Manual Service Xerox Phaser - 5500 - BK - 2 PDF

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 Unpublished rights reserved under the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.
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PCL and HP-GL are trademarks of Hewlett-Packard Corporation in the United States and/or other
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countries.
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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.
ii
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
iii
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
iv
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
vi
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
Contents
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)
Limits and Methods of measurement of radio interference

characteristics of Information Technology Equipment. Class B.
EN 61000-3-2:1995
+A1:1998+A2:1998
(IEC 61000-3-2)
Part 3: Limits - Section 2: Limits for harmonic current emissions

(equipment input current less than or equal to 16A per phase).
EN 61000-3-3:1995
(IEC 61000-3-3)
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.
EN 55024:1998
(CISPR 24)
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
5500N
5500DN
5500DT
5500DX
Maximum Print
Speed (Letter-size
Paper)
50 ppm
50 ppm
50 ppm
50 ppm
50 ppm
Memory
128 MB
128 MB
128 MB
128 MB
256 MB
PostScript Fonts
137
137
137
137
137
Oak PCL 5.0
Yes
Yes
Yes
Yes
Yes
PCL5e/PCL6
Yes
Yes
Yes
Yes
Yes
Job Pipelining
Yes
Yes
Yes
Yes
Yes
PDF Direct Print
Yes
Yes
Yes
Yes
Yes
Resolutions
600 or
True 1200 dpi
600 or
True 1200 dpi
600 or
True 1200 dpi
600 or
True 1200 dpi
600 or
True 1200 dpi
USB, Parallel
Yes
Yes
Yes
Yes
Yes
Ethernet
Capabilities
Optional
Standard
Standard
Standard
Standard
1000-Sheet Feeder
Optional
Optional
Optional
Standard
Standard
Duplex Unit
Optional
Optional
Standard
Standard
Standard
Automatic 2-Sided
Printing (Requires
Duplex Unit)
Optional
Optional
Standard
Standard
Standard
Hard Drive
Optional
Optional
Optional
Optional
Standard
Job Collation
(Hard Drive
Required)
Optional
Optional
Optional
Optional
Standard
Proof Print,
Personal Print,
Secure Print, Saved
Jobs (Hard Drive
Required)
Optional
Optional
Optional
Optional
Standard
2,000-Sheet Feeder
(Requires 1000Sheet Feeder)
Optional
Optional
Optional
Optional
Standard
3,500-Sheet
Finisher (Requires
1000-Sheet Feeder)
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
1-6
2. Stacker/Finisher
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
s5500-010
1. Fuser
3. Drum Cartridge
2. Transfer Roller
4. Toner Cartridge
Consumables
Description
Part Number
Toner Cartridge (30K)
113R00668
Staple Pack
008R12941
Routine Maintenance Items

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

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

0 to 15,000 meters (49,200 feet)
Acoustic Noise
LWA(B)
Idle
Printing
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
Trays
Specifications
Printable Area
All
Within 4 mm of paper edge guaranteed.

Edge-to-edge printing supported.
Supported
Envelopes
Tray 1, Tray 2 (with

Envelope Tray
installed)
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)
Supported Media
Weights
Tray 1,3,4,5,6
Tray 2
Duplex
60-216 g/m2 (16 lb. bond to 133 lb. card stock)
Tray 1
Tray 2
Tray 3
Tray 4
Tray 5
Tray 6
Top (facedown)
Stacker/Finisher
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
Tray Capacity
60-105 g/m2 (16 to 28 lb. bond)

60-163 g/m2
Based on 75 g/m2 (20 lb.) paper stock.

Capacity is reduced for heavier/thicker stock.
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 Pinch Rollers
Exit 2
Duplex Unit
OCT Rollers
A3L Rollers
Pressure Roller
Duplex
Roller
Heat Roller
Transfer Roller
Pinch
Rollers
Drum
Registration
Pinch Roller
Feed Roller
Registration Roller
Tray 2
Pinch Roller
Drive Roller
Tray 3
Pinch Rollers
Tray 4
Nudger Rollers
1000 Sheet Feeder

Tray 5
Take Away Rollers
Feed Rollers
Retard Rollers
2-2
s5500-233
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
Exit 2
Horizontal
Transport
Punch
Stacker Lower
Tray
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 2 Exit Sensor
Exit PWB
FU Roller
Invert Roller
Offset Motor
Rear
Exit Motor
Theory of Operation
Exit Gate Solenoid
s5500-236
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
Gear-19Z/44Z
OCT Roller
Gear-19Z
Gear-19Z
FU Roller
Invert 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
Theory of Operation
s5500-583
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
2-8
Duplex PWB
The Duplex PWB responds to commands, controls paper feed, and reports
sensor/switch status to the Engine Logic Board.
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 Idle 33 74
Gear Roll 28
Gear Roll 28
Gear Idle 33
Gear Idle 42
Lower A3L Roller

Duplex Roller
Gear Idle 33
Gear Roll 28
Upper A3L Roller
s5500-240
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
Tray 5
Nudger Roller
Nudger Roller
Feed Roller
Feed Roller
Retard Roller
Retard Roller
Pinch Roller (Upper)
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
OCT Roller
FU Roller
Exit Pinch Roller

Exit1
OCT Roller
Exit Pinch Roller
Upper A3L Roller

Duplex Roller
Exit 2
Duplex Unit Option

Print Exit
2-10
s5500-241
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
Transfer Roller
Drum Cartridge
Drum
Pinch Roller
Registration Roller
Tray 2
Tray 3
Take Away Roller
Nudger Roller
Tray 4
Pinch Roller
1000 Sheet Feeder

Tray 5
Take Away Roller

Feed Roller
Retard Roller
s5500-242
When the optional 1000-Sheet Feeder is installed under the printer, two additional
500-sheet universal trays are available. These two trays are identical to the 500-sheet
trays standard with the printer. The Feeder Assemblies are also identical to those used
in the printer.
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
2-12
s5500-034
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
s5500-2
Levers in the bottom of the tray are positioned by the trays end guide. Actuators
on the side of the tray close or open the switches in a pattern that correspond to
one of the pre-defined paper sizes.
2-14
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
SW2
SW3
SW4
SW5
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
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
s5500-247
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 (60T)
Gear (38T)
Gear (32T)
Gear (126T)
Gear (37T)
Take Away Roller
s5500-248
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
s5500-249
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
s5500-025
As the paper enters the Finisher it is detected by the Transport Entrance Sensor
activating the Entrance Roller driven by the Finisher Transport Motor. The papers
path inside the Finisher is determined by the Transfer Gate.
The Transfer Gate switches the paper path between the Stacker Lower Tray below or
upwards to the Stacker Upper Tray. Transfer Gate position is under control of the
Printers Engine Logic Board and is switched using the Transfer Gate Solenoid. The
Transfer Gate Solenoid, when energized, positions the Transfer Gate to direct paper
upward. The following illustrates the action and position of the Transfer Gate.
Theory of Operation
2-19
Transfer Rollers
(Driven by Regi Motor)
Gate Sensor
Punch
Entrance Sensor
Transfer Gate
Paper
From H-X'Port
Entrance Rollers
(Driven by Finisher
Transport Motor)
Buffer Roller
(Driven by Regi Motor)
s5500-251
Depending on the position of the Transfer Gate, the paper is further transported into
the Finisher by either the Transfer Rollers or the Buffer Roller. The Gate Sensor
monitors the arrival of paper to the Transfer Gate. The Transfer Rollers or the Buffer
Roller are driven by the Finishers Registration Motor.
This diagram represents the Finisher input as viewed from the front, left-hand corner.
The flow arrows indicate the paper entering from below, encountering the Transfer
Gate and being directed either up or down. The motors, drive belts, Transfer Gate
Solenoid, and Transfer Gate all appear in their actual positions relative to each other.
Registration Motor
Transfer Gate Solenoid
Punch
Transfer Rollers
Punch
Transfer Gate
Entrance Sensor
Entrance Roller Buffer Roller
Finisher Transport Motor
s5500-252
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
s5500-600
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)
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
Eject Motor
Compile Exit Sensor
Eject Clamp
Registration
Motor
Eject Roller Shaft
Buffer Gate
Solenoid
Lower Exit Roller
Compiler Tray
Buffer Roller Buffer Gate
s5500-255
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
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)
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
s5500-256
4. Activate the Punch Motor to move the Cam Plate. The movement of the Cam
Plate lowers the pins along the guide holes to punch the paper. The Cam Plate can
lower the pins in either direction of travel.
The following shows the action of the Cam Plate, Pins, and Punch Motor for a 3-hole
punch operation.
Pin Position
Punch Hole Select Sensor
Pin
Punch Front Sensor
Punch Unit Home Sensor
Cam Plate
Home Position
Punch Motor
3 Hole Position
s5500-257
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.

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.

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
Front Tamper Home Sensor

Front Tamper Motor
s5500-258
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.
Rear Tamper Home Sensor
Front
Rear
(1) (2) (3)
(6) (7) (5) (4)
Rear Tamper
Front Tamper Motor

Front Tamper
Rear Tamper Motor

s5500-259
1. Front Tamper home position
5. Rear Tamper standby position
2. Front Tamper size position
6. Rear Tamper tamping position
3. Front Tamper offset position
7. Rear Tamper offset position
4. Rear Tamper home 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.
Front
Rear
(1)
(3)
Front Tamper Motor
(2)
(6)
Front Tamper
(5)
(4)
Rear Tamper
Rear Tamper Motor
s5500-260
2. Front Tamper tamping position
5. Rear Tamper size position
2-30
Center Tamping
Tampering by the Front and Rear Tampers to center the paper in the tray during
rear stapling (straight) operations.

Front

Rear
(1) (2) (4) (3)
Front Tamper Motor
Front Tamper
(8) (7)
Rear Tamper
(6) (5)
Rear Tamper Motor

s5500-261
2. Front Tamper standby position
6. Rear Tamper standby position
3. Front Tamper tamping position
7. Rear Tamper size 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

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.

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.

