Phaser 5500 Series - 2

Phaser 5500 Laser Printer
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. First Printing: August 2004 071-0873-00
Copyright
Copyright 2004 Xerox Corporation. All Rights Reserved. Unpublished rights reserved under the copyright laws of the United States. Contents of this publication may not be reproduced in any form without permission of Xerox Corporation. Copyright protection claimed includes all forms of matters of copyrightable materials and information now allowed by statutory or judicial law or hereinafter granted, including without limitation, material generated from the software programs which are displayed on the screen such as styles, templates, icons, screen displays, looks, etc. XEROX, The Document Company, the stylized X, CentreWare, infoSMART, Made For Each Other, Phaser, PhaserSMART, and Walk-Up are trademarks of Xerox Corporation in the United States and/or other countries. Adobe Reader, Illustrator, PageMaker, Photoshop, PostScript, ATM, Adobe Brilliant Screens, Adobe Garamond, Adobe Jenson, Birch, Carta, IntelliSelect, Mythos, Quake, and Tekton are trademarks of Adobe Systems Incorporated in the United States and/or other countries. Apple, AppleTalk, LaserWriter, LocalTalk, Macintosh, Mac OS, TrueType, Apple Chancery, Chicago, Geneva, Monaco, New York , and QuickDraw are trademarks of Apple Computer, Inc. in the United States and/or other countries. PCL and HP-GL are trademarks of Hewlett-Packard Corporation in the United States and/or other countries. IBM is a trademark of International Business Machines Corporation in the United States and/or other countries. Windows, Windows NT, and Wingdings are trademarks of Microsoft Corporation in the United States and/or other countries. Novell, NetWare, NDPS, NDS, Novell Directory Services , IPX , and Novell Distributed Print 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.
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Phaser 5500 Printer Options Service Manual
Contents
Service Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi Product Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii Power Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii Electrostatic Discharge (ESD) Precautions. . . . . . . . . . . . . . . . . . . . . . . . xiv Service Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv Regulatory Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii Manual Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix
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
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1000-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000-Sheet Feeder Paper Path Components . . . . . . . . . . . . . . . 1000-Sheet Feeder Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000-Sheet Feeder Drive and Electrical . . . . . . . . . . . . . . . . . . . Finisher/Stacker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Finisher Paper Path Components. . . . . . . . . . . . . . . . . . . . . . . . Finisher Paper Path Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . Punch Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compiler Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stapler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stacker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tray 6 Paper Path Components . . . . . . . . . . . . . . . . . . . . . . . . . Tray 6 Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tray Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000-Sheet Feeder Drive and Electrical . . . . . . . . . . . . . . . . . . .
2-10 2-11 2-14 2-16 2-18 2-19 2-24 2-25 2-28 2-33 2-36 2-42 2-42 2-44 2-46 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
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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
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
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Finisher Bottom Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123 Finisher Door G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-124 Finisher Inner Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-125 Finisher Top Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-126 Door G Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-127 Finisher L/H Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-128 Finisher Top L/H Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-129 Stacker Upper Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-130 Finisher Eject Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-131 Stacker Lower Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132 Stacker Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132 Stacker Left Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-136 Stacker Right Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-138 Stack Height Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-140 Stack Height Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-141 Stacker Encoder Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-142 Lower Tray Upper Limit and No Paper Sensors . . . . . . . . . . . . 3-143 Elevator Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-144 Finisher Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-145 Punch Move Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-147 Finisher Punch Side Registration Sensors 1 & 2 . . . . . . . . . . . 3-148 Punch Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-148 Punch Motor Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . 3-149 Punch Hole Select, Punch Front and Home Sensors . . . . . . . . 3-151 Punch Unit Move Home Sensor . . . . . . . . . . . . . . . . . . . . . . . . 3-153 Finisher Punch Box Set Sensor. . . . . . . . . . . . . . . . . . . . . . . . . 3-154 Finisher Stapler Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-155 Stapler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-158 Stapler Lower Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . 3-159 Stapler Upper Rail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-161 Stapler Move Position Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . 3-162 Finisher Eject Chute Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-163 Sub Paddle Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-166 Cyclone Paddles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-168 Cyclone Paddle Drive Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-168 Eject Clamp Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-172 Eject Clamp Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-174 Eject Clamp Home Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-175 Door H Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-176 Finisher Compiler Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-177 Front/Rear Tamper Home Sensors . . . . . . . . . . . . . . . . . . . . . . 3-180 Compiler Tray No Paper Sensor . . . . . . . . . . . . . . . . . . . . . . . . 3-182 Eject Roller Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-184 Set Clamp Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-186 Eject Motor Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-187 Set Clamp Home Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-188
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vii
Compile Exit Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lower Exit Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . Lower Exit Chute R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paddle Shaft/Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exit Pinch Rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lower Exit Chute (2b) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lower Exit Chute Pinch Rollers . . . . . . . . . . . . . . . . . . . . . . . . Transfer Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Buffer Gate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Buffer Path Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Buffer Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bottom Buffer Chute (3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exit Pinch Rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upper Entrance Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upper Entrance Chute Pinch Rollers . . . . . . . . . . . . . . . . . . . . Transport Entrance Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . Entrance Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Finisher Transport Motor and Belt . . . . . . . . . . . . . . . . . . . . . . Transfer Gate Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Buffer Gate Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stacker Upper Tray Exit Sensor . . . . . . . . . . . . . . . . . . . . . . . . Top Exit Pinch Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Top Exit Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stacker Upper Tray Full Stack Sensor . . . . . . . . . . . . . . . . . . . Upper Exit Chute (2a). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upper Exit Chute Pinch Rollers . . . . . . . . . . . . . . . . . . . . . . . . Gate Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transport Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Finisher Exit Motor and Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . Finisher Registration Motor and Belt . . . . . . . . . . . . . . . . . . . . Horizontal Transport PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . Finisher Main PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-189 3-191 3-196 3-200 3-201 3-202 3-204 3-204 3-206 3-207 3-208 3-211 3-213 3-214 3-216 3-217 3-218 3-222 3-223 3-225 3-226 3-227 3-227 3-233 3-234 3-236 3-236 3-238 3-243 3-245 3-247 3-248 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
viii
5 Wiring Diagrams
Phaser 5500 Option Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Notations Used in Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . 5-2 Phaser 5500 Printer Option Plug/Jack Information. . . . . . . . . . . . 5-3 1000-Sheet Feeder Plug/Jack Designators . . . . . . . . . . . . . . . . . . . . . . . . 5-4 1000-Sheet Feeder Plug/Jack Locators . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Trays 4 and 5 Feeders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Trays 4 and 5 Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 1000-Sheet Feeder Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 General Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Tray 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Tray 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Duplex Unit Plug/Jack Designators . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Duplex Unit Plug/Jack Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Duplex Unit Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Exit 2 Plug/Jack Designators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 Exit 2 Plug/Jack Locator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 Exit 2 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 General Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Exit 2 Motor/Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 Exit 2 Sensor/Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 Tray 6 Plug/Jack Designators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 Tray 6 Plug/Jack Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 Tray 6 Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 Tray 6 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 Tray 6 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 General Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 Tray 6 Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 Tray 6 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 Tray 6 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 Finisher Plug/Jack Designators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 Finisher Plug/Jack Locators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 Horizontal Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 Stapler and Door G Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 Punch and Punch Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 Input Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 Compiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 Upper Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34 Finisher Main PWB, H-XPort PWB and LVPS. . . . . . . . . . . . . . . 5-35
Contents
ix
Finisher Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Wiring (1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Wiring (2/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensors (1/2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensors (2/2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch and Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compiler Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stapler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Punch (1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Punch (2/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-36 5-36 5-37 5-38 5-39 5-40 5-41 5-42 5-43 5-44 5-45 5-46 5-47
Index
Service Terms
Manual Terms
Various terms are used throughout this manual to either provide additional information on a specific topic or to warn of possible danger present during a procedure or action. Be aware of all symbols and terms when they are used, and always read NOTE, CAUTION, and WARNING statements. Consumable: Ink, toner, or 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.
Symbols Marked on the Product

DANGER high voltage.
Protective ground (earth) symbol.
Hot surface on or in the printer. Use caution to avoid personal injury.
The surface is hot while the printer is running. After turning off the power, wait 40 minutes.
00:40
Avoid pinching fingers in the printer. Use caution to avoid personal injury. Use caution (or draws attention to a particular component). Refer to the manual(s) for information.
xii
Power Safety Precautions

Power Source
For 110 VAC printers, do not apply more than 135 volts RMS between the supply conductors or between either supply conductor and ground. For 220 VAC printers, do not apply more than 254 volts RMS between the supply conductors or between either supply conductor and ground. Use only the specified power cord. This manual assumes that the reader is a Xerox-certified service technician. Plug the three-wire power cord (with grounding prong) into a grounded AC outlet only. If necessary, contact a licensed electrician to install a properly grounded outlet. If the product loses its ground connection, contact with conductive parts may cause an electrical shock.
Disconnecting Power
Turning the power off using the On/Off switch does not completely de-energize the printer. You must also disconnect the printer power cord from the AC outlet. Position the power cord so that it is easily accessible during servicing so that you may power down the printer during an emergency.

Disconnect the power plug by pulling the plug, not the cord. Disconnect the power cord in the following cases:

if the power cord or plug is frayed or otherwise damaged, if any liquid or foreign material is spilled into the case, if the printer is exposed to any excess moisture, if the printer is dropped or damaged, if you suspect that the product needs servicing or repair, whenever you clean the product.
Safety
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.
Immediately before handling any semiconductor components assemblies, drain the electrostatic charge from your body. This can be accomplished by touching an earth ground source or by wearing a wrist strap device connected to an earth ground source. Wearing a wrist strap will also prevent accumulation of additional bodily static charges. Be sure to remove the wrist strap before applying power to the unit under test to avoid potential shock. After removing a static sensitive assembly from its anti-static bag, place it on a grounded conductive surface. If the anti-static bag is conductive, you may ground the bag and use it as a conductive surface. Do not use freon-propelled chemicals. These can generate electrical charges sufficient to damage some devices. Do not remove a replacement component or electrical sub-assembly from its protective package until you are ready to install it. Immediately before removing the protective material from the leads of a replacement device, touch the protective material to the chassis or circuit assembly into which the device will be installed. Minimize body motions when handling unpackaged replacement devices. Motion such as your clothes brushing together, or lifting a foot from a carpeted floor can generate enough static electricity to damage an electro-statically sensitive device Handle ICs and EPROMs carefully to avoid bending pins. Pay attention to the direction of parts when mounting or inserting them on Printed Circuit Boards (PCBs).
xiv
Service Safety Summary

General Guidelines
For Xerox-certified service personnel only: Refer also to the preceding Power Safety Precautions. Avoid servicing alone: Do not perform internal service or adjustment of this product unless another person capable of rendering first aid or resuscitation is present. Use care when servicing with power: Dangerous voltages may exist at several points in this product. To avoid personal injury, do not touch exposed connections and components while power is on. Disconnect power before removing the power supply shield or replacing components. Do not wear jewelry: Remove jewelry prior to servicing. Rings, necklaces and other metallic objects could come into contact with dangerous voltages and currents. Power source: This product is intended to operate from a power source that will not apply more then 254 volts RMS for a 220 volt AC outlet or 135 volts RMS for a 110 volt AC outlet between the supply conductors or between either supply conductor and ground. A protective ground connection by way of the grounding conductor in the power cord is essential for safe operation.
Warning Labels
Read and obey all posted warning labels. Throughout the printer, warning labels are displayed on potentially dangerous components. As you service the printer, check to make certain that all warning labels remain in place.
Safety Interlocks
Make sure all covers and the 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.
CLASS 1 LASER PRODUCT

The Phaser 5500 Laser Printer is certified to comply with Laser Product Performance Standards set by the U.S. Department of Health and Human Services as a Class 1 Laser Product. This means that this is a class of laser product that does not emit hazardous laser radiation; this is possible only because the laser beam is totally enclosed during all modes of customer operation. When servicing the printer or laser unit, follow the procedures specified in this manual and there will be no hazards from the laser.
Safety
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 deenergize the printer. You must also disconnect the printer power cord from the AC outlet. Position the power cord so that it is easily accessible during servicing. Warning Do not touch any electrical component unless you are instructed to do so by a service procedure.
S7300-02
Servicing Mechanical Components

When servicing mechanical components within the printer, manually rotate drive assemblies, rollers, and gears. Warning Do not try to manually rotate or manually stop the drive assemblies while any printer motor is running.
S7300-03
Servicing Fuser Components

Warning This printer uses heat to fuse the toner image to media. The Fuser is VERY HOT. Turn the printer power off and wait at least 5 minutes for the Fuser to cool before you attempt to service the Fuser or adjacent components.
xvi
Regulatory Specifications
Federal Communications Compliance
The equipment described in this manual generates and uses radio frequency energy. If it is not installed properly in strict accordance with Xerox instructions, it may cause interference with radio and television reception or may not function properly due to interference from another device. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

Reorient or relocate the receiver (device being interfered with). Increase the separation between the printer and the receiver. Connect the printer into an outlet on a circuit different from that which the receiver is connected. Route the interface cables on the printer away from the receiver Consult the dealer, Xerox service, or an experienced radio/television technician for help.
Changes or modifications not expressly approved by Xerox can affect the emission and immunity compliance and could void the user's authority to operate this product. To ensure compliance, use shielded interface cables. A shielded parallel cable can be purchased directly from Xerox at www.xerox.com/office/5500supplies. Xerox has tested this product to internationally accepted electromagnetic emission and immunity standards. These standards are designed to mitigate interference caused or received by this product in a normal office environment. This product is also suitable for use in a residential environment based on the levels tested. In the United States this product complies with the requirements of an unintentional radiator in part 15 of the FCC rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference; (2) this device must accept any interference received, including interference that may cause undesired operation. This digital apparatus does not exceed the Class B limits for radio noise emissions from digital apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications, ICES-003. Le 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:
In the European Union

following the provisions of the Low Voltage Directive 73/23/EEC and its amendments:
EN 60950 (IEC 60950) Safety of Information Technology Equipment including Electrical Business Equipment
following the provisions of the Electromagnetic Compatibility Directive 89/336/EEC and its amendments:
EN 55022:1998 (CISPR 22) EN 61000-3-2:1995 +A1:1998+A2:1998 (IEC 61000-3-2) EN 61000-3-3:1995 (IEC 61000-3-3) EN 55024:1998 (CISPR 24) Limits and Methods of measurement of radio interference characteristics of Information Technology Equipment. Class B. Part 3: Limits - Section 2: Limits for harmonic current emissions (equipment input current less than or equal to 16A per phase). Part 3: Limits - Section 3: Limitation of voltage fluctuations and flicker in low-voltage supply systems for equipment with rated current less than or equal to 16A. Information technology equipment - Immunity characteristics - Limits and methods of measurement.
This product, if used properly in accordance with the user's instructions is neither dangerous for the consumer nor for the environment. A signed copy of the Declaration of Conformity for this product can be obtained from Xerox.
xviii
Manual Organization
The Xerox Phaser 5500 Laser Printer Service Manual is the primary document used for repairing, maintaining, and troubleshooting the printer. The manual is organized into two books. This volume, Book 2, Phaser 5500 Options includes an overview of option theory, option FRU replacement procedures, parts lists and wiring diagrams. Use this volume after youve isolated a problem internal to a specific option or when a problem arises at the engine/option interface. Use Book 1 for diagnostic and troubleshooting procedures for the printer and all its options.
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.
xx
General Information
In this chapter...

Printer Introduction and Overview Options Consumables and Routine Maintenance Items Option Specifications
Chapter
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.
1-2
Printer Configurations
The following table lists the features of the five Phaser 5500 printer configurations,
Printer Configurations Features 5500B
Maximum Print Speed (Letter-size Paper) Memory PostScript Fonts Oak PCL 5.0 PCL5e/PCL6 Job Pipelining PDF Direct Print Resolutions USB, Parallel Ethernet Capabilities 1000-Sheet Feeder Duplex Unit Automatic 2-Sided Printing (Requires Duplex Unit) Hard Drive Job Collation (Hard Drive Required) Proof Print, Personal Print, Secure Print, Saved Jobs (Hard Drive Required) 2,000-Sheet Feeder (Requires 1000Sheet Feeder) 3,500-Sheet Finisher (Requires 1000-Sheet Feeder) 50 ppm
5500N
50 ppm
5500DN
50 ppm
5500DT
50 ppm
5500DX
50 ppm
128 MB 137 Yes Yes Yes Yes

600 or True 1200 dpi




Yes Optional Optional Optional Optional
Yes Standard Optional Optional Optional
Yes Standard Optional Standard Standard
Yes Standard Standard Standard Standard
Yes Standard Standard Standard Standard
Optional Optional
Optional Optional
Optional Optional
Optional Optional
Standard Standard
Optional
Optional
Optional
Optional
Standard
Optional
Optional
Optional
Optional
Standard
Optional
Optional
Optional
Optional
Standard
General Information
1-3
Available Options

20 GB Hard Drive Additional RAM and NVRAM Exit 2 Configuration Card 1000-Sheet Feeder (Tray 4 & 5) Duplex Unit 3,500-Sheet Stacker 3,500-Sheet Finisher (with hole punch, staple, offset) 2,000-Sheet Feeder (Tray 6) Envelope Tray (replaces Tray 2)
Hard Drive
A 20 GB hard drive is available to enable the Job Collation, Saved Jobs, Proof, 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
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
General Information
1-5
Stacker / Finisher
The Stacker/Finisher increases the output capacity of the printer by 3,500 sheets. Printer output is directed to the Stacker/Finisher by way of Exit 1 and the Horizontal Transport. With Exit 2 installed, the top surface of the Horizontal Transport serves as the top tray and paper output capacity remains at 500 sheets. Depending on the level of Stacker/Finisher options and job specifications, as paper enters the Stacker/ Finisher it is punched, stapled, offset and stacked. Control signals reach the Stacker/ Finisher through a single connector. Power is supplied from the printers AC accessory panel.
2 1
s5500-009
1. Horizontal Transport
2. Stacker/Finisher
1-6
2000-Sheet Feeder
The 2000-Sheet Feeder (Tray 6) nearly doubles the input storage capacity of the printer. The feeder attaches to the right side of printers equipped with the 1000-Sheet Feeder option just below Tray 1/MPT using the supplied docking bracket. Electrical connection to the printer is made by an interface cable.
s5500-013
Envelope Tray
The Envelope Tray replaces Tray 2 to handle up to 35 envelopes.
s5500-014
General Information
1-7
Consumables and Routine Maintenance Items

1 3 4
2
1. Fuser 2. Transfer Roller 3. Drum Cartridge 4. Toner Cartridge
s5500-010
Consumables
Description
Toner Cartridge (30K) Staple Pack
Part Number
113R00668 008R12941
Routine Maintenance Items

Description
Maintenance Kit, 110 V Maintenance Kit, 220 V Drum Cartridge (60K)
Part Number
109R00731 109R00732 113R00670
1-8
Option Part Numbers

Upgrade Kits and Options
Description
128 MB Memory Option 256 MB Memory Option 16 MB Flash Memory DIMM 20 GB Hard Drive Option B to N Network Upgrade Kit 1000-Sheet Feeder (Trays 4 & 5) 2000-Sheet Feeder (Tray 6) Duplex Unit 3,500-Sheet Stacker 3,500-Sheet Finisher (w/ 2or 4-hole punch) 3,500-Sheet Finisher (w/ 3-hole punch) Envelope Tray (replaces Tray 2) 500-Sheet Replacement Tray
Part Number
097S03123 097S03225 097S03125 097S03227 097S03222 097S03218 097S03219 097S03220 097S03221 097S03281 097S03282 097S03286 109R00733
General Information
1-9
Option Specifications
Physical Dimensions
Device
Duplex Unit 1000-Sheet Feeder Stacker/ Finisher Exit 2 Envelope Tray 2000-Sheet Feeder
Height
211 mm (8.3 in.) 280 mm (11.0 in.) 1050mm (41.3 in.) 142 mm (5.6 in.) 76 mm (3.0 in.) 363 mm (14.3 in.)
Width
64 mm (2.52 in.) 540 mm (21.2 in.) 740mm (29.1 in.) 130 mm (5.1 in.) 538 mm (21.2 in.) 385.5 mm (15.1 in.)
Depth
458 mm (18.0 in.) 520 mm (21.1 in.) 650mm (25.6 in.) 460 mm (18.1 in.) 521 mm (20.5 in.) 600 mm (23.6 in.)
Weight
1.8 kg (4 lbs.) 23 kg (50 lbs.) 49kg (108 lbs.) 2 kg (4.4 lbs.) 3.2 kg (7 lbs.) 50 kg (110 lbs.)
Environmental Specifications
Characteristic
Temperature: Operating Transportation Humidity (%RH) Operating Transportation Altitude Operating Transportation* Acoustic Noise LWA(B) Idle Printing
Specification
5 to 32 C (41 to 95 F) -20 to 40 C (-4 to 104 F) 15 to 85 5 to 85 0 to 2,500 meters (8,200) feet) 0 to 15,000 meters (49,200 feet) Engine only 4.00 B 6.80 B With options 7.00 B
* Air transportation in pressurized cargo space
1-10
Tray and Media Specifications

Tray Specifications
Characteristic
Printable Area Supported Envelopes
Trays
All Tray 1, Tray 2 (with Envelope Tray installed) Tray 1,3,4,5,6 Tray 2 Duplex Tray 1 Tray 2 Tray 3 Tray 4 Tray 5 Tray 6 Top (facedown) Stacker/Finisher
Specifications
Within 4 mm of paper edge guaranteed. Edge-to-edge printing supported. COM-10 (4.1 x 9.5 in.) Monarch (3.8 x 7.5 in) DL (110 x 220 mm) C5 (162 x 229 mm) 60-216 g/m2 (16 lb. bond to 133 lb. card stock) 60-105 g/m2 (16 to 28 lb. bond) 60-163 g/m2 100 Sheets / 15 envelopes 500 Sheets / 35 envelopes with Envelope Tray 500 Sheets 500 Sheets 500 Sheets 2000 Sheets 500 Sheets 3000 elevator, 500 in top tray Based on 75 g/m2 (20 lb.) paper stock. Capacity is reduced for heavier/thicker stock.
Supported Media Weights
Tray Capacity
General Information
1-11
1-12
Theory of Operation
In this chapter...

Phaser 5500 Operational Overview Exit 2 Duplex Unit 1000-Sheet Feeder Finisher/Stacker 2000-Sheet Feeder
Section
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 2 Duplex Unit A3L Rollers Pressure Roller Duplex Roller Pinch Rollers Heat Roller Transfer Roller Drum Registration Pinch Roller Registration Roller Tray 2 Nudger Rollers Exit Pinch Rollers
OCT Rollers
Feed Roller Pinch Roller Drive Roller
Tray 3
Pinch Rollers
Tray 4 1000 Sheet Feeder Tray 5
Take Away Rollers Feed Rollers Retard Rollers

s5500-233
2-2
The Phaser 5500 paper paths for paper exiting the Fuser are:

Direct through Exit 1 to the Standard Output Tray (facedown). 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 Horizontal Transport Punch Stacker Lower Tray
Exit 2
Exit 1 Compiler Tray
Stapler
s5500-024
Theory of Operation
2-3
Exit 2
Exit 2 discharges the printed paper out of the printer, sending it either to the Standard Output Tray or loading the Duplex Unit for two-sided printing. Used in conjunction with either the Duplex Unit or the Finisher/Stacker, Exit 2 attaches to the printer directly above Exit 1 and receives power and control signals through a single connector on the lower, left side of the module.
Exit 2
s5500-235
Exit 2 Paper Path Components

Exit 2 paper transport components include:
Exit 2 Pinch Rollers Work together with the OCT Roller to eject paper to the Standard Output Tray. 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.). Face-up (FU), OCT (Offset), Invert Pinch and Invert Rollers These rollers eject or reverse paper direction to load the Duplex Unit. Exit Gate Solenoid The Exit Gate Solenoid switches the Exit Gate, located in Exit 1, to eject paper to the Standard Output Tray or load the Duplex Unit.
2-4
Exit 2 Sensors
Door E Interlock Switch Detects the state, open or closed, of Door E. Exit 2 Exit Sensor The Exit 2 Exit Sensor detects whether paper remains in the output rollers. OCT (Offset) Home Position Sensor The OCT Position Sensor detects the OCT Roller position. Stack Full Sensor This sensor detects whether the Standard Output Tray is full or not using the Stack Full Actuator.
FU Solenoid Full Stack Sensor OCT Position Sensor OCT Roller Door E Interlock Exit PWB Exit 2 Exit Sensor
FU Roller
Invert Roller Offset Motor Rear Exit Motor Exit Gate Solenoid
s5500-236
Theory of Operation
2-5
Exit 2 Drive and Electrical
Exit 2 Motor This motor drives the rollers that move paper to the output tray and reverses to insert paper into the Duplex Unit.
Exit 2 Motor Gear-19Z Gear-19Z/44Z Gear-19Z FU Roller Gear-19Z Invert Roller
Gear-19Z OCT Roller
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
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.
Duplex Paper Handling

Duplex paper handling involves a number of transport rollers and sensors.
Exit 2 Exit Sensor Fuser Exit Sensor Wait Sensor
Registration Sensor
Pre Feed Sensor
s5500-583
Theory of Operation
2-7
Duplex Unit Paper Path Components
A3L Roller Upper and Lower These gear-driven rollers feed the paper printed on the front side, through the Duplex to the printer to print on the rear side. Duplex Roller Drives the paper through the Duplex Unit. Pinch Rollers Both Chutes have multiple Pinch Rollers to maintain pressure on the paper.
Duplex Unit Sensors

Two sensors monitor the Duplex Unit.
Door D Interlock Switch The Door D Interlock Switch detects the status, open or closed of Door D. Wait Sensor The Wait Sensor detects whether paper is present in the Duplex Unit. Paper pauses at this point until it is time to reinsert the sheet to the Registration Roller
Duplex Unit Drive and Electrical

Upper A3L Roller Wait Sensor Duplex PWB Duplex Roller
Duplex Motor
Lower A3L Roller

s5500-239
Duplex PWB The Duplex PWB responds to commands, controls paper feed, and reports sensor/switch status to the Engine Logic Board.
2-8
Duplex Motor The Duplex Motor drives a gear set to the three rollers that feed paper. This is illustrated in the following flow diagram.
Duplex Motor Gear Idle 33 74 Gear Roll 28 Gear Idle 33 Gear Idle 42 Gear Idle 33 Gear Roll 28 Upper A3L Roller
s5500-240
Gear Idle 33 74 Gear Roll 28 Lower A3L Roller Duplex Roller
Theory of Operation
2-9
1000-Sheet Feeder
Paper, supplied from either Tray 4 or 5, is transported through the printer along the paper path shown below.
Tray 4 Nudger Roller Feed Roller Retard Roller Pinch Roller (Upper) Tray 5 Nudger Roller Feed Roller Retard Roller Pinch Roller (Upper) Pinch Roller (Lower) Take Away Roller Take Away Roller Assembly Take Away Roller Registration Roller Transfer Roller Drum Drum Cartridge Heat Roller Pressure Roller Fuser Invert Roller FU Roller OCT Roller Exit Pinch Roller Exit 2 Print Exit Upper A3L Roller Duplex Roller Duplex Unit Option
s5500-241
OCT Roller Exit Pinch Roller Exit1
2-10
1000-Sheet Feeder Paper Path Components

The following is a cross section of the printer and the optional 1000-Sheet Feeder, showing main components directly associated with the paper path and transport.
OCT Roller Exit Pinch Roller Pressure Roller Heat Roller Fuser Drum Cartridge Transfer Roller Drum Pinch Roller Registration Roller Tray 2 Tray 3 Tray 4 1000 Sheet Feeder Tray 5 Take Away Roller Feed Roller Retard Roller
s5500-242
Nudger Roller
Take Away Roller Pinch Roller
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.
Upper and Lower Take Away Rollers The Take Away Roller feeds paper from the feeders into the printer paper path. Upper and Lower Pinch Rollers Upper and Lower Pinch Rollers apply pressure to the paper as its driven along the paper path.
Theory of Operation
2-11
Trays
Paper size is set using the size guides in each tray. Adjust the Front, Rear, and End Guides to match the paper size. The Bottom Plate is used to raise the level of the paper stack for feeding. These tray components appear in the following figure.
End Guide Rear Side Guide
Bottom Plate Front Side Guide

s5500-033
Front, Rear and End Side Guides The Front, Rear, and End Side Guides adjust to different paper sizes by moving them to contact the paper edges and hold it in position. Bottom Plate The Feeders Feed/Lift Motor through the Gear (13T/60T) and Sector Gear (60T) turn the Lift Shaft raising the Bottom Plate which causes the supplied paper to contact the Nudger Roller.
Lift Up Shaft
Sector Gear (60T) Gear 13T/60T
s5500-034
2-12
Feeders
Trays 4 and 5 are functionally equivalent in terms of the Feeder mechanism that moves paper from the tray into the printer. The driving force from each Feeders Feed/Lift Motor is transmitted via a gear assembly to the Feed and Nudger Rollers, moving paper from the tray into the printer.
Feed/Lift Motor Pre Feed Sensor Level Sensor No Paper Sensor Feeder Assembly Paper Size Switch
Front
s5500-245
Theory of Operation
2-13
1000-Sheet Feeder Sensors
Tray 4 Paper Size Switch The Tray 4 Paper Size Switch reports the position of the Front and Rear Side Guides and End Guide to the Engine Logic Board. Tray 5 Paper Size Switch The Tray 5 Paper Size Switch reports the position of the Front and Rear Side Guides and End Guide to the Engine Logic Board. Both Paper Size Switches appear in the following figure.
Paper Size Switch
Front
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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.
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The following table provides the switch states corresponding to the pre-defined paper sizes. The switches are denoted by SW1, SW2, SW3, SW4 and SW5, respectively, when viewed from the front. 1000-Sheet Feeder Pre-Defined Paper Sizes
Paper Size Switch Output Paper size SW1
No tray 5.5" x 8.5" / A5 SEF B5 SEF 8.5" x 13" SEF 8.5" x 14" SEF A4 SEF 8.5" x 11" SEF A4 LEF A3 SEF B5 LEF/Executive LEF 8K SEF (TFX/GCO) B4 SEF 8.5" x 11" LEF 16K LEF (TFX/GCO) 11" x 17" LEF 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1
SW2
0 0 0 1 1 1 1 0 0 1 1 1 1 1 1
SW3
0 1 1 0 0 1 1 1 1 0 0 0 1 1 1
SW4
0 0 1 1 1 0 0 0 1 0 1 1 0 0 1
SW5
0 0 1 0 1 0 1 0 0 1 0 1 0 1 1
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. Feed Out Sensor #4 This sensor, located on the upper chute in front of the Tray 4 Feeder, uses an actuator to determine whether the paper has moved into the printer from the tray. Feed Out Sensor #5 This sensor, located in the chute above the Tray 5 Feeder, uses an actuator to determine whether the paper has moved into the printer from the tray.
Theory of Operation
2-15
Tray 4-5 PWB Door C Interlock Switch
Left Feed Out Sensor #4 Feed Out Sensor #5 Take Away Rollers
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1000-Sheet Feeder Drive and Electrical
Feeder Feed/Lift Motor This motor, one on each Feeder, is activated by the Level Sensor to feed paper and to lift the Bottom Plate. When feeding paper, it rotates forward to drive the Nudger Roller. When lifting the Bottom Plate, it rotates in reverse to drive the tray gears to turn the Lift Shaft. Door C Interlock Switch The Door C Interlock Switch detects whether Door C is open or closed. Take Away Clutch The Take Away Clutch transmits Take Away Motor force to the gear set driving the Take Away Roller. Tray 4-5 PWB The Tray 4-5 PWB controls paper feeding on command from the Engine Logic Board and reports sensor/switch information.
2-16
Tray 4-5 Take Away Motor The rotating force of the Tray 4-5 Take Away Motor is transmitted through the gears to the Take Away Roller as shown in the following flow.
Take Away Motor Gear (22T/40T) Clutch Gear (38T) Gear (126T) Gear (60T) Gear (32T) Gear (37T) Take Away Roller
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Theory of Operation
2-17
Finisher/Stacker
The Finisher is a customer installed option that adds hole punching, stapling (up to 50 sheets) and job stacking with offset (up to 3500 sheets). The Finisher docks with the printer and uses an accessory AC outlet on the printer for power. The Stacker differs from the Finisher by the omission of the paper punch and stapler. The operational descriptions presented in this Chapter cover all the capabilities of the Finisher. Shown below is the paper path for the Standard Output Tray, through Exit 1, the Horizontal Transport, and the Finisher.
Stacker Upper Tray Horizontal Transport Punch Stacker Lower Tray
Compiler Tray Stapler
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2-18
Finisher Paper Path Components

