Phaser 5400

PHASER™ 5400
LASER PRINTER
Service Quick Reference Guide
Phaser™ 5400
Laser Printer
S ervi ce Qui ck R efe renc e Gui de
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 printing: August 2002

Rev. 1
721P58301
Copyright
Copyright © 2002, Xerox Corporation. All Rights Reserved. Unpublished rights reserved
under the copyright laws of the United States. Contents of this publication may not be
reproduced in any form without permission of Xerox Corporation.
Copyright protection claimed includes all forms of matters of copyrightable materials and
information now allowed by statutory or judicial law or hereinafter granted, including
without limitation, material generated from the software programs which are displayed on
the screen such as styles, templates, icons, screen displays, looks, etc.
XEROX®, The Document Company®, the stylized X®, CentreWare®, and DocuPrint® are
registered trademarks of Xerox Corporation. infoSMART™, Phaser™, PhaserPort™,
PhaserSMART™, and PhaserTools™ are trademarks of Xerox Corporation. Total
Satisfaction ServicesSM is a service mark of Xerox Corporation.
Adobe®, Acrobat® Reader®, and PostScript® are registered trademarks of Adobe Systems
Incorporated.
Apple®, LaserWriter®, LocalTalk®, Macintosh®, Mac® OS, and AppleTalk®are

registered trademarks of Apple Computer Incorporated.
PCL® and HP-GL® are registered trademarks of Hewlett-Packard Corporation.
MS-DOS® and Windows® are registered trademarks of Microsoft Corporation.
Novell® and NetWare® are registered trademarks of Novell, Incorporated.
Sun® and Sun Microsystems® are registered trademarks of Sun Microsystems,

Incorporated. SPARC® is a registered trademark of SPARC International, Incorporated.
SPARCstation™ is a trademark of SPARC International, Incorporated, licensed
exclusively to Sun Microsystems, Incorporated.
UNIX® is a registered trademark in the US and other countries, licensed exclusively

through X/Open Company Limited.
This product includes an implementation of LZW licensed under U.S. Patent 4,558,302.
Other marks are trademarks or registered trademarks of the companies with which they
are associated.
ii Phaser 5400 Laser Printer Service Guide

Users Safety Summary
Terms in manual: Various terms are used throughout this manual to either provide
additional information on a specific topic or to warn of possible danger that might be
present during a procedure or action. Be aware of all symbols and terms when they are
used, and always read Note, Caution and Warning messages.
Note: A Note may indicate an operating or maintenance procedure,

practice or condition that is necessary to efficiently accomplish a
task.
A Note may also provide additional information related to a
specific subject or add a comment on the results achieved through
a previous action.
Caution: A Caution indicates an operating or maintenance procedure,
practice or condition that, if not strictly observed, could result in
damage to, or destruction of, equipment.
Warning: A Warning indicates an operating, or maintenance procedure,
practice or condition that, if not strictly observed, could result in
injury or loss of life.
Terms on Product:
Caution: A personal injury hazard exists that may not be apparent. For
example, a panel may cover the hazardous area.
Danger: A personal injury hazard exists in the area where you see the sign.
Power Source: For 110 VAC printers, do not apply more than 130 VAC RMS between
the supply conductors or between either supply conductor and ground. Use only the
specified power cord and connector. For 220 VAC printers, do not apply more than 250
VAC RMS between the supply conductors or between either supply conductor and
ground. Use only the 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

Power Supply and Electrical Components: Before starting any service procedure,
switch off the printer power and unplug the power cord from the wall outlet. If you must
service the printer with power applied, be aware of the potential for electrical shock.
Do not touch any electrical component unless you are instructed to do so by a service
procedure.
S5400-01
Mechanical Components: Manually rotate drive assemblies to inspect sprockets and

gears.
Do not try to manually rotate or manually stop the drive assemblies while any printer motor
is running.
S5400-02
Laser Components
Warning: This printer generates a laser beam as part of the printing
process. The laser beam is a concentrated narrow beam of
infrared light. The laser beam in this machine is invisible.
Although you cannot see the beam, it can still cause severe
eye damage. Direct eye exposure to the laser beam may
cause eye injury or blindness.
To avoid permanent eye damage, follow these directions:
■ Before starting any service procedure, switch off the printer power and unplug
the power cord from the AC wall outlet.
■ Do not disassemble the Raster Output Scanner Assembly (laser scanner) or any
laser component that displays a Laser Warning Sticker.
■ Use caution when you are working around the Raster Output Scanner Assembly
or when you are performing laser related troubleshooting or repair procedures.
■ Never place a mirror or a reflective tool or object in the laser beam path.
■ 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

Fuser Components
Warning: This printer uses heat and pressure to fuse the toner image
to a sheet of paper. The Fuser Assembly is very hot. Switch
off printer power and wait at least 30 minutes for the Fuser
to cool before you attempt to service the Fuser Assembly or
adjacent components.
Safety Components: Make sure covers and panels are in place and that all interlock
switches are all functioning correctly after you have completed a printer service call. If
you bypass, or cheat, an interlock switch during a service call, use extreme caution when
working on or around the printer.
Warning Labels: Throughout the printer, warning labels are displayed on potentially
dangerous components. When you service the printer, check to make certain that all
warning labels are in place.
Most importantly, read and obey all posted warning labels.
Warning: Turning the power off using the On/Off switch does not
de-energize the printer. You must remove the power cord to
disconnect the printer from the main power source. Keep the
power cord accessible for removal in case of an emergency.
Safety Instructions: Read all installation instructions carefully before you plug the
product into a power source.
Care of Product: Disconnect the power plug by pulling the plug, not the cord.
Disconnect the power plug:
■ If the power cord or plug is frayed or otherwise damaged,

■ If any liquid or foreign material is spilled into the case,
■ If the printer is exposed to any excess moisture,
■ If the printer is dropped or damaged,
■ If you suspect that the product needs servicing or repair, or
■ 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

Service Safety Summary
For qualified service personnel only: Refer also to the preceding Users Safety
Summary.
Do not service alone: Do not perform internal service or adjustment of this product
unless another person capable of rendering first aid or resuscitation is present.
Use care when servicing with power: Dangerous voltages may exist at several points in
this product. To avoid personal injury, do not touch exposed connections and components
while power is on.
Disconnect power before removing the power supply shield, soldering or replacing
components.
Do not wear jewelry: Remove jewelry prior to servicing. Rings, necklaces and other
metallic objects could come into contact with dangerous voltages and currents.
Power source: This product is intended to operate from a power source that will not apply
more then 250 VAC rms between the supply conductors or between either supply
conductor and ground. A protective ground connection by way of the grounding
conductor in the power cord is essential for safe operation.
This product is certified under IEC 825 as a Class 1 Laser Product.
CLASS 1 LASER PRODUCT
The Phaser 5400 Laser Printer is certified to comply with Laser Product Performance
Standards set by the U.S. Department of Health and Human Services as a Class 1 Laser
Product. This means that this is a class of laser product that does not emit hazardous laser
radiation; this is possible only because the laser beam is totally enclosed during all modes
of customer operation.
The laser and output of the laser scanner unit produces a beam that, if looked into, could
cause eye damage. Service procedures must be followed exactly as written without
change.
When servicing the machine or laser module, follow the procedures specified in the
manual and there will be no hazards 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

The Laser contained in the Phaser 5400 Laser Printer meets the following standard: Laser
class 3B, maximum 5 mW, wavelength 780 nm.
The following LASER symbol will be displayed at the start of any procedure where
possible exposure to the laser beam exists.
LUOKAN 1 LASERLAITE
KLASS 1 LASER APPARAT
Phaser 5400 Laser Printer Service Guide vii

Federal Communications Commission Compliance
This equipment has been tested and found to comply with the limits set for a Class A
digital device, as stated in Part 15 of the FCC rules. These limits are designed to provide
reasonable protection against harmful interference in a commercial installation. This
equipment generates, uses, and may radiate radio frequency energy. If not installed and
used in accordance with the instructions provided, this equipment may cause disruptive
interference to nearby radio and television communications. Even if the equipment is
installed according to the instructions, there is no guarantee that interference will not
occur in a particular installation. If this equipment does cause disruptive interference to
nearby radio and television reception, switch the equipment off to determine if it is the
true cause of the interference. If the equipment is the cause of the interference, the user
should try to minimize the interference by taking one or more of the following courses of
action:
■ Either re–orient or relocate the radio/television receiving antenna.

