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

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Phaser 5400 Laser Printer Service Guide

Using the Parts List

1.

The numbers shown in each illustration correspond to the parts list number for that
illustration.

2.

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.

3.

The capital letters “C”, “E”, and “S” shown in an illustration stand for C-ring,

E-ring, and Screw, respectively.

4.

A shaded triangle t in an illustration indicates the item is part of an assembly.

5.

The notation “with X~Y” following an part name indicates an assembly that is

made up of components X through Y. For example, “1 (with 2~4)” means part 1
consists of part 2, part 3, and part 4.

6.

The notation “RS” means that the part is a requested spare. Part numbers for these

parts will be provided as soon as they are available.

7.

An asterisk * following a part name indicates the page contains a note about this
part.

8.

The notation “J1<>J2 and P2” is attached to a wire harness. It indicates that
connector jack 1 is attached to one end of the wire harness and connector jack 2 is
attached to the other end that is plugged into plug 2.

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

Page 1: ...Service Quick Reference Guide P H A S E R 5 4 0 0 L A S E R P R I N T E R...

Page 2: ......

Page 3: ...ice personnel only To avoid personal injury do not perform any servicing other than that contained in operating instructions unless you are qualified to do so This printing August 2002 Rev 1 721P58301...

Page 4: ...vice technician for changes to the cord or connector Warning If the product loses the ground connection usage of knobs and controls and other conductive parts can cause an electrical shock Note A Note...

Page 5: ...a concentrated narrow beam of infrared light The laser beam in this machine is invisible Although you cannot see the beam it can still cause severe eye damage Direct eye exposure to the laser beam ma...

Page 6: ...re in place Most importantly read and obey all posted warning labels Warning Turning the power off using the On Off switch does not de energize the printer You must remove the power cord to disconnect...

Page 7: ...nd ground A protective ground connection by way of the grounding conductor in the power cord is essential for safe operation This product is certified under IEC 825 as a Class 1 Laser Product CLASS 1...

Page 8: ...e 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 exposur...

Page 9: ...isruptive interference to nearby radio and television reception switch the equipment off to determine if it is the true cause of the interference If the equipment is the cause of the interference the...

Page 10: ...riques pour les appareils de classe A stipul s das le r glement sur le brouillage radio letrique du Minist re des Communcations du Canada European Notice This equipment was tested and is determined to...

Page 11: ...x Phaser 5400 Laser Printer Service Guide Blank Page...

Page 12: ...l 6 Display Screen 7 Rear Panel 8 Print Engine Assemblies 9 Paper Path Information 15 Printer Specifications 17 RAM and Printer Capabilities 17 Basic Specifications 18 Electrical Specifications 18 Mec...

Page 13: ...ence Repair Analysis Procedure RAP Table 109 Printer Performance Problems 110 Image Quality Troubleshooting 176 Introduction 176 Image Quality Defect Definitions 177 Diagnostics Test Prints Service Te...

Page 14: ...Assembly 252 RRP 1 4 Front Cover 253 RRP 1 5 Lower Left Cover 254 RRP 1 6 HVPS Cover 255 RRP 1 7 Lower Rear Cover 256 RRP 1 8 MBF Gear Cover 257 RRP 1 9 Rear Cover 258 RRP 2 1 Multi sheet Bypass Feede...

Page 15: ...RRP 7 6 Bias Transfer Roller BTR Assembly 304 RRP 8 1 System Controller PWB 305 RRP 8 2 High Voltage Power Supply HVPS Board 307 RRP 8 3 Duplex Interface Board 308 RRP 8 4 Main Fan 309 RRP 8 5 Print E...

Page 16: ...et 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 RRP 12 8 2000 S...

Page 17: ...Stacker HCS 2 of 2 410 PL 11 1 500 Sheet Feeder 1 of 3 412 PL 11 2 500 Sheet Feeder 2 of 3 414 PL 11 3 500 Sheet Feeder 3 of 3 416 PL 12 1 2000 Sheet Feeder 1 of 4 418 PL 12 2 2000 Sheet Feeder 2 of...

Page 18: ...ii Wiring Diagrams 449 Wiring Diagram Notations 449 Organization 450 Master Connection and Wiring Diagram 451 Base Engine Wiring Diagrams 454 500 Sheet Feeder 465 Duplex Assembly 467 1000 Sheet High C...

Page 19: ...xviii Phaser 5400 Laser Printer Service Guide Blank Page...

Page 20: ...12 FRU Assemblies Sensors and Interlock Locations 5 Main Drive 13 Figure 13 FRU Assemblies Sensors and Interlock Locations 6 FRU Circuit Assemblies 14 Figure 14 Paper Path Flow 15 Figure 15 Paper Pat...

Page 21: ...sor Assembly 266 Figure 55 MBF No Paper Sensor Assembly 267 Figure 56 MBF Tray Assembly 268 Figure 57 MBF No Paper Sensor Assembly 268 Figure 58 MBF Feed Solenoid 269 Figure 59 Tray 1 Feed Solenoid 27...

Page 22: ...ply HVPS Board 307 Figure 97 Duplex Interface Board 308 Figure 98 Main Fan 309 Figure 99 Shield Cover 310 Figure 100 Print Engine Controller Board Cover 311 Figure 101 Print Engine Controller Board 31...

Page 23: ...re 140 No Paper Sensor Actuator 350 Figure 141 Sensor Cover 351 Figure 142 Preregistration Sensor 351 Figure 143 Removing the Printer 352 Figure 144 Left Side Cover 354 Figure 145 Upper Rear Cover 355...

Page 24: ...igure 186 500 Sheet Feeder 3 of 3 416 Figure 187 2000 Sheet Feeder 1 of 4 418 Figure 188 2000 Sheet Feeder 2 of 4 420 Figure 189 2000 Sheet Feeder 3 of 4 422 Figure 190 2000 Sheet Feeder 4 of 4 424 Fi...

Page 25: ...Duplex Interface PWB Full Stack Sensor 463 Figure 212 Controller and Control Panel 464 Figure 213 500 Sheet Feeder Tray 2 Wiring Diagram and Signal Information Between Components 465 Figure 214 500 S...

Page 26: ...2 Table 20 Paper Size Actuators 43 Table 21 Error Code C3 Insert Tray 2 or Tray 3 500 Sheet Feeder Troubleshooting Procedure 44 Table 22 Paper Size Actuators 45 Table 23 Error Code C3 2000 Sheet Feede...

Page 27: ...le 49 Error Code PSE 1 Paper Size Jam Troubleshooting Procedure 94 Table 50 Paper Size Actuators 95 Table 51 Error Code U1 Motor Failure Troubleshooting Procedure 96 Table 52 Error Code U2 Laser ROS L...

Page 28: ...500 Sheet Feeder Feed Solenoid Troubleshooting Procedure 161 Table 93 500 Sheet Feeder Motor Troubleshooting Procedure 163 Table 94 500 Sheet Feeder Assembly Not Recognized Troubleshooting Procedure 1...

Page 29: ...Feeder 391 Table 131 PL 4 1 MBF Assembly 393 Table 132 PL 4 2 Paper Handler 395 Table 133 PL 5 1 Paper Transport 397 Table 134 PL 6 1 Rear Cover Assembly with Fuser 399 Table 135 PL 7 1 Frame and Dri...

Page 30: ...nd 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 Ph...

Page 31: ...e paper creating a dry permanent print The printer requires 110 VAC 50 60 Hz or optionally 220 240 VAC 50 60 Hz using 1 1 kw for warm up and approximately 890 watts for a print cycle Power saver mode...

Page 32: ...Kit also a Customer Replaceable Consumable and normally purchased and installed by the customer regardless of Warranty or Contract entitlement consists of two items rated for replacement at 200 000 L...

Page 33: ...Curl Extension 3 Control Panel 4 Paper Support and Stopper 5 Multi sheet Bypass Feeder closed 6 Tray 1 7 Paper Amount Indicator 8 Power Switch Rear view 9 Rear Cover closed 10 Power Cord Receptacle 1...

Page 34: ...A4 Letter Tray shown as Tray 1 A3 Ledger Tray shown as Tray 2 in the 500 sheet Feeder 3 2 000 Sheet Feeder shown as Tray 3 Rear view 4 Optional Duplex Module installed 5 Optional Hard Drive installed...

Page 35: ...to print reports such as the configuration sheet which lists the printer s current settings Figure 6 Control Panel 1 Display screen 2 Four indicator LEDs Online indicator LED Form Feed indicator LED...

Page 36: ...es and Troubleshooting Manual Displays information about the status of the printer or the job in process Examples The printer is online and ready to accept print jobs The printer is processing data Th...

Page 37: ...8 Phaser 5400 Laser Printer Service Guide Rear Panel Figure 7 Rear Panel s5400 344 CR1 View Port LEFT R E A R USB Parallel Ethernet...

Page 38: ...following four FRUs Laser Scanner stand alone unit Print Cartridge contains Bias Charge Roller Cleaning Blade Drum Detack Saw Mag Roller CM Blade Fuser contains Heat Roller Pressure Roller Bias Trans...

Page 39: ...10 Phaser 5400 Laser Printer Service Guide Figure 9 FRU Assemblies Sensors and Interlock Locations 2...

Page 40: ...Phaser 5400 Laser Printer Service Guide 11 Figure 10 FRU Assemblies Sensors and Interlock Locations 3 Detack Saw Registration Bias Transfer Rollers and Paper Transport Assembly...

Page 41: ...12 Phaser 5400 Laser Printer Service Guide Figure 11 FRU Assemblies Sensors and Interlock Locations 4 Fuser Area Full Stack Sensor...

Page 42: ...Phaser 5400 Laser Printer Service Guide 13 Figure 12 FRU Assemblies Sensors and Interlock Locations 5 Main Drive...

Page 43: ...14 Phaser 5400 Laser Printer Service Guide Figure 13 FRU Assemblies Sensors and Interlock Locations 6 FRU Circuit Assemblies...

Page 44: ...ervice Guide 15 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 figur...

Page 45: ...inter Service Guide 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...

Page 46: ...l download space for fonts macros and images Increased throughput for complex pages duplex pages and larger paper sizes A3 Ledger Increased PostScript VM virtual memory Collated sets without the Hard...

Page 47: ...ed on Measured at 72 F 22 C ambient temperature with the specified voltage Ranges of paper sizes A6 Card stock to Tabloid Extra see Table 9 and Table 10 for details Printable area The print quality is...

Page 48: ...0 18 1 27 60 500 Sheet Feeder A4 Letter size 13 4 5 3 50 1 19 7 43 9 17 3 9 5 21 500 Sheet Feeder A3 Ledger size 13 4 5 3 50 1 19 7 58 9 23 2 10 5 23 2000 Sheet Feeder 41 0 16 1 49 0 19 3 50 9 20 0 23...

Page 49: ...t condensation Severe conditions Assured period 48 hours 122 140 F 50 60 C 85 95 RH Without condensation The assured altitude is 0 3000 m above sea level When transported by air in a cargo room pressu...

Page 50: ...fy the specified print quality without shaking the Print Cartridge when consecutively printing on A4 Letter size sheets LEF under the normal conditions with 5 image coverage A double sided print is co...

Page 51: ...3 Ledger SEF S 5 66 6 06 6 83 7 61 D 10 90 11 29 11 60 12 71 A3 SEF S 5 59 5 99 6 76 7 54 D 10 45 10 88 11 59 12 45 Letter LEF S 4 41 4 81 5 58 6 36 D 8 25 8 62 9 36 10 20 A4 LEF S 4 38 4 78 5 55 6 32...

Page 52: ...Control Panel System Menu Table 11 Supported Media and Media Sizes Tray 1 Tray 2 Tray 3 Media Media Size A4 Letter A3 Ledger 2000 Sheet Feeder Multi sheet Bypass Feeder A3 297 x 420 mm SEF 2 SEF A4 2...

Page 53: ...Tray 2000 Sheet Feeder Multi sheet Bypass Feeder Simplex Width 148 297 mm 5 83 11 69 in 210 297 mm 8 27 11 69 in None 76 2 305 mm 3 12 in Length 98 4 216 mm 3 875 8 5 in 139 7 431 8 mm 5 5 17 in None...

Page 54: ...aper Paper with paper fasteners ribbons staples tape etc attached Label stock with exposed backing sheet Printing Accuracy Table 14 Printing Accuracy Item Accuracy Measuring Conditions Registration Le...

Page 55: ...nsumables printer cartridge media etc or Options refer to Xerox Supplies and Accessories on page 428 of this manual Table 15 Components to Be Replaced Periodically Fuser Unit 200 000 prints Letter LEF...

Page 56: ...p Cover 69 RAP 15 Error Code E4 0 Exit Jam Open Rear and Top Cover 72 RAP 16 Error Code E5 Close Covers 74 RAP 17 Insert MBF 76 RAP 18 Close Tray 2 Rear Door Close Tray 3 Rear Door 78 RAP 19 Close Sta...

Page 57: ...iew fault history in the Control Panel using Print Menu Display Faults When the 3 key is pressed the first fault will be displayed Continue to press the 3 key to view the entire fault history It will...

Page 58: ...echnician could take using this technical manual to service the printer engine and options To use the Service Flowchart start at Block 1 to identify the problem After you have identified the problem r...

Page 59: ...the wall outlet 3 Remove the Toner Cartridge and shield it from strong light 4 Inspect the printer interior and remove any foreign matter such as paper clips staples pieces of paper paper dust or tone...

Page 60: ...o to the PRINTER PERFORMANCE area in the Troubleshooting Section of this manual 3 If you have a print image problem go to the IMAGE QUALITY area in the Troubleshooting section of this manual 4 Follow...

Page 61: ...locations and signal names 7 Repair Analysis Procedures may ask you to run a specific diagnostic routine in order to test a component or circuit The Tests Adjustments and Resetting NVRAM sections of t...

