Quick Reference Guide
Page 6
... source. Safety Instructions: Read all posted warning labels. Care of paper. Phaser 5400 Laser Printer Service Guide v If you bypass, or cheat, an interlock switch during a service call . Warning: Turning the power off printer power and wait at least 30 minutes for removal in place. Ground the...service the printer, check to a sheet of Product: Disconnect the power plug by pulling the plug, not the cord. Fuser Components Warning: This printer uses heat and pressure to fuse the toner image to make certain that all functioning correctly after you have completed a printer service call ...
... source. Safety Instructions: Read all posted warning labels. Care of paper. Phaser 5400 Laser Printer Service Guide v If you bypass, or cheat, an interlock switch during a service call . Warning: Turning the power off printer power and wait at least 30 minutes for removal in place. Ground the...service the printer, check to a sheet of Product: Disconnect the power plug by pulling the plug, not the cord. Fuser Components Warning: This printer uses heat and pressure to fuse the toner image to make certain that all functioning correctly after you have completed a printer service call ...
Quick Reference Guide
Page 15
... 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 Sensor Assembly 301 RRP 7.4 Top Cover Interlock Switch 302 RRP 7.5 Left Print Cartridge Guide Assembly 303 RRP 7.6 Bias Transfer Roller... Sensor 327 RRP 11.1 500-Sheet Feeder Removal 328 RRP 11.2 Front Cover 329 RRP 11.3 Left Cover 330 RRP 11.4 Right Cover 331 xiv Phaser 5400 Laser Printer Service Guide
... 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 Sensor Assembly 301 RRP 7.4 Top Cover Interlock Switch 302 RRP 7.5 Left Print Cartridge Guide Assembly 303 RRP 7.6 Bias Transfer Roller... Sensor 327 RRP 11.1 500-Sheet Feeder Removal 328 RRP 11.2 Front Cover 329 RRP 11.3 Left Cover 330 RRP 11.4 Right Cover 331 xiv Phaser 5400 Laser Printer Service Guide
Quick Reference Guide
Page 22
... Stack Full Sensor Actuator 294 Figure 84 Shield Cover 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 Switch 302 Figure 91 Left Print Cartridge Guide Assembly... 117 HCS Paper Sensor 327 Figure 118 Feeder Removal 328 Figure 119 Front Cover 329 Figure 120 Left Cover 330 Figure 121 Right Cover 331 Phaser 5400 Laser Printer Service Guide xxi
... Stack Full Sensor Actuator 294 Figure 84 Shield Cover 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 Switch 302 Figure 91 Left Print Cartridge Guide Assembly... 117 HCS Paper Sensor 327 Figure 118 Feeder Removal 328 Figure 119 Front Cover 329 Figure 120 Left Cover 330 Figure 121 Right Cover 331 Phaser 5400 Laser Printer Service Guide xxi
Quick Reference Guide
Page 25
... No Paper Sensor 470 Figure 219 2000-Sheet Feeder PWB Low Paper Sensor 470 Figure 220 2000-Sheet Feeder PWB Switches 471 xxiv Phaser 5400 Laser Printer Service Guide Tray 2 Wiring Diagram and Signal Information Between Components 465 Figure 214 500-Sheet Feeder - Tray 3 Wiring Diagram and ...Switch, and Tray 1 Paper Size Switch 460 Figure 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 463 Figure 212 Controller and Control Panel 464 Figure ...
... No Paper Sensor 470 Figure 219 2000-Sheet Feeder PWB Low Paper Sensor 470 Figure 220 2000-Sheet Feeder PWB Switches 471 xxiv Phaser 5400 Laser Printer Service Guide Tray 2 Wiring Diagram and Signal Information Between Components 465 Figure 214 500-Sheet Feeder - Tray 3 Wiring Diagram and ...Switch, and Tray 1 Paper Size Switch 460 Figure 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 463 Figure 212 Controller and Control Panel 464 Figure ...