■ Increase the separation between the equipment and the radio/television receiver.
■ Connect the equipment to an AC outlet that is not on the same circuit as the
radio/television receiver.
■ If the previous solutions fail to bring results, you should consult either your equipment
dealer or an experienced radio/television technician.
For more information on interference, refer to the Federal Communications Commission’s
booklet “How to Identify and Resolve Radio-TV Interference 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

Canadian Notice
This digital apparatus does not exceed the Class A limits for radio noise emissions from
digital apparatus as described in the radio interference regulations of the Canadian
Department of Communications.
Avis Canadien
Cet appareil numerique est conforme aux limites émission de bruits radioélectriques pour
les appareils de classe A stipulés das le réglement sur le brouillage radioéletrique du
Ministére des Communcations du Canada.
European Notice
This equipment was tested and is determined to be compliant with VDE requirements for a
Class A device.
Hinweis
Hiermit wird bescheinigt, dass der Babe Laserdrucker, in bereinstimmung mit den
Betimmunngen der Vfg 104ß 984 funkenstört 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

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x Phaser 5400 Laser Printer Service Guide

Table of Contents
Copyright .................................................................................................. ii
Users Safety Summary ........................................................................... iii
Service Safety Summary......................................................................... vi
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix
List of Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxv
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Parts of the Printer ...................................................................................4
Printer Components ...........................................................................4
Printer Options ...................................................................................5
Control Panel .....................................................................................6
Display Screen...................................................................................7
Rear Panel .........................................................................................8
Print Engine Assemblies ..........................................................................9
Paper Path Information ..........................................................................15
Printer Specifications..............................................................................17
RAM and Printer Capabilities...........................................................17
Basic Specifications .........................................................................18
Electrical Specifications ...................................................................18
Mechanical Specifications ...............................................................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

Error Codes and Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Introduction ............................................................................................28
Error messages ...............................................................................28
Measurements .................................................................................29
Service Flowchart ............................................................................29
Repair Analysis Procedure Table...........................................................31
How to Use a Repair Analysis Procedure Table..............................31
How to Follow a Repair Analysis Procedure....................................32
General Notes on Using Repair Analysis Procedures .....................33
Error Codes with Repair Analysis Procedure .........................................35
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Printer Performance Problems Repair Analysis Procedure
(RAP) Table.............................................................................107
Image-Quality Problems Repair Analysis Procedure (RAP) Table ......109
Electrical Interference Repair Analysis Procedure (RAP) Table ..........109
Printer Performance Problems .............................................................110
Image-Quality Troubleshooting ............................................................176
Introduction ....................................................................................176
Image-Quality Defect Definitions ...................................................177
Diagnostics, Test Prints, Service Tests and

NVRAM Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Entering Diagnostics Mode ..................................................................221
System Controller Board Error (Blink) Codes.......................................222
Recommended Corrective Action ..................................................223
Power On LED Sequence..............................................................223
Diagnostics Menu Map ..................................................................224
System Controller Board Test Prints ....................................................226
Main Menu Test Prints .........................................................................226
Configuration Sheet .......................................................................226
System Controller 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

Component Tests .................................................................................235
Reset Menu ..........................................................................................239
Maintenance Kit Counter Reset Procedure..........................................240
Maintenance and Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

Scheduled Maintenance.......................................................................241
Recommended Tools ...........................................................................241
Inspect While Servicing ........................................................................241
General Cleaning (if needed) ...............................................................242
FRU Removal / Replacement Procedures (RRPs) . . . . . . . . . . . 245

Contents - Removal and Replacement Procedures .............................245
Introduction...........................................................................................248
Work Notes...........................................................................................248
Preparation...........................................................................................249
Notations in the RRP text .....................................................................249
Adjustment ...........................................................................................249
Repair Procedures ...............................................................................250
RRP 1.1 Left Side Cover ...............................................................250
RRP 1.2 Right Side Cover .............................................................251
RRP 1.3 Top Cover Assembly .......................................................252
RRP 1.4 Front Cover .....................................................................253
RRP 1.5 Lower Left Cover .............................................................254
RRP 1.6 HVPS Cover ....................................................................255
RRP 1.7 Lower Rear Cover ...........................................................256
RRP 1.8 MBF Gear Cover .............................................................257
RRP 1.9 Rear Cover ......................................................................258
RRP 2.1 Multi-sheet Bypass Feeder (MBF) Assembly ..................259
RRP 2.2 MBF Feed Rollers ...........................................................261
RRP 2.3 MBF Tray 1 Turn Roller Clutch Assembly .......................262
RRP 2.4 Tray 1 Turn Roller Assembly...........................................263
RRP 2.5 MBF Retard Holder Assembly.........................................264
RRP 2.6 Tray 1 No Paper Sensor Assembly .................................266
RRP 2.7 MBF No Paper Sensor Assembly ...................................267
RRP 2.8 MBF Feed Solenoid ........................................................269
RRP 2.9 Tray 1 Feed Solenoid ......................................................270
RRP 2.10 Tray 1 Feed Roller ........................................................271
RRP 2.11 Tray 1 Retard Holder Assembly ....................................272
RRP 3.1 Retard Chute Assembly ..................................................273
RRP 3.2 Rear Chute Assembly .....................................................274
RRP 3.3 Lower Turn Roller Assembly ...........................................275
RRP 3.4 Tray 1 Low Paper Sensor ...............................................276
Phaser 5400 Laser Printer Service Guide xiii

RRP 3.5 Tray 1 Right Guide Assembly .........................................277
RRP 3.6 Tray 1 Left Guide Assembly............................................279
RRP 3.7 CRUM Board...................................................................281
RRP 3.8 MBF Assembly Position Sensor......................................282
RRP 4.1 Paper Transport Assembly..............................................283
RRP 4.2 Registration Actuator.......................................................285
RRP 4.3 Registration Clutch..........................................................286
RRP 4.4 Registration Sensor.........................................................287
RRP 5.1 Fuser Assembly ..............................................................288
RRP 5.2 Stack Full Sensor ............................................................289
RRP 5.3 Exit Roller Assembly .......................................................291
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 [BTR] Assembly..............................304
RRP 8.1 System Controller PWB ..................................................305
RRP 8.2 High-Voltage Power Supply [HVPS] Board.....................307
RRP 8.3 Duplex Interface Board ...................................................308
RRP 8.4 Main Fan .........................................................................309
RRP 8.5 Print Engine Controller Board .........................................310
RRP 8.6 Low-Voltage Power Supply [LVPS] Assembly ................312
RRP 8.7 LVPS FAN.......................................................................313
RRP 8.8 AC Input Assembly..........................................................314
RRP 8.9 Control Panel +5 VDC Power Supply..............................315
RRP 9.1 Duplex Assembly ............................................................317
RRP 10.1 1000-Sheet High Capacity Stacker [HCS] ....................318
RRP 10.2 HCS Top Cover.............................................................319
RRP 10.3 HCS Rear Cover Assembly...........................................320
RRP 10.4 HCS Front Cover...........................................................321
RRP 10.5 HCS Exit Gate Solenoid................................................322
RRP 10.6 HCS Stack Full Sensor .................................................323
RRP 10.7 HCS Stack Full Sensor Actuator ...................................324
RRP 10.8 HCS Drive Motor Assembly ..........................................325
RRP 10.9 HCS Rear Cover Interlock Switch .................................326
RRP 10.10 HCS Paper 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

