Out Paper Sensed(L)+5VDC
10 B4
Tray 5 Feed Out Paper Sensed(L)+5VDC
11 B5
Feed Stop
12 B6
s5500-547
+5VDC
P/J549 P661B J661B P/J101B
+5VDC
B7 9 7 3
SG
B8 8 8 2
Tray 4 Level Up(H)+5VDC
B9 7 9 1
Level Sensor
+5VDC
P/J549 P661B J661B P/J102B
+5VDC
B10 6 10 3
SG
B11 5 11 2
Tray 4 Paper Sensed(L)+5VDC
B12 4 12 1
No Paper Sensor
+5VDC
P/J549 P661B J661B P/J103B
+5VDC
B15 1 15 1
Tray 4 Pre Feed Sensed(L)+5VDC
B14 2 14 2
SG
B13 3 13 3
+3.3VDC
P/J548 P/J820
+3.3VDC
14 1
Tray 4 Size Switch Signal
13 2
SG
12 3
Tray 4 Size Switch S5 On(L)+5VDC
11 4
+5VDC
J548 P841 J841 J821
+5VDC
8 3 1 3
SG
9 2 2 2
Tray 4 Feed Out Paper Sensed(L)+5VDC
10 1 3 1
s5500-548
+5VDC
P/J549 P661A J661A P/J101A
+5VDC
A7 9 7 3
SG
A8 8 8 2
Tray 5 Level Up(H)+5VDC
A9 7 9 1
Level Sensor
+5VDC
P/J549 P661A J661A P/J102A
+5VDC
A10 6 10 3
SG
A11 5 11 2
Tray 5 Paper Sensed(L)+5VDC
A12 4 12 1
No Paper Sensor
+5VDC
P/J549 P661A J661A P/J103A
+5VDC
A15 1 15 1
Tray 5 Pre Feed Sensed(L)+5VDC
A14 2 14 2
SG
A13 3 13 3
+3.3VDC
P/J548 P/J824
+3.3VDC
7 1
Tray 5 Size Switch Signal
6 2
SG
5 3
Tray 5 Size Switch S5 On(L)+5VDC
4 4
+5VDC
J548 P842 J842 J825
+5VDC
1 3 1 3
SG
2 2 2 2
Take Away Sensor Sensed(L)+5VDC
3 1 3 1
124 B-606 Connects the Door D Interlock Switch and Sensor Harness.
212 C-608 Connects the Duplex Motor and Duplex Motor Harness.
541 H-609 Connects the Duplex PWB and Duplex Sensor Harness.
542 H-609 Connects the Duplex PWB and Duplex Motor Harness.
A B C D E F G H I J K L
601
602
603
604
607
608
609 212
610
541
611
542
612
613
614
615
s5500-605
Wait Sensor
P/J417 P/J540 P/J541 P/J123
Duplex Motor
P/J542 P/J212
s5500-582
Duplex PWB
+5VDC
P/J541 P/J123
+5VDC
1 3
SG
2 2
Duplex Sensor Paper Sensed(L)+5VDC
3 1
Wait Sensor
Door D
Interlock Switch
P/J541 J124
SG
4 2
Duplex Open(H)+5VDC
5 1
+24VDC
Duplex Motor
Engine
Logic Board
P/J540 P/J417
+5VDC
1 A1
+24VDC
2 B1
SG
3 A2
RTN
4 B2
Engine To Duplex
5 A3
Duplex To Engine
6 B3
Registration Sensor Paper Sensed(H)+5VDC
7 A4
Registration Clutch On(L)+5VDC
8 B4
s5500-550
111 D-707 Connects the OCT Home 2 Sensor and Exit 2 Harness.
113 F-707 Connects the Full Stack Sensor and Exit 2 Harness.
116 C-706 Connects the Door E Interlock Switch and Exit 2 Harness.
208 B-707 Connects The Exit Drive Motor and Exit 2 Harness.
209 D-708 Connects the Exit Gate Solenoid and Exit 2 Harness.
210 C-708 Connects Face Up Solenoid and Exit 2 Harness. (Not used).
A B C D E F G H I J K L
701
702
703
704
116
705 220 113
111
706
112
707
708
709 208
207
710 210
209
711
712
713
714
715
s5500-551
General Wiring
Exit PWB 1
Motor / Solenoid
Offset Motor
P/J433 P/J606A P/J207
Exit Motor
P/J208
Exit Fan
P/J220
s5500-552
Exit PWB
+24VDC
Offset Motor
Exit Motor
Face Up Solenoid
s5500-553
Exit PWB
+5VDC
P/J434 J606B P606B P/J111
+5VDC
1 16 1 3
OCT 2 Home Sensed(L)+5VDC
2 15 2 1
2
Exit Offset 2
Home Position Sensor
Door E
Interlock Switch
J116
P/J434 J606B P606B 2
Exit 2 Interlock Open(H)+5VDC
13 4 13 1
Exit Fan
P/J434 J606B P606B P220
Exit Fan On(H) +5VDC
14 3 14 4 1
SG M
15 2 15 1 4
2 3
s5500-554
54 E-505 Connects the Feed Out Sensor #6 Harness and Sensor Harness.
57 E-524 Connects the Take Away Motor and Tray 6 Feeder 1 Harness.
67 H-506 Connects the Feed Out Sensor #6 and Feed Out Sensor
Harness.
