Xerox 5400N Quick Reference Guide
Xerox 5400N - Phaser B/W Laser Printer Manual
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- Xerox 5400N | Quick Reference Guide - Page 1
PHASER™ 5400 LASER PRINTER Service Quick Reference Guide - Xerox 5400N | Quick Reference Guide - Page 2
- Xerox 5400N | Quick Reference Guide - Page 3
Phaser™ 5400 Laser Printer Service Quick Reference Guide Warning The following servicing instructions are for use by qualified service personnel only. To avoid personal injury, do not perform any servicing other than that contained in operating instructions unless you are qualified to do so. This - Xerox 5400N | Quick Reference Guide - Page 4
specified power cord and connector. Refer to a qualified service 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. Phaser 5400 Laser Printer Service Guide iii - Xerox 5400N | Quick Reference Guide - Page 5
performing laser related troubleshooting or repair procedures. I Never place a mirror or a reflective tool or object in the laser beam path. I Do not disassemble the printer in such a way that the laser beam can exit the print engine during a print cycle. iv Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 6
needs servicing or repair, or I Whenever you clean the product. Ground the product: Plug the three-wire power cord (with grounding prong) into grounded AC outlets only. If necessary, contact a licensed electrician to install a properly grounded outlet. Phaser 5400 Laser Printer Service Guide v - Xerox 5400N | Quick Reference Guide - Page 7
from the laser. Laser (FDA): Any laser label visible to service must be reproduced in the service manual with location shown or indicated. Safe working procedures and clear warnings concerning precautions to avoid possible exposure must also be included. vi Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 8
Laser Printer meets the following standard: Laser class 3B, maximum 5 mW, wavelength 780 nm. The following LASER symbol will be displayed at the start of any procedure where possible exposure to the laser beam exists. LUOKAN 1 LASERLAITE KLASS 1 LASER APPARAT Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 9
If not installed and used in accordance with the instructions provided, this equipment may cause disruptive interference to Problems". This booklet is available from the U.S. Government Printing Office, Washington D.C. 20402, Stock No. 004-000-00345-4. viii Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 10
ört ist. Der Deutschen Bundespost wurde das Inverkehrbringen dieses Gertëes angqeigt und die Berechtigung zur berprufung der Serie auf Einhaltung der Bestimmungen eingeräumt. Phaser 5400 Laser Printer Service Guide ix - Xerox 5400N | Quick Reference Guide - Page 11
Blank Page x Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 12
19 Environmental Specifications 20 Life Expectancies 21 Conforming Regulations and Standards 21 Printing Speed 22 Printing Media Feeding Means 23 Printing Media 24 Printing Accuracy 25 Components to Be Replaced Periodically 26 Options 26 Phaser 5400 Laser Printer Service Guide xi - Xerox 5400N | Quick Reference Guide - Page 13
Board Test Print 227 Fault History 227 Display Faults 227 Menu Map 227 PS Font List 228 PCL Font List 228 PCL Demo 228 Print Engine Controller Board Test Print 229 Analyzing Test Prints 230 Registration 231 NVRAM Configuration (NVM Config 233 xii Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 14
Reset Menu 239 Maintenance Kit Counter Reset Procedure 240 Maintenance and Cleaning 241 Scheduled Maintenance 241 Recommended Tools 241 Inspect While Servicing 241 General Cleaning Turn Roller Assembly 275 RRP 3.4 Tray 1 Low Paper Sensor 276 Phaser 5400 Laser Printer Service Guide xiii - Xerox 5400N | Quick Reference Guide - Page 15
Fuser Assembly 288 RRP 5.2 Stack Full Sensor 289 RRP 5.3 Exit Roller Assembly 291 RRP 5.4 Stack Full Sensor Actuator 294 RRP 6.1 Main Drive Gear Assembly 295 RRP 7.1 Laser Assembly 297 RRP 7.2 Right Print Cartridge Guide Assembly 299 RRP 7.3 Toner xiv Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 16
Roller Assembly 338 RRP 11.12 Retard Chute Assembly 339 RRP 11.13 Left Tray Guide 340 RRP 11.14 Right Tray Guide 342 RRP 11.15 Retard Holder Assembly 344 RRP 11.16 Retard Turn Roller Assembly 12.25 Right Tray Wires 377 RRP 12.26 Retard Assembly 378 Phaser 5400 Laser Printer Service Guide xv - Xerox 5400N | Quick Reference Guide - Page 17
PL 5.1 Paper Transport 396 PL 6.1 Rear Cover Assembly With Fuser 398 PL 7.1 Frame & Drives 400 PL 8.1 Xerographics 402 Feeder (4 of 4 424 PL 13.1 Duplex Assembly 426 Xerox Supplies and Accessories 428 Plug/Jack Connector Locations 433 Contents 433 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 18
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 Capacity Stacker 468 2000-Sheet Feeder 469 Phaser 5400 Laser Printer Service Guide xvii - Xerox 5400N | Quick Reference Guide - Page 19
Blank Page xviii Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 20
Figure 14 Paper Path Flow 15 Figure 15 Paper Path Components 16 Figure 16 Service Flowchart 30 Figure 17 Fuser Connector P174 134 Figure 18 Light Prints 178 Figure 19 Blank Prints 181 Unfused Image 215 Figure 35 Registration Test Pattern 232 Phaser 5400 Laser Printer Service Guide xix - Xerox 5400N | Quick Reference Guide - Page 21
Assembly 283 Figure 72 Registration Actuator 285 Figure 73 Registration Clutch 286 Figure 74 Registration Sensor 287 Figure 75 Fuser Assembly 288 Figure 76 Lower Exit Chute 289 Figure 77 Upper Exit Chute 290 Figure 78 Stack Full Sensor 290 xx Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 22
295 Figure 85 Gear Drive Assembly 296 Figure 86 Laser Cover 297 Figure 87 Laser Assembly 298 Figure 88 Right Print Cartridge Guide 299 Figure 89 Toner Sensor Assembly 301 Figure 90 Top Cover Interlock 120 Left Cover 330 Figure 121 Right Cover 331 Phaser 5400 Laser Printer Service Guide xxi - Xerox 5400N | Quick Reference Guide - Page 23
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 Figure 146 Lower 373 Figure 164 Drive Shaft Assembly 374 xxii Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 24
LVPS Interlock Switch and Fans 454 Figure 203 Print Engine Controller PWB Fuser Assembly, Fuser PWB 455 Figure 204 Print Engine Controller PWB-Laser and CRUM PWB 456 Figure 205 Print Engine Controller PWB, HVPS and Print Cartridge 457 Phaser 5400 Laser Printer Service Guide xxiii - Xerox 5400N | Quick Reference Guide - Page 25
209 Print Engine Controller PWB Main Motor 461 Figure 210 Print Engine Controller PWB Toner Sensor 462 Figure 211 Print Engine Controller PWB Duplex Interface PWB Full Stack Sensor 470 Figure 220 2000-Sheet Feeder PWB Switches 471 xxiv Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 26
61 Table 31 Paper Jam / Misfeed 500-Sheet Feeder Troubleshooting Procedure . . . . 63 Table 32 Error Code E2-1: Paper Jam / Misfeed 2000-Sheet Feeder Troubleshooting Procedure 65 Table 33 Error Code E2-D: Duplex Jam Troubleshooting Procedure 67 Phaser 5400 Laser Printer Service Guide xxv - Xerox 5400N | Quick Reference Guide - Page 27
Procedure 118 Table 69 Low Paper Tray 1/2/3 Troubleshooting Procedure 119 Table 70 Inoperative Printer Troubleshooting 120 Table 71 Malfunctioning LCD/LED Troubleshooting Procedure 123 Table 72 System Controller Board Voltages at P/J18 125 xxvi Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 28
Image Troubleshooting Procedure 197 Table 110 Black Prints Troubleshooting Procedure 199 Table 111 Background Troubleshooting Procedure 200 Table 112 Uneven Density Troubleshooting Procedure 202 Table 113 Skewed Image Troubleshooting Procedure 204 Phaser 5400 Laser Printer Service Guide xxvii - Xerox 5400N | Quick Reference Guide - Page 29
Paper Transport 397 Table 134 PL 6.1 Rear Cover Assembly with Fuser 399 Table 135 PL 7.1 Frame and Drives 401 Table 136 Xerox Professional Printing Paper 429 Table 151 Xerox Transparency Film 429 Table 152 Xerox Labels 430 Table 153 Options 430 xxviii Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 30
The Phaser 5400 Printer Service Guide is the primary document used for repairing and maintaining the Phaser 5400 Laser Printer. To ensure complete understanding of the product, participation in Xerox Phaser 5400 service training is recommended. Machine Orientation For servicing the Phaser 5400 Laser - Xerox 5400N | Quick Reference Guide - Page 31
System Controller Board interfaces to host computer(s) via Ethernet, USB or Parallel ports, processes PostScript or PCL print files into Image Video data and transmits data and printing commands to the Print Engine Controller Board. I The Phaser 5400 Laser Printer comes standard with one 500-Sheet - Xerox 5400N | Quick Reference Guide - Page 32
when the Maintenance Kit should be replaced. This is a soft error, "Printing may continue regardless of the Maintenance Kit count, but image quality may be compromised." After installing these items, the Maintenance Kit counter must be manually reset. Phaser 5400 Laser Printer Service Guide 3 - Xerox 5400N | Quick Reference Guide - Page 33
Printer Printer Components The base printer contains the following major components: Front view 1 Standard Output Bin 2 Paper Guide / Curl Extension 3 Control Panel 4 Paper Support 2 Front View S5400-03-A 13 9 10 11 12 Figure 3 Rear View 4 S5400-04-A Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 34
Printer Options Front view Rear view 1 1,000-Sheet (High Capacity) Stacker 4 Optional Duplex Module (installed) Bin 5 Optional Hard (shown as Tray 3) 1 2 3 Figure 4 View from Right Front S5400-05-A 4 Figure 5 View from Left Rear 6 5 S5400-06-A Phaser 5400 Laser Printer Service Guide 5 - Xerox 5400N | Quick Reference Guide - Page 35
Xerox Phaser 5400 Printer Control Panel: I Displays printer status and jobs in process. I Provides the means to change printer settings. I Allows you to print reports (such as the configuration sheet, which lists the printer I Value Down key [7] 6 S5400-07-A Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 36
... I The printer is low on toner: Toner Low I A tray is empty (in this case, Tray 2 is empty and no longer is being used to print): Tray 2 Empty I There is a problem (in this case, a paper jam has occurred while feeding from Tray 3): Tray 3 JamOpen Tray 3 Phaser 5400 Laser Printer Service Guide 7 - Xerox 5400N | Quick Reference Guide - Page 37
Rear Panel REAR Figure 7 Rear Panel Ethernet CR1 View Port USB Parallel LEFT s5400-344 8 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 38
following four FRUs: I Laser Scanner: stand-alone unit I Print Cartridge contains: I Bias Charge Roller I Cleaning Blade I Drum I Detack Saw I Mag Roller I CM Blade I Fuser contains: I Heat Roller I Pressure Roller I Bias Transfer Roller: stand-alone unit Phaser 5400 Laser Printer Service Guide 9 - Xerox 5400N | Quick Reference Guide - Page 39
Figure 9 FRU Assemblies, Sensors and Interlock Locations 2 10 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 40
Figure 10 FRU Assemblies, Sensors and Interlock Locations 3 - Detack Saw, Registration & Bias Transfer Rollers and Paper Transport Assembly Phaser 5400 Laser Printer Service Guide 11 - Xerox 5400N | Quick Reference Guide - Page 41
Full Stack Sensor Figure 11 FRU Assemblies, Sensors and Interlock Locations 4 - Fuser Area 12 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 42
Figure 12 FRU Assemblies, Sensors and Interlock Locations 5 - Main Drive Phaser 5400 Laser Printer Service Guide 13 - Xerox 5400N | Quick Reference Guide - Page 43
Figure 13 FRU Assemblies, Sensors and Interlock Locations 6 - FRU Circuit Assemblies 14 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 44
Paper Path Information Paper is fed from the Tray or the Multi-sheet Bypass Feeder (MBF) and transported through the printer to the exit along the paper path shown in the following figure. Figure 14 Paper Path Flow Phaser 5400 Laser Printer Service Guide 15 - Xerox 5400N | Quick Reference Guide - Page 45
The figure below is a cut-away side view of the Phaser 5400 Laser Printer that shows the paper paths and the major components directly related to the paper transportation. Figure 15 Paper Path Components 16 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 46
standard option and is not likely to be seen unless a custom version of the printer were produced. Table 1 Memory Upgrades Memory Upgrades 16-Mbyte DIMM 32-Mbyte DIMM 64-Mbyte DIMM 8-Mbyte Flash DIMM Part Number 097S02356 097S02357 097S02358 097S02360 Phaser 5400 Laser Printer Service Guide 17 - Xerox 5400N | Quick Reference Guide - Page 47
max: 1.2 kw electrical current max 11A 220-240 VAC rated consumption max: 1.3 kw electrical current max 5.5 A Power Consumption, Printing 890 watts/3,045 BTU/hr. 18 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 48
Mechanical Specifications Table 4 Physical Dimensions Height cm / in. Phaser 5400 printer only Printer Clearances Location Clearance (cm / in.) Front 76 / 30 Rear 30 / 12 Left Side 20 / 8 Right Side 10 / 4 Mounting Surface Level within 5° Phaser 5400 Laser Printer Service Guide 19 - Xerox 5400N | Quick Reference Guide - Page 49
Specifications Table 6 Environmental Specifications Environmental Operating: 41 - 95° F (5 - 35° C) 15 - 85% RH (Without conditions for installation condensation) 0 - 3000 m above sea level Horizontal bias within 5° (Printer the Print Cartridge is not Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 50
3rd Edition CSA C22.2 No. 950-M95 and standards 220 V/ 240 V Version: IEC60950 2nd Edition CE Directive Nordic Agency Approvals (NEMKO, SEMKO, SETI, and DEMKO) Phaser 5400 Laser Printer Service Guide 21 - Xerox 5400N | Quick Reference Guide - Page 51
paper is started through the printer. Table 10 Consecutive Printing Speed after the First Sheet Out Paper Size Simplex Mode Duplex Mode (Prints per (Prints per min.) min.) 600 dpi + 1200 LEF 20.0 14.2 The above chart does not include RIP time. 22 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 52
paper weight of 80 g/m2 (20 lbs.). Capacities will differ with other weights. Table 11 Supported Media and Media Sizes Tray 1, Tray 2, Tray 3 Media Media Size A4/Letter A3/Ledger . (3) Only when Defaults = Inches in the Control Panel System Menu. Phaser 5400 Laser Printer Service Guide 23 - Xerox 5400N | Quick Reference Guide - Page 53
humidity environment. I Avoid storing paper in such a way as to cause wrinkling, bending, curling, etc. I Do not unwrap paper until you are ready to use it, and rewrap any paper you are not using. I Do not expose paper to direct sunlight or high humidity. 24 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 54
Media The following media are unacceptable for use in the printer. Their use may cause high rates of jamming and other paper-handling problems: I Excessively thick or thin paper I Heavily textured paper At a distance of 390 mm At a distance of 245 mm Phaser 5400 Laser Printer Service Guide 25 - Xerox 5400N | Quick Reference Guide - Page 55
feeders. Note: Only one can be installed. Part numbers and additional information for Maintenance items (fuser, BTR, etc.), Consumables (printer cartridge, media, etc.) or Options, refer to Xerox Supplies and Accessories on page 428 of this manual. 26 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 56
U4: Fuser Failure Power Off / On 100 RAP 33 Error Code U5: Fan Failure Power Off Now 101 RAP 34 Error Code: 0101 - DIMM 1 102 RAP 35 Error Code: 0102 - DIMM 2 103 RAP 36 Error Code: 0103 - DIMM 3 104 RAP 37 Error Code U6: IOT NVM Fail Power Off / On 105 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 57
printer's web page using a web browser. Enter the printer's IP address as the URL. Select the "Troubleshoot" link and fault history will be displayed. To troubleshoot functional or performance problems cycle power on the printer to see if the error recurs. 28 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 58
in the Service Flowchart after you have completed the tasks outlined in the current block. If you choose not to use the Service Flowchart, it is recommended that you start at the appropriate Repair Analysis Procedure (RAP) Table and proceed from there. Phaser 5400 Laser Printer Service Guide 29 - Xerox 5400N | Quick Reference Guide - Page 59
a part number. Use the Removal and Replacement Procedures (RRPs) to replace a part. 5 Final Checkout Test the printer to be sure you corrected the initial problem and there are no additional problems present. Figure 16 Service Flowchart S5400-03 30 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 60
this manual. 7. Voltage and resistance values presented in the Repair Analysis Procedures are an approximation. Actual readings may vary from the stated values. 8. Primary Repair Analysis Procedures may direct you to a Secondary Repair Analysis Procedure. Phaser 5400 Laser Printer Service Guide 31 - Xerox 5400N | Quick Reference Guide - Page 61
1. Each numbered step in a Repair Analysis Procedure instructs you to perform a certain action or procedure. printer. 4. Manually actuate and deactuate Tray 1 No Paper Sensor. Does the LCD counter increment each time you press and release the actuator? 32 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 62