RRP 11.5 Rear Cover ....................................................................332
RRP 11.6 Drive Assembly .............................................................333
RRP 11.7 Feeder Board ................................................................334
RRP 11.8 Feed Head Assembly ....................................................335
RRP 11.9 Feed Rollers ..................................................................336
RRP 11.10 Feed Solenoid .............................................................337
RRP 11.11 Turn Roller Assembly ..................................................338
RRP 11.12 Retard Chute Assembly ..............................................339
RRP 11.13 Left Tray Guide ...........................................................340
RRP 11.14 Right Tray Guide .........................................................342
RRP 11.15 Retard Holder Assembly .............................................344
RRP 11.16 Retard Turn Roller Assembly ......................................345
RRP 11.17 Paper Size Sensor ......................................................346
RRP 11.18 Paper Tray Sensor ......................................................347
RRP 11.19 No Paper Sensor.........................................................348
RRP 11.20 No Paper Sensor Actuator ..........................................350
RRP 11.21 Preregistration Sensor ................................................351
RRP 12.1 Removing the 2000-Sheet Feeder ................................352
RRP 12.2 Left Side Cover .............................................................354
RRP 12.3 Upper Rear Cover .........................................................355
RRP 12.4 Lower Rear Cover .........................................................356
RRP 12.5 Right Side Cover ...........................................................357
RRP 12.6 Front Cover ...................................................................358
RRP 12.7 Tray Assembly ..............................................................359
RRP 12.8 2000-Sheet Feeder PWB ..............................................360
RRP 12.9 Tray Lift Motor Assembly ..............................................361
RRP 12.10 A4 Paper Size Sensor .................................................362
RRP 12.11 Casters ........................................................................363
RRP 12.12 Harness Assembly ......................................................364
RRP 12.13 Drive Assembly ...........................................................365
RRP 12.14 Feed, Nudger, and Retard Roller ................................366
RRP 12.15 Paper Height Sensor ...................................................367
RRP 12.16 Paper Feed Motor Assembly.......................................368
RRP 12.17 Link Stopper ................................................................369
RRP 12.18 No Paper Sensor.........................................................370
RRP 12.19 No Paper Sensor Actuator ..........................................371
RRP 12.20 Left and Right Wire Cover ...........................................372
RRP 12.21 Shaft Cover Assembly.................................................373
RRP 12.22 Drive Shaft Assembly ..................................................374
RRP 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 xv

FRU Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
Introduction ..........................................................................................381
Organization of this Section...........................................................381
Using the Parts List........................................................................382
Parts Lists ............................................................................................384
PL 1.1 Covers ................................................................................384
PL 2.1 Paper Tray [A3/Ledger] ......................................................386
PL 2.2 Paper Tray [A4/Letter] ........................................................388
PL 3.1 Paper Feeder .....................................................................390
PL 4.1 Multi-sheet Bypass Feeder (MBF) Assembly .....................392
PL 4.2 Paper Handler ....................................................................394
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
PL 9.1 Electrical (1 of 2) ................................................................404
PL 9.2 Electrical (2 of 2) ................................................................406
PL 10.1 High Capacity Stacker [HCS] (1 of 2)...............................408
PL 10.2 High Capacity Stacker [HCS] (2 of 2)...............................410
PL 11.1 500-Sheet Feeder (1 of 3) ................................................412
PL 12.1 2000-Sheet Feeder (1 of 4) ..............................................418
PL 13.1 Duplex Assembly..............................................................426
Xerox Supplies and Accessories..........................................................428
Plug/Jack Connector Locations. . . . . . . . . . . . . . . . . . . . . . . . . . 433

Contents ...............................................................................................433
Plug/Jack (P/J) Locations for the Engine .............................................434
Plug/Jack Location Map 1 - Engine......................................................437
Plug/Jack Location Map 4 - 500-Sheet Feeder ....................................440
Plug/Jack Location Map 5 - Duplex Assembly .....................................442
Plug/Jack Location - 1000-Sheet (High Capacity) Stacker ..................444
Plug/Jack Location - 2000-Sheet Feeder .............................................446
Plug/Jack Location Map 7 - 2000-Sheet Feeder ..................................447
xvi Phaser 5400 Laser Printer Service Guide

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

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xviii Phaser 5400 Laser Printer Service Guide