FS001 E-505 Connects the Door J Interlock Switch and Interlock Harness.
FS002 E-505 Connects the Door J Interlock Switch and Interlock Harness.
FS003 E-507 Connects Docking Interlock Switch and Docking Switch Harness.
FS004 E-507 Connects Docking Interlock Switch and Docking Switch Harness.
Tray 6 Feeder
A B C D E F G H I J K L
501
502
503
54 FS001
504
59 FS002
58 67
61
505
506
507
508
509
510
511 56
FS003
FS004 60
512 62
513
514
515
s5500-556
A B C D E F G H I J K L
516
517
518
519
520
521
52
51
522
8
523 1
2
524
525
3
526 4
5
527
53
6
57
528
529
530
s5500-557
General Wiring
1 Engine 2
Logic
Board P/J415 Paper Size Sensor B
PF55B J800 P/JF03 P/JF01 P/JF51
Level Sensor
P/JF62
Nudger Solenoid
P/JF06 P/JF56 P/JF59
Feed/Lift Motor
P/JF58
s5500-558
P/JF08 FS004
Docking Switch Close(L)+5VDC
2
FS003
SG
1
s5500-559
Tray 6 PWB
+5VDC
P/JF01 PF51 JF51
+5VDC
12 1 3
Tray 6 Size Sensor L Sensed(L)+5VDC
11 2 2
SG
10 3 1
+5VDC
P/JF01 PF52 JF52
+5VDC
9 1 3
Tray 6 Size Sensor R Sensed(L)+5VDC
8 2 2
SG
7 3 1
+5VDC
P/JF01 PF53 JF53
+5VDC
6 1 3
Tray 6 Tray Set(L)+5VDC
5 2 2
SG
4 3 1
Tray In Sensor
+5VDC
P/JF01 PF54 JF54 P/JF67
+5VDC
3 1 3 1
Tray 6 TA Sensor Paper Sensed(H)+5VDC
2 2 2 2
SG
1 3 1 3
s5500-560
Interlock
+24VDC
P/JF06 PF56A JF56A PF59
I/L +24VDC
13 6 1 2 1
Tray 6 Nudger Solenoid(L)+24VDC
14 5 2 1 2
Nudger Solenoid
+5VDC
P/JF02 PF56B JF56B P/JF62
+5VDC
3 1 6 1
Tray 6 Lift Up(H)+5VDC
2 2 5 2
SG
1 3 4 3
Level Sensor
+5VDC
P/JF02 PF56B JF56B P/JF61
+5VDC
6 4 3 1
Tray 6 Feed Paper Sensed(L)+5VDC
5 5 2 2
SG
4 6 1 3
+5VDC
P/JF02 PF56A JF56A P/JF60
+5VDC
9 1 6 1
Tray 6 Paper Sensed(L)+5VDC
8 2 5 2
SG
7 3 4 3
No Paper Sensor
s550-561
8300 G-894 Connects the Finisher Main PWB and I/F Harness.
8302 E-895 Connects the Finisher Main PWB and Main Sensor Harness.
8304 E-892 Connects the Finisher Main PWB and Main Drive Harness.
8305 E-894 Connects the Finisher Main PWB and Elevator Motor.
8306 G-892 Connects the Finisher Main PWB and Punch Drive Harness.
8307 G-893 Connects the Finisher Main PWB and Punch Sensor Harness
8308 F-892 Connects the Finisher Main PWB and Staple Harness.
8309 E-894 Connects the Finisher Main PWB and Compiler Harness.
8310 G-895 Connects the Finisher Main PWB and Horizontal Transport
Harness.
8314 F-896 Connects the Finisher Main PWB and Interlock Harness.
8315 E-896 Connects the Finisher Main PWB and LVPS Harness.
8320 F-853 Connects the Compile Exit Sensor and Compile Sensor Harness
8321 F-881 Connects the Upper Tray Exit Sensor and Upper Tray Exit Sensor
Harness.
8322 F-881 Connects the Upper Tray Full Sensor and Upper Tray Full Sensor
Harness.
8324 E-852 Connects the Eject Clamp Home Sensor and Main Sensor
Harness.