Page 62: ...and the paper trays are in place and all of the interlock switches are actuated 7 All voltage values given in the Repair Analysis Procedures are approximate values Actual measured voltages may vary m...

Page 63: ...the printer is OFF 2 Press and hold buttons 2 and 6 on the Control Panel while you switch printer power ON Continue holding until IOT appears in the display approximately 20 seconds 3 When the Control...

Page 64: ...t Feeder elevator did not reach home position within the prescribed time 2 Paper level sensor on when 2000 Sheet Feeder Tray is opened Open and close 2000 Sheet Feeder paper tray Go to RAP 3 page 46 T...

Page 65: ...Hard Disk Memory Failure Power Off On ESS M Controller memory has failed 32 MB on board Power Off On Remove Options Replace System Controller PWB RRP 8 1 page 305 NV Memory Fail Power Off On ESS N Co...

Page 66: ...rinting Reg Sensor is OFF when the specified time has passed timing from Feed Roll ON Comment Tray 2 misfeed with 500 Sheet Feeder installed as Tray 2 Open Top Cover or Feeder and remove the sheets th...

Page 67: ...nsor is being actuated at Power Up 3 Exit Sensor is ON when the interlock is closed 4 Exit Sensor turns from OFF to ON at Erase Cycle Open Top Cover remove EP Cartridge and remove any paper Go to RAP...

Page 68: ...ve any paper Go to RAP 21 page 84 Duplex Unit Fail or Removed E9 1 E9 Duplex Fail Duplex module removed while power is on Reinstall Duplex Module Go to RAP 22 page 86 Stacker Bin Fail Power Off On E9...

Page 69: ...Motor Power Off On Go to RAP 30 page 96 Laser Failure Power Off On U2 U2 Laser Fail 1 Laser Signal intervals are longer than the Ready time interval 20 seconds after the start of Laser warm up 2 The l...

Page 70: ...s detected during power on 2 A write error is detected during write to the Nonvolatile Memory Power Off On Go to RAP 37 page 105 0101 DIMM 1 DIMM in slot J4 has failed Go to RAP 34 page 102 0101 DIMM...

Page 71: ...agnostics Mode 2 From the Main Menu select Component Test Tray 1 Size press 4 Does the paper size indicated on the LCD match the paper size in Tray 1 Replace Print Engine Controller Board RRP 8 5 page...

Page 72: ...llowing 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...

Page 73: ...PAPER SIZE SENSOR TEST 1 Remove the paper tray 2 Scroll to Sensor Input press 4 3 One at a time press and release each of the size actuators for the problem tray Does the LCD counter increment each t...

Page 74: ...ce each component or troubleshoot each area listed below one at a time until you isolate and solve the problem Print Engine Controller Board RRP 8 5 page 310 Tray 2 3 PL 2 1 page 386 PL 2 2 page 388 L...

Page 75: ...y lower each time you press the Stopper Link Go to Step 3 Replace the Stopper Link RRP 12 17 page 369 3 STOPPER LINK 1 Enter Diagnostics mode 2 From the Main Menu select Component Test Sensor Input pr...

Page 76: ...page 310 Replace the Paper Height Sensor RRP 12 15 page 367 8 SUSPECT COMPONENTS The following printer components and areas are associated with this specific problem One or more of these components or...

Page 77: ...4 MBF TRAY TEST PRINT 1 Enter Diagnostics mode 2 From the Main Menu select Test Print Input Tray MBF press 4 to select MBF as Input Tray 3 From the Main Menu select Test Print Print Pattern press 4 t...

Page 78: ...remove a sheet of paper into the MBF Does the MBF No Paper Actuator move smoothly when paper is inserted then removed Go to Step 10 Replace the actuator 10 MBF NO PAPER SENSOR CHECK 1 Enter Diagnostic...

Page 79: ...No Paper Sensor Actuator Does the No Paper Sensor Actuator move smoothly Go to Step 4 Replace the No Paper Sensor Actuator RRP 11 20 page 350 4 NO PAPER SENSOR 1 Enter Diagnostics mode 2 From the Main...

Page 80: ...asure the voltage between P J13 7 and frame ground as you actuate and deactuate the No Paper Sensor Does the voltage measure 0 9 VDC when deactuated and 2 76 VDC when actuated Replace the Print Engine...

Page 81: ...tep 2 2 STACK FULL SENSOR ACTUATOR INSPECTION Visually inspect the Stack Full Sensor Actuator Does the actuator move freely and appear to be in good condition not broken or damaged Go to Step 3 Replac...

Page 82: ...ge 307 3 Check for continuity between P J502 and P J527 as follows J527 1 and J502 1 J527 2 and J502 2 J527 3 and J502 3 Is there continuity between each of the pins Go to Step 8 Repair or replace the...

Page 83: ...component or troubleshoot each area listed below one at a time until you isolate and solve the problem Stack Full Sensor Actuator RRP 5 4 page 294 Stack Full Sensor RRP 5 2 page 289 Print Engine Cont...

Page 84: ...OR INSPECTION Visually inspect the Stack Full Sensor Actuator Does the actuator appear to be in good condition not broken or damaged and does it move freely when actuated Go to Step 3 Replace the HCS...

Page 85: ...Check for continuity between P J502 and P J527 as follows J527 1 and J502 1 J527 2 and J502 2 J527 3 and J502 3 Is there continuity between the pins Go to Step 8 Repair or replace the HCS Stack Full...

Page 86: ...Repair Analysis Procedure replace each component or troubleshoot each area listed below one at a time until you isolate and solve the problem HCS Stack Full Sensor Actuator RRP 10 7 page 324 HCS Stack...

Page 87: ...the No Paper Sensor Actuator up and release Does the LCD counter increment each time you press and release the No Paper Sensor Actuator Replace the Print Engine Controller Board RRP 8 5 page 310 Go t...

Page 88: ...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 proble...

Page 89: ...ounter increment each time you actuate the Registration Sensor Actuator Replace the Print Engine Controller Board RRP 8 5 page 310 Go to RAP 50 page 135 3 REGISTRATION CLUTCH TEST 1 From the Main Menu...

Page 90: ...specifications Go to Step 4 Replace with paper within size specs 4 MBF FEED ROLLERS CHECK 1 Open the MBF door 2 Enter Diagnostics mode 3 From the Main Menu select Test Print Input Tray MBF press 4 to...

Page 91: ...ution Go to Step 9 Go to Step 10 9 RETARD CHUTE ASSEMBLY INSPECTION 1 Remove the Retard Chute Assembly RRP 3 1 page 273 2 Inspect the retard holder and retard arm for damage Is the Retard Chute Assemb...

Page 92: ...eplace with paper within size specs 4 PROBLEM TRAY REPLACEMENT 1 Remove problem paper tray and install Tray 1 into the problem feeder 2 Enter Diagnostics mode 3 From the Main Menu select Test Print Pr...

Page 93: ...sembly RRP 11 12 page 339 Inspect the Rear Chute Assemblyfor damaged missing or broken Idler Rollers and Springs Replace the Retard Chute Assembly RRP 11 12 page 339 9 SUSPECT COMPONENTS The following...

Page 94: ...printer power OFF 2 Remove the 2000 Sheet Feeder Right Side Cover RRP 12 5 3 Open the Upper Rear Cover 4 Manually rotate the top gear clockwise 5 Inspect the rotation of the 2000 Sheet Feeder Motor A...

Page 95: ...y 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 s...

Page 96: ...pages 0 to stop 4 Print approximately 25 pages or until the above Paper Jam message appears and printing stops 5 Open the Top Cover 6 Remove the Print Cartridge 7 Inspect the position of the paper Is...

Page 97: ...135 7 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 c...

Page 98: ...stics mode 4 From the Main Menu select Component Test Main Motor cheat the Top Cover Interlock and press 4 to start motor Note If continuing to Step 5 allow motor to run until you complete the next st...

Page 99: ...an the Detack Saw or replace the Paper Transport Assembly RRP 4 1 page 283 10 HEAT ROLLER IDLER GEAR TEST Rotate the Heat Roller Idler Gear Does the Heat Roller Idler Gear rotate smoothly Go to Step 1...

Page 100: ...r Analysis Procedure replace each component or troubleshoot each area listed below one at a time until you isolate and solve the problem Main Gear Drive Assembly RRP 6 1 page 295 MBF Gears PL 4 1 page...

Page 101: ...page 310 Go to RAP 67 page 170 3 Does the printer have the Duplex option installed Go to Step 8 Go to Step 4 4 REAR COVER EXIT PINCH ROLLERS CHECK 1 Enter Diagnostics mode 2 From the Main Menu select...

Page 102: ...art motor 5 After a few seconds press 0 to stop motor 6 From the Main Menu select Component Test Exit Motor Rev L press 4 to start motor 0 to stop Does the Exit Motor rotate smoothly in both direction...

Page 103: ...witch Does the Top Cover actuate the Interlock Switch Go to Step 4 Replace the Top Cover RRP 1 3 page 252 4 REMOVE LOWER REAR COVER 1 Switch printer power OFF 2 Remove the Lower Rear Cover RRP 1 7 pag...

Page 104: ...MPONENTS 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 thi...

Page 105: ...nt each time you press and release the actuator Replace the Print Engine Controller Board RRP 8 5 page 310 Go to Step 4 4 NO FROM STEP 4 ABOVE 1 Switch printer power OFF 2 Remove the Left Side Cover R...

Page 106: ...mpletely 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 th...

Page 107: ...the Print Engine Controller Board RRP 8 5 page 310 Go to Step 3 3 NO FROM STEP 3 ABOVE 1 Switch printer power OFF 2 Remove the 2000 Sheet Feeder Lower Rear Cover RRP 12 4 page 356 3 Switch printer po...

Page 108: ...nnot 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 Upper Re...

Page 109: ...ine Controller Board RRP 8 5 page 310 Go to Step 4 4 NO FROM STEP 3 ABOVE 1 Switch printer power OFF 2 Remove the HCS Front Cover RRP 10 4 page 321 3 Disconnect P J524 from the HCS Board 4 Switch prin...

Page 110: ...page 326 9 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...

Page 111: ...erlock 2 Enter Diagnostics mode 3 From the Main Menu select Component Test Dup Motor On Low press 4 Do the Duplex Motor and rollers turn smoothly at low speed Go to Step 4 Replace Duplex Assembly PL 1...

Page 112: ...e Duplex Assembly Repair or replace the Duplex Interface Harness PL 9 1 page 404 9 DUPLEX ROLLERS 1 Remove the Duplex Assembly 2 Inspect the Duplex Assembly rollers for contamination and wear Are the...

Page 113: ...l press 4 while observing the Exit Gate Solenoid 4 Press 4 again while observing the Exit Gate to reverse its exit position Does the Exit Gate Solenoid change position each time 4 is pressed Go to Ste...

Page 114: ...em 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 HCS Motor Assembly RRP 10 8 pag...

Page 115: ...nter power ON 5 Measure the voltage between P19 4 on the Print Engine Controller Board and frame ground Does the voltage measure 1 6 VDC Replace the Print Engine Controller Board RRP 8 5 page 310 Go t...

Page 116: ...is 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 Print Engine Controller...

Page 117: ...inter power OFF 2 Remove the HCS Front Cover RRP 10 4 page 321 3 Disconnect P J514 from the HCS Board 4 Check for continuity between the following pins P514 2 and P19 2 P514 3 and P19 3 P514 4 and P19...

Page 118: ...oblem still occur Go to Step 3 Problem solved 3 HARNESS CONTINUITY CHECK 1 Remove the 2000 Sheet Feeder Harness assembly 2 Check for continuity between the pins as follows J601 1 and J131 7 J601 2 and...

Page 119: ...between J14 1 P141 1 J14 2 P141 2 and J14 3 P141 3 Go to Step 3 Repair or replace the Toner Sensor Harness Assembly as necessary PL 8 1 page 402 3 TONER SENSOR ASSEMBLY REPLACEMENT Replace the Toner S...

Page 120: ...ray 1 2 Remove any paper from the MBF 3 Enter Diagnostics mode 4 From the Main Menu select Component Test Sensor Input Test press 4 to start test 0 to stop 5 Open the MBF Cover and carefully pull down...

Page 121: ...Print Engine Controller Board RRP 8 5 page 310 Go to Step 3 3 CONTINUITY CHECK Perform a continuity check of the harness to the CRUM Board specifically P J 21 1 to P J 211 4 P J 21 2 to P J 211 3 Is t...

Page 122: ...r Board RRP 8 5 page 310 Go to Step 3 3 CONTINUITY CHECK Perform a continuity check of the harness to the CRUM Board specifically P J 21 1 to P J 211 4 P J 21 2 to P J 211 3 Is there continuity betwee...

Page 123: ...place with paper that meets specs 4 INSPECTING GUIDES Inspect the side guides and Paper Stack End Guide in the problem Tray Are all guides properly set for the size of paper installed Go to Step 5 Pro...

Page 124: ...roblem 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 t...

Page 125: ...Assembly Drive Gear Does the Fuser rotate smoothly Go to Step 4 Replace the Fuser 4 REGISTRATION ROLLERS ROTATION CHECK 1 Open the Top Cover 2 Remove the Print Cartridge 3 Manually rotate the Metal Re...

Page 126: ...of the rollers Do the Tray 1 Pick Up Rollers rotate smoothly Go to RAP 47 page 128 Repair or replace the gears or assembly as necessary PL 4 2 page 394 9 SUSPECT COMPONENTS The following printer compo...

Page 127: ...ontroller Board RRP 8 5 page 310 3 SCANNER MOTOR CHECK 1 Enter Diagnostics mode 2 From the Main Menu select Component Test ROS Motor press 4 to start the Laser Scanner Motor 0 to stop Can you hear the...

Page 128: ...pletely 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...