Analysis Procedure instructs you otherwise; before measuring voltages make sure the printer is switched ON, the Xerographic Cartridge and the . If you are unable to fix a problem using the Repair Analysis Procedures, it is recommended troubleshooting. Phaser 5400 Laser Printer Service Guide 33 - Xerox 5400N | Quick Reference Guide - Page 63
manual. Refer to Diagnostics, Test Prints, Service Tests and NVRAM Adjustments on page 219 of this manual. To Enter Diagnostics mode When troubleshooting Diagnostics, you must switch printer power OFF, wait 20 - 30 seconds and switch printer power ON. 34 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 64
-Sheet Feeder Go to RAP 2, page 44. Insert Tray 3 C3: Tray 3 Error Tray 3 is not detected in printer. (All paper size switches not actuated.) Install Tray 3 500-Sheet Feeder Go to RAP 2, page 44. Tray 2 paper. Load paper into MBF Go to RAP 4, page 48 Phaser 5400 Laser Printer Service Guide 35 - Xerox 5400N | Quick Reference Guide - Page 65
power on. 3. Registration is actuated during warm up cycle or an erase cycle. Open Top Cover, remove EP Cartridge. Open and Extend MBF assembly and remove any paper. Go to RAP 9, page 60. Duplex Jam Open Rear and remove any paper. Go to RAP 13, page 67. 36 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 66
500-Sheet Feeder installed as Tray 3. Open Top Cover or Feeder and remove the sheets, then close the cover. Go to RAP 11, page 63. Phaser 5400 Laser Printer Service Guide 37 - Xerox 5400N | Quick Reference Guide - Page 67
, then close the cover. Go to RAP 12, page 65. Paper Jam Open Top Cover Remove Print Cartridge Clear Paper Path E3-1 E3: Reg. Jam Exit Sensor did not actuate within time after the Registration clutch is not closed. Close MBF. Go to RAP 17, page 76. 38 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 68
: 2000-Sheet Feeder installed as Tray 3. Reinstall HCF Go to RAP 24, page 89. Install Print Cartridge J3: EP Cartridge Print Cartridge is not installed. Install the Print Cartridge, or replace with the correct Print Cartridge. Go to RAP 27, page 92. Phaser 5400 Laser Printer Service Guide 39 - Xerox 5400N | Quick Reference Guide - Page 69
. 3. Thermistor circuit is detected to be open. 4. Fuser temperature rises above the set temperature. 5. Heat rod is on for 10 seconds when the Main Drive Motor is stopped, after the Fuser warm up is completed. Power Off/On. Go to RAP 32, page 100. 40 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 70
/ Log Comment Action Fan Failure U5 Power Off Now U5: Fan Fail 1. Fuser Fan has failed. 2. LVPS Fan has failed. Check the Fuser Fan and the LVPS Fan. Power Off/On. Go to RAP 33, page 101 DIMM in slot J6 has failed. Go to RAP 36, page 104. Phaser 5400 Laser Printer Service Guide 41 - Xerox 5400N | Quick Reference Guide - Page 71
the paper tray for Step 7. cracks or breakage and free rotation when the Paper Tray End Guide is moved Is the cam in good condition and does it rotate freely when the Paper Tray End Guide is moved? Replace Tray 1 [PL 2.1, page 386 / PL 2.2, page 388]. 42 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 72
[RRP 8.1, page 305] Table 20 Paper Size Actuators 8.5" A4 B5 Actuator LEF LEF LEF 4 Top X 3 X X X 2 X 1 Bottom X X X A5 LEF X X X 14" SEF X X 8.5" SEF X X A4 SEF X X B4 SEF X Phaser 5400 Laser Printer Service Guide 43 - Xerox 5400N | Quick Reference Guide - Page 73
.13, PL 2.2, Table 2 below. page 340]. page 388]. Do the Tray 2/3 size cams contact the Paper Size Actuators correctly for each size of paper? If problem persists, replace the Tray 2/3 Left Guide Assembly [RRP 11.13, page 340]. 44 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 74
Tray 2/3 [PL 2.1, page 386; PL 2.2, page 388] I Left Guide Assembly [RRP 11.13, page 340] Table 22 Paper Size Actuators Actuator 4 Top 3 2 1 Bottom 8.5" LEF X X X A4 LEF X X B5 LEF X X X A5 LEF X X X 14" SEF X X 8.5" SEF X X A4 SEF X X B4 SEF X Phaser 5400 Laser Printer Service Guide 45 - Xerox 5400N | Quick Reference Guide - Page 75
: 2000-Sheet Feeder Carriage Not In Position Message Troubleshooting Procedure Step Actions and Questions Yes No 1 PROCEDURE still appear? Problem solved. 2 STOPPER LINK Go to 1. Open the 2000-Sheet Feeder Tray Assembly. Step 3. 2. Manually push the Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 76
Feeder Harness [PL 12.2, page 420] I Feeder Harness [PL 9.1, page 404] I Paper Height Sensor [RRP 12.15, page 367] I Wiring and connectors linking the components Phaser 5400 Laser Printer Service Guide 47 - Xerox 5400N | Quick Reference Guide - Page 77
Message Troubleshooting Procedure Step Actions and Questions Yes No 1 Does this problem appear printer and inspect the Bottom Plate. Is the bottom plate raised fully and evenly? Replace the Tray 1 Assembly [PL 2.1, page 386; PL 2.2, page 388]. 48 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 78
or RAP 53, 3. Manually actuate the Tray 1 troubleshoot each area listed below, one at a time, until you isolate and solve the problem. I MBF Tray and components I Print Engine Controller Board [RRP 8.5, page 310] I Wiring and connectors linking the components Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 79
of paper. Table 25 Add Paper To 500-Sheet Feeder Troubleshooting Procedure Step Actions and Questions Yes No 1 PAPER LEVEL Go ACTUATOR Go to 1. Remove the Paper Tray. Step 4. 2. Manually actuate the No Paper Sensor Actuator. Does the No Paper Sensor Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 80
and solve the problem. I Feeder Board [RRP 11.7, page 334] I Print Engine Controller Board [RRP 8.5, page 310] I No Paper Sensor [RRP 11.19, page 348] I Paper Tray [PL 2.1, page 386 / PL 2.2, page 388] I Wiring and connectors linking the components Phaser 5400 Laser Printer Service Guide 51 - Xerox 5400N | Quick Reference Guide - Page 81
is full. Table 26 Error Code C5: Standard Bin Full Troubleshooting Procedure Step Actions and Questions Yes No 1 STACK FULL SENSOR press and release the actuator? correctly. If a problem persists, replace the Print Engine Controller Board [ ]. 52 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 82
: Standard Bin Full Troubleshooting Procedure (cont'd.) Step Actions and Questions Yes No 5 "YES" FROM STEP 3 ABOVE Replace the Go to 1. Switch printer power OFF. Print PL 6.1, page 398 as necessary. Is there continuity between each of the pins? Phaser 5400 Laser Printer Service Guide 53 - Xerox 5400N | Quick Reference Guide - Page 83
Full Troubleshooting Procedure (cont'd.) Step Actions and Questions Yes No 10 SUSPECT COMPONENTS The following printer components and areas are associated with this specific problem. [PL 6.1, page 398] I Wiring and connectors linking the components 54 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 84
full. Table 27 Error Code C5: Stacker Bin Full Troubleshooting Procedure Step Actions and Questions Yes No 1 STACK FULL SENSOR each time you press and release the actuator? problem persists, replace the Print Engine Controller Board [RRP 312]. Phaser 5400 Laser Printer Service Guide 55 - Xerox 5400N | Quick Reference Guide - Page 85
C5: Stacker Bin Full Troubleshooting Procedure (cont'd.) Step Actions and Questions Yes No 5 "YES" FROM STEP 3 ABOVE Replace the Go to 1. Switch printer power OFF. Print Engine continuity between the pins? [PL 10.2, page 410], as necessary. 56 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 86
Troubleshooting Procedure (cont'd.) Step Actions and Questions Yes No 10 SUSPECT COMPONENTS The following printer components and areas are associated with this specific problem. Board [RRP 8.3, page 308] I Stack Full Sensor Harness [PL 10.2, page 410] Phaser 5400 Laser Printer Service Guide 57 - Xerox 5400N | Quick Reference Guide - Page 87
Sheet Feeder Troubleshooting Procedure Step to stop. 3. Manually push the No Paper printer power OFF. 2. Check for continuity between P/J13-1 and P601-1. Print Engine Step 8. Controller Is there continuity between the pins? Board [RRP 8.5, page 310]. 58 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 88
solve the problem. I No Paper Sensor Actuator [RRP 12.19, page 371] I No Paper Sensor [RRP 12.18, page 370] I 2000-Sheet Feeder Board [RRP 12.8, page 360] I Print Engine Controller Board [RRP 8.5, page 310] I Wiring and connectors linking the components Phaser 5400 Laser Printer Service Guide 59 - Xerox 5400N | Quick Reference Guide - Page 89
[0] to stop. 3. Manually actuate the Registration Sensor troubleshoot each area listed below, one at a time, until you isolate and solve the problem. I Wiring and connectors linking the components Print Engine Controller Board [RRP 8.5, page 310]. 60 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 90
2.1, page 259]. 2. Inspect the paper tray for a broken, bent or missing MBF Assembly spring. [RRP 2.1, 3. Check for a broken hinge pin, or anything that would page 259]. prevent the up and down movement of the paper tray. Does the problem continue? Phaser 5400 Laser Printer Service Guide 61 - Xerox 5400N | Quick Reference Guide - Page 91
. 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. I Wiring and connectors linking the components 62 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 92
within specifications? Go to Step 4. Replace with paper within size specs. 4 PROBLEM TRAY REPLACEMENT Go to 1. Remove problem paper tray and install Tray 1 into the Step 5. problem feeder. Is the Feeder Motor rotating? Go to RAP 65, page 167. Phaser 5400 Laser Printer Service Guide 63 - Xerox 5400N | Quick Reference Guide - Page 93
or troubleshoot each area listed below, one at a time, until you isolate and solve the problem. I Feed Tray Assembly [PL 2.1, page 386 / PL 2.2, page 388] I 500-Sheet Feeder Feed Head [RRP 11.8, page 335] I Rear Chute Assembly [RRP 11.12, page 339] 64 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 94
2000-Sheet Feeder Troubleshooting Procedure Step Actions specifications? Replace with fresh paper of the proper size from an unopened ream. 3 FEED MOTOR ASSEMBLY Go to 1. Switch printer appear? Problem solved. 5 TOP GEAR ROTATION Manually rotate Phaser 5400 Laser Printer Service Guide 65 - Xerox 5400N | Quick Reference Guide - Page 95
isolate and solve the problem. I Feed Motor Assembly [RRP 12.16, page 368] I Feed Roller Assembly [RRP 12.14, page 366] I Drive Assembly [RRP 12.13, page 365] I 2000-Sheet Feeder Board [RRP 12.8, page 360] I Wiring and connectors linking the components 66 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 96
breakage, missing teeth, or wear. Is the Drive Belt in good condition? Duplex Assembly [RRP 9.1, page 317]. If Duplex Drive Belt [PL 13.1, page 426]. problem still exists, replace the Print Engine Controller Board [RRP 8.5, page 310]. Phaser 5400 Laser Printer Service Guide 67 - Xerox 5400N | Quick Reference Guide - Page 97
, replace each component or troubleshoot each area listed below, one at a time, until you isolate and solve the problem. I Duplex Unit [RRP 9.1, page 317] I Print Engine Controller Board [RRP 8.5, page 310] I Wiring and connectors linking the components 68 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 98
Fuser Troubleshooting Procedure Step Actions and Questions Yes No 1 Is the paper loaded in the paper tray wrinkled or Replace Go to Step 2. damaged? with fresh, dry paper. 2 Is the paper size within specifications Rubber Registration Roller? Phaser 5400 Laser Printer Service Guide 69 - Xerox 5400N | Quick Reference Guide - Page 99
67, page 170. Input / Sensor Input / press [4] to start test, [0] to stop. Controller 3. Actuate and release the Fuser Exit Sensor. Board Does the LCD counter increment each time you [RRP 8.5, actuate and release the Fuser Exit Sensor? page 310]. 70 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 100
Gear Drive Assembly [RRP 6.1, page 295] I MBF Gears [PL 4.1, page 392] I Paper Transport Assembly [RRP 4.1, page 283] I Fuser Assembly [RRP 5.1, page 288] I Print Engine Controller Board [RRP 8.5, page 310] I Wiring and connectors linking the components Phaser 5400 Laser Printer Service Guide 71 - Xerox 5400N | Quick Reference Guide - Page 101
. 7 FUSER INSPECTION Inspect the Fuser Assembly for obstructions or contamination. Is the Fuser Assembly clean and fee of obstructions? Check the Exit Assembly. Clean or replace as necessary. Clean or replace the Fuser Assembly [RRP 5.1, page 288]. 72 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 102
you isolate and solve the problem. I Fuser Assembly [RRP 5.1, page 288] I Duplex Assembly [RRP 9.1, page 317] I Rear Cover Assembly [RRP 1.9, page 258] I Print Engine Controller Board [RRP 8.5, page 310] I Wiring and connectors linking the components Phaser 5400 Laser Printer Service Guide 73 - Xerox 5400N | Quick Reference Guide - Page 103
open. Table 36 Error Code E5: Close Covers Troubleshooting Procedure Step Actions and Questions Yes No 1 OPEN CLOSE and the Top Cover. Step 2. Is the error message still displayed? Problem solved. 2 REAR COVER Go to 1. Open the Rear Cover. Step Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 104
troubleshoot each area listed below, one at a time, until you isolate and solve the problem. I Top Cover [RRP 1.3, page 252] I Rear Cover [RRP 1.9, page 258] I Print Engine Controller Board [RRP 8.5, page 310] I Wiring and connectors linking the components Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 105
Table 37 Insert MBF Troubleshooting Procedure Step Actions and Questions Yes No 1 PROCEDURE Extend and close the MBF. Does the error code still appear? Go to Step 2. Problem solved. 2 MBF HOME actuated and 0.0 VDC when the switch is deactuated? 76 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 106
each component or troubleshoot each area listed below, one at a time, until you isolate and solve the problem. I MBF Home Switch [RRP 3.8, page 282] I Print Engine Controller Board [RRP 8.5, page 310] I Wiring and connectors linking the components Phaser 5400 Laser Printer Service Guide 77 - Xerox 5400N | Quick Reference Guide - Page 107
Table 38 2000-Sheet Feeder Cover Open Troubleshooting Procedure Step Actions and Questions Yes No 1 UPPER REAR COVER INTERLOCK SWITCH Go to 1. Manually open and close the 2000-Sheet -7 and P13-15 Is there continuity between all pins measured? 78 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 108
or troubleshoot each area listed below, one at a time, until you isolate and solve the problem. I Upper Rear Cover Interlock Switch [PL 12.2, page 420] I Print Engine Controller Board [RRP 8.5, page 310] I Wiring and connectors linking the components) Phaser 5400 Laser Printer Service Guide 79 - Xerox 5400N | Quick Reference Guide - Page 109
Door Troubleshooting Procedure Step Actions and Questions Yes No 1 OPEN/CLOSE REAR COVER Open and close the HCS Rear Cover. Does the error code still appear? Go to Step 2. Problem solved. replace the HCS Harness [PL 10.2, page 308]. page 410]. 80 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 110
you isolate and solve the problem. I HCS Rear Cover Interlock Switch [RRP 10.9, page 326] I Print Engine Controller Board [RRP 8.5, page 310] I HCS Board [PL 10.2, page 410] I Duplex Interface Board [RRP 8.3, page 308] I HCS Harness [PL 10.2, page 410] Phaser 5400 Laser Printer Service Guide 81 - Xerox 5400N | Quick Reference Guide - Page 111
Troubleshooting Procedure Step Actions and Questions Yes No 1 PAPER PATH Open the printer code reappear? Problem solved. printer power ON. 5. Measure the voltage between P/J19-5 and frame ground. Does the voltage measure +3.3 VDC? Go to Step 8. 82 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 112
each component or troubleshoot each area listed below, one at a time, until you isolate and solve the problem. I Duplex Assembly [PL 13.1, page 426] I Print Engine Controller Board [RRP 8.5, page 310] I Duplex Interface Harness Assembly [PL 9.1, page 404] Phaser 5400 Laser Printer Service Guide 83 - Xerox 5400N | Quick Reference Guide - Page 113
Error Code E8-1: Stacker Jam Troubleshooting Procedure Step Actions and Questions Does the Error Code E8-1 still appear? Problem solved. 5 Is the paper discharged from the Idler Gear counter-clockwise Step 7. manually. 2. Observe for correct contact Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 114
, until you isolate and solve the problem. I HCS Motor Assembly [RRP 10.8, page 325] I Print Engine Controller Board [RRP 8.5, page 310] I HCS Sensor [RRP 10.10, page 327] I HCS Assembly [RRP 10.1, page 318] I Wiring and connectors linking the components Phaser 5400 Laser Printer Service Guide 85 - Xerox 5400N | Quick Reference Guide - Page 115
Message Troubleshooting Procedure Step Actions and Questions Yes No 1 PROCEDURE Go to 1. Switch printer power P501-3 and P19-11 I P501-4 and P19-10 I P501-5 and P19-9 problem persists, replace the Duplex Interface Board [RRP 8.3, [PL 9.1, page 404]. I Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 116
listed below, one at a time, until you isolate and solve the problem. I Print Engine Controller Board [RRP 8.5, page 310] I Duplex Assembly [PL 13.1, page 426] I Duplex Interface Board [RRP 8.3, page 308] I Wiring and connectors linking the components) Phaser 5400 Laser Printer Service Guide 87 - Xerox 5400N | Quick Reference Guide - Page 117