List of Figures
Figure 1 Machine Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 2 Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 3 Rear View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 4 View from Right Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 5 View from Left Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 6 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 7 Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 8 Print Engine Assemblies, Sensors and Interlock Locations 1 -
Tray 1 and MBF Paper Path Components 1 . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 9 FRU Assemblies, Sensors and Interlock Locations 2 . . . . . . . . . . . . . . . . . 10
Figure 10 FRU Assemblies, Sensors and Interlock Locations 3 - Detack Saw,
Registration & Bias Transfer Rollers and Paper Transport Assembly . . . 11
Figure 11 FRU Assemblies, Sensors and Interlock Locations 4 - Fuser Area . . . . . . 12
Figure 12 FRU Assemblies, Sensors and Interlock Locations 5 - Main Drive . . . . . . 13
Figure 13 FRU Assemblies, Sensors and Interlock Locations 6 -
FRU Circuit Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 14 Paper Path Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 15 Paper Path Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 16 Service Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 17 Fuser Connector P174 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Figure 18 Light Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Figure 19 Blank Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Figure 20 Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Figure 21 Horizontal (Scan) Deletions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Figure 22 Vertical (Process) Deletions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Figure 23 Spot Deletions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Figure 24 Vertical (Process) Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Figure 25 Horizontal (Scan) Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Figure 26 Residual Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Figure 27 Black Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Figure 28 Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Figure 29 Uneven Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 30 Skewed Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 31 Damaged Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Figure 32 Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Figure 33 Skips / Smears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Figure 34 Unfused Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Figure 35 Registration Test Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
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Figure 36 Removing the Left Side Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Figure 37 Right Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Figure 38 Top Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Figure 39 Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
Figure 40 Lower Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Figure 41 HVPS Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Figure 42 Lower Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Figure 43 MBF Gear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Figure 44 Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Figure 45 MBF Paper Handler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Figure 46 MBF Left Tray Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Figure 47 MBF Right Tray Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Figure 48 MBF Feed Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Figure 49 MBF Tray 1 Turn Roller Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . 262
Figure 50 Tray 1 Turn Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Figure 51 MBF Pick Up Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Figure 52 MBF Tray Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Figure 53 MBF Retard Holder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Figure 54 Tray 1 No Paper Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Figure 55 MBF No Paper Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Figure 56 MBF Tray Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Figure 57 MBF No Paper Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Figure 58 MBF Feed Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Figure 59 Tray 1 Feed Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Figure 60 Tray 1 Feed Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Figure 61 Tray 1 Retard Holder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Figure 62 Rear Chute Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Figure 63 Rear Chute Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Figure 64 Lower Turn Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
Figure 65 Tray 1 Low Paper Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Figure 66 Paper Level Indicator Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Figure 67 Tray 1 Right Guide Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Figure 68 Tray Left Guide Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Figure 69 Removing the CRUM Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Figure 70 MBF Assembly Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Figure 71 Paper Transport 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
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Figure 79 Lower Exit Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Figure 80 Upper Exit Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Figure 81 Upper Exit Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Figure 82 Lower Exit Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Figure 83 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Figure 92 Bias Transfer Roller [BTR] Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
Figure 94 System Controller Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
Figure 95 System Controller Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
Figure 96 High-Voltage Power Supply [HVPS] Board . . . . . . . . . . . . . . . . . . . . . . . 307
Figure 97 Duplex Interface Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
Figure 98 Main Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Figure 100 Print Engine Controller Board Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Figure 101 Print Engine Controller Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Figure 102 Low-Voltage Power Supply [LVPS] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Figure 103 LVPS Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
Figure 104 AC Input Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
Figure 105 Print Engine Controller Board Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Figure 106 +5 VDC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Figure 107 Duplex Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
Figure 108 High Capacity Stacker [HCS] Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 318
Figure 109 HCS Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
Figure 110 HCS Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
Figure 111 HCS Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
Figure 112 Exit Gate Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
Figure 113 HCS Stack Full Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Figure 114 HCS Stack Full Sensor Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
Figure 115 HCS Drive Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Figure 116 HCS Rear Cover Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
Figure 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
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Figure 122 Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
Figure 123 Feeder Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
Figure 124 Feeder Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
Figure 125 Feed Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
Figure 126 Feed Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
Figure 127 Feed Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
Figure 128 Turn Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
Figure 129 Retard Chute Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
Figure 130 Left Tray Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Figure 131 Paper Level Indicator Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
Figure 132 Right Tray Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
Figure 133 Retard Holder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
Figure 134 Turn Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
Figure 135 Paper Size Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
Figure 136 Paper Tray Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
Figure 137 No Paper Sensor Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
Figure 138 Feed Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
Figure 139 No Paper Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
Figure 140 No Paper Sensor Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
Figure 141 Sensor Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
Figure 142 Preregistration Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
Figure 143 Removing the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
Figure 144 Left Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
Figure 145 Upper Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
Figure 146 Lower Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
Figure 147 Right Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
Figure 148 Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
Figure 149 Tray Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
Figure 150 2000-Sheet Feeder Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
Figure 151 Tray Lift Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
Figure 152 Paper Size Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
Figure 153 Casters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Figure 154 Harness Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
Figure 155 Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
Figure 156 Pick, Feed and Retard Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
Figure 157 Paper Height Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
Figure 158 Paper Feed Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
Figure 159 Link Stopper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
Figure 160 No Paper Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
Figure 161 No Paper Sensor Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
Figure 162 Tray Assembly Wire Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
Figure 163 Shaft Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
Figure 164 Drive Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
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Figure 165 Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
Figure 166 Left Tray Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
Figure 167 Right Tray Wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
Figure 168 Feed Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
Figure 169 Retard Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
Figure 170 Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
Figure 171 Paper Tray (A3/Ledger) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
Figure 172 Paper Tray [A4/Letter] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
Figure 173 Paper Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
Figure 174 Multi-sheet Bypass Feeder (MBF) Assembly . . . . . . . . . . . . . . . . . . . . . 392
Figure 175 Paper Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
Figure 176 Paper Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
Figure 177 Rear Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
Figure 178 Frame and Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
Figure 179 Xerographics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Figure 180 Electrical (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Figure 181 Electrical (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Figure 182 High Capacity Stacker (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
Figure 183 High Capacity Stacker (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
Figure 184 500-Sheet Feeder (1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
Figure 187 2000-Sheet Feeder (1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
Figure 191 Duplex Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
Figure 192 CRC Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
Figure 193 P/J Location Map 1 - Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
Figure 196 P/J Location Map 4 - 500-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . 441
Figure 197 P/J Location Map 5 - Duplex Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 443
Figure 198 P/J Location Map 6 - 1000-Sheet High Capacity Stacker . . . . . . . . . . . 445
Figure 199 P/J Location Map 7 - 2000-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . 447
Figure 200 Master Wiring Diagram 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
Figure 201 Master Wiring Diagram 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
Figure 202 Print Engine Controller PWB <–> 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

Figure 206 Print Engine Controller PWB <–> Registration Clutch
and Registration Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
Figure 207 Print Engine Controller PWB <–> Feed Solenoid, Turn Clutch,
No-Paper Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
Figure 208 Print Engine Controller PWB, Low Paper Sensor, MBF Home 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 213 500-Sheet Feeder - Tray 2 Wiring Diagram and Signal Information
Between Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
Figure 214 500-Sheet Feeder - Tray 3 Wiring Diagram and Signal Information
Figure 215 Duplex Assembly - Wiring Diagrams and Signal Information
Figure 216 Master Wiring Diagram, High Capacity Stacker . . . . . . . . . . . . . . . . . . 468
Figure 217 2000-Sheet Feeder - Wiring Diagram and Signal Information
Figure 218 2000-Sheet Feeder PWB <–> 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

List of Tables
Table 1 Memory Upgrades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Table 2 Basic Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Table 3 Electrical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Table 4 Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Table 5 Printer Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Table 6 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Table 7 Life Expectancies of the Print Engine and Options . . . . . . . . . . . . . . . . . . . 21
Table 8 Conforming Regulations and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Table 9 Printing Speed for the First Sheet Out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Table 10 Consecutive Printing Speed after the First Sheet Out. . . . . . . . . . . . . . . . 22
Table 11 Supported Media and Media Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Table 13 Paper Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Table 12 Custom Paper Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Table 14 Printing Accuracy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Table 15 Components to Be Replaced Periodically . . . . . . . . . . . . . . . . . . . . . . . . . 26
Table 16 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Table 18 Error Code / Repair Analysis Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Table 19 Error Code C3: Insert Tray Troubleshooting Procedure . . . . . . . . . . . . . . 42
Table 20 Paper Size Actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Table 21 Error Code C3: Insert Tray 2 (or Tray 3) (500-Sheet Feeder)
Troubleshooting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Table 22 Paper Size Actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Table 23 Error Code C3: 2000-Sheet Feeder Carriage Not In Position Message
Table 24 Add Paper to MBF, Tray 1, 2 or 3 Message
Table 25 Add Paper To 500-Sheet Feeder Troubleshooting Procedure . . . . . . . . . 50
Table 26 Error Code C5: Standard Bin Full Troubleshooting Procedure . . . . . . . . . 52
Table 27 Error Code C5: Stacker Bin Full Troubleshooting Procedure . . . . . . . . . . 55
Table 28 Add Paper to 2000-Sheet Feeder Troubleshooting Procedure . . . . . . . . . 58
Table 29 Error Code E1-1: Paper Jam Tray to Registration
Table 30 Error Code E2-1: Paper Jam Troubleshooting Procedure. . . . . . . . . . . . . 61
Table 31 Paper Jam / Misfeed 500-Sheet Feeder Troubleshooting Procedure . . . . 63
Table 32 Error Code E2-1: Paper Jam / Misfeed 2000-Sheet Feeder
Table 33 Error Code E2-D: Duplex Jam Troubleshooting Procedure . . . . . . . . . . . 67
Phaser 5400 Laser Printer Service Guide xxv

