Page 1 P H A S E R ™ 5 4 0 0 L A S E R P R I N T E R Service Quick Reference Guide...
Page 3 ™ P h a s e r 5 4 0 0 L a s e r P r i n t e r S ervi ce Qui ck R efe renc e Gui d e Warning The following servicing instructions are for use by qualified service personnel only.
Page 4: Users Safety Summary
Users Safety Summary Terms in manual: Various terms are used throughout this manual to either provide additional information on a specific topic or to warn of possible danger that might be present during a procedure or action. Be aware of all symbols and terms when they are Note , Caution and Warning messages.
Page 5 Power Supply and 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. Do not touch any electrical component unless you are instructed to do so by a service procedure.
Page 6 Fuser Components Warning: This printer uses heat and pressure to fuse the toner image to a sheet of paper. The Fuser Assembly is very hot. Switch off printer power and wait at least 30 minutes for the Fuser to cool before you attempt to service the Fuser Assembly or adjacent components.
Page 7: Service Safety Summary
Service Safety Summary For qualified service personnel only: Refer also to the preceding Users Safety Summary. Do not service 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.
Page 8 The Laser contained in the Phaser 5400 Laser Printer meets the following standard: Laser class 3B, maximum 5 mW, wavelength 780 nm. The following LASER symbol will be displayed at the start of any procedure where possible exposure to the laser beam exists. LUOKAN 1 LASERLAITE KLASS 1 LASER APPARAT Phaser 5400 Laser Printer Service Guide...
Page 9 Federal Communications Commission Compliance This equipment has been tested and found to comply with the limits set for a Class A digital device, as stated in Part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference in a commercial installation. This equipment generates, uses, and may radiate radio frequency energy.
Page 10 Canadian Notice This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus as described in the radio interference regulations of the Canadian Department of Communications. Avis Canadien Cet appareil numerique est conforme aux limites émission de bruits radioélectriques pour les appareils de classe A stipulés das le réglement sur le brouillage radioéletrique du Ministére des Communcations du Canada.
Page 11 Blank Page Phaser 5400 Laser Printer Service Guide...
Page 12: Table Of Contents
Table of Contents Copyright ....................ii Users Safety Summary ................iii Service Safety Summary................. vi List of Figures ........xix List of Tables.
Page 13 Error Codes and Messages ......27 Introduction ....................28 Error messages ................28 Measurements .................29 Service Flowchart ................29 Repair Analysis Procedure Table............31...
Page 14 Component Tests .................235 Reset Menu ..................239 Maintenance Kit Counter Reset Procedure..........240 Maintenance and Cleaning......241 Scheduled Maintenance...............241 Recommended Tools ................241 Inspect While Servicing ................241...
Page 15 RRP 3.5 Tray 1 Right Guide Assembly .........277 RRP 3.6 Tray 1 Left Guide Assembly..........279 RRP 3.7 CRUM Board..............281 RRP 3.8 MBF Assembly Position Sensor........282 RRP 4.1 Paper Transport Assembly..........283 RRP 4.2 Registration Actuator............285 RRP 4.3 Registration Clutch............286 RRP 4.4 Registration Sensor............287 RRP 5.1 Fuser Assembly ..............288 RRP 5.2 Stack Full Sensor ............289 RRP 5.3 Exit Roller Assembly ............291...
Page 16 RRP 11.5 Rear Cover ..............332 RRP 11.6 Drive Assembly .............333 RRP 11.7 Feeder Board ..............334 RRP 11.8 Feed Head Assembly ............335 RRP 11.9 Feed Rollers ..............336 RRP 11.10 Feed Solenoid .............337 RRP 11.11 Turn Roller Assembly ..........338 RRP 11.12 Retard Chute Assembly ..........339 RRP 11.13 Left Tray Guide ............340 RRP 11.14 Right Tray Guide ............342 RRP 11.15 Retard Holder Assembly ..........344...
Page 17 PL 12.4 2000-Sheet Feeder (4 of 4) ..........424 PL 13.1 Duplex Assembly..............426 Xerox Supplies and Accessories............428 Plug/Jack Connector Locations......433 Contents ....................433...
Page 18 Wiring Diagrams ........449 Wiring Diagram Notations ..............449 Organization ..................450 Master Connection and Wiring Diagram ........451...
Page 19 Blank Page xviii Phaser 5400 Laser Printer Service Guide...
Page 20: List Of Figures
List of Figures Figure 1 Machine Orientation ..........1 Figure 2 Front View .
Page 21 Figure 36 Removing the Left Side Cover....... . . 250 Figure 37 Right Side Cover .
Page 22 Figure 79 Lower Exit Chute ......... . . 291 Figure 80 Upper Exit Chute .
Page 23 Figure 122 Rear Cover ..........332 Figure 123 Feeder Drive Assembly .
Page 24 Figure 165 Brake Assembly ......... . . 375 Figure 166 Left Tray Wires .
Page 25 Figure 206 Print Engine Controller PWB <–> Registration Clutch and Registration Sensor ........458 Figure 207 Print Engine Controller PWB <–>...
Page 26 List of Tables Table 1 Memory Upgrades ..........17 Table 2 Basic Specifications.
Page 27 Table 34 Error Code E3-1: Paper Jam / Registration To Fuser Troubleshooting Procedure ........69 Table 35 Error Code E4: Exit Jam Troubleshooting Procedure.
Page 28 Table 73 Inoperative Keypad Troubleshooting Procedure ....126 Table 74 Keypad ..........127 Table 75 Main Motor Assembly Troubleshooting Procedure .
Page 29 Table 151 Xerox Transparency Film ........
Page 30: General Information
General Information The Phaser 5400 Printer Service Guide is the primary document used for repairing and maintaining the Phaser 5400 Laser Printer. To ensure complete understanding of the product, participation in Xerox Phaser 5400 service training is recommended. Machine Orientation For servicing the Phaser 5400 Laser Printer, all references to machine orientation are as illustrated below.
Page 31 Phaser 5400 Laser Printer Overview The Phaser 5400 Laser Printer is a 40-page-per-minute monochrome, 600x600 and 1200x1200 dpi laser printer that uses a data-modulated laser beam, standard dry-ink Xerographic imaging process, and heat and pressure fusing to place a computer-generated image onto the surface of a sheet of paper.
Page 32 The Customer-Replaceable Consumable consists of a Print Cartridge, rated at 20,000 pages at 5% coverage. The printer signals “Toner Low” when 2% - 3% toner is remaining. A front panel setting selects whether the user may continue printing (Toner Low = Continue) or must stop and change the cartridge (Toner Low = Stop).
Page 33: Parts Of The Printer
Parts of the Printer Printer Components The base printer contains the following major components: Front view Rear view Standard Output Bin Rear Cover (closed) Paper Guide / Curl Extension Power Cord Receptacle Control Panel LVPS Fan Ventilation Slots Paper Support and Stopper Interface Connectors Multi-sheet Bypass Feeder (closed) (Parallel, USB, Ethernet)
Page 34: Printer Options
Printer Options Front view Rear view 1,000-Sheet (High Capacity) Stacker Optional Duplex Module (installed) Optional Hard Drive (installed) 500-Sheet Feeder Optional Memory DIMMs (installed) (A4/Letter Tray, shown as Tray 1, A3/Ledger Tray, shown as Tray 2 in the 500-sheet Feeder) 2,000-Sheet Feeder (shown as Tray 3) S5400-05-A Figure 4...
Page 35: Control Panel
Control Panel The Xerox Phaser 5400 Printer Control Panel: Displays printer status and jobs in process. Provides the means to change printer settings. Allows you to print reports (such as the configuration sheet, which lists the printer’s current settings) S5400-07-A...
Page 36: Display Screen
Display Screen The control panel’s display screen: Provides access to a hierarchy of menus to configure and control the printer. Access the menus by pressing the Menu keys (labeled 1 or 5). For more information on the menu structure, refer to the Advanced Features and Troubleshooting Manual.
Page 37: Rear Panel
Rear Panel Ethernet View Port Parallel s5400-344 Figure 7 Rear Panel Phaser 5400 Laser Printer Service Guide...
Page 38: Print Engine Assemblies
Print Engine Assemblies Figure 8 Print Engine Assemblies, Sensors and Interlock Locations 1 - Tray 1 and MBF Paper Path Components 1 In the above figure, all of the identified items are contained in the following four FRUs: Laser Scanner: stand-alone unit Print Cartridge contains: Bias Charge Roller Cleaning Blade...
Page 39: Figure 9 Fru Assemblies, Sensors And Interlock Locations 2
Figure 9 FRU Assemblies, Sensors and Interlock Locations 2 Phaser 5400 Laser Printer Service Guide...
Page 40: Figure 10 Fru Assemblies, Sensors And Interlock Locations 3 - Detack Saw, Registration & Bias Transfer Rollers And Paper Transport Assembly
Figure 10 FRU Assemblies, Sensors and Interlock Locations 3 - Detack Saw, Registration & Bias Transfer Rollers and Paper Transport Assembly Phaser 5400 Laser Printer Service Guide...
Page 41: Figure 11 Fru Assemblies, Sensors And Interlock Locations 4 - Fuser Area
Full Stack Sensor Figure 11 FRU Assemblies, Sensors and Interlock Locations 4 - Fuser Area Phaser 5400 Laser Printer Service Guide...
Page 42: Figure 12 Fru Assemblies, Sensors And Interlock Locations 5 - Main Drive
Figure 12 FRU Assemblies, Sensors and Interlock Locations 5 - Main Drive Phaser 5400 Laser Printer Service Guide...
Page 43 Figure 13 FRU Assemblies, Sensors and Interlock Locations 6 - FRU Circuit Assemblies Phaser 5400 Laser Printer Service Guide...
Page 44: Paper Path Information
Paper Path Information Paper is fed from the Tray or the Multi-sheet Bypass Feeder (MBF) and transported through the printer to the exit along the paper path shown in the following figure. Figure 14 Paper Path Flow Phaser 5400 Laser Printer Service Guide...
Page 45: Figure 15 Paper Path Components
The figure below is a cut-away side view of the Phaser 5400 Laser Printer that shows the paper paths and the major components directly related to the paper transportation. Figure 15 Paper Path Components Phaser 5400 Laser Printer Service Guide...
Page 46: Printer Specifications
Printer Specifications RAM and Printer Capabilities The Phaser 5400 Laser Printer is equipped with 32 Mbytes of RAM and is expandable as shown below. Installing additional RAM: Improves system performance. Improves processing of complex jobs. Enables increased graphics at higher resolutions. Improves collation printing.
Page 47: Basic Specifications
Basic Specifications Table 2 Basic Specifications Category Specification Standard configuration Print engine, MBF, 500-sheet Paper Feeder, A4/Letter Cassette (500-sheet universal paper cassette), Print Cartridge Printing method Xerography Exposing method Scanning with a semiconductor laser beam Laser light source Laser Diode (Nominal maximum output: 10 mW) Print image resolution Fixed-resolution version: 600 or 1200 dpi Fusing method...
Page 48: Mechanical Specifications
Mechanical Specifications Table 4 Physical Dimensions Height Width Depth Weight cm / in. cm / in. cm / in. kg / lb. Phaser 5400 printer only 39.5 / 15.6 49.0 / 19.3 46.0 / 18.1 27 / 60 500-Sheet Feeder 13.4 / 5.3 50.1 / 19.7 43.9 / 17.3...
Page 49: Environmental Specifications
Environmental Specifications Table 6 Environmental Specifications Environmental Operating: 41 – 95° F (5 – 35° C) 15 – 85% RH (Without conditions for installation condensation) 0 – 3000 m above sea level Horizontal bias within 5° (Printer unpacked and of level. having the Print Non-operating: -68 –...
Page 50: Life Expectancies
Life Expectancies Table 7 Life Expectancies of the Print Engine and Options Life of HCS Either 600,000 prints or 5 years. Life of Duplex Module Either 600,000 prints or 5 years whichever comes first. Life of Printer Engine Either 600,000 prints on Letter size paper (LEF) or 5 years whichever comes earlier.
Page 51: Printing Speed
Printing Speed Table 9 Printing Speed for the First Sheet Out 10.7 S: Simplex Time Needed for Initial Print (sec) D: Duplex Tray 1 Tray 2 Tray 3 Ledger SEF 5.66 6.06 6.83 7.61 10.90 11.29 11.60 12.71 A3 SEF 5.59 5.99 6.76...
Page 52: Printing Media Feeding Means
Printing Media Feeding Means The Phaser 5400 Laser Printer has the following four print media feeding means: Multi-sheet Bypass Feeder (Standard) 150 sheet capacity A4/Letter Tray (Standard) 500 sheet capacity A3/Ledger Tray (Optional) 500 sheet capacity A4/Letter 2000-Sheet Feeder (Optional) 2000 sheet capacity Note: All capacities assume a typical paper weight of 80 g/m (20 lbs.).
Page 53: Printing Media
Table 12 Custom Paper Sizes Tray 1, Tray 2, Tray 3 Acceptable A4/Letter A3/Ledger 2000-Sheet Multi-sheet Bypass Sizes Tray Tray Feeder Feeder Simplex Width 148 - 297 mm 210 - 297 mm None 76.2 - 305 mm 5.83 - 11.69 in. 8.27 - 11.69 in.
Page 54: Printing Accuracy
Unacceptable Media The following media are unacceptable for use in the printer. Their use may cause high rates of jamming and other paper-handling problems: Excessively thick or thin paper Heavily textured paper Paper that has already been printed on (pre-printed Letterhead is allowed) Wrinkled, torn, or bent paper Moist or wet paper Curled paper...
Page 55: Components To Be Replaced Periodically
Installed as the second or third paper high capacity feeders. Note: Only one can be installed. Part numbers and additional information for Maintenance items (fuser, BTR, etc.), Consumables (printer cartridge, media, etc.) or Options, refer to Xerox Supplies and Accessories on page 428 of this manual.
Page 56: Error Codes And Messages
Error Codes and Messages Contents - Error Codes and Messages RAP 1 Error Code C3: Insert Tray 1 .........42 RAP 2 Error Code C3: Insert Tray 2 Insert Tray 3 .
Page 57: Introduction
Introduction The Control Panel displays error information when sensors report problems with trays or consumables, open covers, jams, system failures or other operating problems. Error codes are usually specific: the word string or code has a special meaning, which makes it important that service and users record errors exactly. Error codes are listed in this section with Repair Analysis Procedures (RAPs) that outline corrective actions that should resolve the error or conflict.
Page 58: Measurements
Measurements Power and signal grounds are connected to frame ground, therefore all circuit troubleshooting can be performed using the metal frame (chassis) as the grounding point. If more information is needed to locate connectors or test points, refer to Plug/Jack Connector Locations on page 433. Unless otherwise specified, the following voltage tolerances are used within this section: Table 17 Voltage Measurements...
Page 59: Identify The Problem
Identify the Problem 1. Verify that the reported problem does exist. 2. Check for any error codes and write them down. 3. Print three test prints. 4. Make note of any print quality problems in the test prints. 5. Make note of any mechanical or electrical abnormalities present. 6.
Page 60: Repair Analysis Procedure Table
Repair Analysis Procedure Table If you used the Service Flowchart, it may have directed you to this section. Follow the Repair Analysis Procedure Table located in this section to help you analyze your printer problem. How to Use a Repair Analysis Procedure Table If you have an error code or error message displayed, refer to the Repair Analysis Procedure in this section and locate the ERROR CODE in the “Error Code”...
Page 61: How To Follow A Repair Analysis Procedure
How to Follow a Repair Analysis Procedure See the RAP Table example below. Each numbered step in a Repair Analysis Procedure instructs you to perform a certain action or procedure. The Actions and Questions box may contain additional information and numbered procedure steps you must follow to perform the action.
Page 62: General Notes On Using Repair Analysis Procedures
General Notes on Using Repair Analysis Procedures Unless indicated otherwise, the instruction “switch ON printer main power” means for you to switch ON printer power and let the printer proceed through power-on diagnostics and warm-up until it is on-line and ready to print. Conventions used to represent connectors: P/J XX means a Plug and its corresponding Jack are connected.
Page 63 Using Printer Diagnostics Repair Analysis Procedures often ask you to enter Diagnostics and perform a specific output test or input test. Diagnostics are built into the Print Engine Controller Board. Use the Control Panel to access and run the various diagnostic routines that are presented in this manual.
Page 64: Error Codes With Repair Analysis Procedure
Error Codes with Repair Analysis Procedure Table 18 Error Code / Repair Analysis Procedure Displayed Fault Diagnostic Message / Action Error Message History Fault Description / Comment Insert Tray 1 C3: Tray 1 Error Install Tray 1 Tray 1 is not detected in printer. (All Go to RAP 1, page paper size switches not actuated.)
Page 65 Table 18 Error Code / Repair Analysis Procedure (cont'd.) Displayed Fault Diagnostic Message / Action Error Message History Fault Description / Comment Remove Output C5: Top Tray Full Empty Top Tray. from Std. Bin Top Tray is declared full when 5 prints Go to RAP 6, page are delivered to the top tray after the...
Page 66 Table 18 Error Code / Repair Analysis Procedure (cont'd.) Displayed Fault Diagnostic Message / Action Error Message History Fault Description / Comment Paper Jam E2-1M E2-1 Misfeed Jam Open Top Cover or Feeder and remove 1. Simplex printing: Reg. Sensor is Open Top Cover the sheets, then close OFF when the specified time has...
Page 67 Table 18 Error Code / Repair Analysis Procedure (cont'd.) Displayed Fault Diagnostic Message / Action Error Message History Fault Description / Comment Tray 3 Jam E2-13 E2-1 Misfeed Jam Open Top Cover or Feeder and remove 1. Simplex printing: Reg. Sensor is Open Tray 3 the sheets, then close OFF when the specified time has...
Page 68 Table 18 Error Code / Repair Analysis Procedure (cont'd.) Displayed Fault Diagnostic Message / Action Error Message History Fault Description / Comment Duplex Jam E7-1 E7: Duplex Jam Open the Rear Cover and remove any paper. 1. Duplex Sensor is not actuated within Open Rear Cover the time after the start of the Duplex Go to RAP 20,...
Page 69 Table 18 Error Code / Repair Analysis Procedure (cont'd.) Displayed Fault Diagnostic Message / Action Error Message History Fault Description / Comment Toner Low J5: Toner Low Replace Print Cartridge. Toner Low is detected after 10 prints while toner sensor is on. Go to RAP 25, page Go to RAP 26,...
Page 70 Table 18 Error Code / Repair Analysis Procedure (cont'd.) Displayed Fault Diagnostic Message / Action Error Message History Fault Description / Comment Fan Failure U5: Fan Fail Check the Fuser Fan and the LVPS Fan. 1. Fuser Fan has failed. Power Off Now 2.
Page 71: Table 19 Error Code C3: Insert Tray Troubleshooting Procedure
RAP 1 Error Code C3: Insert Tray 1 The Tray 1 Assembly is not in place. Table 19 Error Code C3: Insert Tray Troubleshooting Procedure Step Actions and Questions REMOVE & REINSTALL TRAY 1 Go to Problem Step 2. solved. Completely remove and reinstall Tray.
Page 72: Table 20 Paper Size Actuators