A brief description of the main sections of the Finisher paper path are described below:

Horizontal Transport transfers paper from the Printer to the Finisher. Punch Unit provides 2-/4- or 3-hole punch capability. Buffer Path adds a paper path timing delay to maintain throughput speed. 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 Entrance Sensor Belt Exit Sensor

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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.
Theory of Operation
2-19
Transfer Rollers (Driven by Regi Motor) Punch Entrance Sensor Paper From H-X'Port Entrance Rollers (Driven by Finisher Transport Motor) Buffer Roller (Driven by Regi Motor)
Gate Sensor Transfer Gate
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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 Transfer Gate Solenoid
Punch
Transfer Rollers Punch Transfer Gate
Entrance Sensor Entrance Roller Buffer Roller Finisher Transport Motor

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2-20
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. Having been punched, paper being output to the Stacker Upper Tray is directed by the Transfer Gate upward to the two Transfer Rollers. The Transfer Rollers, driven by the Registration Motor feed paper to the Top Exit Roller. The Top Exit Roller is driven by the Finishers Exit Motor and ejects the paper into the Stacker Upper Tray. The Exit Motor continues to run at full forward speed until the Upper Tray Exit Sensor signal goes High, indicating the presence of paper, at which point the Exit Motor decelerates. The following diagram represents the Finisher output path as viewed from the front, left-hand corner. This time both the Punch and Buffer Path components have been removed for simplicity. The flow arrows indicate the paper entering from below, encountering the Transfer Gate and being directed upward. The Exit Motor, Exit Drive Belt, Transfer Gate Solenoid, Transfer Gate, Transfer Rollers, and Exit Roller all appear in their actual positions relative to each other.
Exit Motor
Stacker Upper Tray Exit Sensor Top Exit Roller
Transfer Gate Solenoid
Transfer Rollers
Front
Transfer Gate
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Theory of Operation
2-21
For staple or stacker operations, the paper path changes to include the Buffer Path, Compiler Tray and Eject Clamp. Output is directed to the Stacker Lower Tray. Components included in this lower paper path appear in the following figure.
Compile Exit Sensor Sub Paddle (Driven by Finisher Transport Motor) Eject Clamp (Driven by Eject Clamp Motor) Buffer Roller (Driven by Regi Motor) Buffer Gate
Eject Roller Shaft (Driven by Eject Motor) Compiler Tray Main Paddle Lower Exit Roller (Driven by Exit Motor) (Driven by Finisher Transport Motor) s5500-254
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.
2-22
The following diagram shows the lower output path components as viewed from the front, left-hand corner. With the Punch, Transfer Gate, and Buffer Chutes removed for simplicity The Buffer Path, Compiler Tray, and Eject Clamp are easily seen. The flow arrow shows the paper entering from below, encountering the Buffer Gate and being directed to the Compiler Tray. If the Buffer Gate Solenoid is energized, the sheet would travel downward at the Buffer Roller and would wrap around the roller and meet the next incoming sheet.
Eject Clamp Motor Exit Motor Registration Motor Buffer Gate Solenoid
Eject Motor Compile Exit Sensor Eject Clamp Eject Roller Shaft
Lower Exit Roller Compiler Tray Finisher Transport Motor Buffer Roller Buffer Gate
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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.
Theory of Operation
2-23
The following diagram identifies the components associated with the Compiler Tray and Eject Clamp.
Compile Exit Sensor Sub Paddle (Driven by Finisher Transport Motor) Eject Clamp (Driven by Eject Clamp Motor) Buffer Roller (Driven by Regi Motor) Buffer Gate
Eject Roller Shaft (Driven by Eject Motor) Compiler Tray Main Paddle Lower Exit Roller (Driven by Exit Motor) (Driven by Finisher Transport Motor) s5500-254
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.
Finisher Paper Path Sensors

Sensors along the Finisher paper path. See earlier illustrations for the location of each sensor. Punch, Staple, Stacker, and Compile Tray sensors are listed separately with each component description.
Horizontal Transport Entrance Sensor A photo-interrupter to detect whether paper is fed from sprinter to the Horizontal Transport. The Horizontal Transport Entrance Sensor signal goes High when paper enters the Horizontal Transport. Horizontal Transport Exit Sensor A photo-interrupter to detect whether paper passes through the Horizontal Transport. The Horizontal Transport Exit Sensor goes High when paper reaches this sensor, and goes Low when paper exits the Horizontal Transport. Transport Entrance Sensor Senses the arrival of paper from the Horizontal Transport. 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.
2-24
Buffer Path Sensor A photo-interrupter to detect whether paper is fed toward the Buffer Roller. While paper is present, the actuator is outside the sensing area, and the Buffer Path Sensor signal goes High. Compiler Exit Sensor A photo-interrupter to detect whether paper passes through the Compile Exit Sensor. The Compiler Exit Sensor signal goes High when the actuator is driven out of the sensing area by the paper. When the Compiler Exit Sensor signal goes High, the Front and Rear Tamper Motors on the Compiler Tray are activated. Compiler Tray No Paper Sensor A photo-interrupter to detect whether paper is present in the Complier Tray.While paper is present, the actuator is outside the sensing area, and the Compiler Tray No Paper Sensor signal goes High. Upper Tray Exit Sensor A photo-interrupter to detect whether paper is fed to the Top Exit Roller at the exit side of the Upper Tray. When the paper is fed, the actuator leaves from the sensing area, and the Top Tray Exit Sensor signal goes High. Upper Tray Full Sensor A reflective photo-sensor to detect the stack volume of paper in the Stacker Upper Tray.
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.
Theory of Operation
2-25
Punch Unit Move Home Sensor Punch Front Sensor Punch Move Motor Punch Hole Select Sensor Side Registration Sensor 2
Punch Unit Home Sensor Punch Motor Sensor Punch Motor Side Registration Sensor 1
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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 Pin Punch Front Sensor Punch Unit Home Sensor Home Position Cam Plate
Punch Motor
3 Hole Position
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2-26
Punch Sensors/Motors
Side Registration Sensors 1 and 2 A pair of reflective photo-sensors to detect the side edge of the paper. Paper side edge is detected by the state transition of this sensor while shifting the Punch (containing this sensor) in the direction of paper width. The each Side Registration Sensor signal remains High while paper is present, and goes Low when the papers side edge is detected. The Side Registration 1 Sensor detects the edge of large-width paper, while the Side Registration 2 Sensor is used to detect the edge of narrow-width paper. Punch Unit Move Home Sensor A photo-interrupter to detect the home position of the moving Punch. The Punch Unit Move Home Sensor signal goes High when the home position is detected. Punch Unit Home Sensor A photo-interrupter to detect the home position of the Cam Plate that lowers the punching pins. The Punch Unit Home Sensor signal goes Low when the home position is detected. Punch Hole Select Sensor A photo-interrupter to detect the rear position of the Cam Plate. The Punch Hole Select Sensor signal goes Low when the rear position is detected. This sensor also detects the Cam position to switch the number of holes to punch. Punch Front Sensor A photo-interrupter to detect the front position of the Cam Plate. The Punch Front Sensor signal goes Low when the front position is detected. This sensor is used to determine to which side (front or rear) the Cam Plate should be moved. Punch Motor Encoder Sensor A photo-interrupter to detect pulse generated by the encoder disk attached to the Punch Motor. It counts Punch Motor revolutions, and becomes a trigger to stop the motor (by shutting off the current). Punch Box Set Sensor A photo-interrupter to detect whether the Punch Box is installed. When the Punch Box is preset, the actuator of the box blocks the light transmission of the sensor, causing the Punch Box Set Sensor signal to go Low. Note When the sensor detects that the box is removed for four seconds, the Punch Box Full count is reset to zero.
Punch Box Full A counter stored in NVRAM used to track the number of punches. At the counter value set, a notification is sent. The counter is reset if the Punch Box Set Sensor signal goes High for 4 seconds.
Theory of Operation
2-27
Punch Move Motor A stepping motor to move the Punch in the paper width direction 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 Rear Tamper Motor Compiler Tray No Paper Sensor Front Tamper Home Sensor Front Tamper Motor
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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.
2-28
Tamping
Tamping aligns the paper edges using the Front or Rear Tamper by moving them to the edge of paper by their respective motors. Tamping occurs each time a sheet of paper reaches the Compiler Tray. Additional tamping occurs after tamping the last sheet of a set. The Compiler Tray performs three types of tamping:
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 Tamper Home Sensor Front
Rear Tamper Home Sensor Rear
(1) (2) (3)
(6) (7) (5) (4)
Front Tamper Motor Front Tamper
Rear Tamper Rear Tamper Motor

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1. Front Tamper home position 2. Front Tamper size position 3. Front Tamper offset position 4. Rear Tamper home position
5. Rear Tamper standby position 6. Rear Tamper tamping position 7. Rear Tamper offset position
Theory of Operation
2-29
Rear Tamping Tampering by the Front Tamper with the Rear Tamper fixed at the home position in either rear corner or dual stapling operations.
(1)
(3)
(2)
(6)
(5)
(4)
Front Tamper Motor
Front Tamper
Rear Tamper Rear Tamper Motor

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1. Front Tamper home position 2. Front Tamper tamping position 3. Front Tamper offset position
4. Rear Tamper home position 5. Rear Tamper size position 6. Rear Tamper offset position
2-30
Center Tamping Tampering by the Front and Rear Tampers to center the paper in the tray during rear stapling (straight) operations.
(1) (2) (4) (3)
(8) (7)
(6) (5)
Front Tamper Motor
Front Tamper
Rear Tamper
Rear Tamper Motor

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1. Front Tamper home position 2. Front Tamper standby position 3. Front Tamper tamping position 4. Front Tamper offset position
5. Rear Tamper home position 6. Rear Tamper standby position 7. Rear Tamper size position 8. Rear Tamper offset position
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.
Front Stapling (Corner) Shifts stapled sheets using the Front Tamper by .78 inch (20 mm) to the rear side before ejecting them to the tray.
Theory of Operation
2-31
Rear Stapling (Corner/Straight) For corner-stapled paper with a width of 8.5 inches (216 mm) or more, the Rear Tamper offsets the set by .78 inch (20 mm) to the front side before ejecting them to the tray. 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.
Offset is not executed for small paper.
Compiler Tray Sensors/Motors
Compiler Tray No Paper Sensor A photo-interrupter to detect whether paper is present or not on the Compile Tray. When paper is detected, the actuator leaves the sensing area, which turns the Compile Tray No Paper Sensor signal High. Front Tamper Home Sensor A photo-interrupter to detect the Front Tamper home position. When the Front Tamper comes to the home position, it enters the sensors sensing area, which turns the Front Tamper Home Sensor signal High. Rear Tamper Home Sensor A photo-interrupter to detect the Rear Tamper home position. When the Rear Tamper comes to the home position, it enters the sensors sensing area, which turns the Rear Tamper Home Sensor signal High. Front Tamper Motor A stepping motor to move the Front Tamper. Clockwise rotation of this motor moves the Front Tamper to the rear side. Counterclockwise rotation moves the tamper to the front. Rear Tamper Motor A stepping motor to move the Rear Tamper. Clockwise rotation of this motor moves the Rear Tamper to the front side. Counterclockwise rotation moves the tamper to the rear.
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Stapler
The Stapler staples a set of edge-aligned paper in the Compiler Tray. When stapling, the Stapler Head moves along rails to the paper staple position. The Stapler Head moves to the front side when the right side of paper is stapled, or to the rear side when the left side of paper is stapled. When the Stapler Head moves, the Stapler Move Position Sensor detects the position of the Stapler Head from the presence of a notches on the guide. After the Stapler Head moves to the paper staple position, the bundle of paper is stapled immediately in the Dual Stapling mode, but in the Corner Stapling mode the Stapler Head swings 45 degrees before the bundle of paper is stapled. After the Stapler staples the bundle of paper, the Exit Roller rotates together with the Cyclone Paddles to deliver the stack of paper to the Stacker Lower Tray via the Eject mechanism.
Staple Move Motor
Paper handling direction
Staple Move Position Sensor
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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.
Theory of Operation
2-33
When staple supply is low, the Staple Head Low Staple Sensor detects it and stapling stops automatically displaying an warning message. The message also appears when the Staple Cartridge isnt installed in the Staple Head.
Staple Home Sensor
Self Priming Sensor
Staple Head Low Staple Sensor Staple Motor
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Staple Position
Sheets of paper are tamped on the Compile Tray, and then stapled at specified positions. These are the four stapling positions.
Front corner staple This type of stapling is applied for paper with a width of 8.5 inches (216 mm) more. The Staple Head moves to the front corner and staples a set of paper obliquely (45 degrees) after the Front Tamper aligns the paper to the rear side. Rear corner staple This type of stapling is applied for paper with a width of 8.5 inches (216 mm) more. The Staple Head moves to the rear corner and staples a set of paper obliquely (45 degrees) after the Front Tamper aligns the paper to the rear side. Rear straight staple This type of stapling is applied for paper with a width of less than 8.5 inches (216 mm). The Stapler staples a set of paper in parallel with the paper edge after the Front Tamper aligns the paper to the rear side. 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.
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Rear
Rear
Process direction
Process direction
Front Rear
Front Rear
Process direction
Process direction
Front
Front
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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 Head Low Staple Sensor A photo-interrupter in the Staple Head to detect near end of staples. The Low Staple Sensor signal goes High when the quantity of staples remaining in the cartridge is approximately 20 or less. Staple Head Self Priming Sensor A photo-interrupter in the Staple Head to detect that staples are at the Stapler
Theory of Operation
2-35
Head end, and also to detect failure in stapling. The Self Priming Sensor signal goes Low to indicate that the Staple Head is ready to staple.
Staple Home Sensor A photo-interrupter in the Staple Head to detect the Stapler Head home position and staple failure. This sensor also functions as a trigger to stop the Staple Motor. The Staple Home Sensor signal goes Low while the Stapler Head is at the home position. Stapler Move Motor A DC motor to move the Staple Head. Clockwise rotation of this motor moves the Stapler Head to the rear side, while counterclockwise rotation moves the Stapler Head to the front side. 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
Stacker Upper Tray
The Stacker Upper Tray is a fixed-position, facedown tray with a 500-sheet capacity. Tray content is monitored by a Stack Full Sensor. Once the sensor detects a full stack, exiting of paper to the Stacker Upper Tray is inhibited until the paper is removed or the sensor is cleared.
Stacker Upper Tray Sensors
Stacker Upper Tray Exit Sensor A photo-interrupter to detect that paper has come to the top Exit Roller. When paper reaches the top Exit Roller, the actuator leaves the sensing area and turns the Upper Tray Exit Sensor signal High. Stacker Upper Tray Full Sensor A reflective photo-sensor to detect the paper stack volume. The Upper Tray Full Sensor signal goes High when it detects a full stack.
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Stacker Lower Tray

The Stacker Lower Tray adjusts position according to the state of the two Stack Height Sensors. When paper obscures Stack Height Sensor 1, the sensors signal goes High. This signal is used to control the Elevator Motor. The motor is activated to move the Stacker Lower Tray down until the sensors signal returns to a Low state. If both sensor signals are Low, the Elevator Motor raises the tray to obscure the Stack Height Sensor 2. If Stack Height Sensor 2 signal remains Low, the tray continues to rise until it reaches the No Paper Sensor. If an obstacle blocks the tray from lowering, the tray stops and a warning is reported. The relationship of Elevator Motor motion and Stack Height Sensor state is shown in the following illustration.
Stack Height Sensor 1
Tray: Height Tray: Proper Tray: Low Moves downward Moves upward
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The Stacker No Paper Sensor is switched by an actuator attached to the right-hand Carriage assembly. In case the Stacker Lower Tray goes above the Stacker No Paper Sensor, the Upper Limit Sensor is installed directly above the No Paper Sensor as a lift cutoff for abnormal operation. If paper is removed from the Stacker Lower Tray during printing, it is detected by the Stack Height Sensor 2 which stops the ejection of paper until the tray returns to the Stack Height Sensor 1 sensing area. If paper is removed while printing is stopped, the Elevator Motor will activate in three seconds to move the tray to the Stack Height Sensor 1 sensing area. Apart from the paper height, paper volume is monitored by the Stacker Encoder Sensor. Paper volume detection is needed to prevent jamming or paper falling on the floor. The Stacker Lower Tray maximum volume is 3000 sheets. Paper volume is detected at every 10% (approx. 300 sheets). The default setting for number of stapled sets is 200. The Stacker Lower Tray can continue to stack paper until paper volume reaches either of the limits above.
Theory of Operation
2-37
In the mix stacking mode, all supported paper sizes are allowed until paper volume reaches approximately 300 sheets. Mix stacking occurs in one of the following cases:
A larger sheet of paper is stacked on a smaller sheet. An exception to this is when B5 (257 mm x 182 mm) paper is stacked on A4 (297 mm x 210 mm) paper. 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 The post-processing mode has changed.
The following illustrates the components associated with Stacker operation.
Stack Height Sensors
Eject Clamp Motor Eject Clamp Home Sensor
Eject Motor Set Clamp Home Sensor Stack Height Sensors Set Clamp Clutch Upper Limit Sensor Elevator Motor
Stacker Encoder Sensor
Stacker No Paper Sensor
s5500-266
2-38
Stacker Lower Tray Sensors/Motors
Stack Height Sensors 1 and 2 Detects the height of paper in the Stacker Lower Tray and controls the Elevator Motor. When blocked by paper or the tray, these sensor change state to indicate the tray is above or below the reference level. The High to Low transition point is defined as the reference level. Lower Tray No Paper Sensor A photo-interrupter to detect that the tray is at the highest position, and also to detect no paper. When the actuator enters the sensing area, the emitted light is blocked, switching the Stacker No Paper Sensor signal to High. Lower Tray Upper Limit Sensor A photo-interrupter to limit tray height. When the actuator enters the sensing area, the emitted light is blocked, switching the Upper Limit Sensor signal to High. Stacker Encoder Sensor A photo-interrupter to count pulses of the Encoder attached to the Elevator Shaft. The paper volume is based on this count. Set Clamp Home Sensor A photo-interrupter to detect the Set Clamp home position. This sensor functions as a trigger to control the Set Clamp Clutch. Set Clamp Clutch When activated, this clutch engages the Eject Motor to the Eject Roller. 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. Eject Clamp Motor A DC motor to raise or lower the Eject Clamp when feeding paper from the Punch to the Compiler Tray or from the Compiler Tray to the Stacker Lower Tray.
Theory of Operation
2-39
The following illustration identifies the location of the primary electro-mechanical components inside the Finisher.
Exit Motor Registration Motor Gate Solenoid Eject Motor Buffer Gate Solenoid Finisher Transport Motor Horizontal Transport PWB Finisher Main PWB
s5500-629
Eject Clamp Motor
Elevator Motor
Finisher Interlock
The Finisher is equipped with the following interlock switches.
Door G Interlock Switch: Turns Off when Door G opens, shutting off the +24 VDC line in the Finisher. Door H Interlock Switch Turns Off when Door H opens (Eject Cover), shutting off the +24 VDC line in the Finisher. Door F Interlock Sensor Turns On when Door F, Horizontal Transport top cover, is opened.
2-40
Door H Interlock
Door G Interlock
Door F Interlock
s5500-267
Theory of Operation
2-41
2000-Sheet Feeder
The 2000-Sheet Feeder, when connected to the printer, adds up to 2,000 sheets of paper input capacity. The following describes the major components and operation of the 2000-Sheet Feeder.
Tray 6 Paper Path Components

Paper path components of the 2000-Sheet Feeder include:

Nudger Roller Feed Roller Retard Roller Take Away 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 Feed Roller Nudger Roller Take Away Motor
Paper Retard Roller Nudger Solenoid Feed Out Sensor #6

s5500-268
2-42
The paper feed sequence begins when the Tray 6 PWB receives the feed start signal from the printers Engine Logic Board. The Nudger Solenoid is activated to press the Nudger Roller against the paper in the tray. Next, the Feed/Lift Motor is rotated in the forward direction driving the Nudger Roller to feed paper to the Feed Roller. The Nudger Solenoid remains activated at 24.5 V (high power) for 80 ms. After that, voltage drops to 14.7 V (low power) until the Nudger Solenoid is deactivated. If another feed start signal arrives while the solenoid is at low power, the solenoid remains at low power while pressing the Nudger Roller against the paper. As the end of the sheet reaches the Pre-Feed Sensor. the signal goes High. This deactivates the Nudger Solenoid and separates the Nudger Roller from the paper. The Feed/Lift Motor also decelerates. Feed/Lift Motor start/stop timing and speed are controlled by the Feed/Lift Motor Start signal and the Pre-Feed Sensor.
Take Away Motor
Paper Take Away Roller Feed Out Sensor #6

s5500-269
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.
Theory of Operation
2-43
Feed Start Signal

50 - 300 ms 0 - 100 ms
Nudger Solenoid Feed Motor Pre-Feed Sensor Feed Out Sensor Take Away Motor
50 - 400 ms
s5500-270
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. Docking Interlock Switch When Open transfer of paper from the tray is stopped.
Door J Interlock
Docking Interlock
s5500-271
2-44
Paper Size Sensors Paper size is automatically detected by two sensors, Size Sensors A and B, that are actuated by the Rear Size Guide attached to the tray. The Rear Size Guide adjusts to accommodate the supported paper sizes and is locked by a thumbscrew. 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. Feed Out Sensor #6 The Feed Out Sensor detects whether paper has been fed from the tray. The Feed Out sensor also serves as a trigger to stop the Feed Motor and controls the Take Away Motor speed. The Feed Out Sensor signal goes High when paper is present.
Theory of Operation
2-45
Tray Assembly
The following describes the operation and components related to the 2000-Sheet Feeder tray assembly.
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.
2-46
2. Reverse the Feed/Lift Motor 50 ms after completion of the paper transfer to the printer, then stop the motor after 120 ms. The quick lifting is carried out while the motor is rotating in reverse. The Nudger Solenoid is deactivated during the quick lift. At this time, the Nudger Roll is off the paper, and therefore no paper is fed. The tray doesnt lift when a paper jam occurs in the 2000-Sheet Feeder or when the Door J Interlock or Docking Interlock Switch detects Interlock Open. Bottom Plate lowering occurs when the Tray is opened. The lift mechanism is disengaged and the Bottom Plate lowers by gravity.
Paper Size Settings

Paper size is automatically detected by two sensors, Size Sensors A and B, that are actuated by the Rear Size Guide attached to the tray. The Rear Size Guide adjusts to accommodate the supported paper sizes.
Paper Size Sensor A
Paper Size Sensor B
Rear Size Guide
s5500-274
Detectable paper size and sensor logic level patterns are as follows:
Paper Size
B5/Executive 7.25 x 10.5 8.5 x 11 A4 0 0 1 0 1 0
Size Sensor A
Size Sensor B
Theory of Operation
2-47
Paper size is determined during the printers startup procedure, and is checked again 500 ms after the Tray In Sensor state transitions from Low to High. Paper size is also monitored every 100 ms. The paper size is established following five consecutive readings of the same paper size. If the size sensor state does not match any known pattern, paper size is indeterminate and paper feeding is inhibited.
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.
Level Sensor
Nudger Solenoid Feed/Lift Motor
Front
s5500-275
Detection of remaining paper volume is calculated in one of the following ways. 1. During startup procedure or when the tray is closed: Remaining paper volume is determined based on the time period from Feed/Lift Motor lift until the Tray 6 Level Sensor goes High. 2. During quick lifting while feeding: Remaining paper volume is determined by totaling the initial lifting time, during startup procedure or when the tray is inserted, and the quick lifting time (120 ms per lift). Quick lifting time (120 ms x number of lifting times) + Initial lifting time = Total lifting time 3. When the Tray is removed: No Tray is detected, and therefore the remaining paper volume is zero.
2-48
The following table lists volume indications corresponding to tray lift timing.
Paper Volume Indication
25% 50% 75% FULL
Tray Lift Time (ms)

8798 - 11526 6068 - 8797 3338 - 6067 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.
2000-Sheet Feeder Drive and Electrical

Functions of the sensors and motors of the Feeder outlined below.
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. Take Away Motor The Take Away Motor drives the Take Away Roller to feed paper to the printers paper path. 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.
Theory of Operation
2-49
Tray 6 PWB Located behind the Rear Cover, the Tray 6 PWB manages the 2000-Sheet Feeder based on commands from the Engine Logic Board and reports sensor status.
Tray 6 PWB
PF06 PF08 PF01
PF05
PF04
PF03
PF02
Rear
s5500-331
Door J Interlock Switch When opened, the Door J Interlock cuts 24 V power to the Feed/Lift and Take Away motors and inhibits printing. Docking Interlock Switch When the Docking Interlock is opened, paper feeding from Tray 6 is stopped. Tray In Sensor When the tray is opened, the Tray In sensor inhibits feeding from Tray 6.
2-50
FRU Disassembly
In this chapter...

Overview General Notes on Disassembly Option Disassembly
Section
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
3-2
General Notes on Disassembly

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.
Notations in the Disassembly Text
The notation PLX.X.X appearing above each illustration indicates the FRU Parts List where the subject component is listed. Bold arrows in an illustration show direction of movement when removing a component. To indicated the order of motions for removal, bold arrows may also be numbered. Reverse indicated motions for installation.
FRU Disassembly
3-3
1000-Sheet Feeder Disassembly

The 1000-Sheet Feeder consists of two identical, universal trays, two feeders, and associated sensors incorporated into a common frame. 1000-Sheet Feeder FRUs include:

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 righthand 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.
3-4
Top Cover
1. Pull out Tray 4. (PL20.1.1)
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.
FRU Disassembly
3-5
Right Cover
PL20.1.3
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).
3-6
PL20.1.2
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
Left Cover
1. Remove the Tray 6 docking bracket if present. 2. Remove the two screws securing the Left Cover to the frame.
s5500-279
FRU Disassembly
3-7
3. Lift the Left Cover to release it from the frame. 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.
3-8
Casters
1. Remove Trays 4 and 5. 2. Position the module with its right side down. PL20.1.6 / 7
Front Caster (Stopper)

s5500-281
3. Remove the three screws securing the Caster to the frame. 4. Remove the Caster.
FRU Disassembly
3-9
Paper Size Switch

This procedure describes Tray 4 Size Switch removal. Removal of the Tray 5 switch is essentially the same. 1. Remove Trays 4 and 5. PL20.2.4
Paper Size Switch
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.
3-10
Tray Feeder
This procedure describes Tray 4 Feeder removal. Removal of the Tray 5 feeder is essentially identical. 1. Remove the tray. 2. Remove the Left Cover (page 3-7) 3. Open Door C. PL20.2.7
Support
Left
Feed Out Chute

s5500-282
4. Remove the screw securing the Support to the frame. 5. Remove the bosses left and right securing the Feed Out Chute to the frame and remove the Feed Out Chute.
FRU Disassembly
3-11
Clamp
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.
3-12
Feed/Lift Motor
1. Remove the Feeder (page 3-11). PL2.3.2
Feeder Assembly
Feed/Lift Up Motor
Connector
s5500-104
2. Disconnect the connector from the Feed/Lift Motor. 3. Remove the two Phillips screws securing the Feed/Lift Motor to the Feeder. 4. Remove the Feed/Lift Motor.
FRU Disassembly
3-13
Tray 4 and 5 No Paper Sensor

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.
3-14
Tray 4 and 5 Level Sensor Actuator

Feeder
Bosses
Actuator
Upper Frame
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.
FRU Disassembly
3-15
Tray 4 and 5 Level Sensor

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.
3-16
Tray 4 and 5 Pre-Feed Sensor

Feeder
Pre Feed Sensor

s5500-111
2. Remove the Pre-Feed Sensor from the Front Chute as shown in the figure. 3. Disconnect the connector from the Pre-Feed Sensor.
FRU Disassembly
3-17
Feed Roller
1. Remove the tray. PL2.3.20
Shaft
Oneway Gear (22T) Oneway Clutch
Feed Roll
Front Chute
s5500-114
2. Move the Front Chute in the direction of the arrow. 3. Release the hook securing the Feed Roller to the shaft and remove the Feed Roller.
3-18
Retard Roller
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.
FRU Disassembly
3-19
Nudger Roller
Support Assembly
Nudger Roller
Front Chute
s5500-120
2. Move the Front Chute in the direction of the arrow. 3. Release the hook securing the Nudger Roller to the Shaft as shown in the figure. 4. Remove the Nudger Roller.
3-20
Tray 4 Feed Out Sensor #4

1. Open Door C. PL20.5.3
Chute Bottom View Hooks Feed Out Sensor #4
Left
s5500-284
2. Remove the two screws securing the Chute to the frame. 3. Disconnect the Feed Out Sensor #4 from the harness. 4. Release the hooks securing the Feed Out Sensor #4 to the Chute as shown in the figure. Replacement Note Put the Actuator attached to the Feed Out Sensor #4 into the hole on the Chute.
FRU Disassembly
3-21

Bottom View
Support
Hooks
Chute
Feed Out Sensor #5 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.
3-22
Upper Take Away Roller

E-Ring
Gear Bearing Upper Take Away Roller
E-Ring EL-Clip Chute
Left
s5500-286
2. Remove the two screws securing the Chute. 3. Disconnect the Chute from the harness to remove the Chute. 4. Remove the EL-Clip securing the upper Take Away Roller. 5. Remove the Bearing from the frame. 6. Move the upper Take Away Roller in the direction of the arrow to remove. 7. Remove the left and right E-rings on the upper Take Away Roller, and remove the gear and bearing.
FRU Disassembly
3-23
Lower Take Away Roller

