Xerox “116-324” — fuser unit end-of-life lock vs software exception fault
Joe B.
Reviewed for technical accuracy
Specialities: Xerox fault codes (116-324, 010-397), ESS software exceptions, corrupt job recovery, fuser/drum supplies locks
Xerox 116-324 error — software exception fault vs fuser unit end-of-life lock, safe reset, firmware & print queue fix
Technician
Quick scan first:
• Exact model (Phaser, WorkCentre, VersaLink/AltaLink) and connection type (USB, network, Wi-Fi)?
• What’s on the screen: “116-324 Exception/Software Fault” / “Restart Printer” — or also “Fuser near end of life / “Replace fuser”?
• Did the error appear after a large PDF, driver change (PCL/PS), or firmware update?
• Does it fault immediately at power-on, or only when a particular print job arrives?
Technician
• 116-324 on Xerox is a software/exception failure on the controller (ESS). It’s often triggered by a **corrupt print job**, bad font, or protocol edge case and can loop until the queue is cleared.
• A fuser end-of-life condition is a separate hardware issue that can hard-stop printing (different fault family, e.g., 010-xxx). It may show warnings like “Replace fuser” but typically won’t generate 116-324 by itself.
We’ll treat both: 1) clear or isolate the corrupt job/driver to stop 116-324, 2) check supplies status and plan a safe fuser swap so a genuine end-of-life lock doesn’t halt you later.
Technician
1) Power the printer off.
2) Disconnect the network cable (and USB if present).
3) Power it **on** and let it reach **Ready**. If it stays up, the crash likely came from an incoming job/protocol.
4) On each PC/print server, **pause** the Xerox queue and **delete all pending jobs** (especially the last ERP invoice batch). Empty the Windows “Printers\spool” if needed.
5) Reconnect the network and test a tiny **Config/Test Page** from the device web page (CentreWare) before trying the ERP.
Technician
Step 2 — Try another driver/emulation
• If you’re on **PS (PostScript)**, install the **PCL6** driver (or vice-versa) for this printer and print a small ERP page.
• Disable **advanced printing features** and try **Print As Image** (for PS) to avoid problematic fonts.
• If you print via a TCP/IP port, recreate it as **RAW 9100** (or **LPR** with queue name “lp”) and test again.
• For PDF direct print workflows, re-generate a “lite” PDF (flattened) to rule out corrupt objects.
Technician
• The **116-324 software exception** was job/driver-related and is now resolved.
• The **fuser end-of-life** warning means the hot unit is at its rated limit. Treat it as **planned maintenance** — on many Xerox models a genuine fuser lock/hard stop uses **010-xxx** fault codes rather than 116-324.
Step 3 — Plan the fuser swap
1) Check Machine Status → Supplies for Fuser % and part number.
2) Order the correct voltage/region **fuser module**.
3) Schedule replacement out of hours; after install, confirm supplies show **High/100%** and print a configuration page.
Technician
• Update to the latest **firmware** for your model.
• In the driver, turn off **bi-directional support** and **SNMP status** temporarily (reduces chatter).
• If using a print server, purge old **pending jobs** and corrupt spooled files.
• Test with a **simple local TCP/IP port** directly to the printer (bypassing third-party spoolers) before re-enabling them.
• If the device has an embedded app that intercepts jobs, disable it for a test.
Technician
After installation:
• Reboot once, open **Supplies/Consumables** and verify **Fuser life** is high/near 100%.
• If your model exposes a **Reset Fuser/Reset Supplies** item, run it once with the new module fitted.
• Print a status/configuration page to confirm there are **no active faults** and the **fuser temperature** stabilizes.
Technician
Summary: Xerox 116-324 is a software/exception failure — usually fixed by isolating a corrupt print job, switching **PS ⇄ PCL6**, clearing the queue, and updating firmware. A fuser unit end-of-life condition is separate; plan a genuine fuser replacement to avoid a hard stop. Want help mapping the exact menus and drivers for your model? Open the chat.
Quick answer: the accepted fix
Accepted fix when a Xerox shows 116-324 software/exception fault: boot with network/USB disconnected, clear all print jobs, then test a simple page. Switch drivers (PCL6 or PS), recreate the TCP/IP port, and update firmware. Treat any fuser end-of-life warning separately — plan a fuser module replacement so a true supplies lock doesn’t halt printing later.
Why 116-324 happens (ESS crash, corrupt job, driver language)
Fault 116-324 is commonly an ESS controller software exception. Triggers include malformed PDFs, bad fonts, huge images, or a driver mismatch. Switching the print language (PostScript vs PCL6), clearing the spooler, and applying the latest device firmware typically stop the crash loop. By contrast, a fuser end-of-life lock is a hardware supply stop that uses different codes, and should be resolved by replacing the fuser assembly.
How to verify the fix (clean boot, test page, ERP pilot)
After cleanup, reconnect the network and send a Configuration/Test Page. If it prints, run a small **ERP pilot job** using the alternate driver. With stable output and no **116-324**, re-enable advanced options one by one. Finally, check Supplies to confirm the **fuser life** reading and plan replacement if the device reports “near end-of-life”.
Xerox 116-324 & fuser warning — quick troubleshooting tips
Fix the software exception first, then handle the fuser maintenance.
Quick path: power off → disconnect network/USB → boot to Ready → purge queues → test with alternate PCL6/PS driver and a small file → update firmware → reconnect and verify. Plan a **fuser replacement** if the device shows “fuser near end-of-life” so a hardware lock doesn’t interrupt production later.
Disclaimer: This information is AI-generated and intended for general guidance only. For advice specific to your environment, please consult a verified expert on Whizz-Tech before making decisions.
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FAQ
What does Xerox fault code 116-324 mean?
116-324 is a software/exception failure on the device controller (ESS). It is frequently caused by a corrupt or unsupported print job, protocol/driver issues, or firmware bugs. Clearing the queue, changing drivers (PCL6/PS), and updating firmware usually resolves it.
Is 116-324 the same as a fuser end-of-life lock?
No. A fuser unit end-of-life is a hardware supplies condition (often shown via 010-xxx codes) and requires fuser replacement. 116-324 is a software exception; fix the print job/driver first, then replace the fuser if the device reports “near end-of-life”.
How do I stop the crash loop?
Power off the device, disconnect network/USB, power on to Ready, clear all print queues, reconnect, and test a small page using the alternative driver (PCL6 or PS). Update firmware and recreate the TCP/IP port if needed.
Will replacing the fuser clear 116-324?
Not by itself. Replacing a worn fuser addresses supplies warnings/locks. If 116-324 persists after a fuser change, treat it as a software exception and follow the queue/driver/firmware steps above.
Sources
- Xerox Support — Fault Code 116-324: Exception Failure
- Xerox Support — Fault Code 116-324: Software Exception Fault
- Xerox Support — 116-324 after sending a print job (disconnect network, power cycle)
Filed under: General Printer Problems
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