8325 E-868 Connects the Set Clamp Home Sensor and Main Sensor Harness.
8326 E-821 Connects the Stacker No Paper Sensor and Main Sensor Harness.
8327 E-821 Connects the Upper Limit Sensor and Main Sensor Harness.
8328 D-821 Connects the Stack Encoder Sensor and Main Sensor Harness.
8330 J-821 Connects the Stack Height Sensor 2 and Main Sensor Harness.
8331 E-819 Connects the Stack Height Sensor 1 and Main Sensor Harness.
8334 C-880 Connects the Exit Motor and Main Drive Harness.
8335 D-881 Connects the Registration Motor and Main Drive Harness.
8336 D-866 Connects the Eject Motor and Main Drive Harness.
8338 E-868 Connects the Set Clamp Clutch (Z34) and Main Drive Harness.
8339 C-851 Connects the Eject Clamp Motor and Main Drive Harness.
8340 H-852 Connects the Sub Paddle Solenoid and Main Drive Harness.
8341 C-853 Connects the Transfer Gate Solenoid and Main Drive Harness.
8342 B-884 Connects the Transport Motor and Main Drive Harness.
8344 E-835 Connects the Punch Move Motor and Punch Drive Harness.
8345 C-837 Connects the Punch Motor and Punch Unit Harness.
8346 C-836 Connects the Punch Hole Select Sensor and Punch Unit Harness.
8347 C-836 Connects the Punch Front Sensor and Punch Unit Harness.
8348 C-836 Connects the Punch Home Sensor and Punch Unit Harness.
8349 C-837 Connects the Punch Motor Sensor and Punch Unit Harness.
8350 G-837 Connects the Side Regi Sensor 1 and Punch Unit Harness.
8351 G-837 Connects the Side Regi Sensor 2 and Punch Unit Harness.
8352 C-836 Connects the Punch Move Home Sensor and Punch Sensor
Harness.
8353 C-838 Connects the Punch Box Set Sensor and Punch Box Set Sensor
Harness.
8354 E-826 Connects the Staple Move Position Sensor and Staple Harness.
8358 F-826 Connects the Stapler Move Motor and Staple Harness.
8359 G-869 Connects the Compiler Tray No Paper Sensor and Compiler
Harness.
8360 I-869 Connects the Front Tamper Home Sensor and Compiler Harness.
8361 E-868 Connects the Rear Tamper Home Sensor and Compiler Harness.
8362 F-868 Connects the Rear Tamper Motor and Compiler Harness.
8363 G-869 Connects the Front Tamper Motor and Compiler Harness.
8364 H-852 Connects the Door H Interlock Switch and Interlock Harness.
8365 F-822 Connects the Door G Interlock Switch and Interlock Harness.
8371 I-898 Connects the Horizontal Transport PWB and Horizontal Transport
Harness.
8372 I-898 Connects the Horizontal Transport PWB and Horizontal Transport
1 Harness.
8376 E-895 Connects the Finisher Main PWB and Gate Sensor 1 Harness.
8379 I-807 Connects the Horizontal Transport Entrance Sensor and Horizontal
Transport Harness.
8380 C-807 Connects the Horizontal Transport Motor and Horizontal Transport
Harness.
8381 J-809 Connects the Horizontal Transport Exit Sensor and Horizontal
Transport Harness.
8382 G-810 Connects the Door F Interlock Sensor and Horizontal Transport
Harness.
8392 F-882 Connects the Buffer Path Sensor and Buffer Path Sensor Harness.
8394 B-853 Connects the Buffer Gate Solenoid and Main Drive Harness.
8394 J-898 Connects the Horizontal Transport PWB and Horizontal Transport.
8432 E-882 Connects the Gate Sensor and Gate Sensor Harness.
Horizontal Transport
A B C D E F G H I J K L
801
802
803
804
805
8380 8379
806
807
808
809
8381
810
811 8382
812
813
814
815
s5500-562
A B C D E F G H I J K L
816
817
8331
818
819 8328
820
8327 8330
821
8326
822
8365
823
824
8356
825 8357
826
827
828
8354