Page 129: ...ain Menu select Test Print Print Pattern press 4 to start printing test pages 0 to stop 3 Run 20 to 30 test pages Does the Fuser Failure error code reappear Go to RAP 49 page 133 Problem solved 3 SUSP...

Page 130: ...ch printer power ON 4 Check for 24 VDC between P J161 13 and frame ground 5 Check for 0 6 VDC between P J161 12 and frame ground Are both voltages 24 VDC and 0 6 VDC correct Replace the LVPS RRP 8 6 p...

Page 131: ...Go to Step 3 3 DIMM RETEST VERIFICATION 1 Switch printer power OFF 2 Remove the DIMM from Slot 2 J5 and reinstall it into Slot 1 J4 3 Switch printer power on Is the 0101 DIMM 1 error message still dis...

Page 132: ...Go to Step 3 3 DIMM RETEST VERIFICATION 1 Switch printer power OFF 2 Remove the DIMM from Slot 1 J4 and reinstall it into Slot 2 J5 3 Switch printer power on Is the 0102 DIMM 2 error message still dis...

Page 133: ...Go to Step 3 3 DIMM RETEST VERIFICATION 1 Switch printer power OFF 2 Remove the DIMM from Slot 1 J4 and reinstall it into Slot 3 J6 3 Switch printer power on Is the 0103 DIMM 3 error message still dis...

Page 134: ...e the Print Engine Controller Board RRP 8 5 page 310 4 NON VOLATILE MEMORY CONFIGURATION CODES Check the NVM Data one by one referring to the NVRAM Configuration Table of Non Volatile Memory Configura...

Page 135: ...106 Phaser 5400 Laser Printer Service Guide Blank Page...

Page 136: ...is quick and easy for you including sending a simple print job to the printer The object is merely to print anything on a sheet of paper for evaluation On other occasions follow the procedure as inst...

Page 137: ...e 151 HVPS Assembly RAP 59 on page 153 Electrical Noise RAP 60 on page 157 Low Paper Tray 2 or Tray 3 500 Sheet Feeder RAP 61 on page 159 500 Sheet Feeder Feed Solenoid RAP 62 on page 161 500 Sheet Mo...

Page 138: ...page 190 Vertical Process Streaks RAP 76 on page 192 Horizontal Scan Streaks RAP 77 on page 194 Residual Image Ghosting RAP 78 on page 197 Black Prints RAP 79 on page 199 Background RAP 80 on page 20...

Page 139: ...e not as specified in the following steps the cause must be corrected Caution the customer NOT to connect the machine to the wall outlet Advise the customer that a licensed electrician must correct th...

Page 140: ...tage between Line and Neutral between AC Line and Earth Ground and between Neutral and Earth Ground 2 The voltage between Line and Neutral and between Line and Earth Ground should range from 196 to 24...

Page 141: ...ch 3 Check for pin to pin continuity between P22 and P222 Is there continuity between both pins Replace the Registration Clutch RRP 4 3 on page 286 Repair or replace the Registration Clutch Harness as...

Page 142: ...USPECT 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 is...

Page 143: ...the main power ON 4 Measure the voltage between the bottom of Fuse F101 and P J167 pin 3 Does the voltage match the line voltage Problem Solved Replace the LVPS RRP 8 6 page 312 4 Measure the voltage...

Page 144: ...Phaser 5400 Laser Printer Service Guide 115 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...

Page 145: ...n Table 67 on the LVPS Are all the voltages correct Go to Step 2 Replace the LVPS RRP 8 6 on page 312 2 1 Switch the printer power OFF 2 Reconnect P J161 to the LVPS 3 Switch the printer power ON and...

Page 146: ...PWB 5 1 Switch the printer power OFF 2 Reconnect one of the disconnected plugs 3 Switch the printer power ON 4 Measure the voltages listed in Table 67 Are all the voltages correct Repeat the step wit...

Page 147: ...ly and Ready is displayed on the Control Panel Problem solved Replace the System Controller Board RRP 8 1 page 305 3 OPTIONS ISOLATION 1 Switch printer power OFF 2 Reinstall one of the removed options...

Page 148: ...Test at least one Paper Size switch and the Low Paper Sensor must be actuated 1 Enter Diagnostics mode 2 From the Main Menu select Component Test Sensor Input press 4 to start test 0 to stop 3 Push up...

Page 149: ...116 5 SYSTEM CONTROLLER 3 3 VDC CHECK 1 Remove the Left Side Cover RRP 1 1 page 250 2 On the System Controller Board measure the voltage between P J3 1 and P J3 2 Does the voltage measure 3 3 VDC bet...

Page 150: ...PS measure 24 VDC Replace the System Controller Board 5 VDC Power Supply RRP 8 9 page 315 Replace the LVPS RRP 8 6 page 312 11 REMOVE OPTIONS 1 Switch printer power OFF 2 Remove any options connected...

Page 151: ...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 Wiring and c...

Page 152: ...2 Does the voltage at P J3 1 and P J3 2 measure 3 3 VDC Go to Step 5 Go to Step 3 3 3 3 VDC NO LOAD CHECK ON SYSTEM CONTROLLER BOARD 1 Switch printer power OFF 2 Disconnect P J3 from the System Contr...

Page 153: ...ted and frame ground Do all the voltages listed in the column with P J18 connected measure correctly Go to Step 9 Replace the Control Panel PL 1 1 page 384 9 REMOVE OPTIONS FROM SYSTEM CONTROLLER BOAR...

Page 154: ...ntil you isolate and solve the problem Control Panel Assembly PL 1 1 page 384 Harness Assembly System Controller Board to Control Panel PL 9 1 page 404 Harness Assembly 3 3V PL 9 1 page 404 Power Supp...

Page 155: ...continuity Replace the Control Panel Assembly PL 1 1 page 384 Replace the Wiring Harness PL 9 1 page 404 4 KEYPAD TEST Press keypad buttons 1 3 and 5 7 while observing the LCD Note Keypad numbers inc...

Page 156: ...Phaser 5400 Laser Printer Service Guide 127 Table 74 Keypad Pin Voltage Pin Voltage 1 3 3 VDC 5 3 3 VDC 2 0 VDC 6 1 3 VDC 3 1 3 VDC 7 3 3 VDC 4 0 VDC 8 0 VDC...

Page 157: ...o Step 4 Replace the LVPS RRP 8 6 page 312 4 Is the voltage on pin 6 correct Go to Step 5 Replace the Print Engine Controller Board RRP 8 5 page 310 5 Is the voltage on pin 5 correct Replace the LVPS...

Page 158: ...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 e...

Page 159: ...the Print Engine Controller Board and frame ground measure 24 0 VDC Replace the Print Engine Controller Board RRP 8 5 page 310 Replace the LVPS RRP 8 6 page 312 4 YES FROM STEP 2 ABOVE 1 Enter Diagno...

Page 160: ...t Cartridge Switch Is the tab on the Print Cartridge intact Go to Step 11 Replace the Print Cartridge PL 8 1 page 402 11 LASER SAFETY SWITCH ACTUATOR Press and release the Laser Safety Switch Actuator...

Page 161: ...omponents 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...

Page 162: ...72 3 Is there continuity between P172 1 and P172 3 Go to Step 4 Go to Step 3 3 NO FROM STEP 2 ABOVE 1 Remove the Right Side Cover RRP 1 2 page 251 2 Ensure the Rear Cover is closed 3 Check for continu...

Page 163: ...RRP 8 5 page 310 Replace the LVPS RRP 8 6 page 312 8 SUSPECT COMPONENTS The following printer components and areas are associated with this specific problem One or more of these components or areas ma...

Page 164: ...ged Go to Step 3 Replace the Registration Sensor Actuator RRP 4 2 page 285 3 YES FROM STEP 2 ABOVE 1 Switch printer power OFF 2 Remove the Left Side Cover RRP 1 1 page 250 and the Print Engine Control...

Page 165: ...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 Registration...

Page 166: ...2 Remove the Left Side Cover RRP 1 1 page 250 and the Print Engine Controller Board Cover RRP 8 5 page 310 3 Disconnect P J12 from the Print Engine Controller Board 4 Switch printer power ON CAUTION...

Page 167: ...1 and J121 6 Is there continuity between each of the wires Replace the MBF No Paper Sensor Assembly RRP 2 7 page 267 Replace the MBF Combo Harness PL 4 2 page 394 7 SUSPECT COMPONENTS The following p...

Page 168: ...over RRP 1 1 page 250 4 Remove the Print Engine Controller Board Cover RRP 8 5 page 310 5 Disconnect P J21 from the Print Engine Controller Board 6 Check for continuity between J21 4 and J21 3 as you...

Page 169: ...ctuator RRP 2 6 page 266 3 YES FROM STEP 2 ABOVE 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 3 Disconnect P J1...

Page 170: ...and J121 3 Is there continuity between each of the wires Replace the Tray 1 No Paper Sensor RRP 2 6 page 266 Replace the MBF Combo Harness PL 4 2 page 394 7 SUSPECT COMPONENTS The following printer co...

Page 171: ...Diagnostics mode 2 From the Main Menu select Component Test Sensor Input press 4 to start 0 to stop 3 One at a time press each of the Size Actuators while observing the display Does the LCD counter i...

Page 172: ...and P20 5 when pressing SW2 P20 4 and P20 5 when pressing SW3 P20 3 and P20 5 when pressing SW4 Bottom Is there continuity in each case Replace the Print Engine Controller Board RRP 8 5 page 310 Chec...

Page 173: ...ore 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 eac...

Page 174: ...O FROM STEP 2 ABOVE 1 Remove the MBF Assembly 2 On the MBF Assembly measure the resistance between P121 7 and P121 8 Is the resistance approximately 170 to 185 ohms Repair or replace the MBF Harness P...

Page 175: ...Rollers rotate smoothly without stalling or jerking Problem solved Replace the Turn Roller Clutch RRP 2 3 page 262 or Turn Roller Assembly RRP 2 1 page 259 as necessary 9 SUSPECT COMPONENTS The follow...

Page 176: ...STEP 2 ABOVE 1 Remove the MBF Assembly 2 On the MBF Assembly measure the resistance between P121 9 and P121 10 Is the resistance approximately 90 ohms Repair or replace the MBF Harness PL 9 1 page 40...

Page 177: ...roll to Turn Roll Clutch press 4 to energize clutch 4 Scroll to Tray 1 Feed Sol press 4 Was a sheet of paper fed from Tray 1 to the Registration Rollers Problem solved Replace the Tray 1 Feed Solenoid...

Page 178: ...2 ABOVE 1 Remove the MBF Assembly 2 On the MBF Assembly measure the resistance between P121 11 and P121 12 Is the resistance approximately 90 ohms Repair or replace the MBF Combo Harness PL 4 2 page...

Page 179: ...enu select Component Test MBF Feed Sol press 4 to start 0 to stop 6 Scroll to Main Motor press 4 to start motor Was a sheet of paper fed from the MBF to the Registration Rollers Problem solved Replace...

Page 180: ...e Controller Board RRP 8 5 page 310 Replace the LVPS RRP 8 6 page 312 3 YES FROM STEP 1 ABOVE Measure the voltage between P14 3 and frame ground Does the voltage measure 5 0 VDC Go to Step 4 Replace t...

Page 181: ...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: ...AC TEST 1 Enter Diagnostics mode 2 From the Main Menu select Component Test Charge Roll AC 3 Cheat the Top Cover Interlock switch 4 Measure the AC voltage between the Right Side Guide Charge Terminal...

Page 183: ...7 Go to Step 7 7 NO FROM STEP 6 ABOVE 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 3 Switch printer power ON 4...

Page 184: ...ety practices and avoid getting in close proximity of the contact or meter probe 3 Press 4 to test 0 to stop Does the voltage measure approximately 620 25 VAC Go to Step 12 Replace the HVPS RRP 8 2 pa...

Page 185: ...blem 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 HVPS Assembly RRP 8 2 page 30...

Page 186: ...ct all contacts on the Right Print Cartridge Guide Assembly and the terminals on the Print Cartridge Are the terminals in good condition and contacting properly when the cartridge is installed Go to S...

Page 187: ...lete the test run without shutting down Replace the HVPS Board Assembly RRP 8 2 page 307 Go to Step 11 11 PRINT ENGINE CONTROLLER BOARD REPLACEMENT Replace the Print Engine Controller Board RRP 8 5 pa...

Page 188: ...2 From the Main Menu select Component Test Sensor Input press 4 to start 0 to stop 3 Press and release the Low Paper Sensor Actuator Does the LCD counter increment each time you press and release the...

Page 189: ...een P J13 7 Tray 2 or P J132 8 Tray 3 and frame ground as you actuate and deactuate the Low Paper Sensor Does the voltage measure 0 9 VDC when deactuated and 0 0 VDC when actuated Replace the Print En...

Page 190: ...Assembly 2 Measure the resistance between P135 1 and P135 2 Does the resistance measure approximately 90 ohms Repair or replace the Feed Head Harness PL 11 3 page 416 Replace the Tray 2 3 Feed Soleno...

Page 191: ...J13 4 and frame ground Does the voltage measure 3 2 VDC Check the continuity of the Feeder Harnesses P J132 to P H131 and P J131 to P J13 Repair or replace as necessary PL 11 3 page 416 Replace the Pr...

Page 192: ...the 500 Sheet Feeder Board RRP 11 7 page 334 Go to Step 3 3 24 V CHECK AT P J 13 ON THE PRINT ENGINE CONTROLLER BOARD Measure the voltage at P J 13 3 on the Print Engine Controller Board to frame grou...

Page 193: ...inter 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 3 Disconnect P J13 from the Print Engine Controller Board 4 Switch printer po...

Page 194: ...the Print Engine Controller Board RRP 8 5 page 310 Go to Step 7 7 P136 TO P132 CONTINUITY 1 Switch printer power OFF 2 Remove the Left Cover RRP 11 3 page 330 from the top 500 Sheet Feeder Board and...