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.
2-32
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
s5500-262
Staple Head
Stapling operation is executed by closing the Staple Head. The Staple Head,
containing the Staple Motor, the Staple Head Home Sensor, the Staple Head Self
Priming Sensor, and the Low Staple Sensor, is activated by the Staple Motor. Forward
(clockwise) rotation of the Staple Motor drives the Staple Head to staple a set of
sheets (closed), and returns the Staple Head to the home (open) position. If stapling
fails, the Staple Motor rotates reversely (counterclockwise) to return the Stapler Head
to the home position.
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
s5500-263
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.
2-34
Rear
Process direction
Rear
Process direction
Front
Front
Rear
Rear
Process direction
Front
Process direction
Front
s5500-264
The number of sheets to be stapled is limited to prevent damage to the Stapler. If the
number of sheets per set exceeds the Compile Tray limit set in NVRAM, the sheets
exceeding the limit are ejected to the tray without being stapled. A single sheet set is
also ejected without being stapled. The upper limit of Compile Tray paper capacity
when stapling is set by default to 50 sheets.
When sheets with different sizes and same width (example: A4L and A3S) are present
on the Compile Tray, all the sheets are stapled, and then ejected to the Stacker Lower
Tray. If sheets with different widths are present on the Compile Tray, stapling is
stopped when a different width is detected. These different-width sheets are ejected to
the Stacker Lower Tray.
Stapler Sensors/Motors
Staple Move Position Sensor

A photo-interrupter to detect the Stapler home position, Rear Staple (Corner)
position, and Rear Staple (Straight) position. The Stapler Move Home Position
Sensor signal goes High when the Stapler reaches the home position.
Staple 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

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.
2-36
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
Stack Height
Sensor 2
Tray: Height Tray: Proper

Tray: Low
Moves downward
Moves upward
s5500-265
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.
Eject Clamp Motor
Stack Height Sensors
Eject Clamp
Home Sensor
Eject Motor
Set Clamp
Home Sensor
Stack Height Sensors
Set Clamp Clutch
Elevator Motor
Stacker Encoder
Sensor
Upper Limit Sensor
Stacker No Paper Sensor
2-38
s5500-266
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
Eject Clamp Motor
Gate Solenoid
Eject Motor
Buffer Gate
Solenoid
Finisher
Transport Motor
Horizontal
Transport PWB
Elevator Motor
Finisher Main PWB

s5500-629
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
Take Away
Motor
Feed Roller
Nudger Roller
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 B
Paper Size Sensor A
Rear Size
Guide
s5500-274
Detectable paper size and sensor logic level patterns are as follows:
Paper Size
Size Sensor A
Size Sensor B
B5/Executive
0
8.5 x 11
A4
7.25 x 10.5
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
Tray Lift Time (ms)
25%
8798 - 11526
50%
6068 - 8797
75%
3338 - 6067
FULL
0 - 3337
If the remaining paper volume becomes zero before No-Paper is detected, the
indication remains at 25%. When the No Paper Sensor detects No-Paper, the
indication becomes zero.
When a fault occurs, remaining paper volume is calculated as follows:
1. When the Interlock opens during a lifting operation:
Remaining paper volume is based on the total time until Interlock open and the
time from the Feed Motor forward/reverse rotation until the Level Sensor goes
High.
2. When the power is cycled during a lifting operation:
Remaining paper volume is determined by the lifting time after power On.
3. When the power is cycled while the tray is at the feeding position:
If the Level Sensor signal is High when the power is turned On, the remaining
paper volume before the previous power Off is regarded as the remaining paper.
If the Level Sensor signal is Low when the power is turned On, it is assumed that
the tray has been removed, and the remaining paper volume is based on the time
from the Feed Motor forward/reverse rotation until the Level Sensor signal goes
High.
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.

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
s5500-279
1. Remove the Tray 6 docking bracket if present.

2. Remove the two screws securing the Left Cover to the frame.
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

PL2.3.14
Feeder
No Paper Sensor
Harness
Hooks
Upper Frame
s5500-109
2. Release the hooks securing the Sensor to the Upper Frame as shown in the figure.
3. Disconnect the connector from the No Paper Sensor.
4. Remove the No Paper Sensor.
3-14
Tray 4 and 5 Level Sensor Actuator

PL2.3.13
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

PL2.3.14
Feeder
Harness
Level Sensor
Hook
Upper Frame
Hooks
s5500-110
2. Release the hooks securing the Level Sensor to the Upper Frame as shown in the
figure.
3. Disconnect the connector from the Level Sensor and remove the sensor.
3-16
Tray 4 and 5 Pre-Feed Sensor

PL2.3.15
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
1. Remove the tray.
PL2.3.28
Front Chute
Support Assembly
Retard Roller
s5500-117
2. Release the hook securing the Retard Roller to the shaft as shown in the figure.
3. Remove the Retard Roller.
FRU Disassembly
3-19
Nudger Roller
1. Remove the tray.
PL2.3.32
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

1. Open Door C.
PL20.5.6
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

1. Open Door C.
PL20.5.8
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

1. Open Door C.
PL20.5.8
Chute
E-Ring
Gear
EL Clip
Bearing
Lower Take Away Roller
Left
E-Ring
s5500-287
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

1. Open Door C.
PL20.5.11
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

1. Open Door C.
PL20.5.11
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

1. Open Door C.
PL20.5.27
Bracket
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

PL20.6.2
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

PL20.6.7
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

2. Pull out the tray.
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

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

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

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.
4. Open Door J.
FRU Disassembly
3-37
PL22.7.1
Rear Hinge Bracket

Torsion Spring L
Torsion Spring R
Door J
Torsion
Spring R
Door J
Top Pivot
Shaft
Torsion
Spring L
Top Pivot Shaft
D-Cut
Door J
Longitudinal
Hole
D-Shaped Hole
Torsion Spring L
Rear Hinge
Bracket
s5500-301
5. Remove the two screws securing the Rear Hinge Bracket to the frame.
6. Remove the Rear Hinge Bracket leaving the Top Pivot Shaft and the Torsion
Spring R attached to Door J.
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

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

4. Remove the two screws securing the sensor bracket to the frame.
PL22.1.4
Size Sensor A
Sensor
Bracket
Size Sensor B
JF52
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
s5500-306
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.
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
2. Remove the Front Cover (page 3-37).
3. Remove the Gear Assembly Bracket R PF2 (page 3-44).
PL22.3.6
E-Ring
Pulley
(1)
(2) (3)
Pulley
(3)
Lift Shaft
Powered Bearing
Cables
Guide Wire Ss
Pulley Ss
Cables
Guide Wire L
Pulley L
Cable
Bottom
Plate
Bottom Plate
s5500-309
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
(6)
Lift Shaft
(5)
Pulley
(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).
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

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

6. Open Door J.
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

5. Open Door J.
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

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

2. Open Door J.
PL22.5.15
Actuator
E-Ring
No Paper Sensor
Upper Feeder
Assembly
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

2. Open Door J.
PL22.5.16
No Paper Sensor
PF60
Actuator
Upper Feeder
Assembly
Front
s5500-318
4. Disconnect the No Paper Sensor from the Upper Feeder harness connector
(P/JF60).
5. Release the hooks securing the No Paper Sensor to the Upper Feeder to remove
the sensor.
Replacement Note
After installing the No Paper Sensor, make sure that the actuator falls
smoothly into the recess of the sensor.
3-54
Tray 6 Level Sensor

2. Open Door J.
PL22.5.16
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

2. Open Door J.
PL22.5.20
Nudger Roller
Front
Upper Feeder Assembly
s5500-320
4. Remove the Nudger Roller by compressing the ends of the shaft with your
fingers.
3-56
Tray 6 Feeder Shaft Assembly

2. Open Door J.
4. Remove the Nudger Roller from the Upper Feeder (page 3-56).
PL22.5.19
Upper Frame
Bearing
E-Ring
Bearings
Feeder Shaft
Upper Feeder
Assembly
Front
s5500-321
5. Remove the E-ring securing the Feeder Shaft to the Upper Feeder.
Replacement Note
Note the orientation of the torsion spring on the Feeder Shaft. The anchor
point of the spring is the hole in the plate.
6. Remove the Bearing.
7. Remove the three Bearings attached to the Feeder Shaft to remove the Feeder
Shaft from the Upper Feeder.
FRU Disassembly
3-57
Tray 6 Feed Roller

2. Open Door J.
PL22.5.21
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.
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

5. Open Door J.
6. Remove the Retard Roller (page 3-59).
FRU Disassembly
3-59
PL22.6.1
Feeder
Lower Feeder Assembly
s5500-324
8. Remove the Tray 6 Drive Frame (page 3-49).

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

5. Open Door J.
6. Remove the Retard Roller (page 3-59).
8. Remove the Lower Feeder Assembly (page 3-59).
3-60
PL22.6.8
Lower Chute
Lower Frame
Retard Spring
Bearing
Bearing-6
Retard Shaft
s5500-325
9. Remove the four self-tapping screws securing the Lower Chute to the Lower
Frame.
10. Remove the Lower Chute.
11. Remove the two E-clips securing the two bearings.
12. Remove the Bearings from the two brackets on the Lower Frame.
Note
The Retard Spring is compressed and is not a captured spring. Use care not to
lose or damage the Retard Spring while removing the Retard Shaft.
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

1. Slide the Tray Module out from the optional trays.
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

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

PL22.7.12
Take Away Motor
Harness Clamp
PF57
s5500-328
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.
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

4. Open Door J.
PL22.7.9
Lower Chute Assembly
Take Away Roller Shaft
Take Away Motor

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

4. Open Door J.
PL22.7.17
Hook
N.O.
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
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
Release
Lock
Door D
Front
s5500-333
4. Open Door D.
5. Turn the two locks on the Outer Chute 90 degrees as shown in the figure to
release the Duplex Unit from the printer.
Replacement Note
Rotate the locks until they click while holding the Duplex Unit.
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
s5500-334
2. Remove the two screws securing the Lower Chute to the Outer Chute.
3-70
Stopper
Hook
Inner Chute
Outer Chute
Stopper
Cable Cutout
Duplex Cover
s5500-335
3. Open the Inner Chute.

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

2. Remove the Duplex Unit Chutes and Cover (page 3-70).
Motor Harness
Clamp
Rear
Outer Chute
Motor Bracket
s5500-336
3. Disconnect the connector from the motor harness.