Table 34 Error Code E3-1: Paper Jam / Registration To Fuser
Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Table 35 Error Code E4: Exit Jam Troubleshooting Procedure. . . . . . . . . . . . . . . . . 72
Table 36 Error Code E5: Close Covers Troubleshooting Procedure . . . . . . . . . . . . . 74
Table 37 Insert MBF Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Table 38 2000-Sheet Feeder Cover Open Troubleshooting Procedure . . . . . . . . . . 78
Table 39 Close Stacker Door Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . 80
Table 40 Error Code E7: Duplex Jam Troubleshooting Procedure . . . . . . . . . . . . . . 82
Table 41 Error Code E8-1: Stacker Jam Troubleshooting Procedure . . . . . . . . . . . . 84
Table 42 Duplex Unit Fail or Removed Message
Table 43 Error Code E9-2: Stacker Bin Fail Troubleshooting Procedure . . . . . . . . . 88
Table 44 Error Code E9-3: HCF Fail (2000-Sheet Feeder)
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. . . . 92
Table 48 Error Code J8-1: Print Cartridge OEM ID Mismatch
Table 49 Error Code PSE-1 Paper Size Jam Troubleshooting Procedure . . . . . . . . 94
Table 50 Paper Size Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Table 51 Error Code U1: Motor Failure Troubleshooting Procedure . . . . . . . . . . . . . 96
Table 52 Error Code U2: Laser (ROS (Laser Scanner)) Failure
Table 53 Error Code U4: Fuser Failure Troubleshooting Procedure . . . . . . . . . . . . 100
Table 54 Error Code U5: Fan Fail Troubleshooting Procedure . . . . . . . . . . . . . . . . 101
Table 55 0101 - DIMM 1 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . 102
Table 58 Error Code U6: IOT NVM Failure Troubleshooting Procedure . . . . . . . . . 105
Table 59 Print Performance Problems RAP Table . . . . . . . . . . . . . . . . . . . . . . . . . 107
Table 60 Image-Quality Problems RAP Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Table 61 Electrical Interference RAP Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Table 62 AC Power Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Table 63 Registration Clutch Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . 112
Table 64 DC (LVPS) Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Table 65 LVPS Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Table 66 DC Power Loading Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . 116
Table 67 LVPS Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Table 68 System 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

Table 73 Inoperative Keypad Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . 126
Table 74 Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Table 75 Main Motor Assembly Troubleshooting Procedure . . . . . . . . . . . . . . . . . 128
Table 76 Main Motor Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Table 77 Laser Assembly Troubleshooting Procedure. . . . . . . . . . . . . . . . . . . . . . 130
Table 78 Fuser Assembly Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . 133
Table 79 Registration Sensor Troubleshooting Procedure. . . . . . . . . . . . . . . . . . . 135
Table 80 MBF No Paper Sensor Troubleshooting Procedure . . . . . . . . . . . . . . . . 137
Table 81 Error Code J3: Laser Safety Switch Open Troubleshooting . . . . . . . . . . 139
Table 82 Tray 1 No Paper Sensor Troubleshooting Procedure . . . . . . . . . . . . . . . 140
Table 83 Size Switch Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 142
Table 84 Size Switch Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Table 85 Turn 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 (or Tray 3) / 500-Sheet Feeder
Troubleshooting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Table 92 500-Sheet Feeder Feed Solenoid Troubleshooting Procedure . . . . . . . . 161
Table 93 500-Sheet Feeder Motor Troubleshooting Procedure . . . . . . . . . . . . . . . 163
Table 94 500-Sheet Feeder Assembly Not Recognized
Troubleshooting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Table 95 Exit Sensor Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 167
Table 96 Pre-Registration Sensor Troubleshooting Procedure . . . . . . . . . . . . . . . 168
Table 97 HCS Motor Assembly Message Troubleshooting Procedure . . . . . . . . . 170
Table 98 Hard Disk Formatting Troubleshooting Procedure . . . . . . . . . . . . . . . . . 172
Table 99 Erratic Printer Operation Troubleshooting Procedure . . . . . . . . . . . . . . . 173
Table 100 Image-Quality Defect Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Table 101 Light (Undertoned) Prints Troubleshooting Procedure . . . . . . . . . . . . . 178
Table 102 Blank Prints Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . 181
Table 103 Spots Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Table 104 Horizontal (Scan) Deletions Troubleshooting Procedure . . . . . . . . . . . 185
Table 105 Vertical (Process) Deletions Troubleshooting Procedure . . . . . . . . . . . 188
Table 106 Spot Deletions Troubleshooting Procedure. . . . . . . . . . . . . . . . . . . . . . 190
Table 107 Vertical (Process) Streaks Troubleshooting Procedure. . . . . . . . . . . . . 192
Table 108 Horizontal (Scan) Streaks Troubleshooting Procedure . . . . . . . . . . . . . 194
Table 109 Residual 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

Table 114 Damaged Print Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . 210
Table 115 Registration Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . 212
Table 116 Skips / Smears Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . 214
Table 117 Unfused Image Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . 215
Table 118 Resolution Troubleshooting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . 217
Table 119 System Controller Board Error (Blink) Codes . . . . . . . . . . . . . . . . . . . . . 222
Table 120 System Controller LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Table 121 Diagnostics Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Table 122 Test Print Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Table 123 NVRAM Configuration Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Table 124 Phaser 5400 Fuser Run Temp Conversion Table . . . . . . . . . . . . . . . . . 234
Table 125 Component Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Table 126 Legend: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
Table 127 PL 1.1 Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
Table 128 PL 2.1 Paper Tray [A3/Ledger] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
Table 129 PL 2.2 Paper Tray [A4/Letter] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
Table 130 PL 3.1 Paper Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
Table 131 PL 4.1 MBF Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
Table 132 PL 4.2 Paper Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
Table 133 PL 5.1 Paper Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
Table 134 PL 6.1 Rear Cover Assembly with Fuser . . . . . . . . . . . . . . . . . . . . . . . . 399
Table 135 PL 7.1 Frame and Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Table 136 PL 8.1 Xerographics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Table 137 PL 9.1 Electrical (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Table 138 PL 9.2 Electrical (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Table 139 PL 10.1 High Capacity Stacker (1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . 409
Table 140 PL 10.2 High Capacity Stacker (2 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . 411
Table 141 PL 11.1 500-Sheet Feeder (1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
Table 142 PL 11.2 500-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
Table 143 PL 11.3 500-Sheet Feeder (3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
Table 144 PL 12.1 2000-Sheet Feeder (1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
Table 148 PL 13.1 Duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
Table 149 Customer-Replaceable Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . 429
Table 150 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

General Information
The Phaser 5400 Printer Service Guide is the primary document used for repairing
and maintaining the Phaser 5400 Laser Printer.
To ensure complete understanding of the product, participation in Xerox Phaser 5400
service training is recommended.
Machine Orientation
For servicing the Phaser 5400 Laser Printer, all references to machine orientation are
as illustrated below.
Figure 1 Machine Orientation
Process Direction = paper path
Phaser 5400 Laser Printer Service Guide 1

Phaser 5400 Laser Printer Overview
■ The Phaser 5400 Laser Printer is a 40-page-per-minute monochrome,
600x600 and 1200x1200 dpi laser printer that uses a data-modulated laser
beam, standard dry-ink Xerographic imaging process, and heat and pressure
fusing to place a computer-generated image onto the surface of a sheet of
paper.
■ The printer uses a semiconductor laser in the Laser Scanner (also called
Raster Output Scanner) to generate a 5 milliwatt infrared laser beam. Image
data sent from the host computer modulates the beam, creating a latent
image on the surface of the electrically charged xerographic drum inside the
Print Cartridge.
■ Also inside the Print Cartridge, electrically charged toner is applied to the
drum and it adheres to the latent image, developing it.
■ Paper is fed past the drum, and a bias transfer roller (BTR), behind the paper,
helps to transfer the toner from the drum to the paper.
■ The paper with dry toner statically adhered to it continues to the fuser where
heat and pressure melt and bond the toner to the paper, creating a dry,
permanent print.
The printer requires 110 VAC, 50/60 Hz (or optionally 220-240 VAC 50/60 Hz) using
1.1 kw for warm-up and approximately 890 watts for a print cycle. Power saver mode
reduces power consumption to below 45 W to comply with ENERGY STAR
requirements.
■ Safety interlocks within the printer remove power to the Laser Scanner
(ROS), Fuser heat rod and motor drives whenever the Rear Cover or Top
Cover are opened and when the Print Cartridge is removed.
■ The Print Engine Controller Board controls all printer functions, houses
printer diagnostics and supporting test prints, stores operating parameters,
and signals printer errors.
■ The 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.
■ The Phaser 5400 Laser Printer comes standard with one 500-Sheet
Letter-size tray, a 150 sheet MBF (Multi-sheet Bypass Feeder), and
500-Sheet output bin.
■ Four optional accessories are offered:
■ 500-Sheet Feeder Assembly (two versions, Letter-size or Ledger-size tray)
■ 2000-Sheet Feeder Assembly (for Letter size paper only)
■ Duplex Module
■ 1000-Sheet Stacker Bin (for Letter-size and smaller paper)
2 Phaser 5400 Laser Printer Service Guide