Table 19 Error Code C3: Insert Tray Troubleshooting Procedure (cont'd.) Step Actions and Questions OBSERVING PAPER SIZE ACTUATORS Replace the Replace Tray 1 Left Tray 1 1. Remove the Left Side Cover (RRP 1.1, page 250). Guide [PL 2.1, 2. As you insert Tray 1, observe the size actuators Assembly page 386 (visible under the Print Engine Controller Board metal...
Page 73: Insert Tray
RAP 2 Error Code C3: Insert Tray 2 Insert Tray 3 Table 21 Error Code C3: Insert Tray 2 (or Tray 3) (500-Sheet Feeder) Troubleshooting Procedure Step Actions and Questions REMOVE & REINSTALL TRAY 2/3 Go to Problem Step 2. solved.
Page 74: Table 21 Error Code C3: Insert Tray 2 (Or Tray 3) (500-Sheet Feeder)
Table 21 Error Code C3: Insert Tray 2 (or Tray 3) (500-Sheet Feeder) Troubleshooting Procedure (cont'd.) Step Actions and Questions SUSPECT COMPONENTS The following printer components and areas are associated with this specific problem. One or more of these components or areas may have failed partially or completely.
Page 75: Table 23 Error Code C3: 2000-Sheet Feeder Carriage Not In Position Message Troubleshooting Procedure
RAP 3 Error Code C3-2E: Tray 2 Failure Power Off / On Error Code C3-3E: Tray 3 Failure Power Off / On The 2000-Sheet Feeder Tray Assembly has not been set. Table 23 Error Code C3: 2000-Sheet Feeder Carriage Not In Position Message Troubleshooting Procedure Step Actions and Questions...
Page 76 Table 23 Error Code C3: 2000-Sheet Feeder Carriage Not In Position Message Troubleshooting Procedure (cont'd.) Step Actions and Questions “NO” FROM STEP 5 ABOVE Replace the Replace the Print Engine 2000-Sheet Check for continuity between P/J13-1 and P601-1. Controller Feeder Is there continuity between the pins? Board Harness...
Page 77: Table 24 Add Paper To Mbf, Tray 1, 2 Or 3 Message Troubleshooting Procedure
RAP 4 Load MBF / Load Tray 1 / Load Tray 2 / Load Tray 3 Logic Control on the Print Engine Controller Board detected a problem where a false message to add paper to the MBF or a Paper Tray appears on the LCD. Table 24 Add Paper to MBF, Tray 1, 2 or 3 Message Troubleshooting Procedure...
Page 78 Table 24 Add Paper to MBF, Tray 1, 2 or 3 Message Troubleshooting Procedure (cont'd.) Step Actions and Questions TRAY 1 NO PAPER & LOW PAPER SENSOR Go to Replace the ACTUATORS CHECK Step 8. Tray 1 No Paper 1. Remove Tray 1. Sensor 2.
Page 79: Table 25 Add Paper To 500-Sheet Feeder Troubleshooting Procedure
RAP 5 Load Tray 2 / Load Tray 3 Tray 2 or Tray 3 is out of paper. Table 25 Add Paper To 500-Sheet Feeder Troubleshooting Procedure Step Actions and Questions PAPER LEVEL Go to Load paper Step 2. into the Tray. Check the paper level in the indicated Tray Assembly.
Page 80 Table 25 Add Paper To 500-Sheet Feeder Troubleshooting Procedure (cont'd.) Step Actions and Questions “YES” FROM STEP 5 ABOVE Go to Replace the Step 7. Feeder 1. Switch printer power OFF. Board 2. Reconnect P/J133. [RRP 11.7, 3. Switch printer power ON. 4.
Page 81: Table 26 Error Code C5: Standard Bin Full Troubleshooting Procedure
RAP 6 Error Code C5: Remove Output From Std. Bin Error code indicates the Standard Bin is full. Table 26 Error Code C5: Standard Bin Full Troubleshooting Procedure Step Actions and Questions STACK FULL SENSOR TEST It appears Go to the HCS Step 2.
Page 82 Table 26 Error Code C5: Standard Bin Full Troubleshooting Procedure (cont'd.) Step Actions and Questions “YES” FROM STEP 3 ABOVE Replace the Go to Print Engine Step 6. 1. Switch printer power OFF. Controller 2. Reconnect P/J19 to the Print Engine Controller Board. Board 3.
Page 83 Table 26 Error Code C5: Standard Bin Full Troubleshooting Procedure (cont'd.) Step Actions and Questions SUSPECT COMPONENTS The following printer components and areas are associated with this specific problem. One or more of these components or areas may have failed partially or completely.
Page 84: Table 27 Error Code C5: Stacker Bin Full Troubleshooting Procedure
RAP 7 Error Code C5: Remove Output From Stacker Bin Error code indicates the Stacker Bin is full. Table 27 Error Code C5: Stacker Bin Full Troubleshooting Procedure Step Actions and Questions STACK FULL SENSOR TEST It appears Go to the Stack Step 2.
Page 85 Table 27 Error Code C5: Stacker Bin Full Troubleshooting Procedure (cont'd.) Step Actions and Questions “YES” FROM STEP 3 ABOVE Replace the Go to Print Engine Step 6. 1. Switch printer power OFF. Controller 2. Reconnect P/J19 to the Print Engine Controller Board. Board 3.
Page 86 Table 27 Error Code C5: Stacker Bin Full Troubleshooting Procedure (cont'd.) Step Actions and Questions SUSPECT COMPONENTS The following printer components and areas are associated with this specific problem. One or more of these components or areas may have failed partially or completely.
Page 87: Table 28 Add Paper To 2000-Sheet Feeder Troubleshooting Procedure
RAP 8 Load Tray 2 / Load Tray 3 The last sheet of paper was fed. Table 28 Add Paper to 2000-Sheet Feeder Troubleshooting Procedure Step Actions and Questions PROCEDURE Go to Add paper to Step 2. the tray and Open the 2000-Sheet Feeder paper tray.
Page 88 Table 28 Add Paper to 2000-Sheet Feeder Troubleshooting Procedure (cont'd.) Step Actions and Questions “YES” FROM STEP 4 ABOVE Replace the Replace the Print Engine No Paper 1. Switch printer OFF. Controller Sensor 2. reconnect P/J602 to the Feeder Board. Board [RRP 12.18, 3.
Page 89: Table 29 Error Code E1-1: Paper Jam Tray To Registration Troubleshooting Procedure
RAP 9 Error Code E1-1: Paper Jam Open Top Cover There is a paper jam between the Paper Tray / Paper Handler Assembly and the Registration Sensor. Table 29 Error Code E1-1: Paper Jam Tray to Registration Troubleshooting Procedure Step Actions and Questions REGISTRATION SENSOR ACTUATOR Remove...
Page 90: Table 30 Error Code E2-1: Paper Jam Troubleshooting Procedure
RAP 10 Error Code E2-1M: Paper Jam Open Top Cover Error Code E2-11: Tray 1 Jam Open Tray 1 There is a paper jam between the Tray 1 or MBF and the Registration Sensor. Table 30 Error Code E2-1: Paper Jam Troubleshooting Procedure Step Actions and Questions TEST PRINTS Go to...
Page 91: Rap 55
Table 30 Error Code E2-1: Paper Jam Troubleshooting Procedure (cont'd.) Step Actions and Questions BOTTOM PLATE INSPECTION Go to Replace the Step 8. tray 1. Remove Tray 1 and remove all paper. assembly. 2. Open the printer Top Cover, remove the Print Cartridge and extend the MBF to the paper load position.
Page 92: Table 31 Paper Jam / Misfeed 500-Sheet Feeder Troubleshooting Procedure
RAP 11 Error Code E2-12: Tray 2 Jam Open Tray 2 Error Code E2-13: Tray 3 Jam Open Tray 3 There is a paper jam between a 500-Sheet Feeder Assembly and the Registration Sensor. Table 31 Paper Jam / Misfeed 500-Sheet Feeder Troubleshooting Procedure Step Actions and Questions PROCEDURE...
Page 93 Table 31 Paper Jam / Misfeed 500-Sheet Feeder Troubleshooting Procedure (cont'd.) Step Actions and Questions TURN ROLLER SHAFT TEST Go to Remove the Step 9. 500-Sheet 1. Open the rear door of the 500-Sheet Feeder. Feeder Feed 2. Enter Diagnostics mode. Head 3.
Page 94: Table 32 Error Code E2-1: Paper Jam / Misfeed 2000-Sheet Feeder Troubleshooting Procedure
RAP 12 Error Code E2-12: Tray 2 Jam Open Tray 2 Error Code E2-13: Tray 3 Jam Open Tray 3 A paper jam has occurred in the 2000-Sheet Feeder. Table 32 Error Code E2-1: Paper Jam / Misfeed 2000-Sheet Feeder Troubleshooting Procedure Step Actions and Questions PROCEDURE...
Page 95 Table 32 Error Code E2-1: Paper Jam / Misfeed 2000-Sheet Feeder Troubleshooting Procedure (cont'd.) Step Actions and Questions TEST PRINT Problem Replace the solved. 2000-Sheet Run a test print. Feeder Has the E2-1 Error Code cleared? Board [RRP 12.8, page 360].
Page 96: Table 33 Error Code E2-D: Duplex Jam Troubleshooting Procedure
RAP 13 Error Code E2-D: Duplex Jam Open Rear Cover There is a paper jam between the Duplex Assembly and the Registration Sensor when the paper is re-fed to print a 2nd page. Table 33 Error Code E2-D: Duplex Jam Troubleshooting Procedure Step Actions and Questions Is the paper curled, damaged or damp? Replace with...
Page 97 Table 33 Error Code E2-D: Duplex Jam Troubleshooting Procedure (cont'd.) Step Actions and Questions REGISTRATION SENSOR TEST Replace the Go to Print Engine RAP 50, 1. Enter Diagnostics mode. Controller page 135. 2. From the Main Menu, select Component Test / Sensor Board Input Test / press [4] to start test, [0] to stop.
Page 98: Table 34 Error Code E3-1: Paper Jam / Registration To Fuser
RAP 14 Error Code E3-1: Paper Jam / Open Top Cover There is a paper jam between the Registration Sensor and the Exit Sensor. Table 34 Error Code E3-1: Paper Jam / Registration To Fuser Troubleshooting Procedure Step Actions and Questions Is the paper loaded in the paper tray wrinkled or Replace Go to Step 2.
Page 99 Table 34 Error Code E3-1: Paper Jam / Registration To Fuser Troubleshooting Procedure (cont'd.) Step Actions and Questions PAPER HOLDING AT BTR AND PRINT Go to Replace the CARTRIDGE DRUM Step 8. Paper Transport 1. Remove the Fuser Assembly [RRP 5.1, page 288].
Page 100 Table 34 Error Code E3-1: Paper Jam / Registration To Fuser Troubleshooting Procedure (cont'd.) Step Actions and Questions SUSPECT COMPONENTS The following printer components and areas are associated with this specific problem. One or more of these components or areas may have failed partially or completely.
Page 101: Table 35 Error Code E4: Exit Jam Troubleshooting Procedure
RAP 15 Error Code E4-0: Exit Jam Open Rear and Top Cover There is a paper jam at the Exit Sensor. Table 35 Error Code E4: Exit Jam Troubleshooting Procedure Step Actions and Questions PAPER PATH INSPECTION AND TEST PRINTS Go to Go to Step 3.
Page 102 Table 35 Error Code E4: Exit Jam Troubleshooting Procedure (cont'd.) Step Actions and Questions EXIT AND PINCH ROLLERS CHECK Clean, or Go to replace, the Step 9. 1. Enter Diagnostics mode. Fuser 2. From the Main Menu, select Component Test / Exit Assembly as Motor Fwd L / press [4] to start test, [0] to stop.
Page 103: Table 36 Error Code E5: Close Covers Troubleshooting Procedure
RAP 16 Error Code E5: Close Covers The Top Cover or Rear Cover is open. Table 36 Error Code E5: Close Covers Troubleshooting Procedure Step Actions and Questions OPEN CLOSE TOP COVER AND REAR DOOR Go to Problem Step 2. solved.
Page 104 Table 36 Error Code E5: Close Covers Troubleshooting Procedure (cont'd.) Step Actions and Questions “YES” FROM STEP 6 ABOVE Replace the Check the Print Engine wiring Measure the voltage between the Rear Cover Interlock Controller between the Switch, both terminals orange wires (P/J621 and Board Top Cover P/J622) and frame ground.
Page 105: Table 37 Insert Mbf Troubleshooting Procedure
RAP 17 Insert MBF The Multi-sheet Bypass Feeder (MBF) is extended and is not in the home position. Table 37 Insert MBF Troubleshooting Procedure Step Actions and Questions PROCEDURE Go to Problem Step 2. solved. Extend and close the MBF. Does the error code still appear? MBF HOME SWITCH INSPECTION Go to...
Page 106 Table 37 Insert MBF Troubleshooting Procedure (cont'd.) Step Actions and Questions SUSPECT COMPONENTS The following printer components and areas are associated with this specific problem. One or more of these components or areas may have failed partially or completely. If you cannot isolate this problem using the steps in this Repair Analysis Procedure, replace each component or troubleshoot each area listed below, one at a time, until you isolate and solve the problem.
Page 107: Table 38 2000-Sheet Feeder Cover Open Troubleshooting Procedure
RAP 18 Close Tray 2 Rear Door Close Tray 3 Rear Door The 2000-Sheet Feeder Rear Door is open. Table 38 2000-Sheet Feeder Cover Open Troubleshooting Procedure Step Actions and Questions UPPER REAR COVER INTERLOCK SWITCH Go to Reinstall the Step 2.
Page 108 Table 38 2000-Sheet Feeder Cover Open Troubleshooting Procedure (cont'd.) Step Actions and Questions SUSPECT COMPONENTS The following printer components and areas are associated with this specific problem. One or more of these components or areas may have failed partially or completely.
Page 109: Table 39 Close Stacker Door Troubleshooting Procedure
RAP 19 Close Stacker Door The Rear Cover is open. Table 39 Close Stacker Door Troubleshooting Procedure Step Actions and Questions OPEN/CLOSE REAR COVER Go to Problem Step 2. solved. Open and close the HCS Rear Cover. Does the error code still appear? REAR COVER INTERLOCK SWITCH Go to Replace the...
Page 110 Table 39 Close Stacker Door Troubleshooting Procedure (cont'd.) Step Actions and Questions “YES” FROM STEP 4 ABOVE Replace the Replace the Print Engine HCS Rear 1. Switch printer power OFF. Controller Cover 2. Reconnect P/J524 to the HCS Board. Board Interlock 3.
Page 111: Table 40 Error Code E7: Duplex Jam Troubleshooting Procedure
RAP 20 Error Code E7-1: Duplex Jam Open Rear Cover There is a paper jam between the Exit Assembly and the Duplex Sensor. Table 40 Error Code E7: Duplex Jam Troubleshooting Procedure Step Actions and Questions PAPER PATH Go to Clear all Step 2.
Page 112 Table 40 Error Code E7: Duplex Jam Troubleshooting Procedure (cont'd.) Step Actions and Questions “YES” FROM STEP 6 ABOVE Go to Go to Step 9. Step 8. 1. Switch printer power OFF. 2. Reconnect P/J19 to the Print Engine Controller Board. 3.
Page 113: Table 41 Error Code E8-1: Stacker Jam Troubleshooting Procedure
RAP 21 Error Code E8-1: Stacker Jam Open Rear Cover There is a paper jam at the HCS Sensor. Table 41 Error Code E8-1: Stacker Jam Troubleshooting Procedure Step Actions and Questions Is the lead edge of the paper located within the Go to Go to Step 4.
Page 114 Table 41 Error Code E8-1: Stacker Jam Troubleshooting Procedure (cont'd.) Step Actions and Questions SUSPECT COMPONENTS The following printer components and areas are associated with this specific problem. One or more of these components or areas may have failed partially or completely.
Page 115: Table 42 Duplex Unit Fail Or Removed Message
RAP 22 Error Code: E9-1 Duplex Unit Fail or Removed Table 42 Duplex Unit Fail or Removed Message Troubleshooting Procedure Step Actions and Questions PROCEDURE Go to Replace the Step 2. Print Engine 1. Switch printer power OFF. Controller 2. Remove the Left Side Cover [RRP 1.1, page 250] and Board...
Page 116 Table 42 Duplex Unit Fail or Removed Message Troubleshooting Procedure (cont'd.) Step Actions and Questions SUSPECT COMPONENTS The following printer components and areas are associated with this specific problem. One or more of these components or areas may have failed partially or completely.
Page 117: Table 43 Error Code E9-2: Stacker Bin Fail Troubleshooting Procedure
RAP 23 Error Code E9-2: Stacker Bin Fail Power Off / On Table 43 Error Code E9-2: Stacker Bin Fail Troubleshooting Procedure Step Actions and Questions +3.2 VDC CHECK Go to Go to Step 3. Step 2. 1. Switch print power OFF. 2.
Page 118: Table 44 Error Code E9-3: Hcf Fail (2000-Sheet Feeder)
RAP 24 Error Code E9-3: Tray 2 Failure Power Off / On Tray 3 Failure Power Off / On The HCF has failed or disconnected with Power-On. Table 44 Error Code E9-3: HCF Fail (2000-Sheet Feeder) Troubleshooting Procedure Step Actions and Questions HARNESS CONNECTIONS Go to Secure the...
Page 119: Table 45 Error Code J5: Toner Low Troubleshooting Procedure
RAP 25 Error Code J5: Toner Low The Print Cartridge is nearing end-of-life and should be replaced. Table 45 Error Code J5: Toner Low Troubleshooting Procedure Step Actions and Questions PRINT CARTRIDGE REPLACEMENT Go to Problem Step 2. solved. Install a new Print Cartridge. Does the J5 error code still appear? CONTINUITY CHECK Go to...
Page 120: Table 46 Error Code J5: Toner Low Troubleshooting Procedure
RAP 26 Error Code J5: Toner Low Toner Low is not displayed when the Print Cartridge appears to be empty. Table 46 Error Code J5: Toner Low Troubleshooting Procedure Step Actions and Questions TEST PRINT Go to Problem does Step 2. not exist.
Page 121: Table 47 Error Code J6-1: Replace Print Cartridge Troubleshooting Procedure
RAP 27 Error Code J6-1: Replace Print Cartridge Install Print Cartridge Logic Control on the Print Engine Controller Board detected a problem where a message to replace the Print Cartridge is generated. Table 47 Error Code J6-1: Replace Print Cartridge Troubleshooting Procedure Step Actions and Questions...
Page 122: Table 48 Error Code J8-1: Print Cartridge Oem Id Mismatch
RAP 28 Error Code J8-1: Print Cartridge OEM ID Mismatch A Print Cartridge for a different printer is detected. Table 48 Error Code J8-1: Print Cartridge OEM ID Mismatch Troubleshooting Procedure Step Actions and Questions PRINT CARTRIDGE Go to Problem Step 2.
Page 123: Table 49 Error Code Pse-1 Paper Size Jam Troubleshooting Procedure
RAP 29 Error Code PSE-1: Paper Size Jam Open Rear Cover There is a conflict between the size of paper the printer senses in the paper tray and/or MBF and the size of paper that is actually loaded. Table 49 Error Code PSE-1 Paper Size Jam Troubleshooting Procedure Step...
Page 124: Table 50 Paper Size Actuators
Table 49 Error Code PSE-1 Paper Size Jam Troubleshooting Procedure (cont'd.) Step Actions and Questions PAPER TRAY INSPECTION Replace the Replace Print Engine paper tray 1. Switch printer power OFF. Controller [PL 2.1, 2. Remove the Left Side Cover [RRP 1.1, page 250].
Page 125: Table 51 Error Code U1: Motor Failure Troubleshooting Procedure
RAP 30 Error Code U1: Motor Failure Power Off / On There is a problem with the Main Motor. Table 51 Error Code U1: Motor Failure Troubleshooting Procedure Step Actions and Questions MOTOR ROTATION CHECK Go to Go to Step 4. Step 2.
Page 126 Table 51 Error Code U1: Motor Failure Troubleshooting Procedure (cont'd.) Step Actions and Questions MBF FEED ROLLER ROTATION CHECK Go to Replace the Step 8. MBF Feed 1. Remove all paper from the MBF tray. Roller 2. With the Main Motor still running from Step 6, components sub-step 4, above, select MBF Feed Sol / press [4] to test.
Page 127: Table 52 Error Code U2: Laser (Ros (Laser Scanner)) Failure
RAP 31 Error Code U2: Laser Failure Power Off / On There is a problem with the Laser Assembly. Table 52 Error Code U2: Laser (ROS (Laser Scanner)) Failure Troubleshooting Procedure Step Actions and Questions RESOLUTION CHECK Go to Replace the Step 2.
Page 128 Table 52 Error Code U2: Laser (ROS (Laser Scanner)) Failure Troubleshooting Procedure (cont'd.) Step Actions and Questions SUSPECT COMPONENTS The following printer components and areas are associated with this specific problem. One or more of these components or areas may have failed partially or completely.
Page 129: Table 53 Error Code U4: Fuser Failure Troubleshooting Procedure
RAP 32 Error Code U4: Fuser Failure Power Off / On There is a problem with the Fuser Assembly. Table 53 Error Code U4: Fuser Failure Troubleshooting Procedure Step Actions and Questions POWER OFF / ON Go to Go to RAP 49, Step 2.
Page 130: Table 54 Error Code U5: Fan Fail Troubleshooting Procedure
RAP 33 Error Code U5: Fan Failure Power Off Now The printer is detecting incorrect fan rotation. Table 54 Error Code U5: Fan Fail Troubleshooting Procedure Step Actions and Questions Do both fans rotate when printer power is Go to Go to switched ON? Step 3.
Page 131: Table 55 0101 - Dimm 1 Troubleshooting Procedure
RAP 34 Error Code: 0101 - DIMM 1 DIMM in slot J4 has failed at Power-Up. Table 55 0101 - DIMM 1 Troubleshooting Procedure Step Actions and Questions PROCEDURE Replace the Go to System Step 2. 1. Switch printer power OFF. Controller 2.