Quick Reference Guide
Page 27
... Error Code E9-3: HCF Fail (2000-Sheet Feeder) Troubleshooting Procedure 89 Table 45 Error Code J5: Toner Low Troubleshooting Procedure 90 Table 46 Error Code J5: Toner Low Troubleshooting Procedure 91 Table 47 Error Code J6-1: Replace Print Cartridge Troubleshooting Procedure. . . ....Controller Isolation 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
... Error Code E9-3: HCF Fail (2000-Sheet Feeder) Troubleshooting Procedure 89 Table 45 Error Code J5: Toner Low Troubleshooting Procedure 90 Table 46 Error Code J5: Toner Low Troubleshooting Procedure 91 Table 47 Error Code J6-1: Replace Print Cartridge Troubleshooting Procedure. . . ....Controller Isolation 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
Quick Reference Guide
Page 28
...Roller Clutch Assembly Troubleshooting Procedure 145 Table 86 Tray 1 Feed Solenoid Troubleshooting Procedure 147 Table 87 MBF Feed Solenoid Troubleshooting Procedure 149 Table 88 Toner Sensor Assembly Troubleshooting Procedure 151 Table 89 HVPS Assembly Troubleshooting Procedure 153 Table 90 Electrical Noise Troubleshooting Procedure 157 Table 91 Low Paper Tray 2... 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
...Roller Clutch Assembly Troubleshooting Procedure 145 Table 86 Tray 1 Feed Solenoid Troubleshooting Procedure 147 Table 87 MBF Feed Solenoid Troubleshooting Procedure 149 Table 88 Toner Sensor Assembly Troubleshooting Procedure 151 Table 89 HVPS Assembly Troubleshooting Procedure 153 Table 90 Electrical Noise Troubleshooting Procedure 157 Table 91 Low Paper Tray 2... 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
Quick Reference Guide
Page 31
... and pressure melt and bond the toner to the paper, creating a dry, permanent print. I The printer uses a semiconductor laser in the Laser Scanner (also called Raster Output Scanner) to generate a 5 milliwatt infrared laser beam. I The Phaser 5400 Laser Printer comes standard with one 500-Sheet Letter... printing commands to the Print Engine Controller Board. Phaser 5400 Laser Printer Overview I The Phaser 5400 Laser Printer is fed past the drum, and a bias transfer roller (BTR), behind the paper, helps to transfer the toner from the host computer modulates the beam, creating ...
... and pressure melt and bond the toner to the paper, creating a dry, permanent print. I The printer uses a semiconductor laser in the Laser Scanner (also called Raster Output Scanner) to generate a 5 milliwatt infrared laser beam. I The Phaser 5400 Laser Printer comes standard with one 500-Sheet Letter... printing commands to the Print Engine Controller Board. Phaser 5400 Laser Printer Overview I The Phaser 5400 Laser Printer is fed past the drum, and a bias transfer roller (BTR), behind the paper, helps to transfer the toner from the host computer modulates the beam, creating ...
Quick Reference Guide
Page 32
... front panel when the Maintenance Kit should be manually reset. This is remaining. Phaser 5400 Laser Printer Service Guide 3 The printer signals "Toner Low" when 2% - 3% toner is a soft error, "Printing may continue regardless of the Maintenance Kit count, but image quality may continue printing (Toner Low = Continue) or must be replaced. After installing these items, the Maintenance...
... front panel when the Maintenance Kit should be manually reset. This is remaining. Phaser 5400 Laser Printer Service Guide 3 The printer signals "Toner Low" when 2% - 3% toner is a soft error, "Printing may continue regardless of the Maintenance Kit count, but image quality may continue printing (Toner Low = Continue) or must be replaced. After installing these items, the Maintenance...
Quick Reference Guide
Page 36
... this case, a paper jam has occurred while feeding from Tray 3): Tray 3 JamOpen Tray 3 Phaser 5400 Laser Printer Service Guide 7 For more data: Waiting... I Displays information about the status of menus to accept print jobs: Ready.. I The printer is waiting for more information on toner: Toner Low I The printer is online and ready to configure and control the...