Chute
E-Ring
Gear
EL Clip Bearing Lower Take Away Roller E-Ring

s5500-287
Left
2. Remove the two screws securing the Chute. 3. Disconnect the Chute from the harness to remove the Chute. 4. Remove the EL-Clip securing the lower Take Away Roller. 5. Remove the bearing from the frame. 6. Move the lower Take Away Roller in the direction of the arrow to remove. 7. Remove the left and right E-rings on the lower Take Away Roller and remove the gear and the 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.
3-24
Upper Pinch Roller Assembly

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.
FRU Disassembly
3-25
Lower 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.
3-26
Pinch Roller
1. Open Door C 2. Remove the defective Pinch Roller.(page 3-25 or page 3-26). PL20.5.15
Spring
Pinch Roller
Left
Bracket
s5500-290
3. Place the Pinch Roller upside down. 4. Remove the three Springs that secure the bearings from the bracket. 5. Remove the Pinch Roller. 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.
FRU Disassembly
3-27
Door C Interlock Switch

Bracket Door C Interlock Switch Left

s5500-291
2. Remove the screw securing the bracket to the frame. 3. Disconnect the Door C Interlock Switch from the harness to remove the bracket. 4. Release the hooks securing the switch to the bracket. 5. Remove the switch.
3-28
Tray 4-5 PWB

1. Remove the Rear Cover (page 3-8). PL20.6.1
Tray Module PWB
Rear
s5500-292
2. Disconnect the five connectors and harness from the PWB. 3. Remove the four screws securing the PWB to the frame. 4. Remove the PWB.
FRU Disassembly
3-29
Take Away Clutch

Bracket
Rear
s5500-293
2. Disconnect the Take Away Clutch connector from the bracket. 3. Remove the two screws securing the bracket to the frame.
Bearing Washer Bearing Bracket Shaft Gear (38T) Clutch
E-Ring Rear
s5500-294
3-30
4. Remove the E-ring securing the Gear 38T to the bracket and remove the Gear 38T. 5. Disconnect the Take Away Clutch connector from the Bracket by releasing the hook. 6. Remove the Take Away Clutch. 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

Take Away Motor
Rear
s5500-295
2. Disconnect the harness from the Take Away Motor. 3. Remove the two screws securing the Take Away Motor to the frame. 4. Remove the Take Away Motor.
FRU Disassembly
3-31
2000-Sheet Feeder Disassembly

When servicing the 2000-Sheet Feeder, empty the trays contents, disconnect the data/ power cable from the printer and slide the Tray Module away from the optional trays. This slide capability allows you, in most cases, to service the Tray Module without having to completely separate it from the optional trays. To avoid confusion, these procedures refer to the entire 2000-Sheet Feeder as the Tray Module. The Tray itself is referred to as the tray.
Docking the 2000-Sheet Feeder

For servicing procedures that require removal of the Tray Module, disconnected it from the printer using this procedure. 1. Disconnect the interface cable from the printer. 2. Slide the feeder out from the printer. 3. Release the docking bracket, located at the lower right by pressing the latch toward the rear.
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
Tray 6 Rear Cover

1. Slide the Tray Module away from the printer. PL22.1.14
Tray 6 Rear Cover
s5500-296
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 6 Top Cover

1. Slide the Tray Module away from the printer. 2. Pull out the tray. 3. Remove the Rear Cover (page 3-37).
FRU Disassembly
3-33
PL22.1.1
Top Cover
Tray
s5500-297
4. Remove the two screws on each end securing the Top Cover to the frame. 5. Remove the Top Cover.
3-34
Tray 6 Right Cover

1. Slide the Tray Module away from the printer. PL22.1.2
Tray
Right Cover
s5500-298
2. Remove the four screws securing the Right Cover to the frame. 3. Remove the Right Cover.
FRU Disassembly
3-35
Tray 6 Left Cover

1. Slide the Tray Module away from the printer. 2. Pull out the tray. 3. Remove the Rear Cover (page 3-37). 4. Remove the Top Cover (page 3-33). PL22.2.11
Left Cover
s5500-299
5. Remove the four screws securing the Left Cover to the frame. 6. Remove the Left Cover.
3-36
Tray 6 Front Cover

1. Pull out the tray. PL22.2.1
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.
FRU Disassembly
3-37
PL22.7.1
Rear Hinge Bracket Torsion Spring L
Torsion Spring R
Torsion Spring R
Door J Door J Top Pivot Shaft Torsion Spring L Top Pivot Shaft D-Cut Door J D-Shaped Hole Torsion Spring L Longitudinal Hole
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.
3-38
7. Lift Door J from the rear while holding the Rear Hinge Bracket and Pivot Shaft in place. Move the door assembly to the rear to remove the Pivot Shaft and Torsion Spring from the Front Hinge Bracket. 8. Remove the Top Pivot Shaft, Torsion Spring R and Torsion Spring L from 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
FRU Disassembly
3-39
Tray 6 Casters
1. Unload and completely disconnect the Tray Module from the Printer. PL22.1.8
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.
3-40
Tray 6 Tray In Sensor

1. Slide the Tray Module away from the printer. 2. Pull out the tray. 3. Remove the Rear Cover (page 3-37). 4. Remove the Top Cover (page 3-33). PL22.1.4
Front
Tray In Sensor
s5500-304
5. Disconnect the connector (JF53) from the Tray In Sensor. 6. Release the hooks securing the sensor to the frame to remove the Tray In Sensor. Replacement Note Push the tray into the Tray Module to check that the sensor properly aligns with the tray shutter.
FRU Disassembly
3-41
Tray 6 Paper Size Sensors A/B

1. Slide the Tray Module away from the printer. 2. Pull out the tray. 3. Remove the Rear Cover (page 3-37). 4. Remove the two screws securing the sensor bracket to the frame. PL22.1.4
Sensor Bracket JF52
Size Sensor A Size Sensor B Rear Size Guide 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.
3-42
Tray 6 End Guide Assembly

1. Open the tray. PL22.2.14
E-Ring
Tray End Guide

2. Remove the E-ring securing the End Guide to the tray. 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.
s5500-306
FRU Disassembly
3-43
Tray 6 Gear Assembly

1. Remove the tray (page 3-39). 2. Remove the two E-rings securing the Lift Shaft support and remove the support. 3. Remove the Lift Shaft Drive gear and Transfer gear. PL22.3.8
Gear Assembly
Tray
s5500-308
4. Remove the three screws securing the Gear Assembly. 5. Remove the Gear Assembly by slipping it out from underneath the cable. Replacement Note When installing the Gear Assembly, engage the gears with the tray.
3-44
Tray 6 Cables
1. Remove the tray (page 3-39). 2. Remove the Front Cover (page 3-37). 3. Remove the Gear Assembly Bracket R PF2 (page 3-44). PL22.3.6
E-Ring
(1) (2) (3) Pulley (3) Cables
Pulley
Lift Shaft Powered Bearing
Guide Wire Ss Pulley Ss Cables
Guide Wire L Pulley L
Cable Bottom Plate

s5500-309
Bottom Plate
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).
FRU Disassembly
3-45
8. Detach the ends of the two cables from the Lift Shaft.
Pulley
Pulley
(6) Lift Shaft
(5)
(4) 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.
3-46
17. Remove the two E-rings securing the two Pulley Ss and remove the two Wire Guides Ss and two Pulley Ss. 18. Remove the E-ring securing the Pulley L to remove the Wire Guide L and Pulley L. 19. Remove the two Cables from the Bottom Plate.
Tray Cable Replacement Procedure

The following summarizes the Cable replacement procedure. Refer to the preceding illustrations as a reference while reinstalling the cables. 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.
FRU Disassembly
3-47
18. Fix the Powered Bearing to the Lift Shaft using the E-ring. 19. Install the Gear Assembly Bracket R PF2 (page 3-44). 20. Install the Front Cover (page 3-37). 21. When the Lift Gear is turned by hand, make sure that the Bottom Plate moves upand-down at the rear and front sides simultaneously. 22. Install the tray.
Tray 6 Feeder Assembly

1. Disconnect the Tray Module from the printer (page 3-32). 2. Remove the Rear Cover (page 3-37). 3. Remove the Top Cover (page 3-33). 4. Remove the tray (page 3-39). 5. Open Door J. PL22.4.1
Door J
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.
3-48
Tray 6 Feed/Lift Motor

1. Disconnect the Tray Module from the printer (page 3-32). 2. Remove the Rear Cover (page 3-37). 3. Remove the Top Cover (page 3-33). 4. Remove the tray (page 3-39). 5. Open Door J. 6. Remove the Feeder Assembly (page 3-48). PL22.4.2
Feed/Lift Motor Feeder
(PF58)
s5500-313
7. Disconnect the Feed/Lift Motor connector (PF58) from the Feeder. 8. Remove the four Phillips screws securing the Feed/Lift Motor to the Feeder. 9. Remove the Feed/Lift Motor.
Tray 6 Drive Frame Assembly

1. Slide the Tray Module away from the printer. 2. Disconnect the Tray Module from the printer (page 3-32). 3. Remove the Rear Cover (page 3-37). 4. Remove the Top Cover (page 3-33). 5. Remove the tray (page 3-39). 6. Open Door J. 7. Remove the Feeder Assembly (page 3-48). 8. Remove the Feeder Motor (page 3-49).
FRU Disassembly
3-49
PL22.4.3
Drive Frame Feeder
s5500-314
9. Remove the three screws securing the Drive Frame to the Feeder.
Tray 6 Nudger Solenoid

1. Disconnect the Tray Module from the printer (page 3-32). 2. Remove the Rear Cover (page 3-37). 3. Remove the Top Cover (page 3-33). 4. Remove the tray (page 3-39). 5. Open Door J. 6. Remove the Feeder Assembly (page 3-48). 7. Remove the Feed/Lift Motor (page 3-49). 8. Remove the Drive Frame Assembly (page 3-49).
3-50
PL22.4.5
Link
Rear Frame Pin Nudger Solenoid
Feeder
s5500-315
9. Disconnect the Feeder harness connector from the Solenoid. 10. Remove the two screws securing the Rear Frame to the Feeder and remove the Rear Frame. Replacement Note When installing the solenoid, engage the solenoid with the Link on the Rear Frame.
Tray 6 Pre-Feed Sensor

1. Slide the Tray Module away from the printer. 2. Open Door J. 3. Open the Upper Feeder Assembly using the black release lever located towards the front of the feeder.
FRU Disassembly
3-51
PL22.5.9
Upper Chute
Pre Feed Sensor
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.
3-52
Tray 6 No Paper Sensor Actuator

1. Slide the Tray Module away from the printer. 2. Open Door J. 3. Open the Upper Feeder Assembly using the black release lever located towards the front of the feeder. PL22.5.15
Actuator
E-Ring
No Paper Sensor
s5500-317
4. Remove the E-ring securing the Actuator to the Upper Feeder. 5. Remove the Actuator. Replacement Note The Actuator must fall smoothly into the recess on the No Paper Sensor.
FRU Disassembly
3-53
Tray 6 No Paper Sensor

No Paper Sensor PF60
Actuator
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.
3-54
Tray 6 Level Sensor

Tray 6 Level 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.
FRU Disassembly
3-55
Tray 6 Nudger Roller

Nudger Roller
Front
s5500-320
4. Remove the Nudger Roller by compressing the ends of the shaft with your fingers.
3-56
Tray 6 Feeder Shaft Assembly

1. Slide the Tray Module away from the printer. 2. Open Door J. 3. Open the Upper Feeder Assembly using the black release lever located towards the front of the feeder. 4. Remove the Nudger Roller from the Upper Feeder (page 3-56). PL22.5.19
Upper Frame
Bearing E-Ring Feeder Shaft Bearings
Upper Feeder Assembly Front

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. 6. Remove the Bearing. 7. Remove the three Bearings attached to the Feeder Shaft to remove the Feeder Shaft from the Upper Feeder.
s5500-321
FRU Disassembly
3-57
Tray 6 Feed Roller

Feed Roller
Front
s5500-322
4. Remove the Feed Roller by compressing the shaft ends with your fingers.
3-58
Tray 6 Retard Roller

1. Open Door J. 2. Open the Upper Feeder Assembly using the black release lever located towards the front of the feeder. PL22.6.17
Retard Roller
Front
s5500-323
3. Remove the Retard Roller from the Lower Feeder by compressing the shaft ends with your fingers.
Tray 6 Lower Feeder Assembly

1. Disconnect the Tray Module from the printer (page 3-32). 2. Remove the Rear Cover (page 3-37). 3. Remove the Top Cover (page 3-33). 4. Remove the tray (page 3-39). 5. Open Door J. 6. Remove the Retard Roller (page 3-59). 7. Remove the Feeder Assembly (page 3-48).
FRU Disassembly
3-59
PL22.6.1
Feeder
Lower Feeder Assembly

8. Remove the Tray 6 Drive Frame (page 3-49).
s5500-324
9. Remove the two screws at the rear securing the Lower Feeder Assembly to the Feeder. 10. Remove the Lower Feeder Assembly.
Tray 6 Retard Clutch, Bracket or Spring

1. Disconnect the Tray Module from the printer (page 3-32). 2. Remove the Rear Cover (page 3-37). 3. Remove the Top Cover (page 3-33). 4. Remove the tray (page 3-39). 5. Open Door J. 6. Remove the Retard Roller (page 3-59). 7. Remove the Feeder Assembly (page 3-48). 8. Remove the Lower Feeder Assembly (page 3-59).
3-60
PL22.6.8
Lower Chute
Lower Frame
Bearing Bearing-6 Retard Shaft
Retard Spring
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. 13. Remove the Retard Shaft from the Lower Frame. 14. Remove the Retard Clutch by removing the E-clip and Gear at the Clutch-end of the Retard Shaft. 15. Remove the Retard Bracket by removing the E-clip and Gear at the bracket-end of the Retard Shaft.
FRU Disassembly
3-61
Door J Interlock Switch

1. Slide the Tray Module out from the optional trays. 2. Remove the Right Cover (page 3-35). 3. Open Door J. PL22.7.3
Switch
Bracket Switch
s5500-326
4. Remove the two screws securing the switch bracket. 5. Remove the bracket and switch. 6. Disconnect the two connectors from the base of the switch. 7. Release the hooks securing the switch to the bracket and remove the switch.
3-62

1. Slide the Tray Module out from the optional trays. 2. Remove the Right Cover (page 3-35). 3. Open Door J. PL22.7.6
Lower Chute
Feed Out Sensor
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.
FRU Disassembly
3-63
Tray 6 Take Away Motor

1. Slide the Tray Module out from the optional trays. 2. Remove the tray (page 3-39). 3. Remove the Right Cover (page 3-35). 4. Remove the Rear Cover (page 3-37). PL22.7.12
Take Away Motor
Harness Clamp
PF57
5. Release the harness from the clamp and leave it detached. 6. Disconnect the connector from the motor. 7. Remove the three screws securing the motor bracket to the frame. 8. Remove the motor assembly.
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.
3-64
Take Away Roller Assembly

1. Slide the Tray Module away from the printer. 2. Remove the Right Cover (page 3-35). 3. Remove the Rear Cover (page 3-37). 4. Open Door J. PL22.7.9
Lower Chute Assembly Take Away Motor
Take Away Roller Shaft Bearing K-Clip
s5500-329
5. Remove the Take Away Motor (page 3-64). 6. Remove the trim piece on the front right by removing the two screws and shifting the trim to the right. 7. Remove the two screws at the rear and one screw at the front securing the Lower Chute to the frame. 8. Set the Lower Chute aside. Since the harness connects to the Feed Out Sensor #6 and Interlock Switch, the Lower Chute need not be disconnected from the frame. 9. Shift the Take Away Roller shaft towards the rear to remove the front side of the shaft from the Conductive bearing. 10. Transfer the K-clip to the replacement shaft if required. 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.
FRU Disassembly
3-65
Docking Interlock Switch

1. Slide the Tray Module out from the optional trays. 2. Disconnect the Tray Module from the printer (page 3-32). 3. Remove the Right Cover (page 3-35). 4. Open Door J. PL22.7.17
N.O.
Hook
FS004
Front
COM Docking Interlock Switch
s5500-330
5. Disconnect the connectors attached to the Docking Interlock Switch. 6. Release the hooks securing the switch to the frame and remove the switch. Replacement Note Connect the FS004 connectors to the COM and N.O. terminals on the switch.
3-66
Tray 6 PWB
1. Slide the Tray Module out from the optional trays. 2. Pull out the tray. 3. Remove the Rear Cover (page 3-37). PL22.8.1
Tray 6 PWB
PF06 PF08 PF01
PF05
PF04
PF03
PF02
Rear
s5500-331
4. Disconnect the seven connectors from the PWB. 5. Remove the four screws securing the PWB to the frame. 6. Remove the PWB.
FRU Disassembly
3-67
Duplex Unit Disassembly

Duplex Unit Removal
PL23.1.1
Clamp
Clamp Rear Option Interface Cover
s5500-332
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.
3-68
Outer Chute Lock
Release
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. 6. Remove the Duplex Unit.
FRU Disassembly
3-69
Duplex Unit Chutes and Cover

1. Remove the Duplex Unit (page 3-68). PL23.1.13
Lower Chute
Outer Chute
2. Remove the two screws securing the Lower Chute to the Outer Chute.
s5500-334
3-70
Stopper
Hook
Inner Chute
Outer Chute
Stopper Cable Cutout
Duplex Cover
3. Open the Inner Chute.
s5500-335
4. Release the hook of the Stopper securing the Outer Chute to the Inner Chute. 5. Remove the four screws securing the Outer Chute and the Inner Chute to the Duplex Unit Cover to remove the Chutes. 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).
Clamp
Motor Harness
Rear Outer Chute Motor Bracket

3. Disconnect the connector from the motor harness. 4. Release the motor harness from the clamps on the Outer Chute.
s5500-336
3-72
5. Disconnect the connector from the Door D Interlock Switch (See page 3-74). 6. Remove the three screws securing the motor bracket to the Outer Chute. 7. Remove the latch spring between the front Lever Latch and the Outer Chute. 8. Rotate the latch shaft so the index tabs on the Front Latch Lever and Rear Latch Lever align with the removal notches on the Outer Chute. PL23.1.7
Notch Index Tab
s5500-633
9. Slide the Front and Rear Latch Levers off the latch shaft.
FRU Disassembly
3-73
Door D Interlock Switch

1. Remove the Duplex Unit (page 3-68). 2. Remove the Duplex Unit Chutes and Cover (page 3-70). PL23.1.9
Connector Door D Interlock Switch
Hooks
Motor Bracket Rear Outer Chute

3. Disconnect the connector from the Door D Interlock switch. 4. Release the two hooks securing the switch to the bracket as shown in the figure. 5. Remove the Door D Interlock Switch.
s5500-340
3-74
Wait Sensor Actuator

Wait Sensor
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.
FRU Disassembly
3-75
Duplex Motor
Clamps
Motor Harness
Outer Chute
Left
Duplex Motor
s5500-342
3. Disconnect the harness connector from the harness. 4. Release the harness from the clamps on the Outer Chute. 5. Remove the two screws securing the Duplex Motor to the bracket. 6. Remove the Duplex Motor.
3-76
Duplex Unit PWB

Duplex PWB
Outer Chute
Right
s5500-343
3. Disconnect the three connectors from the Duplex PWB. 4. Remove the two screws securing the Duplex Unit PWB to the Outer Chute. 5. Remove the Duplex PWB.
FRU Disassembly
3-77
Duplex Wait Sensor

Hooks
Wait Sensor
Outer Chute
Left
Outer Chute
s5500-344
3. Disconnect the connector from the sensor. 4. Release the three hooks securing the sensor to the Outer Chute. 5. Rotate the Wait Sensor Actuator. 6. Remove the sensor.
3-78
Exit 2 Disassembly
Exit 2 Transport Assembly
1. Open Door A. PL24.1.1
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.
FRU Disassembly
3-79
Face-Up Roller
1. Open Door A. 2. Remove Exit 2 (page 3-79). 3. Open Exit 2. PL24.1.19
Stopper
Push
Lower Chute
E-Ring
Front Boss L/H Chute High

s5500-348
4. Remove the screw securing the Rear Cover. 5. Remove the hook holding the Stopper. 6. Remove the E-ring securing the Solenoid Link-FU to the L/H Chute High. 7. Release the boss on the right side (front) of the L/H Chute High from the Lower Chute- 2. Remove the right side (front) first, otherwise the Gear may be damaged.
3-80
8. Release the boss on the left side (rear) of the L/H Chute High from the Lower Chute-2 and remove the L/H Chute High.
Upper Chute-FU
L/H Chute High
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.
FRU Disassembly
3-81
Face-Up Roller Stopper Gear 19Z Bearing E-Ring
L/H Chute High 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.
3-82
Invert Roller
1. Open Door A. 2. Remove Exit 2 (page 3-79) 3. Open Exit 2. PL24.1.20
Stopper
Push
Lower Chute
E-Ring

s5500-348
4. Remove the screw securing the Rear Cover 5. Remove the hook holding the Exit 2 Stopper. 6. Remove the E-ring securing the Solenoid Link-FU to the L/H Chute High. 7. Release the boss on the right side (front) of the L/H Chute High from the Lower Chute- 2. Remove the right side (front) first, otherwise the Gear may be damaged.
FRU Disassembly
3-83
8. Release the boss on the left side (rear) of the L/H Chute High from the Lower Chute-2 and remove the L/H Chute High.
Upper Chute-FU
L/H Chute High
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.
3-84
Bearing L/H Chute High
Rear E-Ring Invert Roller
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.
FRU Disassembly
3-85
Exit 2 Tray Guide

1. Open Door A. 2. Remove Exit 2 (page 3-79). 3. Open Exit 2. PL24.2.1
Stopper
Push
Lower Chute
E-Ring

s5500-348
4. Remove the screw securing the Rear Cover 5. Remove the hook holding the Exit 2 Stopper. 6. Remove the E-ring securing the Solenoid Link-FU to the L/H Chute High. 7. Release the boss on the right side (front) of the L/H Chute High from the Lower Chute. Remove the right side (front) first, otherwise the Gear may be damaged.
3-86
8. Release the boss on the left side (rear) of the L/H Chute High from the Lower Chute. 9. Remove the Lower Chute.
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.
Stack Full Actuator

1. Open Door A. 2. Remove Exit 2 (page 3-79). 3. Open Exit 2. 4. Remove the Tray Guide(page 3-86).
FRU Disassembly
3-87
PL24.2.6
Lower Chute
Rear Cover
Tray Guide
Hooks Rear Square Hole Hook
Hook Paper Weight-B Spring Hook Hook
Slit Paper Weight-A
s5500-353
5. Remove the actuator from the spring. 6. Release the hook securing the actuator to the Tray Guide, as shown in the figure. Use care when releasing the Tray Guide hook. 7. Release the spring from the hook on the actuator.
3-88
Offset Gear
1. Open Door A. 2. Remove Exit 2 (page 3-79). 3. Open Exit 2. 4. Remove the Tray Guide (page 3-86). 5. Slide the OCT Roller fully to the right (front). PL24.2.19
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.
FRU Disassembly
3-89
OCT (Offset) Roller

1. Open Door A. 2. Remove Exit 2 (page 3-79). 3. Open Exit 2. 4. Remove the Offset Gear (page 3-89). PL24.2.7
Lower Chute Gear (19Z)
Bearing
Hook Hook 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.
3-90
Exit 2 Pinch Roller

1. Open Door A. 2. Remove Exit 2 (page 3-79). 3. Open Exit 2. 4. Remove the OCT Roller (page 3-90). PL24.2.10
Spring Exit Pinch Roller
Release
E-Ring Roller Bearing OCT Chute Hook
Hook
E-Ring
OCT Roller
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.
s5500-356
FRU Disassembly
3-91
Exit Sensor Actuator

1. Open Door A. 2. Remove Exit 2 (page 3-79). 3. Open Exit 2. 4. Remove the Tray Guide (page 3-86). PL24.2.17
Hook
Actuator Spring
Actuator Spring
Flap
Lower Chute
Front
s5500-357
5. Release the hook of the Exit Sensor Actuator Spring as shown. 6. Place the actuator in the position shown. Move it in the direction of the arrow to release the hook on the Lower Chute.
3-92
7. Remove the Exit Sensor Actuator. 8. Remove the spring attached to the actuator. 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).
Exit 2 Fan Connector
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.
FRU Disassembly
3-93
7. Remove the screw securing the Fan to the Lower Chute 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.
3-94
Door E Interlock Switch

Front
s5500-358
5. Release the harness secured to the guide on the backside of the Lower Chute.
FRU Disassembly
3-95
s5500-359
6. Disconnect the connector from the Interlock Switch. 7. Release the hooks securing the Interlock Switch to the Lower Chute. 8. Remove the Interlock Switch. Replacement Note Return the harness to the guides.
Face-Up Solenoid
3-96
PL24.2.23
Face-Up Solenoid
Positioning Boss
Link
Rear
Front Solenoid Harness

s5500-360
5. Lift the connector secured to the guide on the Lower Chute. 6. Disconnect the Face-Up Solenoid from the connector. 7. Remove the screw securing the Face-Up Solenoid to the Lower Chute 2.
FRU Disassembly
3-97
8. Remove the Face-Up Solenoid. 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

3-98
PL24.2.29
Exit Gate Solenoid
Front
Link Lower Chute
Clamp
s5500-361
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).
3-100
PL24.2.30.
Offset Motor
Rear Lower Chute
Rear
Offset Motor Harness

s5500-362
6. Disconnect the Offset Motor from the junction connector. 7. Remove the two Phillips screws securing the Offset Motor to the Lower Chute. 8. Remove the Offset Motor.
FRU Disassembly
3-101
Exit Sensor
Exit Sensor
Hook Front
Actuator Lower Chute

5. Disconnect the Exit Sensor from the connector.
s5500-363
6. While moving the actuator in the direction of the arrow, release the hooks securing the sensor to the Lower Chute as shown.
3-102
OCT Home Position Sensor

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 OCT Roller (page 3-90). PL24.2.35
OCT Position Sensor
Lower Chute Hooks Offset Gear
LOW CHUTE
Rear
s5500-364
6. Disconnect the OCT Position Sensor from the connector. 7. Release the hooks securing the sensor to the Lower Chute as shown in the figure. 8. Remove the OCT Position Sensor.
FRU Disassembly
3-103
Exit 2 Motor
Rear
Connector
Rear
Exit Motor
Rear Plate Connector

s5500-365
3-104
5. Lift the connectors from the guide on the back of the Lower Chute. 6. Disconnect the Exit Motor from the junction connector. 7. Disconnect the Interlock Switch connector. 8. Remove the two screws securing the Exit connector to the Rear Plate and remove the connector. Turning the connector perpendicular to its mount makes removing the harness somewhat easier. 9. Remove the three screws securing the Rear Plate to the Lower Chute and remove the Rear Plate. 10. Remove the two Phillips screws securing the Exit Motor to the Rear Plate. 11. Remove the Exit Motor. Replacement Note Align the Exit connector so the top side has the most pins.
Full Stack Sensor

Sensor
Hook
Lower Chute
Front
s5500-366
5. Disconnect the sensor from the connector. 6. Release the hooks securing the sensor to the Lower Chute and remove it.
FRU Disassembly
3-105
Finisher/Stacker Disassembly
Horizontal Transport
1. Press at point A to remove the Connector Cover from the Finisher. PL25.1.2
A Converter Cover Right Rear Horizontal Transport

s5500-368
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
4. Remove the two screws securing the Horizontal Transport to the printer. 5. Remove the Horizontal Transport from the printer.
Horizontal Transport Rear Cover

PL25.3.1
Rear Cover
1. Remove the two screws securing the Rear Cover. 2. Remove the Rear Cover in the direction of the arrow.
s5500-370
FRU Disassembly
3-107
Door F
1. Remove the Horizontal Transport (page 3-106). 2. Remove the Rear Cover (page 3-107). 3. Open Door F to release the tension on the hinge springs. PL25.2.9
Square Hole Hinge
Door F Square Hole Hinge
Lower Chute
Hook
Hook
Drive Bracket
s5500-371
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.
3-108
Horizontal Transport Drive Belt

1. Remove the Horizontal Transport (page 3-106). 2. Remove the Rear Cover (page 3-107). PL25.3.2
Motor
Drive Belt Right Shaft Pulley

3. Remove the E-ring securing the pulley. Note Mark the pulley to indicate the outward facing side. 4. Remove the pulley and belt from the shaft. 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.
E-Ring
s5500-372
FRU Disassembly
3-109
Horizontal Transport Right Shaft

1. Remove the Horizontal Transport (page 3-106). 2. Remove the Rear Cover (page 3-107). 3. Remove the Belt Drive and the Pulley (page 3-109). PL25.3.14
Rear
Right Shaft
Bearing Right Shaft
s5500-373
Drive Bracket
Bearing E-Ring
Lower Chute Belts

4. Remove the Bearing on the rear side.
Front
s5500-374
3-110
5. Open Door F. 6. Remove the E-ring on the front. 7. Remove the Bearing on the front of the shaft. 8. Move the Right Shaft in the direction of the arrow to remove it from the hole on the Lower Chute, and then remove Right Shaft from the hole on the drive bracket 9. Remove the Right Shaft from the two belts.
Horizontal Transport Left Shaft

1. Remove the Rear Cover (page 3-107). 2. Open Door F. PL25.3.15
Lower Chute
Belts Front
Left Shaft
Bearing Bracket
s5500-375
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.
FRU Disassembly
3-111
Horizontal Transport Rollers

1. Remove the Horizontal Transport Left Shaft (page 3-111). 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.
3-112
Horizontal Transport Belts

1. Remove the Horizontal Transport (page 3-106). 2. Remove the Rear Cover (page 3-107). 3. Open Door F. 4. Remove the Right Shaft (page 3-110). 5. Remove the Left Shaft (page 3-111). 6. Remove the Rollers (page 3-112). PL25.3.12
Belts
Lower Chute
s5500-377
7. Remove the Belts from the Lower Chute.
Horizontal Transport Motor

1. Remove the Horizontal Transport (page 3-106). 2. Remove the Rear Cover (page 3-107). 3. Remove the Belt Drive (page 3-109).
FRU Disassembly
3-113
PL25.3.7
Motor
Clamp
Connector Rear
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.
s5500-378
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.
3-114
Horizontal Transport Top Cover

1. Remove the Rear Cover (page 3-107). 2. Open Door F. PL25.3.8
Top Cover
Lower Chute
s5500-380
3. Remove the two screws securing the Top Cover to the Lower Chute and remove the Top Cover.
FRU Disassembly
3-115
Door F Interlock Sensor

1. Remove the Horizontal Transport (page 3-106). 2. Turn the Horizontal Transport upside down. PL25.3.19
Door F Interlock Sensor 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.
3-116
Horizontal Transport Entrance Sensor

Entrance Sensor
Bracket
Lower Chute
s5500-601
3. Remove the screw securing the bracket to the Lower Chute. 4. Disconnect the connector from the Entrance Sensor. 5. Release the hooks securing the sensor to the bracket to remove the sensor.
FRU Disassembly
3-117
Horizontal Transport Exit Sensor