Page 132: Table 56 0102 - Dimm 2 Troubleshooting Procedure
RAP 35 Error Code: 0102 - DIMM 2 DIMM in slot J5 has failed at Power-Up. Table 56 0102 - DIMM 2 Troubleshooting Procedure Step Actions and Questions PROCEDURE Replace the Go to System Step 2. 1. Switch printer power OFF. Controller 2.
Page 133: Table 57 0103 - Dimm 3 Troubleshooting Procedure
RAP 36 Error Code: 0103 - DIMM 3 DIMM in slot J6 has failed at Power-Up. Table 57 0103 - DIMM 3 Troubleshooting Procedure Step Actions and Questions PROCEDURE Replace the Go to System Step 2. 1. Switch printer power OFF. Controller 2.
Page 134: Table 58 Error Code U6: Iot Nvm Failure Troubleshooting Procedure
RAP 37 Error Code U6: IOT NVM Fail Power Off / On There is a problem with the Non-Volatile RAM on the Print Engine Controller Board. Table 58 Error Code U6: IOT NVM Failure Troubleshooting Procedure Step Actions and Questions POWER CYCLING Go to Go to...
Page 135 Blank Page Phaser 5400 Laser Printer Service Guide...
Page 136: Troubleshooting
Troubleshooting This topic discusses troubleshooting the printer. Troubleshooting is discussed in the following areas: Printer Performance Problems: Refer to the Repair Analysis Procedure (RAP) Table 59 “Print Performance Problems RAP Table,” on page 107. Image-Quality Problems: Refer to the Repair Analysis Procedure (RAP) Table 60 “Image-Quality Problems RAP Table,”...
Page 137 Table 59 Print Performance Problems RAP Table (cont'd.) Problem Go To MBF No Paper Sensor RAP 51 on page 137 Laser Safety Switch RAP 52 on page 139 Tray 1 No Paper Sensor RAP 53 on page 140 Size Switch RAP 54 on page 142 Turn Roller Clutch Assembly RAP 55 on page 145...
Page 138: Image-Quality Problems Repair Analysis Procedure (Rap) Table
Image-Quality Problems Repair Analysis Procedure (RAP) Table Table 60 Image-Quality Problems RAP Table Problem Go To RAP No. Light (Undertoned) Prints RAP 70 on page 178 Blank Prints RAP 71 on page 181 Spots RAP 72 on page 183 Horizontal (Scan) Deletions RAP 73 on page 185 Vertical (Process) Deletions RAP 74 on page 188...
Page 139: Printer Performance Problems
Printer Performance Problems RAP 38 AC Power There is a possible problem with the AC power. Initial Action Disconnect the AC power cord from the wall outlet. Warning: Improper connection of the grounding conductor can result in the risk of electrical shock. The following must be observed: Never use a ground adapter plug to connect the machine to a power source.
Page 140 Table 62 AC Power Testing Procedure (cont'd.) Step Actions and Questions XL, UK AND AO [220 VAC] Go to Inform Step 4. customer of insufficient voltage or improper wiring. 1. Measure the AC voltage between Line and Neutral, between AC Line and Earth/Ground, and between Neutral and Earth/Ground.
Page 141: Table 63 Registration Clutch Troubleshooting Procedure
RAP 39 Registration Clutch Table 63 Registration Clutch Troubleshooting Procedure Step Actions and Questions PROCEDURE Go to Go to Step 8. Step 2. 1. Enter Diagnostics mode. 2. From the Main Menu, select Component Test / Reg. Clutch / press [4] to test, [0] to stop. Can you hear the Registration Clutch energize? “NO”...
Page 142 Table 63 Registration Clutch Troubleshooting Procedure (cont'd.) Step Actions and Questions REGISTRATION CLUTCH TEST Problem Replace the solved. Registration 1. Switch printer power OFF. Clutch 2. Open the Top Cover and remove the Print Cartridge. [RRP 4.3 on 3. Enter Diagnostics mode. 4.
Page 143: Table 64 Dc (Lvps) Troubleshooting Procedure
RAP 40 DC Power (LVPS) Table 64 DC (LVPS) Troubleshooting Procedure Step Actions and Questions 1. Perform RAP 38 before starting this RAP. Go to Step 2. Replace the 2. If RAP 38 checks out OK, switch the main power OFF AC Input and disconnect the printer power.
Page 144: Table 65 Lvps Voltages
Table 65 LVPS Voltages Red Lead Black Lead Voltage P/J161 pin 10 Frame Ground +5.0 VDC P/J161 pin 11 Frame Ground +3.3 VDC P/J161 pin 3 Frame Ground +24 VDC Phaser 5400 Laser Printer Service Guide...
Page 145: Initial Actions
RAP 41 DC Power Loading Initial Actions Perform RAP 40, DC Power (LVPS) Troubleshooting, before starting this RAP. Warning: AC input voltages can be lethal. Use extreme care while checking the voltages on the LVPS. Disconnect the power cord while checking the continuity of fuses and removing or reinstalling the components.
Page 146: Table 67 Lvps Voltages
Table 66 DC Power Loading Troubleshooting Procedure (cont'd.) Step Actions and Questions Switch the printer power OFF. Reconnect one of the Repeat the Replace the disconnected plugs. Switch the printer power ON. step with the component Measure the voltages listed in Table 67. next just disconnected...
Page 147: Table 68 System Controller Isolation Procedure
RAP 42 System Controller Isolation Table 68 System Controller Isolation Procedure Step Actions and Questions SYSTEM CONTROLLER ISOLATION Go to Go to Step 3. Step 2. 1. Switch printer power OFF. 2. Disconnect all cables connected the rear of the System Controller Board.
Page 148: Table 69 Low Paper Tray 1/2/3 Troubleshooting Procedure
RAP 43 Low Paper Tray 1/2/3 Paper stack in the Paper Tray Assembly is below 50 sheets. Table 69 Low Paper Tray 1/2/3 Troubleshooting Procedure Step Actions and Questions LOAD PAPER Go to Problem Step 2. solved. Insert a full Tray Assembly into the affected position. Does the Error Message reappear? LOW PAPER SENSOR ACTUATOR TEST Go to...
Page 149: Table 70 Inoperative Printer Troubleshooting
RAP 44 Inoperative Printer Printer power cannot be switched ON. Table 70 Inoperative Printer Troubleshooting Step Actions and Questions AC POWER CORD Go to Problem Step 2. solved. Ensure the power cord is properly connected to the wall outlet and to the back of the printer. Does the problem still exist? AC POWER Go to...
Page 150 Table 70 Inoperative Printer Troubleshooting (cont'd.) Step Actions and Questions SYSTEM CONTROLLER +5 VDC CHECK Replace the Go to System Step 9. Measure the voltage between pins 1 and 2 of P/J13 on Controller the System Controller Board. Board Does the voltage between P/J13, pins 1 and 2 [RRP 1.1, measure +5.0 VDC? page...
Page 151 Table 70 Inoperative Printer Troubleshooting (cont'd.) Step Actions and Questions SUSPECT COMPONENTS The following printer components and areas are associated with this specific problem. One or more of these components or areas may have failed partially or completely. If you cannot isolate this problem using the steps in this Repair Analysis Procedure, replace each component or troubleshoot each area listed below, one at a time, until you isolate and solve the problem.
Page 152: Table 71 Malfunctioning Lcd/Led Troubleshooting Procedure
RAP 45 Malfunctioning LCD/LED The Control Panel LCD is erratic. Table 71 Malfunctioning LCD/LED Troubleshooting Procedure Step Actions and Questions PROCEDURE Go to Go to Step 8. Step 2. 1. Switch printer power OFF. 2. Remove any options connected to the System Controller Board.
Page 153 Table 71 Malfunctioning LCD/LED Troubleshooting Procedure (cont'd.) Step Actions and Questions SYSTEM CONTROLLER BOARD +5 VDC NO Replace the Go to LOAD CHECK System Step 7. Controller 1. Switch printer power OFF. Board 2. Disconnect P/J13 from the System Controller Board. 3.
Page 154: Table 72 System Controller Board Voltages At P/J18
Table 71 Malfunctioning LCD/LED Troubleshooting Procedure (cont'd.) Step Actions and Questions SUSPECT COMPONENTS The following printer components and areas are associated with this specific problem. One or more of these components or areas may have failed partially or completely. If you cannot isolate this problem using the steps in this Repair Analysis Procedure, replace each component or troubleshoot each area listed below, one at a time, until you isolate and solve the problem.
Page 155: Table 73 Inoperative Keypad Troubleshooting Procedure
RAP 46 Inoperative Keypad Control Panel is not operative. Table 73 Inoperative Keypad Troubleshooting Procedure Step Actions and Questions PROCEDURE Go to Go to Step 4. Step 2. 1. Enter Diagnostics mode. 2. From the Main Menu, select Component Test / Sensor Input / press [4] to start, [0] to stop.
Page 156: Table 74 Keypad
Table 74 Keypad Voltage Voltage +3.3 VDC +3.3 VDC 0 VDC +1.3 VDC +1.3 VDC +3.3 VDC 0 VDC 0 VDC Phaser 5400 Laser Printer Service Guide...
Page 157: Table 75 Main Motor Assembly Troubleshooting Procedure
RAP 47 Main Motor Assembly Table 75 Main Motor Assembly Troubleshooting Procedure Step Actions and Questions PROCEDURE Problem Go to solved. Step 2. 1. Open the Top Cover. 2. Remove the Print Cartridge. 3. Cheat the Top Cover Interlock. 4. Enter Diagnostics mode. 5.
Page 158: Table 76 Main Motor Harness
Table 75 Main Motor Assembly Troubleshooting Procedure (cont'd.) Step Actions and Questions “NO” FROM STEP 7 ABOVE Replace the Replace the LVPS Print Engine 1. Remove the cheater from the Top Cover Interlock, [RRP 8.6, Controller then reinstall the cheater. page 312].
Page 159 RAP 48 Laser Assembly Table 77 Laser Assembly Troubleshooting Procedure Step Actions and Questions LASER SCANNER MOTOR Go to Go to Step 5. Step 2. 1. Enter Diagnostics mode. 2. From the Main Menu, select Component Test / ROS Motor / press [4] to start, [0] to stop. Do you hear the Laser Scanner motor spin up? “NO”...
Page 160 Table 77 Laser Assembly Troubleshooting Procedure (cont'd.) Step Actions and Questions “NO” FROM STEP 6 ABOVE Replace the Go to Print Engine Step 8. Measure the voltage between P/J21-3 and frame Controller ground. Board Does the voltage P/J21-3 and frame ground [RRP 8.5, measure +5.0 VDC.
Page 161: Table 77 Laser Assembly Troubleshooting Procedure
Table 77 Laser Assembly Troubleshooting Procedure (cont'd.) Step Actions and Questions LASER ASSEMBLY REPLACEMENT Go to Problem Electrical solved. Replace the Laser Assembly [RRP 7.1, page 297]. Noise, Does the problem still appear? page 157. SUSPECT COMPONENTS The following printer components and areas are associated with this specific problem.
Page 162: Table 78 Fuser Assembly Troubleshooting Procedure
RAP 49 Fuser Assembly Warning: If the printer has been switched on, the fuser may be very hot. Table 78 Fuser Assembly Troubleshooting Procedure Step Actions and Questions RESISTANCE MEASUREMENTS Go to Replace the Step 2. Fuser 1. Switch printer power OFF. Assembly 2.
Page 163: Figure 17 Fuser Connector P174
Table 78 Fuser Assembly Troubleshooting Procedure (cont'd.) Step Actions and Questions “YES” FROM STEP 5 ABOVE Replace the Go to Fuser Board Step 7. 1. Reconnect P/J171, P/J172 and P/J17. [RRP 8-8, 2. Switch printer power ON. page 314]. If 3.
Page 164: Table 79 Registration Sensor Troubleshooting Procedure
RAP 50 Registration Sensor Table 79 Registration Sensor Troubleshooting Procedure Step Actions and Questions PROCEDURE It appears Go to Step 2. 1. Open the Top Cover and remove the Print Cartridge. Registration 2. Extend the MBF by lifting, then pulling toward you. Sensor is 3.
Page 165 Table 79 Registration Sensor Troubleshooting Procedure (cont'd.) Step Actions and Questions SUSPECT COMPONENTS The following printer components and areas are associated with this specific problem. One or more of these components or areas may have failed partially or completely. If you cannot isolate this problem using the steps in this Repair Analysis Procedure, replace each component or troubleshoot each area listed below, one at a time, until you isolate and solve the problem.
Page 166: Table 80 Mbf No Paper Sensor Troubleshooting Procedure
RAP 51 MBF No Paper Sensor Table 80 MBF No Paper Sensor Troubleshooting Procedure Step Actions and Questions PROCEDURE It appears Go to the MBF No Step 2. 1. Open the MBF Door and remove all paper from the Paper MBF.
Page 167 Table 80 MBF No Paper Sensor Troubleshooting Procedure (cont'd.) Step Actions and Questions MBF COMBO HARNESS CONTINUITY CHECK Go to Replace the Step 6. MBF Combo 1. Switch printer power OFF. Harness 2. Disconnect P/J121 from the MBF Assembly and [PL 4.2, P/J12 from the Print Engine Controller Board.
Page 168: Table 81 Error Code J3: Laser Safety Switch Open Troubleshooting
RAP 52 Laser Safety Switch The Print Cartridge is not in place or is installed incorrectly. Table 81 Error Code J3: Laser Safety Switch Open Troubleshooting Step Actions and Questions PRINT CARTRIDGE INSPECTION Go to Replace the Step 2. Print 1.
Page 169: Table 82 Tray 1 No Paper Sensor Troubleshooting Procedure
RAP 53 Tray 1 No Paper Sensor Table 82 Tray 1 No Paper Sensor Troubleshooting Procedure Step Actions and Questions PROCEDURE It appears Go to the Tray 1 Step 2. 1. Remove Tray 1. No Paper 2. Enter Diagnostics mode. Sensor is 3.
Page 170 Table 82 Tray 1 No Paper Sensor Troubleshooting Procedure (cont'd.) Step Actions and Questions “NO” FROM STEP 4 ABOVE Go to Replace Step 6. 1. Switch printer power OFF. Harness 2. Disconnect P/J121 from the MBF Assembly and [PL 4.2, P/J12 from the Print Engine Controller Board.
Page 171: Table 83 Size Switch Troubleshooting Procedure
RAP 54 Size Switch The error message indicates a problem with the standard feeder, the 500 Sheet Feeder or the 2000 Sheet Feeder. Table 83 Size Switch Troubleshooting Procedure Step Actions and Questions Is the problem with the 2000 Sheet Feeder? Go to Go to Step 10.
Page 172 Table 83 Size Switch Troubleshooting Procedure (cont'd.) Step Actions and Questions “YES” FROM STEP 6 ABOVE Go to Replace the Step 8. Feeder 1. Reconnect P/J138 to the Feeder Board. Board 2. Switch printer power ON. [RRP 11.7, 3. Measure the voltages in Table 84 on P/J132-5 (Tray 2) or P/J132-6 (Tray 3) as you actuate the switches.
Page 173: Table 84 Size Switch Voltages
Table 83 Size Switch Troubleshooting Procedure (cont'd.) Step Actions and Questions “NO” FROM STEP 8 ABOVE. Replace the Repair or Print Engine replace the Check for continuity between P/J13-5 (Print Engine Controller harness as Controller Board) and P/J131-5 (Tray 2) or P/J13-6 and Board necessary.
Page 174: Table 85 Turn Roller Clutch Assembly Troubleshooting Procedure
RAP 55 Turn Roller Clutch Assembly Table 85 Turn Roller Clutch Assembly Troubleshooting Procedure Step Actions and Questions PROCEDURE Go to Go to Step 8. Step 2. 1. Enter Diagnostics mode. 2. From the Main Menu, select Component Test / Turn Roll Clutch / press [4] to test, [0] to stop.
Page 175 Table 85 Turn Roller Clutch Assembly Troubleshooting Procedure (cont'd.) Step Actions and Questions “YES” FROM STEP 6 ABOVE Go to Replace the Step 8. Print Engine 1. Switch printer power OFF. Controller 2. Reconnect P/J12. Board 3. Enter Diagnostics mode. 4.
Page 176: Table 86 Tray 1 Feed Solenoid Troubleshooting Procedure
RAP 56 Tray 1 Feed Solenoid Table 86 Tray 1 Feed Solenoid Troubleshooting Procedure Step Actions and Questions PROCEDURE Go to Go to Step 8. Step 2. 1. Enter Diagnostics mode. 2. From the Main Menu, select Component Test / Tray 1 Feed Sol / press [4], [0] to stop.
Page 177 Table 86 Tray 1 Feed Solenoid Troubleshooting Procedure (cont'd.) Step Actions and Questions “YES” FROM STEP 6 ABOVE Check for Replace the mechanical Print Engine 1. Switch printer power OFF. binding of Controller 2. Reconnect P/J12. the solenoid Board 3. Enter Diagnostics mode. 4.
Page 178: Table 87 Mbf Feed Solenoid Troubleshooting Procedure
RAP 57 MBF Feed Solenoid Table 87 MBF Feed Solenoid Troubleshooting Procedure Step Actions and Questions PROCEDURE Go to Go to Step 8. Step 2. 1. Enter Diagnostics mode. 2. From the Main Menu, select Component Test / MBF Feed Sol / press [4], [0] to stop. Can you hear the solenoid energize? “NO”...
Page 179 Table 87 MBF Feed Solenoid Troubleshooting Procedure (cont'd.) Step Actions and Questions “YES” FROM STEP 5 ABOVE Check for Replace the mechanical Print Engine 1. Switch printer power OFF. binding of Controller 2. Reconnect P/J12. the solenoid Board 3. Enter Diagnostics mode. 4.
Page 180: Table 88 Toner Sensor Assembly Troubleshooting Procedure
RAP 58 Toner Sensor Assembly Table 88 Toner Sensor Assembly Troubleshooting Procedure Step Actions and Questions PROCEDURE Go to Go to Step 3. Step 2. 1. Switch printer power OFF. 2. Remove the Left Side Cover [RRP 1.1, page 250] and the Print Engine Controller Board Cover [RRP 8.5, page 310].
Page 181 Table 88 Toner Sensor Assembly Troubleshooting Procedure (cont'd.) Step Actions and Questions SUSPECT COMPONENTS The following printer components and areas are associated with this specific problem. One or more of these components or areas may have failed partially or completely. If you cannot isolate this problem using the steps in this Repair Analysis Procedure, replace each component or troubleshoot each area listed below, one at a time, until you isolate and solve the problem.
Page 182: Table 89 Hvps Assembly Troubleshooting Procedure
RAP 59 HVPS Assembly Table 89 HVPS Assembly Troubleshooting Procedure Step Actions and Questions PRINT CARTRIDGE RIGHT GUIDE ASSEMBLY Go to Replace the INSPECTION Step 2. Right Print Cartridge 1. Open the Top Cover and remove the Print Cartridge. Guide 2.
Page 183 Table 89 HVPS Assembly Troubleshooting Procedure (cont'd.) Step Actions and Questions “BTR -” VOLTAGE CHECK Replace the Go to HVPS Step 6. 1. Scroll to “BTR -”. [RRP 8.2, 2. Measure the voltage between the left end of the BTR page 307].
Page 184 Table 89 HVPS Assembly Troubleshooting Procedure (cont'd.) Step Actions and Questions “YES” FROM STEP 3 ABOVE Go to Replace the Step 11. HVPS 1. Scroll to Charge Roll DC. [RRP 8.2, 2. Measure the voltage between the Right Side Guide page 307].
Page 185 Table 89 HVPS Assembly Troubleshooting Procedure (cont'd.) Step Actions and Questions SUSPECT COMPONENTS The following printer components and areas are associated with this specific problem. One or more of these components or areas may have failed partially or completely. If you cannot isolate this problem using the steps in this Repair Analysis Procedure, replace each component or troubleshoot each area listed below, one at a time, until you isolate and solve the problem.
Page 186: Table 90 Electrical Noise Troubleshooting Procedure
RAP 60 Electrical Noise Table 90 Electrical Noise Troubleshooting Procedure Step Actions and Questions PROCEDURE Go to Problem Step 2. solved. 1. Check to see if there is other electrical equipment, such as electrical generators, radio transmitters, or devices using electrical motors, within ten feet of the printer.
Page 187 Table 90 Electrical Noise Troubleshooting Procedure (cont'd.) Step Actions and Questions PAPER TRANSPORT ASSEMBLY Go to Replace the Step 8. Paper 1. Remove the Paper Transport Assembly [RRP 4.1, Transport page 283]. Assembly 2. Check all the wires in the Paper Transport Assembly for continuity.
Page 188: Table 91 Low Paper Tray 2 (Or Tray 3) / 500-Sheet Feeder Troubleshooting Procedure
RAP 61 Low Paper Tray 2 (or Tray 3) / 500-Sheet Feeder Tray 2 and/or Tray 3 have low paper. Table 91 Low Paper Tray 2 (or Tray 3) / 500-Sheet Feeder Troubleshooting Procedure Step Actions and Questions PROCEDURE Go to Problem Step 2.
Page 189 Table 91 Low Paper Tray 2 (or Tray 3) / 500-Sheet Feeder Troubleshooting Procedure (cont'd.) Step Actions and Questions “NO” FROM STEP 5 ABOVE Replace the Repair or Low Paper replace the 1. Switch printer power OFF. Sensor harness as 2.
Page 190: Table 92 500-Sheet Feeder Feed Solenoid Troubleshooting Procedure