8358
829
830
s5500-563
A B C D E F G H I J K L
831
832
8344
833
8352
834 8348
835
836
8351
837
8346
8347
8350
838 8349
839
8345
840
8353
841
842
843
844
845
s5500-564
A B C D E F G H I J K L
846
847
848
8324
8320
849 8340
8364
8339
850
851
852
853
854
855
856
8394 8341
857
858
859
860
s5500-565
A B C D E F G H I J K L
861
862
863
8361
864
8359
8336 8360
865 8325
866
867
868
869
870
871
8338 8362 8363
872
873
874
875
s5500-566
A B C D E F G H I J K L
876
877
878
8392 8321
8322
8432
879
880
881 8334
882
8335
883
884
885
886
8342 8319
887
888
889
890
s5500-567
A B C D E F G H I J K L
891
8304 8308 8389
892 8306
8307
893
8309
8300
894 8305
8301
8376
895
8310
8302
896 8316
8311
8500
897
8317 8315 8313 8314
8372
898
8394
899
8373
900
8371
901
502
902
505
903
904
2
905
s5500-568
H-X'port
P/J8314 Entrance PWB
P/J8380
Horizontal Transport
Door G Sensor
P/J8365 P/J8388
Interlock Switch
P/J8314 H-X'port
Door H P/J8364 P/J8388
Exit Sensor P/J8381
Interlock Switch
Punch 2
Sensor P/J8307 P/J8333 P/J8346 Punch Hole Sensor
Sensor 1
Punch 1
Set Clamp Home P/J8325
Sensor P/J8351 Side Registration
Sensor 2
Eject Clamp P/J8324
Sensor P/J8352 Punch Move Home
Sensor
Stack Height P/J8331
Sensor 1 P/J8353 Punch Box Set Sensor
P/J8355
Stapler
Staple Home Sensor
Ccompiler Tray
P/J8361 Rear Tamper Home Sensor
Buffer Gate P/J8394
Solenoid
P/J8360 Front Tamper Home Sensor
Elevator Motor P/J8305
15 15
Docking Sensor
16 16
IOT Full Sensor
17 17
HTRA ENT Sensor
18 18
HTRA Exit Sensor
19 19
HTRA I/L Sensor
20 20
Reserve
21 21
HTRA MOT Enable
22 22
IF MOT Brake
23 23
Gate SOL Push
24 24
Gate SOL Pull
25 25
RS232C Select
26 26
FIN To H-TRA
27 27
H-TRA To FIN
28 28
SG
29 29
+24VDC
30 30
s5500-571
Horizontal
Transport PWB
Interlock
+24VDC P/J8372 P/J8390 J8379B H-X'port Motor
H-X'port Motor /B
13 1 6 1
I/L +24VDC
3 10 5 2
H-X'port Motor B
12 2 4 3
H-X'port Motor A M
10 4 3 4
I/L +24VDC
15 9 2 5
H-X'port Motor /A
11 3 1 6
+5VDC
P/J8372 P/J8390 P/J8380
+5VDC
9 12 1
Entrance Sensor Paper Sensed(L)+5VDC
8 13 2
SG
7 5 3
+5VDC
P/J8372 P/J8390 P/J8381
+5VDC
6 6 1
Exit Sensor Paper Sensed(L)+5VDC
5 14 2
SG
4 15 3
+5VDC
P/J8372 P/J8390 P/J8382
+5VDC
3 7 1
H-X'port Cover Closed(L)+5VDC
2 8 2
SG
1 16 3
s5500-572
Finisher
Main PWB
+5VDC
P/J8302A J8318A J8318B P/J8392
+5VDC
15 1 3 1
Buffer Path Paper Sensed(L)+5VDC
14 2 2 2
SG
13 3 1 3
+5VDC
P/J8302A J8393A J8393B P/J8322
+5VDC
12 1 3 1
Upper Tray Full Sensed(L)+5VDC
11 2 2 2
SG
10 3 1 3
Upper Tray Full Sensor
+5VDC
P/J8302A J8312A J8312B P/J8321
+5VDC
9 1 3 1
Upper Tray Exit Paper Sensed(L)+5VDC
8 2 2 2
SG
7 3 1 3
+5VDC
P/J8302A J8391A J8391B P/J8320
+5VDC
6 1 3 1
Compile Exit Paper Sensed(L)+5VDC
5 2 2 2
SG
4 3 1 3
Compile Exit Sensor
+5VDC
P/J8302A J8303A J8303B P/J8319
+5VDC
3 1 3 1
Transport Paper Sensed(L)+5VDC
2 2 2 2
SG
1 3 1 3
Transport Entrance
Sensor
+5VDC
P/J8376 J8434A J8434B P/J8432
+5VDC
3 1 3 1
Gate Paper Sensed(H)+5VDC
2 2 2 2
SG
1 3 1 3
Gate Sensor
s5500-573
Finisher
Main PWB
+5VDC
P/J8302B J8441A J8441B P/J8327
+5VDC
20 6 6 1
Upper Limit Sensed(L)+5VDC
19 5 5 2
SG
18 4 4 3
Lower Tray
Upper Limit Sensor
+5VDC
P/J8302B J8441A J8441B P/J8326
+5VDC
17 3 3 1
Stacker Paper Sensed(L)+5VDC
16 2 2 2
SG
15 1 1 3
Lower Tray
No Paper Sensor
+5VDC
P/J8302B P/J8328
+5VDC
14 1 Stacker Encoder
Stacker Encoder Sensor Sensed(L)+5VDC
13 2 Sensor
SG
12 3
+5VDC
P/J8302B P/J8325
+5VDC
11 1 Set Clamp Home
Set Clamp Home Sensed(L)+5VDC