4. Release the motor harness from the clamps on the Outer Chute.
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

PL23.1.9
Connector
Door D
Interlock Switch
Hooks
Motor Bracket
Rear
Outer Chute
s5500-340
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.
3-74
Wait Sensor Actuator

PL23.1.10
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
PL23.1.11
Motor Harness
Clamps
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

PL23.1.12
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

PL23.1.18
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
Front
Boss
L/H Chute High
s5500-348
4. Remove the screw securing the Rear Cover

5. Remove the hook holding the Exit 2 Stopper.
Chute- 2. Remove the right side (front) first, otherwise the Gear may be
damaged.
FRU Disassembly
3-83
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
Invert Roller
E-Ring
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.
3. Open Exit 2.
PL24.2.1
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 Exit 2 Stopper.
Chute. Remove the right side (front) first, otherwise the Gear may be damaged.
3-86
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.
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
Hook
Hooks
Rear
Paper Weight-B
Hook
Square Hole
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.
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.
3. Open Exit 2.
4. Remove the Offset Gear (page 3-89).
PL24.2.7
Bearing
Lower Chute
Gear (19Z)
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.
3. Open Exit 2.
4. Remove the OCT Roller (page 3-90).
PL24.2.10
Spring
Exit Pinch Roller
Release
E-Ring
OCT Chute
Roller Bearing
Hook
Hook
E-Ring
OCT Roller
s5500-356
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.
FRU Disassembly
3-91
Exit Sensor Actuator

1. Open Door A.
3. Open Exit 2.
PL24.2.17
Actuator Spring
Actuator Spring
Hook
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.
3. Open Exit 2.
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
Hole
Exit Fan
Marker
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

1. Open Door A.
3. Open Exit 2.
PL24.2.18
Door E Interlock
Switch
Front
s5500-358
5. Release the harness secured to the guide on the backside of the Lower Chute.
FRU Disassembly
3-95
Door E Interlock
Switch
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
1. Open Door A.
3. Open Exit 2.
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

1. Open Door A.
3. Open Exit 2.
3-98
PL24.2.29
Exit Gate
Solenoid
Front
Link
Clamp
Lower Chute
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.
3. Open Exit 2.
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
1. Open Door A.
3. Open Exit 2.
PL24.2.35
Exit Sensor
Hook
Front
Actuator
Lower Chute
s5500-363
5. Disconnect the Exit Sensor from the connector.

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.
3. Open Exit 2.
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
1. Open Door A.
3. Open Exit 2.
PL24.2.37
Rear
Connector
Exit Motor
Rear
Rear Plate
Connector
3-104
s5500-365
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

1. Open Door A.
3. Open Exit 2.
PL24.2.35
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
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
s5500-370
1. Remove the two screws securing the Rear Cover.

2. Remove the Rear Cover in the direction of the arrow.
FRU Disassembly
3-107
Door F
1. Remove the Horizontal Transport (page 3-106).
3. Open Door F to release the tension on the hinge springs.
PL25.2.9
Square Hole
Door F
Square Hole
Hinge
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

PL25.3.2
Motor
Drive Belt
Right Shaft
E-Ring
Pulley
s5500-372
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.
FRU Disassembly
3-109
Horizontal Transport Right Shaft

3. Remove the Belt Drive and the Pulley (page 3-109).
PL25.3.14
Rear
Right Shaft
Bearing
s5500-373
Right Shaft
Bearing
Drive Bracket
E-Ring
Lower Chute
Belts
Front
s5500-374
4. Remove the Bearing on the rear side.
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

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

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

3. Remove the Belt Drive (page 3-109).
FRU Disassembly
3-113
PL25.3.7
Clamp
Motor
Connector
Rear
s5500-378
4. Open Door F.
5. Remove the two screws securing the Motor Cover and remove the Cover.
6. Disconnect the Motor connector from the harness.
7. Release the Motor harness from the clamp.
Drive Bracket
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

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

2. Turn the Horizontal Transport upside down.
PL25.3.19

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

PL25.3.23
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.
FRU Disassembly
3-117
Horizontal Transport Exit Sensor

PL25.3.21
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.
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
Docking Slots
Printer Docking Plate
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.
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

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
s5500-618
2. Pull the Punch Box toward the front to remove it from the Finisher.
3. Remove the three screws on the front side and one screw on the rear securing the
Dust Box Chute to the Finisher and remove the chute.
4. Disconnect the connector from the Door G Interlock Switch.
5. Release the hooks of the switch by using two fingers to press down the two hooks
on either side or the switch and push the switch towards the front to remove it
from the frame.
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.
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

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
Tray Carriage
Stacker Lower Tray
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

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
3-134
s5500-399
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.
2. Remove the Front Door (page 3-124).
PL25.6.2
Pulley Doc Clutch

Gear
Encoder
Rear
Stacker Lower Tray

s5500-397
position.
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.
2. Remove the Front Door (page 3-124).
PL25.6.8
Pulley Doc Clutch

Gear
Encoder
Rear
Stacker Lower Tray

s5500-397
position.
3-138
Stacker Belt
Belt Clamp
Tray Carriage
Rear
Right Carriage
Pulley T16
Spring
s5500-402
4. Remove the Stacker Bracket (page 3-132).

5. Remove the two screws securing the Tray Carriage.
6. Remove the Spring on the Carriage.
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

PL25.6.13
J8331
Front
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

PL25.6.13
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
Stacker Encoder Sensor

PL25.6.17
Stacker Encoder
Sensor
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

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
3. Loosen the four screws securing the Finisher Main PWB Cover and remove in
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.
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.
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).
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.
3. Remove the Punch (page 3-145).
PL25.7.8
Punch Front Cover
Punch Frame
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.
3-148
PL25.7.9
Holder Frame
Punch Bracket
J8350/J8351
Sensor Bracket
Punch Front Cover
Punch Left Cover
s5500-412
4. Remove the one screw securing the Punch Front Cover.

5. Remove the two screws securing the Punch Left Cover.
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.
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.
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 Front Sensor
J8346
J8347
Bracket
J8348
Punch Home Sensor
s5500-417
5. Disconnect the connector (J8346) from the Punch Hole Select Sensor, connector
(J8347) from the Puncher Front Sensor, or connector (J8348) from the Puncher
Home Sensor.
6. Release the hooks of the sensor to remove the sensor from the bracket.
Replacement Note
When installing the bracket, engage each notch of the bracket and the Punch
Frame. Then tighten the screw while pushing the bracket toward the set
screw.
3-152

1. Open Door G.
2. Remove the Finisher Top Cover (page 3-122).
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
J8353
Sensor Harness
3-154
s5500-617
Finisher Stapler Unit

1. Remove Door G; (page 3-124).
2. Remove the Stapler Cartridge.
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
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
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
Staple Harness
J8356
J8357
Harness Guide
s5500-423
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.
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

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

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

4. Remove the Eject Cover (page 3-131).
PL25.9.1
Harness Clamps
J8340
Right
Sub Paddle Solenoid
s5500-425
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.
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
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

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.
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.
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.
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.
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

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

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

2. Remove the Stacker Top Tray (page 3-130).
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
PL25.9.23
Right
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

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.
3. Remove Lower Rear Cover (page 3-121)
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
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.
3. Remove Lower Rear Cover (page 3-121).
3-180

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

1. Open Door G.
3-182
PL25.10.3
Compiler Tray

J8359
Compiler Tray
Actuator
s5500-445
11. Disconnect the Compiler Tray No Paper Sensor connector (J8359).

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.
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.
13. Remove the E-ring on the rear.
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

PL25.10.15
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).
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

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

PL25.10.18
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.
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
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.
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
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
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.
3-194
Lower Exit Roller

E-Ring
Bearing
Front
s5500-458
Lower Exit Roller
Rear
s5500-459
20. Remove the E-ring securing the Lower Exit Roller shaft on the front.
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.
PL25.11.7
Tension Bracket
Belt
Exit Motor
Rear
Pulleys
s5500-434
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
Tension Bracket
s5500-460
Pulley T17
Bearing
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
Front View
(2)
(3)
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
FRU Disassembly
3-199
Paddle Shaft/Belt
1. Open Door G.
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.
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.
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.
3-202
Front
Lower Exit Chute
s5500-466
3. Open the Lower Exit Chute to the right by hand (Arrow 1).
4. Remove the one screw on the front securing the Lower Exit Chute to the frame.
PL25.12.1
Buffer Gate
Solenoid
Rear
s5500-467
5. Remove the screw on the rear securing the Lower Exit Chute to the frame.
6. Remove the Lower Exit Chute Open from the front (Arrow 2).
FRU Disassembly
3-203
Lower Exit Chute Pinch Rollers

Remove other Pinch Rollers using the same procedure.
1. Open Door G.
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.
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
FRU Disassembly
s5500-470
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.
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
s5500-472
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.
Buffer Path Sensor

1. Open Door G.
4. Remove the L/H Front Cover (page 3-128).
5. Remove the Top L/H Cover (page 3-129).
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.
4. Move the Staple Head to the rear by hand as far as possible.
3-208
PL25.12.13
Front
Buffer Gate
Bottom Buffer Chute
Lower Exit Chute

s5500-474
5. Open the Lower Exit Chute (2b).

6. Lift the Buffer Gate.
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

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.
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.
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.
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.
PL25.12.16
J8319
Upper Entrance
Chute
Sensor Bracket
Left
s5500-481
5. Release the harness from the Sensor Bracket clamp.

6. Disconnect the Transport Entrance Sensor connector (J8319).
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.
(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

1. Open Door G.
PL25.12.19
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
1. Open Door G.
PL25.12.20
Punch Frame
Upper
Entrance Chute
Front
Punch Box
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.
Replacement Note
3-220
Entrance Roller Shaft
Bearing
E-Ring
Front
s5500-487
14. Remove the E-ring securing the Entrance Roller Shaft on the front.
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

Belt
Tension Bracket
s5500-460
2. Loosen the two screws securing the Transport Motor Belt Tension Bracket.
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.
FRU Disassembly
3-223
PL25.12.32
Harness Bracket
Clamp
Link
J8341

Bracket
When Assembling
Guide
Link
Pin
s5500-489
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.
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.
PL25.12.34
Clamp
J8394

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

1. Open Door G.
PL25.13.2
Top Exit Upper Chute
Upper Tray
Exit Sensor
J8321
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.
PL25.13.3
Exit Pinch Roller
Left
Rear
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.
4. Remove the Exit Motor (page 3-243).
FRU Disassembly
3-227
PL25.13.5
Upper Tray
Exit Sensor
J8321
Left
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
s5500-496
9. Open the Upper Exit Chute (2a).

10. Remove the Top Exit Upper Chute and the Top Exit Lower Chute.
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.
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.
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.
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
s5500-499
6. Disconnect the Upper Tray Full Sensor connector (J8322).

7. Remove the screw securing the Upper Tray Full Sensor.
FRU Disassembly
3-233
Upper Exit Chute (2a)

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.
3. Remove the Registration Motor (page 3-245).
4. Remove the Upper Exit Chute (page 3-234).
PL25.13.11
Spring 1.5N
Shaft
Detailed View
Pinch Roller
Spring 1.5N
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.
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.
PL25.13.18
Upper Exit Chute
Front
s5500-504
7. Open the Upper Exit Chute.
3-238

Front
s5500-505
8. Remove the two screws securing the Top Exit Upper Chute at the front.
Top Exit
Upper Chute
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.
Replacement Note
3-240
Transport Roller Shaft

Bearing
Gears
Rear

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

s5500-508

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

PL25.13.30
Tension Bracket
Belt
Exit Motor
Rear
Pulleys
s5500-434
Replacement Note
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

PL25.13.30
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
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

PL25.14.3
Horizontal Transport PWB
Connector Plate
Rear
s5500-512
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.
FRU Disassembly
3-247
Finisher Main PWB

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
P8307
P8300
P8302
P8301
P8311
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
s5500-514
2. Disconnect the three connectors on the LVPS.