below, one at a time, until you isolate and solve the problem. I Print Engine Controller Board [RRP 8.5, page 310] I LVPS [RRP 8.6, page 312] I HCS Board [PL 10.2, page 410] I HCS Harness [PL 10.2, page 410] I Duplex Interface Harness [PL 9.2, page 406] 88 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 118
replace each component or troubleshoot each area listed below, one at a time, until you isolate and solve the problem. I Print Engine Controller Board [RRP 8.5, page 310] I 2000-Sheet Feeder Board [PL 12.2] I 2000-Sheet Feeder Harness Assembly [PL 12.2] Phaser 5400 Laser Printer Service Guide 89 - Xerox 5400N | Quick Reference Guide - Page 119
replace each component or troubleshoot each area listed below, one at a time, until you isolate and solve the problem. I Print Cartridge [PL 8.1, page 402] I Print Engine Controller Board [RRP 8.5, page 310] I Wiring and connectors linking the components 90 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 120
, replace each component or troubleshoot each area listed below, one at a time, until you isolate and solve the problem. I Toner Sensor Assembly [RRP 7.3, page 301] I Print Cartridge [PL 8.1, page 402] I Print Engine Controller Board [RRP 8.5, page 310] Phaser 5400 Laser Printer Service Guide 91 - Xerox 5400N | Quick Reference Guide - Page 121
one at a time, until you isolate and solve the problem. I Wiring and connectors linking the components I Print Cartridge I CRUM Antenna [RRP 3.7, page 281] I Print Engine Controller Board [RRP 8.5, page 310] I System Controller Board [RRP 8.1, page 305] 92 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 122
specifically troubleshoot each area listed below, one at a time, until you isolate and solve the problem. I Wiring and connectors linking the components I Print Cartridge I CRUM Antenna [RRP 3.7, page 281] I Print Engine Controller Board [RRP 8.5, page 310] Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 123
Test / Sensor Input Test / press [4] start, [0] to stop. 2. One at a time, press and release each of the problem tray size actuators. Does the LCD counter increment each time you press and release one of the actuators? Go to RAP 54, page 142. 94 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 124
[PL 3.1, page 390] Table 50 Paper Size Actuators Actuator 4 Top 3 2 1 Bottom 8.5" LEF X X X A4 LEF X X B5 LEF X X X A5 LEF X X X 14" SEF X X 8.5" SEF X X A4 SEF X X B4 SEF X Phaser 5400 Laser Printer Service Guide 95 - Xerox 5400N | Quick Reference Guide - Page 125
Cartridge Step 3. Does the rotor of the Main Motor rotate smoothly? [PL 8.1, page 402]. 3 FUSER ISOLATION Go to 1. Remove the Fuser Assembly [RRP 5.1, page 288]. Step 4. 2. Manually rotate the Fuser Assembly Drive Gear. Does the Fuser , page 128. 96 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 126
the problem. I Main Motor and/or drive gears [PL 7.1, page 400 I Fuser Assembly [RRP 5.1, page 288] I Print Cartridge [PL 8.1, page 402] I Exit Assembly [PL 6.1, page 398] I MBF Feed Roller Assembly [PL 4.1, page 392] I Wiring and connectors linking the components Phaser 5400 Laser Printer Service - Xerox 5400N | Quick Reference Guide - Page 127
RAP 31 Error Code U2: Laser Failure Power Off / On There is a problem with the Laser Assembly. Table 52 Error Code U2: Laser (ROS (Laser Scanner)) Failure Troubleshooting Procedure Step Actions and Questions 130. Go to Step 5. Go to RAP 40, page 114. 98 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 128
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. I Print Engine Controller Board [RRP 8.5, page 310] I Wiring and connectors linking the components Phaser 5400 Laser Printer Service Guide 99 - Xerox 5400N | Quick Reference Guide - Page 129
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. I Fuser Assembly [RRP 5.1, page 288] I Wiring and connectors linking the components 100 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 130
or troubleshoot each area listed below, one at a time, until you isolate and solve the problem. I Cooling Fans [RRP 8.4, page 309 / RRP 8-7, page 313] I Low Voltage Power Supply (LVPS) [RRP 8.6, page 312] I Wiring and connectors linking the components. Phaser 5400 Laser Printer Service Guide 101 - Xerox 5400N | Quick Reference Guide - Page 131
, replace each component or troubleshoot each area listed below, one at a time, until you isolate and solve the problem. I Print Engine Controller Board [RRP 8.1, page 305] I LVPS Power Supply [RRP 8.6, page 312] I Harness Assembly [PL 9.1, page 404] 102 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 132
, replace each component or troubleshoot each area listed below, one at a time, until you isolate and solve the problem. I Print Engine Controller Board [RRP 8.5, page 310] I LVPS Power Supply [RRP 8.6, page 312] I Harness Assembly [PL 9.1, page 404] Phaser 5400 Laser Printer Service Guide 103 - Xerox 5400N | Quick Reference Guide - Page 133
, replace each component or troubleshoot each area listed below, one at a time, until you isolate and solve the problem. I Print Engine Controller Board [RRP 8.5, page 310] I LVPS Power Supply [RRP 8.6, page 312] I Harness Assembly [PL 9.1, page 404] 104 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 134
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. I Print Engine Controller Board [RRP 8.5, page 310] I Wiring and connectors linking the components Phaser 5400 Laser Printer Service Guide 105 - Xerox 5400N | Quick Reference Guide - Page 135
Blank Page 106 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 136
as instructed. Printer Performance Problems Repair Analysis Procedure (RAP) Table Table 59 Print Performance Problems RAP Table Problem Go Laser Assembly RAP 48 on page 130 Fuser Assembly RAP 49 on page 133 Registration Sensor RAP 50 on page 135 Phaser 5400 Laser Printer Service Guide 107 - Xerox 5400N | Quick Reference Guide - Page 137
Table 59 Print Performance Problems RAP Table (cont'd.) Problem Go To MBF No Paper Sensor RAP 51 on page 137 Laser Safety Switch RAP 52 on page 139 Tray 1 No Error Format Hard Disk RAP 68 on page 172 Erratic Printer Operation RAP 69 on page 173 108 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 138
Analysis Procedure (RAP) Table Table 61 Electrical Interference RAP Table Problem Go To RAP No. Electrical Interference - Something is generating RAP 60 on page 157 electrical noise that may be interfering with the normal operation of the printer. Phaser 5400 Laser Printer Service Guide 109 - Xerox 5400N | Quick Reference Guide - Page 139
attempt any maintenance function which is not specifically called out in the service procedures. I Never remove any covers which are fastened with screws, unless so instructed in the service procedures. than 3 VAC. Is the AC voltage within specification? 110 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 140
between Neutral and Ground should be less than 3 VAC. Is the AC line voltage within specification? 3 XL, EUROPE [220 VAC] Go to Step 4. Inform customer of insufficient voltage or each connection. page 114]. Does continuity test per specification? Phaser 5400 Laser Printer Service Guide 111 - Xerox 5400N | Quick Reference Guide - Page 141
Clutch Table 63 Registration Clu.tch Troubleshooting Procedure Step Actions and Questions Yes No FROM STEP 2 ABOVE Replace the Repair or 1. Remove the Print Cartridge and the MBF Assembly [RRP 2.1 on page 259]. Registration replace 283]. 112 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 142
the problem. I Registration Clutch ["RRP 4.3 Registration Clutch"] I Registration Clutch Harness [PL 9.1, page 404] I Print Engine Controller Board [RRP 8.5, page 310] I LVPS Power Supply [RRP 8.6, page 312] I Paper Transport Assy [RRP 4.1, page 283] Phaser 5400 Laser Printer Service Guide 113 - Xerox 5400N | Quick Reference Guide - Page 143
P/ J167 pin 3. Step 3. Does the voltage match the line voltage? 3 1. Switch the main power OFF. Problem 2. Replace fuse F101. Solved. 3. Switch the main power ON. 4. Measure the voltage between the bottom of Fuse sent you here. Go to RAP 41. 114 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 144
Table 65 LVPS Voltages Red Lead Black Lead P/J161 pin 10 Frame Ground P/J161 pin 11 Frame Ground P/J161 pin 3 Frame Ground Voltage +5.0 VDC +3.3 VDC +24 VDC Phaser 5400 Laser Printer Service Guide 115 - Xerox 5400N | Quick Reference Guide - Page 145
J17 (Fuser Control PWB / Fuser) I P/J19 (Duplex Assembly/OCT) I P/J18 (HVPS/Registration Sensor) I P/J20 (Tray 1 Size Sensor/MBF Home Sensor) 5. Switch the printer power ON and measure the voltages listed in Table 67. Are all the voltages correct? 116 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 146
Troubleshooting Procedure (cont'd.) Step Actions and Questions Yes No 4 Switch the printer power OFF. Reconnect one of the Repeat the Replace the disconnected plugs. Switch the printer Frame Ground Frame Ground Voltage +5.0 VDC +3.3 VDC +24.0 VDC Phaser 5400 Laser Printer Service Guide 117 - Xerox 5400N | Quick Reference Guide - Page 147
or troubleshoot each area listed below, one at a time, until you isolate and solve the problem. I System Controller Board [RRP 8.1, page 305] I Print Engine Controller Board [RRP 8.5, page 310 I Printer Options I Wiring and connectors linking the components 118 Phaser 5400 Laser Printer Service - Xerox 5400N | Quick Reference Guide - Page 148
390] manually, then troubleshoot each area listed below, one at a time, until you isolate and solve the problem. I Low Paper Sensor Actuator [RRP 3.4, page 276] I Print Engine Controller Board [RRP 8.5, page 310 I Wiring and connectors linking the components Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 149
Printer Troubleshooting Step Actions and Questions Yes No 1 AC POWER CORD Go to Ensure the power cord is properly connected to the wall Step 2. outlet and to the back of the printer. Does the problem still exist? Problem -2 measure +3.3 VDC? 120 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 150
Table 70 Inoperative Printer Troubleshooting (cont'd.) Step Actions and Questions Yes No 8 SYSTEM VDC? Switch printer power OFF. Install next option and repeat Step 9 until voltage fails. Replace the defective option just installed. Problem solved. Phaser 5400 Laser Printer Service Guide 121 - Xerox 5400N | Quick Reference Guide - Page 151
below, one at a time, until you isolate and solve the problem. I Wiring and connectors linking the components I AC Power I Power Supply [RRP 8.9, page 315] I Print Engine Controller Board [RRP 8.5, page 310] I System Controller Board [RRP 8.1, page 305] 122 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 152
is erratic. Table 71 Malfunctioning LCD/LED Troubleshooting Procedure Step Actions and Questions Yes No 1 PROCEDURE Go to 1. Switch printer power OFF. Step 8. 2. Remove any the voltage between P/J13-1 and P/J13-2 measure +5.0 VDC? Go to Step 6. Phaser 5400 Laser Printer Service Guide 123 - Xerox 5400N | Quick Reference Guide - Page 153
Troubleshooting Procedure (cont'd.) Step Actions and Questions Yes No 6 SYSTEM CONTROLLER BOARD +5 VDC NO Replace the Go to LOAD CHECK System Step 7. 1. Switch printer any option? problem persists, return to initial actions and restart. 124 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 154
Troubleshooting Procedure (cont'd.) Step Actions and Questions Yes No 11 SUSPECT COMPONENTS The following printer components and areas are associated with this specific problem 3.3 VDC 3.3 VDC 1.3 VDC 3.3 VDC 3.3 VDC 3.3 VDC 0.0 VDC 3.3 VDC Phaser 5400 Laser Printer Service Guide 125 - Xerox 5400N | Quick Reference Guide - Page 155
the problem. I Control Panel Assembly [PL 1.1, page 384] I Wiring Harness Assembly, System Controller Board to Control Panel [PL 9.1, page 404] I Wiring Harness Assembly, System Controller Board 3.3 V [PL 9.1, page 404] I Power Supply [PL 9.1, page 404] 126 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 156
Table 74 Keypad Pin Voltage Pin 1 +3.3 VDC 5 2 0 VDC 6 3 +1.3 VDC 7 4 0 VDC 8 Voltage +3.3 VDC +1.3 VDC +3.3 VDC 0 VDC Phaser 5400 Laser Printer Service Guide 127 - Xerox 5400N | Quick Reference Guide - Page 157
Motor Asse. mbly Troubleshooting Procedure Step Actions and Questions Yes No 1 PROCEDURE Problem Go to 1. Open the Top Cover. solved. Step 2. 2. Remove the Print Cartridge. 3. Cheat the 3) to 0 VDC (measured in sub-step 5)? Go to Step 8. 128 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 158
Main Motor Harness From To P/J164-1 Frame Ground P/J164-2 Frame Ground P/J164-5 Frame Ground P/J164-6 Frame Ground P/J164-7 This voltage is valid if printer is set for 1200 DPI. Frame Ground Voltage +24 VDC +24 VDC +3.2 VDC +4.7 VDC +4.7 VDC Phaser 5400 Laser Printer Service Guide 129 - Xerox 5400N | Quick Reference Guide - Page 159
Measure the voltage between P/J21-4 and frame ground. Go to Step 9. Does the voltage between P/J21-4 and frame ground measure +5.0 VDC? Go to Step 7. 130 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 160
Table 77 Laser Assembly Troubleshooting Procedure (cont'd.) Step lift and lower the cartridge. Is there continuity between J21-4 and J21-3 when you lower the cartridge and no continuity when you lift the cartridge? 13 "YES" FROM RRP 8.5, page 310]. Phaser 5400 Laser Printer Service Guide 131 - Xerox 5400N | Quick Reference Guide - Page 161
you isolate and solve the problem. I Laser Assembly [RRP 7.1, page 297] I Print Engine Controller Board [RRP 8.5, page 310] I Harness Assembly [PL 9.2, page 406] I LVPS Power Supply [RRP 8.6, page 312] I CRUM PWB [RRP 3.7, page 281] No Problem solved. 132 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 162
Go to 1. Disconnect P/J171 from the Fuser Board. Step 6. 2. Check for continuity between P17-3 and P171-1, P17-2 and P171-2 and P17-1 and P171-3. Is there continuity between all pins measured? Replace the Fuser Harness Assembly [PL 9.2, page 406]. Phaser 5400 Laser Printer Service Guide 133 - Xerox 5400N | Quick Reference Guide - Page 163
5.1, page 288] I Print Engine Controller Board [RRP 8.5, page 310] I Fuser Board [RRP 8-8, page 314] I LVPS Power Supply [RRP 8.6, page 312] I Fuser Interlock Switch [PL 9.2, page 406] I Harness Assembly [PL 9.2, page 406] Figure 17 Fuser Connector P174 134 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 164
Troubleshooting Procedure Step Actions and Questions Yes No 1 PROCEDURE It appears Go to 1. Open the Top Cover and remove the Print Cartridge the Registration Sensor. problem Does the LCD counter MBF door. 2. Manually actuate the Registration Phaser 5400 Laser Printer Service Guide 135 - Xerox 5400N | Quick Reference Guide - Page 165
listed below, one at a time, until you isolate and solve the problem. I Registration Sensor [RRP 4.4, page 287] I Registration Sensor Actuator [RRP 4.2, page 285] I Print Engine Controller Board [RRP 8.5, page 310] I Harness Assembly [PL 9.1, page 404] 136 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 166
Paper S.ensor Troubleshooting Procedure Step Paper Sensor Actuator. working correctly. If a problem persists, Does the LCD counter increment each time SENSOR ACTUATOR INSPECTION Go to Step 3. 1. Manually move the MBF No Paper Sensor Actuator. Phaser 5400 Laser Printer Service Guide 137 - Xerox 5400N | Quick Reference Guide - Page 167
below, one at a time, until you isolate and solve the problem. I MBF No Paper Sensor Assy [PL 4.2, page 394] I Print Engine Controller Board [RRP 8.5, page 310] I LVPS Power Supply [RRP 8.6, page 312] I Wiring and connectors linking the components 138 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 168
area listed below, one at a time, until you isolate and solve the problem. I Print Cartridge [PL 8.1, page 402] I CRUM Board Assembly [RRP 3.7, page 281] I Print Engine Controller Board [RRP 8.5, page 310] I Wiring and connectors linking the components Phaser 5400 Laser Printer Service Guide 139 - Xerox 5400N | Quick Reference Guide - Page 169
printer power ON. 5. On the Print Engine Controller Board, measure the voltage between P12-6 and frame ground. Does the voltage between P12-6 and frame ground measure +3.28 VDC when the Tray 1 No Paper Sensor is deactuated and 0.0 VDC when actuated? 140 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 170
area listed below, one at a time, until you isolate and solve the problem. I Tray 1 No Paper Sensor [RRP 2.6, page 266] I Print Engine Controller Board [RRP 8.5, page 310] I Harness Assembly [PL 4.2, page 394] I LVPS Power Supply [RRP 8.6, page 312] Phaser 5400 Laser Printer Service Guide 141 - Xerox 5400N | Quick Reference Guide - Page 171
-Sheet Feeder? Go to Step 10. Go to Step 2. 2 500-SHEET FEEDER TROUBLESHOOTING Go to 1. Remove the tray from the problem feeder. Step 3. 2. Inspect the Size Cams on the left side of the paper , replace the Size Sensor Switch [PL 11.3, page 416]. 142 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 172
83 Size Switch Troubleshooting Procedure (cont'd.) Step Actions and Questions Yes No 7 "YES" FROM STEP 6 ABOVE Go to 1. Reconnect P/J138 to the Feeder Board. Step 8. 2. Switch printer power ON. sensor is actuated and infinity when deactuated? Phaser 5400 Laser Printer Service Guide 143 - Xerox 5400N | Quick Reference Guide - Page 173