■ The Customer-Replaceable Consumable consists of a Print Cartridge, rated
at 20,000 pages at 5% coverage. The printer signals “Toner Low” when
2% - 3% toner is remaining. A front panel setting selects whether the user
may continue printing (Toner Low = Continue) or must stop and change the
cartridge (Toner Low = Stop).
■ A Maintenance Kit, also a Customer-Replaceable Consumable and normally
purchased and installed by the customer regardless of Warranty or Contract
entitlement, consists of two items rated for replacement at 200,000 Letter
size pages.
■ Bias Transfer Roller (BTR)
■ Fuser
■ The printer’s Maintenance Kit counter signals on the front panel 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.

Parts of the Printer
Printer Components
The base printer contains the following major components:
Front view Rear view
1 Standard Output Bin 9 Rear Cover (closed)
2 Paper Guide / Curl Extension 10 Power Cord Receptacle
3 Control Panel 11 LVPS Fan Ventilation Slots
4 Paper Support and Stopper 12 Interface Connectors
5 Multi-sheet Bypass Feeder (closed) (Parallel, USB, Ethernet)
6 Tray 1 13 Top cover (closed)
7 Paper Amount Indicator
8 Power Switch
1
2
3
8 S5400-03-A
Figure 2 Front View
13
9
10
11
12 S5400-04-A
Figure 3 Rear View

Printer Options
Front view Rear view
1 1,000-Sheet (High Capacity) Stacker 4 Optional Duplex Module (installed)
Bin 5 Optional Hard Drive (installed)
2 500-Sheet Feeder 6 Optional Memory DIMMs (installed)
(A4/Letter Tray, shown as Tray 1,
A3/Ledger Tray, shown as Tray 2 in
the 500-sheet Feeder)
3 2,000-Sheet Feeder (shown as Tray 3)
S5400-05-A
Figure 4 View from Right Front
6
5 S5400-06-A
Figure 5 View from Left Rear

Control Panel
The Xerox Phaser 5400 Printer Control Panel:
■ Displays printer status and jobs in process.
■ Provides the means to change printer settings.
■ Allows you to print reports (such as the configuration sheet, which lists the
printer’s current settings)
S5400-07-A
Figure 6 Control Panel
1 Display screen
2 Four indicator LEDs:
■ Online indicator LED
■ Form Feed indicator LED
■ Fault indicator LED
■ Data indicator LED
3 Eight control panel keys
■ Online key [0]
■ Enter key [4]
■ Menu Up key [1]
■ Menu Down key [5]
■ Item Up key [2]
■ Item Down key [6]
■ Value Up key [3]
■ Value Down key [7]

Display Screen
The control panel’s display screen:
■ Provides access to a hierarchy of menus to configure and control the printer.
Access the menus by pressing the Menu keys (labeled 1 or 5). For more
information on the menu structure, refer to the Advanced Features and
Troubleshooting Manual.
■ Displays information about the status of the printer (or the job in process):
Examples:
■ The printer is online and ready to accept print jobs:
Ready..
■ The printer is processing data:
Processing..
■ The printer is waiting for more data:
Waiting...
■ The printer is low on toner:
Toner Low
■ A tray is empty (in this case, Tray 2 is empty and no longer is being used to
print):
Tray 2 Empty
■ There is a problem (in this case, a paper jam has occurred while feeding from
Tray 3):
Tray 3 Jam-
Open Tray 3

Rear Panel
Ethernet
CR1
View Port
USB
Parallel
LEFT
R
A
E
R
s5400-344
Figure 7 Rear Panel

Print Engine Assemblies
Figure 8 Print Engine Assemblies, Sensors and Interlock Locations 1 -

Tray 1 and MBF Paper Path Components 1
In the above figure, all of the identified items are contained in the following four
FRUs:
■ Laser Scanner: stand-alone unit
■ Print Cartridge contains:
■ Bias Charge Roller
■ Cleaning Blade
■ Drum
■ Detack Saw
■ Mag Roller
■ CM Blade
■ Fuser contains:
■ Heat Roller
■ Pressure Roller
■ Bias Transfer Roller: stand-alone unit

Figure 9 FRU Assemblies, Sensors and Interlock Locations 2

Figure 10 FRU Assemblies, Sensors and Interlock Locations 3 - Detack
Saw, Registration & Bias Transfer Rollers and Paper Transport Assembly

Full Stack Sensor
Figure 11 FRU Assemblies, Sensors and Interlock Locations 4 - Fuser

Area

Figure 12 FRU Assemblies, Sensors and Interlock Locations 5 - Main
Drive

Figure 13 FRU Assemblies, Sensors and Interlock Locations 6 - FRU
Circuit Assemblies

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

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

Printer Specifications
RAM and Printer Capabilities
The Phaser 5400 Laser Printer is equipped with 32 Mbytes of RAM and is expandable
as shown below. Installing additional RAM:
■ Improves system performance.
■ Improves processing of complex jobs.
■ Enables increased graphics at higher resolutions.
■ Improves collation printing.
Memory Expansion
The base printer contains 32 MB of DRAM installed as a standard. Three option slots
are provided on the System Controller Board to accommodate DIMMs per the
Memory Expansion Options table below. The maximum DRAM memory, both
on-board and added via DIMMs is 192 MB. Memory added beyond this limit is
ignored.
Additional memory provides the following enhanced printer capabilities:
■ Additional font cache
■ Additional download space for fonts, macros and images
■ Increased throughput for complex pages, duplex pages and larger paper sizes
(A3 / Ledger)
■ Increased PostScript VM (virtual memory)
■ Collated sets without the Hard Disk Drive
Note: The printer features three DIMM slots (J4, J5 and J6) for
memory expansion. DRAM DIMMs can be installed in any of
these slots. Refer to the instructions packed with the DIMMs.
You can increase the resident fonts of the printer or create resident macros by
installing a Flash DIMM or hard drive and downloading resources permanently to this
memory. If flash memory is to be used, the 8 MB Flash DIMM can be installed in any
slot (J4, J5 or J6). If a bootable flash DIMM is installed, it must be in J6 slot;
however, this is not a standard option and is not likely to be seen unless a custom
version of the printer were produced.
Table 1 Memory Upgrades
Memory Upgrades Part Number