3. Remove the two screws securing the LVPS to the Finisher.
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
Meaning
C-ring
E-ring
KL
K-clip
Screw
Parts Lists
4-3
1000-Sheet Feeder
Parts List 20.1 1000-Sheet Feeder (Trays 4 & 5)
S
10
6
S
S
S
7
4
S
Left Front
s5500-608
4-4
Parts List 20.1 1000-Sheet Feeder (Trays 4 and 5)

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

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

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

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

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

No.
Name/Description
Part Number
FEEDER ASSEMBLY (with 2~50)
059K26934
TRAY FEED LIFT UP MOTOR
127K38170
BRACKET
SPACER
GEAR (31T)
SPRING
ONEWAY CLUTCH
ONEWAY GEAR
GEAR (13T)
10
BEARING
11
SHAFT
12
FRONT CHUTE
13
ACTUATOR (No Paper Sensor Actuator)
120E22481
14
SENSOR (No Paper or Level Sensor)
930W00113
15
SENSOR (Pre-Feed Sensor)
930W00211
16
WIRE HARNESS
17
GEAR (28T/21T)
18
GEAR (29T)
19
SPRING
20
ROLLER ASSY--Periodic replacement part per 300k prints (included

with 99) (Feed Roller)
21
ONEWAY CLUTCH
22
ONEWAY GEAR (22T)
23
SHAFT
24
CHUTE
25
SPRING
26
FRICTION CLUTH
27
SHAFT-RETARD
28
--
Parts Lists
809E51070
4-11
Parts List 20.4 Feeder (2/2) (Continued)

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

1
Feed Out
Sensor #4
9
8
S
E
8
7
Feed Out
Sensor #5
27
S
26
12
13
25
S
18
161514
13
16
17
19 S
10
(with 11-23)
11 (with 12-16)
16
24
20
23
21
22
4-14
Left Front
s5500-517
Parts List 20.5 Trasportation (Trays 4 & 5)

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

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

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

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

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

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

15
13
E
12
11
10
9
8
16
4
5
S
4-20
Left Front
S
s5500-520

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

7
1
2
6
6
6
6
5 (with 3, 4)
3
4
14 13
E
E
14 13
19 15
10
11 12
E E
18 17
13 14 13 14
E
E
15
16
17 18
S
S
S
99 (Item 6x4Pcs.)
Left Front
s5500-604
4-22

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

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

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

2
1 (with 2-19)
4
S
S
5
E
Tray 6 Pre Feed

Sensor 9
E
S
10
11
10
10
E
10
Tray 6
Level 16
Sensor
12
13
14
16
Tray 6 No Paper
Sensor
15
S
S
Detail A
18
17
19
18
20
21
4-26
Left Front
s5500-522

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

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

No.
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
10
COLLAR
11
CLUTCH ASSY FRICTION (Retard Clutch)
12
BEARING
13
SHAFT ASSY-RET
14
BEARING-6
15
BRACKET ASSY RETARD (with BRACKET and PAD)
16
GEAR 15T
17
ROLLER ASSY RETARD (included with PL22.5.99)
Parts Lists
Part Number
809E41221
005K06700
068K24820
4-29
Parts List 22.7 Tray 6 Drive and Transportation

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

No.
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)
10
BEARING CONDUCTIVE
11
BRACKET HINGE REAR NEW
12
MOTOR ASSY (Take Away Motor)
13
BRACKET ASSY PIVOT
14
SHAFT PIVOT TOP
15
SPRING TOSION R
16
SPRING TOSION L
17
SW IL ASSY DOCKING (Docking Interlock Switch)
Parts Lists
Part Number
802K74970
110E94770
130K88150
059K36260
127K40200
110E10380
4-31
Parts List 22.8 Tray 6 Electrical
S
S
3
3
3
3
3
Left Front
s5500-525
4-32
Parts List 22.8 Tray 6 Electrical

No.
Name/Description
PWB ASSY (Tray 6 PWB)
HARNESS ASSY MAIN
CLAMP WS-2N
CLAMP
WS-1N
Parts Lists
Part Number
960K03100
4-33
Duplex Unit
Parts List 23.1 Duplex Unit
1 (with 2-23)
20
21
14
17
22
6
2
12
18
4
15
5
4
9
19 (PL23.2)
10
2
3
E
11
16
S
23
24
8
13
Rear eft
L
s5500-526
4-34
Parts List 23.1 Duplex Unit

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

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

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

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

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

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

No.
Name/Description
Part Number
29
SOLENOID ASSY (Exit Gate Solenoid)
121K31810
30
MOTOR ASSY OFFSET
127K37951
31
ROLL-PINCH INV
059E98600
32
ROLLER ACTUATOR (included with 99)
33
CHUTE LOW
34
SPRING ACTUATOR (included with 99)
35
SENSOR-PHOTO IN (Exit, Full Stack, and OCT Home Position

Sensor)
36
HARN ASSY EXIT2 C
37
MOTOR ASSY EXIT 2
38
SCREW
39
EXIT 2 FAN
127K39420
40
ACTUATOR FULL-A (Full Stack Actuator A)
120E24660
41
ACTUATOR FULL-B (Full Stack Actuator B)
120E24680
42
SPRING ACT (Full Stack Actuator Spring)
809E60520
99
KIT ACTUATOR (with 17, 32, 34) (Exit Sensor Actuator Kit)
604K23310
4-42
930W00113
127K38261
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.
Name/Description
Part Number
SCREW
026E93560
H-TRANSPORT ASSY (with PL25.2, PL25.3)
022K67720
STAPLE FINISHER (PL25.4~PL25.15)
4
5
6
LABEL
Parts Lists
893E41630
4-45
Parts List 25.2 Horizontal Transport Assembly (1/2)

9 (with 1-8)
1
4
3
2
4
S
S
7
7
7
6
7
6
7
6
6
Lef
t Front
s5500-530
4-46

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

1
S
27 (with 2-7, 10-26, 28-30)

14
12
2
30
28 13
17
3
4 5
28
29
10
13
S
S
16 15
16
7
10
11
28
17
18
30
S
S
6
25
23
30
S
S
Door F
Interlock Sensor
19
18
24
Entrance
Sensor
Exit
Sensor
21
22
S
26
20
9
Lef
t Front
s5500-531
4-48

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

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

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

1
5
S
S
S
S
S
S
3 (with 4, 5, 12)
12
S
S
S
S
12
S
S
S
S
S
4
7
6
11
S
10
11
Left Front
s5500-53
4-52

No.
Name/Description
Part Number
COVER FRONT TOP
802E69880
INTERLOCK SWITCH (Door G Interlock Switch)
110E97990
COVER ASSY FRONT (with 4, 5, 12) (Door G)
802K67130
BRACKET ASSY HINGE
COVER INNER
PLATE DOCKING
SPRING
009E94910
COVER FRONT L/H
802E69860
COVER L/H TOP
802E69850
10
PLATE ASSY DOCKING IOT
11
SCREW
12
BRACKET-COVER
Parts Lists
026E93560
4-53
Parts List 25.6 Finisher Stack
1
S
S
Stacker Encoder
Sensor
17
23
25
S
S
S
22 (with 17)
6
S
8 (with 9-12)
24 (with 25, 26)
7 3
S
S
S
5 11
Stack Height
Sensor 2 13
2 (with 3-5)
4
5
26
S
S
S
7 12
6
5
21 20
E
19 18
15
13 Stack Height
Sensor 1
S
27
17
14
Lower Tray
Upper Limit
Sensor
15
16
E
Lower Tray
No Paper Sensor
16
E
16
E
Left Front
s5500-534
4-54
Parts List 25.6 Finisher Stack

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

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

S
24 Punch Motor 13S
S
6 (with 8)
Side Regi Sensor 1
Sensor
Encoder Sensor
11
11
12
7
S
9 (with 2, 6, 11-16, 22, 23)
10
23
19
25
S
S
S
S
S
S
26
20
S
S
21
Punch Box
Set Sensor
27
4-56
Left Front
s5500-535
Parts List 25.7 Finisher Punch

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

Stapler Only
14 (with 1-10)
2
S
6
1
3
S
S S
10
Staple Move
Position Sensor
S
9
S
S
S
S
12
S
S
13
11
Left Front
s5500-536
4-58
Parts List 25.8 Finisher Staple

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

1 (with 2)
5
4
S S
7 (with 6)
10 (with 11-13)
11
3
8
20
19
18
13
Eject Clamp
Home Sensor
14
S
S
12
26
21
21 25
21
S
22 23
E
S
S
15 16
17
15 17
24
Left Front
s5500-537
4-60

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

Rear Tamper
Home Sensor
2
1 (with 2-8)
2
Front Tamper
Home Sensor
8
3
Compiler Tray
No Paper Sensor
7
10
17 (with 18)
S
S
S
10 10
18 Set Clamp
11
Home Sensor
11
16
15
12
E
14 13
11
9 (with 10)
19
12
E
E
13
Left Front
s5500-538
4-62

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

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

No.
Name/Description
Part Number
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
10
ROLLER ASSY-PINCH, EXIT 1 (Exit Pinch Rollers)
022K67870
11
ROLLER ASSY-PINCH, EXIT 2 (Exit Pinch Rollers)
022K67880
12
SHAFT ASSY-PADDLE (Paddle Shaft)
006K23850
13
BELT-SYNCRONUS Z55 (Paddle Shaft Drive Belt)
423W25554
14
PULLEY T17
020E37730
15
SHAFT-DRIVE PADDLE
16
PULLEY
17
BEARING
18
PULLEY T20
19
GEAR Z23L
20
PULLEY T20
020E37660
21
PULLEY T44/Z20
020E37670
22
GEAR Z23R
Parts Lists
015K65800
105E13100
022K67840
020E37690
4-65
Parts List 25.12 Finisher Transport (1/2)

2
3 4
2 2
1 (with 2-5)
3 4
3
5
34
6
S
S
30
S
S
32
23
33
28 9
31 29
27
24
E
S
25
26 24
21
11
Buffer Path
Sensor
22
S
12
17 17
S
S
18
17
S
19
E
S
9
10 (with 11, 12)
Transport
Entrance
Sensor
17
13
8
16 (with 17-19)
35
20
15
14 (with 8, 15)
S
15 15
15
Left Front
s5500-540
4-66