]. Table 84 Size Switch Voltages Press Actuator Voltage Press Actuators 4 (top) +1.4 VDC 4 & 3 3 +2.3 VDC 4 & 2 2 +2.8 VDC 3 & 2 Voltage +0.4 VDC +0.9 VDC +1.8 VDC Press Actuators 4, 3 & 2 None Voltage 0.0 VDC +3.3 VDC 144 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 174
RAP 55 Turn Roller Clutch Assembly Table 85 Turn Roller Clutc. h Assembly Troubleshooting Procedure Step Actions and Questions Yes No 1 PROCEDURE Go to 1. Enter Diagnostics mode. Board [RRP 8.5, page 310]. Replace the LVPS [RRP 8.6, page 312]. Phaser 5400 Laser Printer Service Guide 145 - Xerox 5400N | Quick Reference Guide - Page 175
Assembly, MBF Combo [PL 4.2, page 394] I Harness Assembly, Paper Handling [PL 9.1, page 404] I LVPS Power Supply [RRP 8.6, page 312] I MBF Assy [RRP 2.1, page 259] 146 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 176
RAP 56 Tray 1 Feed Solenoid Table 86 Tray 1 Feed Sole. noid Troubleshooting Procedure Step Actions and Questions Yes No 1 PROCEDURE Go to 1. Enter Diagnostics mode. Step 8. Board [RRP 8.5, page 310]. Replace the LVPS [RRP 8.6, page 312]. Phaser 5400 Laser Printer Service Guide 147 - Xerox 5400N | Quick Reference Guide - Page 177
below, one at a time, until you isolate and solve the problem. I Feed Solenoid [RRP 2.9, page 270] I Print Engine Controller Board [RRP 8.5, page 310] I Harness Assembly, MBF Combo [PL 4.2, page 394] I Harness Assembly, Paper Handling [PL 9.1, page 404] 148 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 178
RAP 57 MBF Feed Solenoid Table 87 MBF Feed Solen.oid Troubleshooting Procedure Step Actions and Questions Yes No 1 PROCEDURE Go to 1. Enter Diagnostics mode. Step 8. Controller Board [RRP 8.5, page 310]. Replace the LVPS [RRP 8.6, page 312]. Phaser 5400 Laser Printer Service Guide 149 - Xerox 5400N | Quick Reference Guide - Page 179
, one at a time, until you isolate and solve the problem. I MBF Feed Solenoid [RRP 2.8, page 269] I Print Engine Controller Board [RRP 8.5, page 310] I Harness Assembly, MBF Combo [PL 4.2, page 394] I Harness Assembly, Paper Handling [PL 9.1, page 404] 150 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 180
Sensor Assembly Toner Sensor Board and P/J 141 from the Toner Sensor. [RRP 7.3, Harness 3. Check for continuity between all pins of P/J14 and P/J141. page 301]. [PL 8.1, page 402], Is there continuity between all the pins tested? as necessary. Phaser 5400 Laser Printer Service Guide 151 - Xerox 5400N | Quick Reference Guide - Page 181
component or troubleshoot each area listed below, one at a time, until you isolate and solve the problem. I Toner Sensor Assembly [RRP 7.3, page 301] I Print Engine Controller Board [RRP 8.5, page 310] I Harness Assembly, Toner Sensor [PL 8.1, page 402] 152 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 182
measure approximately 620 ±25 VAC? No Replace the Right Print Cartridge Guide Assembly [RRP 7.2, page 299] or the Print Cartridge [PL 8.1, page 402]. Replace the Right Print Cartridge Guide Assembly [RRP 7.2, page 299]. Go to Step 4. Go to Step 5. Phaser 5400 Laser Printer Service Guide 153 - Xerox 5400N | Quick Reference Guide - Page 183
Table 89 HVPS Assembly Troubleshooting Procedure (cont'd.) Step Actions and Questions Yes No 5 "BTR -" Guide and P186 [RRP 8.2, replace wire harness as on the HVPS. page 307]. necessary. 2. Repair or replace as necessary. Does wiring check OK? 154 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 184
FROM STEP 11 ABOVE Go to 1. Remove the Right Print Cartridge Guide Assembly Step 13. [RRP 7.2, page 299]. 2. Remove Problem Replace the Print Engine Controller Board [RRP 8.5, page 310]. Does the problem still appear? HVPS [RRP 8.2, page 307]. solved. Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 185
and solve the problem. I HVPS Assembly [RRP 8.2, page 307] I Print Cartridge Right Guide Assembly [RRP 7.2, page 299] I Harness Assembly, HVPS [PL 9.1, page 404 I Print Cartridge [PL 8.1, page 402] I Print Engine Controller Board [RRP 8.5, page 310] 156 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 186
the Right Print Cartridge Guide Assembly [RRP 7.2, page 299] or the Print Cartridge [PL 8.1, page 402]. Secure the grounding screw properly. Problem solved. Clean the Seal Guide or replace the Right Print Cartridge Guide Assembly [RRP 7.2, page 299]. Phaser 5400 Laser Printer Service Guide 157 - Xerox 5400N | Quick Reference Guide - Page 187
] I Fuser Assembly [RRP 5.1, page 288] I Paper Transport Assembly [RRP 4.1, page 283] I Harness Assembly, HVPS [PL 9.2] Does the problem disappear after replacing one of the above assemblies? Review Step 13. If problem persists, call Technical Support. 158 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 188
2. Reconnect P/J133. 3. Switch printer power ON. 4. Measure the voltage between P/J133-3 and frame ground as you actuate and deactuate the Low Paper Sensor. Does the voltage measure +0.0 VDC when deactuated and +3.2 VDC when actuated? Go to Step 6. Phaser 5400 Laser Printer Service Guide 159 - Xerox 5400N | Quick Reference Guide - Page 189
below, one at a time, until you isolate and solve the problem. I Low Paper Sensor Actuator [RRP 11.18, page 347] I Tray Left Guide Assembly [RRP 11.13, page 340] I Feeder Board [RRP 11-7, page 334] I Print Engine Controller Board [RRP 8.5, page 310] 160 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 190
Feed Solenoid Troubleshooting Procedure Step printer power ON. 4. Measure the voltage between P/J13-3 and frame ground. [P/J132 to P/J131 and P/J131 to P/J13]. [RRP 8.5, page 310]. Does the voltage measure +24 VDC? Repair or replace as necessary. Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 191
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. I Tray 2 (or Tray 3) Feed Solenoid [RRP 11.10, page 337] I Feed Head Harness [PL 11.3, page 416] 162 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 192
component or troubleshoot each area listed below, one at a time, until you isolate and solve the problem. I Print Engine Controller Board [RRP 8.5, page 310] I 500-Sheet Feeder Board [RRP 11.7, page 334] I Wiring and connectors linking the components Phaser 5400 Laser Printer Service Guide 163 - Xerox 5400N | Quick Reference Guide - Page 193
the Feeder Board. 4. Reconnect P/J13 to the Print Engine Controller Board. 5. Switch printer power ON. 6. Measure the voltage between P13-10 on the Print Engine Controller Board and frame ground. Does the voltage measure +1.9 VDC? Go to Step 5. 164 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 194
Reconnect P/J13 to the Print Engine Controller Board. Controller 3. Switch printer power ON. Board 4. Measure the voltage between P13-10 on the Print [RRP 8.5, Engine Controller board and frame ground. page 310]. Does the voltage measure +1.6 VDC? Phaser 5400 Laser Printer Service Guide 165 - Xerox 5400N | Quick Reference Guide - Page 195
or troubleshoot each area listed below, one at a time, until you isolate and solve the problem. I Print Engine Controller Board [RRP 8.5, page 310] I Feeder Board [RRP 11-7, page 334] I Harness, Wiring [PL 9.1, page 404] I Harness, Wiring [PL 11.2, page 414] 166 Phaser 5400 Laser Printer Service - Xerox 5400N | Quick Reference Guide - Page 196
or troubleshoot each area listed below, one at a time, until you isolate and solve the problem. I Print Engine Controller Board [RRP 8.5, page 310] I LVPS [RRP 8.6, page 312] I Fuser Assembly [RRP 5.1, page 288] I Wiring and connectors linking the components Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 197
Sensor Troubleshooting Procedure Step Actions and Questions Yes No 1 PRE-REGISTRATION SENSOR ACTUATOR Go to 1. Open the 500-Sheet Feeder Rear Cover. Step 2. 2. Manually actuate and when actuated? Replace the Feeder Board [RRP 11-7, page 334]. 168 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 198
each component or troubleshoot each area listed below, one at a time, until you isolate and solve the problem. I Print Engine Controller Board [RRP 8.5, page 310] I Pre-Registration Sensor [RRP 11.21, page 351] I Feeder Board [RRP 11.7, page 334] Phaser 5400 Laser Printer Service Guide 169 - Xerox 5400N | Quick Reference Guide - Page 199
Motor HCS Board Assembly [PL 10.2, 3. Switch printer power ON. [PL 10.2, page 410]. 4. On the HCS Board, measure the voltage between page 410]. P/J517-3 and frame ground, then between P/J517-4 and frame ground. Do both voltages measure +24 VDC? 170 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 200
solve the problem. I LVPS [RRP 8.6, page 312] I Duplex Board [RRP 8.3, page 308] I HCS Motor Assembly [RRP 10.8, page 325] I HCS Board [PL 10.2, page 410] I Print Engine Controller Board [RRP 8.5, page 310] I Wiring and connectors linking the components Phaser 5400 Laser Printer Service Guide 171 - Xerox 5400N | Quick Reference Guide - Page 201
problem with the hard disk and requires reformatting. Table 98 Hard Disk Formatting Troubleshooting Procedure Step Actions and Questions Yes No 1 POWER OFF 1. Switch printer When complete, the display will say "Ready" without the error message. 172 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 202
Switch printer power OFF. Step 6. 2. Disconnect P/J168 from the LVPS Assembly. 3. Switch printer power ON. 4. Measure the voltage between P161-10 and frame ground. Does the voltage between P161-10 and frame ground measure +5.0 VDC? Go to Step 11. Phaser 5400 Laser Printer Service Guide 173 - Xerox 5400N | Quick Reference Guide - Page 203
solved. 12 PRINT ENGINE CONTROLLER BOARD REPLACEMENT Go to Step 13. 1. Replace the Print Engine Controller Board ("RRP 8.5 Print Engine Controller Board"). 2. Monitor printer operation. Does the printer display erratic operation? Problem solved. 174 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 204
the problem. I Wiring and connectors linking the components I Interlock switches and circuits I Xerographic components and High Voltage Power Supply (RRP 8.2, page 307) I Computer Interface Cable I Control Panel (RRP 8.9, page 315) I AC Driver Board (RRP 8.8, page 314) Phaser 5400 Laser Printer - Xerox 5400N | Quick Reference Guide - Page 205
Troubleshooting Introduction This section contains image-quality repair procedures to assist in correcting image-quality defects. These procedures provide defect samples, definitions and specifications to verify that the problem has been corrected. 176 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 206
page 181 SPOTS: There are spots of toner on the page. Spots page 183 HORIZONTAL DELETIONS specification. Image page 215 RESOLUTION: At 600 dpi, the two-pixel lines and halftone patches cannot be reproduced clearly on the print. Resolution page 217 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 207
print. Problem solved. Does the image density meet specifications? 3 PRINT CARTRIDGE REPLACEMENT 1. Install a new Print Cartridge. 2. Run a test print. Problem solved. Does the image density meet specifications? No Go to Step 3. Go to Step 4. 178 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 208
read areas? Go to RAP 59, page 153 9 "YES" FROM STEP 8 ABOVE Go to Go to Inspect the toner image on the drum immediately after Step 10. the transfer area (BTR). RAP 59, page 153 Has the toner image on the drum transferred completely to the paper? Phaser 5400 Laser Printer Service Guide 179 - Xerox 5400N | Quick Reference Guide - Page 209
page 297, page 297] I LVPS Assembly [RRP 8.6, page 312] I Right Print Cartridge Guide [RRP 7.2, page 299] I Print Engine Controller Board [RRP 8.5, page 310] I Paper Transport Assembly [RRP 4.1, page 283] I Wiring and connectors linking the components 180 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 210
Print Menu / Config Sheet, problem press [4]. persists, the cables. If the problem Is the Configuration Sheet blank? replace the persists, System replace the Controller System Board Controller [RRP 8.1, Board page 305]. [RRP 8.1, page 305]. Phaser 5400 Laser Printer Service Guide 181 - Xerox 5400N | Quick Reference Guide - Page 211
so that they make better contact with the Print Cartridge, or replace the Right Print Cartridge Guide [RRP 7.2, page 299]. Replace the Right Print Cartridge Guide [RRP 7.2, page 299]. Replace the BTR Assembly [RRP 7.6, page 304]. Go to RAP 59, page 153. 182 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 212
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. 3 BIAS TRANSFER ROLLER (BTR) the BTR Assembly [RRP 7.6, page 304]. Go to RAP 59, page 153. Phaser 5400 Laser Printer Service Guide 183 - Xerox 5400N | Quick Reference Guide - Page 213
BTR Assembly [RRP 7.6, page 304] I Fuser Assembly [RRP 5.1, page 288] I Paper Transport Assembly [RRP 4.1, page 283] I HVPS Board [RRP 8.2, page 307] I Print Engine Controller Board [RRP 8.5, page 310] No Replace the Fuser Assembly [RRP 5.1, page 288]. 184 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 214
Troubleshooting Procedure Step Actions and Questions Yes No 1 INITIAL ACTIONS I Inspect the printer paper path for items such as staples, paper clips, paper scraps and/or other debris. I Check the installation of the Print Cartridge Problem solved. Phaser 5400 Laser Printer Service Guide 185 - Xerox 5400N | Quick Reference Guide - Page 215
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 Pressure Roller. Are the Heat and Pressure Rollers free of scratches (damage) and contamination? 186 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 216
310] I Fuser Assembly [RRP 5.1, page 288] I MBF Assembly [RRP 2.1, page 259] I Registration Clutch [RRP 4.3, page 286] I Rear Chute Assembly [RRP 3.2, page 274] I Turn Roller Assembly [RRP 2-4, page 263] I Wiring and connectors linking the components Phaser 5400 Laser Printer Service Guide 187 - Xerox 5400N | Quick Reference Guide - Page 217
, for contamination or obstructions. Is the paper path free of contamination and obstructions? Go to Step 6. No Problem solved. Problem solved. Remove any obstructions from the laser beam path. Remove obstructions or contamination from the paper path. 188 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 218
, until you isolate and solve the problem. I BTR Assembly [RRP 7.6, page 304] I Laser Assembly [RRP 7.1, page 297] I Fuser Assembly [RRP 5.1, page 288] I Print Engine Controller Board [RRP 8.5, page 310] I Wiring and connectors linking the components Phaser 5400 Laser Printer Service Guide 189 - Xerox 5400N | Quick Reference Guide - Page 219
remove the Print Cartridge and inspect the toner image on the drum just after the transfer area (BTR). Was the toner image on the drum transferred to the paper? No Problem solved. Problem solved. Replace the BTR Assembly [RRP 7.6, page 304]. 190 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 220
replace each component or troubleshoot each area listed below, one at a time, until you isolate and solve the problem. I BTR Assembly [RRP 7.6, page 304] I Paper Transport Assembly [RRP 4.1, page 283] No Replace the Fuser Assembly [RRP 5.1, page 288]. Phaser 5400 Laser Printer Service Guide 191 - Xerox 5400N | Quick Reference Guide - Page 221
the computer or problem the cables. If Does the Configuration Sheet exhibit vertical streaks? persists, the problem replace the persists, System replace the Controller System Board Controller [RRP 8.1, Board page 305]. [RRP 8.1, page 305]. 192 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 222
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 Pressure Roller. Are the Heat and Pressure Rollers free of scratches (damage) and contamination? Phaser 5400 Laser Printer Service Guide 193 - Xerox 5400N | Quick Reference Guide - Page 223
the Controller System Board Controller [RRP 8.1, Board page 305]. [RRP 8.1, page 305]. 4 PRINT CARTRIDGE REPLACEMENT 1. Install a new Print Cartridge. 2. Run a Test Print. Are the horizontal streaks gone? Problem solved. Go to Step 5. 194 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 224
area free of streaks? 9 "YES" FROM STEP 8 ABOVE Go to Inspect the toner image on the drum immediately after Step 10. the transfer area (BTR). Was the toner image on the drum transferred to the paper? Replace the BTR Assembly [RRP 7.6, page 304]. Phaser 5400 Laser Printer Service Guide 195 - Xerox 5400N | Quick Reference Guide - Page 225
right side up. 6. Open the fuse jam access cover. 7. Rotate the fuser idler gear manually and inspect the Pressure Roller. Are the Heat and Pressure Rollers free of scratches (damage) and contamination? Replace the Fuser Assembly [RRP 5.1, page 288]. 196 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 226
Step 4. 4 BIAS TRANSFER ROLLER INSPECTION Go to Inspect the BTR Assembly for contamination and wear. Step 5. Is the BTR free of contamination and wear? No Problem solved. Problem solved. Replace the BTR Assembly [RRP 7.6, page 304]. Phaser 5400 Laser Printer Service Guide 197 - Xerox 5400N | Quick Reference Guide - Page 227
I BTR Assembly [RRP 7.6, page 304] I Fuser Assembly [RRP 5.1, page 288] I HVPS Board [RRP 8.2, page 307] I Right Print Cartridge Guide [RRP 7.2, page 299] I Wiring and connectors linking the components No Replace the Fuser Assembly [RRP 5.1, page 288]. 198 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 228