16-Mbyte DIMM 097S02356
8-Mbyte Flash DIMM 097S02360

Basic Specifications
Table 2 Basic Specifications
Category Specification
Standard configuration Print engine, MBF, 500-sheet Paper Feeder, A4/Letter Cassette
(500-sheet universal paper cassette), Print Cartridge
Printing method Xerography
Exposing method Scanning with a semiconductor laser beam
Laser light source Laser Diode (Nominal maximum output: 10 mW)
Print image resolution Fixed-resolution version: 600 or 1200 dpi
Fusing method Applying heat and pressure with rolls
Warm-up time Within 60 seconds from a cold start after power (nominal 120 V,
220 V) is switched on.(Measured at 72° F (22° C) ambient
temperature with the specified voltage)
Ranges of paper sizes A6 Card stock to Tabloid Extra (see Table 9 and Table 10 for
details).
Printable area The print quality is not guaranteed in a 4 mm border from all edges
in the printable area.
Paper capacity 650 sheets to 3150 sheets, depending on options.
Output Tray capacity About 500 printed sheets standard; plus 1000 Letter size or smaller
sheets in the optional Stacker.
Electrical Specifications
Table 3 Electrical Specifications
AC Power Required 120 V Version: 120 VAC (90 ~ 140 V), 50/60 Hz (47 ~ 63 Hz),
220 VAC Version: 220 VAC (198 ~ 264 V), 50/60 Hz (47 ~ 63 Hz)
Max. Power Required 110-127 VAC rated consumption max: 1.2 kw electrical current max
(during warm-up) 11A
220-240 VAC rated consumption max: 1.3 kw electrical current max
5.5 A
Power Consumption, 890 watts/3,045 BTU/hr.
Printing

Mechanical Specifications
Table 4 Physical Dimensions
Height Width Depth Weight
cm / in. cm / in. cm / in. kg / lb.
Phaser 5400 printer only 39.5 / 15.6 49.0 / 19.3 46.0 / 18.1 27 / 60
500-Sheet Feeder 13.4 / 5.3 50.1 / 19.7 43.9 / 17.3 9.5 / 21
A4 Letter size
500-Sheet Feeder 13.4 / 5.3 50.1 / 19.7 58.9 / 23.2 10.5 / 23
A3 Ledger size
2000-Sheet Feeder 41.0 / 16.1 49.0 / 19.3 50.9 / 20.0 23 / 51
1000-Sheet Stacker 35.5 / 14.0 49.0 / 19.3 32.0 / 12.6 5 / 11
Table 5 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°

Environmental Specifications
Table 6 Environmental Specifications
Environmental Operating: 41 – 95° F (5 – 35° C) 15 – 85% RH (Without
conditions for installation condensation) 0 – 3000 m above sea level Horizontal bias within 5°
(Printer unpacked and of level.
having the Print Non-operating: -68 – 104° F (-20 – 40° C) 5 – 85% RH (Without
Cartridge installed) condensation) 0 – 3000 m above sea level
Environmental When the Print Cartridge is packed together:
conditions for storage of • Normal conditions (Assured period: 12 months) 32 – 95° F
a printer packed for (0 – 35° C) 15 – 80% RH (Without condensation)
shipping • Severe conditions (Assured period: 1 month) -68 – 32° or
95 – 104° F (-20 – 0° or 35 – 40° C) 5 –15 or 80 – 95% RH (Without
condensation)
When the Print Cartridge is not packed together:

• Normal conditions (Assured period: 12 months) -68 – 122° F
(-20 – 50° C) 5 – 85% RH (Without condensation)
• Severe conditions (Assured period: 48 hours) 122 – 140° F
(50 – 60° C) 85 – 95% RH (Without condensation)
• The assured altitude is 0 – 3000 m above sea level.
When transported by air in a cargo room pressurized over

70.93 kPa, the assured altitude is 0 – 15000 m.
Environmental • Normal conditions (Assured period: 24 months) 32 – 95° F
conditions for storage of (0 – 35° C) 15 – 80% RH (Without condensation)
the Print Cartridge in the • Severe conditions (Assured period: 1 month) -68 – 32° or
packed condition 95 – 104° F (-20 – 0° or 35 – 40° C) 5 –15 or 80 – 95% RH (Without
condensation)
The assured altitude is 0 – 3000 m above sea level.
When transported by air in a cargo room pressurized over
70.93 kPa, the assured altitude is 0 – 15000 m.
The unpacked Print Cartridge remains intact for 12 months in the
above non-operating environmental conditions for the printer.
Noise generation Printing: 58.1 dB (A)
Stand by: 31.4 dB (A)
Impulse: 63.5 dB (A)
Dust generation 0.1 mg/m3 or less
Ozone generation 0.02 ppm or less in Time Weighted Average (TWA)
Illumination Under 3000 Lux (Direct sunlight must be avoided)

Life Expectancies
Table 7 Life Expectancies of the Print Engine and Options
Life of HCS Either 600,000 prints or 5 years.
Life of Duplex Module Either 600,000 prints or 5 years whichever comes first.
Life of Printer Engine Either 600,000 prints on Letter size paper (LEF) or 5 years whichever
comes earlier. A double-sided print is counted as two prints.
Life of Paper Feeder 600K for each: 500-Sheet and 2000-Sheet feeders
Life of Print Cartridge 20,000 prints (average) The life of the Print Cartridge is defined as the
number of prints which satisfy the specified print quality without
shaking the Print Cartridge when consecutively printing on A4/Letter
size sheets (LEF) under the normal conditions with 5% image
coverage. A double-sided print is counted as two prints.
Maintenance Kit 200,000 prints
Conforming Regulations and Standards

Table 8 Conforming Regulations and Standards
Laser safety regulations 100 V / 120 V Version: US FDA 21 CFR, Sections 1010 & 1040,
Sub-chapter J, Chapter 1
220 V / 240 V Version: IEC825 Class I Laser Product
EMI (Electromagnetic 120 V Version (USA): FCC Part 15 subpart B, Class A (ANSI
Interference) regulations C63.4/11.4D)
220 V / 240 V Version (EC):EN55022
(CISPR Publication 22), Class A
Other safety regulations 100 V / 120 V Version: UL 1950 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)

Printing Speed
Table 9 Printing Speed for the First Sheet Out
10.7 S: Simplex Time Needed for Initial Print (sec)
D: Duplex MBF Tray 1 Tray 2 Tray 3
Ledger SEF S 5.66 6.06 6.83 7.61
D 10.90 11.29 11.60 12.71
A3 SEF S 5.59 5.99 6.76 7.54
D 10.45 10.88 11.59 12.45
Letter LEF S 4.41 4.81 5.58 6.36
D 8.25 8.62 9.36 10.20
A4 LEF S 4.38 4.78 5.55 6.32
D 8.05 8.57 9.16 10.16
Statement S 3.97 4.37 5.14 5.92
LEF D 7.25 7.67 8.33 9.13
The above chart does not include RIP time.

Note: RIP time is the time expended from when the printer gets the
command to print to where 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 Ledger SEF 19.0 14.0
image quality A3 SEF 19.0 14.0
Letter LEF 40.0 28.6
A4 LEF 40.0 28.6
True 1200 dpi Ledger SEF 9.5 7.0
A3 SEF 9.5 7.1
Letter LEF 20.0 14.1
A4 LEF 20.0 14.2
The above chart does not include RIP time.