RAP 62 500-Sheet Feeder Feed Solenoid The 500-Sheet Feeder is not feeding paper or not feeding paper at the correct time. Table 92 500-Sheet Feeder Feed Solenoid Troubleshooting Procedure Step Actions and Questions PROCEDURE Go to Go to Step 10. Step 2.
Page 191 Table 92 500-Sheet Feeder Feed Solenoid Troubleshooting Procedure (cont'd.) Step Actions and Questions “YES” FROM STEP 4 ABOVE Check for Go to mechanical Step 8. 1. Switch printer power OFF. binding of 2. Reconnect P/J133. the solenoid 3. Enter Diagnostics mode. 4.
Page 192: Table 93 500-Sheet Feeder Motor Troubleshooting Procedure
RAP 63 500-Sheet Motor Logic Control on the Print Engine Controller Board detects a problem with the 500-Sheet Feeder Main Motor. Table 93 500-Sheet Feeder Motor Troubleshooting Procedure Step Actions and Questions +24 V CHECK AT P/J 140 ON 500-SHEET Go to Replace the FEEDER BOARD...
Page 193: Table 94 500-Sheet Feeder Assembly Not Recognized Troubleshooting Procedure
RAP 64 500-Sheet Feeder Assembly Not Recognized Print Engine Controller Board does not recognize the Feeder Assembly. Table 94 500-Sheet Feeder Assembly Not Recognized Troubleshooting Procedure Step Actions and Questions PROCEDURE Go to Reseat the Step 2. Feeder and 1. Check the alignment of the printer to the 500-Sheet printer to Feeder and the alignment of the top 500-Sheet obtain...
Page 194 Table 94 500-Sheet Feeder Assembly Not Recognized Troubleshooting Procedure (cont'd.) Step Actions and Questions “NO” FROM STEP 4 ABOVE Replace the Repair or Feeder replace the 1. Switch printer power OFF. Board harness 2. Disconnect P/J13 from the Print Engine Controller [RRP 11-7, between Board and P/J132 from the Feeder Board.
Page 195 Table 94 500-Sheet Feeder Assembly Not Recognized Troubleshooting Procedure (cont'd.) Step Actions and Questions P/J13 and P/J132 CONTINUITY CHECK Replace the Repair or Feeder replace the 1. Switch printer power OFF. Board harness 2. Remove the 500-Sheet Feeder Left Cover [RRP 11.3, [RRP 11-7, between page...
Page 196: Table 95 Exit Sensor Troubleshooting Procedure
RAP 65 Exit Sensor Table 95 Exit Sensor Troubleshooting Procedure Step Actions and Questions PROCEDURE Replace the Go to Print Engine Step 2. 1. Enter Diagnostics mode. Controller 2. From the Main Menu, select Component Test / Sensor Board Input / press [4], to start, [0] to stop. 3.
Page 197: Table 96 Pre-Registration Sensor Troubleshooting Procedure
RAP 66 Pre-Registration Sensor Table 96 Pre-Registration Sensor Troubleshooting Procedure Step Actions and Questions PRE-REGISTRATION SENSOR ACTUATOR Go to Replace the Step 2. Pre- 1. Open the 500-Sheet Feeder Rear Cover. Registration 2. Manually actuate and deactuate the Pre-Registration Sensor Sensor Actuator.
Page 198 Table 96 Pre-Registration Sensor Troubleshooting Procedure (cont'd.) Step Actions and Questions “YES” FROM STEP 6 ABOVE Replace the Check for Print Engine continuity 1. Switch printer power OFF. Controller between 2. Remove the printer Left Side Cover [RRP 1.1, Board P/J132 and page 250] and the Print Engine Controller Board...
Page 199: Table 97 Hcs Motor Assembly Message Troubleshooting Procedure
RAP 67 HCS Motor Assembly Table 97 HCS Motor Assembly Message Troubleshooting Procedure Step Actions and Questions +24 VDC MEASUREMENT Go to Replace the Step 2. LVPS 1. Switch printer power OFF. [RRP 8.6, 2. Remove the HVPS Cover [RRP 1.6, page 255].
Page 200 Table 97 HCS Motor Assembly Message Troubleshooting Procedure (cont'd.) Step Actions and Questions SUSPECT COMPONENTS The following printer components and areas are associated with this specific problem. One or more of these components or areas may have failed partially or completely.
Page 201: Table 98 Hard Disk Formatting Troubleshooting Procedure
RAP 68 Disk Error Format Hard Disk Logic Control on the Print Engine Controller Board has sensed a problem with the hard disk and requires reformatting. Table 98 Hard Disk Formatting Troubleshooting Procedure Step Actions and Questions POWER OFF 1. Switch printer OFF and wait 20 - 30 seconds before proceeding with sub-step 2.
Page 202: Table 99 Erratic Printer Operation Troubleshooting Procedure
RAP 69 Erratic Printer Operation The printer has a variety of problems that are not identified by displayed error codes or messages. Problems may range from incomplete or garbled display text to intermittent power shutdowns. Table 99 Erratic Printer Operation Troubleshooting Procedure Step Actions and Questions PRINTER OPERATING ENVIRONMENT CHECK Go to...
Page 203 Table 99 Erratic Printer Operation Troubleshooting Procedure (cont'd.) Step Actions and Questions RETEST Go to Go to Step 12. Step 7. 1. Switch printer power OFF. 2. Reconnect P/J168 to the LVPS Assembly. 3. Switch printer power ON, entering Diagnostics mode. 4.
Page 204 Table 99 Erratic Printer Operation Troubleshooting Procedure (cont'd.) Step Actions and Questions ELECTRICAL NOISE CHECK Go to Problem Step 14. solved. 1. Go to RAP 60 (Electrical Interference) and troubleshoot for a possible internal or external interference problem. 2. After you finish with RAP 60, return to this step and monitor printer operation.
Page 205: Image-Quality Troubleshooting
Image-Quality Troubleshooting Introduction This section contains image-quality repair procedures to assist in correcting image-quality defects. These procedures provide defect samples, definitions and specifications to help identify the type of defect that exists, the test pattern to use, and actions required to correct the defects. Throughout these procedures, the term “vertical”...
Page 206: Image-Quality Defect Definitions
Image-Quality Defect Definitions The System Controller Test Print is used to evaluate each of the print-quality parameters. Each area of the test pattern is used for a print-quality parameter. The areas and the print-quality parameters are listed in Image-Quality Checkout. Table 100 Image-Quality Defect Definitions Defect Definitions Go To:...
Page 207: Figure 18 Light Prints
RAP 70 Light (Undertoned) Prints The overall image density is too light. Figure 18 Light Prints Table 101 Light (Undertoned) Prints Troubleshooting Procedure Step Actions and Questions INITIAL ACTIONS Inspect the printer paper path for items such as staples, paper clips, paper scraps and/or other debris. Check the installation of the Print Cartridge.
Page 208 Table 101 Light (Undertoned) Prints Troubleshooting Procedure (cont'd.) Step Actions and Questions METAL GROUNDING CONTACT INSPECTION Go to Reform or Step 5. clean the 1. Remove the Print Cartridge. metal 2. Inspect the metal contacts on the Right Print Cartridge contacts so Guide.
Page 209 Table 101 Light (Undertoned) Prints Troubleshooting Procedure (cont'd.) Step Actions and Questions SUSPECT COMPONENTS The following printer components and areas are associated with this specific problem. One or more of these components or areas may have failed partially or completely. If you cannot isolate this problem using the steps in this Repair Analysis Procedure, replace each component or troubleshoot each area listed below, one at a time, until you isolate and solve the problem.
Page 210: Figure 19 Blank Prints
RAP 71 Blank Prints No visible image anywhere on the output print. Figure 19 Blank Prints Table 102 Blank Prints Troubleshooting Procedure Step Actions and Questions INITIAL ACTIONS Inspect the printer paper path for items such as staples, paper clips, paper scraps and/or other debris. Check the installation of the Print Cartridge.
Page 211 Table 102 Blank Prints Troubleshooting Procedure (cont'd.) Step Actions and Questions PRINT CARTRIDGE REPLACEMENT Problem Go to solved. Step 5. 1. Install a new Print Cartridge. 2. Run a test print. Is there a normal image on the paper? METAL CONTACT INSPECTION Go to Reform or Step 6.
Page 212: Figure 20 Spots
RAP 72 Spots There are spots of toner randomly scatter on the page. Figure 20 Spots Table 103 Spots Troubleshooting Procedure Step Actions and Questions INITIAL ACTIONS Check that the paper supply is clean, dry and fresh (recycled paper may have spots). Inspect the printer paper path for items such as staples, paper clips, paper scraps and/or other debris.
Page 213 Table 103 Spots Troubleshooting Procedure (cont'd.) Step Actions and Questions FUSER INSPECTION Go to Replace the Step 6. Fuser 1. Open the Exit Assembly. Assembly Warning: If the printer has been powered ON, [RRP 5.1, the Fuser will be hot. Use extreme care page 288].
Page 214: Figure 21 Horizontal (Scan) Deletions
RAP 73 Horizontal (Scan) Deletions A deletion is an area of the print where the image is missing or extreme light. Horizontal deletions extend across the page in the scan direction. Figure 21 Horizontal (Scan) Deletions Table 104 Horizontal (Scan) Deletions Troubleshooting Procedure Step Actions and Questions INITIAL ACTIONS Inspect the printer paper path for items such as...
Page 215 Table 104 Horizontal (Scan) Deletions Troubleshooting Procedure (cont'd.) Step Actions and Questions PRINT CARTRIDGE REPLACEMENT Go to Problem Step 6. solved. 1. Install a new Print Cartridge. 2. Run a Test Print. Are horizontal deletions still present? BIAS TRANSFER ROLLER (BTR) INSPECTION Go to Replace the Step 7.
Page 216 Table 104 Horizontal (Scan) Deletions Troubleshooting Procedure (cont'd.) Step Actions and Questions SUSPECT COMPONENTS The following printer components and areas are associated with this specific problem. One or more of these components or areas may have failed partially or completely. If you cannot isolate this problem using the steps in this Repair Analysis Procedure, replace each component or troubleshoot each area listed below, one at a time, until you isolate and solve the problem.
Page 217: Figure 22 Vertical (Process) Deletions
RAP 74 Vertical (Process) Deletions A deletion is an area of the print where the image is missing or extremely light. Vertical band deletions are deletions which extend across the page in the process direction. Figure 22 Vertical (Process) Deletions Table 105 Vertical (Process) Deletions Troubleshooting Procedure Step Actions and Questions...
Page 218 Table 105 Vertical (Process) Deletions Troubleshooting Procedure (cont'd.) Step Actions and Questions BIAS TRANSFER ROLLER (BTR) INSPECTION Go to Replace the Step 7. Inspect the BTR Assembly for contamination and wear. Assembly Is the BTR free of contamination and wear? [RRP 7.6, page 304].
Page 219: Figure 23 Spot Deletions
RAP 75 Spot Deletions Solid areas are marked with irregular white areas. Figure 23 Spot Deletions Table 106 Spot Deletions Troubleshooting Procedure Step Actions and Questions INITIAL ACTIONS 1. Check that the paper supply is dry and fresh. 2. Inspect the printer paper path for items such as staples, paper clip, paper scraps and/or debris.
Page 220 Table 106 Spot Deletions Troubleshooting Procedure (cont'd.) Step Actions and Questions FUSER INSPECTION Go to Replace the Step 6. Fuser 1. Open the Exit Assembly. Assembly Warning: If the printer has been powered ON, [RRP 5.1, the Fuser will be hot. Use extreme care page 288].
Page 221: Figure 24 Vertical (Process) Streaks
RAP 76 Vertical (Process) Streaks Extraneous dark lines/bands in the process direction (in the direction of paper travel). Figure 24 Vertical (Process) Streaks Table 107 Vertical (Process) Streaks Troubleshooting Procedure Step Actions and Questions INITIAL ACTIONS Check that the paper supply is dry and fresh. Inspect the printer paper path for items such as staples, paper clips, paper scraps and/or debris.
Page 222 Table 107 Vertical (Process) Streaks Troubleshooting Procedure (cont'd.) Step Actions and Questions PRINT CARTRIDGE REPLACEMENT Problem Go to solved. Step 5. 1. Install a new Print Cartridge. 2. Run a Test Print. Are the vertical streaks gone? LASER BEAM PATH INSPECTION Go to Remove any Step 6.
Page 223: Figure 25 Horizontal (Scan) Streaks
RAP 77 Horizontal (Scan) Streaks There are black lines running horizontally across the page (at a right angle to the direction of paper travel). Figure 25 Horizontal (Scan) Streaks Table 108 Horizontal (Scan) Streaks Troubleshooting Procedure Step Actions and Questions INITIAL ACTIONS Check that the paper supply is dry and fresh.
Page 224 Table 108 Horizontal (Scan) Streaks Troubleshooting Procedure (cont'd.) Step Actions and Questions METAL CONTACT INSPECTION Go to Step 6. Reform or clean the 1. Remove the Print Cartridge. metal contact 2. Inspect the metal contact on the Right Print Cartridge so that it Guide.
Page 225 Table 108 Horizontal (Scan) Streaks Troubleshooting Procedure (cont'd.) Step Actions and Questions FUSER INSPECTION Go to Replace the RAP 60, Fuser 1. Open the Exit Assembly. page 157 Assembly Warning: If the printer has been powered ON, [RRP 5.1, the Fuser will be hot. Use extreme page 288].
Page 226: Figure 26 Residual Image
RAP 78 Residual Image The image from a previous print, which was not removed during the cleaning process, has been developed on the current print. Figure 26 Residual Image Table 109 Residual Image Troubleshooting Procedure Step Actions and Questions INITIAL ACTIONS Inspect the printer paper path for items such as staples, paper clips, paper scraps and/or debris.
Page 227 Table 109 Residual Image Troubleshooting Procedure (cont'd.) Step Actions and Questions FUSER INSPECTION Go to Replace the Step 6. Fuser 1. Open the Exit Assembly. Assembly Warning: If the printer has been powered ON, [RRP 5.1, the Fuser will be hot. Use extreme care page 288].
Page 228: Figure 27 Black Prints
RAP 79 Black Prints A totally black output print. There is toner on the paper with no visible image. s5400-038 Figure 27 Black Prints Table 110 Black Prints Troubleshooting Procedure Step Actions and Questions INITIAL ACTIONS Replace the Go to system Step 2.
Page 229: Figure 28 Background
RAP 80 Background There is toner contamination on all or part of the page. The contamination appears as a very light gray dusting. Figure 28 Background Table 111 Background Troubleshooting Procedure Step Actions and Questions INITIAL ACTIONS Inspect the printer paper path for items such as staples, paper clips, paper scraps and/or debris.
Page 230 Table 111 Background Troubleshooting Procedure (cont'd.) Step Actions and Questions PAPER TRANSPORT ASSEMBLY BAFFLE Go to Remove and GROUNDING Step 5. clean the contact 1. Remove the Print Cartridge. areas of the 2. Check for continuity from the front opening, between metal parts of the Paper Transport Assembly and the Paper printer frame.
Page 231: Figure 29 Uneven Density
RAP 81 Uneven Density Image Density varies within the page in either direction. s5400_363 Figure 29 Uneven Density Table 112 Uneven Density Troubleshooting Procedure Step Actions and Questions INITIAL ACTIONS Load fresh, dry paper. Check that the correct Print Cartridge is properly installed and not empty.
Page 232 Table 112 Uneven Density Troubleshooting Procedure (cont'd.) Step Actions and Questions FUSER INSPECTION Go to Replace the Step 6. Fuser 1. Open the Exit Assembly. Assembly Warning: If the printer has been powered ON, [RRP 5.1, the Fuser will be hot. Use extreme care page 288].
Page 233: Figure 30 Skewed Image
RAP 82 Skewed Image The image is not parallel to the edges of the print sheet. Figure 30 Skewed Image Table 113 Skewed Image Troubleshooting Procedure Step Actions and Questions INITIAL ACTIONS Check the paper tray(s) installation and the paper in the tray(s).
Page 234 Table 113 Skewed Image Troubleshooting Procedure (cont'd.) Step Actions and Questions DUPLEX ASSEMBLY INSPECTION Clean, Go to Step 6. repair or 1. Inspect the Duplex Assembly for worn or replace the contaminated parts or rollers. Duplex 2. Inspect the Duplex Assembly paper path for obstructions.
Page 235 Table 113 Skewed Image Troubleshooting Procedure (cont'd.) Step Actions and Questions PAPER TRANSPORT ASSEMBLY INSPECTION Go to Clean, repair Step 34 or replace Inspect the Paper Transport Assembly for wear, the Paper obstructions or contamination. Transport Is the Paper Transport Assembly free of wear, Assembly obstructions and contamination? [RRP 4.1,...
Page 236 Table 113 Skewed Image Troubleshooting Procedure (cont'd.) Step Actions and Questions TRAY 1 ENVELOPE FEED ROLLERS Go to Clean or INSPECTION Step 21. replace the Tray 1 Inspect the Tray 1 Envelope Feed Rollers for wear or Envelope contamination. Feed Rollers Are the Tray 1 Envelope Feed Rollers free of as necessary wear and contamination?
Page 237 Table 113 Skewed Image Troubleshooting Procedure (cont'd.) Step Actions and Questions FEED CHUTE INSPECTION Go to Clean or Step 29. replace the Inspect the Feed Chute between Tray 2 and Tray 1 for Feed Chute obstructions and contamination. as necessary Is the Feed Chute free of obstructions and [RRP 3.1, contamination?
Page 238 Table 113 Skewed Image Troubleshooting Procedure (cont'd.) Step Actions and Questions SUSPECT COMPONENTS The following printer components and areas are associated with this specific problem. One or more of these components or areas may have failed partially or completely. If you cannot isolate this problem using the steps in this Repair Analysis Procedure, replace each component or troubleshoot each area listed below, one at a time, until you isolate and solve the problem.
Page 239: Figure 31 Damaged Print
RAP 83 Damaged Print The printed page comes out of the printer either wrinkled, creased, or torn. Figure 31 Damaged Print Table 114 Damaged Print Troubleshooting Procedure Step Actions and Questions INITIAL ACTIONS Check that the paper supply is dry and fresh. Check that rollers and other components in the paper path are clean and unobstructed.
Page 240 Table 114 Damaged Print Troubleshooting Procedure (cont'd.) Step Actions and Questions PAPER PATH INSPECTION Go to Remove Step 6. obstructions Inspect the paper path between the feed tray and the exit tray for contamination or obstructions. contamination Is the paper path free of obstructions and from the contamination? paper path.
Page 241: Figure 32 Registration
(page 231). adjustment Is the printer registration set correctly? procedure [page 231]. NEW PRINT JOB Problem Contact solved. Xerox Have the customer send another print job. Customer Is the print image properly registered? Support. Phaser 5400 Laser Printer Service Guide...
Page 242 Table 115 Registration Troubleshooting Procedure (cont'd.) Step Actions and Questions “YES” FROM STEP 3 ABOVE The following printer components and areas are associated with this specific problem. One or more of these components or areas may have failed partially or completely.
Page 243: Figure 33 Skips / Smears
RAP 85 Skips / Smears A skip is a disturbance of the image that lengthens or shortens the image in the process direction. A smear is a darkening across the process direction or a repeat of the image in the process direction. Figure 33 Skips / Smears Table 116 Skips / Smears Troubleshooting Procedure Step...
Page 244: Figure 34 Unfused Image
RAP 86 Unfused Image The printed image is not fully fused to the paper. The image rubs off easily. Figure 34 Unfused Image Table 117 Unfused Image Troubleshooting Procedure Step Actions and Questions INITIAL ACTIONS Ensure that the paper is within specification. PAPER REPLACEMENT Go to Problem...
Page 245 Table 117 Unfused Image Troubleshooting Procedure (cont'd.) Step Actions and Questions FUSER INSPECTION Go to Replace the Step 7. Fuser 1. Open the Exit Assembly. Assembly Warning: If the printer has been powered ON, [RRP 5.1, the Fuser will be hot. Use extreme care page 288].