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

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

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

11
11
11
11
17
10
14
14
14
11
12
12
12
18
14
12 13 1
17
18
17
12
13
13
2
S
S
16
11
3
16
12
S
13
S
S
S
13
1113
11
S
S
S
13 13
S
S
S
S
S
16
S
S
S
S
S
S
S 7
Left Front
s5500-542
4-70
Parts List 25.14 Finisher Electrical

No.
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
962K27560
LVPS-C
105K21080
10
EDGE SADDLE
11
CLAMP
12
CLAMP
13
CLAMP
14
EDGE SADDLE
15
16
EDGE SADDLE
17
CLAMP
18
CLAMP
Parts Lists
Part Number
960K03140
960K03130
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.
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)
10
HARNESS ASSY LVPS
11
HARNESS ASSY INTERLOCK
Parts Lists
Part Number
962K27550
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
Coordinates
Remarks
101A
C-304
Connects the Tray 5 Level Sensor and Tray 5 Harness.
101B
C-304
Connects the Tray 4 Level Sensor and Tray 4 Harness.
102A
D-305
Connects the Tray 5 No Paper Sensor and Tray 5 Harness.
102B
D-305
Connects the Tray 4 No Paper Sensor and Tray 4 Harness.
103A
D-306
Connects the Tray 5 Pre Feed Sensor and Tray 5 Harness.
103B
D-306
Connects the Tray 4 Pre Feed Sensor and Tray 4 Harness.
202A
B-304
Connects the Tray 5 Feed/Lift Motor and Tray 5 Harness.
202B
B-304
Connects the Tray 4 Feed/Lift Motor and Tray 4 Harness.
541
F-323
Connects the Tray 4-5 PWB and Tray Module Harness.
548
E-323
Connects the Tray 4-5 PWB and Size Switch Harness.
549A
F-324
Connects the Tray 4-5 PWB and Feeder Harness.
549B
F-324
Connects the Tray 4-5 PWB and Feeder Harness.
552
F-323
Connects the Tray 4-5 PWB and T/A Harness.
554
F-323
Connects the Tray 4-5 PWB and Interlock Switch Harness.
661A
D-309
Connects the Tray 5 Harness and Feeder Harness.
661B
D-308
Connects the Tray 4 Harness and Feeder Harness.
812
D-308
Connects the Door C Interlock Switch and Interlock Harness.
820
G-307
Connects Tray 5 Paper Size Switch and Size Switch Harness.
821
E-308
Connects Feed Out Sensor #4 and the Sensor Harness.
822
I-322
Connects the Take Away Clutch and Take Away Harness.
824
G-308
Connects Tray 5 Paper Size Switch and Size Switch Harness.
825
E-309
Connects Feed Out Sensor #5 and the Sensor Harness.
826
G-324
Connects the Take Away Motor and Take Away Harness.
841
I-320
Connects the Feed Out Sensor #4 Harness and the Size Switch
Harness.
842
D-308
Connects the Feed Out Sensor #5 Harness and the Size Switch
Harness.
5-4
1000-Sheet Feeder Plug/Jack Locators

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

314
315
s5500-544
Wiring Diagrams
5-5
Trays 4 and 5 Electrical
316
317
318
554
822
541
319
841
548
320
321
322
323
324
325
326
826
327
552
549A
549B
328
329
330
s5500-545
5-6
1000-Sheet Feeder Wiring Diagrams

General Wiring
Engine
Logic
Board
Tray 4-5
PWB
P/J413
P/J541
Drive
P/J552
P/J554
P/J822
Take Away Clutch
P/J826
Take Away Motor
FS812
FS813
P/J549
P/J661
P/J220B
Feed/Lift Motor
P/J101B
Level Sensor
P/J102B
No Paper Sensor
P/J103B
Pre Feed Sensor
Tray 4
P/J820
Paper Size Switch
P/J841
P/J821
Feed Out Sensor #4
P/J661
P/J220A
Feed/Lift Motor
P/J101A
Level Sensor
P/J102A
No Paper Sensor
P/J103A
Pre Feed Sensor
P/J548
P/J549
Tray 5
P/J548
P/J842
P/J824
Paper Size Switch
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
1
Take Away Clutch
Take Away Motor
+24VDC
P/J522
7
+5VDC
6
5
4
3
2
1
+24VDC
P/J826
1
RTN
Take Away Motor On(L)+5VDC
+5VDC
SG
Main Motor Clock
M/C Clock
Door C
Interlock Switch
P/J554
2
1
Left Cover Open(H)+5VDC

SG
FS812
1
FS813
1
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
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
FMOT3 /B
FMOT3 /A
+24VDC
+24VDC
FMOT3 B
FMOT3 A
J661B
P/J220B
15 1
14 2
13 3
12 4
11 5
10 6
+5VDC
P/J549
B7
B8
B9
P661B
+5VDC
SG
Tray 4 Level Up(H)+5VDC
J661B
P/J101B
Level Sensor
+5VDC
P/J549
B10
B11
B12
P661B
+5VDC
SG
Tray 4 Paper Sensed(L)+5VDC
J661B
P/J102B
6 10
5 11
4 12
No Paper Sensor
+5VDC
P/J549
B15
B14
B13
P661B
+5VDC
Tray 4 Pre Feed Sensed(L)+5VDC
SG
J661B
P/J103B
1 15
2 14
3 13
Pre Feed Sensor

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

+5VDC
J548
8
9
10
+5VDC
SG
P841
J841
J821
Feed Out Sensor #4

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

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

Engine
Logic Board
Duplex PWB
P/J417
P/J540
P/J541
Wait Sensor
P/J123
P/J124
P/J542
Duplex Motor
P/J212
s5500-582
Duplex PWB
+5VDC
P/J541
SG
2
3
P/J123
+5VDC
Duplex Sensor Paper Sensed(L)+5VDC
1
Wait Sensor
Door D
Interlock Switch
P/J541
5
J124
SG
Duplex Open(H)+5VDC
+24VDC
Duplex Motor
P/J542
1
2
3
4
5
P212
+24VDC
Duplex Motor A
Duplex Motor B
Duplex Motor /A
Duplex Motor /B
J212
5
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
Coordinates
Remarks
111
D-707
Connects the OCT Home 2 Sensor and Exit 2 Harness.
112
F-708
Connects the Exit 2 Sensor and Exit 2 Harness.
113
F-707
Connects the Full Stack Sensor and Exit 2 Harness.
116
C-706
Connects the Door E Interlock Switch and Exit 2 Harness.
207
C-707
Connects the Offset Motor and Exit 2 Harness.
208
B-707
Connects The Exit Drive Motor and Exit 2 Harness.
209
D-708
Connects the Exit Gate Solenoid and Exit 2 Harness.
210
C-708
Connects Face Up Solenoid and Exit 2 Harness. (Not used).
220
D-706
Connects the Exit 2 Fan to the Exit 2 Harness.
5-14
Exit 2 Plug/Jack Locator

B
701
702
703
704
116
220
705
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
1
Exit PWB
Motor / Solenoid
P/J433
P/J606A
P/J207
P/J208
P/J209
P/J434
P/J606B
Sensor / Fan
Offset Motor
Exit Motor
Exit Gate Solenoid
P/J209
Face Up Solenoid
P/J111
Exit Offset 2
Home Position Sensor
P/J112
P/J113
P/J116
P/J220
Exit Sensor
Full Stack Sensor
Exit Fan
s5500-552
5-16
Exit 2 Motor/Solenoid
Exit PWB
+24VDC
Offset Motor
P/J433
1
2
3
4
5
+24VDC
J606A
Offset Motor2 A
Offset Motor2 B
Offset Motor2 /A
Offset Motor2 /B
P606A P207
J207
14 1
13 2
12 3
11 4
10 5
Exit Motor
P/J433
6
7
8
9
10
P/J433
11
12
+24VDC
J606A
Exit Motor A
Exit Motor B
Exit Motor /A
Exit Motor /B
+24VDC
P606A P208
6
5 10
4 11
3 12
J606A
Exit Gate Solenoid On(L)+24VDC
J208
P606A P209
J209
Exit Gate Solenoid
P/J433
13
14
+24VDC
FUT Gate Solenoid On(L)+24VDC
J606A
P606A P210
J210
2 13
1 14
2
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
P606B
P/J111
16 1
15 2
3
1
2
Exit Offset 2
Home Position Sensor
P/J434
3
4
+5VDC
Exit 2 Paper Sensed(L)+5VDC
J606B
P606B
P/J112
14 3
13 4
3
1
2
Exit Sensor
P/J434
5
6
7
8
10
+5VDC
Full Stack 2 Sensed(L)+5VDC
+5VDC
SG
J606B
P606B
12
11
10
9
7
P/J113
5
6
7
8
10
3
1
2
Full Stack Sensor
SJ1
1
2
3
4
8
6
7
P/J434
12
11
Exit 2 Detected(L)+5VDC
Face Up Tray Detected(L)+5VDC
J606B
P606B
5 12
6 11
Door E
Interlock Switch
P/J434
13
Exit 2 Interlock Open(H)+5VDC
P/J434
14
15
Exit Fan On(H) +5VDC

SG
J606B
J116
2
1
P606B
4 13
Exit Fan
J606B
P606B
3 14
2 15
P220
4 1
1 4
2 3
s5500-554
5-18
Tray 6 Plug/Jack Designators

Tray 6 Plug/Jack Designators
P/J
Coordinates
Remarks
G-523
Connects the Tray 6 PWB and Sensor Harness.
G-523
Connects the Tray 6 PWB and Tray 6 Feeder 1 Harness.
G-524
Connects the Tray 6 PWB and Tray 6 Harness.
G-524
Connects the Tray 6 PWB and Tray 6 Harness.
F-524
Connects the Tray 6 PWB and Interlock Switch Harness.
F-524
Connects the Tray 6 PWB and Tray 6 Feeder 1 Harness.
G-523
Connects the Tray 6 PWB and Docking Switch Harness.
51
F-521
Connects the Paper Size Sensor A and Sensor Harness.
52
G-521
Connects the Paper Size Sensor B and Sensor Harness.
53
F-525
Connects the Tray In Sensor and Sensor Harness.
54
E-505
Connects the Feed Out Sensor #6 Harness and Sensor Harness.
56
C-506
Connects the Tray 6 Feeder Harness and Tray 6 Feeder 1

Harness.
57
E-524
Connects the Take Away Motor and Tray 6 Feeder 1 Harness.
58
D-506
Connects the Feed/Lift Motor and Tray 6 Feeder Harness.
59
D-506
Connects the Nudger Solenoid and Tray 6 Feeder Harness.
60
G-506
Connects the No Paper Sensor and Tray 6 Feeder Harness.
61
H-506
Connects the Pre-feed Sensor and Tray 6 Feeder Harness.
62
H-506
Connects the Level Sensor and Tray 6 Feeder Harness.
67
H-506
Connects the Feed Out Sensor #6 and Feed Out Sensor