the window of the Laser Assembly. 2. Run a Test Print. Is the print half white and half black? Yes Replace the system controller board [RRP 8.1, page 305]. Problem solved. Go to RAP 48, page 130. No Go to Step 2. Go to Step 3. Go to RAP 59, page 153. Phaser 5400 Laser Printer Service Guide 199 - Xerox 5400N | Quick Reference Guide - Page 229
through the print cycle. 2. Carefully remove the Print Cartridge and inspect the toner image on the drum just before the transfer area (BTR). Are the undeveloped areas of the drum clean and without background? No Go to Step 3. Go to RAP 59, page 153 200 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 230
Remove and clean the contact areas of the Paper Transport Assembly [RRP 4.1, page 283]. Reinstall the assembly so that it is grounded properly. If the problem persists, replace the Paper Transport Assembly [RRP4-1]. Go to Step 6. Phaser 5400 Laser Printer Service Guide 201 - Xerox 5400N | Quick Reference Guide - Page 231
Go to Inspect the BTR Assembly for contamination and wear. Step 5. Is the BTR free of contamination and wear? No There is no problem with the printer. Check the customer's application. Problem solved. Replace the BTR Assembly [RRP 7.6, page 304]. 202 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 232
the Laser Assembly [RRP 7.1, page 297]. 7 UNFUSED DENSITY Replace the Replace the Examine the print on the paper before the Fuser. Does the unfused image on the paper display even density? Fuser Assembly [RRP 5.1, page 288]. BTR [RRP 7.6, page 304]. Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 233
obstructions or worn/damaged parts found in the Exit Assembly? Yes Go to Step 3. Clean, repair or replace the Fuser Assembly [RRP 5.1, page 288]. Clean, repair or replace the Rear Cover Assembly [RRP 1-9]. No Go to Step 7. Go to Step 4. Go to Step 5. 204 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 234
Table 113 Skewed Image Troubleshooting Procedure (cont'd.) Step Actions and Questions Yes 5 DUPLEX ASSEMBLY INSPECTION Clean, 1. Inspect the 4.1, page 283]. Clean or replace the BTR as necessary [RRP 7.6, page 304]. Replace the Print Cartridge. Phaser 5400 Laser Printer Service Guide 205 - Xerox 5400N | Quick Reference Guide - Page 235
Table 113 Skewed Image Troubleshooting Procedure (cont'd.) Step Actions and Questions Yes 12 PAPER TRANSPORT ASSEMBLY INSPECTION Go to Inspect the page 287]. Go to Step 24. Clean or replace the Tray 1 Feed Rollers as necessary [RRP 2.10, page 271]. 206 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 236
Table 113 Skewed Image Troubleshooting Procedure (cont'd.) Step Actions and Questions Yes 20 TRAY 1 ENVELOPE FEED ROLLERS INSPECTION Go to Step 21. Inspect 11.12, page 339]. Clean or replace the 2000-Sheet Feeder Pick Roller [RRP 12.14, page 366]. Phaser 5400 Laser Printer Service Guide 207 - Xerox 5400N | Quick Reference Guide - Page 237
Table 113 Skewed Image Troubleshooting Procedure (cont'd.) Step Actions and Questions Yes 28 FEED CHUTE INSPECTION Go to Inspect the Feed Chute between Tray 2 Retard Roller [RRP 11.12, page 339] Clean or replace the Feed Chute [RRP 11.12, page 339]. 208 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 238
Troubleshooting Procedure (cont'd.) Step Actions and Questions Yes No 34 SUSPECT COMPONENTS The following printer components and areas are associated with this specific problem Rollers I Tray 1 Feed Chute I Tray 1 Lower Turn Roller I Tray 1 Rear Chute Phaser 5400 Laser Printer Service Guide 209 - Xerox 5400N | Quick Reference Guide - Page 239
jam access cover. 7. Rotate the fuser idler gear manually and inspect the Pressure Roller. Are the Heat and Pressure Rollers free of scratches (damage) and contamination? No Go to Step 3. Problem solved. Replace the Fuser Assembly [RRP 5.1, page 288]. 210 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 240
2-4] I Feed Roller [RRP 2.10, page 271] I Tray Assembly [PL 2.1 / PL 2.2] No Remove obstructions or contamination from the paper path. Replace the damaged or contaminated roller. Problem solved. Phaser 5400 Laser Printer Service Guide 211 - Xerox 5400N | Quick Reference Guide - Page 241
correctly? Go to Step 5. 4 NEW PRINT JOB Have the customer send another print job. Is the print image properly registered? Problem solved. No Go to Step 3. Perform the registration adjustment procedure [page 231]. Contact Xerox Customer Support. 212 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 242
Controller Board [RRP 8.1, page 305]. I Paper Transport [RRP 4-1, page 283] If misregistration occurs across the process direction, replace in sequence as necessary: I Laser Assembly [RRP 7.1, page 297] I System Controller Board [RRP 8.1, page 305] Phaser 5400 Laser Printer Service Guide 213 - Xerox 5400N | Quick Reference Guide - Page 243
Transport [RRP 4.1, page 283]. I Main Drive components [RRP 6.1, page 295]. I Fuser Assembly [RRP 5.1, page 288]. Does the defect still occur? Yes No Go to Step 3. Problem solved. Replace the Print Cartridge [PL 8.1, page 402]. Problem solved. 214 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 244
within specification? Yes No Go to Step 3. Problem solved. Go to Step 5. Go to Step 4. Increase the fuser temperature by one increment and run 25 test prints. Recheck / repeat as necessary. Problem solved. Go to Step 6. Go to RAP 70, page 178. Phaser 5400 Laser Printer Service Guide 215 - Xerox 5400N | Quick Reference Guide - Page 245
you isolate and solve the problem. I Fuser Assembly [RRP 5.1, page 288] I Print Engine Controller Board [RRP 8.5, page 310] I LVPS [RRP 8.6, page 312] No Replace the Fuser Assembly [RRP 5.1, page 288]. Replace the Fuser Assembly [RRP 5.1, page 288]. 216 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 246
. Does the Test Print output resolution appear to be acceptable? 3 SEQUENTIAL REPLACEMENT Replace as necessary until the defect component is found, in the following sequence: I Laser Assembly [RRP 7.1, page 297 I HVPS [RRP 8.2, page 307] Phaser 5400 Laser Printer Service Guide 217 - Xerox 5400N | Quick Reference Guide - Page 247
Blank Page 218 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 248
the System Menu (in Menu Mode) and can be preset to Off, 15, 30, 60, 90, 120 or 180 minutes. When the printer is in the power saving state, it takes longer to start printing the first page, because it can take up to 30 seconds to warm up the fuser. Phaser 5400 Laser Printer Service Guide 219 - Xerox 5400N | Quick Reference Guide - Page 249
sheets and print test/demo prints. The Menu Mode also enables the operator to set, change or adjust various features/options available in the Phaser 5400 Laser Printer. If an option is not installed, the menu items for that option will not be displayed. 220 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 250
the NVRAM submenus, "Enter Password" will be displayed. Sequentially press [0], [7], [3], [4] to gain entry. 5. To exit Diagnostics, you must switch printer power OFF for 10 seconds, then switch printer power ON for normal operation in the On Line mode. Phaser 5400 Laser Printer Service Guide 221 - Xerox 5400N | Quick Reference Guide - Page 251
- DIMM2 11 DIMM board 2 failure DIMM 3 0103 0103 - DIMM3 12 DIMM board 3 failure XIE 2000 2000 - XIE 15 Xerox Image Enhancement RAM, PWPM OR VDMA failure Memory 5000 5000 - MEMORY None Memory size not large enough to load the system software 222 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 252
no Ethernet link found ON: Indicates Ethernet link found RXD CR 2 Yellow OFF: Indicates no activity on Ethernet link ON: Indicates activity on Ethernet link Phaser 5400 Laser Printer Service Guide 223 - Xerox 5400N | Quick Reference Guide - Page 253
Laser Density (R) Read-only Fuser Stdby Temp (R) Read-only Fuser Run Temp Front Tray Size Front Tray Opt (R) Read-only Process Tray 1 Process Tray 2 Process Tray 3 Process MBF Scan Tray 1 Scan Tray 2 Scan Tray 3 Scan MBF Full Stack Count 224 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 254
[5] to display: ⇒ Press [2] or [6] to display: ⇓ Component Test Print Counter Sensor Input Fuser Temp Set Fuser Temp Read IOT ROM Checksum MBF Feed Sol Tray 1 Feed Sol Tray 2 Feed Sol Tray 3 3 Size Main Menu Component Test Press [3] or [7] to display: ⇓ Phaser 5400 Laser Printer Service Guide 225 - Xerox 5400N | Quick Reference Guide - Page 255
, technicians, and/or system administrators. 1. From the "Ready" menu, press [1] or [5] until "Print Menu" is displayed. 2. Press [2] or [6] until "Config Sheet" is displayed. 3. Press [4] and a printer configuration sheet is printed. 226 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 256
to the printer for reference by users, technicians, and/or system administrators. 1. From the "Ready" menu, press [1] or [5] until "Print Menu" is displayed. 2. Press [2] or [6] until "Menu Map" is displayed. 3. Press [4] and the menu map is printed. Phaser 5400 Laser Printer Service Guide 227 - Xerox 5400N | Quick Reference Guide - Page 257
off the printer's capabilities and may be left with the user after a repair is completed. 1. From the "Ready" menu, press [1] until "Print Menu" is displayed. 2. Press [2] until "PCL Demo" is displayed. 3. Press [4] and the PCL Demo test page is printed. 228 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 258
Print Enter Diagnostics Mode. Refer to page 221 for instructions on entering Diagnostics and page 224 for navigating the Diagnostics menu. The Print Engine Controller Board Test can test most of the printer's functional areas as well as print quality. Phaser 5400 Laser Printer Service Guide 229 - Xerox 5400N | Quick Reference Guide - Page 259
along the paper path. 1. Enter Printer Diagnostics and generate a test print from every input tray, using Duplex (if installed) and outputting to all output trays. 2. Follow the paper along the paper path to locate the cause of the problem. 230 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 260
two measurements should be equal (see Figure 35). 7. If either measurement does not meet specification perform the adjustment below. 8. Repeat steps 1 through 6 for each paper tray. Adjustment Press [3] or [7] again to scroll to a new setting / value. Phaser 5400 Laser Printer Service Guide 231 - Xerox 5400N | Quick Reference Guide - Page 261
to scroll to "Test Print." 8. Press [2] or [6] to scroll "Print 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 . Figure 35 Registration Test Pattern 232 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 262
instructions on entering Diagnostics Mode. Some parameters are "read-only" and cannot be changed. Refer to the Read/Write column in the table for specifics. The Control Panel Legend to the right will aid in navigating . Press [4] to set and exit. Phaser 5400 Laser Printer Service Guide 233 - Xerox 5400N | Quick Reference Guide - Page 263
. 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 Heat Roll Temp Centigrade .0° E 67 198° 388.4° F 6A 201° 393.8° a. Shaded Cells = Default 234 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 264
operation, identifying problems and isolating faulty Panel legend below to help navigate through the Component Test menu. Fuser temperature setting value for duration. 1. Press [4] to start test. 2. Displays current Fuser temperature. 3. Press [4] to stop. Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 265
Feed Sol 2 sec. Tray 3 Feed Sol 2 sec. Turn Roll Clutch 5 min. Reg. Clutch Main Motor 2 sec. 5 min. Procedure / Comment 1. Press [4] to display for duration. 2. Displays a ROM checksum test. 2. Main Motor runs for duration. 3. Press [0] to stop. 236 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 266
min. Fan Motor High 5 min. Dup Motor On Low 5 min. Dup Motor On Hi 5 min. Exit Motor Fwd L Exit Motor Rev L Exit Motor Rev H 5 min. 5 min. 5 min. ROS Motor 5 min the Laser Scanner Motor for duration. 3. Press [0] to stop. Note: Print Cartridge Phaser 5400 Laser Printer Service Guide 237 - Xerox 5400N | Quick Reference Guide - Page 267
-On Duration Dev Bias AC 5 min. Dev Bias DC 5 min. BTR - 5 min. BTR + 5 min. MBF Tray Size Tray 1 Size Tray 2 Size Tray 3 Size 4 sec. 4 sec. 4 min. 4 min. Procedure / Comment 1. Press [4] . Press [4] to start display Tray 3 size for duration. 238 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 268
panel key causes the PCL Demo page to print). printer is switched OFF. 2. Press and hold [0] and [4] while switching printer power ON. Continue pressing [0] and [4] until asterisks begin appearing across the Control Panel display (LCD). Xerox Phaser™ 5400 Phaser 5400 Laser Printer Service Guide 239 - Xerox 5400N | Quick Reference Guide - Page 269
Value Down s5400-350 The Maintenance Kit is a customer purchased, Customer-Replaceable Unit (CRU). The interval for replacement is 200K prints. For Maintenance Kit part numbers, see Xerox Supplies and Accessories in the FRU Parts Lists on page 428. 240 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 270
Inspect While Servicing The above represents all the scheduled maintenance for this printer; however, it is important for all qualified service technicians to always inspect and clean "on-the-fly" whenever repairing or otherwise servicing the printer. Phaser 5400 Laser Printer Service Guide 241 - Xerox 5400N | Quick Reference Guide - Page 271
the drum from the light. 3. Remove the fuser. 4. Remove the paper trays. 5. Clean all printer rollers, except the Bias Transfer Roller, with a lint-free cloth dampened slightly with cold water. Caution: Never apply alcohol to the Bias Transfer Roller. 242 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 272
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 Bias Transfer Roller. b. Vacuum any toner visible. c. Reinstall the Bias Transfer Roller. Phaser 5400 Laser Printer Service Guide 243 - Xerox 5400N | Quick Reference Guide - Page 273
Blank Page 244 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 274
the Service Representative to restore the product to within specification after fault isolation. Not all Replacement Procedures are included in this Quick Reference Guide. In RRP 3.4 Tray 1 Low Paper Sensor 276 RRP 3.5 Tray 1 Right Guide Assembly 277 Phaser 5400 Laser Printer Service Guide 245 - Xerox 5400N | Quick Reference Guide - Page 275
338 RRP 11.12 Retard Chute Assembly 339 RRP 11.13 Left Tray Guide 340 RRP 11.14 Right Tray Guide 342 RRP 11.15 Retard Holder Assembly 344 RRP 11.16 Retard Turn Roller Assembly 345 RRP 11.17 Paper Size Sensor 346 RRP 11.18 Paper Tray Sensor 347 246 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 276
12.23 Brake Assembly 375 RRP 12.24 Left Tray Wires ...376 RRP 12.25 Right Tray Wires 377 RRP 12.26 Retard Assembly 378 Phaser 5400 Laser Printer Service Guide 247 - Xerox 5400N | Quick Reference Guide - Page 277
type and size screw. Using the wrong screw can damage tapped holes. Do not use excessive force to either remove or install either a screw or a printer part. Warning: Unplug the AC power cord from the AC wall outlet before removing any printer part. 248 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 278
removing or replacing a component. Adjustment The Phaser 5400 printer does not contain any field adjustable components. Warning: Use of controls or adjustments other than those specified in this manual may result in an exposure to dangerous laser light. Phaser 5400 Laser Printer Service Guide 249 - Xerox 5400N | Quick Reference Guide - Page 279
Removing the Left Side Cover 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 the components in the reverse order. 250 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 280
and remove the Print Cartridge. Cover the cartridge to protect it from light. Note: Place paper inside the Print Cartridge cavity to catch any to the printer. 7. Remove the Right Side Cover. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 251 - Xerox 5400N | Quick Reference Guide - Page 281
10.1 1000-Sheet High Capacity Stacker [HCS]). 3. Open the Top Cover and remove the Print Cartridge. 4. Cover the cartridge to protect it from light. 5. Remove the Left Side Cover (RRP 1.1 Left Side Cover). Reinstall the components in the reverse order. 252 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 282
Remove the two screws that secure the Front Cover to the printer. 10.Lift, then pull the Front Cover out to remove. Replacement 1. Reinstall the components in the reverse order. 2. Align the two hooks on the Front Cover with the holes in the printer. Phaser 5400 Laser Printer Service Guide 253 - Xerox 5400N | Quick Reference Guide - Page 283
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 Left Cover. Replacement Reinstall the components in the reverse order. 254 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 284
the Stopper. 5. Remove the six screws that secure the HVPS Cover to the printer. 6. Lower the cover and disconnect P/J502 and P/J505 from the Duplex Interface PWB. 7. Remove the HVPS Cover. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 255 - Xerox 5400N | Quick Reference Guide - Page 285
Rear Cover 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 Reinstall the components in the reverse order. 256 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 286
come off with the cover. 5. Release the locking tabs and remove the harness from the MBF Cover. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 257 - Xerox 5400N | Quick Reference Guide - Page 287