Page 246: Table 118 Resolution Troubleshooting Procedure
RAP 87 Resolution The two pixel lines and halftone patches cannot be reproduced clearly on the print. Table 118 Resolution Troubleshooting Procedure Step Actions and Questions INITIAL ACTIONS Check that the print density is set to the default value. PRINT CARTRIDGE REPLACEMENT Problem Go to solved.
Page 247 Blank Page Phaser 5400 Laser Printer Service Guide...
Page 248: Nvram Adjustments
Diagnostics, Test Prints, Service Tests and NVRAM Adjustments The printer has four modes of operation: On-Line Mode Power Saver Mode Diagnostics Mode Menu Mode On-Line Mode On-Line is the printer’s normal operating mode. In this mode, the printer is on line, under the control of the System Controller Board, and ready to generate output.
Page 249: Menu Mode
Diagnostics Diagnostics available to the technician are built into the System Controller Board. Test prints are available from the System Controller (in normal or On-Line Mode) and the Print Engine Controller Board (in Diagnostics mode) to test functionality and make adjustments. You can use Diagnostics to: Test the operation of printer switches and sensors.
Page 250: Entering Diagnostics Mode
Press and hold buttons [2] and [6] on the Control Panel while you switch ON printer main power. Continue holding until IOT? appears in the display (approximately 20 seconds). Xerox Phaser™ 5400 On Line Form Feed ! Fault Data On Line...
Page 251: System Controller Board Error (Blink) Codes
DIMM board 2 failure DIMM 3 0103 0103 - DIMM3 DIMM board 3 failure 2000 2000 - XIE Xerox Image Enhancement RAM, PWPM OR VDMA failure Memory 5000 5000 - MEMORY None Memory size not large enough to load the system software...
Page 252: Recommended Corrective Action
Recommended Corrective Action For most of the blink code errors, the System Controller Board should be replaced. For Hard Disk and DIMM slot errors, the cause of the error could be either the System Controller Board or the plugged-in accessory. If the blink error points to a (HD or RAM) component that is not even installed, the System Controller is to blame.
Page 253: Diagnostics Menu Map
Diagnostics Menu Map The table below summarizes the operation of the Control Panel keys in Diagnostics Mode. Note: An asterisk (*) indicates a factory default setting. Table 121 Diagnostics Menu Map Press [1] or [5] to display: ⇒ Main Menu Test Print Press [2] or [6] to display: ⇓...
Page 254 Table 121 Diagnostics Menu Map (cont'd.) Press [1] or [5] to display: ⇒ Main Menu Component Test Press [2] or [6] to display: ⇓ Press [3] or [7] to display: ⇓ Component Test Print Counter Sensor Input Fuser Temp Set Fuser Temp Read IOT ROM Checksum MBF Feed Sol...
Page 255: System Controller Board Test Prints
System Controller Board Test Prints Note: System Controller Board Test Prints are available from the Main Menu without entering Diagnostics Mode. A variety of test prints are available to aid in determining the quality of output from the printer and to assist in troubleshooting problems. Most test prints are available from the Main Menu (in Menu Mode).
Page 256: System Controller Board Test Print
System Controller Board Test Print The “Test Print” is a multi-purpose print displaying a wide variety of objects including text, multi-positional thin/thick lines, black painted areas, gray scale, fine alignment graduations to facilitate checking registration, lead edge and side edge alignment, etc. Normally, running this test print delivers two identical pages.
Page 257: Ps Font List
PS Font List The PS Font List produces a list of internally available PostScript fonts. Use this single test page for a print quality check. While in the menu mode, press [1] or [5] until “Print Menu” is displayed. Press [2] or [6] until “PS Font List” is displayed. Press [4] and the PS font list is printed.
Page 258: Print Engine Controller Board Test Print
Print Engine Controller Board Test Print Enter Diagnostics Mode. Refer to page 221 for instructions on entering Diagnostics page 224 for navigating the Diagnostics menu. The Print Engine Controller Board Test Print is used to bypass the System Controller Board. The “Print Pattern” test print is an excellent tool for isolating and diagnosing printer feed, paper path, registration and image-quality problems.
Page 259: Analyzing Test Prints
Analyzing Test Prints Test prints provide several uses in troubleshooting printer problems. Isolating problems to either the Print Engine Controller Board or to the System Controller Board and host software. Locating feed and paper transport problems. Detecting print-quality and image registration problems. Note: Always check Fault History and appropriate RAPs before initiating additional tests or investigations.
Page 260: Registration
Registration Purpose To adjust the registration in the scan direction and the process direction. To Set Default Tray Enter Diagnostics Mode and press [1] or [5] to scroll to “Main Menu / Test Print”. Ensure the paper guides are properly set to match the paper size. Press [2] or [6] to scroll to “Input Tray”.
Page 261: Figure 35 Registration Test Pattern
Note: Each increment of change equals approximately one-half millimeter. In the scan direction increasing the value moves the image to the right and decreasing the value moves the image to the left. In the process direction increasing the value moves the image toward the trail edge and decreasing the value moves the image towards the lead edge.
Page 262: Nvram Configuration (Nvm Config)
NVRAM Configuration (NVM Config) The Non-Volatile RAM (NVRAM, or NVM) stores critical control parameters of the mechanical and electromagnetic components of the printer. The following allows service personnel to view status and/or change NVM settings. Notes: Information displayed here requires entering Diagnostics Mode.
Page 263: Table 124 Phaser 5400 Fuser Run Temp Conversion Table
Table 123 NVRAM Configuration Menu (cont'd.) Scan Tray 2 [3] or [7] 0 ~ 7 Press [3] or [7] to scroll to desired setting. Press [4] to set and exit. Scan Tray 3 [3] or [7] 0 ~ 7 Press [3] or [7] to scroll to desired setting.
Page 264: Table 125 Component Tests
Component Tests Note: Before entering Diagnostics Mode, it is recommended to print a Configuration Sheet for reference. Component Control Output tests are used to aid in verifying proper component operation, identifying problems and isolating faulty components. Access the Component Test sequence from Diagnostics Mode. Refer to Entering Diagnostics Mode on page 221 for how to enter Diagnostics Mode.
Page 265 Table 125 Component Tests (cont'd.) Press [1] or [5] to display: Main Menu Component Test Press [2] or [6] Displayed Turn -On to display: ⇓ Result: ⇓ Duration Procedure / Comment IOT ROM IOT ROM 3 sec. 1. Press [4] to display for duration. 2.
Page 266 Table 125 Component Tests (cont'd.) Press [1] or [5] to display: Main Menu Component Test Press [2] or [6] Displayed Turn -On to display: ⇓ Result: ⇓ Duration Procedure / Comment Detack Saw 5 min. 1. Press [4] to start test. 2.
Page 267 Table 125 Component Tests (cont'd.) Press [1] or [5] to display: Main Menu Component Test Press [2] or [6] Displayed Turn -On to display: ⇓ Result: ⇓ Duration Procedure / Comment Dev Bias AC 5 min. 1. Press [4] to start test. 2.
Page 268: Reset Menu
To enter the Reset Menu, make certain the printer is switched OFF. Press and hold [0] and [4] while switching printer power ON. Continue pressing [0] and [4] until asterisks begin appearing across the Control Panel display (LCD). Xerox Phaser™ 5400 On Line Form Feed...
Page 269 Item Down Value Down s5400-350 The Maintenance Kit is a customer purchased, Customer-Replaceable Unit (CRU). The interval for replacement is 200K prints. For Maintenance Kit part numbers, see Xerox Supplies and Accessories in the FRU Parts Lists on page 428.
Page 270: Scheduled Maintenance
Maintenance and Cleaning Scheduled Maintenance The Phaser 5400 Laser Printer is designed and tested to require little maintenance. A User Maintenance Kit (P/N 109R00521 for 110 volt printers and 109R00522 for 220 volt printers) contains: Replacement Fuser Bias Transfer Roller Cleaning Cloth The printer will tell the user when to install the User Maintenance Kit (200,000 prints).
Page 271: General Cleaning (If Needed)
Areas to inspect and clean while in the printer: Feed rollers for wear, dirt/grime/dust Paper Bins for dust, lint, debris Paper paths for debris Laser print cartridge area for spilled toner Cabinet interior Multi-sheet Bypass Feeder roller and retard pad Duplex Unit rollers and paper path All exit rollers General overall appearance for signs of abuse, wear, unfriendly environment...
Page 272 Clean the laser window with puffs of air from the suction bulb. Alternately, you can vacuum the window clean. Vacuum out the interior of the printer. Carefully clean the area around the Bias Transfer Roller for impacted toner. Remove the Bias Transfer Roller. Vacuum any toner visible.
Page 273 Blank Page Phaser 5400 Laser Printer Service Guide...
Page 274: Contents - Removal And Replacement Procedures
FRU Removal / Replacement Procedures (RRPs) This section contains the removal and replacement procedures that enables the Service Representative to restore the product to within specification after fault isolation. Not all Replacement Procedures are included in this Quick Reference Guide. In most cases, to reinstall a part, simply reverse the Removal Procedure shown.
Page 275 RRP 3.6 Tray 1 Left Guide Assembly ................... 279 RRP 3.7 CRUM Board ......................281 RRP 3.8 MBF Assembly Position Sensor ................282 RRP 4.1 Paper Transport Assembly ..................283 RRP 4.2 Registration Actuator ....................285 RRP 4.3 Registration Clutch ....................286 RRP 4.4 Registration Sensor ....................
Page 276 RRP 11.19 No Paper Sensor ....................348 RRP 11.20 No Paper Sensor Actuator ..................350 RRP 11.21 Preregistration Sensor..................351 RRP 12.1 Removing the 2000-Sheet Feeder ................352 RRP 12.2 Left Side Cover......................354 RRP 12.3 Upper Rear Cover ....................355 RRP 12.4 Lower Rear Cover ....................356 RRP 12.5 Right Side Cover ....................357 RRP 12.6 Front Cover ......................358 RRP 12.7 Tray Assembly.......................359...
Page 277: Work Notes
Introduction This repair subsection contains instructions for removal and replacement tasks. A removal and/or replacement task is included when it is not obvious how components are removed and replaced, or when special conditions (such as an adjustment) must be met during these tasks. Step-by-step removal procedures for a specific component or assembly are provided.
Page 278: Notations In The Rrp Text
Preparation Before you begin any Removal and Replacement Procedure: Switch OFF the printer power and disconnect the power cord from the AC wall outlet. Remove the Laser Print (EP) Cartridge and protect it from exposure to light by covering it with a piece of opaque plastic sheeting or by placing it in a light-tight container.
Page 279: Figure 36 Removing The Left Side Cover
Repair Procedures RRP 1.1 Left Side Cover (See PL 1.1 Covers) Figure 36 Removing the Left Side Cover Removal Warning: Switch off the power and disconnect the Power Cord. Slide the Left Cover toward the rear of the printer. Remove the Left Side Cover. Replacement Reinstall the components in the reverse order.
Page 280: Figure 37 Right Side Cover
RRP 1.2 Right Side Cover (See PL 1.1 Covers) Figure 37 Right Side Cover Removal Warning: Switch off the power and disconnect the Power Cord. Open the Rear Cover. Remove the HCS, if installed (RRP 10.1 1000-Sheet High Capacity Stacker [HCS]). Open the Top Cover and remove the Print Cartridge.
Page 281: Figure 38 Top Cover Assembly
RRP 1.3 Top Cover Assembly (See PL 1.1 Covers) Figure 38 Top Cover Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Open the Rear Cover. Remove the HCS, if installed (RRP 10.1 1000-Sheet High Capacity Stacker [HCS]). Open the Top Cover and remove the Print Cartridge.
Page 282: Figure 39 Front Cover
RRP 1.4 Front Cover (See PL 1.1 Covers) Figure 39 Front Cover Removal Warning: Switch off the power and disconnect the Power Cord. Open the Rear Cover. Remove the HCS, if installed (RRP 10.1 1000-Sheet High Capacity Stacker [HCS]). Open the Top Cover and remove the Print Cartridge. Cover the cartridge to protect it from light.
Page 283: Figure 40 Lower Left Cover
RRP 1.5 Lower Left Cover (See PL 1.1 Covers) Figure 40 Lower Left Cover Removal Warning: Switch off the power and disconnect the Power Cord. Remove the Left Side Cover (RRP 1.1 Left Side Cover). Remove the two screws that secure the Lower Left Cover to the printer. Remove the Lower Left Cover.
Page 284: Figure 41 Hvps Cover
RRP 1.6 HVPS Cover (See PL 7.1 Frame & Drives) Figure 41 HVPS Cover Removal Warning: Switch off the power and disconnect the Power Cord. Remove the Rear Cover (RRP 1.9 Rear Cover). Remove the Duplex Assembly, if installed (RRP 9.1 Duplex Assembly). Remove the screw that secures the Left Duplex Stopper to the printer.
Page 285: Figure 42 Lower Rear Cover
RRP 1.7 Lower Rear Cover (See PL 7.1 Frame & Drives) Figure 42 Lower Rear Cover Removal Warning: Switch off the power and disconnect the Power Cord. Remove the four screws that secure the Lower Rear Cover to the printer. Remove the Lower Rear Cover.
Page 286: Figure 43 Mbf Gear Cover
RRP 1.8 MBF Gear Cover (See PL 4.2 Paper Handler) Figure 43 MBF Gear Cover Removal Warning: Switch off the power and disconnect the Power Cord. Remove the MBF Assembly (RRP 2.1 Multi-sheet Bypass Feeder (MBF) Assembly). Remove the screw that secures the Left MBF Gear Cover to the left side of the Paper Handler.
Page 287: Figure 44 Rear Cover
RRP 1.9 Rear Cover (See PL 6.1 Rear Cover Assembly With Fuser) Figure 44 Rear Cover Removal Warning: Switch off the power and disconnect the Power Cord. Open the Rear Cover. Disconnect P/J527 and P/J528 and release clamp. Remove the two screws that secure the Rear Cover support straps to the Rear Cover.
Page 288: Figure 45 Mbf Paper Handler Assembly
RRP 2.1 Multi-sheet Bypass Feeder (MBF) Assembly (See PL 4.2 Paper Handler) Figure 45 MBF Paper Handler Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Remove Tray 1. Open and extend the MBF Assembly to the paper load position. Remove the screw that secures the cover to the left side of the MBF Assembly.
Page 289: Figure 46 Mbf Left Tray Stop
Figure 46 MBF Left Tray Stop Figure 47 MBF Right Tray Stop Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide...
Page 290: Figure 48 Mbf Feed Roller Assembly
RRP 2.2 MBF Feed Rollers (See PL 4.1 Multi-sheet Bypass Feeder (MBF) Assembly) Figure 48 MBF Feed Roller Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Remove the MBF Assembly (RRP 2.1 Multi-sheet Bypass Feeder (MBF) Assembly).
Page 291: Figure 49 Mbf Tray 1 Turn Roller Clutch Assembly
RRP 2.3 MBF Tray 1 Turn Roller Clutch Assembly (See PL 4.1 Multi-sheet Bypass Feeder (MBF) Assembly) Figure 49 MBF Tray 1 Turn Roller Clutch Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Remove the MBF Assembly (RRP 2.1 Multi-sheet Bypass Feeder (MBF) Assembly).
Page 292: Figure 50 Tray 1 Turn Roller Assembly
RRP 2.4 Tray 1 Turn Roller Assembly (See PL 4.1 Multi-sheet Bypass Feeder (MBF) Assembly) Figure 50 Tray 1 Turn Roller Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Remove the MBF Assembly (RRP 2.1 Multi-sheet Bypass Feeder (MBF) Assembly).
Page 293: Figure 51 Mbf Pick Up Shaft
RRP 2.5 MBF Retard Holder Assembly (See PL 4.2 Paper Handler) Figure 51 MBF Pick Up Shaft Removal Warning: Switch off the power and disconnect the Power Cord. Remove the MBF Assembly (RRP 2.1 Multi-sheet Bypass Feeder (MBF) Assembly). Remove the MBF Gear Cover (RRP 1.8 MBF Gear Cover). Remove the Pick-up Spring from the MBF Pick-up Gear.
Page 294: Figure 52 Mbf Tray Assembly
Figure 52 MBF Tray Assembly Figure 53 MBF Retard Holder Assembly Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide...
Page 295: Figure 54 Tray 1 No Paper Sensor Assembly
RRP 2.6 Tray 1 No Paper Sensor Assembly (See PL 4.2 Paper Handler) Figure 54 Tray 1 No Paper Sensor Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Remove the MBF Assembly (RRP 2.1 Multi-sheet Bypass Feeder (MBF) Assembly).
Page 296: Figure 55 Mbf No Paper Sensor Assembly
RRP 2.7 MBF No Paper Sensor Assembly (See PL 4.2 Paper Handler) Figure 55 MBF No Paper Sensor Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Remove the MBF Assembly (RRP 2.1 Multi-sheet Bypass Feeder (MBF) Assembly).
Page 297: Figure 56 Mbf Tray Assembly
Figure 56 MBF Tray Assembly Figure 57 MBF No Paper Sensor Assembly Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide...
Page 298: Figure 58 Mbf Feed Solenoid
RRP 2.8 MBF Feed Solenoid (See PL 4.2 Paper Handler) Figure 58 MBF Feed Solenoid Removal Warning: Switch off the power and disconnect the Power Cord. Remove the MBF Assembly (RRP 2.1 Multi-sheet Bypass Feeder (MBF) Assembly). Remove the MBF Gear Cover (RRP 1.8 MBF Gear Cover). Remove the Pick-up Spring from the MBF Pick-up Gear.
Page 299: Figure 59 Tray 1 Feed Solenoid
RRP 2.9 Tray 1 Feed Solenoid (See PL 4.2 Paper Handler) Figure 59 Tray 1 Feed Solenoid Removal Warning: Switch off the power and disconnect the Power Cord. Remove the MBF Assembly (RRP 2.1 Multi-sheet Bypass Feeder (MBF) Assembly). Remove the MBF Gear Cover (RRP 1.8 MBF Gear Cover). Remove the Pick-up Spring from the Tray 1 Pick-up Gear.
Page 300: Figure 60 Tray 1 Feed Roller
RRP 2.10 Tray 1 Feed Roller (See PL 4.1 Multi-sheet Bypass Feeder (MBF) Assembly) Figure 60 Tray 1 Feed Roller Removal Warning: Switch off the power and disconnect the Power Cord. Remove the MBF Assembly (RRP 2.1 Multi-sheet Bypass Feeder (MBF) Assembly).
Page 301: Figure 61 Tray 1 Retard Holder Assembly
RRP 2.11 Tray 1 Retard Holder Assembly (See PL 3.1 Paper Feeder) Figure 61 Tray 1 Retard Holder Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Open the Top Cover and remove the Print Cartridge. Cover the cartridge to protect it from light.
Page 302: Figure 62 Rear Chute Assembly
RRP 3.1 Retard Chute Assembly (See PL 3.1 Paper Feeder) Figure 62 Rear Chute Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Open the Top Cover and remove the Print Cartridge. Cover the cartridge to protect it from light.
Page 303: Figure 63 Rear Chute Assembly
RRP 3.2 Rear Chute Assembly (See PL 3.1 Paper Feeder) Figure 63 Rear Chute Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Open the Top Cover and remove the Print Cartridge. Cover the cartridge to protect it from light.
Page 304: Figure 64 Lower Turn Roller Assembly
RRP 3.3 Lower Turn Roller Assembly (See PL 3.1 Paper Feeder) Figure 64 Lower Turn Roller Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Open the Top Cover and remove the Print Cartridge. Cover the cartridge to protect it from light.
Page 305: Figure 65 Tray 1 Low Paper Sensor
RRP 3.4 Tray 1 Low Paper Sensor (See PL 3.1 Paper Feeder) Figure 65 Tray 1 Low Paper Sensor Removal Warning: Switch off the power and disconnect the Power Cord. Open the Top Cover and remove the Print Cartridge. Cover the cartridge to protect it from light.
Page 306: Figure 66 Paper Level Indicator Arm