Harness.
FS001
E-505
Connects the Door J Interlock Switch and Interlock Harness.
FS002
E-505
Connects the Door J Interlock Switch and Interlock Harness.
FS003
E-507
Connects Docking Interlock Switch and Docking Switch Harness.
FS004
E-507
Connects Docking Interlock Switch and Docking Switch Harness.
Wiring Diagrams
5-19
Tray 6 Plug/Jack Locator

Tray 6 Feeder
A
501
502
503
FS001
FS002
54
59
504
58
67
61
505
506
507
508
509
510
511
512
56
FS003
FS004
60
62
513
514
515
s5500-556
5-20
Tray 6 Drive
A
516
517
518
519
520
52
521
51
522
8
1
523
524
525
3
4
526
5
53
527
6
57
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/J800
P/JF03
P/JF01
P/JF51
P/JF04
P/JF52
Door J
Interlock Switch
FS001
P/JF05
P/JF53
FS002
Docking
Interlock Switch
FS003
P/JF54
P/JF67
P/JF56
P/JF60
P/JF08
P/JF02
Paper Size Sensor B
Paper Size Sensor A
Tray In Sensor
Feed Out Sensor #6
No Paper Sensor
FS004
Tray 6
PWB
P/JF61
P/JF62
P/JF06
P/JF56
P/JF59
P/JF58
P/JF57
Pre Feed Sensor
Level Sensor
Nudger Solenoid
Feed/Lift Motor
Take Away Motor
s5500-558
5-22
Tray 6 Interface
Tray 6 PWB

P/JF08
2
Docking Switch Close(L)+5VDC
FS003
SG
FS004
Interlock
+24VDC
P/JF05
PF55B
J800B
14
13
12
11
10
Engine
Logic Board
Engine To Tray 6
P/J415
6
Tray 6 To Engine
Feed Out
PF55A
J800A
P/JF04
FS001
+24VDC
P/JF03
FS002
I/L +24VDC
Feed Stop
P/J415
2
SYS Reset
1
P/J800
RTN
SG
+24VDC
P/J414
3
2
1
s5500-559
Wiring Diagrams
5-23
Tray 6 Sensors
Tray 6 PWB
+5VDC
P/JF01
12
11
10
+5VDC
PF51
Tray 6 Size Sensor L Sensed(L)+5VDC

SG
JF51
1
1
Paper Size Sensor B
+5VDC
P/JF01
9
8
7
+5VDC
PF52
Tray 6 Size Sensor R Sensed(L)+5VDC

SG
JF52
1
1
Paper Size Sensor A
+5VDC
P/JF01
6
5
4
+5VDC
PF53
Tray 6 Tray Set(L)+5VDC

SG
JF53
1
1
Tray In Sensor
+5VDC
P/JF01
3
2
1
+5VDC
Tray 6 TA Sensor Paper Sensed(H)+5VDC
SG
PF54
JF54
P/JF67
3
Feed Out Sensor #6
s5500-560
5-24
Tray 6 Drive
Tray 6 PWB
+24VDC
Feed/Lift Motor
P/JF06
5
4
6
2
3
1
P/JF56
6
Tray 6 Feed Motor B

+24VDC
Tray 6 Feed Motor NB
Tray 6 Feed Motor NA
+24VDC
Tray 6 Feed Motor A
P/JF58
6
Take Away Motor

+24VDC
P/JF06
11
8
9
10
12
7
Tray 6 T/A Motor NB
PF57
Tray 6 T/A Motor NA

+24VDC
+24VDC
Tray 6 T/A Motor B
Tray 6 T/A Motor A
JF57
7
Interlock
+24VDC
P/JF06
13
14
I/L +24VDC
PF56A
Tray 6 Nudger Solenoid(L)+24VDC
JF56A
PF59
Nudger Solenoid
+5VDC
P/JF02
3
2
1
+5VDC
PF56B
Tray 6 Lift Up(H)+5VDC

SG
JF56B
P/JF62
3
Level Sensor
+5VDC
P/JF02
6
5
4
+5VDC
PF56B
Tray 6 Feed Paper Sensed(L)+5VDC

SG
JF56B
P/JF61
3
Pre Feed Sensor
+5VDC
P/JF02
9
8
7
+5VDC
SG
PF56A
JF56A
P/JF60
3
No Paper Sensor
s550-561
Wiring Diagrams
5-25
Finisher Plug/Jack Designators

Finisher Plug/Jack Designators
P/J
Coordinates
Remarks
E-903
Connects the LVPS and AC Inlet Harness.
502
B-902
Connects the LVPS and LVPS Harness.
505
B-902
Connects the LVPS and LVPS Harness.
8300
G-894
Connects the Finisher Main PWB and I/F Harness.
8301
G-894
Not connected.
8302
E-895
Connects the Finisher Main PWB and Main Sensor Harness.
8304
E-892
Connects the Finisher Main PWB and Main Drive Harness.
8305
E-894
Connects the Finisher Main PWB and Elevator Motor.
8306
G-892
Connects the Finisher Main PWB and Punch Drive Harness.
8307
G-893
Connects the Finisher Main PWB and Punch Sensor Harness
8308
F-892
Connects the Finisher Main PWB and Staple Harness.
8309
E-894
Connects the Finisher Main PWB and Compiler Harness.
8310
G-895
Connects the Finisher Main PWB and Horizontal Transport

Harness.
8311
E-896
Not connected.
8313
F-896
Not connected.
8314
F-896
Connects the Finisher Main PWB and Interlock Harness.
8315
E-896
Connects the Finisher Main PWB and LVPS Harness.
8316
G-896
Not connected.
8317
E-896
Not connected.
8319
E-883
Connects the Transport Entrance Sensor and Harness.
8320
F-853
Connects the Compile Exit Sensor and Compile Sensor Harness
8321
F-881
Connects the Upper Tray Exit Sensor and Upper Tray Exit Sensor
Harness.
8322
F-881
Connects the Upper Tray Full Sensor and Upper Tray Full Sensor
Harness.
5-26
Finisher Plug/Jack Designators (Continued)

P/J
Coordinates
Remarks
8324
E-852
Connects the Eject Clamp Home Sensor and Main Sensor

Harness.
8325
E-868
Connects the Set Clamp Home Sensor and Main Sensor Harness.
8326
E-821
Connects the Stacker No Paper Sensor and Main Sensor Harness.
8327
E-821
Connects the Upper Limit Sensor and Main Sensor Harness.
8328
D-821
Connects the Stack Encoder Sensor and Main Sensor Harness.
8330
J-821
Connects the Stack Height Sensor 2 and Main Sensor Harness.
8331
E-819
Connects the Stack Height Sensor 1 and Main Sensor Harness.
8334
C-880
Connects the Exit Motor and Main Drive Harness.
8335
D-881
Connects the Registration Motor and Main Drive Harness.
8336
D-866
Connects the Eject Motor and Main Drive Harness.
8338
E-868
Connects the Set Clamp Clutch (Z34) and Main Drive Harness.
8339
C-851
Connects the Eject Clamp Motor and Main Drive Harness.
8340
H-852
Connects the Sub Paddle Solenoid and Main Drive Harness.
8341
C-853
Connects the Transfer Gate Solenoid and Main Drive Harness.
8342
B-884
Connects the Transport Motor and Main Drive Harness.
8344
E-835
Connects the Punch Move Motor and Punch Drive Harness.
8345
C-837
Connects the Punch Motor and Punch Unit Harness.
8346
C-836
Connects the Punch Hole Select Sensor and Punch Unit Harness.
8347
C-836
Connects the Punch Front Sensor and Punch Unit Harness.
8348
C-836
Connects the Punch Home Sensor and Punch Unit Harness.
8349
C-837
Connects the Punch Motor Sensor and Punch Unit Harness.
8350
G-837
Connects the Side Regi Sensor 1 and Punch Unit Harness.
8351
G-837
Connects the Side Regi Sensor 2 and Punch Unit Harness.
8352
C-836
Connects the Punch Move Home Sensor and Punch Sensor

Harness.
8353
C-838
Connects the Punch Box Set Sensor and Punch Box Set Sensor
Harness.
8354
E-826
Connects the Staple Move Position Sensor and Staple Harness.
8356
F-826
Connects the Staple Head and Staple Harness.
Wiring Diagrams
5-27
Finisher Plug/Jack Designators (Continued)

P/J
Coordinates
Remarks
8357
F-826
Connects the Staple Head and Staple Harness.
8358
F-826
Connects the Stapler Move Motor and Staple Harness.
8359
G-869
Connects the Compiler Tray No Paper Sensor and Compiler

Harness.
8360
I-869
Connects the Front Tamper Home Sensor and Compiler Harness.
8361
E-868
Connects the Rear Tamper Home Sensor and Compiler Harness.
8362
F-868
Connects the Rear Tamper Motor and Compiler Harness.
8363
G-869
Connects the Front Tamper Motor and Compiler Harness.
8364
H-852
Connects the Door H Interlock Switch and Interlock Harness.
8365
F-822
Connects the Door G Interlock Switch and Interlock Harness.
8371
I-898
Connects the Horizontal Transport PWB and Horizontal Transport

Harness.
8372
I-898
Connects the Horizontal Transport PWB and Horizontal Transport

1 Harness.
8373
I-898
Not connected.
8376
E-895
Connects the Finisher Main PWB and Gate Sensor 1 Harness.
8379
I-807
Connects the Horizontal Transport Entrance Sensor and Horizontal

Transport Harness.
8380
C-807
Connects the Horizontal Transport Motor and Horizontal Transport

Harness.
8381
J-809
Connects the Horizontal Transport Exit Sensor and Horizontal

Transport Harness.
8382
G-810
Connects the Door F Interlock Sensor and Horizontal Transport

Harness.
8389
F-892
Not connected.
8392
F-882
Connects the Buffer Path Sensor and Buffer Path Sensor Harness.
8394
B-853
Connects the Buffer Gate Solenoid and Main Drive Harness.
8394
J-898
Connects the Horizontal Transport PWB and Horizontal Transport.
8432
E-882
Connects the Gate Sensor and Gate Sensor Harness.
8452
C-839
Not connected.
8500
I-898
Not connected.
5-28
Finisher Plug/Jack Locators

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

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

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

A
891
8304 8308 8389

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

General Wiring (1/2)
P/J8300
LVPS
Power
P/J2
Door G
Interlock Switch
P/J8365
Door H
Interlock Switch
P/J8364
P/J502
P/J8310
P/J8315
H-X'port
Motor
P/J8314
H-X'port
Entrance
Sensor
P/J505
P/J8388
P/J8314
Gate Sensor
Sensors 1
Buffer Path
Sensor
P/J8432
P/J8392
P/J8434
P/J8376
P/J8318
P/J8302
Upper Tray Full P/J8322