Bracket
Exit Sensor
Lower Chute
s5500-602
3. Remove the screw securing the bracket to the Lower Chute. 4. Disconnect the connector from the Exit Sensor. 5. Release the hooks securing the sensor to the bracket to remove the sensor.
3-118
Finisher Docking
1. Disconnect the Finisher power cord and connection cable from the the printer. 2. Disconnect theHorizontal Transport cable of the from the Finisher. 3. Open Door G. PL25.1.3
Door G
Docking Plate
s5500-382
FRU Disassembly
3-119
Boss Printer Docking Plate Docking Slots

s5500-383
1. Move the Finisher to the right while pulling the Docking Plate toward you. 2. Close Door G.
Finisher Upper Rear Cover

1. Remove the Connector Cover by pushing at point A to release the lock. 2. Disconnect the Horizontal Transport cable from the Finisher. PL25.4.11
A Upper Rear Cover Connector Cover

s5500-384
3. Remove the four screws securing the Upper Rear Cover to the Finisher and remove the cover.
3-120
Finisher Lower Rear Cover

1. Remove the Upper Rear Cover (page 3-120). PL25.4.9
Lower Rear Cover

s5500-385
2. Remove the four screws securing the Lower Rear Cover to the Finisher and remove the cover.
FRU Disassembly
3-121
Finisher Top Cover

1. Open Door G. 2. Remove the Upper Rear Cover (page 3-120). 3. Remove the Stacker Upper Tray (page 3-130). PL25.4.1
Top 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.
3-122
Finisher Bottom Cover

PL25.4.6
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.
FRU Disassembly
3-123
Finisher Door G
1. Open Door G. PL25.5.3
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.
3-124
Finisher Inner Cover

1. Remove Door G (page 3-124). PL25.5.5
Inner Cover Door G

s5500-389
2. Remove the four screws securing the inner Cover to Door G and remove the Inner Cover.
FRU Disassembly
3-125
Finisher Top Front Cover

1. Remove Door G (page 3-124). 2. Remove the Stacker Top Tray (page 3-130). 3. Remove Finisher Top Cover (page 3-122) PL25.5.1
Top Front 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.
3-126
Door G Interlock Switch

1. Open the Front Door. PL25.5.2
Dust Box Chute
Connector
Interlock Switch
2. Pull the Punch Box toward the front to remove it from the Finisher.
s5500-618
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.
FRU Disassembly
3-127
Finisher L/H Front Cover

1. Open Door G. PL25.5.8
Door G
L/H Front Cover
s5500-391
2. Remove the two screws securing the L/H Front Cover to the Finisher and remove the cover.
3-128
Finisher Top L/H Cover

1. Open Door G. 2. Remove the Upper Rear Cover (page 3-120). 3. Remove the Front L/H Cover. (page 3-128). PL25.5.9
Top L/H 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.
FRU Disassembly
3-129
Stacker Upper Tray

PL25.4.3
Stacker Upper Tray
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.
3-130
Finisher Eject Cover

1. Remove Door G (page 3-124). 2. Remove the Stacker Upper Tray (page 3-130). 3. Remove the Finisher Upper Rear Cover (page 3-120). PL25.4.4
Eject Cover
Right
4. Remove the two screws securing the Eject Cover to the Finisher. 5. Remove the Eject Cover.
FRU Disassembly
3-131
Stacker Lower Tray

PL25.4.5
Hooks Stacker Lower Tray Tray Carriage

s5500-395
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.
Stacker Bracket Assembly

1. Remove the Upper Rear Cover (page 3-120). 2. Remove the Lower Rear Cover (page 3-121).
3-132
PL25.6.24
Rear
Main PWB Cover

s5500-396
Pulley Doc Clutch Gear
Encoder
Rear
Stacker Lower Tray

s5500-397
3. Loosen the four screws securing the Finisher Main PWB Cover and remove it in the direction of the arrow.
FRU Disassembly
3-133
4. 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.
Stacker Encoder Sensor J8328 Bracket Clamp
Clamp
s5500-398
P8305
Main PWB
s5500-399
3-134
5. Release the harness from the cable restraint clamps. 6. Disconnect the connector (J8328) from the Stacker Encoder Sensor. 7. Disconnect the connector (P8305) on the Finisher Main PWB. 8. Remove the one screw securing the Sensor Bracket and remove it from the Stacker Bracket.
Stacker Bracket Encoder

s5500-400
9. Release the hook of the Encoder to remove. 10. Remove the three screws securing the Stacker Bracket.
FRU Disassembly
3-135
Stacker Left Belt

Do not to remove both Carriage Assemblies (Left/Right). When removing them, work on one at a time. After repairing one, work on the other. If both are removed together, a misalignment could occur binding the Stacker Tray. 1. Remove the Upper Rear Cover (page 3-120). 2. Remove the Front Door (page 3-124). PL25.6.2
Encoder
Rear
Stacker Lower Tray

s5500-397
3-136
Stacker Belt
Belt Clamp
Tray Carriage
Front Left Carriage Spring Pulley T18

s5500-401
4. Remove the two screws securing the Tray Carriage. 5. Remove the Spring. 6. Remove the screw securing the upper side of the Belt Clamp. 7. Remove the upper side of the Belt Clamp. 8. Detach, the Carriage with the Stacker Belt from the Finisher. 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.
FRU Disassembly
3-137
Stacker Right Belt

Do not to remove both Carriage Assemblies (Left/Right). When removing them, work on one at a time. After repairing one, work on the other. If both are removed together, a misalignment could occur binding the Stacker Tray. 1. Remove the Upper Rear Cover (page 3-120). 2. Remove the Front Door (page 3-124). PL25.6.8
Encoder
Rear
Stacker Lower Tray

s5500-397
3-138
Stacker Belt
Belt Clamp Tray Carriage
Rear
Right Carriage Pulley T16

4. Remove the Stacker Bracket (page 3-132). 5. Remove the two screws securing the Tray Carriage. 6. Remove the Spring on the Carriage.
Spring
s5500-402
7. Remove the one screw securing the upper side of the Belt Clamp. 8. Remove upper side of the Belt Clamp. 9. Remove the Carriage and Stacker Belt from the Finisher. 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.
FRU Disassembly
3-139

1. Remove Door G (page 3-124). PL25.6.13
J8331 Front Stack Height Sensor 1
s5500-403
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.
3-140

J8330
Rear
s5500-404
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.
FRU Disassembly
3-141

Bracket J8328 Harness Clamp
Rear Stacker Bracket

s5500-405
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.
3-142
Lower Tray Upper Limit and No Paper Sensors

1. Remove the Upper Rear Cover (page 3-120). 2. Remove the Stacker Bracket Assembly (page 3-132). PL25.6.17
Upper Limit Sensor Rear Stacker No Paper Sensor
J8327 (Yellow)
J8326
Upper Limit Sensor Stacker No Paper Sensor

s5500-406
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.
FRU Disassembly
3-143
Elevator Motor
1. Remove the Upper Rear Cover (page 3-120). 2. Remove the Lower Rear Cover (page 3-121). 3. Loosen the four screws securing the Finisher Main PWB Cover and remove in the direction of the arrow.
Rear
Main PWB Cover

s5500-396
4. Remove the two screws securing the Elevator Motor to the Stacker Bracket. PL25.6.26
Pulley T60
Belt
Elevator Motor
Stacker Bracket
s5500-407
5. Remove the Elevator Motor in the direction of the arrow while removing the Belt.
3-144
Finisher Punch
There are five settings for the Finisher Punch: 2-/3-hole, 2-/4-hole, 3-hole, 2-hole and, no punch. Although the following removal procedures are for the 2-/3-hole version, the procedures apply to all punch-equipped Finishers. 1. Open the Front Door. 2. Remove the Upper Rear Cover (page 3-120). PL25.7.1
Belt
J8344
Punch Move Home Sensor Sensor Bracket
Rear Punch Bracket J8352
Punch Frame J8346
Rear
s5500-408
3. Release the two harnesses of the Punch from the clamp. 4. Remove the three screws securing the Rear Punch Bracket to the frame and remove the bracket. 5. Disconnect the connector (J8344) from the Punch Move Motor. 6. Disconnect the connector (J8346) from the Punch Hole Select Sensor. 7. Release the harness Punch Move Home Sensor from the clamp on the Sensor Bracket. 8. Disconnect the connector (J8352) from the Punch Unit Move Home Sensor.
FRU Disassembly
3-145
9. Remove the screw securing the Punch Unit Move Home Sensor bracket and move the bracket aside. 10. Disconnect the connector (J8344) from the Punch Move Motor.
Front Punch Frame Front Punch Bracket

s5500-409
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.
3-146
Punch Move Motor

1. Remove the Finisher Top Cover (page 3-122). 2. Disconnect the connector (J8344) from the Punch Move Motor. PL25.7.4
Punch Move Motor Cover
Punch Move Motor Bracket
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.
FRU Disassembly
3-147
Finisher Punch Side Registration Sensors 1 & 2

1. Open Door G. 2. Remove the Upper Rear Cover (page 3-120). 3. Remove the Punch (page 3-145). PL25.7.8
Punch Frame
Punch Front Cover
J8350 J8351 Side Registration Chute

s5500-411
4. Remove the one screw securing the Punch Front Cover. 5. Remove the two screws securing the Side Registration Chute, to the Punch Frame. A harness connects the Side Registration Chute and the Punch Frame. The chute does not detach from the Punch Frame. 6. Remove the two screws securing the Sensor Bracket to the Side Registration Chute. 7. Disconnect the connectors from the sensors. Connector (J8350) for the Side Regi Sensor 1 and connector (J8351) for the Side Regi Sensor 2.
Punch Bracket Assembly

There are five settings for the Finisher Punch: 2-/3-hole, 2-/4-hole, 3-hole, 2-hole and, no punch. Although the following removal procedures are for the 2-/3-hole version, the procedures apply to all punch-equipped Finishers. 1. Open Door G. 2. Remove the Upper Rear Cover (page 3-120). 3. Remove the Punch (page 3-145).
3-148
PL25.7.9
Holder Frame
Punch Bracket
J8350/J8351
Sensor Bracket
Punch Front Cover
Punch Left Cover

4. Remove the one screw securing the Punch Front Cover. 5. Remove the two screws securing the Punch Left Cover.
s5500-412
6. Remove the three screws securing the Holder Frame to the Punch Bracket and remove the Holder Frame. 7. Disconnect the connectors (J8350 and J8351) from the Side Regi Sensors. 8. Remove the two screws securing the Sensor Bracket.
Punch Motor Bracket Assembly

1. Open Door G. 2. Remove the Upper Rear Cover (page 3-120). 3. Remove the Punch (page 3-145).
FRU Disassembly
3-149
PL25.7.14
Actuator
Punch Motor Encoder Sensor
Bracket
Clamp
Punch Motor
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.
3-150
5. Disconnect the connector (J8349) from the Punch Motor Encoder Sensor. 6. Remove the harness connected to the motor and sensor from the clamp. 7. Remove the two Phillips-head screws securing the Punch Motor Assembly to the Punch Frame and remove. Replacement Note Engage the gears of the motor to the Punch Frame.
Punch Hole Select, Punch Front and Home Sensors

1. Open Door G. 2. Remove the Upper Rear Cover (page 3-120). 3. Slide the Punch to the rear. 4. Remove the Phillips-head screw securing the bracket.
Bracket Punch Frame
s5500-416
FRU Disassembly
3-151
PL25.7.15
Punch Hole Select Sensor J8346 J8347 Bracket Punch Front Sensor
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.
3-152
Punch Unit Move Home Sensor

1. Open Door G. 2. Remove the Finisher Top Cover (page 3-122). 3. Remove the Upper Rear Cover (page 3-120). PL25.7.17
Sensor Bracket Rear Punch Bracket
J8352
Punch Frame
s5500-418
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.
FRU Disassembly
3-153
Finisher Punch Box Set Sensor

1. Open Door G. 2. Remove the Punch Waste Box 3. Reach in through the front and gently push either up or down to release the sensor. 4. Disconnect the harness from the sensor and remove it from the Finisher. PL25.7.21
Door G
Punch Box Set Sensor
J8353
Sensor Harness
s5500-617
3-154
Finisher Stapler Unit

1. Remove Door G; (page 3-124). 2. Remove the Stapler Cartridge. 3. Remove the Upper Rear Cover (page 3-120). 4. Remove the Lower Rear Cover (page 3-121). PL25.8.1
Stapler Cartridge
Stapler Head
s5500-419
FRU Disassembly
3-155
Rear
Main PWB Cover

s5500-396
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.
3-156
8. Release the harness from the clamp.
J8327 (Yellow) J8326
Stapler Unit
Rear
Hook
Square Hole
Stapler Unit
Front
s5500-420
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.
FRU Disassembly
3-157
Stapler Assembly
1. Open Door G. 2. Move the Staple Head to the front. 3. Remove the Staple Cartridge. PL25.8.2
Stapler Head
Stapler Holder
Stapler Cover
Upper Carriage
J8354 Ground Terminal J8356 J8357 Harness Guide

4. Remove the one screw securing the Stapler Cover. 5. Disconnect the two connectors (J8356 and J8357) from the Staple Head and the connector (J8354) from the Staple Move Position Sensor. 6. Remove the two screws on the sides of the Staple Head securing the Stapler Holder to the Upper Carriage. At the same time, detach the ground terminal.
s5500-423
Staple Harness
3-158
7. Remove the two screws securing the Staple Head to the Stapler Holder. Replacement Note Make sure the harness is not pinched between the Carriage and Holder.
Stapler Lower Carriage Assembly

1. Remove the Stapler Unit (page 3-155). 2. Remove the five screws securing the Rail Base to the Stapler Frame. PL25.8.2
Stapler Assembly
Harness Clamps Staple Harness
Stapler Frame
s5500-421
3. Unplug the harness from the Lower Carriage Motor. 4. Remove the screw securing the harness bracket to the Lower Carriage Assembly.
FRU Disassembly
3-159
Lower Carriage
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.
3-160
Stapler Upper Rail

1. Remove the Stapler Unit (page 3-155). 2. Remove the Lower Carriage Assembly (page 3-159). 3. Separate the carriage halves and remove from the rail. PL25.8.10
Upper Rail
Rail Base
Stapler Frame
s5500-632
4. Remove the six screws securing the Upper Rail to the Rail Base.
FRU Disassembly
3-161
Stapler Move Position Sensor

1. Remove Door G (page 3-124). 2. Remove the Stapler Cartridge. 3. Remove the Upper Rear Cover (page 3-120). 4. Remove the Lower Rear Cover (page 3-121). 5. Remove the Stapler Unit (page 3-155). 6. Remove the Stapler Assembly (page 3-158). PL25.8.5
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.
3-162
Finisher Eject Chute Assembly

1. Remove Door G (page 3-124). 2. Remove the Upper Rear Cover (page 3-120). 3. Remove the Stacker Upper Tray (page 3-130). 4. Remove the Eject Cover (page 3-131). PL25.9.1
Harness Clamps
J8340
Right Sub Paddle Solenoid

5. Remove the Eject Clamp Bracket (page 3-172). 6. Disconnect the Sub Paddle Solenoid connector (J8340) from the Main Drive Harness. 7. Release the harness of the Sub Paddle Solenoid from the two clamps.
s5500-425
FRU Disassembly
3-163
Rear
Eject Pinch Shaft Lever Bearing E-Ring 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.
3-164
Eject Pinch Shaft 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
Eject Chute
s5500-428
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).
FRU Disassembly
3-165
16. Lift the Eject Pinch Shaft from the Eject Chute.
Right Door H Interlock Switch Actuator
Bracket
Eject Chute
s5500-429
Replacement Note Make sure the Door H Interlock Switch actuator, pictured above, is placed under the bracket on the Eject Chute.
Sub Paddle Solenoid

1. Remove the Stacker Upper Tray (page 3-130).
3-166
PL25.9.3
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
Sub Paddle Solenoid
s5500-431
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.
FRU Disassembly
3-167
Cyclone Paddles
The Eject Chute has two Cyclone Paddles. The removal procedures are the same for both. 1. Remove the Stacker Upper Tray (page 3-130). PL25.9.6
Cyclone Paddle
Pulley T16
Eject Chute
s5500-432
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
Cyclone Paddle Drive Shaft

1. Open Door A. 2. Remove the Upper Rear Cover (page 3-120). 3. Remove the Stacker Upper Tray (page 3-130). 4. Remove the Eject Cover (page 3-131). 5. Remove the Eject Clamp Bracket (page 3-172). 6. Remove the Eject Chute (page 3-163).
3-168
PL25.9.9
Paddle Shaft Bearing E-Rings Set Screw Knob 2C
Front
s5500-433
7. Loosen the set screw securing the Knob 2C on the shaft. 8. Pull the Knob 2C off the Cyclone Paddle Drive Shaft. 9. Remove the two E-rings securing the Cyclone Paddle Drive Shaft on the front. 10. Remove the Bearing.
FRU Disassembly
3-169
Tension Bracket
Belt
Exit Motor
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.
3-170
Rear
Paddle Shaft
Bearing 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.
FRU Disassembly
3-171
Eject Clamp Bracket

1. Remove the Upper Rear Cover (page 3-120). 2. Remove the Stacker Upper Tray (page 3-130). PL25.9.10
Tie Plate
Right Pinch Springs Eject Chute

s5500-436
3. Push down on the two Pinch Springs to remove them from the Eject Chute.
3-172
Rear
Eject Clamp Bracket
Eject Clamp Motor
Gear-Cam Z70 J8339 Eject Clamp Home Sensor J8324

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.
FRU Disassembly
3-173
7. Remove the Eject Clamp Bracket by rotating the Gear-Cam Z70 so the actuator on the Eject Clamp Bracket is retracted from the recess of the Eject Clamp Home Sensor. 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.
Eject Clamp Motor

1. Remove the Upper Rear Cover (page 3-120). 2. Remove the Stacker Upper Tray (page 3-130). 3. Remove the Eject Clamp Bracket (page 3-172). PL25.9.11
Eject Clamp Bracket
Eject Clamp Motor
s5500-438
4. Remove the two screws securing the Eject Clamp Motor to the Eject Clamp Bracket and remove the motor.
3-174
Eject Clamp Home Sensor

1. Remove the Upper Rear Cover (page 3-120). 2. Remove the Stacker Top Tray (page 3-130). 3. Remove the Eject Clamp Bracket (page 3-172). PL25.9.13
Eject Clamp Bracket
Bracket
s5500-439
4. Release the hooks of the Eject Clamp Home Sensor to remove it from the Eject Clamp Bracket.
FRU Disassembly
3-175
Door H Interlock
1. Remove the Stacker Upper Tray (page 3-130). PL25.9.23
Right
Door H Interlock Switch
Eject Chute
Bracket Tie Plate
s5500-440
2. Disconnect the Door H Interlock connector (J8364) from the harness. 3. Release the Door H Interlock harness from the two clamps. 4. Remove the one screw securing the Switch Bracket to the Tie Plate. 5. Remove the Switch Bracket from the square hole on the Tie Plate. 6. Remove the two screws securing the Door H Interlock to the Bracket.
3-176
Door H Interlock Switch Actuator
Interlock Bracket
Eject Chute
s5500-441
Replacement Note Install the Door H Interlock so the actuator is placed under the Interlock Bracket on the Eject Chute.
Finisher Compiler Tray

1. Open Door G. 2. Remove the Upper Rear Cover (page 3-120). 3. Remove Lower Rear Cover (page 3-121) 4. Remove the Stacker Upper Tray (page 3-130). 5. Remove the Eject Cover (page 3-131). 6. Remove the Stapler Unit (page 3-155). 7. Remove the Eject Clamp Bracket (page 3-172). 8. Remove the Eject Chute (page 3-163). 9. Remove the Eject Bracket (page 3-187). 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.
FRU Disassembly
3-177
PL25.10.1
Rear
Main PWB Cover

s5500-396
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.
3-178
13. Remove the screw, located inside the Finisher, securing the center of the Compiler Tray to the frame.
s5500-593
FRU Disassembly
3-179
14. Release the Compiler Tray locks by pushing the bosses on the front and rear toward the inside of the Finisher and remove the Compiler Tray in the direction of the arrow.
Compiler Tray
Right Front View Rear View
Boss Compiler Tray
Boss
Compiler Tray
s5500-443
Front/Rear Tamper Home Sensors

The removal procedures for both Tamper Home Sensors are identical. The removal procedure for the Front Tamper Home Sensor is described here. 1. Open Door G. 2. Remove the Upper Rear Cover (page 3-120). 3. Remove Lower Rear Cover (page 3-121). 4. Remove the Stacker Upper Tray (page 3-130).
3-180
5. Remove the Eject Cover (page 3-131). 6. Remove the Stapler Unit (page 3-155). 7. Remove the Eject Clamp Bracket (page 3-172). 8. Remove the Eject Chute (page 3-163). 9. Remove the Eject Bracket (page 3-187). 10. Remove the Compiler Tray (page 3-177). PL25.10.2
Compiler Tray
Rear Tamper Home Sensor Front Tamper Home Sensor
Compiler Tray
J8360
Front Tamper Home Sensor

s5500-444
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.
FRU Disassembly
3-181
Compiler Tray No Paper Sensor

1. Open Door G. 2. Remove the Upper Rear Cover (page 3-120). 3. Remove Lower Rear Cover (page 3-121). 4. Remove the Stacker Upper Tray (page 3-130). 5. Remove the Eject Cover (page 3-131). 6. Remove the Stapler Unit (page 3-155). 7. Remove the Eject Clamp Bracket (page 3-172). 8. Remove the Eject Chute (page 3-163). 9. Remove the Eject Bracket (page 3-187). 10. Remove the Compiler Tray (page 3-177).
3-182
PL25.10.3
Compiler Tray
Compiler Tray No Paper Sensor J8359 Compiler Tray
Actuator
11. Disconnect the Compiler Tray No Paper Sensor connector (J8359).
s5500-445
12. Release the hooks of the Compiler Tray No Paper Sensor to remove the Sensor from the Compiler Tray. 13. Remove the Actuator in the direction of the arrow.
FRU Disassembly
3-183
Eject Roller Shaft

1. Open Door G. 2. Remove the Upper Rear Cover (page 3-120). 3. Remove Lower Rear Cover (page 3-121). 4. Remove the Stacker Upper Tray (page 3-130). 5. Remove the Eject Cover (page 3-131). 6. Remove the Stapler Unit (page 3-155). 7. Remove the Eject Clamp Bracket (page 3-172). 8. Remove the Eject Chute (page 3-163). 9. Remove the Eject Bracket (page 3-187). 10. Remove the Compiler Tray (page 3-177). PL25.10.9
Eject Roller Shaft
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.
3-184
Bearing Eject Roller Shaft 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.
Eject Roller Shaft Rear

s5500-450
FRU Disassembly
3-185
17. Move the Eject Roller Shaft to the rear, then remove the front end of the two shafts from the two holes in the frame. Next, move the Eject Roller Shaft in the direction of the arrow to remove the two shafts from the rear holes and the Finisher.
Set Clamp Clutch

Eject Motor
J8336 Set Clamp Spring Eject Bracket J8325
Set Clamp Home Sensor
Set Clamp Actuator Clutch Z34

s5500-452
2. Disconnect the Eject Motor connector (J8336). 3. Disconnect the Set Clamp Home Sensor connector (J8325). 4. Release the harness from the clamp. 5. Disconnect the Set Clamp Clutch (Z34) connector (J8338). 6. Release the clutch harness from the clamp. 7. Remove the screw securing the Set Clamp Spring. 8. Turn the Set Clamp Actuator to clear the sensor and remove the actuator from the shaft by releasing the hook. 9. Remove the Clutch Z34. Replacement Note Fit the clutch stop into the notch of the Eject Bracket at the 12:00 position.
3-186
Eject Motor Bracket Assembly

1. Remove the Upper Rear Cover (page 3-120). 2. Remove the Clutch Z34 (page 3-186). PL25.10.17
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.
FRU Disassembly
3-187

Rear Set Clamp Actuator Set Clamp Actuator
J8325
Eject Bracket
s5500-454
2. Disconnect the Set Clamp Home Sensor connector (J8325). 3. Rotate the actuator by hand so the actuator retracts from the recess of the sensor. 4. Release the hooks of the Set Clamp Home Sensor to remove it from the Eject Bracket.
3-188
Compile Exit Sensor

1. Open Door G. 2. Remove the Upper Rear Cover (page 3-120). 3. Remove Lower Rear Cover (page 3-121). 4. Remove the Stacker Upper Tray (page 3-130). 5. Remove the Eject Cover (page 3-131). 6. Remove the Stapler Unit (page 3-155). 7. Remove the Eject Clamp Bracket (page 3-172). 8. Remove the Eject Chute (page 3-163). 9. Remove the Eject Bracket (page 3-187). 10. Remove the Compiler Tray (page 3-177). 11. Remove the Eject Roller Shaft (page 3-184). 12. Remove the Lower Chute, Exit R (page 3-196). PL25.11.3
Tension Bracket
Belt
Exit Motor
Rear
Pulleys
s5500-434
13. Loosen the two screws securing the Exit Motor Belt Tension Bracket.
FRU Disassembly
3-189
14. Move the Tension Bracket in the direction of the arrow to relieve belt tension and remove the Belt from the pulleys.
Upper Exit Chute
Front View
Rear View
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.
3-190
Compiler Exit Sensor
Sensor Bracket
Upper Exit Chute
s5500-456
17. Remove the Upper Exit Chute. 18. Release the hooks of the Compile Exit Sensor to remove the sensor from the Bracket. 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.
Lower Exit Roller Assembly

1. Open Door G. 2. Remove the Upper Rear Cover (page 3-120). 3. Remove Lower Rear Cover (page 3-121). 4. Remove the Stacker Upper Tray (page 3-130). 5. Remove the Eject Cover (page 3-131). 6. Remove the Stapler Unit (page 3-155). 7. Remove the Eject Clamp Bracket (page 3-172). 8. Remove the Eject Chute (page 3-163). 9. Remove the Eject Bracket (page 3-187). 10. Remove the Compiler Tray (page 3-177). 11. Remove the Eject Roller Shaft (page 3-184). 12. Remove the Lower Chute, Exit R (page 3-196).
FRU Disassembly
3-191
PL25.11.6
Tension Bracket
Belt
Exit Motor
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.
3-192
Upper Exit Chute
Front View
Rear View
s5500-455
16. Remove the two screws each on the front and rear securing the Upper Exit Chute. 17. Remove the Upper Exit Chute.
FRU Disassembly
3-193
Rear
Lower Exit Roller
Bearing Pulley T20

s5500-457
18. Release the hook of Pulley T20 attached to the Lower Exit Roller shaft and remove the pulley. 19. Remove the Bearing.
3-194
Lower Exit Roller E-Ring Front Bearing

s5500-458
Lower Exit Roller
Rear
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.
FRU Disassembly
3-195
Lower Exit Chute R

1. Open Door G. 2. Remove the Upper Rear Cover (page 3-120). 3. Remove Lower Rear Cover (page 3-121). 4. Remove the Stacker Upper Tray (page 3-130). 5. Remove the Eject Cover (page 3-131). 6. Remove the Stapler Unit (page 3-155). 7. Remove the Eject Clamp Bracket (page 3-172). 8. Remove the Eject Chute (page 3-163). 9. Remove the Eject Bracket (page 3-187). 10. Remove the Compiler Tray (page 3-177). 11. Remove the Eject Roller Shaft (page 3-184). PL25.11.7
Tension Bracket
Belt
Exit Motor
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.
3-196
Belt Pulley T17 Bearing
Tension Bracket
Finisher Transport Motor
s5500-460
Paddle Shaft Drive Belt
Lower Exit Chute R Paddle Shaft

s5500-461
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.
FRU Disassembly
3-197
Rear
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.
3-198
(1) Right
Lower Exit Chute
(2) (3)
Front View
Rear View
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.
FRU Disassembly
3-199
Paddle Shaft/Belt
1. Open Door G. 2. Remove the Upper Rear Cover (page 3-120). 3. Remove Lower Rear Cover (page 3-121). 4. Remove the Stacker Upper Tray (page 3-130). 5. Remove the Eject Cover (page 3-131). 6. Remove the Stapler Unit (page 3-155). 7. Remove the Eject Clamp Bracket (page 3-172). 8. Remove the Eject Chute (page 3-163). 9. Remove the Eject Bracket (page 3-187). 10. Remove the Compiler Tray (page 3-177). 11. Remove the Eject Roller Shaft (page 3-184). 12. Remove the Lower Exit Chute R (page 3-196). PL25.11.12
E-Ring Bearing Paddle Shaft Drive Belt
Paddle Shaft
Bearing
Front
E-Ring
Lower Exit Chute R
s5500-465
3-200
13. Remove the two E-rings securing the Paddle Shaft to the Lower Exit Chute R. 14. Remove the Bearing. 15. Move the Paddle Shaft to the front to remove the Bearing on the front end from the Lower Exit Chute R and remove the Paddle Shaft from the Lower Exit Chute R. 16. Remove the Paddle Shaft Drive Belt from the Paddle Shaft.
Exit Pinch Rollers

1. Open Door G. 2. Remove the Upper Rear Cover (page 3-120). 3. Remove Lower Rear Cover (page 3-121). 4. Remove the Stacker Upper Tray (page 3-130). 5. Remove the Eject Cover (page 3-131). 6. Remove the Stapler Unit (page 3-155). 7. Remove the Eject Clamp Bracket (page 3-172). 8. Remove the Eject Chute (page 3-163). 9. Remove the Eject Bracket (page 3-187). 10. Remove the Compiler Tray (page 3-177). 11. Remove the Eject Roller Shaft (page 3-184). 12. Remove the Lower Exit Chute R (page 3-196). 13. Remove the Paddle Shaft (page 3-200).
FRU Disassembly
3-201
PL25.11.10
Exit Pinch Rollers 2S
Exit Pinch Rollers 1S
Lower Exit Chute R
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.
Lower Exit Chute (2b)

1. Open Door G. 2. Remove the Upper Rear Cover (page 3-120).
3-202
Front Lower Exit Chute

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
s5500-466
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).
FRU Disassembly
3-203
Lower Exit Chute Pinch Rollers

Remove other Pinch Rollers using the same procedure. 1. Open Door G. 2. Remove the Upper Rear Cover (page 3-120). 3. Remove the Lower Exit Chute (page 3-202). PL25.12.2
Spring 1.9N Shaft
Pinch Roller
Lower Exit Chute
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).
3-204
Front Gate Lower Exit Chute

s5500-469
3. Open the Lower Exit Chute (2b) to the right by hand. PL25.12.6
Gate
Link
Rear
s5500-470
FRU Disassembly
3-205
4. Remove the Transfer Gate Solenoid Bracket on the rear (page 3-223). 5. Remove the Link. 6. Move the Gate in the direction of the arrow to remove from the front. 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.
3-206
Lower Exit Chute
Buffer Gate
5. Open the Lower Exit Chute (2b) to the right by hand. 6. Remove the Buffer Gate in the direction of the arrows. Replacement Note Install the Buffer Gate with the hole facing the rear.
s5500-472
Buffer Path 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).
FRU Disassembly
3-207
PL25.12.12
Buffer Path Sensor Sensor Bracket
J8392
Top Buffer Chute
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.
3-208
PL25.12.13
Front
Bottom Buffer Chute

5. Open the Lower Exit Chute (2b). 6. Lift the Buffer Gate.
Buffer Gate
Lower Exit Chute

s5500-474
7. Open the Bottom Buffer Chute (3) downward.
E-Ring Bearing Front Buffer Roller Shaft

s5500-475
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
Gear Z46
Bearing
s5500-477
11. Release the hook of the Gear Z46 and slide the shaft toward the front and out of the gear. 12. Remove the Bearing.
3-210
PL25.12.13
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.
Bottom Buffer Chute (3)

1. Open Door G. 2. Remove the Upper Rear Cover (page 3-120). 3. Remove the Buffer Roller (page 3-208). Caution When removing the Buffer Chute, ensure not to break the retaining tab off the frame.
FRU Disassembly
3-211
PL25.12.14
Retaining Tab
Hole On Rear Frame
Boss
Bottom Buffer Chute
s5500-479
4. Bend the retaining tab to allow removal of the Buffer Chute. 5. Remove the two bosses on the rear of the Bottom Buffer Chute from the two holes on the rear frame.
3-212
Exit Pinch Rollers

Remove the other three Pinch Rollers using this same procedure. 1. Open the Front Door. 2. Remove the Upper Rear Cover (page 3-120). 3. Remove the Buffer Roller Assembly (page 3-208). 4. Remove the Bottom Buffer Chute (page 3-211). PL25.12.15
Exit Pinch
Bottom Buffer Chute

s5500-480
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.
FRU Disassembly
3-213
Upper Entrance Chute

1. Open Door G. 2. Remove the Upper Rear Cover (page 3-120). 3. Remove the L/H Front Cover (page 3-128). 4. Remove the Top L/H Cover (page 3-129). PL25.12.16
Transport Entrance Sensor
J8319
Upper Entrance Chute Sensor Bracket
Left
5. Release the harness from the Sensor Bracket clamp. 6. Disconnect the Transport Entrance Sensor connector (J8319).
s5500-481
3-214
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.
FRU Disassembly
3-215
Upper Entrance Chute Pinch Rollers

The Upper Entrance Chute has four Pinch Rollers. Remove any of these rollers with this procedure. 1. Open Door G. 2. Remove the Upper Rear Cover (page 3-120). 3. Remove the L/H Front Cover (page 3-128). 4. Remove the Top L/H Cover (page 3-129). (PL25.12.17) Entrance Pinch Rollers
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.
3-216

J8319
Sensor Bracket
Left
s5500-484
5. Release the harness from the Sensor Bracket clamp. 6. Disconnect the Transport Entrance Sensor connector (J8319). 7. Remove the one screw securing the Sensor Bracket to the Upper Entrance Chute and remove the bracket. 8. Remove the one screw securing the Transport Entrance Sensor to the Sensor Bracket and remove the sensor. Replacement Note Install the sensor in the direction shown in the figure.
FRU Disassembly
3-217
Entrance Roller
Punch Frame Upper Entrance Chute
Punch Box
Front
s5500-485
5. Remove the Punch Box from the Finisher. 6. Remove the Punch Box Entrance Guide. 7. Remove the screw securing the Knob to the Upper Entrance Chute. 8. Open the Upper Entrance Chute
3-218
Belt
Tension Bracket
s5500-460
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.
FRU Disassembly
3-219
Bearing
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.
3-220
Entrance Roller Shaft
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.
FRU Disassembly
3-221
Finisher Transport Motor and Belt

1. Remove the Upper Rear Cover (page 3-120).
Belt
Tension Bracket
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
3-222
4. Disconnect the Transport Motor, connector (J8342), from the harness. 5. Remove the two screws securing the Finisher Transport Motor Bracket. 6. Remove the two screws securing the Finisher Transport Motor to the Bracket. 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.