RRP 3.5 Tray 1 Right Guide Assembly (See PL 3.1 Paper Feeder) Figure 66 Paper Level Indicator Arm Removal Warning: Switch off the power and disconnect the Power Cord. Open the Rear Cover. Open the Top Cover and remove the Print Cartridge. Cover the cartridge to protect it from light.
Page 307: Figure 67 Tray 1 Right Guide Assembly
13.Remove the four screws that secure the Tray 1 Right Guide Assembly to the printer. 14.Use a small screwdriver to pry up on the locking tab that locks the guide assembly to the bottom of the printer. 15.Remove the Tray 1 Right Guide Assembly. Figure 67 Tray 1 Right Guide Assembly Replacement Reinstall the components in the reverse order.
Page 308: Figure 68 Tray Left Guide Assembly
RRP 3.6 Tray 1 Left Guide Assembly (See PL 3.1 Paper Feeder) Figure 68 Tray Left Guide Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Open the Top Cover and remove the Print Cartridge. Cover the cartridge to protect it from light.
Page 309 Use a small screwdriver to pry up on the locking tab that locks the guide assembly to the bottom of the printer. Disconnect P/J202 and P/J127 from the guide assembly. 10.Remove the Tray 1 Left Guide Assembly. Replacement Reinstall the components in the reverse order. Note: Ensure that all alignment pins are properly inserted in the frame holes before replacing the six screws.
Page 310: Figure 69 Removing The Crum Board
RRP 3.7 CRUM Board (See PL 8.1 Xerographics) Left CRU Guide CRUM Board Laser Safety Switch CRUM Antenna s5400-361 Figure 69 Removing the CRUM Board Removal Warning: Switch off the power and disconnect the Power Cord. Remove the Left CRU Guide (RRP 7.5 Left Print Cartridge Guide Assembly). Disengage the two hooks securing the CRUM Board to the CRU Guide.
Page 311: Figure 70 Mbf Assembly Position Sensor
RRP 3.8 MBF Assembly Position Sensor (See PL 4.2 Paper Handler) Figure 70 MBF Assembly Position Sensor Removal Warning: Switch off the power and disconnect the Power Cord. Open the Top Cover and remove the Print Cartridge. Cover the cartridge to protect it from light.
Page 312: Figure 71 Paper Transport Assembly
RRP 4.1 Paper Transport Assembly (See PL 5.1 Paper Transport) Figure 71 Paper Transport Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Open the Rear Cover. Remove the Fuser Assembly (RRP 5.1 Fuser Assembly). Open the Top Cover and remove the Print Cartridge. Cover the cartridge to protect it from light.
Page 313 12.Disconnect P/J222 from the bottom of the Registration Clutch. 13.Remove the four screws that secure the Paper Transport Assembly to the printer. Note: When removing the Paper Transport Assembly, do not touch the BTR Roller with your hands. Oil from your hands can cause copy quality problems.
Page 314: Figure 72 Registration Actuator
RRP 4.2 Registration Actuator (See PL 5.1 Paper Transport) Figure 72 Registration Actuator Removal Warning: Switch off the power and disconnect the Power Cord. Open the Rear Cover. Remove the Fuser Assembly (RRP 5.1 Fuser Assembly). Open the Top Cover and remove the Print Cartridge. Cover the cartridge to protect it from light.
Page 315: Figure 73 Registration Clutch
RRP 4.3 Registration Clutch (See PL 5.1 Paper Transport) Figure 73 Registration Clutch Removal Warning: Switch off the power and disconnect the Power Cord. Open the Rear Cover. Remove the Fuser Assembly (RRP 5.1 Fuser Assembly). Open the Top Cover and remove the Print Cartridge. Cover the cartridge to protect it from light.
Page 316: Figure 74 Registration Sensor
RRP 4.4 Registration Sensor (See PL 5.1 Paper Transport) Figure 74 Registration Sensor Removal Warning: Switch off the power and disconnect the Power Cord. Open the Rear Cover. Remove the Fuser Assembly (RRP 5.1 Fuser Assembly). Open the Top Cover and remove the Print Cartridge. Cover the cartridge to protect it from light.
Page 317: Figure 75 Fuser Assembly
RRP 5.1 Fuser Assembly (See PL 6.1 Rear Cover Assembly With Fuser) Figure 75 Fuser Assembly Removal Warnings: Switch off the power and disconnect the Power Cord. If the printer has been in operation, the Fuser may be hot. Caution: When handling the fuser, use care to prevent damage to the entrance guide.
Page 318: Figure 76 Lower Exit Chute
RRP 5.2 Stack Full Sensor (See PL 6.1 Rear Cover Assembly With Fuser) Figure 76 Lower Exit Chute Removal Warning: Switch off the power and disconnect the Power Cord. Open and remove the Rear Cover (RRP 1.9 Rear Cover). Remove the four screws that secure the Lower Exit Chute Assembly. Remove the assembly.
Page 319: Figure 77 Upper Exit Chute
Release the three locking tabs and remove the sensor from the holder. Disconnect P/J507 from the Stack Full Sensor. Figure 77 Upper Exit Chute Figure 78 Stack Full Sensor Replacement Reinstall the components in the reverse order. Note: The two shoulder screws go in the right end of the Lower Exit Chute Assembly (see Figure 76).
Page 320: Figure 79 Lower Exit Chute
RRP 5.3 Exit Roller Assembly (See PL 6.1 Rear Cover Assembly With Fuser) Figure 79 Lower Exit Chute Removal Warning: Switch off the power and disconnect the Power Cord. Open the Rear Cover. Remove the Rear Cover (RRP 1.9 Rear Cover). Remove the four screws that secure the Lower Exit Chute Assembly.
Page 321: Figure 80 Upper Exit Chute
Figure 80 Upper Exit Chute Figure 81 Upper Exit Roller Assembly Phaser 5400 Laser Printer Service Guide...
Page 322: Figure 82 Lower Exit Roller Assembly
Figure 82 Lower Exit Roller Assembly Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide...
Page 323: Figure 83 Stack Full Sensor Actuator
RRP 5.4 Stack Full Sensor Actuator (See PL 6.1 Rear Cover Assembly With Fuser) Figure 83 Stack Full Sensor Actuator Removal Warning: Switch off the power and disconnect the Power Cord. Open the Rear Cover. Remove the Rear Cover (RRP 1.9 Rear Cover). Remove the Stack Full Sensor (RRP 5.2 Stack Full Sensor).
Page 324: Figure 84 Shield Cover
RRP 6.1 Main Drive Gear Assembly (See PL 7.1 Frame & Drives) Figure 84 Shield Cover Removal Note: The Drive Gear Assembly includes both the Main Drive Motor Gear Assembly and Motor Assembly. Warning: Switch off the power and disconnect the Power Cord. Remove the Lower Rear Cover (RRP 1.7 Lower Rear Cover).
Page 325: Figure 85 Gear Drive Assembly
11.Disconnect CN2 from the Motor Drive PWB. 12.In the next step, there are arrows stamped into the metal indicating the eight screws to remove. 13.Remove the eight screws that secure the Gear Assembly to the printer. 14.Remove the Gear Assembly and Motor from the printer. Figure 85 Gear Drive Assembly Replacement Reinstall the components in the reverse order.
Page 326: Figure 86 Laser Cover
RRP 7.1 Laser Assembly (See PL 8.1 Xerographics) Figure 86 Laser Cover Removal Caution: These components are susceptible to electrostatic discharge. Observe all ESD procedures to avoid damage. Warning: Switch off the power and disconnect the Power Cord. Open the Rear Cover. Open the Top Cover and remove the Print Cartridge.
Page 327: Figure 87 Laser Assembly
Disconnect P/J112 and the in-line connector P/J114 from the Laser Assembly. Remove the four screws that secure the Laser Assembly to the printer. 10.Remove the Laser Assembly. Figure 87 Laser Assembly Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide...
Page 328: Figure 88 Right Print Cartridge Guide
RRP 7.2 Right Print Cartridge Guide Assembly (See PL 8.1 Xerographics) Figure 88 Right Print Cartridge Guide Removal Warning: Switch off the power and disconnect the Power Cord. Remove the Lower Rear Cover (RRP 1.7 Lower Rear Cover). Open and remove the Rear Cover (RRP 1.9 Rear Cover). Remove the Fuser Assembly (RRP 5.1 Fuser Assembly) Open the Top Cover and remove the Print Cartridge.
Page 329 Remove the Left Side Cover (RRP 1.1 Left Side Cover). Remove the Top Cover Assembly (RRP 1.3 Top Cover Assembly). Remove the HVPS Cover (RRP 1.6 HVPS Cover). Remove the BTR Assembly (RRP 7.6 Bias Transfer Roller [BTR] Assembly). Disconnect P/J186 (R) and P/J187 (W) from the HVPS PWB. 10.Disconnect P/J177 and P/J178 from the Fuser Interlock Switch.
Page 330: Figure 89 Toner Sensor Assembly
RRP 7.3 Toner Sensor Assembly (See PL 8.1 Xerographics) Figure 89 Toner Sensor Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Open the Top Cover and remove the Print Cartridge. Cover the cartridge to protect it from light. Disconnect P/J141.
Page 331: Figure 90 Top Cover Interlock Switch
RRP 7.4 Top Cover Interlock Switch (See PL 8.1 Xerographics) Figure 90 Top Cover Interlock Switch Removal Warning: Switch off the power and disconnect the Power Cord. Open the Rear Cover. Open the Top Cover. Remove the Left Side Cover (RRP 1.1 Left Side Cover). Remove the Top Cover Assembly (RRP 1.3 Top Cover Assembly).
Page 332: Figure 91 Left Print Cartridge Guide Assembly
RRP 7.5 Left Print Cartridge Guide Assembly (See PL 8.1 Xerographics) Figure 91 Left Print Cartridge Guide Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Open the Rear Cover. Open the Top Cover and remove the Print Cartridge. Cover the cartridge to protect it from light.
Page 333: Figure 92 Bias Transfer Roller [Btr] Assembly
RRP 7.6 Bias Transfer Roller [BTR] Assembly (See PL 5.1 Paper Transport) Figure 92 Bias Transfer Roller [BTR] Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Open the Top Cover and remove the Print Cartridge. Cover the cartridge to protect it from light.
Page 334: Figure 93 Shield Cover
RRP 8.1 System Controller PWB (See PL 9.1 Electrical (1 of Figure 93 Shield Cover Removal Caution: These components are susceptible to electrostatic discharge. Observe all ESD procedures to avoid damage. Warning: Turn the power off and disconnect the Power Cord. Remove the Left Side Cover (RRP 1.1 Left Side Cover).
Page 335: Figure 94 System Controller Board Assembly
10.Remove the two screws that secure the parallel connector to the frame assembly. 11.Remove the three screws that secures the System Controller PWB to the frame assembly. Remove the System Controller PWB. Figure 94 System Controller Board Assembly Figure 95 System Controller Board Replacement Reinstall the components in the reverse order.
Page 336: Figure 96 High-Voltage Power Supply [Hvps] Board
RRP 8.2 High-Voltage Power Supply [HVPS] Board (See PL 9.1 Electrical (1 of Figure 96 High-Voltage Power Supply [HVPS] Board Removal Caution: These components are susceptible to electrostatic discharge. Observe all ESD procedures to avoid damage. Warning: Turn the power off and disconnect the Power Cord. Remove the Rear Cover (RRP 1.9 Rear Cover).
Page 337: Figure 97 Duplex Interface Board
RRP 8.3 Duplex Interface Board (See PL 11.1 500-Sheet Feeder (1 of Figure 97 Duplex Interface Board Removal Caution: These components are susceptible to electrostatic discharge. Observe all ESD procedures to avoid damage. Warning: Switch off the power and disconnect the Power Cord. Remove the Rear Cover (RRP 1.9 Rear Cover).
Page 338: Figure 98 Main Fan
RRP 8.4 Main Fan (See PL 9.1 Electrical (1 of Figure 98 Main Fan Removal Caution: These components are susceptible to electrostatic discharge. Observe all ESD procedures to avoid damage. Warning: Switch off the power and disconnect the Power Cord. Remove the Lower Rear Cover (RRP 1.7 Lower Rear Cover).
Page 339: Figure 99 Shield Cover
RRP 8.5 Print Engine Controller Board (See PL 9.1 Electrical (1 of Figure 99 Shield Cover Removal Caution: These components are susceptible to electrostatic discharge. Observe all ESD procedures to avoid damage. Warning: Switch off the power and disconnect the Power Cord. Remove the Left Side Cover (RRP 1.1 Left Side Cover) Loosen the two thumb screws that secure the System Controller PWB Shield Cover and remove the cover.
Page 340: Figure 100 Print Engine Controller Board Cover
Figure 100 Print Engine Controller Board Cover Figure 101 Print Engine Controller Board Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide...
Page 341: Figure 102 Low-Voltage Power Supply [Lvps]
RRP 8.6 Low-Voltage Power Supply [LVPS] Assembly (See PL 9.2 Electrical (2 of Figure 102 Low-Voltage Power Supply [LVPS] Removal Caution: These components are susceptible to electrostatic discharge. Observe all ESD procedures to avoid damage. Warning: Switch off the power and disconnect the Power Cord. Remove the Lower Rear Cover (RRP 1.7 Lower Rear Cover).
Page 342: Figure 103 Lvps Fan
RRP 8.7 LVPS FAN (See PL 9.2 Electrical (2 of Figure 103 LVPS Fan Removal Caution: These components are susceptible to electrostatic discharge. Observe all ESD procedures to avoid damage. Warning: Switch off the power and disconnect the Power Cord. Remove the Lower Rear Cover (RRP 1.7 Lower Rear Cover).
Page 343: Figure 104 Ac Input Assembly
RRP 8.8 AC Input Assembly (See PL 9.2 Electrical (2 of Figure 104 AC Input Assembly Removal Caution: These components are susceptible to electrostatic discharge. Observe all ESD procedures to avoid damage. Warning: Switch off the power and disconnect the Power Cord. Remove the Lower Rear Cover (RRP 1.7 Lower Rear Cover).
Page 344: Figure 105 Print Engine Controller Board Cover
RRP 8.9 Control Panel +5 VDC Power Supply (See PL 9.2 Electrical (2 of Figure 105 Print Engine Controller Board Cover Removal Caution: These components are susceptible to electrostatic discharge. Observe all ESD procedures to avoid damage. Warning: Switch off the power and disconnect the Power Cord. Remove the Left Cover (RRP 1.1 Left Side Cover).
Page 345: Figure 106 +5 Vdc Power Supply
Disconnect P/J169 from the +5 VDC power Supply. Remove the two screws that secure the +5 VDC Power Supply. Remove the Power Supply. Figure 106 +5 VDC Power Supply Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide...
Page 346: Figure 107 Duplex Assembly
RRP 9.1 Duplex Assembly (See PL 13.1 Duplex Assembly) Figure 107 Duplex Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Open the Rear Cover. Remove Left Cover (RRP 1.1 Left Side Cover). Pull the top of the Duplex Assembly away from the printer to disengage the two hooks securing the unit.
Page 347: Figure 108 High Capacity Stacker [Hcs] Assembly
RRP 10.1 1000-Sheet High Capacity Stacker [HCS] (See PL 10.1 High Capacity Stacker [HCS] (1 of Figure 108 High Capacity Stacker [HCS] Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Open the printer Rear Cover. Loosen the thumb screw located on the inside of the right frame. Lift the High Capacity Stacker (HCS) straight up and remove.
Page 348: Figure 109 Hcs Top Cover
RRP 10.2 HCS Top Cover (See PL 10.1 High Capacity Stacker [HCS] (1 of Figure 109 HCS Top Cover Removal Warning: Switch off the power and disconnect the Power Cord. Open the HCS Rear Cover. Remove the HCS Output Bin. Remove the four screws that secure the Top Cover.
Page 349: Figure 110 Hcs Rear Cover
RRP 10.3 HCS Rear Cover Assembly (See PL 10.1 High Capacity Stacker [HCS] (1 of Figure 110 HCS Rear Cover Removal Warning: Switch off the power and disconnect the Power Cord. Open the HCS Rear Cover. Carefully press in on the right bracket to disengage the cover from the frame. Remove the cover.
Page 350: Figure 111 Hcs Front Cover
RRP 10.4 HCS Front Cover (See PL 10.1 High Capacity Stacker [HCS] (1 of Figure 111 HCS Front Cover Removal Warning: Switch off the power and disconnect the Power Cord. Open the HCS Rear Cover. Remove the HCS Top Cover (RRP 10.2 HCS Top Cover). Remove the four screws that secure the Front Cover.
Page 351: Figure 112 Exit Gate Solenoid
RRP 10.5 HCS Exit Gate Solenoid (See PL 10.1 High Capacity Stacker [HCS] (1 of Figure 112 Exit Gate Solenoid Removal Warning: Switch off the power and disconnect the Power Cord. Open the printer Rear Cover. Press the locking tab and disconnect P/J519 from the Rear Cover. Press the locking tab on the Solenoid Assembly and remove the solenoid.
Page 352: Figure 113 Hcs Stack Full Sensor
RRP 10.6 HCS Stack Full Sensor (See PL 10.2 High Capacity Stacker [HCS] (2 of Figure 113 HCS Stack Full Sensor Removal Warning: Switch off the power and disconnect the Power Cord. Open the HCS Rear Cover. Remove the HCS Top Cover (RRP 10.2 HCS Top Cover). Disconnect P/J521 from the Stack Full Sensor.
Page 353: Figure 114 Hcs Stack Full Sensor Actuator
RRP 10.7 HCS Stack Full Sensor Actuator (See PL 10.2 High Capacity Stacker [HCS] (2 of Figure 114 HCS Stack Full Sensor Actuator Removal Warning: Switch off the power and disconnect the Power Cord. Open the HCS Rear Cover. Remove the HCS Top Cover (RRP 10.2 HCS Top Cover). Remove the Stack Full Sensor (RRP 10.6 HCS Stack Full Sensor).
Page 354: Figure 115 Hcs Drive Motor Assembly
RRP 10.8 HCS Drive Motor Assembly (See PL 10.2 High Capacity Stacker [HCS] (2 of Figure 115 HCS Drive Motor Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Open the HCS Rear Cover. Remove the HCS Top Cover (RRP 10.2 HCS Top Cover). Disconnect P/J518 from the Drive Motor.
Page 355: Figure 116 Hcs Rear Cover Interlock Switch
RRP 10.9 HCS Rear Cover Interlock Switch (See PL 10.2 High Capacity Stacker [HCS] (2 of Figure 116 HCS Rear Cover Interlock Switch Removal Warning: Switch off the power and disconnect the Power Cord. Open the HCS Rear Cover. Remove the HCS Top Cover (RRP 10.2 HCS Top Cover). Disconnect P/J525 from the interlock switch.
Page 356: Figure 117 Hcs Paper Sensor
RRP 10.10 HCS Paper Sensor (See PL 10.2 High Capacity Stacker [HCS] (2 of Figure 117 HCS Paper Sensor Removal Warning: Switch off the power and disconnect the Power Cord. Open the HCS Rear Cover. Remove the HCS Top Cover (RRP 10.2 HCS Top Cover). Remove the HCS Front Cover (RRP 10.4 HCS Front Cover).
Page 357: Figure 118 Feeder Removal
RRP 11.1 500-Sheet Feeder Removal (See PL 11.1 500-Sheet Feeder (1 of Figure 118 Feeder Removal Removal Warning: Switch off the power and disconnect the Power Cord. Remove the HCS, if installed (RRP 10.1 1000-Sheet High Capacity Stacker [HCS]). Remove Tray 1 from the printer. Remove the two screws that secure the printer to the Optional Paper Feeder.
Page 358: Figure 119 Front Cover
RRP 11.2 Front Cover (See PL 11.1 500-Sheet Feeder (1 of Figure 119 Front Cover Removal Warning: Switch off the power and disconnect the Power Cord. Remove the paper tray from the feeder. Loosen the two screws that secure the front cover. Pull out on the top of the Front Cover and lift slightly to remove the cover.
Page 359: Figure 120 Left Cover
RRP 11.3 Left Cover (See PL 11.1 500-Sheet Feeder (1 of Figure 120 Left Cover Removal Warning: Switch off the power and disconnect the Power Cord. Remove the paper tray from the feeder. Remove the Front Cover (RRP 11.2 Front Cover). Remove the five screws that secure the Left Cover.
Page 360: Figure 121 Right Cover
RRP 11.4 Right Cover (See PL 11.1 500-Sheet Feeder (1 of Figure 121 Right Cover Removal Warning: Switch off the power and disconnect the Power Cord. Remove the paper tray from the feeder. Remove the Front Cover (RRP 11.2 Front Cover). Remove the five screws that secure the Right Cover.
Page 361: Figure 122 Rear Cover
RRP 11.5 Rear Cover (See PL 11.1 500-Sheet Feeder (1 of Figure 122 Rear Cover Removal Warning: Switch off the power and disconnect the Power Cord. Open the Rear Cover. Carefully pry the left hinge pin (as viewed from the rear of the feeder) out of the printer frame.
Page 362: Figure 123 Feeder Drive Assembly
RRP 11.6 Drive Assembly (See PL 11.2 500-Sheet Feeder (2 of Figure 123 Feeder Drive Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Remove the paper tray from the feeder. Remove the Front Cover (RRP 11.2 Front Cover). Remove the Left Cover (RRP 11.3 Left Cover) Disconnect P/J13B from the Feeder PWB.
Page 363: Figure 124 Feeder Board
