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Make/Model Information:

  • Brand:   Xerox
  • Models included:
    • Xerox Phaser 5400

File Information:

  • Type:   Factory Service Manual (FSM)
  • Language:   English
  • Number of pages:   504
  • File size:  ∼ 9.70  MB
  • File Format:   PDF only
  • SME Watermarks:   None
  • Password lock:   No
  • Edit/copy/modify:   Yes
  • SKU:   BMXX-1021

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Service Quick Reference Guide
PHASER™ 5400
LASER PRINTER
Phaser˙5400˙Laser˙Printer˙Service˙Guide xi
Table˙of˙Contents
Users˙Safety˙Summary˙
Service˙Safety˙Summary
List˙of˙Figures˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙xix
List˙of˙Tables.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙xxv
General˙Information˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙1
Parts˙of˙the˙Printer˙
Printer˙Components
Printer˙Options
Control˙Panel˙
Display˙Screen
Rear˙Panel
Print˙Engine˙Assemblies˙
Paper˙Path˙Information˙
Printer˙Specifications
RAM˙and˙Printer˙Capabilities
Basic˙Specifications
Electrical˙Specifications˙
Mechanical˙Specifications˙
Environmental˙Specifications
Life˙Expectancies
Conforming˙Regulations˙and˙Standards
Printing˙Speed˙
Printing˙Media˙Feeding˙Means˙
Printing˙Media
Printing˙Accuracy
Components˙to˙Be˙Replaced˙Periodically˙
Options˙
xii Phaser˙5400˙Laser˙Printer˙Service˙Guide
Error˙Codes˙and˙Messages˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.27
Introduction˙
Error˙messages˙
Measurements˙
Service˙Flowchart˙
Repair˙Analysis˙Procedure˙Table
How˙to˙Use˙a˙Repair˙Analysis˙Procedure˙Table
How˙to˙Follow˙a˙Repair˙Analysis˙Procedure
General˙Notes˙on˙Using˙Repair˙Analysis˙Procedures˙
Error˙Codes˙with˙Repair˙Analysis˙Procedure
Troubleshooting˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.107
Printer˙Performance˙Problems˙Repair˙Analysis˙Procedure
(RAP)˙Table
Image-Quality˙Problems˙Repair˙Analysis˙Procedure˙(RAP)˙Table˙
Electrical˙Interference˙Repair˙Analysis˙Procedure˙(RAP)˙Table˙
Printer˙Performance˙Problems
Image-Quality˙Troubleshooting˙
Introduction˙
Image-Quality˙Defect˙Definitions˙
Diagnostics,˙Test˙Prints,˙Service˙Tests˙and
NVRAM˙Adjustments˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.219
Entering˙Diagnostics˙Mode˙
System˙Controller˙Board˙Error˙(Blink)˙Codes
Recommended˙Corrective˙Action˙
Power˙On˙LED˙Sequence
Diagnostics˙Menu˙Map˙
System˙Controller˙Board˙Test˙Prints
Main˙Menu˙Test˙Prints˙
Configuration˙Sheet˙
System˙Controller˙Board˙Test˙Print˙
Fault˙History
Display˙Faults˙
Menu˙Map
PS˙Font˙List˙