... this case, a paper jam has occurred while feeding from Tray 3): Tray 3 JamOpen Tray 3 Phaser 5400 Laser Printer Service Guide 7 For more data: Waiting... I Displays information about the status of menus to accept print jobs: Ready.. I The printer is waiting for more information on toner: Toner Low I The printer is online and ready to configure and control the...
Quick Reference Guide
Page 56
... RAP 24 Error Code E9-3: Tray 2 Failure Power Off / On Tray 3 Failure Power Off / On .89 RAP 25 Error Code J5: Toner Low 90 RAP 26 Error Code J5: Toner Low 91 RAP 27 Error Code J6-1: Replace Print Cartridge Install Print Cartridge 92 RAP 28 Error Code J8-1: Print Cartridge OEM...: Fan Failure Power Off Now 101 RAP 34 Error Code: 0101 - DIMM 3 104 RAP 37 Error Code U6: IOT NVM Fail Power Off / On 105 Phaser 5400 Laser Printer Service Guide 27 Error Codes and Messages Contents - DIMM 2 103 RAP 36 Error Code: 0103 - Error Codes and Messages RAP 1 Error Code C3: Insert...
... RAP 24 Error Code E9-3: Tray 2 Failure Power Off / On Tray 3 Failure Power Off / On .89 RAP 25 Error Code J5: Toner Low 90 RAP 26 Error Code J5: Toner Low 91 RAP 27 Error Code J6-1: Replace Print Cartridge Install Print Cartridge 92 RAP 28 Error Code J8-1: Print Cartridge OEM...: Fan Failure Power Off Now 101 RAP 34 Error Code: 0101 - DIMM 3 104 RAP 37 Error Code U6: IOT NVM Fail Power Off / On 105 Phaser 5400 Laser Printer Service Guide 27 Error Codes and Messages Contents - DIMM 2 103 RAP 36 Error Code: 0103 - Error Codes and Messages RAP 1 Error Code C3: Insert...
Quick Reference Guide
Page 59
...-free cloth to clean the printer interior. If the Toner Cartridge appears obviously damaged, replace it from the printer. 7. Check for damaged wires, loose connections, toner leakage, and damaged or obviously worn parts. 8. Take voltage readings at various test points. Figure 16 Service Flowchart S5400-03 30 Phaser 5400 Laser Printer Service Guide Make note of any...
...-free cloth to clean the printer interior. If the Toner Cartridge appears obviously damaged, replace it from the printer. 7. Check for damaged wires, loose connections, toner leakage, and damaged or obviously worn parts. 8. Take voltage readings at various test points. Figure 16 Service Flowchart S5400-03 30 Phaser 5400 Laser Printer Service Guide Make note of any...
Quick Reference Guide
Page 69
... up does not complete within 110 seconds. 3. Go to RAP 30, page 96. Thermistor circuit is actuated. Go to RAP 32, page 100. 40 Phaser 5400 Laser Printer Service Guide Paper Size Jam PSE-1 Open Rear Cover Paper Size Error There is a conflict between the size of the paper, which is detected by... to RAP 25, page 90. Table 18 Error Code / Repair Analysis Procedure (cont'd.) Displayed Fault Diagnostic Message / Error Message History Fault Description / Log Comment Action Toner Low J5 J5: Toner Low Replace Print Toner Low is detected after start of Main Motor.
... up does not complete within 110 seconds. 3. Go to RAP 30, page 96. Thermistor circuit is actuated. Go to RAP 32, page 100. 40 Phaser 5400 Laser Printer Service Guide Paper Size Jam PSE-1 Open Rear Cover Paper Size Error There is a conflict between the size of the paper, which is detected by... to RAP 25, page 90. Table 18 Error Code / Repair Analysis Procedure (cont'd.) Displayed Fault Diagnostic Message / Error Message History Fault Description / Log Comment Action Toner Low J5 J5: Toner Low Replace Print Toner Low is detected after start of Main Motor.