Sensor
P/J8393
Upper Tray Exit P/J8321

Sensor
P/J8312
Compiler Exit
Sensor
P/J8320
P/J8391
X'port Entrance P/J8319

Sensor
P/J8303
Upper Limit
Sensor
H-X'port
Exit Sensor
P/J8388
H-X'port
Interlock
Sensor
Sensors 2
P/J8390
P/J8372
Horizontal
Transport
PWB
P/J8380
P/J8381
P/J8382
P/J8383
P/J8373
P/J8344 Bracket Assy-Motor,
P/J8306
Punch
P/J8332
P/J8345 Punch Motor
P/J8333
P/J8346 Punch Hole Sensor
P/J8348 Punch Home Sensor
P/J8349 Punch Motor Sensor
P/J8328
P/J8350 Side Registration
Sensor 1
Set Clamp Home P/J8325

Sensor
P/J8351 Side Registration
Sensor 2
Eject Clamp
Sensor
10
P/J8347 Punch Front Sensor
P/J8327
Stacker No Paper P/J8326

Sensor
Stacker Encoder
Sensor
P/J8379
P/J8384
Finisher
Main PWB
P/J8307
P/J8371
P/J400
Punch 2
Engine
Logic Board
P/J8324
Punch 1
P/J8352 Punch Move Home
Sensor
Stack Height
Sensor 1
P/J8331
Stack Height
Sensor 2
P/J8330
P/J8355
P/J8353 Punch Box Set Sensor
s5500-569
5-36
General Wiring (2/2)
5 Exit Motor
P/J8334
P/J8304
P/J8308
P/J8354 Staper Move Home

Position Sensor
Registration Motor P/J8335
Transport Motor
6 Eject Clamp
Motor
P/J8356
P/J8342
P/J8357 Staple Motor
P/J8339
Set Clamp
Clutch Motor
P/J8338
Sub Paddle
Solenoid
P/J8340
Transport Gate
Solenoid
P/J8341
Buffer Gate
Solenoid
P/J8394
P/J8358
P/J8309
Clutch Solenoids
Low Staple Sensor

Staple Ready Sensor
Staple Home Sensor
Stapler
Bracket Assy-Eject P/J8336
Staple Move Motor
P/J8362 Rear Tamper Motor
P/J8363 Front Tamper Motor
P/J8361 Rear Tamper Home Sensor
P/J8360 Front Tamper Home Sensor

Elevator Motor
P/J8305
Ccompiler Tray
Motors
Stapler Assembly
Finisher
Main PWB
P/J8359 Compiler Tray

No Paper Sensor
s5500-570
Wiring Diagrams
5-37
Power
Engine
Logic Board
Finisher Main PWB

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
Door G
Interlock Switch
J8314
3
2
SG
Front SW
J8388
2
+24VDC
J8314
1
P/J505
LVPS SQ
3
LVPS SQ
4
On/Off
P/J502
1
2
5
6
+24VDC
Supply
3 4 1
J2
+24VDC
+24VDC
RTN
RTN
I/L+24VDC
Eject Cover
J8315
3
6
P/J8315
1
4
2
5
J8365
1A
1B
Door H
Interlock Switch
Interlock
+24VDC
J8388
1
LVPS
J8365
2A
2B
Line
Nut
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
J8364
2
1
3
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
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
H-X'port Motor
J8379B
10
+5VDC
P/J8372
9
8
7
+5VDC
Entrance Sensor Paper Sensed(L)+5VDC
SG
P/J8390
P/J8380
12
13
3
H-X'port Entrance Sensor
+5VDC
P/J8372
6
5
4
+5VDC
Exit Sensor Paper Sensed(L)+5VDC
SG
P/J8390
P/J8381
14
15
3
H-X'port Exit Sensor
+5VDC
P/J8372
3
2
1
+5VDC
H-X'port Cover Closed(L)+5VDC
SG
P/J8390
P/J8382
16
3
s5500-572
Wiring Diagrams
5-39
Sensors (1/2)
Finisher
Main PWB
+5VDC
P/J8302A
15
14
13
J8318A
+5VDC
Buffer Path Paper Sensed(L)+5VDC
SG
J8318B P/J8392
1
3
Buffer Path Sensor
+5VDC
P/J8302A
12
11
10
J8393A
+5VDC
Upper Tray Full Sensed(L)+5VDC
SG
J8393B P/J8322
1
3
Upper Tray Full Sensor
+5VDC
P/J8302A
9
8
7
J8312A
+5VDC
Upper Tray Exit Paper Sensed(L)+5VDC
SG
J8312B P/J8321
1
3
Upper Tray Exit Sensor
+5VDC
P/J8302A
6
5
4
J8391A
+5VDC
Compile Exit Paper Sensed(L)+5VDC
SG
J8391B P/J8320
1
3
Compile Exit Sensor
+5VDC
P/J8302A
3
2
1
J8303A
+5VDC
Transport Paper Sensed(L)+5VDC
SG
J8303B P/J8319
1
3
Transport Entrance
Sensor
+5VDC
P/J8376
3
2
1
J8434A
+5VDC
Gate Paper Sensed(H)+5VDC
SG
J8434B P/J8432
1
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
J8441B
6
5
4
6
5
4
P/J8327
1
2
3
Lower Tray
Upper Limit Sensor
+5VDC
P/J8302B
17
16
15
+5VDC
Stacker Paper Sensed(L)+5VDC
SG
J8441A
J8441B
3
2
1
3
2
1
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
P/J8302B
11
9
4
+5VDC
Set Clamp Home Sensed(L)+5VDC
SG
P/J8325
1
2
3
Set Clamp Home

Sensor
P/J8302B
8
7
6
+5VDC
Eject Clamp Up(L)+5VDC
SG
P/J8324
1
2
3
Eject Clamp Home

Sensor
Stacker Encoder
Sensor
+5VDC
+5VDC
+5VDC
P/J8302B
5
4
3
2
1
P/J8331
Stack Height Sensor 2 Clock

+5VDC
Stack Height Sensor 1 Sensed(L)+5VDC
SG
1
2
3
4
5
+5VDC
P/J8302A
20
19
+5VDC
18
Stack Height Sensor 2 Sensed(L)+5VDC
17
SG
16
J8440A
J8440B P/J8330
1
2
3
4
5
5
4
3
2
1
1
2
3
4
5
s5500-574
Wiring Diagrams
5-41
Motors
Finisher
Main PWB
Interlock
+24VDC
Exit Motor
P/J8304
2
4
1
3
6
5
P/J8334
1
2
3
4
5
6
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
Registration Motor
I/L +24VDC
Registration Motor
Registration Motor
I/L +24VDC
Registration Motor
A
/A
B
/B
P/J8335
1
2
3
4
5
6
Eject Motor
Interlock
+24VDC
P/J8304
15
12
17
19
14
21
Eject Motor A
I/L +24VDC
Eject Motor /A
Eject Motor B
I/L +24VDC
Eject Motor /B
P/J8336
1
2
3
4
5
6
Transport Motor
Interlock
+24VDC
P/J8304
23
16
25
27
18
29
Transport Motor
I/L +24VDC
Transport Motor
Transport Motor
I/L +24VDC
Transport Motor
A
/A
B
/B
P/J8342
1
2
3
4
5
6
s5500-575
5-42
Clutch and Solenoids

Finisher
Main PWB
Eject Clamp Motor

P/J8304
31
33
Interlock
+24VDC
P/J8304
20
22
Eject Clamp Motor CCW On(H)+24VDC

Eject Clamp Motor CW On(H)+24VDC
Set Clamp Clutch On(L)+24VDC

I/L +24VDC
P/J8339
2
1
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
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
Rear Tamper Motor

P/J8309
19
+24VDC
18
17
16
15
Rear Tamper Motor /B
J8461B
Rear Tamper Motor B

Rear Tamper Motor /A
+24VDC
Rear Tamper Motor A
J8461A J8362B
1
19
1 6
18
3 4
17
4 3
16
5 2
15
6 1
Front Tamper Motor

P/J8309
14
+24VDC
13
12
11
10
Front Tamper Motor /B
J8461B
Front Tamper Motor B

Front Tamper Motor /A
+24VDC
Front Tamper Motor A
J8461A J8363B
6
10
1 6
11
3 4
12
4 3
13
5 2
10 14
6 1
+5VDC
P/J8309
9
8
7
+5VDC
Rear Tamper Home Sensed(L)+5VDC
J8461B
SG
J8461A P/J8361
11 7
12 8
13 9
3
+5VDC
P/J8309
6
5
4
J8461B
+5VDC
Front Tamper Home Sensed(L)+5VDC
SG
J8461A P/J8360
14 6
15 5
16 4
3
+5VDC
P/J8309
3
2
1
J8461B
+5VDC
Compiler Tray Paper Sensed(L)+5VDC
SG
J8461A P/J8359
17 3
18 2
19 1
3
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
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/J8308
10
9
8
7
Staple Motor+
Staple Motor+
Staple MotorStaple Motor-
P/J8357
1
2
3
4
Staple Head
Low Staple Sensor
Staple Head
Self Prime
Sensor
Staple Head
Home Sensor
Staple Motor
Staple Head
Move Motor
Interlock
+24VDC
P/J8308
3
6
5
1
4
2
Staple Move Motor

I/L +24VDC
Staple Move Motor
Staple Move Motor
I/L +24VDC
Staple Move Motor
/A
A
B
/B
P/J8358
1
2
3
4
5
6
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
Punch Unit Motor

P/J8306
7
3
6
5
2
1
Punch Move Motor

I/L +24VDC
Punch Move Motor
Punch Move Motor
I/L +24VDC
Punch Move Motor
P/J8344
1
2
3
4
5
6
A
/A
B
/B
Punch Motor
P/J8306
8
7
Punch Motor CCW On(H)+24VDC

Punch Motor CW On(H)+24VDC
P/J8332
2
1
P/J8345
2
1
P/J8333
1
2
3
P/J8346
3
2
1
+5VDC
P/J8307
Anode
B12
Punch Hole Sel Sensor Sensed(L)+5VDC
B11
SG
B10

+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
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
Index
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
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-1
2000-Sheet Feeder (cont.)