9 2 Sensor
SG
4 3
+5VDC
P/J8302B P/J8324
+5VDC
8 1 Eject Clamp Home
Eject Clamp Up(L)+5VDC
7 2 Sensor
SG
6 3
P/J8302B P/J8331
Stack Height Sensor 2 Clock
+5VDC 5 1
Stack Height Sensor 1 Clock
4 2
+5VDC
3 3
Stack Height Sensor 1 Sensed(L)+5VDC
2 4
SG
1 5
Stack Height Sensor 1
s5500-574
Finisher
Main PWB Exit Motor
Interlock
+24VDC P/J8304 P/J8334
Exit Motor A
2 1
I/L +24VDC
4 2
Exit Motor /A
1 3
Exit Motor B M
3 4
I/L +24VDC
6 5
Exit Motor /B
5 6
Registration Motor
Interlock
+24VDC P/J8304 P/J8335
Registration Motor A
7 1
I/L +24VDC
8 2
Registration Motor /A
9 3
Registration Motor B M
11 4
I/L +24VDC
10 5
Registration Motor /B
13 6
Eject Motor
Interlock
+24VDC P/J8304 P/J8336
Eject Motor A
15 1
I/L +24VDC
12 2
Eject Motor /A
17 3
Eject Motor B M
19 4
I/L +24VDC
14 5
Eject Motor /B
21 6
Transport Motor
Interlock
+24VDC P/J8304 P/J8342
Transport Motor A
23 1
I/L +24VDC
16 2
Transport Motor /A
25 3
Transport Motor B M
27 4
I/L +24VDC
18 5
Transport Motor /B
29 6
s5500-575
Interlock
+24VDC P/J8304 J8338B
Set Clamp Clutch On(L)+24VDC
20 1 2
I/L +24VDC
22 2 1
Clutch Z34
Interlock
+24VDC P/J8304 P/J8340
Sub Paddle Solenoid On(L)+24VDC
24 2
I/L +24VDC
26 1
Interlock
+24VDC P/J8304 P/J8341
Transport Gate Solenoid Push(L)+24VDC
30 1
I/L +24VDC
28 2
Transport Gate Solenoid Pull(L)+24VDC
32 3
Transfer Gate
Solenoid
Interlock
+24VDC P/J8304 P/J8394
Buffer Gate Solenoid Push(L)+24VDC
35 1
I/L +24VDC
34 2
Buffer Gate Solenoid Pull(L)+24VDC
36 3
Buffer Gate Solenoid
Elevator Motor
P/J8305
Elevator Motor Down(H)+24VDC
1
Elevator Motor Up(H)+24VDC M
2
s5500-576
+5VDC
P/J8309 J8461B J8461A P/J8361
+5VDC
9 11 7 1
Rear Tamper Home Sensed(L)+5VDC
8 12 8 2
SG
7 13 9 3
+5VDC
P/J8309 J8461B J8461A P/J8360
+5VDC
6 14 6 1
Front Tamper Home Sensed(L)+5VDC
5 15 5 2
SG
4 16 4 3
+5VDC
P/J8309 J8461B J8461A P/J8359
+5VDC
3 17 3 1
Compiler Tray Paper Sensed(L)+5VDC
2 18 2 2
SG
1 19 1 3
s5500-577
Finisher
Main PWB
+5VDC
P/J8308 P/J8354
+5VDC
18 1
Stapler Home Position Sensed(L)+5VDC
17 2
SG
16 3
Stapler Move Position Sensor
Stapler Assembly
Staple Head
Move Motor
Interlock
+24VDC P/J8308 P/J8358
Staple Move Motor /A
3 1
I/L +24VDC
6 2
Staple Move Motor A
5 3
Staple Move Motor B M
1 4
I/L +24VDC
4 5
Staple Move Motor /B
2 6
s5500-5
Finisher
Main PWB
+5VDC
P/J8307 P/J8355 P/J8353
+5VDC
A1 1 1
Punch Box Set(L)+5VDC
A2 2 2
SG
A3 3 3
Punch Box Set
Sensor
+5VDC
P/J8307 P/J8352
+5VDC
A4 1
Punch Unit Home Sensed(L)+5VDC
A5 2
SG
A6 3
Punch Unit Move
Home Sensor
+5VDC
P/J8307 P/J8333 P/J8351
+5VDC
A7 18 1
Side Registration Sensor 2 Sensed(L)+5VDC
A8 17 2
SG
A9 16 3
Side Registration
Sensor 2
+5VDC
P/J8307 P/J8333 P/J8350
+5VDC
A10 15 1
Side Registration Sensor 1 Sensed(L)+5VDC
A11 14 2
SG
A12 13 3
Side Registration
Sensor 1
+5VDC
P/J8307 P/J8333 P/J8349
+5VDC
B1 12 1
Punch Motor Encoder Sensor Sensed(L)+5VDC
B2 11 2
SG
B3 10 3
Punch Motor
Encoder Sensor
s5500-579
Finisher
Main PWB Punch Unit Motor
Interlock
+24VDC P/J8306 P/J8344
Punch Move Motor A
7 1
I/L +24VDC
3 2
Punch Move Motor /A
6 3
Punch Move Motor B M
5 4
I/L +24VDC
2 5
Punch Move Motor /B
1 6
Punch Motor
+5VDC
P/J8307 P/J8333 P/J8346
Anode
B12 1 3
Punch Hole Sel Sensor Sensed(L)+5VDC
B11 2 2
SG
B10 3 1
Punch Hole Select Sensor
+5VDC
P/J8307 P/J8333 P/J8347
Anode
B9 4 3
Punch Front Sensor Sensed(L)+5VDC
B8 5 2
SG
B7 6 1
Punch Front Sensor
+5VDC
P/J8307 P/J8333 P/J8348
Anode
B6 7 3