hand while removing the straps from the posts. 4. With the cover positioned as shown, lift the left end (as viewed from the rear of the printer) of the Rear Cover and remove. Replacement Reinstall the components in the reverse order. 258 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 288
the MBF Assembly until it stops. 11.Lift the front of the paper handler 1.5 to 2 in. (38 to 51 mm) and remove the MBF Assembly. Phaser 5400 Laser Printer Service Guide 259 - Xerox 5400N | Quick Reference Guide - Page 289
Figure 46 MBF Left Tray Stop Figure 47 MBF Right Tray Stop Replacement Reinstall the components in the reverse order. 260 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 290
right and remove. Replacement Reinstall the components in the reverse order. Note: Arrows of the back side of the Feed Rollers indicate direction of rotation. Phaser 5400 Laser Printer Service Guide 261 - Xerox 5400N | Quick Reference Guide - Page 291
. Replacement 1. Reinstall the components in the reverse order. 2. Ensure that the tab on the clutch is positioned on the pin on the Paper Handler. 262 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 292
the bearing from the right end of the Turn Roller Assembly Shaft. 7. Remove the Turn Roller Assembly. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 263 - Xerox 5400N | Quick Reference Guide - Page 293
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. Insert a screwdriver between the left side of the MBF and until it can be lifted out of the MBF base. 264 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 294
Figure 52 MBF Tray Assembly Figure 53 MBF Retard Holder Assembly Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 265 - Xerox 5400N | Quick Reference Guide - Page 295
the sensor assembly bracket. 6. Release the sensor harness from the harness clamps and remove the sensor. Replacement Reinstall the components in the reverse order. 266 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 296
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 bracket. 7. Insert a screwdriver between the left side of the on the bottom of the Sensor Assembly and remove the sensor. Phaser 5400 Laser Printer Service Guide 267 - Xerox 5400N | Quick Reference Guide - Page 297
Figure 56 MBF Tray Assembly Figure 57 MBF No Paper Sensor Assembly Replacement Reinstall the components in the reverse order. 268 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 298
Gear Cover). 3. Remove the Pick-up Spring from the MBF Pick-up Gear. 4. Disconnect P/J123 from the MBF Feed Solenoid. 5. Remove the screw that secures the MBF Feed Solenoid to the MBF Assembly. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 269 - Xerox 5400N | Quick Reference Guide - Page 299
). 3. Remove the Pick-up Spring from the Tray 1 Pick-up Gear. 4. Disconnect P/J135 from the Tray 1 Feed Solenoid. 5. Remove the screw that secures the Tray 1 Feed Solenoid to the MBF Assembly. Replacement Reinstall the components in the reverse order. 270 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 300
Rollers. Replacement Reinstall the components in the reverse order. Note: The arrows on the side of the Envelope Feed Rollers indicate the direction of rotation. Phaser 5400 Laser Printer Service Guide 271 - Xerox 5400N | Quick Reference Guide - Page 301
power and disconnect the Power Cord. 1. Open the Top Cover and remove the Print Cartridge. Cover the cartridge to protect it from light. 2. Remove Tray 1. 3. Remove the MBF Assembly (RRP front. Replacement Reinstall the components in the reverse order. 272 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 302
Open the Top Cover and remove the Print Cartridge. Cover the cartridge to protect it from light. 2. Remove printer. 5. Lift up on the right end of the chute. 6. Pull the right end forward and remove. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 303
Print Cartridge. Cover the cartridge to printer. 6. Bias the Rear Chute to the left. Pull the top of the chute forward and remove it from the printer. Use care not to damage the ground tabs. Replacement Reinstall the components in the reverse order. 274 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 304
the power and disconnect the Power Cord. 1. Open the Top Cover and remove the Print Cartridge. Cover the cartridge to protect it from light. 2. Remove Tray 1. 3. Remove the MBF Assembly (RRP . Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 275 - Xerox 5400N | Quick Reference Guide - Page 305
Cartridge. Cover the cartridge Guide Assembly (RRP 3.6 Tray 1 Left Guide Assembly). 6. Disconnect plug from the sensor. 7. Release the locking tabs and remove the sensor from the Guide Assembly. Replacement Reinstall the components in the reverse order. 276 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 306
Guide Assembly (See PL 3.1 Paper Feeder) Figure 66 Paper Level Indicator Arm Removal Warning: Switch off the power and disconnect the Power Cord. 1. Open the Rear Cover. 2. Open the Top Cover and remove the Print Cartridge. Cover the cartridge printer. Phaser 5400 Laser Printer Service Guide 277 - Xerox 5400N | Quick Reference Guide - Page 307
.Use a small screwdriver to pry up on the locking tab that locks the guide assembly to the bottom of the printer. 15.Remove the Tray 1 Right Guide Assembly. Figure 67 Tray 1 Right Guide Assembly Replacement Reinstall the components in the reverse order. 278 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 308
(MBF) Assembly). 5. Remove the Retard Chute Assembly (RRP 3.1 Retard Chute Assembly). 6. From the left side of the printer, disconnect P/J201 from the Tray 1 Size Sensor. 7. Remove the six screws that secure the Tray 1 left Guide Assembly to the printer. Phaser 5400 Laser Printer Service Guide 279 - Xerox 5400N | Quick Reference Guide - Page 309
J202 and P/J127 from the guide assembly. 10.Remove the Tray 1 Left Guide Assembly. Replacement Reinstall the components in the reverse order. Note: Ensure that all alignment pins are properly inserted in the frame holes before replacing the six screws. 280 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - 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 the components in the reverse order. Phaser 5400 Laser Printer Service Guide 281 - Xerox 5400N | Quick Reference Guide - Page 311
6. Remove Tray 1 Left Guide Assembly (RRP 3.6 Tray 1 Left Guide Assembly) 7. Remove the two screws and remove the cover. 8. Release the locking tabs and remove the sensor from the Guide Assembly. Replacement Reinstall the components in the reverse order. 282 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 312
Cord. 1. Open the Rear Cover. 2. Remove the Fuser Assembly (RRP 5.1 Fuser Assembly). 3. Open the Top Cover and remove the Print Cartridge. Cover the cartridge to protect it from light. 4. Remove Tray 1. 5. assembly. 11.Remove the wires from cable clamps. Phaser 5400 Laser Printer Service Guide 283 - Xerox 5400N | Quick Reference Guide - Page 313
Roller with your hands. Oil from your hands can cause copy quality problems. 14.Guide the high voltage leads through the holes in the printer frame as you remove the Paper Transport Assembly. Replacement Reinstall the components in the reverse order. 284 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 314
Cover. 2. Remove the Fuser Assembly (RRP 5.1 Fuser Assembly). 3. Open the Top Cover and remove the Print Cartridge. Cover the cartridge to protect it from spring from the Registration Actuator. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 285 - Xerox 5400N | Quick Reference Guide - Page 315
Cord. 1. Open the Rear Cover. 2. Remove the Fuser Assembly (RRP 5.1 Fuser Assembly). 3. Open the Top Cover and remove the Print Cartridge. Cover the cartridge to protect it from light. 4. Remove Tray 1. Reinstall the components in the reverse order. 286 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 316
1. Open the Rear Cover. 2. Remove the Fuser Assembly (RRP 5.1 Fuser Assembly). 3. Open the Top Cover and remove the Print Cartridge. Cover the cartridge to protect it from light. 4. Remove Tray Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 287 - Xerox 5400N | Quick Reference Guide - Page 317
the Fuser Locking Lever to the left (as viewed from the rear). 3. Lift the left tab to disconnect P/J174 then lift both the left and right tabs to remove. Replacement Reinstall the components in the reverse order. Note: Install the locating pins first. 288 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 318
RRP 5.2 Stack Full Sensor (See PL 6.1 Rear Cover Assembly With Fuser) Figure 76 Lower Exit Chute Removal Warning: Switch off the power and disconnect the Power Cord. 1. Rear Cover. 5. Remove the Stack Full Sensor Holder and Actuator from the Rear Cover. Phaser 5400 Laser Printer Service Guide 289 - Xerox 5400N | Quick Reference Guide - Page 319
components in the reverse order. Note: The two shoulder screws go in the right end of the Lower Exit Chute Assembly (see Figure 76). 290 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 320
RRP 5.3 Exit Roller Assembly (See PL 6.1 Rear Cover Assembly With Fuser) Figure 79 Lower Exit Chute Removal Warning: Switch off the power and disconnect the Power Cord. 1. Open left until the right end is free of the Rear Cover. Remove the Exit Roller. Phaser 5400 Laser Printer Service Guide 291 - Xerox 5400N | Quick Reference Guide - Page 321
Figure 80 Upper Exit Chute Figure 81 Upper Exit Roller Assembly 292 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 322
Figure 82 Lower Exit Roller Assembly Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 293 - Xerox 5400N | Quick Reference Guide - Page 323
RRP 5.4 Stack Full Sensor Actuator (See PL 6.1 Rear Cover Assembly With Fuser) Figure 83 Stack Full Sensor Actuator Removal Warning: Switch off the power and disconnect actuator out of the holder. Replacement Reinstall the components in the reverse order. 294 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 324
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 it from light. 6. Remove Tray System Controller PWB (RRP 8.1 System Controller PWB). Phaser 5400 Laser Printer Service Guide 295 - Xerox 5400N | Quick Reference Guide - Page 325
the eight screws to remove. 13.Remove the eight screws that secure the Gear Assembly to the printer. 14.Remove the Gear Assembly and Motor from the printer. 11 13 14 Figure 85 Gear Drive Assembly Replacement Reinstall the components in the reverse order. 296 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 326
the screw that secures the Right Side Cover to the Laser Cover. 6. Remove the Front Cover (RRP 1.4 Front Cover). 7. Remove the six screws that secure the Laser Cover to the printer. Move the top of the right cover to the right and remove the Laser Cover. Phaser 5400 Laser Printer Service Guide 297 - Xerox 5400N | Quick Reference Guide - Page 327
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. Figure 87 Laser Assembly Replacement Reinstall the components in the reverse order. 298 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 328
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 Assembly) 4. Open the Top Cover and remove the Print Cartridge. Cover the cartridge to protect it from light. Phaser 5400 Laser Printer Service Guide 299 - Xerox 5400N | Quick Reference Guide - Page 329
Link is not attached to the Guide Assembly and may fall into the printer when the guide assembly is removed. 15.Remove the Right Print Cartridge Guide Assembly and Pin Link from the printer. Replacement Reinstall the components in the reverse order. 300 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 330
light. 2. Disconnect P/J141. 3. Release Toner Sensor Assembly Harness from the cable clamps and retainers. 4. Release the two locking tabs and remove the Toner Sensor Assembly from the printer. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 301 - Xerox 5400N | Quick Reference Guide - Page 331
(RRP 1.2 Right Side Cover). 6. Remove the screw that secures the Interlock Switch to the Right Print Cartridge Guide Assembly. 7. Disconnect P/J623 from the Interlock Switch. Remove the switch. Replacement Reinstall the components in the reverse order. 302 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 332
that secure the Print Cartridge Left Guide Assembly to the printer. 7. Remove the Print Cartridge Left Guide Assembly from the printer. 8. Remove the Left Guide Link Assembly from the printer. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 303 - Xerox 5400N | Quick Reference Guide - Page 333
the cartridge to protect it from light. Note: During 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 Reinstall the components in the reverse order. 304 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 334
3. Remove the 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 System Controller PWB. 9. If installed, remove the Hard Disk Drive. Phaser 5400 Laser Printer Service Guide 305 - Xerox 5400N | Quick Reference Guide - Page 335
System Controller PWB. 6 5 Figure 94 System Controller Board Assembly 11 10 Figure 95 System Controller Board Replacement Reinstall the components in the reverse order. 306 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 336
yellow wire removed in step 3, be certain to route it under the HVPS board. 4. Remove the four screws that secure the HVPS PWB to the printer. 5. Remove the HVPS PWB. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 307 - Xerox 5400N | Quick Reference Guide - Page 337
Cover). 3. DIsconnect P/J501, P/J504, and P/J506 from the Duplex Interface PWB. 4. Remove the two screws that secure the Duplex Interface PWB to the printer. 5. Remove the Duplex Interface PWB. Replacement Reinstall the components in the reverse order. 308 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 338
and remove the Print Cartridge. Cover the cartridge to protect it from printer. 10.Remove Fan Harness from all clamps. 11.Remove the screw that secures the Main Fan to the printer. Remove the fan. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 339
, P/J18, P/J19, P/J20, P/J21, and P/J22 from the Print Engine Controller PWB. 5. Remove the four screws that secure the Print Engine Controller PWB to the printer. Slide the Print Engine Controller PWB to the right and remove. 310 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 340
Figure 100 Print Engine Controller Board Cover Figure 101 Print Engine Controller Board Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 311 - Xerox 5400N | Quick Reference Guide - Page 341
that secure the LVPS Assembly to the printer. 4. Remove the LVPS Assembly. Replacement Reinstall the components in the reverse order. Note: Reinstall the silver and gold screws in the correct position noted in step 3 or the threads can be stripped. 312 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 342
. 4. Remove the two screws that secure the LVPS Fan to the LVPS Assembly. 5. Remove the LVPS Fan. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 313 - Xerox 5400N | Quick Reference Guide - Page 343
to the LVPS Assembly. 8. Flex the Right Cover out as you remove the AC Input Assembly. Replacement Reinstall the components in the reverse order. 314 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 344
). 2. Loosen the two thumb nuts and remove the System Controller PWB Shield Cover. 3. Remove the four screws that secure the MCU Cover. Remove the cover. Phaser 5400 Laser Printer Service Guide 315 - Xerox 5400N | Quick Reference Guide - Page 345
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. Figure 106 +5 VDC Power Supply Replacement Reinstall the components in the reverse order. 316 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 346
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. 4. Pull the Duplex Assembly out and up to remove. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 317 - Xerox 5400N | Quick Reference Guide - Page 347
[HCS] Assembly Removal Warning: Switch off the power and 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 . Replacement Reinstall the components in the reverse order. 318 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 348
Output Bin. 3. Remove the four screws that secure the Top Cover. 4. Lift the cover up to remove. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 319 - Xerox 5400N | Quick Reference Guide - Page 349
press in on the right bracket to disengage the cover from the frame. 3. Remove the cover. Replacement Reinstall the components in the reverse order. 320 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 350
(RRP 10.2 HCS Top Cover). 3. Remove the four screws that secure the Front Cover. Remove the cover. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 321 - Xerox 5400N | Quick Reference Guide - Page 351
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 Solenoid Assembly and remove the solenoid. Replacement Reinstall the components in the reverse order. 322 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 352
Cover). 3. Disconnect P/J521 from the Stack Full Sensor. 4. Release the three locking tabs and remove the sensor. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 323 - Xerox 5400N | Quick Reference Guide - Page 353