Quick Reference Guide
Page 119
... 310]. 3. 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 Go to 1. RAP 25 Error Code J5: Toner Low The Print Cartridge is nearing end-of these components or areas may have failed partially or completely. Does the...
... 310]. 3. 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 Go to 1. RAP 25 Error Code J5: Toner Low The Print Cartridge is nearing end-of these components or areas may have failed partially or completely. Does the...
Quick Reference Guide
Page 120
... Procedure, replace each component or troubleshoot each time you isolate and solve the problem. Table 46 Error Code J5: Toner Low Troubleshooting Procedure Step Actions and Questions Yes No 1 TEST PRINT 1. Go to stop. 5. Problem does not ...Toner Sensor? 4 SUSPECT COMPONENTS The following printer components and areas are associated with this specific problem. Definitions, Does the print quality meet specifications? 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...
... Procedure, replace each component or troubleshoot each time you isolate and solve the problem. Table 46 Error Code J5: Toner Low Troubleshooting Procedure Step Actions and Questions Yes No 1 TEST PRINT 1. Go to stop. 5. Problem does not ...Toner Sensor? 4 SUSPECT COMPONENTS The following printer components and areas are associated with this specific problem. Definitions, Does the print quality meet specifications? 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...
Quick Reference Guide
Page 137
...59 Print Performance Problems RAP Table (cont'd.) Problem Go To MBF No Paper Sensor RAP 51 on page 137 Laser Safety Switch RAP 52 on page 139 Tray 1 No Paper Sensor RAP 53 on page 140 Size Switch ... RAP 55 on page 145 Tray 1 Feed Solenoid RAP 56 on page 147 MBF Feed Solenoid RAP 57 on page 149 Toner Sensor Assembly RAP 58 on page 151 HVPS Assembly RAP 59 on page 153 Electrical Noise RAP 60 on page 157 Low ... Assembly RAP 67 on page 170 Disk Error Format Hard Disk RAP 68 on page 172 Erratic Printer Operation RAP 69 on page 173 108 Phaser 5400 Laser Printer Service Guide
...59 Print Performance Problems RAP Table (cont'd.) Problem Go To MBF No Paper Sensor RAP 51 on page 137 Laser Safety Switch RAP 52 on page 139 Tray 1 No Paper Sensor RAP 53 on page 140 Size Switch ... RAP 55 on page 145 Tray 1 Feed Solenoid RAP 56 on page 147 MBF Feed Solenoid RAP 57 on page 149 Toner Sensor Assembly RAP 58 on page 151 HVPS Assembly RAP 59 on page 153 Electrical Noise RAP 60 on page 157 Low ... Assembly RAP 67 on page 170 Disk Error Format Hard Disk RAP 68 on page 172 Erratic Printer Operation RAP 69 on page 173 108 Phaser 5400 Laser Printer Service Guide
Quick Reference Guide
Page 145
...Power Loading Troubleshooting Procedure Step Actions and Questions Yes No 1 Switch the printer power OFF. listed in Table 67. Are all the voltages correct? 116 Phaser 5400 Laser Printer Service Guide Are all the voltages correct? Remove the Lower Rear Go ...to Step 5. Are all the P/Js to Step 3. 3 1. Replace the 2. Go to the LVPS. 3. Switch the printer power OFF. 2. I P/J21 (Print Cartridge Sensor) I P/J14 (Toner Sensor) ...
...Power Loading Troubleshooting Procedure Step Actions and Questions Yes No 1 Switch the printer power OFF. listed in Table 67. Are all the voltages correct? 116 Phaser 5400 Laser Printer Service Guide Are all the voltages correct? Remove the Lower Rear Go ...to Step 5. Are all the P/Js to Step 3. 3 1. Replace the 2. Go to the LVPS. 3. Switch the printer power OFF. 2. I P/J21 (Print Cartridge Sensor) I P/J14 (Toner Sensor) ...