PCL˙Font˙List:˙
PCL˙Demo:˙
Print˙Engine˙Controller˙Board˙Test˙Print˙
Analyzing˙Test˙Prints˙
Registration˙
NVRAM˙Configuration˙(NVM˙Config)˙
Phaser˙5400˙Laser˙Printer˙Service˙Guide xiii
Component˙Tests
Reset˙Menu
Maintenance˙Kit˙Counter˙Reset˙Procedure
Maintenance˙and˙Cleaning.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙241
Scheduled˙Maintenance
Recommended˙Tools˙
Inspect˙While˙Servicing
General˙Cleaning˙(if˙needed)˙
FRU˙Removal˙/˙Replacement˙Procedures˙(RRPs)˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙245
Contents˙-˙Removal˙and˙Replacement˙Procedures
Introduction
Work˙Notes
Preparation
Notations˙in˙the˙RRP˙text
Adjustment˙
Repair˙Procedures˙
RRP˙1.1˙Left˙Side˙Cover˙
RRP˙1.2˙Right˙Side˙Cover˙
RRP˙1.3˙Top˙Cover˙Assembly
RRP˙1.4˙Front˙Cover˙
RRP˙1.5˙Lower˙Left˙Cover
RRP˙1.6˙HVPS˙Cover
RRP˙1.7˙Lower˙Rear˙Cover˙
RRP˙1.8˙MBF˙Gear˙Cover˙
RRP˙1.9˙Rear˙Cover
RRP˙2.1˙Multi-sheet˙Bypass˙Feeder˙(MBF)˙Assembly
RRP˙2.2˙MBF˙Feed˙Rollers˙
RRP˙2.3˙MBF˙Tray˙1˙Turn˙Roller˙Clutch˙Assembly
RRP˙2.4˙Tray˙1˙Turn˙Roller˙Assembly
RRP˙2.5˙MBF˙Retard˙Holder˙Assembly
RRP˙2.6˙Tray˙1˙No˙Paper˙Sensor˙Assembly
RRP˙2.7˙MBF˙No˙Paper˙Sensor˙Assembly˙
RRP˙2.8˙MBF˙Feed˙Solenoid˙
RRP˙2.9˙Tray˙1˙Feed˙Solenoid
RRP˙2.10˙Tray˙1˙Feed˙Roller˙
RRP˙2.11˙Tray˙1˙Retard˙Holder˙Assembly˙
RRP˙3.1˙Retard˙Chute˙Assembly˙
RRP˙3.2˙Rear˙Chute˙Assembly˙
RRP˙3.3˙Lower˙Turn˙Roller˙Assembly˙
RRP˙3.4˙Tray˙1˙Low˙Paper˙Sensor˙
xiv Phaser˙5400˙Laser˙Printer˙Service˙Guide
RRP˙3.5˙Tray˙1˙Right˙Guide˙Assembly˙
RRP˙3.6˙Tray˙1˙Left˙Guide˙Assembly
RRP˙3.7˙CRUM˙Board
RRP˙3.8˙MBF˙Assembly˙Position˙Sensor
RRP˙4.1˙Paper˙Transport˙Assembly
RRP˙4.2˙Registration˙Actuator
RRP˙4.3˙Registration˙Clutch
RRP˙4.4˙Registration˙Sensor
RRP˙5.1˙Fuser˙Assembly˙
RRP˙5.2˙Stack˙Full˙Sensor˙
RRP˙5.3˙Exit˙Roller˙Assembly˙
RRP˙5.4˙Stack˙Full˙Sensor˙Actuator
RRP˙6.1˙Main˙Drive˙Gear˙Assembly˙
RRP˙7.1˙Laser˙Assembly
RRP˙7.2˙Right˙Print˙Cartridge˙Guide˙Assembly˙
RRP˙7.3˙Toner˙Sensor˙Assembly
RRP˙7.4˙Top˙Cover˙Interlock˙Switch˙
RRP˙7.5˙Left˙Print˙Cartridge˙Guide˙Assembly
RRP˙7.6˙Bias˙Transfer˙Roller˙[BTR]˙Assembly
RRP˙8.1˙System˙Controller˙PWB˙
RRP˙8.2˙High-Voltage˙Power˙Supply˙[HVPS]˙Board
RRP˙8.3˙Duplex˙Interface˙Board˙
RRP˙8.4˙Main˙Fan˙
RRP˙8.5˙Print˙Engine˙Controller˙Board˙
RRP˙8.6˙Low-Voltage˙Power˙Supply˙[LVPS]˙Assembly˙
RRP˙8.7˙LVPS˙FAN
RRP˙8.8˙AC˙Input˙Assembly
RRP˙8.9˙Control˙Panel˙+5˙VDC˙Power˙Supply
RRP˙9.1˙Duplex˙Assembly˙
RRP˙10.1˙1000-Sheet˙High˙Capacity˙Stacker˙[HCS]˙
RRP˙10.2˙HCS˙Top˙Cover
RRP˙10.3˙HCS˙Rear˙Cover˙Assembly
RRP˙10.4˙HCS˙Front˙Cover