center of the actuator until the right end is free of the assembly. 5. Remove the actuator. Replacement Reinstall the components in the reverse order. 324 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 354
the two screws that secure the Motor Bracket to the HCS. 5. Remove the Drive Motor and bracket. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 325 - Xerox 5400N | Quick Reference Guide - Page 355
Cover). 3. Disconnect P/J525 from the interlock switch. 4. Release the two locking tabs and remove the switch. Replacement Reinstall the components in the reverse order. 326 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 356
from the Paper Sensor. 5. Release the two locking tabs that secure the sensor and remove the sensor. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 327 - Xerox 5400N | Quick Reference Guide - Page 357
Feeder. Warning: To avoid possible personal injury associated with lifting heavy objects, have someone assist you in removing the printer and setting it in a safe place. 4. Remove the printer. Replacement Reinstall the components in the reverse order. 328 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 358
cover. 3. Pull out on the top of the Front Cover and lift slightly to remove the cover. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 329 - Xerox 5400N | Quick Reference Guide - Page 359
(RRP 11.2 Front Cover). 3. Remove the five screws that secure the Left Cover. Remove the cover. Replacement Reinstall the components in the reverse order. 330 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 360
Cover (RRP 11.2 Front Cover). 3. Remove the five screws that secure the Right Cover. Remove the cover. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 331 - Xerox 5400N | Quick Reference Guide - Page 361
. 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 cover out and up. Remove the cover. Replacement Reinstall the components in the reverse order. 332 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 362
3. Remove the Left Cover (RRP 11.3 Left Cover) 4. Disconnect P/J13B from the Feeder PWB. 5. Remove the four screws that secure the Drive Assembly to the printer frame. Remove the Drive Assembly. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 333 - Xerox 5400N | Quick Reference Guide - Page 363
(RRP 11.3 Left Cover) 4. Disconnect P/J13B, P/J133, P/J138, P/J132, and P/J136 from the Feeder PWB. 5. Remove the two screws that secure the PWB to the printer frame. Remove the PWB. Replacement Reinstall the components in the reverse order. 334 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 364
125 Feed Head Assembly Removal Warning: Switch off the power and disconnect the Power Cord. 1. Remove the printer from the 500-Sheet Feeder (RRP 11.1 500-Sheet Feeder Removal). 2. Remove the paper tray from Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 335 - Xerox 5400N | Quick Reference Guide - Page 365
Figure 126 Feed Rollers Removal Warning: Switch off the power and disconnect the Power Cord. 1. Remove the printer from the 500-Sheet Feeder (RRP 11.1 500-Sheet Feeder Removal). 2. Remove the paper tray from Rollers indicate the direction of rotation. 336 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 366
Feed Solenoid Removal Warning: Switch off the power and disconnect the Power Cord. 1. Remove the printer from the 500-Sheet Feeder (RRP 11.1 500-Sheet Feeder Removal). 2. Remove the paper tray . Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 337 - Xerox 5400N | Quick Reference Guide - Page 367
128 Turn Roller Assembly Removal Warning: Switch off the power and disconnect the Power Cord. 1. Remove the printer from the 500-Sheet Feeder (RRP 11.1 500-Sheet Feeder Removal). 2. Remove the paper tray from Reinstall the components in the reverse order. 338 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 368
Retard Chute Assembly Removal Warning: Switch off the power and disconnect the Power Cord. 1. Remove the printer from the 500-Sheet Feeder (RRP 11.1 500-Sheet Feeder Removal). 2. Remove the paper tray from Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 339 - Xerox 5400N | Quick Reference Guide - Page 369
RRP 11.13 Left Tray Guide (See PL 11.3 500-Sheet Feeder (3 of 3)) Figure 130 Left Tray Guide 340 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 370
harness clip from the Feeder PWB. 8. Remove the seven screws that secure the Left Tray Guide to the feeder. 9. Use a small screwdriver to pry up the locking tab. 10.Remove the Left Tray Guide. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 341 - Xerox 5400N | Quick Reference Guide - Page 371
stud on the frame. 9. Move the paper level assembly forward and remove from the feeder. 10.Remove the five screws that secure the Right Tray Guide to the feeder. 11.Use a small screwdriver to pry up the locking tab. 12.Remove the Right Tray Guide. 342 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 372
Figure 132 Right Tray Guide Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 343 - Xerox 5400N | Quick Reference Guide - Page 373
Retard Holder Assembly Removal Warning: Switch off the power and disconnect the Power Cord. 1. Remove the printer from the 500-Sheet Feeder (RRP 11.1 500-Sheet Feeder Removal). 2. Remove the paper tray from Reinstall the components in the reverse order. 344 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 374
Turn Roller Assembly Removal Warning: Switch off the power and disconnect the Power Cord. 1. Remove the printer from the 500-Sheet Feeder (RRP 11.1 500-Sheet Feeder Removal). 2. Remove the paper tray from Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 345 - Xerox 5400N | Quick Reference Guide - Page 375
Chute Assembly). 7. Remove the Left Tray Guide (RRP 11.13 Left Tray Guide). 8. Disconnect P/J139 from the back of the Paper Size Sensor. 9. Release the two locking tabs and remove the sensor. Replacement Reinstall the components in the reverse order. 346 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 376
Retard Chute Assembly). 7. Remove the Left Tray Guide (RRP 11.13 Left Tray Guide). 8. Disconnect P/J137 from the back of the Tray Sensor. 9. Release the three locking tabs and remove the sensor. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 347 - Xerox 5400N | Quick Reference Guide - Page 377
No Paper Sensor Cover Removal Warning: Switch off the power and disconnect the Power Cord. 1. Remove the printer from the 500-Sheet Feeder (RRP 11.1 500-Sheet Feeder Removal). 2. Remove the paper tray from secures the sensor cover and remove the cover. 348 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 378
the three locking tabs and remove the sensor. Figure 138 Feed Solenoid Figure 139 No Paper Sensor Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 349 - Xerox 5400N | Quick Reference Guide - Page 379
No Paper Sensor Actuator Removal Warning: Switch off the power and disconnect the Power Cord. 1. Remove the printer from the 500-Sheet Feeder (RRP 11.1 500-Sheet Feeder Removal). 2. Remove the paper tray from Reinstall the components in the reverse order. 350 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 380
Removal Warning: Switch off the power and disconnect the Power Cord. Figure 141 Sensor Cover 1. Remove the printer from the 500-Sheet Feeder (RRP 11.1 500-Sheet Feeder Removal). 2. Remove the paper tray from Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 351 - Xerox 5400N | Quick Reference Guide - Page 381
RRP 12.1 Removing the 2000-Sheet Feeder (See PL 12.1 2000-Sheet Feeder (1 of 4)) Figure 143 Removing the Printer 352 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 382
the printer. 6. If a 500-Sheet Feeder is installed, remove the paper tray, remove the two screws that secure the 500-Sheet Feeder to the 2000-Sheet Feeder, and remove the 500-Sheet Feeder. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 353 - Xerox 5400N | Quick Reference Guide - Page 383
secure the Left Side Cover. 2. Pull the top of the cover out and up to remove. Replacement Reinstall the components in the reverse order. 354 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 384
in on the left or right bracket to disengage the end of the cover. 3. Remove the cover. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 355 - Xerox 5400N | Quick Reference Guide - Page 385
the Lower Rear Cover. 2. Loosen three screws that secure the Lower Rear Cover. 3. Remove the cover. Replacement Reinstall the components in the reverse order. 356 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 386
that secure the Right Side Cover. 2. Pull the top of the cover out and up to remove. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 357 - Xerox 5400N | Quick Reference Guide - Page 387
that secure the front cover. 3. Pull the top of the cover out and up to remove. Replacement Reinstall the components in the reverse order. 358 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 388
. 3. Push and hold the button on the Left Rail to release the latch. 4. Remove the Tray Assembly. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 359 - Xerox 5400N | Quick Reference Guide - Page 389
, P/J604, P/J605, P/J606, and P/J607. 3. Remove the four screws that secure the PWB. 4. Remove the PWB. Replacement Reinstall the components in the reverse order. 360 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 390
PWB. 4. Remove the three screws that secure the Lift Motor Assembly. 5. Remove the Tray Lift Motor Assembly. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 361 - Xerox 5400N | Quick Reference Guide - Page 391
). 2. Disconnect P/J612 from the Paper Size Sensor. 3. Release the two locking tabs and remove the Sensor. Replacement Reinstall the components in the reverse order. 362 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 392
4)) Figure 153 Casters Removal Warning: Switch off the power and disconnect the Power Cord. 1. Remove the Printer / 500-Sheet Feeder (RRP 11.1 500-Sheet Feeder Removal). 2. Remove the Left Foot. 3. Remove Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 363 - Xerox 5400N | Quick Reference Guide - Page 393
PWB. 5. Release the harness from all cable clamps. 6. Remove the two screws that secure the harness connector to the frame. 7. Guide the harness through the holes in the frame as you remove it. Replacement Reinstall the components in the reverse order. 364 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 394
Drive Assembly. 5. Remove the screw that secures the front of the Drive Assembly. 6. Remove the Drive Assembly. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 365 - Xerox 5400N | Quick Reference Guide - Page 395
on the Roller you wish to change. 5. Slide the Roller off the end of the shaft. Replacement Reinstall the components in the reverse order. 366 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 396
you release the three locking tabs that secure the Paper Height Sensor. 3. Disconnect P/J611 from the sensor. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 367 - Xerox 5400N | Quick Reference Guide - Page 397
the Feeder Frame. 4. Remove the Paper Feed Motor Assembly. 5. Disconnect P/J609 from the Feed Motor Assembly. Replacement Reinstall the components in the reverse order. 368 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 398
-Sheet Feeder Tray Assembly (RRP 12.7 Tray Assembly). 3. Unhook the torsion spring from the Link Stopper. 4. Pull up on the locking tab and remove the Link Stopper. 5. Remove the Torsion Spring. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 369 - Xerox 5400N | Quick Reference Guide - Page 399
the No Paper Sensor. 3. Release the three locking tabs that secure the sensor 4. Remove the sensor. Replacement Reinstall the components in the reverse order. 370 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 400
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 actuator from the Actuator Support. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 371 - Xerox 5400N | Quick Reference Guide - Page 401
Cover to the Tray Assembly. 3. Pull the top of the cover out and up to remove. Replacement Reinstall the components in the reverse order. 372 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 402
). 2. Remove the four screws that secure the Shaft Cover Assembly to the Tray Assembly. 3. Remove the cover. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 373 - Xerox 5400N | Quick Reference Guide - Page 403
screws that secure the Drive Shaft Bracket to the shaft cover. 5. Remove the Drive Shaft Assembly. Replacement Reinstall the components in the reverse order. 374 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 404
). 2. Remove the two screws that secure the Brake Assembly to the Tray Assembly. 3. Remove the Brake Assembly. Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 375 - Xerox 5400N | Quick Reference Guide - Page 405
. 8. Remove the wires down through the holes in the tray assembly. Replacement 1. Ensure the black plastic wire guides are at the top of the pulleys. 2. Reinstall the components in the reverse order. 3. The longer wire goes to the front of the tray. 376 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 406
. 6. Remove the wires down through the holes in the tray assembly. Replacement 1. Ensure the black plastic wire guides are at the top of the pulleys. 2. Reinstall the components in the reverse order. 3. The longer wire goes to the front of the tray. Phaser 5400 Laser Printer Service Guide 377 - Xerox 5400N | Quick Reference Guide - Page 407
gear. 4. Remove the screw that secures the Stopper Gear, then remove the gear. 5. Remove Gear 22T from the Retard Shaft. 6. Open the Rear Door. 378 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 408
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. Figure 169 Retard Assembly Replacement Reinstall the components in the reverse order. Phaser 5400 Laser Printer Service Guide 379 - Xerox 5400N | Quick Reference Guide - Page 409
Blank Page 380 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 410
or kit precedes the bracket, the item numbers of the piece parts follow it. Part Number Index: this index lists all the spared parts in the system in numerical order. Each number is followed by a reference to the parts list on which the part may be found. Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 411
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 to the other end that is plugged into plug 2. 382 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 412
item 1.2.1 (PL1.2, line item 1). Note: Only parts showing part numbers are available for support. Parts not showing part numbers are available on the parent assembly. Table 126 Legend: Identifier Meaning C C-ring E E-ring KL E-clip S Screw Phaser 5400 Laser Printer Service Guide 383 - Xerox 5400N | Quick Reference Guide - Page 413
Parts Lists PL 1.1 Covers 25 24 27 26 22 Figure 170 Covers 384 23 (with 18, 22) s5400-202 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 414
, Left Lower Left Cover Label Front [P/O Item 23] Cover Assy, Front [with 18, 22] Label, Access Cover 3 [P/O item 1] Stand Cover, Pop Up Badge Cleaning Brush Kit, Hardware (includes screws and E-rings) Phaser 5400 Laser Printer Service Guide 385 - Xerox 5400N | Quick Reference Guide - Page 415
PL 2.1 Paper Tray [A3/Ledger] Figure 171 Paper Tray (A3/Ledger) 386 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 416
] [P/O item 1] Latch Assembly [left] [P/O item 1] Cover Assembly, Tray [with 20, 28] [P/O item 1] Plate, Mini Bottom [P/O item 1] Rack [left] [P/O item 1] Spring, N/F Center [P/O item 1] Plate, Tray [P/O item 1] Hardware Kit (includes screws and E-rings) Phaser 5400 Laser Printer Service Guide 387 - Xerox 5400N | Quick Reference Guide - Page 417
PL 2.2 Paper Tray [A4/Letter] Figure 172 Paper Tray [A4/Letter] 388 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 418
, Max Paper Label, Set Paper Latch Cover, Latch [right] Cover, Latch [left] Latch Assembly [left] Cap, Side [right] Cover, Handle Plate, Mini Bottom Rack [left] Spring, N/F Center Plate, Tray Hardware Kit (includes screws and E-rings) Phaser 5400 Laser Printer Service Guide 389 - Xerox 5400N | Quick Reference Guide - Page 419
PL 3.1 Paper Feeder Figure 173 Paper Feeder 390 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 420
Sensor, Tray 1 Low Paper Sensor Actuator, Tray 1 Low Paper [P/O item 20] Spring, Tray 1 Low Paper Sensor Actuator [P/O item 20] Lever, Retard [P/O item 8] Spring, Release [P/O item 8] Clip, Ground [P/O item 16] Kit, Hardware (includes screws and E-rings) Phaser 5400 Laser Printer Service Guide 391 - Xerox 5400N | Quick Reference Guide - Page 421
PL 4.1 Multi-sheet Bypass Feeder (MBF) Assembly Figure 174 Multi-sheet Bypass Feeder (MBF) Assembly 392 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 422
item 1] Spring Roller, Tray 1 Feed Shaft, MBF Turn Roller [P/O item 1] Label [P/O item 1] Kit, Gear [includes 6, 16, 17 & PL 4.1B items 23 & 24] Kit, Feed Roller [2 pieces] Kit, Envelope Feed Roller [2 pieces] Kit, Hardware (includes screws and E-rings) Phaser 5400 Laser Printer Service Guide 393 - Xerox 5400N | Quick Reference Guide - Page 423
PL 4.2 Paper Handler (includes 9, 18-20) Figure 175 Paper Handler 394 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 424