Quick Reference Guide
Page 180
... +5.0 VDC when the cartridge is in place and 0.0 VDC when the cartridge is raised? 5 TONER SENSOR HARNESS CONTINUITY Replace the Repair or CHECK Toner replace the 1. Phaser 5400 Laser Printer Service Guide 151 Step 3. 2. Measure the voltage between all the pins tested? Replace the LVPS... between P/J16-9 on the Print Engine Controller Board and frame ground. Switch printer power ON. 7. Does the voltage measure +2.0 VDC? Step 4. Switch printer power OFF. 2. Disconnect P/J14 from the Toner Sensor. [RRP 7.3, Harness 3. Does the voltage measure + 24.0 VDC?...
... +5.0 VDC when the cartridge is in place and 0.0 VDC when the cartridge is raised? 5 TONER SENSOR HARNESS CONTINUITY Replace the Repair or CHECK Toner replace the 1. Phaser 5400 Laser Printer Service Guide 151 Step 3. 2. Measure the voltage between all the pins tested? Replace the LVPS... between P/J16-9 on the Print Engine Controller Board and frame ground. Switch printer power ON. 7. Does the voltage measure +2.0 VDC? Step 4. Switch printer power OFF. 2. Disconnect P/J14 from the Toner Sensor. [RRP 7.3, Harness 3. Does the voltage measure + 24.0 VDC?...
Quick Reference Guide
Page 181
...] 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 If you isolate and solve the problem. Table 88 Toner Sensor Assembly Troubleshooting Procedure (cont'd.) Step Actions and Questions Yes No 6 SUSPECT COMPONENTS The following printer components and areas are associated with this Repair Analysis...
...] 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 If you isolate and solve the problem. Table 88 Toner Sensor Assembly Troubleshooting Procedure (cont'd.) Step Actions and Questions Yes No 6 SUSPECT COMPONENTS The following printer components and areas are associated with this Repair Analysis...
Quick Reference Guide
Page 206
...the Background specification. Loss or stretching of the image in the direction of scanning. page 214 UNFUSED IMAGE: Part of or all of toner on the print. (Inboard to Outboard): Displacement of paper movement. Image page 215 RESOLUTION: At 600 dpi, the two-pixel lines and...line darkness and solid area density image varies across the in Image-Quality Checkout. page 212 SKIPS / SMEARS: Skip - Resolution page 217 Phaser 5400 Laser Printer Service Guide 177 Blank Prints page 181 SPOTS: There are spots of the image is unfused. Horizontal (Scan) Deletions page 185 VERTICAL ...
...the Background specification. Loss or stretching of the image in the direction of scanning. page 214 UNFUSED IMAGE: Part of or all of toner on the print. (Inboard to Outboard): Displacement of paper movement. Image page 215 RESOLUTION: At 600 dpi, the two-pixel lines and...line darkness and solid area density image varies across the in Image-Quality Checkout. page 212 SKIPS / SMEARS: Skip - Resolution page 217 Phaser 5400 Laser Printer Service Guide 177 Blank Prints page 181 SPOTS: There are spots of the image is unfused. Horizontal (Scan) Deletions page 185 VERTICAL ...
Quick Reference Guide
Page 208
... Cartridge. Are the metal contacts intact and free of contamination? Generate a Test Print and switch printer power OFF Step 9. Phaser 5400 Laser Printer Service Guide 179 Reform or clean the metal contacts so that they make better contact with sharp,... black, easily read areas? Is the laser beam path free obstructions? Replace the BTR [RRP 7.6, page 304]. 8 "YES" FROM STEP 7 ABOVE Go to Step 6. Carefully remove the Print Cartridge and inspect the toner...
... Cartridge. Are the metal contacts intact and free of contamination? Generate a Test Print and switch printer power OFF Step 9. Phaser 5400 Laser Printer Service Guide 179 Reform or clean the metal contacts so that they make better contact with sharp,... black, easily read areas? Is the laser beam path free obstructions? Replace the BTR [RRP 7.6, page 304]. 8 "YES" FROM STEP 7 ABOVE Go to Step 6. Carefully remove the Print Cartridge and inspect the toner...