Punch Home Sensor Sensed(L)+5VDC
B5 8 2
SG
B4 9 1
Punch Home Sensor
s5500-580
Index Index-1
2000-Sheet Feeder (cont.) B
No Paper Sensor, 2-45
Buffer Gate, 2-22
part number, 4-27
location, 2-22
removal, 3-54
part number, 4-67
wiring, 5-25
removal, 3-206
Nudger Solenoid, 2-42
Buffer Gate Solenoid, 2-22
removal, 3-50
connector designator, 5-28
wiring, 5-25
part number, 4-67
option part number, 1-9
removal, 3-225
paper lift operation, 2-46
wiring diagram, 5-43
paper size sensing, 2-45
Buffer Path, 2-19
Paper Size Sensor, 2-47 operational description, 2-22
part number, 4-19 Buffer Roller, 2-22
removal, 3-42 function, 2-22
wiring, 5-24 location, 2-22
Pre-Feed Sensor, 2-45 part number, 4-67
part number, 4-27 removal, 3-208
removal, 3-51
wiring, 5-25
Pulley, 2-46
C
part number, 4-23 clearances, 1-10
removal, 3-45 Compiler Tray, 2-19
PWB, 2-43 Compile Exit Sensor, 2-25
part number, 4-33 connector designator, 5-26
removal, 3-67 function, 2-31
replacement rollers, 4-27 location, 2-22
Take Away Motor, 2-42 wiring, 5-40
part number, 4-31 components, 2-28
removal, 3-64 Front Tamper Home Sensor, 2-32
wiring, 5-25 connector designator, 5-28
Take Away Roller removal, 3-180
part number, 4-31 limitations, 2-28
removal, 3-65 location, 2-22
tray components, 2-46 No Paper Sensor, 2-25
Tray In Sensor, 2-50 connector designator, 5-28
part number, 4-19 function, 2-32
removal, 3-41 removal, 3-182
tray removal, 3-39 operational description, 2-23
Wire Guide part number, 4-63
part number, 4-23 Rear Tamper Home Sensor, 2-32
removal, 3-45 connector designator, 5-28
removal, 3-180
removal, 3-177
sensors, 2-32
tamping, 2-29
tamping motors, 2-32
wiring diagram, 5-44
Index-2 Phaser 5500 Printer Options Service Manual
Configuration Card, 1-4 Door H Interlock, 2-40
consumables, 1-8 connector designator, 5-28
part numbers, 1-8 location, 2-41
Staple Pack, 1-8 part number, 4-61
Toner Cartridge, 1-8 removal, 3-176
Cyclone Paddles wiring diagram, 5-38
part number, 4-61 Door J Interlock, 2-50
removal, 3-168 connector designator, 5-19
location, 2-44
part number, 4-31
D removal, 3-62
Docking Interlock, 2-50 wiring diagram, 5-23
connector designator, 5-19 Drum Cartridge, 1-8
location, 2-44 location, 1-8
part number, 4-31 part number, 1-8
removal, 3-66 Duplex Unit, 1-5, 4-35
wiring diagram, 5-23 dimensions, 1-10
Door C Interlock, 2-16 Duplex Motor, 2-9
connector designator, 5-4 connector designator, 5-11
location, 2-16 drive train, 2-9
part number, 4-15 part number, 4-35
removal, 3-28 removal, 3-76
wiring diagram, 5-8 latch removal, 3-72
Door D Interlock, 2-8 operational description, 2-7
connector designator, 5-11 option part number, 1-9
part number, 4-35 PWB, 2-8
removal, 3-74 connector designators, 5-11
wiring diagram, 5-13 location, 2-8
Door E Interlock, 2-5 part number, 4-35
connector designator, 5-14 removal, 3-77
location, 2-5 removal, 3-68
part number, 4-41 replacement part number, 4-35
removal, 3-95 roller locations, 2-8
wiring diagram, 5-18 Wait Sensor, 2-8
Door F Interlock, 2-40 removal, 3-78
connector designator, 5-28 wiring diagram, 5-13
location, 2-41
part number, 4-49
removal, 3-116 E
wiring diagram, 5-39 Eject Chute, 2-23
Door G Interlock, 2-40 Door H Interlock, 3-163
connector designator, 5-28 removal, 3-163
location, 2-41 Eject Clamp, 2-23
part number, 4-53 component locations, 2-38
removal, 3-127
wiring diagram, 5-38
Index Index-3
Eject Clamp (cont.) Exit 2 (cont.)