Page 195: ...ed between all pins Replace the Feeder Board RRP 11 7 page 334 Repair or replace the harness between P J13 and P J131 PL 9 1 page 404 or between P J131 and P J132 PL 11 2 10 SUSPECT COMPONENTS The fol...

Page 196: ...C Replace the Print Engine Controller Board RRP 8 5 page 310 Replace the LVPS RRP 8 6 page 312 4 FUSER EXIT SENSOR 1 Switch printer power OFF 2 Reconnect P J17 to the Print Engine Controller Board 3 S...

Page 197: ...RP 11 3 page 330 3 Disconnect P J133 from the Feeder Board 4 Switch printer power ON 5 Measure the voltage between P133 7 and frame ground the between P133 9 and frame ground Do both voltages measure...

Page 198: ...nuity between P J132 and P J131 the between P J131 and P J13 Repair replace as necessary 7 SUSPECT COMPONENTS The following printer components and areas are associated with this specific problem One o...

Page 199: ...8 and frame ground Does the voltage measure 24 VDC Go to Step 4 Go to Step 3 3 CONTINUITY CHECK 1 Switch printer power OFF 2 Check for continuity between P J504 and P J514 as follows J504 1 and J514...

Page 200: ...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 LVPS RRP 8 6 page 312 Duplex Board RRP...

Page 201: ...rocedure Step Actions and Questions Yes No 1 POWER OFF 1 Switch printer OFF and wait 20 30 seconds before proceeding with sub step 2 2 Press and hold 0 and 4 as you switch printer power ON 3 You may r...

Page 202: ...C wall outlet 2 Use a digital multimeter to monitor the voltage at the AC wall outlet 3 Monitor the AC voltage for 30 minutes or longer Does the voltage at the AC wall outlet meet printer specificatio...

Page 203: ...d 9 INTERFACE CABLE REPLACEMENT 1 Replace the Interface Cable connecting the host computer to the printer if applicable IF NOT APPLICABLE GO TO STEP 10 2 Run test prints from the host computer Does th...

Page 204: ...the communication problem 15 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 yo...

Page 205: ...cal and horizontal for paper fed from that particular tray Cleaning procedures should always be performed before beginning any Print Quality Repair procedure Be sure that the paper meets printer speci...

Page 206: ...Scan Streaks page 194 RESIDUAL IMAGES The image from a previous print which was not removed during the cleaning process has been developed on the current print Residual Image page 197 BLACK PRINTS The...

Page 207: ...staples paper clips paper scraps and or other debris Check the installation of the Print Cartridge Check that the Print Cartridge ground contact points are clean Ensure there are no obstructions in th...

Page 208: ...obstructions Is the laser beam path free obstructions Go to Step 7 Clean the laserwindow and remove any obstructions from the laser beam path 7 BIAS TRANSFER ROLLER INSPECTION Inspect the Bias Transf...

Page 209: ...nt or troubleshoot each area listed below one at a time until you isolate and solve the problem BTR Assembly RRP 7 6 page 304 Fuser Assembly RRP 5 1 page 288 HVPS Board RRP 8 2 page 307 Laser Assembly...

Page 210: ...eet feeds 2 TEST PRINTS 1 Enter Diagnostics mode 2 From the Main Menu select Test Print Print Pattern press 4 to start 0 to stop 3 Run at least five test prints Are the test prints blank Go to Step 4...

Page 211: ...the BTR Assembly RRP 7 6 page 304 8 YES FROM STEP 7 ABOVE 1 Generate a Test Print and switch printer power OFF halfway through the print cycle 2 Carefully remove the Print Cartridge and inspect the to...

Page 212: ...r components in the paper path are clean and unobstructed 2 PRINT CARTRIDGE REPLACEMENT 1 Install a new Print Cartridge 2 Run a Test Print Are the spots gone Problem solved Go to Step 3 3 BIAS TRANSFE...

Page 213: ...ge and contamination Go to Step 6 Replace the Fuser Assembly RRP 5 1 page 288 6 SUSPECT COMPONENTS The following printer components and areas are associated with this specific problem One or more of t...

Page 214: ...Print Pattern press 4 to start 3 Run approximately five test prints then press 0 to stop Do the test prints exhibit horizontal deletions Go to Step 4 Go to Step 3 3 SYSTEM CONTROLLER TEST PRINT 1 Swit...

Page 215: ...m deletions Go to Step 8 Go to RAP 59 page 153 8 YES FROM STEP 7 ABOVE Inspect the toner image on the drum immediately after the transfer area BTR Was the toner image on the drum transferred to the pa...

Page 216: ...ime until you isolate and solve the problem HVPS Board RRP 8 2 page 307 Right Print Cartridge Guide RRP 7 2 page 299 BTR Assembly RRP 7 6 page 304 Paper Transport Assembly RRP 4 1 page 283 Laser Assem...

Page 217: ...sure there are no obstructions in the Laser Beam path Check that the rollers and other components in the paper path are clean and unobstructed 2 PAPER REPLACEMENT 1 Load fresh dry paper 2 Run a Test P...

Page 218: ...ct the Pressure Roller Are the Heat and Pressure Rollers free of scratches damage and contamination Go to Step 8 Replace the Fuser Assembly RRP 5 1 page 288 8 SUSPECT COMPONENTS The following printer...

Page 219: ...at the Print Cartridge contact points are clean 2 PAPER REPLACEMENT 1 Load fresh dry paper 2 Run a Test Print Are spot deletions still present Go to Step 3 Problem solved 3 PRINT CARTRIDGE REPLACEMENT...

Page 220: ...Heat and Pressure Rollers free of scratches damage and contamination Go to Step 6 Replace the Fuser Assembly RRP 5 1 page 288 6 SUSPECT COMPONENTS The following printer components and areas are assoc...

Page 221: ...r obstructions 2 PRINT ENGINE CONTROLLER TEST PRINTS 1 Enter Diagnostics mode 2 From the Main Menu select Test Print Print Pattern press 4 to start 3 After approximately five prints have run press 0 t...

Page 222: ...Step 7 Replace the BTR Assembly RRP 7 6 page 304 7 FUSER INSPECTION 1 Open the Exit Assembly Warning If the printer has been powered ON the Fuser will be hot Use extreme care when handling the Fuser 2...

Page 223: ...attern press 4 to start 3 After approximately 5 prints have run press 0 to stop Do the test prints have horizontal streaks Go to Step 4 Go to Step 3 3 SYSTEM CONTROLLER TEST PRINT 1 Switch printer pow...

Page 224: ...ROLLER INSPECTION Inspect the BTR Assembly for contamination and wear Is the BTR free of contamination and wear Go to Step 8 Replace the BTR Assembly RRP 7 6 page 304 8 YES FROM STEP 7 ABOVE 1 Generat...

Page 225: ...wn 4 Rotate the fuser idler gear manually and inspect the Heat Roller 5 Turn the Fuser Assembly right side up 6 Open the fuse jam access cover 7 Rotate the fuser idler gear manually and inspect the Pr...

Page 226: ...d or debris Check the installation of the Print Cartridge Check that the Print Cartridge ground contact points are clean Verify the fuser temperature NVM 2 PAPER REPLACEMENT 1 Load fresh dry paper 2 R...

Page 227: ...d contamination Go to Step 6 Replace the Fuser Assembly RRP 5 1 page 288 6 SUSPECT COMPONENTS The following printer components and areas are associated with this specific problem One or more of these...

Page 228: ...r board RRP 8 1 page 305 Go to Step 2 2 INSPECTIONS and Checks Inspect the printer paper path for items such as staples paper clips paper scraps and or debris Check the installation of the Print Cartr...

Page 229: ...e Print Cartridge Check that the Print Cartridge ground contact points are clean Ensure the machine covers are in place and fit well so no outside light can enter 2 PRINT CARTRIDGE REPLACEMENT 1 Insta...

Page 230: ...roblem solved Go to Step 6 6 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...

Page 231: ...structed Remove the Print Cartridge and check the Left and Right Guide for wear contamination obstructions etc Clean the laser window 2 TEST PRINT Run a Test Print Does the Test Print image contain un...

Page 232: ...essure Rollers free of scratches damage and contamination Go to Step 6 Replace the Fuser Assembly RRP 5 1 page 288 6 YES FROM STEP 5 ABOVE 1 Generate a Test Print and switch printer power OFF halfway...

Page 233: ...xed if the printer is so equipped If not equipped with a Duplex Module skip to Step 4 below Does the skewed image appear only on duplexed prints Go to Step 3 Go to Step 7 3 FUSER INSPECTION 1 Inspect...

Page 234: ...ge secure mounting and or obstructions 2 Check the Registration Sensor Actuator for damage freedom of operation obstructions or contamination Does the Registration Sensor Actuator move freely and is t...

Page 235: ...ON Inspect the MBF Chute for obstructions and contamination Is the MBF Chute free of obstructions and contamination Go to Step 17 Clean the MBF Chute as necessary 17 REGISTRATION SENSOR INSPECTION 1 I...

Page 236: ...nation Is the Feed Chute free of obstructions and contamination Go to Step 34 Clean or replace the Tray 1 Feed Chute RRP 3 1 page 273 24 Does the skew occur on prints fed from Tray 2 Go to Step 25 Go...

Page 237: ...tion Go to Step 34 Clean or replace the Tray 1 Rear Chute as necessary RRP 3 1 page 273 31 TRAY 3 FEED ROLLERS INSPECTION Inspect the Tray 3 Feed Rollers for wear or contamination Are the Tray 3 Feed...

Page 238: ...ea listed below one at a time until you isolate and solve the problem Fuser Assembly Exit Assembly Duplex Assembly Registration Sensor Registration Sensor Actuator Registration Rollers Bias Transfer R...

Page 239: ...to RAP 82 page 204 Go to Step 3 3 PAPER REPLACEMENT 1 Replace paper with fresh dry standard paper 2 Run a Test Print Is the paper still damaged Go to Step 4 Problem solved 4 FUSER INSPECTION 1 Open th...

Page 240: ...the print still damaged Go to Step 8 Problem solved 8 SUSPECT COMPONENTS The following printer components and areas are associated with this specific problem One or more of these components or areas m...

Page 241: ...dry and fresh and loaded correctly Check that the Paper Tray guides are set correctly Check that rollers and other components in the paper path are clean and unobstructed 2 TEST PRINT Run a Test Prin...

Page 242: ...quence as necessary Registration Clutch RRP 4 3 page 286 Main Gear Drive RRP 6 1 page 295 Registration Sensor RRP 4 4 page 287 Print Engine Controller Board RRP 8 5 page 310 System Controller Board RR...

Page 243: ...estions Yes No 1 INITIAL ACTIONS Check that the paper supply is dry and fresh Ensure that the paper is within specification Check that the paper path for any obstructions or debris 2 TEST PRINT Run a...

Page 244: ...dard paper 2 Run a Test Print Is the problem still present Go to Step 3 Problem solved 3 CHECK FUSER SETTING Refer to Non Volatile Memory Setup Mode and check the Fuser Setting Is the NV code set to f...

Page 245: ...jam access cover 2 Rotate the fuser idler gear manually and inspect the contact between the Heat Roller and the Pressure Roller along the rotation Do the Heat and Pressure Rollers contact each other u...

Page 246: ...alue 2 PRINT CARTRIDGE REPLACEMENT 1 Install a new Print Cartridge PL 8 1 page 402 2 From the Ready Menu press 1 or 5 to scroll to Menus Print Menu then press 2 or 6 to scroll to Print Menu Test Print...

Page 247: ...218 Phaser 5400 Laser Printer Service Guide Blank Page...

Page 248: ...printer is on line the On Line LED is illuminated steadily indicating data reception transmission analysis and printing are allowed When the On Line LED is blinking the printer is receiving or process...

Page 249: ...f printer motors solenoids and electric clutches Generate a test pattern to check printer operation and xerographic functions Read component usage logs Read and change operational parameters Analyze a...

Page 250: ...ill reenter its normal boot sequence To try again power down the printer wait 20 30 seconds and begin at step 1 above again 4 Diagnostics Mode menus are navigated like On Line Mode menus Use buttons 1...

Page 251: ...ntroller PWB boot ROM failure ASIC 0001 0001 ASIC 4 System Controller PWB ASIC controller failure Timer 0001 0001 TIMER 4 System Controller Timer failure PWPM 0001 0001 PWPM 5 System Controller PWPM f...

Page 252: ...Power On LED Sequence The following LEDs on the System Controller Board aid in identifying faults during the Power On sequence The LEDs provide status information in all powered ON operating modes Tab...

Page 253: ...Tray Tray 1 Input Tray Tray 2 Input Tray Tray 3 Input Tray MBF Output Tray Output Tray Standard Output Tray HCS Duplex Duplex Off Duplex On Press 1 or 5 to display Main Menu NVM Config Note When prom...

Page 254: ...d IOT ROM Checksum MBF Feed Sol Tray 1 Feed Sol Tray 2 Feed Sol Tray 3 Feed Sol Turn Roll Clutch Reg Clutch Main Motor Detack Saw Fan Motor High DUP Motor On Low DUP Motor On Hi Exit Motor Fwd L Exit...

Page 255: ...rint Menu are PCL or PostScript files processed and printed like a file from a host computer These files test image processing as well as the printer s mechanical function Printer default settings in...

Page 256: ...press 1 or 5 until Print Menu is displayed 2 Press 2 or 6 until Display Faults is displayed 3 Press 3 to view the most recent fault Continuing to press 3 will display earlier faults in order with page...

Page 257: ...ist Several pages of internal PCL fonts is provided with this test This is another useful print with which to gauge print quality 1 From the Ready menu press 1 or 5 until Print Menu is displayed 2 Pre...

Page 258: ...tes a factory default setting By selecting various combinations of Input Tray Output Tray and Duplex ON OFF you can test most of the printer s functional areas as well as print quality Table 122 Test...