In this procedure, do not remove the Harness Bracket from the Finisher. Remove the two screws securing the Harness Bracket to facilitate removal of the Transfer Gate Solenoid. Also, when removing the Transfer Gate Solenoid, remove the Link as well.When the Link is removed, the Trasfer Gate might detach inside the Finisher. If the Transfer Gate becomes detached, use the procedure on page 3-204 to replace it. 1. Open Door G. 2. Remove the Upper Rear Cover (page 3-120).
FRU Disassembly
3-223
PL25.12.32
Harness Bracket
Clamp
Link
J8341
When Assembling
Transfer Gate Solenoid Bracket Guide
Link Pin
3. Disconnect the Transfer Gate Solenoid connector (J8341). 4. Release the harness of the Transfer Gate Solenoid from the clamp. 5. Remove the two screws securing the Harness Bracket. 6. Remove the two screws securing the Transfer Gate Solenoid Bracket. 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.
s5500-489
3-224
Buffer Gate Solenoid

When removing the Buffer Gate Solenoid, remove the Link as well.When the Link is removed, the Gate might detach inside the Finisher. If the Gate becomes detached, use the procedure on page 3-204 to replace it. 1. Open Door G. 2. Remove the Upper Rear Cover (page 3-120). PL25.12.34
Clamp
J8394
Buffer Gate Solenoid Bracket Link Rear
When Assembling Pin
Guide Link
s5500-490
3. Disconnect the Buffer Gate Solenoid connector (J8394). 4. Release the Buffer Gate Solenoid harness from the clamp. 5. Remove the two screws securing the Buffer Gate Solenoid Bracket to the Finisher and remove the bracket.
FRU Disassembly
3-225
Stacker Upper Tray Exit Sensor

1. Open Door G. 2. Remove the Upper Rear Cover (page 3-120). 3. Remove the Top Cover (page 3-122). PL25.13.2
Top Exit Upper Chute
J8321
Upper Tray Exit Sensor
Rear
Left
s5500-491
4. Disconnect the Stacker Upper Tray Exit Sensor connector (J8321). 5. Release the sensor hooks to remove the sensor from the Top Exit Upper Chute.
3-226
Top Exit Pinch Rollers

Remove the other three Top Exit Pinch Rollers using this same procedure. 1. Open Door G. 2. Remove the Upper Rear Cover (page 3-120). 3. Remove the Top Cover (page 3-122). PL25.13.3
Exit Pinch Roller
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.
Top Exit Roller

1. Open Door G. 2. Remove the Upper Rear Cover (page 3-120). 3. Remove the Top Cover (page 3-122). 4. Remove the Exit Motor (page 3-243).
FRU Disassembly
3-227
PL25.13.5
Upper Tray Exit Sensor J8321
Left Top Exit Upper Chute

s5500-493
Top Exit Lower Chute
Top Exit Roller
s5500-494
5. Disconnect the Upper Tray Exit Sensor connector (J8321). 6. Release the harness from the harness clamps.
3-228
For Top Exit Upper Chute
For Top Exit Lower Chute
Front
s5500-495
7. Remove the two screws each on the front and rear securing the Top Exit Upper Chute to the Finisher.
FRU Disassembly
3-229
8. Remove the two screws each on the front and rear securing the Top Exit Lower Chute to the Finisher.
For Top Exit Upper Chute
For Top Exit Lower Chute
Rear
9. Open the Upper Exit Chute (2a). 10. Remove the Top Exit Upper Chute and the Top Exit Lower Chute.
s5500-496
3-230
Top Exit Roller Shaft Bearing Gear
Rear
s5500-497
11. Release the hook to remove the Gear from the Top Exit Roller shaft. 12. Remove the Bearing.
FRU Disassembly
3-231
Top Exit Roller Shaft 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.
3-232
Stacker Upper Tray Full Stack 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 Exit Motor (page 3-243). 5. Remove the Top Exit Roller (page 3-227). PL25.13.7
J8322
Upper Tray Full Sensor
Rear
6. Disconnect the Upper Tray Full Sensor connector (J8322). 7. Remove the screw securing the Upper Tray Full Sensor.
s5500-499
FRU Disassembly
3-233
Upper Exit Chute (2a)

1. Open the Front Door. 2. Remove the Upper Rear Cover (page 3-120). 3. Remove the Registration Motor (page 3-245). PL25.13.10
Upper Exit Chute
Rear
s5500-500
4. Remove the three screws securing the hinge of the Upper Exit Chute on the rear.
3-234
Upper Exit Chute
Front
s5500-501
5. Remove the Upper Exit Chute from the Finisher by removing the hinge from the square hole on the rear frame.
FRU Disassembly
3-235
Upper Exit Chute Pinch Rollers

1. Open Door G. 2. Remove the Upper Rear Cover (page 3-120). 3. Remove the Registration Motor (page 3-245). 4. Remove the Upper Exit Chute (page 3-234). PL25.13.11
Spring 1.5N Detailed View Spring 1.5N Shaft Pinch Roller
Pinch Roller
Upper Exit Chute
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).
3-236
PL25.13.15
Sensor Bracket
Gate Sensor
Left
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.
FRU Disassembly
3-237
Transport Rollers
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). PL25.13.18
Upper Exit Chute
Front
7. Open the Upper Exit Chute.
s5500-504
3-238
Top Exit Upper Chute Front

s5500-505
8. Remove the two screws securing the Top Exit Upper Chute at the front.
Rear
s5500-506
FRU Disassembly
3-239
9. Remove the two screws securing the Top Exit Upper Chute at the rear. 10. Push the Top Exit Upper Chute toward the paper exit side slightly so the rubber roller of the Transport Roller can be removed from the square holes in the Top Exit Upper Chute. There is no need to remove the Top Exit Upper Chute. 11. Remove the two screws securing the Harness Bracket. Remove only the two screws to allow the removal of the gear. Do not remove the Harness Bracket.
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.
3-240
Transport Roller Shaft Bearing
Gears
Rear
Transport Roller Shaft Bearing

s5500-507
14. Remove the Gear attached to the Transport Roller shaft on the rear. 15. Remove the Bearing.
FRU Disassembly
3-241
16. Remove the E-ring securing the Transport Roller shaft on the front.
Transport Roller Shaft
E-Ring
Bearings
Front E-Ring
Transport Roller Shaft

s5500-508
17. Remove the Bearing. 18. Move the Transport Roller shaft to the front to remove the rear end of the shaft from the hole in the rear frame. 19. Remove the shaft from the Finisher.
3-242
Finisher Exit Motor and Belt

Tension Bracket
Belt
Exit Motor
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.
FRU Disassembly
3-243
Bracket
Exit Motor
J8334
s5500-509
4. Disconnect the Exit Motor connector (J8334). 5. Remove the two screws securing the Exit Motor Bracket. 6. Remove the two screws securing the Exit Motor to the bracket. Replacement Note Put the two bosses of chassis into the two holes on the Exit Motor Bracket.
3-244
Finisher Registration Motor and Belt

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.
FRU Disassembly
3-245
Bracket
Registration Motor
J8335
s5500-511
5. Disconnect the Registration Motor connector (J8335). 6. Remove the two screws securing the Registration Motor Bracket. 7. Remove the two screws securing the Registration Motor to the bracket. 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.
3-246
Horizontal Transport PWB

Horizontal Transport Connector Plate
Rear
2. Remove the screw securing the Horizontal Transport Connector plate. 3. Disconnect the three connectors on the Horizontal Transport PWB. 4. Remove the two screws securing the PWB to the Finisher and remove.
s5500-512
FRU Disassembly
3-247
Finisher Main PWB

1. Remove the Upper Rear Cover (page 3-120). 2. Remove the Lower Rear Cover (page 3-121). PL25.14.5
Rear
Main PWB Cover

s5500-396
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.
3-248
Rear
Main PWB P8304 P8308 P8389
P8306 P8309 P8305 P8302 P8311 P8307 P8300 P8301 P8310
P8317 P8315 P8313 P8314 P8316

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

2. Disconnect the three connectors on the LVPS. 3. Remove the two screws securing the LVPS to the Finisher.
s5500-514
3-250
Parts Lists
In this chapter...

Serial Number Format Using the Parts List Option Parts
Chapter
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 2000Sheet 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 1000Sheet Feeder are not serialized.
Using the Parts List

No.: The callout number from the exploded part diagram. 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. A black triangle preceding a number followed by a parenthetical statement in an illustrated parts list means the item is a parent assembly, made up of the individual parts called out in parentheses. 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.
4-2
The notation J1<>J2 and P2 is attached to a wire harness. It indicates that connector Jack 1 is attached to one end of the wire harness and connector J2 is attached to the other end that is plugged into P2.
Note Only parts showing part numbers are available for ordering by support. Parts without numbers are available on the parent assembly. Abbreviations
Abbreviation
C E KL S
Meaning
C-ring E-ring K-clip Screw
Parts Lists
4-3
1000-Sheet Feeder
Parts List 20.1 1000-Sheet Feeder (Trays 4 & 5)
S S
1
S
10 6
S S S
7 4
2 6
S Left Front s5500-608
4-4
Parts List 20.1 1000-Sheet Feeder (Trays 4 and 5)

No.
1 2 3 4 5 6 7 8 9 10
Name/Description
TOP COVER FOOT COVER RIGHT COVER LEFT COVER REAR COVER CASTER (Stopper) CASTER FOOT ADJUSTER BRACKET REAR RH 2T BRACKET REAR LH 2T
Part Number
802E54731 802E54740 802E54750 802E54762
017K93132 017K93121
Parts Lists
4-5
Parts List 20.2 Tray (1/2) and Feeder (1/2)

4
S
6
S
7 (PL20.4.1)
S
14
10 12 13 11
S S
13
9 (with 12,13) 2 8 (PL20.4.1) 1 (1/2Pcs.) (PL20.3) 3
10 12 13 13
S
9 (with 12,13)
Left Front
99 (with 2, 3, PL2.1.3, PL2.1.10, PL2.1.11, PL2.1.12)

s5500-609
4-6
Parts List 20.2 Tray (1/2) and Feeder (1/2) (Trays 4 and 5)
No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 99
Name/Description
TRAY 4/5 ASSEMBLY (PL20.3 part of 99) LABEL (No. 4) LABEL (No. 5) TRAY 4/5 PAPER SIZE SWITCH TRAY SPACER TRAY STOPPER TRAY 4 FEEDER (PL20.4.1) TRAY 5 FEEDER (PL20.4.1) CHUTE FEED OUT (with 12 and 13) COVER SENSOR COVER FDR CHUTE FEED OUT PAD ASSY LH LOW BLOCK SLIDE LOCK KIT TRAY (with 2, 3, PL2.1.3, PL2.1.10, PL2.1.11, PL2.1.12)
Part Number
110K11680 014E51110 003E58700 059K26934 059K26934 054K27550
109R00733
Parts Lists
4-7
Parts List 20.3 Tray (2/2)

1 (with 2-26)
A E E
16
17
10
13
12
C
14 8 5 24 9
S S
15 8
18 20
S
25
A C S D
15
23
6 11
21 22
25
26 19
2
S
Left Front s5500-193
4-8

No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 96
Name/Description
TRAY ASSEMBLY (with 5~26) TRAY COVER LABEL (MAX) BOTTOM PAD FRONT SIDE GUIDE TRAY PAD REAR SIDE GUIDE BOTTOM PLATE TRAY SIDE GUIDE ACTUATOR GUIDE ACTUATOR SPRING PINION GEAR END GUIDE SPRING END GUIDE ACTUATOR LINK COUPLING GEAR (13T) GEAR (13T/60T) SECTOR GEAR (60T) BRACKET LIFT UP SHAFT STOPPER SEAL KIT, LABEL (XOG)
Part Number
109R00733
Parts Lists
4-9
Parts List 20.4 Feeder (2/2)

1 (with 2-50) 15 Sensor
Pre Feed
43
C
44
3 42 40 14 Level Sensor
S
45 45
S
17 14
A
18 10 6 5
E
No Paper Sensor
S
9 11 36 A
S
39
13 21 20 38 33 20 31 22 12
E
39
19 30 23 48
S C
4 B 8
46
35
34 50 37 16 27 99 (with 20x3Pcs.) 29 20 26
Front Right s5500-194
49
S
47
S
24 25
4-10
Parts List 20.4 Feeder (2/2)

No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Name/Description
FEEDER ASSEMBLY (with 2~50) TRAY FEED LIFT UP MOTOR BRACKET SPACER GEAR (31T) SPRING ONEWAY CLUTCH ONEWAY GEAR GEAR (13T) BEARING SHAFT FRONT CHUTE ACTUATOR (No Paper Sensor Actuator) SENSOR (No Paper or Level Sensor) SENSOR (Pre-Feed Sensor) WIRE HARNESS GEAR (28T/21T) GEAR (29T) SPRING ROLLER ASSY--Periodic replacement part per 300k prints (included with 99) (Feed Roller) ONEWAY CLUTCH ONEWAY GEAR (22T) SHAFT CHUTE SPRING FRICTION CLUTH SHAFT-RETARD --
Part Number
059K26934 127K38170
120E22481 930W00113 930W00211
809E51070
21 22 23 24 25 26 27 28
Parts Lists
4-11
Parts List 20.4 Feeder (2/2) (Continued)

No.
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 99
Name/Description
SPACER GEAR (33T) SHAFT-NUDGER -GEAR (25T) LOWER FRAME BEARING GEAR (27T) LEVER BEARING WASHER UPPER FRAME HOLDER HARNESS CTR HOLDER HARNESS REAR HOLDER HARNESS UPPER HOLDER HARNESS PS1 (ALT) CLAMP MINI-SADDLE (ALT) RAIL SUPPORT RETARD SUPPORT NUDGER HOLDER SPRING KIT ROLLS (with 20 x 3 pcs.)Periodic replacement (per 300k print)
Part Number
604K20530
4-12
This page intentionally left blank.
Parts Lists
4-13
Parts List 20.5 Transportation

1
S
4
E
Feed Out Sensor #4
9 8
S E E
8 7 6
Feed Out Sensor #5
27
S
26
S
13
S
12
25 161514 17 13 16
11 (with 12-16)
18
S
16
S
19 S
10 (with 11-23)
24 20 23
S
21 22
4-14
Parts List 20.5 Trasportation (Trays 4 & 5)

No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
Name/Description
CHUTE COVER TRAY 4 FEED OUT SENSOR (Feed Out Sensor #4) WIRE HARNESS CHUTE TRAY 5 FEED OUT SENSOR (Feed Out Sesnor #5) WIRE HARNESS TAKEAWAY ROLL ASSEMBLY (Take Away Roller) BEARING LEFT COVER ASSEMBLY (11~23) ROLL ASSEMBLY (with 12~16) BRACKET BEARING BEARING PINCH ROLL SPRING CHUTE ACTUATOR HOOK LEFT COVER SPRING LATCH} HANDLE BRACKET SUPPORT BRACKET ASSEMBLY LEFT COVER INTERLOCK SWITCH (Door C Interlock)
Part Number
130K64121 962K18171
130K64471 962W18900 059K26250
802K53504 030K75471
830E45710
110E10620
Parts Lists
4-15
Parts List 20.6 Drive and Electrical

14 13 14
1
S
8 2 4
15 16
6
E
5 3
S
11
9 10
12 11
Rear Left
s5500-518
4-16
Parts List 20.6 Drive and Electrical (Trays 4 & 5)

No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 98
Name/Description
TRAY MODULE PWB (Tray 4-5 PWB) CLUTCH (Take Away Clutch) BRACKET SHAFT BEARING GEAR (38T) MAIN MOTOR (Take Away Motor) GEAR (22T/40T) GEAR (126T) GEAR (60T) GEAR (37T) GEAR (32T) WIRE HARNESS GASKET BEARING WASHER-PLAIN, NYN KIT GEAR (with 6,8,9,10,11,12)
Part Number
160K97457 121K31530
007K88301
604K23280
Parts Lists
4-17
2000-Sheet Feeder (Tray 6)

Parts List 22.1 Tray 6 (HCF) Covers
S
2
S S
14
S S
S S
S S
S S S
Paper Size 4 Sensor B
16
S
15
4 Paper Size
Sensor A
12
S
16 17
3
S
3
S
S S S S S S
5 6
4 Tray In
Sensor
(PL22.4.1)
11
7
S S S
9 8
S S S S S S
8 9
S S S
8
S S S
8
S
(PL22.2 & PL22.3)
10
Left Front S
10
s5500-519
4-18
Parts List 22.1 Tray 6 (HCF) Covers

No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 COVER REAR HCF MOUNTING BRACKET (includes 16, 2 thumbscrews) (Docking Plate) MOUNTING BRACKET SCREWS (Docking Plate Screw) COVER FRONT SIDE (Right Front Cover) 003K91881 802E77080 802E69470
Name/Description
COVER TOP LG HCF (Tray 6 Top Cover) COVER RH HCF RAIL ASSY SLIDE SENSOR (Tray In and Paper Size Sensors) SPRING LEVER LATCH PLATE ASSY CASTER W CASTER RACK FR FOOT ADJUSTER RAIL ASSY TRAY COVER LH HCF BRKT-ASSY SENSOR
Part Number
802K74950
130K55590 009E84690 011E16000
017E92820
802E69460
Parts Lists
4-19

1
S S
14 (with 8-13, 15) 15 13

E S S
12
S
11 10
E
9 8 16 6
E
4 5
S Left Front S s5500-520
4-20

No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Name/Description
COVER ASSY FRONT MAGNET CATCH TRAY --LEVER LATCH LATCH ASSY TRAY STD SPRING -BRKT END FRAME PLATE END SPRING COMP WASHR PLATE END TOP PIN GUIDE GUIDE ASSY END (with 8~13, 15) LABEL END TOP WASHR WAVE
Part Number
802K74960 121E92880
011E16000
009E84690
032K97550
Parts Lists
4-21

7 1 2
6 6 6 5 (with 3, 4) 3 4 6
14 13
E E
9
E
14 13
E
19 15
E E
10 11 12
E E
18 17
13 14 13 14
E E E E
15
S S S
16 17 18
99 (Item 6x4Pcs.)
4-22

No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 99
Name/Description
GUIDE ASSY SIDE R GUIDE ASSY SIDE F PAD BOTTOM PLATE BOTTOM PLATE ASSY BOTTOM (with 3, 4) CABLE (included with 99) SCREW GUIDE TRAY BRKT ASSY GEAR R PF2 BEARING POWERD SHAFT LIFT BEARING POWERD WASHER PULLEY S GUIDE WIRE S PULLEY TRAY GEAR FRONT TRAY PULLEY L GUIDE WIRE L GEAR LIFT KIT CABLE TRAY (item 6x4pcs.)
Part Number
019E58620
826E11700 015K65530
020E99571 032E99390
020E37630 032E22410
604K19980
Parts Lists
4-23
Parts List 22.4 Tray 6 Feeder (1/3)

1 (with 2-18, PL22.5, PL22.6) 2 3
S S S S S S S S
10
11 12 13 14
E
4 (with 5) 5
S S
(PL22.6)
15
16 17
18
6
S S
7
S
8 (PL22.5)
S S S Left Front s5500-521
4-24

No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Name/Description
FEEDER ASSEMBLY HCF (with 2-8, PL22.5, PL22.6) MOTOR ASSEMBLY HCF (Tray 6 Feed/Lift Motor) FRAME ASSEMBLY DRIVE FRAME ASSEMBLY REAR (with 5) SOLENOID ASSY (Nudger Solenoid) HOLDER BLOCK FRAME ASSY FRONT GEAR-25T BEARING SHAFT ASSY GEAR-25T BEARING GEAR-19T BRACKET GEAR-40T SPRING SPACER SPACER
Part Number
059K41250 127K37901
801K04741
Parts Lists
4-25

2 3 4
S S
1 (with 2-19) 5
E
7
E
8 A
Tray 6 Pre Feed Sensor 9

E S
11 10 10 12 13
Tray 6 Level 16 Sensor
10
E
10
16
Tray 6 No Paper Sensor
15
14
S S
Detail A 18 19 18 20 21
17
E
4-26

No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 99
Name/Description
FEEDER ASSY UPPER (with 2~19) LATCH SPRING LATCH SHAFT LATCH LEVER FRAME ASSY UPPER PIN DRIVE GEAR 25T FEED SENSOR ASSY (Pre-Feed Sensor) CLAMP MINI-SADDLE GUIDE HARN ASSY FEEDER (J560-P59, P62, P60, P61) CHUTE UPPER REAR CHUTE UPPER ACTUATOR SENSOR-PHOTO IN (No Paper and Level Sensor) BEARING SPACER SHAFT ASSY FEEDER ROLL ASSY NUD (Nudger Roller included with 99) ROLL ASSY FEED (Feed Roller included with 99) KIT FEED ROLL (with 20, 21 and PL22.6.17)
Part Number
003E59570 809E41180
011K97840
930W00211
120E21900 930W00112
006K23122
604K23290
Parts Lists
4-27

2 1 (with 2-17)
4 3
S S
8 (with 9-16) 9
E
10
11
12
E
7 13
E
14
15
17
16
Left Front
s5500-523
4-28

No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Name/Description
FEEDER ASSY LOWER (with 2~17) CHUTE LOWER FRAME ASSY-LOWER HCF LEVER RETARD SPRING RET DOWN SLIDE RETARD SPRING RETARD SHAFT ASSY RETARD (with 9-16) GEAR 22T COLLAR CLUTCH ASSY FRICTION (Retard Clutch) BEARING SHAFT ASSY-RET BEARING-6 BRACKET ASSY RETARD (with BRACKET and PAD) GEAR 15T ROLLER ASSY RETARD (included with PL22.5.99)
Part Number
809E41221
005K06700
068K24820
Parts Lists
4-29
Parts List 22.7 Tray 6 Drive and Transportation

1 14
15 2 (with 3-8) 3
S S S
16 6 5
Feed Out # 6 Sensor S S
13
7 8
S
8 9
S S
17
KL
10
11 12
S S
Left Front
s5500-524
4-30
Parts List 22.7 Tray 6 Drive and Transportation

No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Name/Description
COVER ASSY TOP S (Door J) CHUTE ASSY LOW (with 3~8) SWITCH (Door J Interlock Switch) BRACKET SWITCH CHUTE LOW SENSOR ASSY TA (Feed Out Sensor #6number BRACKET SENSOR TA CLAMP ROLLER ASSYTA P (Take Away Roller Assembly) BEARING CONDUCTIVE BRACKET HINGE REAR NEW MOTOR ASSY (Take Away Motor) BRACKET ASSY PIVOT SHAFT PIVOT TOP SPRING TOSION R SPRING TOSION L SW IL ASSY DOCKING (Docking Interlock Switch)
Part Number
802K74970
110E94770
130K88150
059K36260
127K40200
110E10380
Parts Lists
4-31
Parts List 22.8 Tray 6 Electrical
2 3 3 3
S
1
S S
3 4 5
3 3 3
Left Front
s5500-525
4-32
Parts List 22.8 Tray 6 Electrical

No.
1 2 3 4 5
Name/Description
PWB ASSY (Tray 6 PWB) HARNESS ASSY MAIN CLAMP WS-2N CLAMP WS-1N
Part Number
960K03100
Parts Lists
4-33
Duplex Unit
Parts List 23.1 Duplex Unit
1 (with 2-23) 20
21 17 22 6 2 4 5 4 9
S S S
14
12 18 15 19 (PL23.2) 10
2 2 3 3
S
11 23 24
16
13
Rear eft L
s5500-526
4-34
Parts List 23.1 Duplex Unit

No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Name/Description
TRANS ASSY DUP (with 2~23) GEAR ROLL 28T GEAR IDLE 33/74T GEAR IDLE 33T GEAR IDLE 42T LEVER LATCH RR (Rear Latch Lever) LEVER LATCH FR (Front Latch Lever) CHUTE LOWER SWITCH-I/L, CAB (Door D Interlock Switch) ACTUATOR DUP (Wait Sensor Actuator) MOTOR ASSY DUP (Duplex Motor) PWBA DUPLEX (Duplex Unit PWB) COVER DUP (Door D) SPRING LATCH (Latch Spring) SPRING ACTUATOR DUP (Wait Sensor Actuator Spring) BRACKET MOTOR PLATE LATCH (Latch Plate) SENSOR-PHOTO IN (Wait Sensor) INNER CHUTE ASSEMBLY (PL23.2) HARN ASSY DUP SNR HARN ASSY DUP MOT HARN ASSY DUP A FAN-DUP DUCT-DUP
Part Number
059K33842
011E14581 011E14590
110E93440 120E21261 127K39480 960K01423 802E55172 809E37170 809E37280
930W00113
Parts Lists
4-35
Parts List 23.2 Inner Chute Assembly

10
(1/4Pcs.)
9
(1/4Pcs.)
2 6 10
(1/2Pcs.)
9 4
(1/2Pcs.)
7 8 10 (1/4Pcs.) 7 4 3 3 3 1 5 3 3
Rear eft L
2 3
9
(1/4Pcs.)
s5500-527
4-36
Parts List 23.2 Inner Chute Assembly Duplex Module

No.
1 2 3 4 5 6 7 8 9 10 99
Name/Description
STOPPER DUP LOCK DUP BEARING DUP PIN DUP CHUTE OUTER CHUTE INNER ROLLER DUP A3L ROLLER ASSY DUP ROLLER PINCH DUP (included with 99) SPRING PINCH DUP (included with 99) KIT, PINCH ROLLER (10 each 23.02.09, 23.02.10)
Part Number
003E59810
604K23300
Parts Lists
4-37
Exit 2
Parts List 24.1 Exit 2 L/H Upper Chute Assembly
1 (with 2-26, PL24.2) 26
13 25 11 12
10
9
S
17
6 7 8
17 16 22 21
E S A
18
16 20
19 5 4
23
24
A S
15 14
Front ight R
s5500-581
4-38
Parts List 24.1 Exit 2 L/H Upper Chute Assembly

No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
Name/Description
TRANS ASSY EXIT 2 (with 2~26 from PL-24.2) HANDLE LATCH GATE-EXIT,2 SPRING-GATE 2 CHUTE-UPPER,FU STOPPER EXIT 2 COVER GEAR GEAR-52Z GEAR-19Z PLATE-EARTH INV COVER FUP EXIT PLATE-EARTH FU ELIMINATOR EXIT ROLL PINCH SPRING-PINCH FUP BEARING BEARING CHUTE LH HIGH ROLL ASSY-FU ROLL ASSY-INV BRKT ASSY TRAY BRKT ASSY LINK LINK-FU SPRING LATCH FRONT EXIT 2 COVER REAR EXIT 2 COVER
Part Number
059K31620 003E60160
809E50480
003E60180
809E37170
Parts Lists
4-39
Parts List 24.2 Exit 2 Tray Guide Assembly

36 24 32 22 34 18 23 33 15 14 3 27
S B S S A S S
39 25
S
35
99
(with 17, 32, 34)
25 26 12
17 37 8 9 38 19 35 27 30 20 21
31
E
28
29 1
12
13
E
7 10 5
4
A
2
C
41 4 11
Front ight R s5500-528
16
B
40
42
4-40
Parts List 24.2 Exit 2 Tray Guide Assembly