RRP 11.7 Feeder Board (See PL 11.2 500-Sheet Feeder (2 of Figure 124 Feeder Board Removal Caution: These components are susceptible to electrostatic discharge. Observe all ESD procedures to avoid damage. Warning: Switch off the power and disconnect the Power Cord. Remove the paper tray from the feeder.
Page 364: Figure 125 Feed Head Assembly
RRP 11.8 Feed Head Assembly (See PL 11.3 500-Sheet Feeder (3 of Figure 125 Feed Head Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Remove the printer from the 500-Sheet Feeder (RRP 11.1 500-Sheet Feeder Removal). Remove the paper tray from the feeder.
Page 365: Figure 126 Feed Rollers
RRP 11.9 Feed Rollers (See PL 11.2 500-Sheet Feeder (2 of Figure 126 Feed Rollers Removal Warning: Switch off the power and disconnect the Power Cord. Remove the printer from the 500-Sheet Feeder (RRP 11.1 500-Sheet Feeder Removal). Remove the paper tray from the feeder. Remove the Front Cover (RRP 11.2 Front Cover).
Page 366: Figure 127 Feed Solenoid
RRP 11.10 Feed Solenoid (See PL 11.2 500-Sheet Feeder (2 of Figure 127 Feed Solenoid Removal Warning: Switch off the power and disconnect the Power Cord. Remove the printer from the 500-Sheet Feeder (RRP 11.1 500-Sheet Feeder Removal). Remove the paper tray from the feeder. Remove the Front Cover (RRP 11.2 Front Cover).
Page 367: Figure 128 Turn Roller Assembly
RRP 11.11 Turn Roller Assembly (See PL 11.2 500-Sheet Feeder (2 of Figure 128 Turn Roller Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Remove the printer from the 500-Sheet Feeder (RRP 11.1 500-Sheet Feeder Removal). Remove the paper tray from the feeder.
Page 368: Figure 129 Retard Chute Assembly
RRP 11.12 Retard Chute Assembly (See PL 11.3 500-Sheet Feeder (3 of Figure 129 Retard Chute Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Remove the printer from the 500-Sheet Feeder (RRP 11.1 500-Sheet Feeder Removal). Remove the paper tray from the feeder.
Page 369: Figure 130 Left Tray Guide
RRP 11.13 Left Tray Guide (See PL 11.3 500-Sheet Feeder (3 of Figure 130 Left Tray Guide Phaser 5400 Laser Printer Service Guide...
Page 370 Removal Warning: Switch off the power and disconnect the Power Cord. Remove the printer from the 500-Sheet Feeder (RRP 11.1 500-Sheet Feeder Removal). Remove the paper tray from the feeder. Remove the Front Cover (RRP 11.2 Front Cover). Remove the Left Cover (RRP 11.3 Left Cover). Remove the 500-Sheet Feed Head Assembly (RRP 11.8 Feed Head Assembly).
Page 371: Figure 131 Paper Level Indicator Actuator
RRP 11.14 Right Tray Guide (See PL 11.3 500-Sheet Feeder (3 of Figure 131 Paper Level Indicator Actuator Removal Warning: Switch off the power and disconnect the Power Cord. Remove the printer from the 500-Sheet Feeder (RRP 11.1 500-Sheet Feeder Removal).
Page 372: Figure 132 Right Tray Guide
Figure 132 Right Tray Guide Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide...
Page 373: Figure 133 Retard Holder Assembly
RRP 11.15 Retard Holder Assembly (See PL 11.3 500-Sheet Feeder (3 of Figure 133 Retard Holder Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Remove the printer from the 500-Sheet Feeder (RRP 11.1 500-Sheet Feeder Removal). Remove the paper tray from the feeder.
Page 374: Figure 134 Turn Roller Assembly
RRP 11.16 Retard Turn Roller Assembly (See PL 11.2 500-Sheet Feeder (2 of Figure 134 Turn Roller Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Remove the printer from the 500-Sheet Feeder (RRP 11.1 500-Sheet Feeder Removal).
Page 375: Figure 135 Paper Size Sensor
RRP 11.17 Paper Size Sensor (See PL 11.3 500-Sheet Feeder (3 of Figure 135 Paper Size Sensor Removal Warning: Switch off the power and disconnect the Power Cord. Remove the printer from the 500-Sheet Feeder (RRP 11.1 500-Sheet Feeder Removal). Remove the paper tray from the feeder.
Page 376: Figure 136 Paper Tray Sensor
RRP 11.18 Paper Tray Sensor (See PL 11.3 500-Sheet Feeder (3 of Figure 136 Paper Tray Sensor Removal Warning: Switch off the power and disconnect the Power Cord. Remove the printer from the 500-Sheet Feeder (RRP 11.1 500-Sheet Feeder Removal). Remove the paper tray from the feeder.
Page 377: Figure 137 No Paper Sensor Cover
RRP 11.19 No Paper Sensor (See PL 11.2 500-Sheet Feeder (2 of Figure 137 No Paper Sensor Cover Removal Warning: Switch off the power and disconnect the Power Cord. Remove the printer from the 500-Sheet Feeder (RRP 11.1 500-Sheet Feeder Removal).
Page 378: Figure 138 Feed Solenoid
Remove the No Paper Actuator (RRP 11.20 No Paper Sensor Actuator). Release the Paper Feed Solenoid and rotate feed Rollers to allow access to the sensor. Disconnect P/J134 from the No Paper Sensor 10.Release the three locking tabs and remove the sensor. Figure 138 Feed Solenoid Figure 139 No Paper Sensor Replacement...
Page 379: Figure 140 No Paper Sensor Actuator
RRP 11.20 No Paper Sensor Actuator (See PL 11.2 500-Sheet Feeder (2 of Figure 140 No Paper Sensor Actuator Removal Warning: Switch off the power and disconnect the Power Cord. Remove the printer from the 500-Sheet Feeder (RRP 11.1 500-Sheet Feeder Removal).
Page 380: Figure 141 Sensor Cover
RRP 11.21 Preregistration Sensor (See PL 11.2 500-Sheet Feeder (2 of Removal Warning: Switch off the power and disconnect the Power Cord. Figure 141 Sensor Cover Remove the printer from the 500-Sheet Feeder (RRP 11.1 500-Sheet Feeder Removal). Remove the paper tray from the feeder. Remove the Front Cover (RRP 11.2 Front Cover).
Page 381: Figure 143 Removing The Printer
RRP 12.1 Removing the 2000-Sheet Feeder (See PL 12.1 2000-Sheet Feeder (1 of Figure 143 Removing the Printer Phaser 5400 Laser Printer Service Guide...
Page 382 Removal Warning: Switch off the power and disconnect the Power Cord. Lock the front casters on the 2000-Sheet Feeder. Remove the HCS, if installed (RRP 10.1 1000-Sheet High Capacity Stacker [HCS]). Remove Tray 1 from the printer. Remove the two screws that secure the printer. Note: For safety reasons, have someone assist you in removing the printer and setting it in a safe place.
Page 383: Figure 144 Left Side Cover
RRP 12.2 Left Side Cover (See PL 12.1 2000-Sheet Feeder (1 of Figure 144 Left Side Cover Removal Warning: Switch off the power and disconnect the Power Cord. Remove the two screws that secure the Left Side Cover. Pull the top of the cover out and up to remove. Replacement Reinstall the components in the reverse order.
Page 384: Figure 145 Upper Rear Cover
RRP 12.3 Upper Rear Cover (See PL 12.1 2000-Sheet Feeder (1 of Figure 145 Upper Rear Cover Removal Warning: Switch off the power and disconnect the Power Cord. Open the Upper Rear Cover. Carefully push in on the left or right bracket to disengage the end of the cover. Remove the cover.
Page 385: Figure 146 Lower Rear Cover
RRP 12.4 Lower Rear Cover (See PL 12.4 2000-Sheet Feeder (4 of Figure 146 Lower Rear Cover Removal Warning: Switch off the power and disconnect the Power Cord. Remove the two screws that secure the top of the Lower Rear Cover. Loosen three screws that secure the Lower Rear Cover.
Page 386: Figure 147 Right Side Cover
RRP 12.5 Right Side Cover (See PL 12.1 2000-Sheet Feeder (1 of Figure 147 Right Side Cover Removal Warning: Switch off the power and disconnect the Power Cord. Remove the two screws that secure the Right Side Cover. Pull the top of the cover out and up to remove. Replacement Reinstall the components in the reverse order.
Page 387: Figure 148 Front Cover
RRP 12.6 Front Cover (See PL 12.1 2000-Sheet Feeder (1 of Figure 148 Front Cover Removal Warning: Switch off the power and disconnect the Power Cord. Open the 2000-Sheet Feeder Tray. Remove the two screws that secure the front cover. Pull the top of the cover out and up to remove.
Page 388: Figure 149 Tray Assembly
RRP 12.7 Tray Assembly (See PL 12.4 2000-Sheet Feeder (4 of Figure 149 Tray Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Pull the 2000-Sheet Feeder Tray out until it stops. Remove all paper from the tray. Push and hold the button on the Left Rail to release the latch.
Page 389: Figure 150 2000-Sheet Feeder Board
RRP 12.8 2000-Sheet Feeder PWB (See PL 12.2 2000-Sheet Feeder (2 of Figure 150 2000-Sheet Feeder Board Removal Caution: These components are susceptible to electrostatic discharge. Observe all ESD procedures to avoid damage. Warning: Switch off the power and disconnect the Power Cord. Remove the Lower Rear Cover (RRP 12.4 Lower Rear Cover).
Page 390: Figure 151 Tray Lift Motor Assembly
RRP 12.9 Tray Lift Motor Assembly (See PL 12.2 2000-Sheet Feeder (2 of Figure 151 Tray Lift Motor Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Remove the Lower Rear Cover (RRP 12.4 Lower Rear Cover). Open the 2000-Sheet Feeder tray.
Page 391: Figure 152 Paper Size Sensor
RRP 12.10 A4 Paper Size Sensor (See PL 12.2 2000-Sheet Feeder (2 of Figure 152 Paper Size Sensor Removal Warning: Switch off the power and disconnect the Power Cord. Remove the 2000-Sheet Feeder Tray Assembly (RRP 12.7 Tray Assembly). Disconnect P/J612 from the Paper Size Sensor. Release the two locking tabs and remove the Sensor.
Page 392: Figure 153 Casters
RRP 12.11 Casters (See PL 12.2 2000-Sheet Feeder (2 of Figure 153 Casters Removal Warning: Switch off the power and disconnect the Power Cord. Remove the Printer / 500-Sheet Feeder (RRP 11.1 500-Sheet Feeder Removal). Remove the Left Foot. Remove the Left Side Cover (RRP 12.2 Left Side Cover). Remove all paper from the 2000-Sheet Feeder tray.
Page 393: Figure 154 Harness Assembly
RRP 12.12 Harness Assembly (See PL 12.2 2000-Sheet Feeder (2 of Figure 154 Harness Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Remove the Printer / 500-Sheet Feeder (RRP 11.1 500-Sheet Feeder Removal). Remove the Left Side Cover (RRP 12.2 Left Side Cover). Remove the Lower Rear Cover (RRP 12.4 Lower Rear Cover).
Page 394: Figure 155 Drive Assembly
RRP 12.13 Drive Assembly (See PL 12.2 2000-Sheet Feeder (2 of Figure 155 Drive Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Open the Upper Rear Cover. Remove the screw that secures the back of the Drive Assembly. Remove the Tray Assembly (RRP 12.7 Tray Assembly).
Page 395: Figure 156 Pick, Feed And Retard Rollers
RRP 12.14 Feed, Nudger, and Retard Roller (See PL 12.3 2000-Sheet Feeder (3 of Figure 156 Pick, Feed and Retard Rollers Removal Warning: Switch off the power and disconnect the Power Cord. Open the 2000-Sheet Feeder tray. Open the Upper Rear Cover. From the rear loosen the two thumb screws and remove the paper baffle.
Page 396: Figure 157 Paper Height Sensor
RRP 12.15 Paper Height Sensor (See PL 12.3 2000-Sheet Feeder (3 of Figure 157 Paper Height Sensor Removal Warning: Switch off the power and disconnect the Power Cord. Remove the 2000-Sheet Feeder Tray Assembly (RRP 12.7 Tray Assembly). Hold the Nudger Assembly down as you release the three locking tabs that secure the Paper Height Sensor.
Page 397: Figure 158 Paper Feed Motor Assembly
RRP 12.16 Paper Feed Motor Assembly (See PL 12.3 2000-Sheet Feeder (3 of Figure 158 Paper Feed Motor Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Remove the Right Side Cover (RRP 12.5 Right Side Cover). Remove the E-ring that secures the 47T gear.
Page 398: Figure 159 Link Stopper
RRP 12.17 Link Stopper (See PL 12.3 2000-Sheet Feeder (3 of Figure 159 Link Stopper Removal Warning: Switch off the power and disconnect the Power Cord. Remove the Retard Assembly (RRP 12.26 Retard Assembly). Remove the 2000-Sheet Feeder Tray Assembly (RRP 12.7 Tray Assembly). Unhook the torsion spring from the Link Stopper.
Page 399: Figure 160 No Paper Sensor
RRP 12.18 No Paper Sensor (See PL 12.3 2000-Sheet Feeder (3 of Figure 160 No Paper Sensor Removal Warning: Switch off the power and disconnect the Power Cord. Remove the Tray Assembly (RRP 12.7 Tray Assembly). Disconnect P/J610 from the No Paper Sensor. Release the three locking tabs that secure the sensor Remove the sensor.
Page 400: Figure 161 No Paper Sensor Actuator
RRP 12.19 No Paper Sensor Actuator (See PL 12.3 2000-Sheet Feeder (3 of Figure 161 No Paper Sensor Actuator Removal Warning: Switch off the power and disconnect the Power Cord. Remove the Tray Assembly (RRP 12.7 Tray Assembly). Release the four locking tabs that secure the actuator and support. Remove the actuator from the Actuator Support.
Page 401: Figure 162 Tray Assembly Wire Covers
RRP 12.20 Left and Right Wire Cover (See PL 12.4 2000-Sheet Feeder (4 of Figure 162 Tray Assembly Wire Covers Removal Warning: Switch off the power and disconnect the Power Cord. Open the 2000-Sheet Feeder Tray Assembly until it stops. Remove the two screws that secure the Wire Cover to the Tray Assembly.
Page 402: Figure 163 Shaft Cover Assembly
RRP 12.21 Shaft Cover Assembly (See PL 12.4 2000-Sheet Feeder (4 of Figure 163 Shaft Cover Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Remove the 2000-Sheet Feeder Tray Assembly (RRP 12.7 Tray Assembly). Remove the four screws that secure the Shaft Cover Assembly to the Tray Assembly.
Page 403: Figure 164 Drive Shaft Assembly
RRP 12.22 Drive Shaft Assembly (See PL 12.4 2000-Sheet Feeder (4 of Figure 164 Drive Shaft Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Remove the 2000-Sheet Feeder Tray Assembly (RRP 12.7 Tray Assembly). Remove the Shaft Cover Assembly (RRP 12.21 Shaft Cover Assembly). Align the Drive Shaft Assembly with the hole in the Shaft Cover Assembly.
Page 404: Figure 165 Brake Assembly
RRP 12.23 Brake Assembly (See PL 12.4 2000-Sheet Feeder (4 of Figure 165 Brake Assembly Removal Warning: Switch off the power and disconnect the Power Cord. Remove the 2000-Sheet Feeder Tray Assembly (RRP 12.7 Tray Assembly). Remove the two screws that secure the Brake Assembly to the Tray Assembly. Remove the Brake Assembly.
Page 405: Figure 166 Left Tray Wires
RRP 12.24 Left Tray Wires (See PL 12.4 2000-Sheet Feeder (4 of Figure 166 Left Tray Wires Removal Warning: Switch off the power and disconnect the Power Cord. Remove the 2000-Sheet Feeder Tray Assembly (RRP 12.7 Tray Assembly). Remove the Shaft Cover Assembly (RRP 12.21 Shaft Cover Assembly). Remove the Brake Assembly (RRP 12.23 Brake Assembly).
Page 406: Figure 167 Right Tray Wires
RRP 12.25 Right Tray Wires (See PL 12.4 2000-Sheet Feeder (4 of Figure 167 Right Tray Wires Removal Warning: Switch off the power and disconnect the Power Cord. Remove the 2000-Sheet Feeder Tray Assembly (RRP 12.7 Tray Assembly). Remove the Shaft Cover Assembly (RRP 12.21 Shaft Cover Assembly). Remove the Right Wire Cover (RRP 12.20 Left and Right Wire Cover).
Page 407: Figure 168 Feed Gears
RRP 12.26 Retard Assembly (See PL 12.3 2000-Sheet Feeder (3 of Figure 168 Feed Gears Removal Warning: Switch off the power and disconnect the Power Cord. Remove the 2000-Sheet Feeder Tray Assembly (RRP 12.7 Tray Assembly). Remove the Right Side Cover (RRP 12.5 Right Side Cover). Remove the E-ring that secures the 50T Gear to the Feeder Shaft, then remove the gear.
Page 408: Figure 169 Retard Assembly
Release the spring from the left end (as viewed from the rear) of the Retard Support. Remove the two screws that secure the Retard Support Assembly to the feeder. Lift the Retard Support Assembly, slide it to the right and remove. Figure 169 Retard Assembly Replacement Reinstall the components in the reverse order.
Page 409 Blank Page Phaser 5400 Laser Printer Service Guide...
Page 410: Organization Of This Section
FRU Parts List Introduction The Parts List section provides exploded-view illustrations of all spared subsystem components and a listing of the corresponding part numbers. The illustrations show the relationships between parts. Changes to the printer may be made to accommodate improved components as they become available.
Page 411: Using The Parts List
Using the Parts List The numbers shown in each illustration correspond to the parts list number for that illustration. Throughout this manual, parts are identified by the prefix “PL”, followed by a number, a decimal point, and another number. For example, PL3.1.12 means the part is item 12 of parts list 3.1.
Page 412: Table 126 Legend
A notation “(part of item 1.1)” indicates that the part is included with item 1.2.1 (PL1.2, line item 1). Note: Only parts showing part numbers are available for support. Parts not showing part numbers are available on the parent assembly. Table 126 Legend: Identifier Meaning...
Page 413: Figure 170 Covers
Parts Lists PL 1.1 Covers 23 (with 18, 22) s5400-202 Figure 170 Covers Phaser 5400 Laser Printer Service Guide...
Page 414: Table 127 Pl 1.1 Covers
Table 127 PL 1.1 Covers ID No. Part Number Name / Description 802K29441 Cover Assembly, Top [includes 2~5, 7-15, 26, 29, 30, Door, Top Access [P/O item 1] Stopper, Left [P/O item 1] Bracket, Left [P/O item 1] 048E64291 Cap, Top Cover Bracket, Right [P/O item 1] Stopper, Right [P/O item 1] Cover, Top [P/O item 1]...
Page 415: Figure 171 Paper Tray (A3/Ledger)
PL 2.1 Paper Tray [A3/Ledger] Figure 171 Paper Tray (A3/Ledger) Phaser 5400 Laser Printer Service Guide...
Page 416: Table 128 Pl 2.1 Paper Tray [A3/Ledger]
Table 128 PL 2.1 Paper Tray [A3/Ledger] ID No. Part Number Name / Description 109R00523 Tray Assembly, [A3/Ledger (includes 2~37)] Bottom [P/O item 1] Sprint, Latch [P/O item 1] Plate, Side Guide [left] [P/O item 1] Plate, Side Guide [right] [P/O item 1] Lever, Side [right] [P/O item 1] Latch Assembly [right] [P/O item 1] Spring, Long [P/O item 1]...
Page 417: Figure 172 Paper Tray [A4/Letter]
PL 2.2 Paper Tray [A4/Letter] Figure 172 Paper Tray [A4/Letter] Phaser 5400 Laser Printer Service Guide...
Page 418: Table 129 Pl 2.2 Paper Tray [A4/Letter]
Table 129 PL 2.2 Paper Tray [A4/Letter] ID No. Part Number Name / Description 109R00524 Tray Assembly, A4/Letter [includes 2~33] Plate Assembly, Bottom Spring, Latch Plate, Side Guide [left] Plate, Side Guide [right] Lever, Side [right] Latch Assembly [right] Spring Spring, Ground End Guide End Guide, Spring Plate...
Page 419: Figure 173 Paper Feeder
PL 3.1 Paper Feeder Figure 173 Paper Feeder Phaser 5400 Laser Printer Service Guide...
Page 420: Table 130 Pl 3.1 Paper Feeder
Table 130 PL 3.1 Paper Feeder ID No. Part Number Name / Description 054K13043 Chute Assembly, Rear [includes 2~4] Chute, Rear [P/O item 1] Roller, Pinch [P/O item 1] Spring, Pinch [P/O item 1] Rod, Paper Level Indicator [P/O item 16] Collar, Paper Level Indicator [P/O item 16] Guide Assembly, Tray 1 [with 5, 6 &...
Page 421: Figure 174 Multi-Sheet Bypass Feeder (Mbf) Assembly
PL 4.1 Multi-sheet Bypass Feeder (MBF) Assembly Figure 174 Multi-sheet Bypass Feeder (MBF) Assembly Phaser 5400 Laser Printer Service Guide...
Page 422: Table 131 Pl 4.1 Mbf Assembly
Table 131 PL 4.1 MBF Assembly ID No. Part Number Name / Description 059K19206 MBF Assembly [includes 2, 5~11, 13~24 (PL 4.2 items 2~5, 7~11, 13~16 & 18~27, 29~31)] Tray Assembly [P/O item 1] 003K85592 Latch Assembly [left] Guide, Upper 809E35460 Spring, MBF 1 [P/O item 1] Gear, Pick Up [P/O item 1 &...
Page 423: Figure 175 Paper Handler
PL 4.2 Paper Handler (includes 9, 18-20) Figure 175 Paper Handler Phaser 5400 Laser Printer Service Guide...
Page 424: Table 132 Pl 4.2 Paper Handler
Table 132 PL 4.2 Paper Handler ID No. Part Number Name / Description 600K72192 Holder Assembly, Retard [includes 2~4] Spring, NIP [P/O item 1] Holder, Retard [P/O item 1] Pad, Retard [P/O item 1] Spring N/F 600K72223 Kit, Gear [includes 23, 24 & PL 4.1 (items 6, 16 & 17)] Clamp [P/O PL 4.1 item 1] Pin, Idler [P/O PL 4.1 item 1] Sensor, No/Low Paper...
Page 425: Figure 176 Paper Transport