RRP˙10.5˙HCS˙Exit˙Gate˙Solenoid
RRP˙10.6˙HCS˙Stack˙Full˙Sensor˙
RRP˙10.7˙HCS˙Stack˙Full˙Sensor˙Actuator˙
RRP˙10.8˙HCS˙Drive˙Motor˙Assembly˙
RRP˙10.9˙HCS˙Rear˙Cover˙Interlock˙Switch˙
RRP˙10.10˙HCS˙Paper˙Sensor
RRP˙11.1˙500-Sheet˙Feeder˙Removal
RRP˙11.2˙Front˙Cover˙
RRP˙11.3˙Left˙Cover
RRP˙11.4˙Right˙Cover˙
Phaser˙5400˙Laser˙Printer˙Service˙Guide xv
RRP˙11.5˙Rear˙Cover
RRP˙11.6˙Drive˙Assembly˙
RRP˙11.7˙Feeder˙Board˙
RRP˙11.8˙Feed˙Head˙Assembly
RRP˙11.9˙Feed˙Rollers
RRP˙11.10˙Feed˙Solenoid˙
RRP˙11.11˙Turn˙Roller˙Assembly
RRP˙11.12˙Retard˙Chute˙Assembly˙
RRP˙11.13˙Left˙Tray˙Guide˙
RRP˙11.14˙Right˙Tray˙Guide˙
RRP˙11.15˙Retard˙Holder˙Assembly˙
RRP˙11.16˙Retard˙Turn˙Roller˙Assembly˙
RRP˙11.17˙Paper˙Size˙Sensor˙
RRP˙11.18˙Paper˙Tray˙Sensor˙
RRP˙11.19˙No˙Paper˙Sensor
RRP˙11.20˙No˙Paper˙Sensor˙Actuator˙
RRP˙11.21˙Preregistration˙Sensor˙
RRP˙12.1˙Removing˙the˙2000-Sheet˙Feeder˙
RRP˙12.2˙Left˙Side˙Cover˙
RRP˙12.3˙Upper˙Rear˙Cover˙
RRP˙12.4˙Lower˙Rear˙Cover˙
RRP˙12.5˙Right˙Side˙Cover˙
RRP˙12.6˙Front˙Cover˙
RRP˙12.7˙Tray˙Assembly˙
RRP˙12.8˙2000-Sheet˙Feeder˙PWB˙
RRP˙12.9˙Tray˙Lift˙Motor˙Assembly˙
RRP˙12.10˙A4˙Paper˙Size˙Sensor
RRP˙12.11˙Casters
RRP˙12.12˙Harness˙Assembly˙
RRP˙12.13˙Drive˙Assembly˙
RRP˙12.14˙Feed,˙Nudger,˙and˙Retard˙Roller˙
RRP˙12.15˙Paper˙Height˙Sensor
RRP˙12.16˙Paper˙Feed˙Motor˙Assembly
RRP˙12.17˙Link˙Stopper˙
RRP˙12.18˙No˙Paper˙Sensor
RRP˙12.19˙No˙Paper˙Sensor˙Actuator˙
RRP˙12.20˙Left˙and˙Right˙Wire˙Cover
RRP˙12.21˙Shaft˙Cover˙Assembly
RRP˙12.22˙Drive˙Shaft˙Assembly
RRP˙12.23˙Brake˙Assembly˙
RRP˙12.24˙Left˙Tray˙Wires
RRP˙12.25˙Right˙Tray˙Wires˙
RRP˙12.26˙Retard˙Assembly
xvi Phaser˙5400˙Laser˙Printer˙Service˙Guide
FRU˙Parts˙List˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.381
Introduction˙
Organization˙of˙this˙Section
Using˙the˙Parts˙List
Parts˙Lists˙
PL˙1.1˙Covers˙
PL˙2.1˙Paper˙Tray˙[A3/Ledger]˙
PL˙2.2˙Paper˙Tray˙[A4/Letter]˙
PL˙3.1˙Paper˙Feeder˙
PL˙4.1˙Multi-sheet˙Bypass˙Feeder˙(MBF)˙Assembly˙
PL˙4.2˙Paper˙Handler˙
PL˙5.1˙Paper˙Transport˙
PL˙6.1˙Rear˙Cover˙Assembly˙With˙Fuser˙
PL˙7.1˙Frame˙&˙Drives˙
PL˙8.1˙Xerographics˙
PL˙9.1˙Electrical˙(1˙of˙2)˙
PL˙9.2˙Electrical˙(2˙of˙2)˙
PL˙10.1˙High˙Capacity˙Stacker˙[HCS]˙(1˙of˙2)
PL˙10.2˙High˙Capacity˙Stacker˙[HCS]˙(2˙of˙2)
PL˙11.1˙500-Sheet˙Feeder˙(1˙of˙3)˙
PL˙11.2˙500-Sheet˙Feeder˙(2˙of˙3)˙
PL˙11.3˙500-Sheet˙Feeder˙(3˙of˙3)˙
PL˙12.1˙2000-Sheet˙Feeder˙(1˙of˙4)˙
PL˙12.2˙2000-Sheet˙Feeder˙(2˙of˙4)˙
PL˙12.3˙2000-Sheet˙Feeder˙(3˙of˙4)˙
PL˙12.4˙2000-Sheet˙Feeder˙(4˙of˙4)˙
PL˙13.1˙Duplex˙Assembly
Xerox˙Supplies˙and˙Accessories