No.
1 2 3 4 5 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 ROLL ASSY OCT (OCT Roller) BEARING GEAR-19Z ROLLER PINCH EXIT (Exit 2 Pinch Roller) SPRING PINCH EXIT LATCH SPRING LATCH FRONT PLATE ASSY-FRONT PLATE-EARTH 2 PLATE EARTH 3 ACUTATOR EXIT (included with 99) SWITCH-I/L, CAB (Door E Interlock Switch) GEAR-OFFSET 2 (Offset Gear) PLATE ASSY-REAR SPRING LATCH REAR LINK-SOL FU SOLENOID ASSY FU GEAR-20Z SHAFT-GEAR GEAR-19Z/44Z SPRING PINCH INV LINK-GATE EXIT 809E50171 012E11390 012E11680 110E93440 807E00211 059E99342 809E55001 003E60171 059K26760
Name/Description
GUIDE-TRAY, 2 ELIMINATOR EXIT BEARING BEARING ROLL CHUTE-OCT 2
Part Number
Parts Lists
4-41
Parts List 24.2 Exit 2 Tray Guide Assembly (Continued)

No.
29 30 31 32 33 34 35
Name/Description
SOLENOID ASSY (Exit Gate Solenoid) MOTOR ASSY OFFSET ROLL-PINCH INV ROLLER ACTUATOR (included with 99) CHUTE LOW SPRING ACTUATOR (included with 99) SENSOR-PHOTO IN (Exit, Full Stack, and OCT Home Position Sensor) HARN ASSY EXIT2 C MOTOR ASSY EXIT 2 SCREW EXIT 2 FAN ACTUATOR FULL-A (Full Stack Actuator A) ACTUATOR FULL-B (Full Stack Actuator B) SPRING ACT (Full Stack Actuator Spring) KIT ACTUATOR (with 17, 32, 34) (Exit Sensor Actuator Kit)
Part Number
121K31810 127K37951 059E98600
930W00113
36 37 38 39 40 41 42 99
127K38261
127K39420 120E24660 120E24680 809E60520 604K23310
4-42
This page intentionally left blank.
Parts Lists
4-43
Finisher/Stacker Parts
Parts List 25.1 Finisher/Stacker Unit
3 (PL25.4 - PL25.15)
2 (PL25.2, PL25.3) 1 1
Lef
t Front
s5500-529
4-44
Parts List 25.1 Finisher/Stacker Unit

No.
1 2 3 4 5 6 LABEL 893E41630
Name/Description
SCREW H-TRANSPORT ASSY (with PL25.2, PL25.3) STAPLE FINISHER (PL25.4~PL25.15)
Part Number
026E93560 022K67720
Parts Lists
4-45
Parts List 25.2 Horizontal Transport Assembly (1/2)

9 (with 1-8) 1
4
S
2 4
S S S S
5 8
7 7 6 7 6 7 6 7 7 6 6
Lef t Front
s5500-530
4-46

No.
1 2 3 4 5 6 7 8 9
Name/Description
COVER TOP, C HINGE ASSEMBLY (LEFT) HINGE ASSEMBLY (RIGHT) BRACKET-MAGNET SPRING-CHUTE PINCH ROLL SPRING-PINCH UPPER CHUTE COVER ASSEMBLY TOP (with 1~8) (Door F)
Part Number
022E27660 809E55330
802E64420
Parts Lists
4-47

1
S
27 (with 2-7, 10-26, 28-30) 14 12 2 17 3 4 5

E
28 13 28 13
S
30
S
29
10
28
11
E
30
S S
S 16 15 16 7 10
17
E
18
6 25 23
S S
18 30 24 Exit Sensor 26 21
S
Door F Interlock Sensor 19 22

S
8 9
Entrance Sensor
20
Lef
t Front s5500-531
4-48

No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Name/Description
REAR COVER BELT-DRIVE PULLEY BEARING BRACKET-DRIVE COVER-MOTOR H-TRANSPORT MOTOR TOP COVER PAPER GUIDE BEARING BEARING BELT ROLL SHAFT ASSY RIGHT SHAFT ASSY LEFT BRACKET-BEARING COVER-BEARING MAGNET H-TRANSPORT INTERLOCK SENSOR (Door F Interlock) BRACKET H-TRANSPORT EXIT SENSOR BRACKET H-TRANSPORT ENTRANCE SENSOR BRACKET LOWER CHUTE WIRE HARNESS CHUTE ASSY LOW (with 2~7, 10~26, 28~30) BEARING ROLLER SUPPORT BUSH SADDLE CLAMP MINI-CLAMP
Part Number
023E20480
127K39900 802E64430 038E31190
023E20020
022K67730 022K67740
121E92720 130E82540
130K63280
130K61250
Parts Lists
4-49
Parts List 25.4 Finisher/Stacker Covers (1/2)

S S
1 3
S S
11
S
2 4 5
S S S
10
S S S
6
S
9
S
12
12
8 8
Left Front
s5500-532
4-50

No.
1 2 3 4 5 6 7 8 9 10 11 12
Name/Description
COVER TOP GUIDE TRAY SPRING TRAY ASSY SCT (Stacker Upper Tray) COVER EJECT TRAY ASSY STACKER (Stacker Lower Tray) COVER BOTTOM CASTER CASTER COVER REAR LOWER COVER-CONNECTOR H-TRA COVER REAR UPPER NUT M12X1.25
Part Number
802E69840
050K51270
050K51280 802E69810 017E97220 017E97230 802E69830 802E69870 802E69820
Parts Lists
4-51

1 5
S S S S E
3 (with 4, 5, 12) 12
S S
S S S S E S S S S S S
12
8 7 11
S
10
11
Left Front
s5500-53
4-52

No.
1 2 3 4 5 6 7 8 9 10 11 12
Name/Description
COVER FRONT TOP INTERLOCK SWITCH (Door G Interlock Switch) COVER ASSY FRONT (with 4, 5, 12) (Door G) BRACKET ASSY HINGE COVER INNER PLATE DOCKING SPRING COVER FRONT L/H COVER L/H TOP PLATE ASSY DOCKING IOT SCREW BRACKET-COVER
Part Number
802E69880 110E97990 802K67130
009E94910 802E69860 802E69850
026E93560
Parts Lists
4-53
Parts List 25.6 Finisher Stack
1
S S
17
24 (with 25, 26) 23

S S S S S
8 (with 9-12) 3 6 5 7 3
S S S S
S S
25
4 5
2 (with 3-5)
22 (with 17) 26
S S S
6 5
Stack Height Sensor 2 13

S
5 11
7 12
21 20
E
19 18
E
15
13 Stack Height
Sensor 1
S
27 17
Lower Tray Upper Limit Sensor Lower Tray No Paper Sensor
14 15
E
16
E
16
E
16
E Left Front s5500-534
4-54
Parts List 25.6 Finisher Stack

No.
1 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
Name/Description
CARRIAGE TRAY CARRIAGE ASSY L (with 3~5) BELT STACKER CARRIAGE ASSY L CLAMP BELT SPRING BEARING CARRIAGE CARRIAGE ASSY R (with 9~12) BELT STACKER CARRIAGE ASSY R ACTUATOR COVER ASSY SENSOR (Stack Height Sensor 1 & 2) SHAFT-ELEV BEARING PULLEY T18 SENSOR (Stacker Encoder, Upper Limit, and No Paper Sensor) PULLEY DOC. CLUTCH GEAR DOC. CLUTCH SPRING DOC. WASHER BRACKET ASSY (with 17) ENCODER BRACKET ASSY STACKER (with 25, 26) BELT (Elevator Motor Belt) MOTOR ASSY DC (Elevator Motor) BEARING 10X6
Part Number
023E21520
019E58660 809E56850
802K67140
130E82530
146E01770
423W27654 127K40300
Parts Lists
4-55
Parts List 25.7 Finisher Punch

1 (with 2-18) 18 (with 17)
S S S S S
17
S S S S
4
S
Punch Hole Select Sensor
16 15
S
22
S S S
15
Punch Front Sensor
15 T Punch Home
Sensor
Side Regi Sensor 2
6 (with 8)
Side Regi Sensor 1
11 14 (with 12, 13) S 24 Punch Motor 13S

S S
8
S
7
S
11 12
S
11
9 (with 2, 6, 11-16, 22, 23)
Encoder Sensor
10
23 19
25
S S S
S S S S S
26
S S S S
20 21
Punch Box Set Sensor
27
4-56
Parts List 25.7 Finisher Punch

No.
1
Name/Description
FRAME ASSY PUNCH, 3-HOLE (with 2~18) FRAME ASSY PUNCH, ALL 2-4-HOLE (with 2~18)
Part Number
801K16760 801K16770 962K27650
2 3 4 5 6 7 8 9
HARNESS ASSY PUNCH UNIT COVER MOTOR PUNCH BRACKET ASSY MOTOR PUNCH HOLDER-FRAME ASSY BRACKET ASSY SENSOR HOL (with 8) COVER-FRONT, PUNCH SENSOR (Side Registration Sensors 1 & 2) BRACKET ASSY PUNCH 3-HOLE (with 2, 6, 11~16, 22, 23) BRACKET ASSY PUNCH 2 & 4-HOLE (with 2, 6, 11~16, 22, 23)
015K65880
015K65840
030K76630 030K76640
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
COVER-LEFT, PUNCH GUIDE ASSY MOTOR ASSY (Punch Motor) SENSOR (Punch Motor Encoder Sensor) BRACKET ASSY (with 12, 13) (Punch Motor Assembly) SENSOR (Punch Hole Select, Home, and Front Sensors) BRACKET 2&4 (REF ONLY) SENSOR (Punch Move Home Sensor) BRACKET ASSY-SENSOR (with 17) CHUTE DUST BOX ENTRANCE DUST BOX SENSOR (Punch Box Set Sensor) CHUTE ASSY-S REGI GUIDE BOX BRACKET-OPB PUNCH BRACKET-OPB FRAME F BRACKET HARNESS ASSY PUNCH BOX SET 060K95790 130E82530 130E82530 015K65920 130E87380
Parts Lists
4-57
Parts List 25.8 Finisher Staple

Stapler Only 14 (with 1-10) 2
S S
7 6
3
S S S S
S S
10
Staple Move S Position Sensor

S S
8 9
S S
S S S
S S
12 13
S
11
4-58
Parts List 25.8 Finisher Staple

No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Name/Description
CARTRIDEGE ASSY STAPLES (Staple Cartridge) STAPLER ASSY (Staple Head) COVER STAPLER HOLDER STAPLER (Staple Head Cover) SENSOR (Stapler Move Position Sensor) GUIDE HARNESS, STAPLER HARNESS ASSY STAPLE CARRIAGE ASSY UPPER, STAPLER CARRIAGE ASSY LOWER, STAPLER RAIL-UPPER FRAME ASSY STAPLER BASE-RAIL (REF ONLY) STOPPER-CHUTE (REF ONLY) STAPLER UNIT (with 1~10) (REF ONLY)
Part Number
050K51250 029K92070 802E69750
130E82530
962K27660
041K94750 001E66640
Parts Lists
4-59
Parts List 25.9 Finisher Eject (1/3)

1 (with 2) 5 6 7 (with 6) 6 4
S S S S S
10 (with 11-13) 11
S S S
3 8 9
12 13
20 19 18
S E S
26
21
21 25 21
S
22 23
14
15 16 17
S E
15 17
24
4-60

No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
Name/Description
CHUTE ASSY EJECT (with 2) (Door H) MAGNET 25N SOLENOID ASSY (Sub Paddle Solenoid) BRACKET SOLENOID SPRING-PINCH PADDLE-CYCLONE SHAFT ASSY-EJECT PINCH (with 6) SPRING SOLENOID SHAFT ASSY PADDLE (Cyclone Paddle Drive Shaft) BRACKET ASSY-EJECT CLAMP (with 11~13) MOTOR ASSY-DC (Eject Clamp Motor) BRACKET EJECT CLAMP SENSOR (Eject Clamp Home Sensor) LEVER ASSY BEARING GEAR Z23 BEARING GEAR-CAM Z70 GEAR Z23L GEAR Z68L/Z20L CLAMP BRACKET SWITCH SENSOR ASSY (Door H Interlock) KNOB ASSY-ENT EDGE SADDLE CLAMP CHUTE ASSY EJECT UNIT (with 1~7 REF ONLY)
Part Number
121E92890 121K34620
033E92850 006K24160 809E56880
127K40290
130E82540 011K97710 413W77559 807E04700 413W11660
110E11590 003K13600
Parts Lists
4-61

Rear Tamper Home Sensor
2 1 (with 2-8) 2
Front Tamper Home Sensor
8 4
S
6
S S S
17 (with 18)
S S S
7 10 18 Set Clamp
Home Sensor
10 10 11 11 11
16
15
E
12
9 (with 10) 19
S
14 13
12
E E
13
4-62

No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Name/Description
TRAY ASSY-COMPILER (with 2~8) SENSOR (Front and Rear Tamper Home Sensors) SENSOR (Compiler Tray No Paper Sensor) ACTUATOR-PAPER -MOTOR ASSY 2 (Front Tamper Motor) MOTOR ASSY (Rear Tamper Motor) HARNESS ASSY COMPILER SHAFT ASSY-EJECT ROLL (with 10) (Eject Roller Shaft) PADDLE-SET CLAMP GUIDE-PADDLE BEARING BEARING GEAR CLUTCH Z24 (Set Clamp Clutch) ACTUATOR SET CLAMP BRACKET ASSY-EJECT (with 18) (Eject Motor Bracket Assembly) SENSOR (Set Clamp Home Sensor) PLATE
Part Number
050K51260 130E82530 130E82540
006K23840
121K34630 120E24310 015K65850 130E82540
Parts Lists
4-63

1 (with 2, 3)
S S
2
Compile Exit Sensor
4
S
5 6 7 (with 8-13) 8 11
S S E
11
10
10
15
9 13 14
12
18 22 20 19
17
16
E
9
S S E
21
S S
Left Front
s5500-539
4-64

No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Name/Description
BRACKET ASSY-SENSOR (with 2, 3) HARNESS ASSY COMP SNR SENSOR ASSY (Compile Exit Sensor) ELIMINATOR CHUTE UPPER EXIT ROLL ASSY-EXIT LOW (Lower Exit Roller) CHUTE ASSY-LOWER, EXIT R (with 8~13) CHUTE ASSY-LOWER, EXIT R BEARING ROLLER ASSY-PINCH, EXIT 1 (Exit Pinch Rollers) ROLLER ASSY-PINCH, EXIT 2 (Exit Pinch Rollers) SHAFT ASSY-PADDLE (Paddle Shaft) BELT-SYNCRONUS Z55 (Paddle Shaft Drive Belt) PULLEY T17 SHAFT-DRIVE PADDLE PULLEY BEARING PULLEY T20 GEAR Z23L PULLEY T20 PULLEY T44/Z20 GEAR Z23R
Part Number
015K65800
105E13100
022K67840
022K67870 022K67880 006K23850 423W25554 020E37730
020E37690
020E37660 020E37670
Parts Lists
4-65
Parts List 25.12 Finisher Transport (1/2)

2 1 (with 2-5) 3 4
2 2
3 4 3
5 34
S S
6 30
S S
7 8
32 23 24
E S S S S
33
28 9 31 29 27
S E S
8 8
S
25
S
26 24 12
Buffer Path Sensor
S S
21
11
E S
22 17 17
S S
18 17
S
19 17
9 10 (with 11, 12)
13 16 (with 17-19) 35 20 15
S S
8 14 (with 8, 15)
S S
15 15
15
4-66

No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
Name/Description
CHUTE ASSY-UPPER EXIT OPEN (with 2~5) ROLLER-PINCH SPRING 1.9N SHAFT SPRING-TORSION GATE (Transfer Gate) GATE-BUFFER (Buffer Gate) MAGNET 25N BEARING CHUTE ASSY BUFFER TOP (with 11, 12) BRACKET-SENSOR SENSOR ASSY (Buffer Path Sensor) ROLL ASSY-BUFFER (Buffer Roller) CHUTE ASSY-BUFFER BOTTOM (with 8, 15) CHUTE ASSY-PINCH, EXIT CHUTE ASSY-UPPER, ENT (with 17~19) ROLLER ASSY-PINCH, ENT BRACKET-SENSOR SENSOR (Transprot {Xport} Entrance Sensor) ROLL ASSY-ENT (Entrance Roller) MOTOR ASSY (Transport Motor) BRACKET MOTOR BELT (Transport Belt) PULLEY SPRING-TENSION BRACKET ASSY-TENSION BEARING GEAR Z46 PULLEY T20 LINK-BUFFER (Buffer Gate Solenoid Link) GEAR Z23 BRACKET ASSY SOL (Transfer Gate Solenoid) LINK (Transfer Gate Solenoid Link) BRACKET ASSY SOL (Buffer Gate Solenoid) KNOB
Part Number
054K27140
050E89750 050E89760 121E92890 413W11660 054K27180
130K88190 022K67890 054K27160
054K27110
130E87370 022K67810 127K40280
423W87054 020E37740 809E56840
020E37660 012E11990 807E04700 015K65810 012E11980 015K65820
Parts Lists
4-67

3
S S
3
S
3
S
1 (with 2, 3) 2 30
S
29
S S S S
Upper Tray Exit Sensor
4
Upper Tray Full Sensor
30 28
S
5
S
29 22 S
S E
24 23
25 26 9 E
S S S S
7 6 (with 7)
22 24 27
E S S
S E
21 20
8 9
S S S S S E
22 21 23
E
20
19 18
9
E E
9 18 11 12 11
S
12 13
12 11 12
13 11
17
S S
10 (with 11-13)
14 (with 15-17)
Left Front S
16 15 Gate Sensor
s5500-541
4-68

No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Name/Description
CHUTE ASSY UPPER, TOP EXIT R (with 2, 3) SENSOR (Stacker Upper Tray Exit Sensor) ROLLER ASSY-PINCH, EXIT (Top Exit Pinch Rollers) CHUTE ASSY LOWER, TOP EXIT R ROLL ASSY-EXIT TOP (Top Exit Roller) BRACKET ASSY-SENSOR (with 7) SENSOR (Stacker Upper Tray Full Stack Sensor) MAGNET 25N BEARING CHUTE ASSY-LOWER, TOP EXIT L (with 11~13) ROLLER-PINCH (Lower Top Exit Pinch Rollers) SPRING 1.5N SHAFT CHUTE ASSY-UPPER, TOP EXIT L (with 15~17) SENSOR (Gate Sensor) HARNESS ASSY-SNR BRACKET-SENSOR ROLL ASSY-TRANSPORT (Transport Rollers) PULLEY T53/Z23 BEARING PULLEY PULLEY BRACKET ASSY-TENSION SPRING-TENSION PULLEY T20/Z20 GEAR BELT (Registration Belt) BELT (Exit Belt) BRACKET MOTOR MOTOR ASSY (Exit or Registration Motor)
Part Number
130K88190 022K67860
022K67830
130E87370 121E92890
054K27120
130E84140
022K67820
020E37690 020E37740
809E56840 020E37700 807E04720 423W40054 423W86454
127K40280
Parts Lists
4-69
Parts List 25.14 Finisher Electrical

11 11 11 11 14 14 11 12 13 14 12 14 12 13 1
S S
17 10 18 17 18 17 16
S
12 12 13
2
S S
11 12
S
3 16
S S S
13 13
S S S S S S S S
1113 11
13 13
S S S
16
S S S
S 7
4-70
Parts List 25.14 Finisher Electrical

No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Name/Description
BRACKET HARNESS BRACKET HARNESS L/H PWB H-TRA (Horizontal Transport PWB) HARNESS ASSY H-TRA I/F PWB MAIN-C (Finisher Main PWB) BRACKET-PWBA MAIN PLATE PWBA MAIN HARNESS ASSY AC INLET LVPS-C EDGE SADDLE CLAMP CLAMP CLAMP EDGE SADDLE EDGE SADDLE CLAMP CLAMP
Part Number
960K03140
960K03130
962K27560 105K21080
Parts Lists
4-71
Parts List 25.15 Finisher Harness
3 4 5 6 7
Punch Only 8
10 11 1
Left Front
2
s5500-543
4-72
Parts List 25.15 Finisher Harness

No.
1 2 3 4 5 6 7 8 9 10 11
Name/Description
HARNESS ASSY MAIN SNR HARNESS ASSY MAIN DRIVE HARNESS ASSY I/F (Finisher to IOT) HARNESS ASSY X'PORT ENT SNR HARNESS ASSY BUFFER SNR HARNESS ASSY TOP EXIT SNR HARNESS ASSY TOP SNR HARNESS ASSY PUNCH DRIVE (Punch-equipped only) HARNESS ASSY PUNCH SNR (Punch-equipped only) HARNESS ASSY LVPS HARNESS ASSY INTERLOCK
Part Number
962K27550
Parts Lists
4-73
4-74
Wiring Diagrams
In this chapter...

Notations Used in Wiring Diagrams Option Plug/Jack Locators Option Wiring Diagrams
Chapter
Phaser 5500 Option Wiring

Notations Used in Wiring Diagrams
The symbols in the interconnection wiring diagram are described below. Note that the description of general symbols is omitted.
Symbol
Description
Represents an interconnection between parts using wiring harness or wire, and indicates its signal name/ contents. The arrow > or < on the line represents the direction of signal flow. Represents an interconnection between parts using wiring harness or wire, which differs according to the specifications, and indicates its signal name/contents. The arrow > or < on the line represents the direction of signal flow. Represents a connection between parts using a conductive member such as a plate spring, and indicates its signal name/contents. The arrow > or < on the line represents the direction of signal flow. Represents a function and a logical value (High (H) or Low (L)) of a signal when the function is activated. The voltage indicates a value when the signal is High. The arrow indicates the direction of signal flow. Represents a function and a logical value (High (H) or Low (L)) of a signal when the function is in a detectable state. The voltage indicates a value when the signal is High. The arrow indicates the direction of signal flow. Represents a connection between lead wires.
Represents a connection between parts by tightening of a screw. Represents a connection between A and A.
24 VDC
The DC voltage indicates an approximate value measured when the negative side is connected to a signal ground (SG). Indicates a signal ground (SG).
5-2
Symbol
Description
Indicates a frame ground (FG).
Indicates a return. RTN Represents a connector. The connector and PIN Nos. are shown at the upper and lower parts respectively. P,- indicates the plug side of the connector. J,> indicates the jack side of the connector.
Represents a connection terminal with a plate spring on the printed circuit board. The connector No. is indicated inside the box. Represents a connector directly connected to the printed circuit board. The connector No. is indicated inside the box.
Represents a part. PL X.Y.Z indicates the item Z of the plate (PL) X.Y described in Chapter 5 Parts List.
Represents a functional part within a part, and indicates the name of the functional part.
Indicates a reference item associated with the section.
Phaser 5500 Printer Option Plug/Jack Information

The Plug/Jack locators for each option consist of the P/J Locator Tables and the P/J Locator Diagrams. Each table lists the plug/jack numbers in numerical order. The coordinates column lists the diagram coordinates for the location of the connector. A brief description of each connection is included in the remarks column. Following the Plug/Jack information for each option, the wiring diagrams depict the interconnections between major components.
Wiring Diagrams
5-3
1000-Sheet Feeder Plug/Jack Designators

1000-Sheet Feeder Plug/Jack Designators
P/J
101A 101B 102A 102B 103A 103B 202A 202B 541 548 549A 549B 552 554 661A 661B 812 820 821 822 824 825 826 841
Coordinates
C-304 C-304 D-305 D-305 D-306 D-306 B-304 B-304 F-323 E-323 F-324 F-324 F-323 F-323 D-309 D-308 D-308 G-307 E-308 I-322 G-308 E-309 G-324 I-320
Remarks
Connects the Tray 5 Level Sensor and Tray 5 Harness. Connects the Tray 4 Level Sensor and Tray 4 Harness. Connects the Tray 5 No Paper Sensor and Tray 5 Harness. Connects the Tray 4 No Paper Sensor and Tray 4 Harness. Connects the Tray 5 Pre Feed Sensor and Tray 5 Harness. Connects the Tray 4 Pre Feed Sensor and Tray 4 Harness. Connects the Tray 5 Feed/Lift Motor and Tray 5 Harness. Connects the Tray 4 Feed/Lift Motor and Tray 4 Harness. Connects the Tray 4-5 PWB and Tray Module Harness. Connects the Tray 4-5 PWB and Size Switch Harness. Connects the Tray 4-5 PWB and Feeder Harness. Connects the Tray 4-5 PWB and Feeder Harness. Connects the Tray 4-5 PWB and T/A Harness. Connects the Tray 4-5 PWB and Interlock Switch Harness. Connects the Tray 5 Harness and Feeder Harness. Connects the Tray 4 Harness and Feeder Harness. Connects the Door C Interlock Switch and Interlock Harness. Connects Tray 5 Paper Size Switch and Size Switch Harness. Connects Feed Out Sensor #4 and the Sensor Harness. Connects the Take Away Clutch and Take Away Harness. Connects Tray 5 Paper Size Switch and Size Switch Harness. Connects Feed Out Sensor #5 and the Sensor Harness. Connects the Take Away Motor and Take Away Harness. Connects the Feed Out Sensor #4 Harness and the Size Switch Harness. Connects the Feed Out Sensor #5 Harness and the Size Switch Harness.
842
D-308
5-4
1000-Sheet Feeder Plug/Jack Locators

Trays 4 and 5 Feeders
A 301 302 303 304 305 306 307 308 309 310
Tray 4 : 202B Tray 5 : 202A
Tray 4 : 101B Tray 5 : 101A Tray 4 : 102B Tray 5 : 102A Tray 4 : 103B Tray 5 : 103A 820
812 842 661B 661A
824
821 311 825 312 313 314 315

s5500-544
Tray 4 Feeder Assembly Tray 5 Feeder Assembly
Wiring Diagrams
5-5
Trays 4 and 5 Electrical
A 316 317 318
554 319 548 320 321 322 323 324 325 326 826 327 552 328 329 330
s5500-545
541
822 841
549A 549B
5-6
1000-Sheet Feeder Wiring Diagrams

General Wiring
Engine Logic Board

P/J413
Tray 4-5 PWB

P/J541 P/J552
Drive
P/J822
1
Take Away Clutch
P/J826
Take Away Motor
P/J554
FS812 FS813
Door C Interlock Switch
P/J549
P/J661
P/J220B
Feed/Lift Motor
Tray 4
P/J101B
Level Sensor
P/J102B
No Paper Sensor
P/J103B
Pre Feed Sensor Paper Size Switch
P/J548
P/J820
P/J841
P/J821
Feed Out Sensor #4
P/J549
P/J661
P/J220A
Feed/Lift Motor
Tray 5
P/J101A
Level Sensor
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
Wiring Diagrams
5-7
Drive
Tray 4-5 PWB
+24VDC
P/J522 9 8
Take Away Clutch On(L)+24VDC +24VDC
P822 1 2 2 1 Take Away Clutch
+24VDC P/J522 7 +5VDC 6 5 4 3 2 1 +24VDC RTN Take Away Motor On(L)+5VDC +5VDC SG Main Motor Clock M/C Clock P/J826 1 2 3 4 5 6 7
Take Away Motor
Door C Interlock Switch P/J554 2 1 FS812 1 FS813 1
Left Cover Open(H)+5VDC SG
Engine Logic Board P/J541 1 2 3 4 5 6 7 8 9 10 11 12 Engine To 2TM 2TM To Engine Tray 4 Feed/Lift Motor On(H)+5VDC Tray 5 Feed/Lift Motor On(H)+5VDC +5VDC SG +24VDC RTN Feed Ready Tray 4 Feed Out Paper Sensed(L)+5VDC Tray 5 Feed Out Paper Sensed(L)+5VDC Feed Stop P/J413 A1 A2 A3 A4 A5 A6 B1 B2 B3 B4 B5 B6
s5500-547
5-8
Tray 4
Tray 4-5 PWB Feed/Lift Motor

+24VDC P/J549 B1 B2 B3 B4 B5 B6 P661B 15 1 14 2 13 3 12 4 11 5 10 6 J661B P/J220B 6 5 4 3 2 1 M
FMOT3 /B FMOT3 /A +24VDC +24VDC FMOT3 B FMOT3 A
+5VDC P/J549 B7 B8 B9 +5VDC SG Tray 4 Level Up(H)+5VDC P661B 9 8 7 7 8 9 J661B P/J101B 3 2 1
Level Sensor
+5VDC P/J549 B10 B11 B12 +5VDC SG Tray 4 Paper Sensed(L)+5VDC P661B 6 10 5 11 4 12 J661B P/J102B 3 2 1
No Paper Sensor
+5VDC P/J549 B15 B14 B13 +5VDC Tray 4 Pre Feed Sensed(L)+5VDC SG P661B 1 15 2 14 3 13 J661B P/J103B 1 2 3
Pre Feed Sensor

+3.3VDC P/J548 14 13 12 11 +3.3VDC Tray 4 Size Switch Signal SG Tray 4 Size Switch S5 On(L)+5VDC P/J820 1 2 3 4
Paper Size Switch

+5VDC J548 8 9 10 +5VDC SG Tray 4 Feed Out Paper Sensed(L)+5VDC P841 3 2 1 1 2 3 J841 J821 3 2 1
Feed Out Sensor #4 s5500-548
Wiring Diagrams
5-9
Tray 5
Tray 4-5 PWB
Feed/Lift Motor
+24VDC
P/J549 A1 A2 A3 A4 A5 A6
FMOT4 /B FMOT4 /A +24VDC +24VDC FMOT4 B FMOT4 A
P6614 15 1 14 2 13 3 12 4 11 5 10 6
J661A
P/J220A 6 5 4 3 2 1 M
+5VDC P/J549 A7 A8 A9 +5VDC SG Tray 5 Level Up(H)+5VDC P661A 9 8 7 7 8 9 J661A P/J101A 3 2 1 Level Sensor +5VDC P/J549 A10 A11 A12 +5VDC SG Tray 5 Paper Sensed(L)+5VDC P661A 6 10 5 11 4 12 J661A P/J102A 3 2 1 No Paper Sensor +5VDC P/J549 A15 A14 A13 +5VDC Tray 5 Pre Feed Sensed(L)+5VDC SG P661A 1 15 2 14 3 13 J661A P/J103A 1 2 3 Pre Feed Sensor +3.3VDC P/J548 7 6 5 4 +3.3VDC Tray 5 Size Switch Signal SG Tray 5 Size Switch S5 On(L)+5VDC P/J824 1 2 3 4 Paper Size Switch +5VDC J548 1 2 3 +5VDC SG Take Away Sensor Sensed(L)+5VDC P842 3 2 1 1 2 3 J842 J825 3 2 1 Feed Out Sensor #5
s5500-549
5-10
Duplex Unit Plug/Jack Designators

Duplex Unit Plug/Jack Designators
P/J
123 124 212 540 541 542
Coordinates
D-606 B-606 C-608 H-608 H-609 H-609
Remarks
Connects the Wait Sensor and Sensor Harness. Connects the Door D Interlock Switch and Sensor Harness. Connects the Duplex Motor and Duplex Motor Harness. Connects the Duplex PWB and Duplex Harness. Connects the Duplex PWB and Duplex Sensor Harness. Connects the Duplex PWB and Duplex Motor Harness.
Wiring Diagrams
5-11
Duplex Unit Plug/Jack Locator
A 601 602 603 604 605 606 607 608 609 610 611 612 613 614 615
124
123 540
212
541 542
s5500-605
5-12
Duplex Unit Wiring Diagrams