Eject Clamp Home Sensor Fan, 2-6
part number, 4-61 part number, 4-42
removal, 3-175 removal, 3-93
location, 2-23 wiring, 5-18
operational description, 2-23 Full Stack Sensor, 2-5
Eject Clamp Motor, 2-39 part number, 4-42
connector designator, 5-27 removal, 3-105
part number, 4-61 wiring, 5-18
removal, 3-174 Interlock Switch, 2-5
Elevator Motor, 2-37 part number, 4-41
Belt part number, 4-55 removal, 3-95
part number, 4-55 Invert Roller, 2-4
removal, 3-144 removal, 3-83
Envelope Tray, 1-7 OCT Home Position Sensor, 2-5
dimensions, 1-10 part number, 4-42
option part number, 1-9 removal, 3-103
supported envelopes, 1-11 OCT Roller, 2-4
Exit 1, 2-3 part number, 4-41
Exit Gate, 2-4 removal, 3-90
Exit 2, 1-4 Offset Gear, 2-6
components, 2-4 part number, 4-41
dimensions, 1-10 removal, 3-89
Exit Gate Solenoid, 2-4 Offset Motor, 2-6
connector designator, 5-14 connector designator, 5-14
part number, 4-42 drive train, 2-6
removal, 3-98 location, 2-5
wiring, 5-17 part number, 4-42
Exit Motor, 2-6 removal, 3-100
connector designator, 5-14 wiring, 5-17
drive train, 2-6 operational description, 2-4
part number, 4-42 Pinch Roller, 2-4
removal, 3-104 part number, 4-41
wiring, 5-17 removal, 3-91
Exit Roller, 2-4 removal, 3-79
Exit Sensor, 2-5 roller location, 2-2
Actuator Kit, 4-42 sensors, 2-5
part number, 4-42 Exit Gate Solenoid
removal, 3-102 connector designator, 5-14
wiring, 5-18 part number, 4-42
Face-up Roller, 2-4 removal, 3-98
removal, 3-80 wiring diagram, 5-17
Face-up Solenoid, 2-4 Exit PWB, 2-6
connector designator, 5-14 location, 2-5
removal, 3-96
wiring diagram, 5-17
Index Index-5
Finisher (cont.) Finisher (cont.)
Paddle Shaft, 2-23 Stacker Lower Tray, 2-37
Belt part number, 4-65 part number, 4-51
Belt removal, 3-200 removal, 3-132
part number, 4-65 Stacker Upper Tray, 2-36
removal, 3-200 part number, 4-51
paper path, 2-3 removal, 3-130
Punch, 2-25 stacking, 2-22
part number, 4-57 Stapler, 2-33
removal, 3-145 part number, 4-59
wiring, 5-46 removal, 3-155
Punch Box Set Sensor Sub Paddle Solenoid, 2-23
part number, 4-57 connector designator, 5-27
removal, 3-154 part number, 4-61
Punch Motor wiring, 5-43
connector designator, 5-27 Transfer Gate, 2-19
part number, 4-57 part number, 4-67
removal, 3-149 Transfer Gate Solenoid, 2-19
Punch Move Motor connector designator, 5-27
part number, 4-57 part number, 4-67
Punch Move motor removal, 3-223
connector designator, 5-27 Transport Entrance Sensor, 2-24
Punch operation, 2-21 connector designator, 5-26
Punch Waste Box function, 2-19
part number, 4-57 part number, 4-67
Registration Motor removal, 3-217
Belt part number, 4-69 Transport Motor, 2-19
connector designator, 5-27 Belt part number, 4-67
location, 2-40 connector designator, 5-27
part number, 4-69 location, 2-40
removal, 3-245 part number, 4-67
Set Clamp Clutch removal, 3-222
connector designator, 5-27 Full Stack Sensor, 2-5
part number, 4-63 Fuser, 1-8
removal, 3-186 location, 1-8
Set Clamp Home Sensor, 2-39
part number, 4-63
removal, 3-188 G
Stack Height Sensors, 2-39 Gate Sensor, 2-24
part number, 4-55 connector designator, 5-28
removal, 3-140 function, 2-20
Stacker Belt part number, 4-69
part number, 4-55 removal, 3-236
removal, 3-136 wiring diagram, 5-40
Index Index-7
Exit Motor N
Belt part number, 4-69
networking
connector, 5-27
option, 1-4
location, 2-40
Nudger Roller, 2-2
part number, 4-69
part number, 4-12
removal, 3-243
removal, 3-20
Punch Motor
Nudger Solenoid
connector, 5-27
connector designator, 5-19
part number, 4-57
wiring, 5-25
removal, 3-149
NVRAM
wiring, 5-47
option part number, 1-9
Punch Move Motor options, 1-4
connector, 5-27
part number, 4-57
removal, 3-147 O
wiring, 5-47 Offset Motor
Registration Motor connector designator, 5-14
Belt part number, 4-69 location, 2-5
connector, 5-27 part number, 4-42
part number, 4-69 wiring diagram, 5-17
removal, 3-245 options, 1-4
Transport Motor 1000-Sheet Feeder, 1-5
Belt part number, 4-67 2000-Sheet Feeder, 1-7
connector, 5-27 Duplex Unit, 1-5
location, 2-40 Envelope Tray, 1-7
part number, 4-67 Exit 2, 1-4
removal, 3-222 Hard Drive, 1-4