Page 259: ...he host computer but does not occur when you print from Diagnostics the problem may be in the System Controller Board in the print driver software or in the application software on the host computer 5...

Page 260: ...ch tray Measure the distance from the top edge of the paper to the top edge of the image C and measure the distance from the bottom edge of the paper to the bottom edge of the image D These two measur...

Page 261: ...rint Pattern and press 4 The printer begins printing test pages with the print pattern seen in the figure below 9 Measure the distance from the left edge of the paper to the left edge of the image and...

Page 262: ...When password is requested sequentially press 0 7 3 4 to gain entry default Resolution R 3 or 7 N A D N A press 0 to exit Laser Density R 3 or 7 N A 4 N A press 0 to exit Fuser Stdby Temp R 3 or 7 N A...

Page 263: ...A Press 3 or 7 to scroll to desired setting Press 4 to set and exit Table 124 Phaser 5400 Fuser Run Temp Conversion Table NVM Fuser Run Temp Component Test Fuser Temp Read Heat Roll Temp Centigrade C...

Page 264: ...uding the System Controller Board or options HCF High Capacity Feeder Option MBF or MSI Multi sheet Bypass Feeder Table 125 Component Tests Press 1 or 5 to display Main Menu Component Test Press 2 or...

Page 265: ...or click and short duration motor run when pressing 4 Turn Roll Clutch 5 min 1 Press 4 to actuate Tray 1 Feed Clutch 2 Press 0 to stop Note Actuating this test may feed one or more sheets of paper to...

Page 266: ...tor Reverse at low speed or Press 0 to stop Exit Motor Rev H 5 min 1 Press 4 to start test 2 Operates the Exit Motor Reverse at high speed 3 Press 0 to stop ROS Motor 5 min 1 Press 4 to start test 2 O...

Page 267: ...0 to stop BTR 5 min 1 Press 4 to start test 2 The Bias Transfer Roller is positively charged for duration 3 Press 0 to stop MBF Tray Size 4 sec Press 4 to display MBF tray size for duration Tray 1 Si...

Page 268: ...s the internal Hard Drive if installed Formats the Hard Drive if installed Entering Reset Menu 1 To enter the Reset Menu make certain the printer is switched OFF 2 Press and hold 0 and 4 while switchi...

Page 269: ...olding until IOT appears in the display approximately 20 seconds 3 When the Control Display shows IOT release buttons 2 and 6 then press and hold button 0 and 5 You have 10 seconds to release 2 and 6...

Page 270: ...nts in the Diagnostics Test Prints Services Tests and NVRAM Adjustments section of this manual for this procedure Recommended Tools Standard service tools used in printer repair Toner vacuum such as t...

Page 271: ...f having to service the printer in the future The frequency of use and the type of paper a customer prints on determines how critical cleaning the machine is Users of ordinary Bond paper copier paper...

Page 272: ...r from the suction bulb Alternately you can vacuum the window clean 7 Vacuum out the interior of the printer 8 Carefully clean the area around the Bias Transfer Roller for impacted toner a Remove the...

Page 273: ...244 Phaser 5400 Laser Printer Service Guide Blank Page...

Page 274: ...RRP 1 1 Left Side Cover 250 RRP 1 2 Right Side Cover 251 RRP 1 3 Top Cover Assembly 252 RRP 1 4 Front Cover 253 RRP 1 5 Lower Left Cover 254 RRP 1 6 HVPS Cover 255 RRP 1 7 Lower Rear Cover 256 RRP 1 8...

Page 275: ...oltage Power Supply LVPS Assembly 312 RRP 8 7 LVPS FAN 313 RRP 8 8 AC Input Assembly 314 RRP 8 9 Control Panel 5 VDC Power Supply 315 RRP 9 1 Duplex Assembly 317 RRP 10 1 1000 Sheet High Capacity Stac...

Page 276: ...RRP 12 9 Tray Lift Motor Assembly 361 RRP 12 10 A4 Paper Size Sensor 362 RRP 12 11 Casters 363 RRP 12 12 Harness Assembly 364 RRP 12 13 Drive Assembly 365 RRP 12 14 Feed Nudger and Retard Roller 366...

Page 277: ...st components within a procedure Cautions Always reinstall the correct type and size screws Using the wrong screw can damage tapped holes Do not use excessive force to either remove or install a part...

Page 278: ...power for the Fuser to cool before you work on or around the Fuser Notations in the RRP text The notation rear of a component in place or removed refers to the surface of the component that is when i...

Page 279: ...Side Cover See PL 1 1 Covers Removal Warning Switch off the power and disconnect the Power Cord 1 Slide the Left Cover toward the rear of the printer 2 Remove the Left Side Cover Replacement Reinstall...

Page 280: ...p Cover and remove the Print Cartridge Cover the cartridge to protect it from light Note Place paper inside the Print Cartridge cavity to catch any dropped hardware 4 Remove the Left Side Cover RRP 1...

Page 281: ...is secured by three types of screws Note the type and position of each of the screws as they are removed This information will be required for replacement of the screws 6 Remove the eight screws that...

Page 282: ...nt Cartridge cavity to catch any dropped hardware 5 Remove the Left Side Cover RRP 1 1 Left Side Cover 6 Remove the Top Cover Assembly RRP 1 3 Top Cover Assembly 7 Open the MBF Assembly Door lift slig...

Page 283: ...rning Switch off the power and disconnect the Power Cord 1 Remove the Left Side Cover RRP 1 1 Left Side Cover 2 Remove the two screws that secure the Lower Left Cover to the printer 3 Remove the Lower...

Page 284: ...Duplex Assembly 3 Remove the screw that secures the Left Duplex Stopper to the printer Remove the Stopper 4 Remove the screw that secures the Right Duplex Stopper to the printer Remove the Stopper 5 R...

Page 285: ...L 7 1 Frame Drives Removal Warning Switch off the power and disconnect the Power Cord 1 Remove the four screws that secure the Lower Rear Cover to the printer 2 Remove the Lower Rear Cover Replacement...

Page 286: ...ti sheet Bypass Feeder MBF Assembly 2 Remove the screw that secures the Left MBF Gear Cover to the left side of the Paper Handler 3 Release the three locking tabs and remove the MBF Gear Cover 4 The M...

Page 287: ...nnect P J527 and P J528 and release clamp 3 Remove the two screws that secure the Rear Cover support straps to the Rear Cover Support Rear Cover with one hand while removing the straps from the posts...

Page 288: ...front of the cover and rotate the cover clockwise to remove with the left hand while pulling the rear piece toward you to release the alignment pin with the right hand 5 Release the harness from the u...

Page 289: ...260 Phaser 5400 Laser Printer Service Guide Replacement Reinstall the components in the reverse order Figure 46 MBF Left Tray Stop Figure 47 MBF Right Tray Stop...

Page 290: ...Feed Roller lift the locking tab on the Left MBF Roller Core and slide the core to the left Slide the MBF Feed Roller to the left and remove 3 For the Right Feed Roller lift the locking tab on the Rig...

Page 291: ...ector P J124 4 Remove the screw that secures the Tray 1 No Paper Sensor Assembly Bracket to the bottom of the Paper handler 5 Note the harness path then remove the Turn Roller Clutch harness from the...

Page 292: ...mbly 2 Remove the MBF Gear Cover RRP 1 8 MBF Gear Cover 3 Remove the Turn Roller Clutch RRP 2 3 MBF Tray 1 Turn Roller Clutch Assembly 4 Remove the bearing located behind the Turn Roller Clutch 5 Remo...

Page 293: ...BF Pick up Gear and remove the gear 5 Move the MBF Pick up Shaft to the right and remove the shaft from the MBF 6 Remove the screw that secures the support bracket to the MBF Remove the bracket 7 Inse...

Page 294: ...Phaser 5400 Laser Printer Service Guide 265 Replacement Reinstall the components in the reverse order Figure 52 MBF Tray Assembly Figure 53 MBF Retard Holder Assembly...

Page 295: ...F Gear Cover RRP 1 8 MBF Gear Cover 3 Disconnect P J126 from the sensor assembly 4 Remove the screw that secures the Tray 1 No Paper Sensor Assembly Bracket to the MBF 5 Use a small screwdriver to car...

Page 296: ...bs on the MBF Pick Up Gear and remove the gear 5 Move the MBF Pick Up Shaft to the right and remove the shaft from the MBF 6 Remove the screw that secures the support bracket to the MBF and remove the...

Page 297: ...268 Phaser 5400 Laser Printer Service Guide Replacement Reinstall the components in the reverse order Figure 56 MBF Tray Assembly Figure 57 MBF No Paper Sensor Assembly...

Page 298: ...e MBF Assembly RRP 2 1 Multi sheet Bypass Feeder MBF Assembly 2 Remove the MBF Gear Cover RRP 1 8 MBF Gear Cover 3 Remove the Pick up Spring from the MBF Pick up Gear 4 Disconnect P J123 from the MBF...

Page 299: ...Assembly RRP 2 1 Multi sheet Bypass Feeder MBF Assembly 2 Remove the MBF Gear Cover RRP 1 8 MBF Gear Cover 3 Remove the Pick up Spring from the Tray 1 Pick up Gear 4 Disconnect P J135 from the Tray 1...

Page 300: ...3 Release the Tray 1 Feed Solenoid 4 Rotate the Feed Rollers up 5 Press locking tab that secures the Left Roller Core 6 Slide the Left Roller Core to the left 7 Slide the Feed Roller to the left and r...

Page 301: ...Print Cartridge Cover the cartridge to protect it from light 2 Remove Tray 1 3 Remove the MBF Assembly RRP 2 1 Multi sheet Bypass Feeder MBF Assembly 4 Remove the Retard Chute Assembly RRP 3 1 Retard...

Page 302: ...the Print Cartridge Cover the cartridge to protect it from light 2 Remove Tray 1 3 Remove the MBF Assembly RRP 2 1 Multi sheet Bypass Feeder MBF Assembly 4 Tilt the top of the Retard Chute Assembly to...

Page 303: ...ht 2 Remove Tray 1 3 Remove the MBF Assembly RRP 2 1 Multi sheet Bypass Feeder MBF Assembly 4 Remove the Retard Chute Assembly RRP 3 1 Retard Chute Assembly 5 Remove the two screws that secure the Rea...

Page 304: ...et Bypass Feeder MBF Assembly 4 Remove the Retard Chute Assembly RRP 3 1 Retard Chute Assembly 5 Remove the E ring from the right end of the Lower Turn Roller 6 Remove the right bearing 7 Release the...

Page 305: ...ect it from light 2 Remove Tray 1 3 Remove the MBF Assembly RRP 2 1 Multi sheet Bypass Feeder MBF Assembly 4 Remove the Retard Chute Assembly RRP 3 1 Retard Chute Assembly 5 Remove Tray 1 Left Guide A...

Page 306: ...er 5 Remove the Top Cover Assembly RRP 1 3 Top Cover Assembly 6 Remove the Right Side Cover RRP 1 2 Right Side Cover 7 Remove the MBF Assembly RRP 2 1 Multi sheet Bypass Feeder MBF Assembly 8 Remove t...

Page 307: ...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 Repla...

Page 308: ...ridge to protect it from light 2 Remove Tray 1 3 Remove the Left Side Cover RRP 1 1 Left Side Cover 4 Remove the MBF Assembly RRP 2 1 Multi sheet Bypass Feeder MBF Assembly 5 Remove the Retard Chute A...

Page 309: ...the guide assembly to the bottom of the printer 9 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 orde...

Page 310: ...the Power Cord 1 Remove the Left CRU Guide RRP 7 5 Left Print Cartridge Guide Assembly 2 Disengage the two hooks securing the CRUM Board to the CRU Guide 3 Remove the CRUM Board Replacement Reinstall...

Page 311: ...ay 1 3 Remove the Left Side Cover RRP 1 1 Left Side Cover 4 Remove the MBF Assembly RRP 2 1 Multi sheet Bypass Feeder MBF Assembly 5 Remove the Retard Chute Assembly RRP 3 1 Retard Chute Assembly 6 Re...

Page 312: ...r the cartridge to protect it from light 4 Remove Tray 1 5 Remove the MBF Assembly RRP 2 1 Multi sheet Bypass Feeder MBF Assembly 6 Remove the Left Side Cover RRP 1 1 Left Side Cover 7 Remove the Top...

Page 313: ...er 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 14 Guide the high v...

Page 314: ...the Left Side Cover RRP 1 1 Left Side Cover 7 Remove the Top Cover Assembly RRP 1 3 Top Cover Assembly 8 Remove the HVPS Cover RRP 1 6 HVPS Cover 9 Remove the Paper Transport Assembly RRP 4 1 Paper Tr...

Page 315: ...ght 4 Remove Tray 1 5 Remove the MBF Assembly RRP 2 1 Multi sheet Bypass Feeder MBF Assembly 6 Remove the Left Side Cover RRP 1 1 Left Side Cover 7 Remove the Top Cover Assembly RRP 1 3 Top Cover Asse...

Page 316: ...move the MBF Assembly RRP 2 1 Multi sheet Bypass Feeder MBF Assembly 6 Remove the Left Side Cover RRP 1 1 Left Side Cover 7 Remove the Top Cover Assembly RRP 1 3 Top Cover Assembly 8 Remove the HVPS C...

Page 317: ...ration the Fuser may be hot Caution When handling the fuser use care to prevent damage to the entrance guide 1 Open the Rear Cover 2 Move the Fuser Locking Lever to the left as viewed from the rear 3...

Page 318: ...he Rear Cover RRP 1 9 Rear Cover 2 Remove the four screws that secure the Lower Exit Chute Assembly Remove the assembly 3 Remove the four screws that secure the Upper Exit Chute Remove the top of the...

Page 319: ...ve the sensor from the holder 7 Disconnect P J507 from the Stack Full Sensor Replacement Reinstall the components in the reverse order Note The two shoulder screws go in the right end of the Lower Exi...