4.1 item 1] Harness, MBF Combo [P121~P122, P123, P124, J125 & J126] Cover Plate, Lower Ground [P/O PL 4.1 item 1] Plate, Ground [P/O PL 4.1 item 1] Holder, Retard Pad [P/O PL 4.1 item 1] Kit, Hardware (includes screws and E-rings) Phaser 5400 Laser Printer Service Guide 395 - Xerox 5400N | Quick Reference Guide - Page 425
PL 5.1 Paper Transport Figure 176 Paper Transport 396 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 426
roller shaft] [P/O Item 1] Roller, Registration [metal shaft] [P/O Item 1] Bearing, Left [rubber roller shaft] [P/O Item 1] Clutch, Registration Sensor, Registration Kit, Actuator Roller, Bias Transfer [BTR] Kit, Hardware (includes screws and E-rings) Phaser 5400 Laser Printer Service Guide 397 - Xerox 5400N | Quick Reference Guide - Page 427
PL 6.1 Rear Cover Assembly With Fuser 1 (with 22~~3218,,3330,,3352~,3377) ~52, 55) 24 31 36 35 33 26 25 37 35 23 33 3288 97 ( 3208 27 98 (with 27x2 ea.) Figure 177 Rear Cover Assembly 9944 ((with 2~~1100,,1133~~2222, ,2367) ~41) s5400-209 398 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 428
, Exit Cover (with 28, 30x2 pcs) 1 Kit, Exit Strap (with 27x2pcs) 109R00521 1 Kit, Usage, (Fuser 110V~BTR) with 33, (PL5.1.18)) 109R00522 1 Kit, Usage, (Fuser 220V~BTR) with 33, (PL5.1.18)) 600K76430 Kit, Hardware (includes screws and E-rings) Phaser 5400 Laser Printer Service Guide 399 - Xerox 5400N | Quick Reference Guide - Page 429
PL 7.1 Frame & Drives Figure 178 Frame and Drives 400 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 430
, High Voltage Bracket, HCS [right] Stopper, Duplex [left] Stopper, Duplex [right] Cover, HVPS Motor [P/O item 10] Controller Board, Main Drive Motor [P/O item 10] Cover, Drawer Kit, Hardware (includes screws and E-rings) Phaser 5400 Laser Printer Service Guide 401 - Xerox 5400N | Quick Reference Guide - Page 431
PL 8.1 Xerographics 2 (with 3, 4, 18) 18 13 22 99 (with 14, 19) Figure 179 Xerographics 402 s5400-212 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 432
Interlock Switch (P/O Item 5) Sensor Assembly, Toner Sensor Assembly, Print Cartridge Laser label Link Assembly, Left [P/O Item 99] Guide, Print Cartridge [left] Wire Harness, Interlock Kit, Link (with 14, 19) Kit, Hardware (includes screws and E-rings) Phaser 5400 Laser Printer Service Guide 403 - Xerox 5400N | Quick Reference Guide - Page 433
PL 9.1 Electrical (1 of 2) Figure 180 Electrical (1 of 2) 404 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 434
Harness, Full DUP-1 [J502-J527] 1 Harness, Flap-1 [J505-J528] 1 Fan, Fuser Cooling 1 Cover, Fuser Fan 1 Harness, STK-1 [J504-J526] 1 Harness, P/H [J12-J121, J128] 1 DIMM Drive, Hard Disk (20 GB) Kit, Hardware (includes screws and E-rings) Phaser 5400 Laser Printer Service Guide 405 - Xerox 5400N | Quick Reference Guide - Page 435
PL 9.2 Electrical (2 of 2) Figure 181 Electrical (2 of 2) 406 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 436
, J17, J171, J177, J178 & J182] Harness, Fuser [220 VAC] [J174, J17, J171, J177, J178 & J182] Inlet [reference only] [P/O Item 2] Board [reference only] [P/O Item 2] Cover, Inlet Resistor, Flicker (220V only) Kit, Hardware (includes screws and E-rings) Phaser 5400 Laser Printer Service Guide 407 - Xerox 5400N | Quick Reference Guide - Page 437
PL 10.1 High Capacity Stacker [HCS] (1 of 2) Figure 182 High Capacity Stacker (1 of 2) s5400-215 408 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 438
Rear [P/O Item 4] Holder, Magnet [P/O Item 4] Roller, Turn Pinch [P/O Item 4] Spring, HCS Pinch [P/O Item 4] P/H, Assembly, HCS [same as PL 14.2, item 1] Top [P/O Item 12] Spring [P/O Item 12] Cap [P/O Item 12] Kit, Hardware (includes screws and E-rings) Phaser 5400 Laser Printer Service Guide 409 - Xerox 5400N | Quick Reference Guide - Page 439
PL 10.2 High Capacity Stacker [HCS] (2 of 2) 2 (with 4) 38 35 35 36 9 16 9 34 Figure 183 High Capacity Stacker (2 of 2) s5400-216 410 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 440
Bearing, Exit Roller Shaft Chute, HCS Screw, Spring Frame, Side [right] Support [right] Roller, Inlet Harness, STK-0 [J514-P526] Support [left] Motor Assembly, HCS Gear Gear, 29T , Collar Clamp Label, SP HCS Kit, Hardware (includes screws and E-rings) Phaser 5400 Laser Printer Service Guide 411 - Xerox 5400N | Quick Reference Guide - Page 441
PL 11.1 500-Sheet Feeder (1 of 3) Figure 184 500-Sheet Feeder (1 of 3) 412 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 442
Cover, Left Cover, Rear [P/O item 2] Roller Assembly, Pinch [includes 8~10] Holder [P/O item 2] [P/O item 7] Spring Torsion [P/O item 2] [P/O item 7] Roller, Pinch [P/O item 2] [P/O item 7] Cover, Right Label Kit, Hardware (includes screws and E-rings) Phaser 5400 Laser Printer Service Guide 413 - Xerox 5400N | Quick Reference Guide - Page 443
PL 11.2 500-Sheet Feeder (2 of 3) Figure 185 500-Sheet Feeder (2 of 3) 414 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 444
Assembly, Envelope Feed Roller, Feed Roller, Core Shaft, Pick Up Gear, Pick Up Spring, Pick Up 300 Solenoid, Feed Gear, 17T Shaft, Gear Harness, Tray 2/3 J134 ] Motor Assembly [P/O item 32] Kit, No Paper Sensor Kit, Hardware (includes screws and E-rings) Phaser 5400 Laser Printer Service Guide 415 - Xerox 5400N | Quick Reference Guide - Page 445
PL 11.3 500-Sheet Feeder (3 of 3) Figure 186 500-Sheet Feeder (3 of 3) 416 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 446
, Paper Size Sensor, Low Paper Actuator, Low Paper Sensor Spring Harness, J138 [J138-J139] Harness, J133 [J133-J13A, P135, J137] Spring, Tray 1 Arm, Tray 1 [right] Arm, Tray 1 [left] Cap, Tray 1 Edge, Saddle Kit, Hardware (includes screws and E-rings) Phaser 5400 Laser Printer Service Guide 417 - Xerox 5400N | Quick Reference Guide - Page 447
PL 12.1 2000-Sheet Feeder (1 of 4) Figure 187 2000-Sheet Feeder (1 of 4) 418 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 448
, Magnetic Cover/Door, Rear Cover, Rear Bottom Cover Assembly, Side [right] Cover, Front Assembly, Frame & Drive [reference only] Tray Assembly, 2000-Sheet Feeder Screw Foot Kit, Hardware (includes screws and E-rings) Phaser 5400 Laser Printer Service Guide 419 - Xerox 5400N | Quick Reference Guide - Page 449
PL 12.2 2000-Sheet Feeder (2 of 4) Figure 188 2000-Sheet Feeder (2 of 4) 420 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 450
Tray Feed Motor [J607, J615] Drive Assembly, 2000-Sheet Feeder Assembly, Chute Feed Out Edge, Saddle Switch, Tray Interlock Switch, Rear Cover Interlock Switch, Limit Kit, Hardware (includes screws and E-rings) Phaser 5400 Laser Printer Service Guide 421 - Xerox 5400N | Quick Reference Guide - Page 451
PL 12.3 2000-Sheet Feeder (3 of 4) Figure 189 2000-Sheet Feeder (3 of 4) 422 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 452
~33] Shaft, 2000-Sheet Feeder Support Assembly, Nudger Gear, 25T Gear, 31T Clutch Assembly, One-Way Gear, 25T Clutch Bearing Kit, No Paper Actuator [includes 21 &22] Kit, 2000-Sheet Feeder Gear [includes 14~16] Kit, Hardware (includes screws and E-rings) Phaser 5400 Laser Printer Service Guide 423 - Xerox 5400N | Quick Reference Guide - Page 453
PL 12.4 2000-Sheet Feeder (4 of 4) Figure 190 2000-Sheet Feeder (4 of 4) 424 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 454
Feeder Tray Side Guide [includes 3 & 5] Kit, Elevator Wire Guide [includes 6 & 7] Kit, Elevator Wire [includes 8 & 9] Kit, 2000-Sheet Feeder Elevator Shaft [includes 18~20] Kit, Drive Gear [includes 14~16] Kit, Hardware (includes screws and E-rings) Phaser 5400 Laser Printer Service Guide 425 - Xerox 5400N | Quick Reference Guide - Page 455
PL 13.1 Duplex Assembly 23 13 15 15 23 15 12 13 23 30 29 31 98 (with 37, 38) 98 (with 12x6 ea., 14, 24) Figure 191 Duplex Assembly 13 13 13 31 s5400-224 426 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 456
Pinch Label, Handle Left Label, Handle Right Case, Duplex Motor Damper, Exit Motor Plate, Reinforcement Label, SP Duplex Kit, Duplex Motor Case Assembly (with 37,38) Kit, Roller (with item 12x3 pcs), 14, 24 Kit, Hardware (includes screws and E-rings) Phaser 5400 Laser Printer Service Guide 427 - Xerox 5400N | Quick Reference Guide - Page 457
quality and/or prevent printing. I Keep consumables and maintenance items in supply. I Add or replace when prompted by the printer. To order supplies and accessories, contact your local dealer, or visit the Xerox web site: www.xerox.com/officeprinting 428 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 458
Maintenance Kit Contains: a Fuser Cartridge, Bias Transfer Roll, cleaning cloth, and instructions. 200,000 prints 109R00521 for 110 V (60 Hz) 109R00522 for 220 V (50 Hz) * Average life of a Laser Print Cartridge is based on page coverage of 5 percent using Letteror A4-size paper. The printer - Xerox 5400N | Quick Reference Guide - Page 459
Xerox Labels Size A4 (Metric Letter) 210 x 297 mm Letter (U.S.) 8.5 x 11 in. Description 24 labels per sheet 30 labels per sheet Part Number 3R96178 3R4469 Table 153 Options Option and Features 097S02711 097S02712 097S02714 097S02715 097S02713 430 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 460
I Memory kits available in three configurations, packaged in single units each: I 16 Mbytes I 32 Mbytes I 64 Mbytes 097S02356 097S02357 097S02358 Flash Memory (DIMMS) I Provides 8 Mbytes of memory for storage of downloaded fonts and overlays 097S02360 Phaser 5400 Laser Printer Service Guide 431 - Xerox 5400N | Quick Reference Guide - Page 461
Blank Page 432 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 462
Feeder 441 Plug/Jack Location Map 5 - Duplex Assembly 443 Plug/Jack Location Map 6 - High Capacity Stacker 445 Plug/Jack Location Map 7 - 2000-Sheet Feeder 447 Phaser 5400 Laser Printer Service Guide 433 - Xerox 5400N | Quick Reference Guide - Page 463
to System Controller PWB. 112 G-23 Laser Assembly P/J 11 Print Engine Controller 113 D-23 Laser Assembly P/J 115 LD Laser Assembly 114 H-22 Laser Assembly P/J 11 Print Engine Controller 115 G-23 Laser Assembly P/J 113 SOS Laser Assembly 434 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 464
C-7 Toner Sensor Fuser PWB 181 E-34 HVPS P/J 18 Print Engine Controller 182 D-33 HVPS P/J 174 Fuser Assembly 183 G-8 Reg Sensor P/J 18 Print Engine Controller 185 E-33 HVPS Paper Transport BTR 186 C-33 HVPS Print Cartridge Charge Roll Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 465
'd.) Map & P/J Number Connect to... Other and connected to... 187 C-33 HVPS Print Cartridge Dev Bias 188 E-33 HVPS Paper Transport Detack Saw 201 H-26 Size Switch P/J 20 Print P/J 162 LVPS 623 H-7 Top Cover Interlock SW P/J 162 LVPS 436 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 466
Plug/Jack Location Map 1 - Engine Figure 193 P/J Location Map 1 - Engine Phaser 5400 Laser Printer Service Guide S5400-321 437 - Xerox 5400N | Quick Reference Guide - Page 467
Plug/Jack Location Map 2 - Engine Figure 194 P/J Location Map 2 - Engine S5400-322 S5400-322 438 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 468
Plug/Jack Location Map 3 - Engine Figure 195 P/J Location Map 3 - Engine Phaser 5400 Laser Printer Service Guide S5400-323 439 - Xerox 5400N | Quick Reference Guide - Page 469
135 Feed Solenoid P/J 13A - P/J 134 No Paper Senor P/J 137 Low Paper Sensor P/J 13P - P/J 13C Pre Reg Sensor P/J 13A - P/J 133 Feeder PWB P/J 133 Feeder PWB P/J 131 Printer or Second Feeder P/J 133 Feeder PWB P/J 139 Size Switch P/J 138 Feeder PWB Motor 440 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 470
Figure 196 P/J Location Map 4 - 500-Sheet Feeder S5400-324 Phaser 5400 Laser Printer Service Guide 441 - Xerox 5400N | Quick Reference Guide - Page 471
Connect 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 Sensor 513 F8 Duplex Jam Sensor. P/J 512 Duplex PWB 442 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 472
Figure 197 P/J Location Map 5 - Duplex Assembly Phaser 5400 Laser Printer Service Guide 443 - Xerox 5400N | Quick Reference Guide - Page 473
E6 Feeder PWB P/J 525 Rear Cover Interlock 525 D5 Rear Cover Interlock. P/J 524 Stacker PWB 526 B8 Stacker Connector P/J 514 - P/J 504 Duplex Interface PWB 444 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 474
s5400-332 Figure 198 P/J Location Map 6 - 1000-Sheet High Capacity Stacker Phaser 5400 Laser Printer Service Guide 445 - Xerox 5400N | Quick Reference Guide - Page 475
Locations - 2000-Sheet Feeder Map & P/J Number Connect to... Other and connected to... 131 B7 Printer or second feeder P/J601 HCF PWB 513A G-8 Stack Height Sensor P/J 603 HCF PWB 513B F-8 No 614 HCF PWB 615 C8 Drive Motor P/J 607 HCF PWB 446 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 476
Plug/Jack Location Map 7 - 2000-Sheet Feeder Figure 199 P/J Location Map 7 - 2000-Sheet Feeder Phaser 5400 Laser Printer Service Guide S5400-335 447 - Xerox 5400N | Quick Reference Guide - Page 477
Blank Page 448 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 478
in the CD Service Manual. For more detailed information, refer to the On-Line CD version which contains complete wiring information. The following circuit notations are used to describe components and signal paths throughout the Master Wiring Diagram. Phaser 5400 Laser Printer Service Guide 449 - Xerox 5400N | Quick Reference Guide - Page 479
Fuser Assembly, Fuser PWB (page 455) I Figure 204 Print Engine Controller PWB-Laser and CRUM PWB (page 456) I Figure 205 Print Engine Controller PWB, HVPS and Print Cartridge I Figure 210 Print Engine Controller PWB Toner Sensor (page 462) I Figure 211 Print Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 480
Master Connection and Wiring Diagram Figure 200 Master Wiring Diagram 1 of 2 Phaser 5400 Laser Printer Service Guide 451 - Xerox 5400N | Quick Reference Guide - Page 481
Figure 201 Master Wiring Diagram 2 of 2 452 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 482
Sensor Solenoid Start Of Scan - associated with the Laser Scanner timing Switch Take Away Note: The Duplex Interface PWB and the components connected to it by means of P/J503, P/J504, and P/J505 are the components of the Duplex Assembly and HCS. Phaser 5400 Laser Printer Service Guide 453 - Xerox 5400N | Quick Reference Guide - Page 483
Base Engine Wiring Diagrams Figure 202 Print Engine Controller PWB LVPS Interlock Switch and Fans 454 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 484
Figure 203 Print Engine Controller PWB Fuser Assembly, Fuser PWB Phaser 5400 Laser Printer Service Guide 455 - Xerox 5400N | Quick Reference Guide - Page 485
Figure 204 Print Engine Controller PWB-Laser and CRUM PWB 456 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 486
White Red White Red Yellow P/J 181 Figure 205 Print Engine Controller PWB, HVPS and Print Cartridge Phaser 5400 Laser Printer Service Guide 457 - Xerox 5400N | Quick Reference Guide - Page 487
Figure 206 Print Engine Controller PWB Registration Clutch and Registration Sensor 458 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 488
Figure 207 Print Engine Controller PWB Feed Solenoid, Turn Clutch, No-Paper Sensor Phaser 5400 Laser Printer Service Guide 459 - Xerox 5400N | Quick Reference Guide - Page 489
Figure 208 Print Engine Controller PWB, Low Paper Sensor, MBF Home Switch, and Tray 1 Paper Size Switch 460 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 490
Figure 209 Print Engine Controller PWB Main Motor Phaser 5400 Laser Printer Service Guide 461 - Xerox 5400N | Quick Reference Guide - Page 491
Figure 210 Print Engine Controller PWB Toner Sensor 462 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 492
Figure 211 Print Engine Controller PWB Duplex Interface PWB Full Stack Sensor Phaser 5400 Laser Printer Service Guide 463 - Xerox 5400N | Quick Reference Guide - Page 493
Figure 212 Controller and Control Panel 464 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 494
500-Sheet Feeder P/J134 P/J13C Figure 213 500-Sheet Feeder - Tray 2 Wiring Diagram and Signal Information Between Components Phaser 5400 Laser Printer Service Guide 465 - Xerox 5400N | Quick Reference Guide - Page 495
Figure 214 500-Sheet Feeder - Tray 3 Wiring Diagram and Signal Information Between Components 466 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 496
Duplex Assembly Figure 215 Duplex Assembly - Wiring Diagrams and Signal Information Between Components Phaser 5400 Laser Printer Service Guide 467 - Xerox 5400N | Quick Reference Guide - Page 497
1000-Sheet (High Capacity Stacker) Figure 216 Master Wiring Diagram, High Capacity Stacker 468 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 498
2000-Sheet Feeder Figure 217 2000-Sheet Feeder - Wiring Diagram and Signal Information Between Components Phaser 5400 Laser Printer Service Guide 469 - Xerox 5400N | Quick Reference Guide - Page 499
Figure 218 2000-Sheet Feeder PWB No Paper Sensor Figure 219 2000-Sheet Feeder PWB Low Paper Sensor 470 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 500
Figure 220 2000-Sheet Feeder PWB Switches Phaser 5400 Laser Printer Service Guide 471 - Xerox 5400N | Quick Reference Guide - Page 501
Blank Page 472 Phaser 5400 Laser Printer Service Guide - Xerox 5400N | Quick Reference Guide - Page 502
- Xerox 5400N | Quick Reference Guide - Page 503
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Service Quick Reference Guide
PHASER™ 5400
LASER PRINTER