Plug/Jack˙Connector˙Locations.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.433
Contents
Plug/Jack˙(P/J)˙Locations˙for˙the˙Engine˙
Plug/Jack˙Location˙Map˙1˙-˙Engine
Plug/Jack˙Location˙Map˙2˙-˙Engine
Plug/Jack˙Location˙Map˙3˙-˙Engine
Plug/Jack˙Location˙Map˙4˙-˙500-Sheet˙Feeder
Plug/Jack˙Location˙Map˙5˙-˙Duplex˙Assembly˙
Plug/Jack˙Location˙-˙1000-Sheet˙(High˙Capacity)˙Stacker˙
Plug/Jack˙Location˙-˙2000-Sheet˙Feeder
Plug/Jack˙Location˙Map˙7˙-˙2000-Sheet˙Feeder
Phaser˙5400˙Laser˙Printer˙Service˙Guide xvii
Wiring˙Diagrams˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙.˙449
Wiring˙Diagram˙Notations˙
Organization
Master˙Connection˙and˙Wiring˙Diagram
Base˙Engine˙Wiring˙Diagrams
500-Sheet˙Feeder
Duplex˙Assembly˙
1000-Sheet˙(High˙Capacity˙Stacker)˙
2000-Sheet˙Feeder
Phaser˙5400˙Laser˙Printer˙Service˙Guide 77
6 SUSPECT˙COMPONENTS
The˙following˙printer˙components˙and˙areas˙are
associated˙with˙this˙specific˙problem.˙One˙or˙more˙of
these˙components˙or˙areas˙may˙have˙failed˙partially˙or
completely.˙If˙you˙cannot˙isolate˙this˙problem˙using˙the
steps˙in˙this˙Repair˙Analysis˙Procedure,˙replace˙each
component˙or˙troubleshoot˙each˙area˙listed˙below,˙one
at˙a˙time,˙until˙you˙isolate˙and˙solve˙the˙problem.
 MBF˙Home˙Switch˙[RRP˙3.8, page˙282]
 Print˙Engine˙Controller˙Board˙[RRP˙8.5, page˙310]
 Wiring˙and˙connectors˙linking˙the˙components
Table˙37˙Insert˙MBF˙Troubleshooting˙Procedure˙(cont'd.)
Step˙Actions˙and˙Questions Yes˙No
Phaser˙5400˙Laser˙Printer˙Service˙Guide 215
RAP˙86˙Unfused˙Image
The˙printed˙image˙is˙not˙fully˙fused˙to˙the˙paper.˙The
image˙rubs˙off˙easily.
Figure˙34˙Unfused˙Image
Table˙117˙Unfused˙Image˙Troubleshooting˙Procedure
Step˙Actions˙and˙Questions Yes˙No
1 INITIAL˙ACTIONS
 Ensure˙that˙the˙paper˙is˙within˙specification.
2 PAPER˙REPLACEMENT
1.˙Replace˙paper˙with˙fresh,˙dry˙standard˙paper.
2.˙Run˙a˙Test˙Print.
Is˙the˙problem˙still˙present?
Step˙3.
Problem
solved.
3 CHECK˙FUSER˙SETTING
Refer˙to˙Non-Volatile˙Memory˙Setup˙Mode˙and˙check
the˙Fuser˙Setting.
Is˙the˙NV˙code˙set˙to˙factory˙default˙value?
Step˙5.
Step˙4.
4 RESET˙TO˙FACTORY˙DEFAULT
1.˙Set˙NV˙code˙to˙the˙factory˙default˙value.
2.˙Run˙25˙Test˙Prints.
Is˙the˙problem˙still˙present?
Increase˙the
temperature
increment
and˙run˙25
test˙prints.
Recheck˙/
repeat˙as
necessary.
Problem
solved.
5 Is˙the˙overall˙print˙density˙within˙specification? Go˙to
Step˙6.
RAP˙70,
page˙178.
352 Phaser˙5400˙Laser˙Printer˙Service˙Guide
RRP˙12.1˙Removing˙the˙2000-Sheet˙Feeder
(See PL˙12.1˙2000-Sheet˙Feeder˙(1˙of˙4))
Figure˙143˙Removing˙the˙Printer


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