Page 320: ...r Assembly 6 Release the three locking tabs and remove the Gear Z15 from Upper Exit Roller Assembly 7 Remove the left and right bearings from the Exit Roller 8 Remove the two paper tabs from the shaft...

Page 321: ...292 Phaser 5400 Laser Printer Service Guide Figure 80 Upper Exit Chute Figure 81 Upper Exit Roller Assembly...

Page 322: ...Phaser 5400 Laser Printer Service Guide 293 Replacement Reinstall the components in the reverse order Figure 82 Lower Exit Roller Assembly...

Page 323: ...al Warning Switch off the power and disconnect the Power Cord 1 Open the Rear Cover 2 Remove the Rear Cover RRP 1 9 Rear Cover 3 Remove the Stack Full Sensor RRP 5 2 Stack Full Sensor 4 Carefully pull...

Page 324: ...Lower Rear Cover RRP 1 7 Lower Rear Cover 2 Open the Rear Cover 3 Remove the Fuser Assembly RRP 5 1 Fuser Assembly 4 Open the Top Cover and remove the Print Cartridge 5 Cover the cartridge to protect...

Page 325: ...ep 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...

Page 326: ...r 2 Open the Top Cover and remove the Print Cartridge Cover the cartridge to protect it from light 3 Remove the Left Side Cover RRP 1 1 Left Side Cover 4 Remove the Top Cover Assembly RRP 1 3 Top Cove...

Page 327: ...nect P J112 and the in line connector P J114 from the Laser Assembly 9 Remove the four screws that secure the Laser Assembly to the printer 10 Remove the Laser Assembly Replacement Reinstall the compo...

Page 328: ...off the power and disconnect the Power Cord 1 Remove the Lower Rear Cover RRP 1 7 Lower Rear Cover 2 Open and remove the Rear Cover RRP 1 9 Rear Cover 3 Remove the Fuser Assembly RRP 5 1 Fuser Assembl...

Page 329: ...he Fuser Interlock Switch 11 Disconnect P J162 from the LVPS PWB 12 Remove all disconnected harnesses from cable clamps 13 Remove the two screws that secure the right guide assembly 14 Guide harnesses...

Page 330: ...Open the Top Cover and remove the Print Cartridge Cover the cartridge to protect it from light 2 Disconnect P J141 3 Release Toner Sensor Assembly Harness from the cable clamps and retainers 4 Releas...

Page 331: ...e the Left Side Cover RRP 1 1 Left Side Cover 4 Remove the Top Cover Assembly RRP 1 3 Top Cover Assembly 5 Remove the Right Side Cover RRP 1 2 Right Side Cover 6 Remove the screw that secures the Inte...

Page 332: ...3 Remove the Left Side Cover RRP 1 1 Left Side Cover 4 Remove the Top Cover Assembly RRP 1 3 Top Cover Assembly 5 Remove the BTR Assembly RRP 7 6 Bias Transfer Roller BTR Assembly 6 Remove the two scr...

Page 333: ...g the following steps do not touch the black Roller part of the BTR Oil from your hands can cause copy quality problems 2 Lift the orange handle on the left end of the BTR Assembly Pull up on the hand...

Page 334: ...e four screws that secure the rear of the System Controller PWB Assembly to the printer 4 Disconnect P J3 P J13 and P J18 from the System Controller PWB 5 Remove the seven screws that secure the Syste...

Page 335: ...nnector to the frame assembly 11 Remove the three screws that secures the System Controller PWB to the frame assembly Remove the System Controller PWB Replacement Reinstall the components in the rever...

Page 336: ...nect the Power Cord 1 Remove the Rear Cover RRP 1 9 Rear Cover 2 Remove the HVPS Cover RRP 1 6 HVPS Cover 3 Disconnect P J181 P J182 P J186 P J187 P J188 P J185 from the HVPS PWB Caution When reconnec...

Page 337: ...damage Warning Switch off the power and disconnect the Power Cord 1 Remove the Rear Cover RRP 1 9 Rear Cover 2 Remove the HVPS Cover RRP 1 6 HVPS Cover 3 DIsconnect P J501 P J504 and P J506 from the...

Page 338: ...1000 Sheet High Capacity Stacker HCS 4 Remove the Left Side Cover RRP 1 1 Left Side Cover 5 Open the Top Cover and remove the Print Cartridge Cover the cartridge to protect it from light 6 Remove the...

Page 339: ...Cover RRP 1 1 Left Side Cover 2 Loosen the two thumb screws that secure the System Controller PWB Shield Cover and remove the cover 3 Remove the four screws that secure the Print Engine Controller PWB...

Page 340: ...Phaser 5400 Laser Printer Service Guide 311 Replacement Reinstall the components in the reverse order Figure 100 Print Engine Controller Board Cover Figure 101 Print Engine Controller Board...

Page 341: ...163 P J162 and P J161 from the LVPS Assembly Caution In the next step when removing the four LVPS mounting screws take note of the color Two are silver colored and two have a slight gold tint The gold...

Page 342: ...es to avoid damage Warning Switch off the power and disconnect the Power Cord 1 Remove the Lower Rear Cover RRP 1 7 Lower Rear Cover 2 Disconnect P J166 from the LVPS Assembly 3 Remove the Fan Harness...

Page 343: ...ground from the frame take note there are two star washers One washer is under the wire terminal and the other is under the screw head Be certain to reinstall properly 3 Remove the screw that secures...

Page 344: ...electrostatic discharge Observe all ESD procedures to avoid damage Warning Switch off the power and disconnect the Power Cord 1 Remove the Left Cover RRP 1 1 Left Side Cover 2 Loosen the two thumb nut...

Page 345: ...ervice Guide 4 Disconnect P J169 from the 5 VDC power Supply 5 Remove the two screws that secure the 5 VDC Power Supply Remove the Power Supply Replacement Reinstall the components in the reverse orde...

Page 346: ...and disconnect the Power Cord 1 Open the Rear Cover 2 Remove Left Cover RRP 1 1 Left Side Cover 3 Pull the top of the Duplex Assembly away from the printer to disengage the two hooks securing the unit...

Page 347: ...d disconnect the Power Cord 1 Open the printer Rear Cover 2 Loosen the thumb screw located on the inside of the right frame 3 Lift the High Capacity Stacker HCS straight up and remove 4 Remove HCS Sol...

Page 348: ...er HCS 1 of 2 Removal Warning Switch off the power and disconnect the Power Cord 1 Open the HCS Rear Cover 2 Remove the HCS Output Bin 3 Remove the four screws that secure the Top Cover 4 Lift the cov...

Page 349: ...ity Stacker HCS 1 of 2 Removal Warning Switch off the power and disconnect the Power Cord 1 Open the HCS Rear Cover 2 Carefully press in on the right bracket to disengage the cover from the frame 3 Re...

Page 350: ...1 of 2 Removal Warning Switch off the power and disconnect the Power Cord 1 Open the HCS Rear Cover 2 Remove the HCS Top Cover RRP 10 2 HCS Top Cover 3 Remove the four screws that secure the Front Co...

Page 351: ...emoval Warning Switch off the power and disconnect the Power Cord 1 Open the printer Rear Cover 2 Press the locking tab and disconnect P J519 from the Rear Cover 3 Press the locking tab on the Solenoi...

Page 352: ...Warning Switch off the power and disconnect the Power Cord 1 Open the HCS Rear Cover 2 Remove the HCS Top Cover RRP 10 2 HCS Top Cover 3 Disconnect P J521 from the Stack Full Sensor 4 Release the thre...

Page 353: ...wer Cord 1 Open the HCS Rear Cover 2 Remove the HCS Top Cover RRP 10 2 HCS Top Cover 3 Remove the Stack Full Sensor RRP 10 6 HCS Stack Full Sensor 4 Move the actuator to the left Carefully flex the ce...

Page 354: ...he power and disconnect the Power Cord 1 Open the HCS Rear Cover 2 Remove the HCS Top Cover RRP 10 2 HCS Top Cover 3 Disconnect P J518 from the Drive Motor 4 Remove the two screws that secure the Moto...

Page 355: ...l Warning Switch off the power and disconnect the Power Cord 1 Open the HCS Rear Cover 2 Remove the HCS Top Cover RRP 10 2 HCS Top Cover 3 Disconnect P J525 from the interlock switch 4 Release the two...

Page 356: ...isconnect the Power Cord 1 Open the HCS Rear Cover 2 Remove the HCS Top Cover RRP 10 2 HCS Top Cover 3 Remove the HCS Front Cover RRP 10 4 HCS Front Cover 4 Disconnect P J523 from the Paper Sensor 5 R...

Page 357: ...10 1 1000 Sheet High Capacity Stacker HCS 2 Remove Tray 1 from the printer 3 Remove the two screws that secure the printer to the Optional Paper Feeder Warning To avoid possible personal injury associ...

Page 358: ...arning Switch off the power and disconnect the Power Cord 1 Remove the paper tray from the feeder 2 Loosen the two screws that secure the front cover 3 Pull out on the top of the Front Cover and lift...

Page 359: ...emoval Warning Switch off the power and disconnect the Power Cord 1 Remove the paper tray from the feeder 2 Remove the Front Cover RRP 11 2 Front Cover 3 Remove the five screws that secure the Left Co...

Page 360: ...emoval Warning Switch off the power and disconnect the Power Cord 1 Remove the paper tray from the feeder 2 Remove the Front Cover RRP 11 2 Front Cover 3 Remove the five screws that secure the Right C...

Page 361: ...g Switch off the power and disconnect the Power Cord 1 Open the Rear Cover 2 Carefully pry the left hinge pin as viewed from the rear of the feeder out of the printer frame 3 Pull the right end of the...

Page 362: ...ord 1 Remove the paper tray from the feeder 2 Remove the Front Cover RRP 11 2 Front Cover 3 Remove the Left Cover RRP 11 3 Left Cover 4 Disconnect P J13B from the Feeder PWB 5 Remove the four screws t...

Page 363: ...arning Switch off the power and disconnect the Power Cord 1 Remove the paper tray from the feeder 2 Remove the Front Cover RRP 11 2 Front Cover 3 Remove the Left Cover RRP 11 3 Left Cover 4 Disconnect...

Page 364: ...the Front Cover RRP 11 2 Front Cover 4 Remove the Left Cover RRP 11 3 Left Cover 5 Disconnect P J13A P J13P and P J135 from the Feed Head Assembly 6 Remove the screw that secures the Feed Head to the...

Page 365: ...the 500 Sheet Feed Head Assembly RRP 11 8 Feed Head Assembly 6 Release the Feed Solenoid 7 Rotate the Feed Rollers up 8 Press the left locking tab and slide the Roller core to the left 9 Slide the Ro...

Page 366: ...eder RRP 11 1 500 Sheet Feeder Removal 2 Remove the paper tray from the feeder 3 Remove the Front Cover RRP 11 2 Front Cover 4 Remove the Left Cover RRP 11 3 Left Cover 5 Remove the 500 Sheet Feed Hea...

Page 367: ...the feeder 3 Remove the Front Cover RRP 11 2 Front Cover 4 Remove the Left Cover RRP 11 3 Left Cover 5 Remove the 500 Sheet Feed Head Assembly RRP 11 8 Feed Head Assembly 6 Remove the two screws that...

Page 368: ...eet Feeder Removal 2 Remove the paper tray from the feeder 3 Remove the Front Cover RRP 11 2 Front Cover 4 Remove the Left Cover RRP 11 3 Left Cover 5 Remove the 500 Sheet Feed Head Assembly RRP 11 8...

Page 369: ...340 Phaser 5400 Laser Printer Service Guide RRP 11 13 Left Tray Guide See PL 11 3 500 Sheet Feeder 3 of 3 Figure 130 Left Tray Guide...

Page 370: ...Front Cover 4 Remove the Left Cover RRP 11 3 Left Cover 5 Remove the 500 Sheet Feed Head Assembly RRP 11 8 Feed Head Assembly 6 Remove the Retard Chute RRP 11 12 Retard Chute Assembly 7 Disconnect P...

Page 371: ...RRP 11 4 Right Cover 5 Remove the 500 Sheet Feed Head Assembly RRP 11 8 Feed Head Assembly 6 Remove the Retard Chute RRP 11 12 Retard Chute Assembly 7 Carefully push down on the locking tab that secur...

Page 372: ...Phaser 5400 Laser Printer Service Guide 343 Replacement Reinstall the components in the reverse order Figure 132 Right Tray Guide...

Page 373: ...the paper tray from the feeder 3 Remove the Front Cover RRP 11 2 Front Cover 4 Remove the Left Cover RRP 11 3 Left Cover 5 Remove the 500 Sheet Feed Head Assembly RRP 11 8 Feed Head Assembly 6 Remove...

Page 374: ...r 3 Remove the Front Cover RRP 11 2 Front Cover 4 Remove the Left Cover RRP 11 3 Left Cover 5 Remove the 500 Sheet Feed Head Assembly RRP 11 8 Feed Head Assembly 6 Remove the Retard Chute RRP 11 12 Re...

Page 375: ...the feeder 3 Remove the Front Cover RRP 11 2 Front Cover 4 Remove the Left Cover RRP 11 3 Left Cover 5 Remove the 500 Sheet Feed Head Assembly RRP 11 8 Feed Head Assembly 6 Remove the Retard Chute RR...

Page 376: ...om the feeder 3 Remove the Front Cover RRP 11 2 Front Cover 4 Remove the Left Cover RRP 11 3 Left Cover 5 Remove the 500 Sheet Feed Head Assembly RRP 11 8 Feed Head Assembly 6 Remove the Retard Chute...

Page 377: ...ove the printer from the 500 Sheet Feeder RRP 11 1 500 Sheet Feeder Removal 2 Remove the paper tray from the feeder 3 Remove the Front Cover RRP 11 2 Front Cover 4 Remove the Left Cover RRP 11 3 Left...