part number, 4-27
removal, 3-54
wiring, 5-25
Nudger Solenoid, 2-42
removal, 3-50
wiring, 5-25
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
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
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
Index-2
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
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
function, 2-31
location, 2-22
wiring, 5-40
components, 2-28
Front Tamper Home Sensor, 2-32
removal, 3-180
limitations, 2-28
location, 2-22
function, 2-32
removal, 3-182
part number, 4-63
Rear Tamper Home Sensor, 2-32
removal, 3-180
removal, 3-177
sensors, 2-32
tamping, 2-29
tamping motors, 2-32
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
Door C Interlock, 2-16
location, 2-16
part number, 4-15
removal, 3-28
wiring diagram, 5-8
Door D Interlock, 2-8
part number, 4-35
removal, 3-74
Door E Interlock, 2-5
location, 2-5
part number, 4-41
removal, 3-95
Door F Interlock, 2-40
location, 2-41
part number, 4-49
removal, 3-116
Door G Interlock, 2-40
location, 2-41
part number, 4-53
removal, 3-127
Index
5-19
5-4
5-11
5-14
5-28
Door H Interlock, 2-40

location, 2-41
part number, 4-61
removal, 3-176
Door J Interlock, 2-50
location, 2-44
part number, 4-31
removal, 3-62
Drum Cartridge, 1-8
location, 1-8
part number, 1-8
Duplex Unit, 1-5, 4-35
dimensions, 1-10
Duplex Motor, 2-9
drive train, 2-9
part number, 4-35
removal, 3-76
latch removal, 3-72
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
E
5-28
Eject Chute, 2-23

Door H Interlock, 3-163
removal, 3-163
Eject Clamp, 2-23
component locations, 2-38
Index-3
Eject Clamp (cont.)

part number, 4-61
removal, 3-175
location, 2-23
Eject Clamp Motor, 2-39
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
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
part number, 4-42
removal, 3-98
wiring, 5-17
Exit Motor, 2-6
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
removal, 3-96
Index-4
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
drive train, 2-6
location, 2-5
part number, 4-42
removal, 3-100
wiring, 5-17
Pinch Roller, 2-4
part number, 4-41
removal, 3-91
removal, 3-79
roller location, 2-2
sensors, 2-5
Exit Gate Solenoid
part number, 4-42
removal, 3-98
Exit PWB, 2-6
location, 2-5
F
Feed Out Sensor #4, 2-15
location, 2-16
part number, 4-15
removal, 3-21
wiring, 5-9
location, 2-16
part number, 4-15
removal, 3-22
wiring, 5-10
function, 2-42
part number, 4-31
removal, 3-63
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
Index
Finisher (cont.)
dimensions, 1-10
docking, 3-119
Eject Clamp, 2-23
Eject Clamp Motor, 2-23
location, 2-40
part number, 4-61
removal, 3-174
Eject Motor
part number, 4-63
removal, 3-187
location, 2-40
part number, 4-55
removal, 3-144
Exit Motor, 2-21
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
Index-5
Finisher (cont.)
Paddle Shaft, 2-23
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
part number, 4-57
removal, 3-154
Punch Motor
part number, 4-57
removal, 3-149
Punch Move Motor
part number, 4-57
Punch Move motor
Punch operation, 2-21
Punch Waste Box
part number, 4-57
Registration Motor
location, 2-40
part number, 4-69
removal, 3-245
Set Clamp Clutch
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
Index-6
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
part number, 4-61
wiring, 5-43
Transfer Gate, 2-19
part number, 4-67
Transfer Gate Solenoid, 2-19
part number, 4-67
removal, 3-223
Transport Entrance Sensor, 2-24
function, 2-19
part number, 4-67
removal, 3-217
Transport Motor, 2-19
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
function, 2-20
part number, 4-69
removal, 3-236
Hard Drive, 1-4

Door F Interlock, 2-40
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
part number, 4-45
PWB
location, 2-40
part number, 4-71
removal, 3-247
removal, 3-106
Transport Belt, 2-19
part number, 4-49
removal, 3-113
maintenance, 1-8
Drum Cartridge, 1-8
Fuser, 1-8
Transfer Roller, 1-8
Maintenance Kit, 1-8
Memory, 1-2
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
function, 2-39
part number, 4-55
removal, 3-144
J
job offset, 2-31
L
LVPS
part number, 4-71
removal, 3-250
Index
Index-7
Exit Motor
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
connector, 5-27
part number, 4-69
removal, 3-245
Transport Motor
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
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
Index-8
N
networking
option, 1-4
Nudger Roller, 2-2
part number, 4-12
removal, 3-20
Nudger Solenoid
wiring, 5-25
NVRAM
options, 1-4
O
Offset Motor
location, 2-5
part number, 4-42
options, 1-4
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
Paper Size Switch
location, 2-14
part number, 4-7
removal, 3-10
Pinch Roller, 2-2
Printer
configurations, 1-3
options, 1-4
transport components, 2-2
Punch, 2-21
part number, 4-57
Punch Box Set Sensor, 2-27
part number, 4-57
removal, 3-154
Punch Front Sensor, 2-27
location, 2-26
part number, 4-57
removal, 3-151
Punch Hole Select Sensor, 2-27
location, 2-26
part number, 4-57
removal, 3-151
Punch Home Sensor
function, 2-27
part number, 4-57
removal, 3-151
Punch Motor, 2-26
function, 2-28
location, 2-26
part number, 4-57
removal, 3-149
wiring, 5-47
Punch Motor Encoder Sensor, 2-27
Punch Move Home Sensor, 2-27
location, 2-26
part number, 4-57
removal, 3-153
Punch Move Motor, 2-25
function, 2-28
location, 2-26
part number, 4-57
removal, 3-147
Index
wiring, 5-47
Punch Waste Box
part number, 4-57
removal, 3-145
sensor wiring, 5-46
Side Registration Sensor
location, 2-26
Punch Waste Box, 2-27
counter, 2-27
R
Registration Motor, 2-23
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
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
Finisher
Buffer Path Sensor, 2-25
Door G Interlock Switch, 2-40
Door H Interlock Switch, 2-40
Gate Sensor, 2-24
Index-9
Sensor (cont.)
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
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
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
Tray 6
Docking Interlock Switch, 2-44
Door J Interlock Switch, 2-44
Level Sensor, 2-45
Paper Size Sensors, 2-45
Tray In Sensor, 2-50
Index-10
Set Clamp Clutch, 2-39

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
job offset, 2-31
mixed stacking, 2-38
maximum capacity, 2-37
mixed stacking, 2-38
function, 2-37
location, 2-38
part number, 4-55
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

Exit Sensor, 2-25
function, 2-36
part number, 4-69
removal, 3-226
part number, 4-51
removal, 3-130
Stack Full Sensor, 2-25
function, 2-36
part number, 4-69
removal, 3-233
Staple Head, 2-33
exploded view, 3-158
movements, 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
function, 2-35
part number, 4-59
removal, 3-162
staple positions, 2-34
Staple Self Priming Sensor, 2-33
Stapler, 2-33
removal, 3-155
sheet limitation, 2-28
Staple Cartridge
part number, 4-59
Staple Head, 2-33
Index
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
Sub Paddle Solenoid, 2-23
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
part number, 4-67
removal, 3-204, 3-223
Transfer Roller, 1-8
location, 1-8
part number, 4-67
Transport Motor, 2-19
part number, 4-67
Tray
capacities, 1-11
Envelope Tray, 1-7
envelopes, 1-11
Index-11
Tray (cont.)
Stacker Lower Tray
part number, 4-51
removal, 3-132
Stack Height Sensors, 2-37
part number, 4-51
removal, 3-130
Standard Output Tray, 1-2
universal, 2-12
Tray 4-5, 1-5
part number, 4-15
removal, 3-28
part number, 4-15
removal, 3-21
wiring, 5-9
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
part number, 4-11
removal, 3-14
Paper Size Guides, 2-12
part number, 4-7
removal, 3-10
signal definitions, 2-15
part number, 4-11
removal, 3-17
Index-12
Tray 4-5 (cont.)

PWB, 2-16
location, 2-16
part number, 4-17
removal, 3-29
Take Away Clutch, 2-16
part number, 4-17
removal, 3-30
wiring, 5-8
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
removal, 3-63
wiring, 5-24
Feed Roller, 2-42
part number, 4-27
removal, 3-58
feed timing, 2-44
Feed/lift Motor
part number, 4-11, 4-25
removal, 3-49
wiring, 5-25
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
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
paper lift operation, 2-46
Paper Size Sensor, 2-45
locations, 2-47
part number, 4-19
removal, 3-42
wiring, 5-24
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
Retard Clutch
part number, 4-29
removal, 3-60
Retard Roller, 2-42
part number, 4-27
removal, 3-59
Index
Take Away Motor, 2-42, 2-49

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
part number, 4-35
removal, 3-78
Wiring Diagram
conventions, 5-2
Index-13
071-0873-00 A

Manual Service Xerox Phaser - 5500 - BK - 2 PDF

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Manual Service Xerox Phaser - 5500 - BK - 2 PDF

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Phaser 5500 Laser Printer

Phaser 5500 Printer Options Service Manual

Phaser 5500 Printer Options Service Manual

Door C Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Duplex Unit Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68

Phaser 5500 Printer Options Service Manual

Finisher Bottom Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123

Compile Exit Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Phaser 5500 Printer Options Service Manual

Finisher Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Avoid pinching fingers in the printer. Use caution to avoid

Phaser 5500 Printer Options Service Manual

Power Safety Precautions

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.

Electrostatic Discharge (ESD) Precautions

Immediately before handling any semiconductor components assemblies, drain

Do not use freon-propelled chemicals. These can generate electrical charges

Do not remove a replacement component or electrical sub-assembly from its

Immediately before removing the protective material from the leads of a

Minimize body motions when handling unpackaged replacement devices. Motion

Handle ICs and EPROMs carefully to avoid bending pins.

Pay attention to the direction of parts when mounting or inserting them on

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

Reorient or relocate the receiver (device being interfered with).

Increase the separation between the printer and the receiver.

Consult the dealer, Xerox service, or an experienced radio/television technician

In the European Union

Safety of Information Technology Equipment including Electrical Business

following the provisions of the Electromagnetic Compatibility Directive 89/336/EEC

Limits and Methods of measurement of radio interference

Part 3: Limits - Section 2: Limits for harmonic current emissions

Part 3: Limits - Section 3: Limitation of voltage fluctuations and flicker

Information technology equipment - Immunity characteristics - Limits

Phaser 5500 Printer Options Service Manual

Book 1 - Print Engine

Phaser 5500 Printer Options Service Manual

Printer Introduction and Overview

Consumables and Routine Maintenance Items

Printer Introduction and Overview

Phaser 5500 Printer Options Service Manual

Oak PCL 5.0

PDF Direct Print

Additional RAM and NVRAM

1000-Sheet Feeder (Tray 4 & 5)

3,500-Sheet Finisher (with hole punch, staple, offset)

2,000-Sheet Feeder (Tray 6)

Envelope Tray (replaces Tray 2)