Engine Logic Board Duplex PWB
P/J417
P/J540
P/J541
P/J123
Wait Sensor
P/J124
P/J542
P/J212
Duplex Motor
s5500-582
Duplex PWB +5VDC P/J541 1 2 3 +5VDC SG Duplex Sensor Paper Sensed(L)+5VDC P/J123 3 2 1 Wait Sensor
P/J541 4 5 +24VDC
SG Duplex Open(H)+5VDC
J124 2 1
Duplex Motor P/J542 1 2 3 4 5 P212 5 4 3 2 1 1 2 3 4 5 M J212
+24VDC Duplex Motor A Duplex Motor B Duplex Motor /A Duplex Motor /B
Engine Logic Board P/J540 1 2 3 4 5 6 7 8 +5VDC +24VDC SG RTN Engine To Duplex Duplex To Engine Registration Sensor Paper Sensed(H)+5VDC Registration Clutch On(L)+5VDC P/J417 A1 B1 A2 B2 A3 B3 A4 B4
s5500-550
Wiring Diagrams
5-13
Exit 2 Plug/Jack Designators

Exit 2 Plug/Jack Designators
P/J
111 112 113 116 207 208 209 210 220
Coordinates
D-707 F-708 F-707 C-706 C-707 B-707 D-708 C-708 D-706
Remarks
Connects the OCT Home 2 Sensor and Exit 2 Harness. Connects the Exit 2 Sensor and Exit 2 Harness. Connects the Full Stack Sensor and Exit 2 Harness. Connects the Door E Interlock Switch and Exit 2 Harness. Connects the Offset Motor and Exit 2 Harness. Connects The Exit Drive Motor and Exit 2 Harness. Connects the Exit Gate Solenoid and Exit 2 Harness. Connects Face Up Solenoid and Exit 2 Harness. (Not used). Connects the Exit 2 Fan to the Exit 2 Harness.
5-14
Exit 2 Plug/Jack Locator

A B C D E F G H I J K L
701
702
703
704
116
705
220
111
113 112
706
707
708
709
208
207
710
210 209
711
712
713
714
715
s5500-551
Wiring Diagrams
5-15
Exit 2 Wiring Diagrams

General Wiring
Exit PWB
1
Motor / Solenoid
P/J433 P/J606A P/J207 Offset Motor
P/J208
Exit Motor
P/J209
Exit Gate Solenoid
P/J209
Face Up Solenoid
P/J434
P/J606B
P/J111
Exit Offset 2 Home Position Sensor
Sensor / Fan
P/J112
Exit Sensor
P/J113
Full Stack Sensor
P/J116
P/J220
Exit Fan
s5500-552
5-16
Exit 2 Motor/Solenoid
Exit PWB +24VDC
Offset Motor P/J433 1 2 3 4 5 J606A 14 1 13 2 12 3 11 4 10 5 P606A P207 5 4 3 2 1 1 2 3 4 5 M J207
+24VDC Offset Motor2 A Offset Motor2 B Offset Motor2 /A Offset Motor2 /B
Exit Motor P/J433 6 7 8 9 10 J606A 9 8 7 6 6 7 8 9 P606A P208 5 4 3 2 1 1 2 3 4 5 M J208
+24VDC Exit Motor A Exit Motor B Exit Motor /A Exit Motor /B
5 10
P/J433 11 12
+24VDC Exit Gate Solenoid On(L)+24VDC
J606A 4 11 3 12
P606A P209 2 1 1 2
J209
Exit Gate Solenoid
P/J433 13 14
+24VDC FUT Gate Solenoid On(L)+24VDC
J606A 2 13 1 14
P606A P210 2 1 1 2
J210
Face Up Solenoid
s5500-553
Wiring Diagrams
5-17
Exit 2 Sensor/Fan
Exit PWB +5VDC P/J434 1 2 +5VDC OCT 2 Home Sensed(L)+5VDC J606B 16 1 15 2 P606B P/J111 3 1 2 Exit Offset 2 Home Position Sensor P/J434 3 4 J606B 14 3 13 4 P606B P/J112 3 1 2 Exit Sensor
+5VDC Exit 2 Paper Sensed(L)+5VDC
P/J434 5 6 7 8 10
+5VDC Full Stack 2 Sensed(L)+5VDC +5VDC SG
J606B 12 11 10 9 7 5 6 7 8 10
P606B
P/J113 3 1 2 Full Stack Sensor
SJ1 1 2 3 4 8 6 7 P/J434 12 11 J606B 5 12 6 11 P606B
Exit 2 Detected(L)+5VDC Face Up Tray Detected(L)+5VDC
Door E Interlock Switch P/J434 13 J606B 4 13 P606B J116 2 1
Exit 2 Interlock Open(H)+5VDC
Exit Fan P/J434 14 15 Exit Fan On(H) +5VDC SG J606B 3 14 2 15 P606B P220 4 1 1 4 2 3 M
s5500-554
5-18
Tray 6 Plug/Jack Designators

Tray 6 Plug/Jack Designators
P/J
1 2 3 4 5 6 8 51 52 53 54 56
Coordinates
G-523 G-523 G-524 G-524 F-524 F-524 G-523 F-521 G-521 F-525 E-505 C-506
Remarks
Connects the Tray 6 PWB and Sensor Harness. Connects the Tray 6 PWB and Tray 6 Feeder 1 Harness. Connects the Tray 6 PWB and Tray 6 Harness. Connects the Tray 6 PWB and Tray 6 Harness. Connects the Tray 6 PWB and Interlock Switch Harness. Connects the Tray 6 PWB and Tray 6 Feeder 1 Harness. Connects the Tray 6 PWB and Docking Switch Harness. Connects the Paper Size Sensor A and Sensor Harness. Connects the Paper Size Sensor B and Sensor Harness. Connects the Tray In Sensor and Sensor Harness. Connects the Feed Out Sensor #6 Harness and Sensor Harness. Connects the Tray 6 Feeder Harness and Tray 6 Feeder 1 Harness. Connects the Take Away Motor and Tray 6 Feeder 1 Harness. Connects the Feed/Lift Motor and Tray 6 Feeder Harness. Connects the Nudger Solenoid and Tray 6 Feeder Harness. Connects the No Paper Sensor and Tray 6 Feeder Harness. Connects the Pre-feed Sensor and Tray 6 Feeder Harness. Connects the Level Sensor and Tray 6 Feeder Harness. Connects the Feed Out Sensor #6 and Feed Out Sensor Harness. Connects the Door J Interlock Switch and Interlock Harness. Connects the Door J Interlock Switch and Interlock Harness. Connects Docking Interlock Switch and Docking Switch Harness. Connects Docking Interlock Switch and Docking Switch Harness.
57 58 59 60 61 62 67
E-524 D-506 D-506 G-506 H-506 H-506 H-506
FS001 FS002 FS003 FS004
E-505 E-505 E-507 E-507
Wiring Diagrams
5-19
Tray 6 Plug/Jack Locator

Tray 6 Feeder
501
502
503
504
59 58
54
FS001 FS002 67 61
505
506
507
508
509
510
511
56 FS003 FS004 60 62
512
513
514
515
s5500-556
5-20
Tray 6 Drive
516
517
518
519
520
521
52 51
522
8 1 2
523
524
525
3
526
4 5 53 6 57
527
528
529
530
s5500-557
Wiring Diagrams
5-21
Tray 6 Wiring Diagrams

General Wiring
Engine Logic Board P/J415 P/J414
2 PF55B J800 P/JF03 P/JF04 P/JF52 P/JF01 P/JF51 Paper Size Sensor B
P/J800
Paper Size Sensor A
FS001 FS002
P/JF05
P/JF53
Tray In Sensor
P/JF54 Docking Interlock Switch FS003 FS004 Tray 6 PWB P/JF08 P/JF02 P/JF56
P/JF67
Feed Out Sensor #6
P/JF60
No Paper Sensor
P/JF61
Pre Feed Sensor
P/JF62
Level Sensor
P/JF06
P/JF56
P/JF59
Nudger Solenoid
P/JF58
Feed/Lift Motor
P/JF57
Take Away Motor
s5500-558
5-22
Tray 6 Interface
Tray 6 PWB P/JF08 2 1 FS004 FS003 Docking Interlock Switch
Docking Switch Close(L)+5VDC SG
Interlock +24VDC P/JF05 2 1 I/L +24VDC +24VDC FS002 FS001
P/JF03 14 13 12 11 10 9 8 7
PF55B 1 2 3 4 5 6 7 8 PF55A 1 2 3 4 5 6 4 2 1 8 7 6 5 4 3 2 1
J800B
Engine Logic Board Engine To Tray 6 Tray 6 To Engine Feed Out Tray 6 Paper Sensed(L)+5VDC J800A P/J415 6 5 4 3
6 5 4 3 2 1 P/JF04 1 2 3
6 5 4 3 2 1 P/J800 RTN SG +24VDC P/J414 3 2 1 Feed Stop SYS Reset P/J415 2 1
s5500-559
Wiring Diagrams
5-23
Tray 6 Sensors
Tray 6 PWB
+5VDC P/JF01 12 11 10 +5VDC Tray 6 Size Sensor L Sensed(L)+5VDC SG PF51 1 2 3 3 2 1 Paper Size Sensor B +5VDC P/JF01 9 8 7 +5VDC Tray 6 Size Sensor R Sensed(L)+5VDC SG PF52 1 2 3 3 2 1 Paper Size Sensor A +5VDC P/JF01 6 5 4 +5VDC Tray 6 Tray Set(L)+5VDC SG PF53 1 2 3 3 2 1 Tray In Sensor +5VDC P/JF01 3 2 1 +5VDC Tray 6 TA Sensor Paper Sensed(H)+5VDC SG PF54 1 2 3 3 2 1 JF54 P/JF67 1 2 3 Feed Out Sensor #6 s5500-560 JF53 JF52 JF51
5-24
Tray 6 Drive
Tray 6 PWB +24VDC P/JF06 5 4 6 2 3 1 P/JF56 6 5 4 3 2 1 P/JF58 6 5 4 3 2 1
Feed/Lift Motor
Tray 6 Feed Motor B +24VDC Tray 6 Feed Motor NB Tray 6 Feed Motor NA +24VDC Tray 6 Feed Motor A
Take Away Motor +24VDC P/JF06 11 8 9 10 12 7 Interlock +24VDC P/JF06 13 14 I/L +24VDC Tray 6 Nudger Solenoid(L)+24VDC PF56A 6 5 1 2 JF56A PF59 2 1 1 2 Nudger Solenoid PF57 7 6 5 4 3 2 1 2 3 4 5 6 M JF57
Tray 6 T/A Motor NB Tray 6 T/A Motor NA +24VDC +24VDC Tray 6 T/A Motor B Tray 6 T/A Motor A
+5VDC P/JF02 3 2 1 +5VDC Tray 6 Lift Up(H)+5VDC SG PF56B 1 2 3 6 5 4 JF56B P/JF62 1 2 3 Level Sensor +5VDC P/JF02 6 5 4 +5VDC Tray 6 Feed Paper Sensed(L)+5VDC SG PF56B 4 5 6 3 2 1 JF56B P/JF61 1 2 3 Pre Feed Sensor +5VDC P/JF02 9 8 7 +5VDC Tray 6 Paper Sensed(L)+5VDC SG PF56A 1 2 3 6 5 4 JF56A P/JF60 1 2 3 No Paper Sensor s550-561
Wiring Diagrams
5-25
Finisher Plug/Jack Designators

Finisher Plug/Jack Designators
P/J
2 502 505 8300 8301 8302 8304 8305 8306 8307 8308 8309 8310
Coordinates
E-903 B-902 B-902 G-894 G-894 E-895 E-892 E-894 G-892 G-893 F-892 E-894 G-895
Remarks
Connects the LVPS and AC Inlet Harness. Connects the LVPS and LVPS Harness. Connects the LVPS and LVPS Harness. Connects the Finisher Main PWB and I/F Harness. Not connected. Connects the Finisher Main PWB and Main Sensor Harness. Connects the Finisher Main PWB and Main Drive Harness. Connects the Finisher Main PWB and Elevator Motor. Connects the Finisher Main PWB and Punch Drive Harness. Connects the Finisher Main PWB and Punch Sensor Harness Connects the Finisher Main PWB and Staple Harness. Connects the Finisher Main PWB and Compiler Harness. Connects the Finisher Main PWB and Horizontal Transport Harness. Not connected. Not connected. Connects the Finisher Main PWB and Interlock Harness. Connects the Finisher Main PWB and LVPS Harness. Not connected. Not connected. Connects the Transport Entrance Sensor and Harness. Connects the Compile Exit Sensor and Compile Sensor Harness Connects the Upper Tray Exit Sensor and Upper Tray Exit Sensor Harness. Connects the Upper Tray Full Sensor and Upper Tray Full Sensor Harness.
8311 8313 8314 8315 8316 8317 8319 8320 8321
E-896 F-896 F-896 E-896 G-896 E-896 E-883 F-853 F-881
8322
F-881
5-26
Finisher Plug/Jack Designators (Continued)

P/J
8324
Coordinates
E-852
Remarks
Connects the Eject Clamp Home Sensor and Main Sensor Harness. Connects the Set Clamp Home Sensor and Main Sensor Harness. Connects the Stacker No Paper Sensor and Main Sensor Harness. Connects the Upper Limit Sensor and Main Sensor Harness. Connects the Stack Encoder Sensor and Main Sensor Harness. Connects the Stack Height Sensor 2 and Main Sensor Harness. Connects the Stack Height Sensor 1 and Main Sensor Harness. Connects the Exit Motor and Main Drive Harness. Connects the Registration Motor and Main Drive Harness. Connects the Eject Motor and Main Drive Harness. Connects the Set Clamp Clutch (Z34) and Main Drive Harness. Connects the Eject Clamp Motor and Main Drive Harness. Connects the Sub Paddle Solenoid and Main Drive Harness. Connects the Transfer Gate Solenoid and Main Drive Harness. Connects the Transport Motor and Main Drive Harness. Connects the Punch Move Motor and Punch Drive Harness. Connects the Punch Motor and Punch Unit Harness. Connects the Punch Hole Select Sensor and Punch Unit Harness. Connects the Punch Front Sensor and Punch Unit Harness. Connects the Punch Home Sensor and Punch Unit Harness. Connects the Punch Motor Sensor and Punch Unit Harness. Connects the Side Regi Sensor 1 and Punch Unit Harness. Connects the Side Regi Sensor 2 and Punch Unit Harness. Connects the Punch Move Home Sensor and Punch Sensor Harness. Connects the Punch Box Set Sensor and Punch Box Set Sensor Harness. Connects the Staple Move Position Sensor and Staple Harness. Connects the Staple Head and Staple Harness.
8325 8326 8327 8328 8330 8331 8334 8335 8336 8338 8339 8340 8341 8342 8344 8345 8346 8347 8348 8349 8350 8351 8352
E-868 E-821 E-821 D-821 J-821 E-819 C-880 D-881 D-866 E-868 C-851 H-852 C-853 B-884 E-835 C-837 C-836 C-836 C-836 C-837 G-837 G-837 C-836
8353
C-838
8354 8356
E-826 F-826
Wiring Diagrams
5-27
Finisher Plug/Jack Designators (Continued)

P/J
8357 8358 8359
Coordinates
F-826 F-826 G-869
Remarks
Connects the Staple Head and Staple Harness. Connects the Stapler Move Motor and Staple Harness. Connects the Compiler Tray No Paper Sensor and Compiler Harness. Connects the Front Tamper Home Sensor and Compiler Harness. Connects the Rear Tamper Home Sensor and Compiler Harness. Connects the Rear Tamper Motor and Compiler Harness. Connects the Front Tamper Motor and Compiler Harness. Connects the Door H Interlock Switch and Interlock Harness. Connects the Door G Interlock Switch and Interlock Harness. Connects the Horizontal Transport PWB and Horizontal Transport Harness. Connects the Horizontal Transport PWB and Horizontal Transport 1 Harness. Not connected. Connects the Finisher Main PWB and Gate Sensor 1 Harness. Connects the Horizontal Transport Entrance Sensor and Horizontal Transport Harness. Connects the Horizontal Transport Motor and Horizontal Transport Harness. Connects the Horizontal Transport Exit Sensor and Horizontal Transport Harness. Connects the Door F Interlock Sensor and Horizontal Transport Harness. Not connected. Connects the Buffer Path Sensor and Buffer Path Sensor Harness. Connects the Buffer Gate Solenoid and Main Drive Harness. Connects the Horizontal Transport PWB and Horizontal Transport. Connects the Gate Sensor and Gate Sensor Harness. Not connected. Not connected.
8360 8361 8362 8363 8364 8365 8371
I-869 E-868 F-868 G-869 H-852 F-822 I-898
8372
I-898
8373 8376 8379
I-898 E-895 I-807
8380
C-807
8381
J-809
8382
G-810
8389 8392 8394 8394 8432 8452 8500
F-892 F-882 B-853 J-898 E-882 C-839 I-898
5-28
Finisher Plug/Jack Locators

801
802
803
804
805
8380
8379
806
807
808
809
8381
810
811
8382
812
813
814
815
s5500-562
Wiring Diagrams
5-29
Stapler and Door G Interlock

816
817
8331
818
819
8328
820
8327
821
8330
8326
822
823
8365
824
8356
825
8357
826
827
828
8354
8358
829
830
s5500-563
5-30
Punch and Punch Box

831
832
8344
833
8352
834
8348
835
836
8351
837
8346 8347 8350
838
8349 8345
839
840
8353
841
842
843
844
845
s5500-564
Wiring Diagrams
5-31
Input Drive
846
847
848
8324 8320
849
8340 8364 8339
850
851
852
853
854
855
856
8394
8341
857
858
859
860
s5500-565
5-32
Compiler
861
862
863
8361
864
8336 8325
8359 8360
865
866
867
868
869
870
871
8338
8362
8363
872
873
874
875
s5500-566
Wiring Diagrams
5-33
Upper Exit
876
877
878
8392 8432
8321 8322
879
880
881
8334
882
8335
883
884
885
886
8342
887
8319
888
889
890
s5500-567
5-34
Finisher Main PWB, H-XPort PWB and LVPS

891
8304 8308 8389 8306 8307 8309 8300 8305 8376 8301 8310 8316 8500 8317 8315 8313 8314 8372
892
893
894
895
8302
896
8311
897
898
8394
899
8373
900
901
8371 502
902
903
505
904
2
905
s5500-568
Wiring Diagrams
5-35
Finisher Wiring Diagrams

General Wiring (1/2)
1 Engine Logic Board 2
P/J400
P/J8300
P/J8310
P/J8371
LVPS
P/J502 P/J505
P/J8315
H-X'port Motor H-X'port Entrance Sensor H-X'port Exit Sensor H-X'port Interlock Sensor
P/J8379
P/J8390
P/J8372
Power
P/J2
P/J8314
Door G Interlock Switch Door H Interlock Switch 3 Gate Sensor Buffer Path Sensor
P/J8365
P/J8388 P/J8314
P/J8364
P/J8388
P/J8381
P/J8432
P/J8434
P/J8376
P/J8382 P/J8383 P/J8384 P/J8344 Bracket Assy-Motor, P/J8373
P/J8392
P/J8318
P/J8302
Sensors 1
Upper Tray Full P/J8322 Sensor Upper Tray Exit P/J8321 Sensor Compiler Exit Sensor
P/J8320
P/J8393
Finisher Main PWB

P/J8306
Punch
10
P/J8312 P/J8332 P/J8391 P/J8307 P/J8303 P/J8333
P/J8345 Punch Motor P/J8346 Punch Hole Sensor P/J8347 Punch Front Sensor P/J8348 Punch Home Sensor P/J8349 Punch Motor Sensor P/J8350 Side Registration P/J8351 Side Registration
X'port Entrance P/J8319 Sensor 4 Upper Limit Sensor

P/J8327
Stacker No Paper P/J8326 Sensor Stacker Encoder Sensor

P/J8328
Sensors 2
Set Clamp Home P/J8325 Sensor Eject Clamp Sensor Stack Height Sensor 1 Stack Height Sensor 2
P/J8324
Sensor 2 Sensor
P/J8352 Punch Move Home P/J8331 P/J8353 Punch Box Set Sensor
P/J8355
P/J8330
s5500-569
5-36
Punch 1
Sensor 1
Punch 2
P/J8380
General Wiring (2/2)
5 Exit Motor
P/J8334
P/J8304
P/J8308 P/J8354 Staper Move Home Position Sensor Stapler Assembly 8
Registration Motor P/J8335
Motors
Bracket Assy-Eject P/J8336
Finisher Main PWB P/J8356
Transport Motor
P/J8342
P/J8357 Staple Motor
6 Eject Clamp Motor Set Clamp Clutch Motor Sub Paddle Solenoid Transport Gate Solenoid Buffer Gate Solenoid Elevator Motor
P/J8339
P/J8358
Staple Move Motor
P/J8338 P/J8309 P/J8340 P/J8363 Front Tamper Motor P/J8341 P/J8361 Rear Tamper Home Sensor P/J8394 P/J8360 Front Tamper Home Sensor P/J8305 P/J8359 Compiler Tray No Paper Sensor s5500-570 P/J8362 Rear Tamper Motor 7
Clutch Solenoids
Wiring Diagrams
5-37
Ccompiler Tray
Stapler
Low Staple Sensor Staple Ready Sensor Staple Home Sensor
Power
Engine Logic Board P/J416 1 Fuser Exit 2 LVPS SQ 3 4 5 7 Regi Clutch On 8 Engine To Fin 9 Fin To Engine 10 SG 11 P/J8300 11 10 9 8 7 6 4 3 2 1 Finisher Main PWB J8314 3 2 J8388 2 J8365 2A 2B J8365 1A 1B Door G Interlock Switch SG Front SW +24VDC
Interlock +24VDC J8388 1 I/L+24VDC Eject Cover
Door H Interlock Switch J8364 2 1 3
LVPS P/J505 LVPS SQ 3 LVPS SQ 4 P/J502 1 2 5 6 +24VDC +24VDC RTN RTN J8315 3 6 P/J8315 1 4 2 5
J8314 1
On/Off
+24VDC Supply
3 4 1
J2
J8310 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
+24VDC +24VDC RTN RTN IF MOT Current IF MOT Phase HT/IF MOT CLK MOT Reset IF MOT ENB IF ENT Sensor IF Exit Sensor DEC Home Sensor SG +5VDC DEC Clutch DRV Docking Sensor IOT Full Sensor HTRA ENT Sensor HTRA Exit Sensor HTRA I/L Sensor Reserve HTRA MOT Enable IF MOT Brake Gate SOL Push Gate SOL Pull RS232C Select FIN To H-TRA H-TRA To FIN SG +24VDC
Horizontal Transport PWB J8371 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 s5500-571
5-38
Line Nut
Horizontal Transport PWB Interlock +24VDC
P/J8372 13 3 12 10 15 11
H-X'port Motor /B I/L +24VDC H-X'port Motor B H-X'port Motor A I/L +24VDC H-X'port Motor /A
P/J8390 1 10 2 4 9 3
J8379B 6 5 4 3 2 1 1 2 3 4 5 6
H-X'port Motor
+5VDC P/J8372 9 8 7 +5VDC Entrance Sensor Paper Sensed(L)+5VDC SG P/J8390 12 13 5 P/J8380 1 2 3 H-X'port Entrance Sensor +5VDC P/J8372 6 5 4 +5VDC Exit Sensor Paper Sensed(L)+5VDC SG P/J8390 6 14 15 P/J8381 1 2 3 H-X'port Exit Sensor +5VDC P/J8372 3 2 1 +5VDC H-X'port Cover Closed(L)+5VDC SG P/J8390 7 8 16 P/J8382 1 2 3 Door F Interlock Sensor
s5500-572
Wiring Diagrams
5-39
Sensors (1/2)
Finisher Main PWB +5VDC P/J8302A 15 14 13 +5VDC Buffer Path Paper Sensed(L)+5VDC SG J8318A 1 2 3 3 2 1 J8318B P/J8392 1 2 3 Buffer Path Sensor +5VDC P/J8302A 12 11 10 +5VDC Upper Tray Full Sensed(L)+5VDC SG J8393A 1 2 3 3 2 1 J8393B P/J8322 1 2 3 Upper Tray Full Sensor +5VDC P/J8302A 9 8 7 +5VDC Upper Tray Exit Paper Sensed(L)+5VDC SG J8312A 1 2 3 3 2 1 J8312B P/J8321 1 2 3 Upper Tray Exit Sensor +5VDC P/J8302A 6 5 4 +5VDC Compile Exit Paper Sensed(L)+5VDC SG J8391A 1 2 3 3 2 1 J8391B P/J8320 1 2 3 Compile Exit Sensor +5VDC P/J8302A 3 2 1 +5VDC Transport Paper Sensed(L)+5VDC SG J8303A 1 2 3 3 2 1 J8303B P/J8319 1 2 3 Transport Entrance Sensor +5VDC P/J8376 3 2 1 +5VDC Gate Paper Sensed(H)+5VDC SG J8434A 1 2 3 3 2 1 J8434B P/J8432 1 2 3 Gate Sensor s5500-573
5-40
Sensors (2/2)
Finisher Main PWB +5VDC P/J8302B 20 19 18 +5VDC Upper Limit Sensed(L)+5VDC SG J8441A 6 5 4 6 5 4 J8441B P/J8327 1 2 3 Lower Tray Upper Limit Sensor +5VDC P/J8302B 17 16 15 +5VDC Stacker Paper Sensed(L)+5VDC SG J8441A 3 2 1 3 2 1 J8441B P/J8326 1 2 3 Lower Tray No Paper Sensor +5VDC P/J8302B 14 13 12 +5VDC Stacker Encoder Sensor Sensed(L)+5VDC SG P/J8328 1 2 3 Stacker Encoder Sensor
+5VDC P/J8302B 11 9 4 +5VDC Set Clamp Home Sensed(L)+5VDC SG P/J8325 1 2 3 Set Clamp Home Sensor
+5VDC P/J8302B 8 7 6 +5VDC Eject Clamp Up(L)+5VDC SG P/J8324 1 2 3 Eject Clamp Home Sensor
+5VDC
P/J8302B 5 4 3 2 1
Stack Height Sensor 2 Clock Stack Height Sensor 1 Clock +5VDC Stack Height Sensor 1 Sensed(L)+5VDC SG
P/J8331 1 2 3 4 5 Stack Height Sensor 1
+5VDC
P/J8302A Stack Height Sensor 1 Clock 20 Stack Height Sensor 2 Clock 19 +5VDC 18 Stack Height Sensor 2 Sensed(L)+5VDC 17 SG 16
J8440A 1 2 3 4 5 5 4 3 2 1
J8440B P/J8330 1 2 3 4 5 Stack Height Sensor 2 s5500-574
Wiring Diagrams
5-41
Motors
Finisher Main PWB Interlock +24VDC P/J8304 2 4 1 3 6 5 P/J8334 1 2 3 4 5 6
Exit Motor
Exit Motor A I/L +24VDC Exit Motor /A Exit Motor B I/L +24VDC Exit Motor /B
Registration Motor Interlock +24VDC P/J8304 7 8 9 11 10 13 P/J8335 1 2 3 4 5 6
Registration Motor I/L +24VDC Registration Motor Registration Motor I/L +24VDC Registration Motor
A /A B /B
Eject Motor Interlock +24VDC P/J8304 15 12 17 19 14 21 P/J8336 1 2 3 4 5 6
Eject Motor A I/L +24VDC Eject Motor /A Eject Motor B I/L +24VDC Eject Motor /B
Transport Motor Interlock +24VDC P/J8304 23 16 25 27 18 29 P/J8342 1 2 3 4 5 6
Transport Motor I/L +24VDC Transport Motor Transport Motor I/L +24VDC Transport Motor
A /A B /B
s5500-575
5-42
Clutch and Solenoids