Page 378: ...uator 8 Release the Paper Feed Solenoid and rotate feed Rollers to allow access to the sensor 9 Disconnect P J134 from the No Paper Sensor 10 Release the three locking tabs and remove the sensor Repla...

Page 379: ...0 Sheet Feeder Removal 2 Remove the paper tray from the feeder 3 Remove the Front Cover RRP 11 2 Front Cover 4 Remove the Left Cover RRP 11 3 Left Cover 5 Remove the 500 Sheet Feed Head Assembly RRP 1...

Page 380: ...paper tray from the feeder 3 Remove the Front Cover RRP 11 2 Front Cover 4 Remove the Left Cover RRP 11 3 Left Cover 5 Remove the Feed Head Assembly RRP 11 8 Feed Head Assembly 6 Remove the screw tha...

Page 381: ...352 Phaser 5400 Laser Printer Service Guide RRP 12 1 Removing the 2000 Sheet Feeder See PL 12 1 2000 Sheet Feeder 1 of 4 Figure 143 Removing the Printer...

Page 382: ...S 3 Remove Tray 1 from the printer 4 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 5 Remove the p...

Page 383: ...2000 Sheet Feeder 1 of 4 Removal Warning Switch off the power and disconnect the Power Cord 1 Remove the two screws that secure the Left Side Cover 2 Pull the top of the cover out and up to remove Rep...

Page 384: ...eder 1 of 4 Removal Warning Switch off the power and disconnect the Power Cord 1 Open the Upper Rear Cover 2 Carefully push in on the left or right bracket to disengage the end of the cover 3 Remove t...

Page 385: ...of 4 Removal Warning Switch off the power and disconnect the Power Cord 1 Remove the two screws that secure the top of the Lower Rear Cover 2 Loosen three screws that secure the Lower Rear Cover 3 Re...

Page 386: ...000 Sheet Feeder 1 of 4 Removal Warning Switch off the power and disconnect the Power Cord 1 Remove the two screws that secure the Right Side Cover 2 Pull the top of the cover out and up to remove Rep...

Page 387: ...er 1 of 4 Removal Warning Switch off the power and disconnect the Power Cord 1 Open the 2000 Sheet Feeder Tray 2 Remove the two screws that secure the front cover 3 Pull the top of the cover out and u...

Page 388: ...ing Switch off the power and disconnect the Power Cord 1 Pull the 2000 Sheet Feeder Tray out until it stops 2 Remove all paper from the tray 3 Push and hold the button on the Left Rail to release the...

Page 389: ...arge Observe all ESD procedures to avoid damage Warning Switch off the power and disconnect the Power Cord 1 Remove the Lower Rear Cover RRP 12 4 Lower Rear Cover 2 Disconnect P J601 P J602 P J603 P J...

Page 390: ...er and disconnect the Power Cord 1 Remove the Lower Rear Cover RRP 12 4 Lower Rear Cover 2 Open the 2000 Sheet Feeder tray 3 Disconnect P J605 from the PWB 4 Remove the three screws that secure the Li...

Page 391: ...al Warning Switch off the power and disconnect the Power Cord 1 Remove the 2000 Sheet Feeder Tray Assembly RRP 12 7 Tray Assembly 2 Disconnect P J612 from the Paper Size Sensor 3 Release the two locki...

Page 392: ...RP 11 1 500 Sheet Feeder Removal 2 Remove the Left Foot 3 Remove the Left Side Cover RRP 12 2 Left Side Cover 4 Remove all paper from the 2000 Sheet Feeder tray 5 Tilt the 2000 Sheet Feeder onto its l...

Page 393: ...Removal 2 Remove the Left Side Cover RRP 12 2 Left Side Cover 3 Remove the Lower Rear Cover RRP 12 4 Lower Rear Cover 4 Disconnect P J601 from the 2000 Sheet Feeder PWB 5 Release the harness from all...

Page 394: ...Cord 1 Open the Upper Rear Cover 2 Remove the screw that secures the back of the Drive Assembly 3 Remove the Tray Assembly RRP 12 7 Tray Assembly 4 Disconnect P J615 from the Drive Assembly 5 Remove...

Page 395: ...wer Cord 1 Open the 2000 Sheet Feeder tray 2 Open the Upper Rear Cover 3 From the rear loosen the two thumb screws and remove the paper baffle 4 From the rear of the feeder carefully lift the locking...

Page 396: ...the power and disconnect the Power Cord 1 Remove the 2000 Sheet Feeder Tray Assembly RRP 12 7 Tray Assembly 2 Hold the Nudger Assembly down as you release the three locking tabs that secure the Paper...

Page 397: ...wer Cord 1 Remove the Right Side Cover RRP 12 5 Right Side Cover 2 Remove the E ring that secures the 47T gear Remove the gear 3 Remove the two screws that secure the motor to the Feeder Frame 4 Remov...

Page 398: ...e Power Cord 1 Remove the Retard Assembly RRP 12 26 Retard Assembly 2 Remove the 2000 Sheet Feeder Tray Assembly RRP 12 7 Tray Assembly 3 Unhook the torsion spring from the Link Stopper 4 Pull up on t...

Page 399: ...Warning Switch off the power and disconnect the Power Cord 1 Remove the Tray Assembly RRP 12 7 Tray Assembly 2 Disconnect P J610 from the No Paper Sensor 3 Release the three locking tabs that secure t...

Page 400: ...l Warning Switch off the power and disconnect the Power Cord 1 Remove the Tray Assembly RRP 12 7 Tray Assembly 2 Release the four locking tabs that secure the actuator and support 3 Remove the actuato...

Page 401: ...Switch off the power and disconnect the Power Cord 1 Open the 2000 Sheet Feeder Tray Assembly until it stops 2 Remove the two screws that secure the Wire Cover to the Tray Assembly 3 Pull the top of t...

Page 402: ...Warning Switch off the power and disconnect the Power Cord 1 Remove the 2000 Sheet Feeder Tray Assembly RRP 12 7 Tray Assembly 2 Remove the four screws that secure the Shaft Cover Assembly to the Tra...

Page 403: ...0 Sheet Feeder Tray Assembly RRP 12 7 Tray Assembly 2 Remove the Shaft Cover Assembly RRP 12 21 Shaft Cover Assembly 3 Align the Drive Shaft Assembly with the hole in the Shaft Cover Assembly 4 Remove...

Page 404: ...Warning Switch off the power and disconnect the Power Cord 1 Remove the 2000 Sheet Feeder Tray Assembly RRP 12 7 Tray Assembly 2 Remove the two screws that secure the Brake Assembly to the Tray Assemb...

Page 405: ...RP 12 23 Brake Assembly 4 Remove the Left Wire Cover RRP 12 20 Left and Right Wire Cover 5 Remove the E ring that secures the 33 Gear and remove the gear 6 Remove the Cable Pulley from the shaft 7 Rem...

Page 406: ...Cover Assembly 3 Remove the Right Wire Cover RRP 12 20 Left and Right Wire Cover 4 Remove the E ring that secures the Cable Pulley Remove the pulley 5 Remove the E rings and pulleys from the two shaf...

Page 407: ...Cord 1 Remove the 2000 Sheet Feeder Tray Assembly RRP 12 7 Tray Assembly 2 Remove the Right Side Cover RRP 12 5 Right Side Cover 3 Remove the E ring that secures the 50T Gear to the Feeder Shaft then...

Page 408: ...nd as viewed from the rear of the Retard Support 8 Remove the two screws that secure the Retard Support Assembly to the feeder 9 Lift the Retard Support Assembly slide it to the right and remove Repla...

Page 409: ...380 Phaser 5400 Laser Printer Service Guide Blank Page...

Page 410: ...the same illustration or in a series of associated illustrations The parts which are spared are indicated by a part number in the Part Number column Conversely the lack of a part number for any given...

Page 411: ...an illustration indicates the item is part of an assembly 5 The notation with X Y following an part name indicates an assembly that is made up of components X through Y For example 1 with 2 4 means pa...

Page 412: ...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 assembl...

Page 413: ...384 Phaser 5400 Laser Printer Service Guide Parts Lists PL 1 1 Covers Figure 170 Covers s5400 202 25 24 27 22 23 with 18 22 26...

Page 414: ...0 1 Latch Right P O item 1 11 1 Latch Left P O item 1 12 1 Tray Guide Right P O item 1 13 1 Tray Guide Left P O item 1 14 1 Tray Extension P O item 1 15 050E88420 1 Tray Stopper 16 101K37901 1 Control...

Page 415: ...386 Phaser 5400 Laser Printer Service Guide PL 2 1 Paper Tray A3 Ledger Figure 171 Paper Tray A3 Ledger...

Page 416: ...5 1 Pinion P O item 1 16 1 Cover Bottom long P O item 1 17 1 Gear Sector long P O item 1 18 1 Gear Idler P O item 1 19 1 Lock End Guide P O item 1 20 1 Cover Tray 1 P O item 1 21 1 Cam Size long P O i...

Page 417: ...388 Phaser 5400 Laser Printer Service Guide PL 2 2 Paper Tray A4 Letter Figure 172 Paper Tray A4 Letter...

Page 418: ...0 1 End Guide 11 1 End Guide Spring Plate 12 1 Guide End Plate 13 1 Housing Tray 1 short 14 1 Rack 15 1 Pinion 16 1 Cover Bottom short 17 1 Gear Sector short 18 1 Gear Idler 19 1 Lock End Guide 20 1 C...

Page 419: ...390 Phaser 5400 Laser Printer Service Guide PL 3 1 Paper Feeder Figure 173 Paper Feeder...

Page 420: ...P O item 8 15 1 Gear Turn P O item 8 16 604K01890 1 Guide Assembly Tray 1 right includes 5 6 17 19 17 1 Guide Tray 1 right P O item 16 18 1 Actuator GG P O Item 16 19 1 Spring Paper Level Indicator P...

Page 421: ...392 Phaser 5400 Laser Printer Service Guide PL 4 1 Multi sheet Bypass Feeder MBF Assembly Figure 174 Multi sheet Bypass Feeder MBF Assembly...

Page 422: ...1 11 5 Bearing 8 P O item 1 12 003K85941 1 Latch Assembly right 13 121K20060 1 Clutch Tray 1 Turn Roller 14 059K13064 1 Roller Assembly Tray 1 Turn 15 1 Bracket P O item 1 16 1 Gear Tray 1 Pick Up P O...

Page 423: ...394 Phaser 5400 Laser Printer Service Guide PL 4 2 Paper Handler Figure 175 Paper Handler includes 9 18 20...

Page 424: ...Sensor P O item 12 14 1 Sensor No Paper P O item 12 15 1 Holder Tray 1 Sensor P O item 12 16 050K43611 1 Door MBF 17 019K94921 1 Sensor MBF No Low Paper includes 9 18 20 18 1 Spring MBF No Low Paper S...

Page 425: ...396 Phaser 5400 Laser Printer Service Guide PL 5 1 Paper Transport Figure 176 Paper Transport...

Page 426: ...on P O item 1 8 1 Gear Registration rubber roller shaft P O Item 1 9 1 Bearing Right rubber roller shaft P O Item 1 10 1 Gear Registration metal shaft P O Item 1 11 2 Bearing metal shaft P O Item 1 12...

Page 427: ...sembly With Fuser Figure 177 Rear Cover Assembly s5400 209 24 23 31 25 37 36 35 35 33 33 38 26 27 99 with 33 30 29 28 28 27 97 with 28 30x2 ea 98 with 27x2 ea 94 with 2 10 13 22 37 41 1 with 2 28 30 3...

Page 428: ...item 31 18 162K43700 1 Harness Full Stack Sensor P O item 1 19 1 Spring Exit Gate P O item 1 20 1 Gate Exit P O item 1 21 059K11893 1 Shaft Rear Cover Roller P O item 1 22 1 Chute Upper Exit P O item...

Page 429: ...400 Phaser 5400 Laser Printer Service Guide PL 7 1 Frame Drives Figure 178 Frame and Drives...

Page 430: ...1 Clamp 9 3 Clamp 10 007K86761 1 Gear Assembly Drive includes 4 11 12 11 1 Motor Assembly includes 19 20 P O item 10 12 1 Gear Assembly Main Drive Motor P O item 10 13 1 Harness HCS Bush 14 1 Bush Hi...

Page 431: ...402 Phaser 5400 Laser Printer Service Guide PL 8 1 Xerographics Figure 179 Xerographics s5400 212 18 2 with 3 4 18 13 22 99 with 14 19...

Page 432: ...tem 5 7 1 Wire Assembly Developer P O item 5 8 1 Wire Assembly Xerographic P O item 5 9 1 Seal Guide P O item 5 10 1 Plate Developer P O item 5 11 1 Plate Xerographic P O item 5 12 1 Guide Print Cartr...

Page 433: ...404 Phaser 5400 Laser Printer Service Guide PL 9 1 Electrical 1 of 2 Figure 180 Electrical 1 of 2...

Page 434: ...Cooling 13 055E33041 1 Cover Fuser Fan 14 162K43542 1 Harness STK 1 J504 J526 15 162K42610 1 Harness P H J12 J121 J128 16 162K42640 1 Harness Tray 2 3 Feeder J13 P131 17 162K42821 1 Harness System Co...

Page 435: ...406 Phaser 5400 Laser Printer Service Guide PL 9 2 Electrical 2 of 2 Figure 181 Electrical 2 of 2...

Page 436: ...162K42800 1 Harness System Controller 5V J169 J168 J13 5 127E81781 1 Fan LVPS Exhaust 6 1 Inlet Assembly includes 11 13 P O Item 2 7 1 Cord Power US 8 1 Fuse P O Item 2 9 110E98300 1 Switch Rear Cove...