PL 5.1 Paper Transport Figure 176 Paper Transport Phaser 5400 Laser Printer Service Guide...
Page 426: Table 133 Pl 5.1 Paper Transport
Table 133 PL 5.1 Paper Transport ID No. Part Number Name / Description 054K18572 Transport Assembly, Paper [includes 2~15] Transport, Chute [P/O item 1] Bearing, BTR [P/O item 1] Spring BTR [P/O item 1] Actuator, Registration [P/O item 17] Spring, Sensor [P/O item 17] Spring, Registration [P/O item 1] Gear, Registration [rubber roller shaft] [P/O Item 1] Bearing, Right [rubber roller shaft] [P/O Item 1]...
Page 427: Figure 177 Rear Cover Assembly
PL 6.1 Rear Cover Assembly With Fuser (with 2~31, 33, 35~37) 1 (with 2~28, 30, 32, 37~52, 55) 97 (with 28, 30x2 ea.) 99 (with 33) 98 (with 27x2 ea.) 94 (with 2~10, 13~22, 26) 94 (with 2~10, 13~22, 37~41) s5400-209 Figure 177 Rear Cover Assembly Phaser 5400 Laser Printer Service Guide...
Page 428: Table 134 Pl 6.1 Rear Cover Assembly With Fuser
Table 134 PL 6.1 Rear Cover Assembly with Fuser ID No. Part Name / Description Number 14, 38 ID Numbers not used 802K04577 Cover Assembly, Rear [includes 2-31, 33, 35-37] Gear Assembly, Cover Gate [P/O item 1] Gear, Z20/20 [P/O item 1] Spring, Cover Gate Gear [P/O item 1] Gear, Z37 [P/O item 1] Gear, Z27 [P/O item 1]...
Page 429: Figure 178 Frame And Drives
PL 7.1 Frame & Drives Figure 178 Frame and Drives Phaser 5400 Laser Printer Service Guide...
Page 430: Table 135 Pl 7.1 Frame And Drives
Table 135 PL 7.1 Frame and Drives ID No. Part Number Name / Description Cover, Laser Bracket, HCS [left] Cover, Lower Rear 809E10940 Kit, Main Drive Motor Spring [2 pieces] [P/O item 11] Clamp Clamp, Laser Clamp Clamp Clamp 007K86761 Gear Assembly, Drive [includes 4, 11 &...
Page 431: Figure 179 Xerographics
PL 8.1 Xerographics 2 (with 3, 4, 18) 99 (with 14, 19) s5400-212 Figure 179 Xerographics Phaser 5400 Laser Printer Service Guide...
Page 432: Table 136 Pl 8.1 Xerographics
Table 136 PL 8.1 Xerographics ID No. Part Number Name / Description 113R00495 Cartridge, Print 062K10803 Laser Scanner Assembly, (with 3, 4, 18) Harness Assembly, Laser Scanner [J115-1~J115-2] Scanner, Laser (Reference only) [P/O Item 2] 032K93933 Guide Assembly, Print Cartridge [right] (with 6~12,15) Harness Assembly, Interlock (J162~J621, J622, J623) [P/O item 5] Wire Assembly, Developer [P/O item 5]...
Page 433: Figure 180 Electrical (1 Of 2)
PL 9.1 Electrical (1 of 2) Figure 180 Electrical (1 of 2) Phaser 5400 Laser Printer Service Guide...
Page 434: Table 137 Pl 9.1 Electrical (1 Of 2)
Table 137 PL 9.1 Electrical (1 of 2) ID No. Part Number Name / Description 160K83452 Board, System Controller Kit, Cover Assembly [includes 3~6] Cover, Shield Screw, Thumb Cover, Print Engine Controller Board (MCU) 802K35520 Panel, Rear 105K19330 Board, 5 VDC Power Supply 105K19091 Board, High Voltage Power Supply (HVPS) 160K74360...
Page 435: Figure 181 Electrical (2 Of 2)
PL 9.2 Electrical (2 of 2) Figure 181 Electrical (2 of 2) Phaser 5400 Laser Printer Service Guide...
Page 436: Table 138 Pl 9.2 Electrical (2 Of 2)
Table 138 PL 9.2 Electrical (2 of 2) ID No. Part Number Name / Description 162K42681 Harness, Low Voltage Power Supply (LVPS) [J161-J16, J506] 105K19080 Power Supply, Low Voltage [110 VAC] 105K19170 Power Supply, Low Voltage [220 VAC] 962K05780 Harness, System Controller [3.3V] [J163-J3] 162K42800 Harness, System Controller [5V] [J169-J168, J13] 127E81781...
Page 437: Figure 182 High Capacity Stacker (1 Of 2)
PL 10.1 High Capacity Stacker [HCS] (1 of 2) s5400-215 Figure 182 High Capacity Stacker (1 of 2) Phaser 5400 Laser Printer Service Guide...
Page 438: Table 139 Pl 10.1 High Capacity Stacker (1 Of 2)
Table 139 PL 10.1 High Capacity Stacker (1 of 2) ID No. Part Number Name / Description 097S02715 Stacker Assembly, High Capacity (HCS) (with 2-8, 10-19) 802E24491 Cover, Top [P/O Item 1] 036E91371 Weight, Paper [P/O Item 1] 802K26211 Cover Assembly, Rear (with 5~8) [P/O Item 1] Cover, Rear [P/O Item 4] Holder, Magnet [P/O Item 4] Roller, Turn Pinch [P/O Item 4]...
Page 439: Figure 183 High Capacity Stacker (2 Of 2)
PL 10.2 High Capacity Stacker [HCS] (2 of 2) 2 (with 4) s5400-216 Figure 183 High Capacity Stacker (2 of 2) Phaser 5400 Laser Printer Service Guide...
Page 440: Table 140 Pl 10.2 High Capacity Stacker (2 Of 2)
Table 140 PL 10.2 High Capacity Stacker (2 of 2) ID No. Part Number Qty Name / Description 8, 16-17, 34-36 ID Numbers not used 001K74193 Paper Handling, HCS Assembly (with 2-7, 10-15, 18-33, 37-41) [same PL 14.1.10] Eliminator Assembly, Static [with 3, 4, 6, 7] Bracket, Stack Full Eliminator 162K63540...
Page 441: Figure 184 500-Sheet Feeder (1 Of 3)
PL 11.1 500-Sheet Feeder (1 of 3) Figure 184 500-Sheet Feeder (1 of 3) Phaser 5400 Laser Printer Service Guide...
Page 442: Table 141 Pl 11.1 500-Sheet Feeder (1 Of 3)
Table 141 PL 11.1 500-Sheet Feeder (1 of 3) ID No. Part Number Name / Description 097S02712 Feeder Assembly, Complete [w/A4 CST] 097S02711 Feeder Assembly, Complete [w/A3 CST] [customer purchased item] 802K11761 Cover Assembly, Rear [includes 3, 6 & 8~10] Latch [P/O item 2] 802E03103 Cover, Front...
Page 443: Figure 185 500-Sheet Feeder (2 Of 3)
PL 11.2 500-Sheet Feeder (2 of 3) Figure 185 500-Sheet Feeder (2 of 3) Phaser 5400 Laser Printer Service Guide...
Page 444: Table 142 Pl 11.2 500-Sheet Feeder
Table 142 PL 11.2 500-Sheet Feeder ID No. Part Number Name / Description Feeder Assembly, Complete [P/O PL 11.1, item 1] [customer purchased item] 015K39481 Bracket Assembly, Gear 28 Sub-Assembly, Feeder [same as PL 11.3, item1] 054K14729 Head Assembly, Feed [includes 5~22] Gear, Turn Bearing Roller Assembly, Turn...
Page 445: Figure 186 500-Sheet Feeder (3 Of 3)
PL 11.3 500-Sheet Feeder (3 of 3) Figure 186 500-Sheet Feeder (3 of 3) Phaser 5400 Laser Printer Service Guide...
Page 446: Table 143 Pl 11.3 500-Sheet Feeder (3 Of 3)
Table 143 PL 11.3 500-Sheet Feeder (3 of 3) ID No. Part Number Name / Description Feeder Assembly, Complete [customer purchased item] Frame Assembly Rod, Paper Level Indicator [P/O Item 15] Collar Assembly, Paper Level Indicator [P/O Item 15] Lever, Retard [P/O item 7] Spring, Release [P/O item 7] 054K13055 Chute Assembly, Retard [includes 8~14]...
Page 447: Figure 187 2000-Sheet Feeder (1 Of 4)
PL 12.1 2000-Sheet Feeder (1 of 4) Figure 187 2000-Sheet Feeder (1 of 4) Phaser 5400 Laser Printer Service Guide...
Page 448: Table 144 Pl 12.1 2000-Sheet Feeder (1 Of 4)
Table 144 PL 12.1 2000-Sheet Feeder (1 of 4) ID No. Part Number Name / Description 097S02714 2000-Sheet Feeder Complete 048K77441 Cover Assembly, Side [left] 048K77533 Cover Assembly, Rear [includes 4 & 5] Holder, Magnetic Cover/Door, Rear 802K05400 Cover, Rear Bottom 048K77451 Cover Assembly, Side [right] 048K69591...
Page 449: Figure 188 2000-Sheet Feeder (2 Of 4)
PL 12.2 2000-Sheet Feeder (2 of 4) Figure 188 2000-Sheet Feeder (2 of 4) Phaser 5400 Laser Printer Service Guide...
Page 450: Table 145 Pl 12.2 2000-Sheet Feeder (2 Of 4)
Table 145 PL 12.2 2000-Sheet Feeder (2 of 4) ID No. Part Number Name / Description Assembly, Frame & Drive [includes 2~20] Bushing 160K74350 Board, 2000-Sheet Feeder 162K47560 Harness, 2000-Sheet Feeder SW [J604-J612, J613, J614] Clamp 127K24971 Motor Assembly, Tray Lift Bracket, 2000-Sheet Feeder Board Guide, Tray 110E93440...
Page 451: Figure 189 2000-Sheet Feeder (3 Of 4)
PL 12.3 2000-Sheet Feeder (3 of 4) Figure 189 2000-Sheet Feeder (3 of 4) Phaser 5400 Laser Printer Service Guide...
Page 452: Table 146 Pl 12.3 2000-Sheet Feeder (3 Of 4)
Table 146 PL 12.3 2000-Sheet Feeder (3 of 4) ID No. Part Number Name / Description 050K38810 Retard Assembly, 2000-Sheet Feeder [includes 2~7] 600K78460 Feed Roller Kit, [3 pieces] Spacer [P/O item 1] Clutch Assembly, Friction [P/O item 1] Shaft Assembly, Retard [P/O item 1] Bearing, S6 [P/O item 1] Support, Retard [P/O item 1] 809E20551...
Page 453: Figure 190 2000-Sheet Feeder (4 Of 4)
PL 12.4 2000-Sheet Feeder (4 of 4) Figure 190 2000-Sheet Feeder (4 of 4) Phaser 5400 Laser Printer Service Guide...
Page 454: Table 147 Pl 12.4 2000-Sheet Feeder (4 Of 4)
Table 147 PL 12.4 2000-Sheet Feeder (4 of 4) ID No. Part Number Name / Description Tray Assembly, 2000-Sheet Feeder [includes 2~25] Housing Assembly, 2000-Sheet Feeder Guide, Side [left] [P/O item 26] 019K94630 Brake Assembly Guide, Side [right] [P/O item 26] Pulley [P/O item 27] Guide, Wire [P/O item 27] Wire 2 [P/O item 28]...
Page 455: Figure 191 Duplex Assembly
PL 13.1 Duplex Assembly 98 (with 37, 38) 98 (with 12x6 ea., 14, 24) s5400-224 Figure 191 Duplex Assembly Phaser 5400 Laser Printer Service Guide...
Page 456: Table 148 Pl 13.1 Duplex
Table 148 PL 13.1 Duplex ID No. Part Number Qty Name / Description 4, 13, 15, 23, 31 ID Numbers not used 097S02713 Duplex Assembly (with 2, 3, 5-12, 14, 16-22, 24-30, 32-40) Motor Assembly, Exit Cover, Duplex Motor Gear, Z18/37 Clamp Bracket Assembly, Duplex Left Gear, Z15...
Page 457: Figure 192 Crc Locations
Keep consumables and maintenance items in supply. Add or replace when prompted by the printer. To order supplies and accessories, contact your local dealer, or visit the Xerox web site: www.xerox.com/officeprinting Phaser 5400 Laser Printer Service Guide...
Page 458: Table 149 Customer-Replaceable Consumables
* Average life of a Laser Print Cartridge is based on page coverage of 5 percent using Letter- or A4-size paper. The printer displays a message on the control panel when the toner is low and when you need to replace the Laser Print Cartridge. Table 150 Xerox Professional Printing Paper Item Size...
Page 459: Table 152 Xerox Labels
Table 151 Xerox Transparency Film (cont'd.) Item Size Part Number Xerox Paperback, Clear Letter (U. S.) 3R3028 8.5 x 11 in. Xerox Type C, Plain A4 (Metric Letter) 3R96002 210 x 297 mm Table 152 Xerox Labels Size Description Part Number...
Page 460 Table 153 Options (cont'd.) Option and Features Part Number Memory (DIMMs) Increases the font capability and enhances the speed of data transfer and complex page processing Memory kits available in three configurations, packaged in single units each: 16 Mbytes 32 Mbytes 097S02356 64 Mbytes 097S02357...
Page 461 Blank Page Phaser 5400 Laser Printer Service Guide...
Page 462: Contents
Plug/Jack Connector Locations Contents P/J Tables Plug/Jack Location Table 154 - Engine ........434 Plug/Jack Location Table 155 - 500-Sheet Feeder .
Page 463 Plug/Jack (P/J) Locations for the Engine Use the table and maps in this section to locate specific plug/jack (P/J) connectors within the printer. To find the location of a P/J within the printer; Locate the P/J connector number in the first column of the table. Locate the corresponding coordinates in the second column, such as I7 or J7.
Page 464 (cont'd.) Table 154Plug/Jack Connector Locations - Engine Map & Number Connect to... Other and connected to... MBF Assembly P/J 12 Print Engine Controller P/J 122 MBF Solenoid P/J 123 Tray 1 Solenoid P/J 124 Turn Roll Clutch P/J 125 MBF No Paper Sensor P/J 126 Tray 1 No Paper Sensor MBF Solenoid P/J 121 MBF Assembly...
Page 465 (cont'd.) Table 154Plug/Jack Connector Locations - Engine Map & Number Connect to... Other and connected to... C-33 HVPS Print Cartridge Dev Bias E-33 HVPS Paper Transport Detack Saw H-26 Size Switch P/J 20 Print Engine Controller H-26 MBF Home Sw P/J 20 Print Engine Controller CRUM PWB P/J 21 Print Engine Controller...
Page 466: Figure 193 P/J Location Map 1 - Engine
Plug/Jack Location Map 1 - Engine S5400-321 Figure 193 P/J Location Map 1 - Engine Phaser 5400 Laser Printer Service Guide...
Page 467: Figure 194 P/J Location Map 2 - Engine
Plug/Jack Location Map 2 - Engine S5400-322 S5400-322 Figure 194 P/J Location Map 2 - Engine Phaser 5400 Laser Printer Service Guide...
Page 468: Figure 195 P/J Location Map 3 - Engine
Plug/Jack Location Map 3 - Engine S5400-323 Figure 195 P/J Location Map 3 - Engine Phaser 5400 Laser Printer Service Guide...
Page 469: Plug/Jack Location Map 4 - 500-Sheet Feeder
Plug/Jack Location Map 4 - 500-Sheet Feeder Table 155Map 4 - 500-Sheet Feeder Map & Number Connect to... Other and connected... In Line Connector P/J 134 No Paper Sensor P/J 133 Feeder PWB Pre Reg Sensor P/J 13P - P/J 133 Feeder PWB In Line Connector P/J 13C Pre Reg Sensor P/J 133 Feeder PWB...
Page 470: Figure 196 P/J Location Map 4 - 500-Sheet Feeder
S5400-324 Figure 196 P/J Location Map 4 - 500-Sheet Feeder Phaser 5400 Laser Printer Service Guide...
Page 471: Plug/Jack Location Map 5 - Duplex Assembly
Plug/Jack Location Map 5 - Duplex Assembly Table 156Plug/Jack Connector Locations Map & Number Connect to... Other and Connected to... Connects the Duplex Assembly (Duplex PWB) to the Printer. Duplex PWB. P/J 509 Duplex Drive Motor Duplex Drive Motor. P/J 508 Duplex PWB Duplex PWB.
Page 472: Figure 197 P/J Location Map 5 - Duplex Assembly
Figure 197 P/J Location Map 5 - Duplex Assembly Phaser 5400 Laser Printer Service Guide...
Page 473 Plug/Jack Location - 1000-Sheet (High Capacity) Stacker Table 157Plug/Jack Connector Locations - 1000-Sheet (High Capacity) Stacker Map & Number Connect to... Other and connected to... Feeder PWB P/J 526 - P/J 504 Duplex Interface Pwb Stacker PWB P/J 518 Stacker Motor Stacker Motor P/J 517 Stacker PWB Exit Gate Solenoid.
Page 474: Figure 198 P/J Location Map 6 - 1000-Sheet High Capacity Stacker
s5400-332 Figure 198 P/J Location Map 6 - 1000-Sheet High Capacity Stacker Phaser 5400 Laser Printer Service Guide...
Page 475 Plug/Jack Location - 2000-Sheet Feeder Table 158Plug/Jack Connector Locations - 2000-Sheet Feeder Map & Number Connect to... Other and connected to... Printer or second feeder P/J601 HCF PWB 513A G-8 Stack Height Sensor P/J 603 HCF PWB 513B F-8 No Paper Sensor P/J 602 HCF PWB HCF PWB P/J 131...
Page 476: Figure 199 P/J Location Map 7 - 2000-Sheet Feeder
Plug/Jack Location Map 7 - 2000-Sheet Feeder S5400-335 Figure 199 P/J Location Map 7 - 2000-Sheet Feeder Phaser 5400 Laser Printer Service Guide...
Page 477 Blank Page Phaser 5400 Laser Printer Service Guide...
Page 478: Wiring Diagram Notations
Wiring Diagrams Wiring Diagram Notations This section of the manual contains a Master Wiring Diagram for the printer. The Master Wiring Diagram shows the interconnections of the major subsystems. More detailed wiring diagrams are contained in the CD Service Manual. For more detailed information, refer to the On-Line CD version which contains complete wiring information.
Page 479: Figure 202 Print Engine Controller Pwb <-> Lvps
Organization Base Engine Master Wiring Diagram - Figure 200 Figure 201 Wiring Diagrams and Signal Description between Components Figure 202 Print Engine Controller PWB <–> LVPS <–> Interlock Switch and Fans (page 454) Figure 203 Print Engine Controller PWB <–> Fuser Assembly, Fuser PWB (page 455) Figure 204 Print Engine Controller PWB-Laser and CRUM PWB (page 456) Figure 205 Print Engine Controller PWB, HVPS and Print Cartridge (page...
Page 480: Figure 200 Master Wiring Diagram 1 Of 2
Master Connection and Wiring Diagram Figure 200 Master Wiring Diagram 1 of 2 Phaser 5400 Laser Printer Service Guide...
Page 481: Figure 201 Master Wiring Diagram 2 Of 2
Figure 201 Master Wiring Diagram 2 of 2 Phaser 5400 Laser Printer Service Guide...
Page 482 Table 159 Legend: Counter-Clockwise No Paper Clutch Neutral - associated with electrical power to the printer CONN Connector Offset Clockwise REGI Registration Ground Fault Indicator Sensor HVPS High Voltage Power Supply Solenoid INTLK Interlock Start Of Scan - associated with the Laser Scanner timing LVPS Low Voltage Power Supply...
Page 483: Base Engine Wiring Diagrams
Base Engine Wiring Diagrams Figure 202 Print Engine Controller PWB <–> LVPS <–> Interlock Switch and Fans Phaser 5400 Laser Printer Service Guide...
Page 484: Figure 203 Print Engine Controller Pwb <-> Fuser Assembly, Fuser Pwb
Figure 203 Print Engine Controller PWB <–> Fuser Assembly, Fuser PWB Phaser 5400 Laser Printer Service Guide...
Page 485: Figure 204 Print Engine Controller Pwb-Laser And Crum Pwb
Figure 204 Print Engine Controller PWB-Laser and CRUM PWB Phaser 5400 Laser Printer Service Guide...
Page 486: Figure 205 Print Engine Controller Pwb, Hvps And Print Cartridge
White White Yellow P/J 181 Figure 205 Print Engine Controller PWB, HVPS and Print Cartridge Phaser 5400 Laser Printer Service Guide...
Page 487 Figure 206 Print Engine Controller PWB <–> Registration Clutch and Registration Sensor Phaser 5400 Laser Printer Service Guide...
Page 488 Figure 207 Print Engine Controller PWB <–> Feed Solenoid, Turn Clutch, No-Paper Sensor Phaser 5400 Laser Printer Service Guide...
Page 489: Figure 208 Print Engine Controller Pwb, Low Paper Sensor, Mbf Home Switch
Figure 208 Print Engine Controller PWB, Low Paper Sensor, MBF Home Switch, and Tray 1 Paper Size Switch Phaser 5400 Laser Printer Service Guide...
Page 490: Figure 209 Print Engine Controller Pwb <-> Main Motor
Figure 209 Print Engine Controller PWB <–> Main Motor Phaser 5400 Laser Printer Service Guide...
Page 491: Figure 210 Print Engine Controller Pwb <-> Toner Sensor
Figure 210 Print Engine Controller PWB <–> Toner Sensor Phaser 5400 Laser Printer Service Guide...
Page 492: Figure 211 Print Engine Controller Pwb <-> Duplex Interface Pwb
Figure 211 Print Engine Controller PWB <–> Duplex Interface PWB <–> Full Stack Sensor Phaser 5400 Laser Printer Service Guide...
Page 493: Figure 212 Controller And Control Panel
Figure 212 Controller and Control Panel Phaser 5400 Laser Printer Service Guide...
Page 494: Figure 213 500-Sheet Feeder - Tray 2 Wiring Diagram And Signal Information
500-Sheet Feeder P/J134 P/J13C Figure 213 500-Sheet Feeder - Tray 2 Wiring Diagram and Signal Information Between Components Phaser 5400 Laser Printer Service Guide...
Page 495: Figure 214 500-Sheet Feeder - Tray 3 Wiring Diagram And Signal Information
Figure 214 500-Sheet Feeder - Tray 3 Wiring Diagram and Signal Information Between Components Phaser 5400 Laser Printer Service Guide...
Page 496: Figure 215 Duplex Assembly - Wiring Diagrams And Signal Information
Duplex Assembly Figure 215 Duplex Assembly - Wiring Diagrams and Signal Information Between Components Phaser 5400 Laser Printer Service Guide...
Page 497: Figure 216 Master Wiring Diagram, High Capacity Stacker
1000-Sheet (High Capacity Stacker) Figure 216 Master Wiring Diagram, High Capacity Stacker Phaser 5400 Laser Printer Service Guide...
Page 498: Figure 217 2000-Sheet Feeder - Wiring Diagram And Signal Information
2000-Sheet Feeder Figure 217 2000-Sheet Feeder - Wiring Diagram and Signal Information Between Components Phaser 5400 Laser Printer Service Guide...
Page 499: Figure 218 2000-Sheet Feeder Pwb <-> No Paper Sensor
Figure 218 2000-Sheet Feeder PWB <–> No Paper Sensor Figure 219 2000-Sheet Feeder PWB <–> Low Paper Sensor Phaser 5400 Laser Printer Service Guide...
Page 500: Figure 220 2000-Sheet Feeder Pwb <-> Switches
Figure 220 2000-Sheet Feeder PWB <–> Switches Phaser 5400 Laser Printer Service Guide...
Page 501 Blank Page Phaser 5400 Laser Printer Service Guide...
Page 503 7 2 1 P 5 8 3 0 1...

This manual is also suitable for:

Phaser 5400

Xerox 5400N - Phaser B/W Laser Printer Service Quick Reference Manual

Table of Contents

List of Figures

General Information

Error Codes and Messages

Contents - Error Codes and Messages

Troubleshooting

Table of Contents

Quick Links

Chapters

Troubleshooting

Related Manuals for Xerox 5400N - Phaser B/W Laser Printer

Summary of Contents for Xerox 5400N - Phaser B/W Laser Printer