Finisher motor locations, 2-40 memory, 1-4
Horizontal Transport Motor networking, 1-4
part number, 4-49 part numbers, 1-9
removal, 3-113 Stacker/Finisher, 1-6
Tray 4-5
Take Away Motor, 2-17
part number, 4-17 P
wiring, 5-8 paper
Tray 6 specifications, 1-11
Feed/lift Motor stacking mixed sizes, 2-38
location, 2-42 Paper Size Sensor
part number, 4-25 connector designators, 5-19
removal, 3-49 wiring diagram, 5-24
timing, 2-43 Paper Size Switch
Take Away Motor location, 2-14
location, 2-42, 2-43 part number, 4-7
part number, 4-31 removal, 3-10
removal, 3-64 Pinch Roller, 2-2
Index Index-9
Sensor (cont.) Set Clamp Clutch, 2-39
Horizontal Transport, 2-19 connector designator, 5-27
Door F Interlock Sensor, 2-40 part number, 4-63
Entrance Sensor, 2-24 removal, 3-186
Exit Sensor, 2-24 specifications
Punch, 2-27 clearances, 1-10
Motor Encoder Sensor, 2-27 environmental, 1-10
Punch Box Set Sensor, 2-27 noise, 1-10
Punch Front Sensor, 2-27 paper, 1-11
Punch Hole Select Sensor, 2-27 tray capacities, 1-11
Punch Move Home Sensor, 2-25 Stacker, 1-6
Punch Unit Home Sensor, 2-27 Belt
Side Registration Sensor 1, 2-25 part number, 4-55
Side Registration Sensor 2, 2-25 removal, 3-136
Stacker Lower Tray, 2-39 components, 2-38
No Paper Sensor, 2-37 dimensions, 1-10
Set Clamp Home Sensor, 2-39 Elevator Motor, 2-37
Stack Height Sensor 1, 2-37 job offset, 2-31
Stack Height Sensor 2, 2-37 mixed stacking, 2-38
Stacker Encoder Sensor, 2-37 operational description, 2-18
Upper Limit Sensor, 2-37 option part number, 1-9
Stacker Upper Tray, 2-36 Stacker Lower Tray, 2-22
Exit Sensor, 2-25 maximum capacity, 2-37
Stack Full Sensor, 2-25 mixed stacking, 2-38
Staple Head No Paper Sensor, 2-39
sensor locations, 2-34 function, 2-37
Stapler, 2-35 location, 2-38
Low Staple Sensor, 2-34 part number, 4-55
Move Position Sensor, 2-33 operational description, 2-37
Self Priming Sensor, 2-33 part number, 4-51
Staple Head Home Sensor, 2-33 removal, 3-132
Tray 4-5, 2-15 sensor locations, 2-38
Door C Interlock Switch, 2-16 Stack Height Sensor
Level Sensor, 2-15 function, 2-39
No Paper Sensor, 2-15 location, 2-38
Paper Size Switch, 2-14 part number, 4-55
Pre-Feed Sensor, 2-15 Stacker Encoder Sensor, 2-39
Tray 6 part number, 4-55
Docking Interlock Switch, 2-44 Upper Limit Sensor, 2-39
Door J Interlock Switch, 2-44 function, 2-37
Level Sensor, 2-45 location, 2-38
No Paper Sensor, 2-45 part number, 4-55
Paper Size Sensors, 2-45
Pre-Feed Sensor, 2-43
Tray In Sensor, 2-50
Index Index-11
Tray (cont.) Tray 4-5 (cont.)
Stacker Lower Tray PWB, 2-16
part number, 4-51 location, 2-16
removal, 3-132 part number, 4-17
Stack Height Sensors, 2-37 removal, 3-29
Stacker Upper Tray, 2-36 Take Away Clutch, 2-16
part number, 4-51 connector designator, 5-4
removal, 3-130 part number, 4-17
Standard Output Tray, 1-2 removal, 3-30
universal, 2-12 wiring, 5-8
Tray 4-5, 1-5 Take Away Motor, 2-17
Door C Interlock Switch connector designator, 5-4
connector designator, 5-4 drive train, 2-17
part number, 4-15 part number, 4-17
removal, 3-28 removal, 3-31
Feed Out Sensor #4, 2-15 wiring, 5-8
connector designator, 5-4 Take Away Roller, 2-11
part number, 4-15 part number, 4-15
removal, 3-21 removal, 3-23
wiring, 5-9 Tray 6, 1-7
Feed Out Sensor #5, 2-15 Cables, 2-46
connector designator, 5-4 part number, 4-23
part number, 4-15 removal, 3-45
removal, 3-22 dimensions, 1-10
wiring, 5-10 docking, 3-32
Feeder, 2-13 Docking Interlock Switch, 2-44
part number, 4-7 part number, 4-31
removal, 3-11 removal, 3-66
wiring diagram, 5-9 wiring, 5-23
Level Sensor, 2-15 Door J Interlock Switch, 2-50
part number, 4-11 part number, 4-31
removal, 3-16 wiring, 5-23
No Paper Sensor, 2-15 Feed Out Sensor #6, 2-42
part number, 4-11 removal, 3-63
removal, 3-14 wiring, 5-24
Paper Size Guides, 2-12 Feed Roller, 2-42
Paper Size Switch, 2-14 part number, 4-27
part number, 4-7 removal, 3-58
removal, 3-10 feed timing, 2-44
signal definitions, 2-15 Feed/lift Motor
Pre-Feed Sensor, 2-15 connector designator, 5-19
part number, 4-11 part number, 4-11, 4-25
removal, 3-17 removal, 3-49
wiring, 5-25
Index Index-13
071-0873-00 A