Page 437: ...408 Phaser 5400 Laser Printer Service Guide PL 10 1 High Capacity Stacker HCS 1 of 2 Figure 182 High Capacity Stacker 1 of 2 s5400 215...

Page 438: ...h 5 8 P O Item 1 5 1 Cover Rear P O Item 4 6 1 Holder Magnet P O Item 4 7 4 Roller Turn Pinch P O Item 4 8 4 Spring HCS Pinch P O Item 4 9 10 001K74192 1 P H Assembly HCS same as PL 14 2 item 1 11 802...

Page 439: ...410 Phaser 5400 Laser Printer Service Guide PL 10 2 High Capacity Stacker HCS 2 of 2 Figure 183 High Capacity Stacker 2 of 2 s5400 216 2 with 4 38 36 16 35 35 9 9 34...

Page 440: ...2 Sensor Jam 10 1 Chute Assembly HCS Exit with 11 14 11 1 Chute Assembly 12 10 Bearing Exit 13 1 Roller 14 1 Shaft 15 1 Chute HCS 18 1 Screw Spring 19 1 Frame Side right 20 1 Support right 21 2 Roller...

Page 441: ...412 Phaser 5400 Laser Printer Service Guide PL 11 1 500 Sheet Feeder 1 of 3 Figure 184 500 Sheet Feeder 1 of 3...

Page 442: ...er purchased item 2 802K11761 1 Cover Assembly Rear includes 3 6 8 10 3 2 Latch P O item 2 4 802E03103 1 Cover Front 5 802E28501 1 Cover Left 6 1 Cover Rear P O item 2 7 019K94731 1 Roller Assembly Pi...

Page 443: ...414 Phaser 5400 Laser Printer Service Guide PL 11 2 500 Sheet Feeder 2 of 3 Figure 185 500 Sheet Feeder 2 of 3...

Page 444: ...Ground 13 1 Roller Assembly Feed includes 14 17 14 600K73132 2 Roller Assembly Envelope Feed 15 059K14641 1 Roller Feed 16 2 Roller Core 17 1 Shaft Pick Up 18 1 Gear Pick Up 19 809E35460 1 Spring Pic...

Page 445: ...416 Phaser 5400 Laser Printer Service Guide PL 11 3 500 Sheet Feeder 3 of 3 Figure 186 500 Sheet Feeder 3 of 3...

Page 446: ...rt Bearing P O item 7 11 2 Bearing 8T P O item 7 12 019K94613 1 Holder Assembly Retard P O item 7 13 1 Arm Retard P O item 7 14 1 Gear Turn left P O item 7 15 604K01890 1 Guide Assembly right includes...

Page 447: ...418 Phaser 5400 Laser Printer Service Guide PL 12 1 2000 Sheet Feeder 1 of 4 Figure 187 2000 Sheet Feeder 1 of 4...

Page 448: ...8K77441 1 Cover Assembly Side left 3 048K77533 1 Cover Assembly Rear includes 4 5 4 2 Holder Magnetic 5 1 Cover Door Rear 6 802K05400 1 Cover Rear Bottom 7 048K77451 1 Cover Assembly Side right 8 048K...

Page 449: ...420 Phaser 5400 Laser Printer Service Guide PL 12 2 2000 Sheet Feeder 2 of 4 Figure 188 2000 Sheet Feeder 2 of 4...

Page 450: ...000 Sheet Feeder Board 8 2 Guide Tray 9 110E93440 1 Sensor A4 Paper 10 9 Clamp 11 017E91980 2 Caster 12 017E91970 2 Caster Locking 13 600K78420 1 Kit Roller 2 pieces 14 162K43610 1 Harness 2000 Sheet...

Page 451: ...422 Phaser 5400 Laser Printer Service Guide PL 12 3 2000 Sheet Feeder 3 of 4 Figure 189 2000 Sheet Feeder 3 of 4...

Page 452: ...tem 35 15 1 Gear 22T P O item 35 16 1 Gear 47T P O item 35 17 007K86890 1 Motor Assembly Feed 18 162K47530 1 Harness 2000 Sheet Feeder Feed Motor J606 J609 19 600K78440 Kit Link Stopper Spring 20 1 St...

Page 453: ...424 Phaser 5400 Laser Printer Service Guide PL 12 4 2000 Sheet Feeder 4 of 4 Figure 190 2000 Sheet Feeder 4 of 4...

Page 454: ...ver Assembly Shaft 14 1 Shaft Assembly Drive P O item 30 15 007E55100 1 Gear Bevel P O item 30 16 1 Bearing P O item 30 17 1 Bracket Gear 18 1 Shaft Assembly Elevator P O item 29 19 1 Pulley Cable P O...

Page 455: ...426 Phaser 5400 Laser Printer Service Guide PL 13 1 Duplex Assembly Figure 191 Duplex Assembly s5400 224 23 23 23 30 13 15 15 15 12 13 29 31 13 13 13 31 98 with 37 38 98 with 12x6 ea 14 24...

Page 456: ...earing Exit 18 2 Pulley 16T Duplex 19 2 Collar 20 023E15680 1 Belt 160 S2M 21 1 Frame Duplex 22 130K59671 1 Sensor Assembly Duplex 24 Roller Assembly lower P O item 28 25 1 Holder Duplex Pinch 26 1 Bo...

Page 457: ...on that should be taken to avert a shutdown An empty Laser Print Cartridge or expended maintenance item may reduce print quality and or prevent printing Keep consumables and maintenance items in suppl...

Page 458: ...Description Part Number Standard Papers Xerox 4024 DP Letter U S 8 5 x 11 in 20 lbs 75 g m2 3R721 Xerox Business Multi purpose 4200 Letter U S 8 5 x 11 in 20 lbs 75 g m2 3R2047 Xerox 4024 DP 3 hole pu...

Page 459: ...e Additional Replacement Tray only 109R00524 500 Sheet Feeder with A3 Ledger size tray Additional media tray and feeder A3 Ledger size tray is interchangeable with Tray 1 or any 500 Sheet Feeder 097S0...

Page 460: ...r and complex page processing Memory kits available in three configurations packaged in single units each 16 Mbytes 32 Mbytes 64 Mbytes 097S02356 097S02357 097S02358 Flash Memory DIMMS Provides 8 Mbyt...

Page 461: ...432 Phaser 5400 Laser Printer Service Guide Blank Page...

Page 462: ...sembly 442 Plug Jack Location Table 157 High Capacity Stacker 444 Plug Jack Location Table 158 2000 Sheet Feeder 446 P J Maps Plug Jack Location Map 1 Engine 437 Plug Jack Location Map 2 Engine 438 Pl...

Page 463: ...oller P J 112 Laser Assembly P J 114 Laser Assembly 12 I 17 Print Engine Controller P J 121 MBF Assembly P J 128 P J 127 Tray 1 Low Paper Sensor 13 I 18 Printer Engine COntroller P J 131 Second Feeder...

Page 464: ...21 Rear Cover Interlock SW P J 622 Rear Cover Interlock SW P J 623 Top Cover Interlock SW 163 F 42 LVPS P J 311 System Controller 164 F 42 LVPS Main Motor Control PWB 165 E 41 LVPS Fuser Fan 166 E 41...

Page 465: ...int Engine Controller 502 I 34 Duplex Interface PWB P J 527 P J 507 Full Stack Sensor 503 I 34 Duplex Interface PWB Duplex PWB 504 I 34 Duplex Interface PWB P J 526 505 I 34 Duplex Interface PWB P J 5...

Page 466: ...Phaser 5400 Laser Printer Service Guide 437 Plug Jack Location Map 1 Engine Figure 193 P J Location Map 1 Engine S5400 321...

Page 467: ...438 Phaser 5400 Laser Printer Service Guide Plug Jack Location Map 2 Engine Figure 194 P J Location Map 2 Engine S5400 322 S5400 322...

Page 468: ...Phaser 5400 Laser Printer Service Guide 439 Plug Jack Location Map 3 Engine Figure 195 P J Location Map 3 Engine S5400 323...

Page 469: ...PWB 131 B8 Printer or Second Feeder P J 136 Feeder PWB 131 B10 Third Feeder P J 132 Feeder PWB 132 D4 Feeder PWB P J 131 Third Feeder 133 B4 Feeder PWB P J 135 Feed Solenoid P J 13A P J 134 No Paper S...

Page 470: ...Phaser 5400 Laser Printer Service Guide 441 Figure 196 P J Location Map 4 500 Sheet Feeder S5400 324...

Page 471: ...ect to Other and Connected to 503 D7 Connects the Duplex Assembly Duplex PWB to the Printer 508 C8 Duplex PWB P J 509 Duplex Drive Motor 509 C7 Duplex Drive Motor P J 508 Duplex PWB 510 C7 Duplex PWB...

Page 472: ...Phaser 5400 Laser Printer Service Guide 443 Figure 197 P J Location Map 5 Duplex Assembly...

Page 473: ...17 F6 Stacker PWB P J 518 Stacker Motor 518 C6 Stacker Motor P J 517 Stacker PWB 519 J9 Exit Gate Solenoid P J 528 P J 505 Duplex Interface PWB 520 E6 Stacker PWB P J 521 Stack Full Sensor P J 523 Jam...

Page 474: ...Phaser 5400 Laser Printer Service Guide 445 Figure 198 P J Location Map 6 1000 Sheet High Capacity Stacker s5400 332...

Page 475: ...WB 601 I5 HCF PWB P J 131 602 J5 HCF PWB P J 513B No Paper Sensor 603 J5 HCF PWB P J P J 513A Stack Height Sensor 604 J4 HCF PWB P J 614 Tray in Switch P J 613 Rear Cover Interlock P J 612 Paper Size...

Page 476: ...Phaser 5400 Laser Printer Service Guide 447 Plug Jack Location Map 7 2000 Sheet Feeder Figure 199 P J Location Map 7 2000 Sheet Feeder S5400 335...

Page 477: ...448 Phaser 5400 Laser Printer Service Guide Blank Page...

Page 478: ...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 vers...

Page 479: ...209 Print Engine Controller PWB Main Motor page 461 Figure 210 Print Engine Controller PWB Toner Sensor page 462 Figure 211 Print Engine Controller PWB Duplex Interface PWB Full Stack Sensor page 463...

Page 480: ...Phaser 5400 Laser Printer Service Guide 451 Master Connection and Wiring Diagram Figure 200 Master Wiring Diagram 1 of 2...

Page 481: ...452 Phaser 5400 Laser Printer Service Guide Figure 201 Master Wiring Diagram 2 of 2...

Page 482: ...CCW Counter Clockwise NOP No Paper CL Clutch NUT Neutral associated with electrical power to the printer CONN Connector HCS Offset CW Clockwise REGI Registration GFI Ground Fault Indicator SNR Sensor...

Page 483: ...454 Phaser 5400 Laser Printer Service Guide Base Engine Wiring Diagrams Figure 202 Print Engine Controller PWB LVPS Interlock Switch and Fans...

Page 484: ...Phaser 5400 Laser Printer Service Guide 455 Figure 203 Print Engine Controller PWB Fuser Assembly Fuser PWB...

Page 485: ...456 Phaser 5400 Laser Printer Service Guide Figure 204 Print Engine Controller PWB Laser and CRUM PWB...

Page 486: ...Phaser 5400 Laser Printer Service Guide 457 Figure 205 Print Engine Controller PWB HVPS and Print Cartridge P J 181 White Red Yellow Red White...

Page 487: ...458 Phaser 5400 Laser Printer Service Guide Figure 206 Print Engine Controller PWB Registration Clutch and Registration Sensor...

Page 488: ...Phaser 5400 Laser Printer Service Guide 459 Figure 207 Print Engine Controller PWB Feed Solenoid Turn Clutch No Paper Sensor...

Page 489: ...460 Phaser 5400 Laser Printer Service Guide Figure 208 Print Engine Controller PWB Low Paper Sensor MBF Home Switch and Tray 1 Paper Size Switch...

Page 490: ...Phaser 5400 Laser Printer Service Guide 461 Figure 209 Print Engine Controller PWB Main Motor...

Page 491: ...462 Phaser 5400 Laser Printer Service Guide Figure 210 Print Engine Controller PWB Toner Sensor...

Page 492: ...Phaser 5400 Laser Printer Service Guide 463 Figure 211 Print Engine Controller PWB Duplex Interface PWB Full Stack Sensor...

Page 493: ...464 Phaser 5400 Laser Printer Service Guide Figure 212 Controller and Control Panel...

Page 494: ...Phaser 5400 Laser Printer Service Guide 465 500 Sheet Feeder Figure 213 500 Sheet Feeder Tray 2 Wiring Diagram and Signal Information Between Components P J134 P J13C...

Page 495: ...466 Phaser 5400 Laser Printer Service Guide Figure 214 500 Sheet Feeder Tray 3 Wiring Diagram and Signal Information Between Components...

Page 496: ...Phaser 5400 Laser Printer Service Guide 467 Duplex Assembly Figure 215 Duplex Assembly Wiring Diagrams and Signal Information Between Components...

Page 497: ...468 Phaser 5400 Laser Printer Service Guide 1000 Sheet High Capacity Stacker Figure 216 Master Wiring Diagram High Capacity Stacker...

Page 498: ...Phaser 5400 Laser Printer Service Guide 469 2000 Sheet Feeder Figure 217 2000 Sheet Feeder Wiring Diagram and Signal Information Between Components...

Page 499: ...470 Phaser 5400 Laser Printer Service Guide Figure 218 2000 Sheet Feeder PWB No Paper Sensor Figure 219 2000 Sheet Feeder PWB Low Paper Sensor...

Page 500: ...Phaser 5400 Laser Printer Service Guide 471 Figure 220 2000 Sheet Feeder PWB Switches...

Page 501: ...472 Phaser 5400 Laser Printer Service Guide Blank Page...

Page 502: ......

Page 503: ...7 2 1 P 5 8 3 0 1...

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