Finisher Main PWB P/J8304 31 33 Eject Clamp Motor CCW On(H)+24VDC Eject Clamp Motor CW On(H)+24VDC P/J8339 2 1 M Eject Clamp Motor
Interlock +24VDC
P/J8304 20 22
Set Clamp Clutch On(L)+24VDC I/L +24VDC
J8338B 1 2 2 1 Clutch Z34
Interlock +24VDC
P/J8304 24 26
Sub Paddle Solenoid On(L)+24VDC I/L +24VDC
P/J8340 2 1 Sub Paddle Solenoid
Interlock +24VDC
P/J8304 30 28 32
Transport Gate Solenoid Push(L)+24VDC I/L +24VDC Transport Gate Solenoid Pull(L)+24VDC
P/J8341 1 2 3 Transfer Gate Solenoid
Interlock +24VDC
P/J8304 35 34 36
Buffer Gate Solenoid Push(L)+24VDC I/L +24VDC Buffer Gate Solenoid Pull(L)+24VDC
P/J8394 1 2 3 Buffer Gate Solenoid
Elevator Motor P/J8305 1 2
Elevator Motor Down(H)+24VDC Elevator Motor Up(H)+24VDC
s5500-576
Wiring Diagrams
5-43
Compiler Tray
Finisher Main PWB P/J8309 19 +24VDC 18 17 16 15 Rear Tamper Motor /B Rear Tamper Motor B Rear Tamper Motor /A +24VDC Rear Tamper Motor A J8461B 1 2 3 4 5 19 18 17 16 15 J8461A J8362B 1 6 3 4 4 3 5 2 6 1 M Rear Tamper Motor
Front Tamper Motor P/J8309 14 +24VDC 13 12 11 10 +5VDC P/J8309 9 8 7 +5VDC Rear Tamper Home Sensed(L)+5VDC SG J8461B 11 7 12 8 13 9 J8461A P/J8361 1 2 3 Rear Tamper Home Sensor +5VDC P/J8309 6 5 4 +5VDC Front Tamper Home Sensed(L)+5VDC SG J8461B 14 6 15 5 16 4 J8461A P/J8360 1 2 3 Front Tamper Home Sensor +5VDC P/J8309 3 2 1 +5VDC Compiler Tray Paper Sensed(L)+5VDC SG J8461B 17 3 18 2 19 1 J8461A P/J8359 1 2 3 Compiler Tray No Paper Sensor J8461B 6 7 8 9 10 11 12 13 J8461A J8363B 1 6 3 4 4 3 5 2 6 1 M
Front Tamper Motor /B Front Tamper Motor B Front Tamper Motor /A +24VDC Front Tamper Motor A
10 14
s5500-577
5-44
Stapler
Finisher Main PWB +5VDC P/J8308 18 17 16 +5VDC Stapler Home Position Sensed(L)+5VDC SG P/J8354 1 2 3 Stapler Move Position Sensor
Stapler Assembly
+5VDC
P/J8308 15 14 13 12 11 P/J8308 10 9 8 7
SG Low Staple Sensed(L)+5VDC Staple Ready Sensed(L)+5VDC Staple Head Home Sensed(L)+5VDC +5VDC
P/J8356 1 2 3 4 5 P/J8357 1 2 3 4
Staple Head Low Staple Sensor Staple Head Self Prime Sensor Staple Head Home Sensor
Staple Motor+ Staple Motor+ Staple MotorStaple Motor-
Staple Motor
Staple Head Move Motor Interlock +24VDC P/J8308 3 6 5 1 4 2 P/J8358 1 2 3 4 5 6
Staple Move Motor I/L +24VDC Staple Move Motor Staple Move Motor I/L +24VDC Staple Move Motor
/A A B /B
s5500-5
Wiring Diagrams
5-45
Punch (1/2)
Finisher Main PWB +5VDC P/J8307 A1 A2 A3 +5VDC Punch Box Set(L)+5VDC SG P/J8355 1 2 3 P/J8353 1 2 3 Punch Box Set Sensor +5VDC P/J8307 A4 A5 A6 +5VDC Punch Unit Home Sensed(L)+5VDC SG P/J8352 1 2 3 Punch Unit Move Home Sensor +5VDC P/J8307 A7 A8 A9 +5VDC Side Registration Sensor 2 Sensed(L)+5VDC SG P/J8333 18 17 16 P/J8351 1 2 3 Side Registration Sensor 2 +5VDC P/J8307 A10 A11 A12 +5VDC Side Registration Sensor 1 Sensed(L)+5VDC SG P/J8333 15 14 13 P/J8350 1 2 3 Side Registration Sensor 1 +5VDC P/J8307 P/J8333 +5VDC B1 12 Punch Motor Encoder Sensor Sensed(L)+5VDC B2 11 SG B3 10 P/J8349 1 2 3 Punch Motor Encoder Sensor s5500-579
5-46
Punch (2/2)
Finisher Main PWB Interlock +24VDC P/J8306 7 3 6 5 2 1 P/J8344 1 2 3 4 5 6
Punch Unit Motor
Punch Move Motor I/L +24VDC Punch Move Motor Punch Move Motor I/L +24VDC Punch Move Motor
A /A B /B
Punch Motor P/J8306 8 7 +5VDC P/J8307 Anode B12 Punch Hole Sel Sensor Sensed(L)+5VDC B11 SG B10 P/J8333 1 2 3 P/J8346 3 2 1 Punch Hole Select Sensor +5VDC P/J8307 B9 B8 B7 Anode Punch Front Sensor Sensed(L)+5VDC SG P/J8333 4 5 6 P/J8347 3 2 1 Punch Front Sensor +5VDC P/J8307 B6 B5 B4 Anode Punch Home Sensor Sensed(L)+5VDC SG P/J8333 7 8 9 P/J8348 3 2 1 Punch Home Sensor P/J8332 2 1 P/J8345 2 1
Punch Motor CCW On(H)+24VDC Punch Motor CW On(H)+24VDC
s5500-580
Wiring Diagrams
5-47
5-48
Index
Numerics
1000-Sheet Feeder, 1-5 dimensions, 1-10 Feed Out Sensor, 2-15 location, 2-16 part numbers, 4-15 removal, 3-21 wiring, 5-10 Feed/lift Motor, 2-16 operational description, 2-16 part number, 4-11 removal, 3-13 wiring, 5-10 Feeder, 2-13 part number, 4-7 removal, 3-11 wiring, 5-9 Level Sensor, 2-15 part number, 4-11 removal, 3-16 No Paper Sensor, 2-15 part number, 4-11 removal, 3-14 option part number, 1-9 paper handling, 2-10 Paper Size Switch, 2-14 part number, 4-7 removal, 3-10 Pre-Feed Sensor, 2-15 part number, 4-11 removal, 3-17 PWB, 2-16 location, 2-16 part number, 4-17 removal, 3-29 replacement rollers, 4-12 roller location, 2-2 sensors, 2-15 1000-Sheet Feeder (cont.) Take Away Clutch, 2-16 part number, 4-17 removal, 3-31 wiring, 5-8 Take Away Motor, 2-17 part number, 4-17 removal, 3-31 Take Away Roller, 2-11 part number, 4-15 removal, 3-23 tray operation, 2-12 2000-Sheet Feeder, 1-7 Cable, 2-46 part number, 4-23 removal, 3-45 dimensions, 1-10 docking, 3-32 Feed Out Sensor, 2-45 part number, 4-31 removal, 3-63 wiring, 5-24 feed timing, 2-44 Feed/lift Motor, 2-42 part number, 4-25 removal, 3-49 wiring, 5-25 Feeder, 2-42 components, 2-42 part number, 4-25 removal, 3-48 wiring, 5-25 interlock wiring, 5-23 Level Sensor, 2-45, 2-46 part number, 4-27 removal, 3-55 wiring, 5-25
Index
Index-1
2000-Sheet Feeder (cont.) No Paper Sensor, 2-45 part number, 4-27 removal, 3-54 wiring, 5-25 Nudger Solenoid, 2-42 removal, 3-50 wiring, 5-25 option part number, 1-9 paper lift operation, 2-46 paper size sensing, 2-45 Paper Size Sensor, 2-47 part number, 4-19 removal, 3-42 wiring, 5-24 Pre-Feed Sensor, 2-45 part number, 4-27 removal, 3-51 wiring, 5-25 Pulley, 2-46 part number, 4-23 removal, 3-45 PWB, 2-43 part number, 4-33 removal, 3-67 replacement rollers, 4-27 Take Away Motor, 2-42 part number, 4-31 removal, 3-64 wiring, 5-25 Take Away Roller part number, 4-31 removal, 3-65 tray components, 2-46 Tray In Sensor, 2-50 part number, 4-19 removal, 3-41 tray removal, 3-39 Wire Guide part number, 4-23 removal, 3-45
B
Buffer Gate, 2-22 location, 2-22 part number, 4-67 removal, 3-206 Buffer Gate Solenoid, 2-22 connector designator, 5-28 part number, 4-67 removal, 3-225 wiring diagram, 5-43 Buffer Path, 2-19 operational description, 2-22 Buffer Roller, 2-22 function, 2-22 location, 2-22 part number, 4-67 removal, 3-208
C
clearances, 1-10 Compiler Tray, 2-19 Compile Exit Sensor, 2-25 connector designator, 5-26 function, 2-31 location, 2-22 wiring, 5-40 components, 2-28 Front Tamper Home Sensor, 2-32 connector designator, 5-28 removal, 3-180 limitations, 2-28 location, 2-22 No Paper Sensor, 2-25 connector designator, 5-28 function, 2-32 removal, 3-182 operational description, 2-23 part number, 4-63 Rear Tamper Home Sensor, 2-32 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
Configuration Card, 1-4 consumables, 1-8 part numbers, 1-8 Staple Pack, 1-8 Toner Cartridge, 1-8 Cyclone Paddles part number, 4-61 removal, 3-168
D
Docking Interlock, 2-50 connector designator, location, 2-44 part number, 4-31 removal, 3-66 wiring diagram, 5-23 Door C Interlock, 2-16 connector designator, location, 2-16 part number, 4-15 removal, 3-28 wiring diagram, 5-8 Door D Interlock, 2-8 connector designator, part number, 4-35 removal, 3-74 wiring diagram, 5-13 Door E Interlock, 2-5 connector designator, location, 2-5 part number, 4-41 removal, 3-95 wiring diagram, 5-18 Door F Interlock, 2-40 connector designator, location, 2-41 part number, 4-49 removal, 3-116 wiring diagram, 5-39 Door G Interlock, 2-40 connector designator, location, 2-41 part number, 4-53 removal, 3-127 wiring diagram, 5-38 5-19
5-4
5-11
5-14
5-28
Door H Interlock, 2-40 connector designator, 5-28 location, 2-41 part number, 4-61 removal, 3-176 wiring diagram, 5-38 Door J Interlock, 2-50 connector designator, 5-19 location, 2-44 part number, 4-31 removal, 3-62 wiring diagram, 5-23 Drum Cartridge, 1-8 location, 1-8 part number, 1-8 Duplex Unit, 1-5, 4-35 dimensions, 1-10 Duplex Motor, 2-9 connector designator, 5-11 drive train, 2-9 part number, 4-35 removal, 3-76 latch removal, 3-72 operational description, 2-7 option part number, 1-9 PWB, 2-8 connector designators, 5-11 location, 2-8 part number, 4-35 removal, 3-77 removal, 3-68 replacement part number, 4-35 roller locations, 2-8 Wait Sensor, 2-8 removal, 3-78 wiring diagram, 5-13
E
5-28 Eject Chute, 2-23 Door H Interlock, 3-163 removal, 3-163 Eject Clamp, 2-23 component locations, 2-38
Index
Index-3
Eject Clamp (cont.) Eject Clamp Home Sensor part number, 4-61 removal, 3-175 location, 2-23 operational description, 2-23 Eject Clamp Motor, 2-39 connector designator, 5-27 part number, 4-61 removal, 3-174 Elevator Motor, 2-37 Belt part number, 4-55 part number, 4-55 removal, 3-144 Envelope Tray, 1-7 dimensions, 1-10 option part number, 1-9 supported envelopes, 1-11 Exit 1, 2-3 Exit Gate, 2-4 Exit 2, 1-4 components, 2-4 dimensions, 1-10 Exit Gate Solenoid, 2-4 connector designator, 5-14 part number, 4-42 removal, 3-98 wiring, 5-17 Exit Motor, 2-6 connector designator, 5-14 drive train, 2-6 part number, 4-42 removal, 3-104 wiring, 5-17 Exit Roller, 2-4 Exit Sensor, 2-5 Actuator Kit, 4-42 part number, 4-42 removal, 3-102 wiring, 5-18 Face-up Roller, 2-4 removal, 3-80 Face-up Solenoid, 2-4 connector designator, 5-14 removal, 3-96 wiring diagram, 5-17
Exit 2 (cont.) Fan, 2-6 part number, 4-42 removal, 3-93 wiring, 5-18 Full Stack Sensor, 2-5 part number, 4-42 removal, 3-105 wiring, 5-18 Interlock Switch, 2-5 part number, 4-41 removal, 3-95 Invert Roller, 2-4 removal, 3-83 OCT Home Position Sensor, 2-5 part number, 4-42 removal, 3-103 OCT Roller, 2-4 part number, 4-41 removal, 3-90 Offset Gear, 2-6 part number, 4-41 removal, 3-89 Offset Motor, 2-6 connector designator, 5-14 drive train, 2-6 location, 2-5 part number, 4-42 removal, 3-100 wiring, 5-17 operational description, 2-4 Pinch Roller, 2-4 part number, 4-41 removal, 3-91 removal, 3-79 roller location, 2-2 sensors, 2-5 Exit Gate Solenoid connector designator, 5-14 part number, 4-42 removal, 3-98 wiring diagram, 5-17 Exit PWB, 2-6 location, 2-5
Index-4
F
Feed Out Sensor #4, 2-15 connector designator, 5-4 location, 2-16 part number, 4-15 removal, 3-21 wiring, 5-9 Feed Out Sensor #5, 2-15 connector designator, 5-4 location, 2-16 part number, 4-15 removal, 3-22 wiring, 5-10 Feed Out Sensor #6, 2-45 connector designator, 5-19 function, 2-42 part number, 4-31 removal, 3-63 wiring diagram, 5-24 Feed Roller, 2-2 part number, 4-12 removal, 3-18 Finisher, 1-6 Buffer Gate, 2-22 part number, 4-67 removal, 3-206 Buffer Gate Solenoid, 2-22 part number, 4-67 removal, 3-225 Buffer Path, 2-19 Buffer Path Sensor, 2-25 part number, 4-67 removal, 3-207 Buffer Roller, 2-22 part number, 4-67 removal, 3-208 Compile Exit Sensor, 2-23 part number, 4-65 removal, 3-189 Compiler Tray, 2-22 function, 2-23 part number, 4-63 removal, 3-177 Cyclone Paddles, 2-23 part number, 4-61 removal, 3-168
Finisher (cont.) dimensions, 1-10 docking, 3-119 Eject Clamp, 2-23 Eject Clamp Motor, 2-23 connector designator, 5-27 location, 2-40 part number, 4-61 removal, 3-174 Eject Motor connector designator, 5-27 part number, 4-63 removal, 3-187 Elevator Motor, 2-37 Belt part number, 4-55 location, 2-40 part number, 4-55 removal, 3-144 Exit Motor, 2-21 Belt part number, 4-69 connector designator, 5-27 location, 2-40 part number, 4-69 removal, 3-243 Gate Sensor, 2-24 location, 2-20 part number, 4-69 removal, 3-236 Horizontal Transport, 2-19 part number, 4-45 removal, 3-106 job offset, 2-31 LVPS location, 3-250 part number, 4-71 removal, 3-250 Main PWB location, 2-40 part number, 4-71 removal, 3-248 major components, 2-3 operational description, 2-18 option part number, 1-9
Index
Index-5
Finisher (cont.) Paddle Shaft, 2-23 Belt part number, 4-65 Belt removal, 3-200 part number, 4-65 removal, 3-200 paper path, 2-3 Punch, 2-25 part number, 4-57 removal, 3-145 wiring, 5-46 Punch Box Set Sensor part number, 4-57 removal, 3-154 Punch Motor connector designator, 5-27 part number, 4-57 removal, 3-149 Punch Move Motor part number, 4-57 Punch Move motor connector designator, 5-27 Punch operation, 2-21 Punch Waste Box part number, 4-57 Registration Motor Belt part number, 4-69 connector designator, 5-27 location, 2-40 part number, 4-69 removal, 3-245 Set Clamp Clutch connector designator, 5-27 part number, 4-63 removal, 3-186 Set Clamp Home Sensor, 2-39 part number, 4-63 removal, 3-188 Stack Height Sensors, 2-39 part number, 4-55 removal, 3-140 Stacker Belt part number, 4-55 removal, 3-136
Finisher (cont.) Stacker Lower Tray, 2-37 part number, 4-51 removal, 3-132 Stacker Upper Tray, 2-36 part number, 4-51 removal, 3-130 stacking, 2-22 Stapler, 2-33 part number, 4-59 removal, 3-155 Sub Paddle Solenoid, 2-23 connector designator, 5-27 part number, 4-61 wiring, 5-43 Transfer Gate, 2-19 part number, 4-67 Transfer Gate Solenoid, 2-19 connector designator, 5-27 part number, 4-67 removal, 3-223 Transport Entrance Sensor, 2-24 connector designator, 5-26 function, 2-19 part number, 4-67 removal, 3-217 Transport Motor, 2-19 Belt part number, 4-67 connector designator, 5-27 location, 2-40 part number, 4-67 removal, 3-222 Full Stack Sensor, 2-5 Fuser, 1-8 location, 1-8
G
Gate Sensor, 2-24 connector designator, 5-28 function, 2-20 part number, 4-69 removal, 3-236 wiring diagram, 5-40
Index-6
H
Hard Drive, 1-4 option part number, 1-9 Horizontal Transport, 2-19 Door F Interlock, 2-40 Door F Interlock Sensor part number, 4-49 removal, 3-116 Drive Belt part number, 4-49 removal, 3-109 Entrance Sensor, 2-24 part number, 4-49 removal, 3-117 Exit Sensor, 2-24 part number, 4-49 removal, 3-118 Finisher interface wiring, 5-38 function, 1-6 Motor, 2-19 part number, 4-49 removal, 3-113 operational description, 2-19 part number, 4-45 PWB connector designator, 5-28 location, 2-40 part number, 4-71 removal, 3-247 removal, 3-106 Transport Belt, 2-19 part number, 4-49 removal, 3-113 wiring diagram, 5-39
M
maintenance, 1-8 Drum Cartridge, 1-8 Fuser, 1-8 Transfer Roller, 1-8 Maintenance Kit, 1-8 Memory, 1-2 option part number, 1-9 options, 1-4 motors Duplex Motor, 2-9 drive train, 2-9 part number, 4-35 removal, 3-76 wiring, 5-13 Exit 2 Exit Motor, 2-6 part number, 4-42 removal, 3-104 wiring, 5-17 Offset Motor, 2-6 part number, 4-42 removal, 3-100 wiring, 5-17 Finisher, 2-40 Eject Clamp Motor connector, 5-27 function, 2-39 location, 2-40 part number, 4-61 removal, 3-174 Eject Motor connector, 5-27 function, 2-39 location, 2-40 Elevator Motor, 2-37 Belt part number, 4-55 connector designator, 5-26 function, 2-39 part number, 4-55 removal, 3-144 wiring diagram, 5-43
J
job offset, 2-31
L
LVPS connector designator, 5-26 part number, 4-71 removal, 3-250 wiring diagram, 5-38
Index
Index-7
Exit Motor Belt part number, 4-69 connector, 5-27 location, 2-40 part number, 4-69 removal, 3-243 Punch Motor connector, 5-27 part number, 4-57 removal, 3-149 wiring, 5-47 Punch Move Motor connector, 5-27 part number, 4-57 removal, 3-147 wiring, 5-47 Registration Motor Belt part number, 4-69 connector, 5-27 part number, 4-69 removal, 3-245 Transport Motor Belt part number, 4-67 connector, 5-27 location, 2-40 part number, 4-67 removal, 3-222 Finisher motor locations, 2-40 Horizontal Transport Motor part number, 4-49 removal, 3-113 Tray 4-5 Take Away Motor, 2-17 part number, 4-17 wiring, 5-8 Tray 6 Feed/lift Motor location, 2-42 part number, 4-25 removal, 3-49 timing, 2-43 Take Away Motor location, 2-42, 2-43 part number, 4-31 removal, 3-64
N
networking option, 1-4 Nudger Roller, 2-2 part number, 4-12 removal, 3-20 Nudger Solenoid connector designator, 5-19 wiring, 5-25 NVRAM option part number, 1-9 options, 1-4
O
Offset Motor connector designator, 5-14 location, 2-5 part number, 4-42 wiring diagram, 5-17 options, 1-4 1000-Sheet Feeder, 1-5 2000-Sheet Feeder, 1-7 Duplex Unit, 1-5 Envelope Tray, 1-7 Exit 2, 1-4 Hard Drive, 1-4 memory, 1-4 networking, 1-4 part numbers, 1-9 Stacker/Finisher, 1-6
P
paper specifications, 1-11 stacking mixed sizes, 2-38 Paper Size Sensor connector designators, 5-19 wiring diagram, 5-24 Paper Size Switch location, 2-14 part number, 4-7 removal, 3-10 Pinch Roller, 2-2
Index-8
Printer configurations, 1-3 options, 1-4 transport components, 2-2 Punch, 2-21 operational description, 2-25 part number, 4-57 Punch Box Set Sensor, 2-27 connector designator, 5-27 part number, 4-57 removal, 3-154 Punch Front Sensor, 2-27 connector designator, 5-27 location, 2-26 part number, 4-57 removal, 3-151 Punch Hole Select Sensor, 2-27 connector designator, 5-27 location, 2-26 part number, 4-57 removal, 3-151 Punch Home Sensor connector designator, 5-27 function, 2-27 part number, 4-57 removal, 3-151 Punch Motor, 2-26 connector designator, 5-27 function, 2-28 location, 2-26 part number, 4-57 removal, 3-149 wiring, 5-47 Punch Motor Encoder Sensor, 2-27 connector designator, 5-27 Punch Move Home Sensor, 2-27 connector designator, 5-27 location, 2-26 part number, 4-57 removal, 3-153 Punch Move Motor, 2-25 connector designator, 5-27 function, 2-28 location, 2-26 part number, 4-57 removal, 3-147
wiring, 5-47 Punch Waste Box part number, 4-57 removal, 3-145 sensor wiring, 5-46 Side Registration Sensor connector designator, 5-27 location, 2-26 operational description, 2-27 Punch Waste Box, 2-27 counter, 2-27
R
Registration Motor, 2-23 Belt part number, 4-69 connector designator, 5-27 location, 2-40 part number, 4-69 removal, 3-245 Retard Roller, 2-2 part number, 4-12 removal, 3-19 roller locations, 2-2
S
Sensor Compiler Tray, 2-32 Exit Sensor, 2-25 Front Tamper Home, 2-31 No Paper Sensor, 2-25 Rear Tamper Home, 2-31 Duplex Unit Wait Sensor, 2-7 Exit 2, 2-5 Door E Interlock Switch, 2-5 Exit Sensor, 2-5 OCT Home Position Sensor, 2-5 Feed Out Sensor #4, 2-15 Feed Out Sensor #5, 2-15 Feed Out Sensor #6, 2-42 Finisher Buffer Path Sensor, 2-25 Door G Interlock Switch, 2-40 Door H Interlock Switch, 2-40 Gate Sensor, 2-24 Transport Entrance Sensor, 2-24
Index
Index-9
Sensor (cont.) Horizontal Transport, 2-19 Door F Interlock Sensor, 2-40 Entrance Sensor, 2-24 Exit Sensor, 2-24 Punch, 2-27 Motor Encoder Sensor, 2-27 Punch Box Set Sensor, 2-27 Punch Front Sensor, 2-27 Punch Hole Select Sensor, 2-27 Punch Move Home Sensor, 2-25 Punch Unit Home Sensor, 2-27 Side Registration Sensor 1, 2-25 Side Registration Sensor 2, 2-25 Stacker Lower Tray, 2-39 No Paper Sensor, 2-37 Set Clamp Home Sensor, 2-39 Stack Height Sensor 1, 2-37 Stack Height Sensor 2, 2-37 Stacker Encoder Sensor, 2-37 Upper Limit Sensor, 2-37 Stacker Upper Tray, 2-36 Exit Sensor, 2-25 Stack Full Sensor, 2-25 Staple Head sensor locations, 2-34 Stapler, 2-35 Low Staple Sensor, 2-34 Move Position Sensor, 2-33 Self Priming Sensor, 2-33 Staple Head Home Sensor, 2-33 Tray 4-5, 2-15 Door C Interlock Switch, 2-16 Level Sensor, 2-15 No Paper Sensor, 2-15 Paper Size Switch, 2-14 Pre-Feed Sensor, 2-15 Tray 6 Docking Interlock Switch, 2-44 Door J Interlock Switch, 2-44 Level Sensor, 2-45 No Paper Sensor, 2-45 Paper Size Sensors, 2-45 Pre-Feed Sensor, 2-43 Tray In Sensor, 2-50
Set Clamp Clutch, 2-39 connector designator, 5-27 part number, 4-63 removal, 3-186 specifications clearances, 1-10 environmental, 1-10 noise, 1-10 paper, 1-11 tray capacities, 1-11 Stacker, 1-6 Belt part number, 4-55 removal, 3-136 components, 2-38 dimensions, 1-10 Elevator Motor, 2-37 job offset, 2-31 mixed stacking, 2-38 operational description, 2-18 option part number, 1-9 Stacker Lower Tray, 2-22 maximum capacity, 2-37 mixed stacking, 2-38 No Paper Sensor, 2-39 function, 2-37 location, 2-38 part number, 4-55 operational description, 2-37 part number, 4-51 removal, 3-132 sensor locations, 2-38 Stack Height Sensor function, 2-39 location, 2-38 part number, 4-55 Stacker Encoder Sensor, 2-39 part number, 4-55 Upper Limit Sensor, 2-39 function, 2-37 location, 2-38 part number, 4-55
Index-10
Stacker Upper Tray, 2-36 Exit Sensor, 2-25 connector designator, 5-26 function, 2-36 part number, 4-69 removal, 3-226 part number, 4-51 removal, 3-130 Stack Full Sensor, 2-25 connector designator, 5-26 function, 2-36 part number, 4-69 removal, 3-233 Staple Head, 2-33 connector designator, 5-27 exploded view, 3-158 movements, 2-33 operational description, 2-33 part number, 4-59 Staple Head Home Sensor, 2-33 function, 2-36 location, 2-34 Staple Head Low Staple Sensor, 2-34 function, 2-35 location, 2-34 Staple Head Self Priming Sensor function, 2-35 location, 2-34 Staple Motor, 2-33 function, 2-36 location, 2-34 Staple Move Position Sensor, 2-33 connector designator, 5-27 function, 2-35 part number, 4-59 removal, 3-162 staple positions, 2-34 Staple Self Priming Sensor, 2-33 wiring diagram, 5-45 Stapler, 2-33 operational description, 2-33 removal, 3-155 sheet limitation, 2-28 Staple Cartridge part number, 4-59 Staple Head, 2-33
Stapler (cont.) Staple Head Low Staple Sensor location, 2-34 Staple Head sensor locations, 2-34 Staple Motor, 2-33 staple positions, 2-34 Stapler Move Motor, 2-36 wiring diagram, 5-45 Sub Paddle Solenoid, 2-23 connector designator, 5-27 part number, 4-61 removal, 3-166 wiring, 5-43
T
tamping, 2-29 center, 2-31 front, 2-29 motors, 2-32 rear, 2-30 sensor removal, 3-180 Toner Cartridge, 1-8 location, 1-8 part number, 1-8 Transfer Gate, 2-19 part number, 4-67 removal, 3-204 Transfer Gate Solenoid, 2-19 connector designator, 5-27 part number, 4-67 removal, 3-204, 3-223 wiring diagram, 5-43 Transfer Roller, 1-8 location, 1-8 Transport Entrance Sensor, 2-19 part number, 4-67 Transport Motor, 2-19 Belt part number, 4-67 connector designator, 5-27 part number, 4-67 Tray capacities, 1-11 Envelope Tray, 1-7 envelopes, 1-11
Index
Index-11
Tray (cont.) Stacker Lower Tray part number, 4-51 removal, 3-132 Stack Height Sensors, 2-37 Stacker Upper Tray, 2-36 part number, 4-51 removal, 3-130 Standard Output Tray, 1-2 universal, 2-12 Tray 4-5, 1-5 Door C Interlock Switch connector designator, 5-4 part number, 4-15 removal, 3-28 Feed Out Sensor #4, 2-15 connector designator, 5-4 part number, 4-15 removal, 3-21 wiring, 5-9 Feed Out Sensor #5, 2-15 connector designator, 5-4 part number, 4-15 removal, 3-22 wiring, 5-10 Feeder, 2-13 part number, 4-7 removal, 3-11 wiring diagram, 5-9 Level Sensor, 2-15 part number, 4-11 removal, 3-16 No Paper Sensor, 2-15 part number, 4-11 removal, 3-14 Paper Size Guides, 2-12 Paper Size Switch, 2-14 part number, 4-7 removal, 3-10 signal definitions, 2-15 Pre-Feed Sensor, 2-15 part number, 4-11 removal, 3-17
Tray 4-5 (cont.) PWB, 2-16 location, 2-16 part number, 4-17 removal, 3-29 Take Away Clutch, 2-16 connector designator, 5-4 part number, 4-17 removal, 3-30 wiring, 5-8 Take Away Motor, 2-17 connector designator, 5-4 drive train, 2-17 part number, 4-17 removal, 3-31 wiring, 5-8 Take Away Roller, 2-11 part number, 4-15 removal, 3-23 Tray 6, 1-7 Cables, 2-46 part number, 4-23 removal, 3-45 dimensions, 1-10 docking, 3-32 Docking Interlock Switch, 2-44 part number, 4-31 removal, 3-66 wiring, 5-23 Door J Interlock Switch, 2-50 part number, 4-31 wiring, 5-23 Feed Out Sensor #6, 2-42 removal, 3-63 wiring, 5-24 Feed Roller, 2-42 part number, 4-27 removal, 3-58 feed timing, 2-44 Feed/lift Motor connector designator, 5-19 part number, 4-11, 4-25 removal, 3-49 wiring, 5-25
Index-12
Tray 6 (cont.) Feeder components, 2-42 part number, 4-25 removal, 3-48 Level Sensor part number, 4-27 removal, 3-55 wiring, 5-25 No Paper Sensor, 2-45 part number, 4-27 removal, 3-54 wiring, 5-25 Nudger Roller, 2-42 part number, 4-27 removal, 3-56 Nudger Solenoid, 2-49 function, 2-43 part number, 4-25 removal, 3-50 wiring, 5-25 option part number, 1-9 paper lift operation, 2-46 Paper Size Sensor, 2-45 connector designators, 5-19 locations, 2-47 part number, 4-19 removal, 3-42 wiring, 5-24 Pre-Feed Sensor, 2-43 part number, 4-27 removal, 3-51 Pulley, 2-46 part number, 4-23 removal, 3-45 PWB, 2-43, 2-50 connections, 2-50 part number, 4-33 removal, 3-67 replacement rollers, 4-27 Retard Clutch part number, 4-29 removal, 3-60 Retard Roller, 2-42 part number, 4-27 removal, 3-59
Take Away Motor, 2-42, 2-49 operational description, 2-43 part number, 4-31 removal, 3-64 wiring, 5-25 Take Away Roller part number, 4-31 removal, 3-65 Tray In Sensor part number, 4-19 removal, 3-41 wiring, 5-24 tray removal, 3-39 Wire Guide part number, 4-23 removal, 3-45
U
universal tray, 2-12 upgrades, 1-9
W
Wait Sensor, 2-8 connector designator, 5-11 part number, 4-35 removal, 3-78 wiring diagram, 5-13 Wiring Diagram conventions, 5-2
Index
Index-13

Phaser 5500 Series - 2

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Phaser 5500 Laser Printer

Service Manual Book 2 - Options

Phaser 5500 Printer Options Service Manual

Phaser 5500 Printer Options Service Manual

Phaser 5500 Printer Options Service Manual

Phaser 5500 Printer Options Service Manual

Phaser 5500 Printer Options Service Manual

Symbols Marked on the Product

Protective ground (earth) symbol.

Hot surface on or in the printer. Use caution to avoid personal injury.

Phaser 5500 Printer Options Service Manual

Power Safety Precautions

Electrostatic Discharge (ESD) Precautions

Phaser 5500 Printer Options Service Manual

Service Safety Summary

CLASS 1 LASER PRODUCT

Servicing Electrical Components

Servicing Mechanical Components

Servicing Fuser Components

Phaser 5500 Printer Options Service Manual

In the European Union

Phaser 5500 Printer Options Service Manual

Book 1 - Print Engine

Phaser 5500 Printer Options Service Manual

Printer Introduction and Overview

Phaser 5500 Printer Options Service Manual

128 MB 137 Yes Yes Yes Yes

128 MB 137 Yes Yes Yes Yes

128 MB 137 Yes Yes Yes Yes

128 MB 137 Yes Yes Yes Yes

256 MB 137 Yes Yes Yes Yes

Yes Optional Optional Optional Optional

Yes Standard Optional Optional Optional

Yes Standard Optional Standard Standard

Yes Standard Standard Standard Standard

Yes Standard Standard Standard Standard

Phaser 5500 Printer Options Service Manual

Phaser 5500 Printer Options Service Manual

Consumables and Routine Maintenance Items

Routine Maintenance Items

Phaser 5500 Printer Options Service Manual

Option Part Numbers

* Air transportation in pressurized cargo space

Phaser 5500 Printer Options Service Manual

Tray and Media Specifications

Supported Media Weights

Phaser 5500 Printer Options Service Manual

Phaser 5500 Options Operational Overview

Feed Roller Pinch Roller Drive Roller

Tray 4 1000 Sheet Feeder Tray 5

Take Away Rollers Feed Rollers Retard Rollers

Phaser 5500 Printer Options Service Manual

Stacker Upper Tray Horizontal Transport Punch Stacker Lower Tray

Exit 1 Compiler Tray

Exit 2 Paper Path Components

Phaser 5500 Printer Options Service Manual

Exit 2 Drive and Electrical

Exit 2 Motor Gear-19Z Gear-19Z/44Z Gear-19Z FU Roller Gear-19Z Invert Roller

Gear-19Z OCT Roller

Offset Motor Gear-Offset2 OCT Chute OCT Roller

Phaser 5500 Printer Options Service Manual

Duplex Paper Handling