Printing Media Feeding Means
The Phaser 5400 Laser Printer has the following four print media feeding means:
1. Multi-sheet Bypass Feeder (Standard) 150 sheet capacity
2. A4/Letter Tray (Standard) 500 sheet capacity
3. A3/Ledger Tray (Optional) 500 sheet capacity
4. A4/Letter 2000-Sheet Feeder (Optional) 2000 sheet capacity
Note: All capacities assume a typical 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 2000-Sheet Multi-sheet
Feeder Bypass
Feeder
A3 297 x 420 mm - SEF(2) - SEF
A4 210 x 297 mm LEF LEF LEF LEF
A5 148 x 210 mm LEF(2) LEF(2) - LEF
A6 105 x 148 mm - - - LEF(1)
B4-JIS 257 x 364 mm - SEF - SEF
B5-JIS 182 x 257 mm LEF(2) LEF(2) - LEF
Statement 5.5 x 8.5 in. LEF(3) LEF(3) - LEF
Executive 7.25 x 10.5 in. LEF(3) LEF(3) - LEF
Letter 8.5 x 11 in. LEF LEF LEF LEF
Folio 8.5 x 13 in. - SEF - SEF
Legal 8.5 x 14 in. - SEF - SEF
Ledger 11 x 11 in. - SEF(3) - SEF
Envelopes
COM-10 4.1 x 9.5 in. LEF(1)(3) - - LEF(1)
Monarch 3.8 x 7.5 in. LEF(1)(3) - - LEF(1)
DL 110 x 220 mm LEF(1)(2) - - LEF(1)
C5 162 x 229 LEF(1) - - LEF(1)
Transparencies
A4 210 x 297 mm LEF(1) LEF(1) - LEF(1)
Letter 8.5 x 11 in. LEF(1) LEF(1) - LEF(1)
Labels
A4 210 x 297 mm LEF(1) LEF(1) - LEF(1)
Letter 8.5 x 11 in. LEF(1) LEF(1) - LEF(1)
SEF = Short-Edge Feed, LEF = Long-Edge Feed

(1)
Simplex (one-sided) printing only.
(2) Only when Defaults = Millimeters in the Control Panel System Menu.
(3)
Only when Defaults = Inches in the Control Panel System Menu.

Table 12 Custom Paper Sizes
Tray 1, Tray 2, Tray 3
Acceptable A4/Letter A3/Ledger 2000-Sheet Multi-sheet Bypass
Sizes Tray Tray Feeder Feeder
Simplex
Width 148 - 297 mm 210 - 297 mm None 76.2 - 305 mm
5.83 - 11.69 in. 8.27 - 11.69 in. 3 - 12 in.
Length 98.4 - 216 mm 139.7 - 431.8 mm None 98.4 - 508 mm
3.875 - 8.5 in. 5.5 - 17 in. 3.875 - 20 in.
Duplex
Width 182 - 297 mm 210 - 297 mm None 182 - 297 mm
7.16 - 11.69 in. 7.16 - 11.69 in.
Length 139.7 - 216 mm 139.7 - 431.8 mm None 139.7 - 341.8 mm
5.5 - 8.5 in. 5.5 - 17 in.
Printing Media
Table 13 Paper Weights
Acceptable Weights Input Source
2
60-200 g/m (16 lb. bond to 110 lbs. card stock) Main 500-Sheet Tray
Optional 500-Sheet Feeders
2000-Sheet Feeder
60-135 g/m2 (16 lb. bond to 36 lbs. bond) Multi-sheet Bypass Feeder
60-105 g/m2 (16 lb. bond to 28 lbs. bond) Duplex Module
Storing Paper
■ Store the paper on a flat surface, in a relatively low-humidity environment.
■ Avoid storing paper in such a way as to cause wrinkling, bending, curling,
etc.
■ Do not unwrap paper until you are ready to use it, and rewrap any paper you
are not using.
■ Do not expose paper to direct sunlight or high humidity.

Unacceptable Media
The following media are unacceptable for use in the printer. Their use may cause high
rates of jamming and other paper-handling problems:
■ Excessively thick or thin paper
■ Heavily textured paper
■ Paper that has already been printed on (pre-printed Letterhead is allowed)
■ Wrinkled, torn, or bent paper
■ Moist or wet paper
■ Curled paper
■ Paper with an electrostatic charge
■ Glued paper
■ Paper with special coating
■ Paper unable to withstand a temperature of 150° C
(302° F)
■ Thermal paper
■ Carbon paper
■ Paper with paper fasteners, ribbons, staples, tape, etc. attached
■ Label stock with exposed backing sheet
Printing Accuracy
Table 14 Printing Accuracy
Item Accuracy Measuring
Conditions
Registration Lead Edge 2.0 mm
Side Edge 2.5 mm
Skew 2.0 mm At a distance of 245 mm
Orthogonality 1.3 mm At a distance of 195 mm
In direction of paper travel 1.0 mm For 390 mm straight line
At right angle of direction of 0.7 mm For 245 mm Straight line
Linearity paper travel
At 40 degree angle to 1.5 mm For 347 mm straight line
direction of paper travel
Parallelism 2.0 mm Over 390 mm straight
lines
In direction of paper travel 100 0.8% At a distance of 390 mm
Magnification At right angle to direction of 100 0.5% At a distance of 245 mm
paper travel

Components to Be Replaced Periodically
Note: The Maintenance Kit is a user-installable consumable, not a
warranty item. It is supplied and installed by the customer at
regular intervals as indicated by the Control Panel. If Service
personnel supply this kit, the customer must be billed for it.
Table 15 Components to Be Replaced Periodically

Fuser Unit 200,000 prints (Letter LEF)
Bias Transfer Roll 200,000 prints (Letter LEF)
Options
The basic Phaser 5400 Laser Printer configuration consists of the base engine and a
Paper Feeder (Standard feeder) with a A4/Letter 500-sheet universal cassette. There
are various customer installed options available for the Phaser 5400 Laser Printer.
Table 16 Options
Option Description
A3/Ledger cassette (500-sheet universal Can hold regular size cut sheet up to the
cassette) A3/Ledger size.
A4/Letter cassette (500-sheet universal Can hold regular size cut sheet up to the
cassette) A4/Letter size.
Duplex Module Makes duplex printing possible.
1000-Sheet Stacker Bin Stacks printed sheets, without offset.
A4/500-Sheet Feeder Installed as a second or third.
A3/500-Sheet Feeder Installed as a second or third.
Memory DIMMs See RAM and printer capabilities
Hard Drive
2000-Sheet Feeder Installed as the second or third paper high
capacity feeders.
Note: Only one can be installed.
Part numbers and additional information for Maintenance items (fuser, BTR, etc.),
Consumables (printer cartridge, media, etc.) or Options, refer to Xerox Supplies and
Accessories on page 428 of this manual.

Error Codes and Messages
Contents - Error Codes and Messages
RAP 1 Error Code C3: Insert Tray 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
RAP 2 Error Code C3: Insert Tray 2 Insert Tray 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
RAP 3 Error Code C3-2E: Tray 2 Failure Power Off / On Error Code C3-3E: Tray 3 Failure
Power Off / On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
RAP 4 Load MBF / Load Tray 1 / Load Tray 2 / Load Tray 3 . . . . . . . . . . . . . . . . . . . . . .48
RAP 5 Load Tray 2 / Load Tray 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
RAP 6 Error Code C5: Remove Output From Std. Bin . . . . . . . . . . . . . . . . . . . . . . . . . . .52
RAP 7 Error Code C5: Remove Output From Stacker Bin . . . . . . . . . . . . . . . . . . . . . . . .55
RAP 8 Load Tray 2 / Load Tray 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
RAP 9 Error Code E1-1: Paper Jam Open Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . .60
RAP 10 Error Code E2-1M: Paper Jam Open Top Cover Error Code E2-11: Tray 1 Jam
Open Tray 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
RAP 11 Error Code E2-12: Tray 2 Jam Open Tray 2 Error Code E2-13: Tray 3 Jam Open
Tray 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
RAP 12 Error Code E2-12: Tray 2 Jam Open Tray 2 Error Code E2-13: Tray 3 Jam Open
Tray 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
RAP 13 Error Code E2-D: Duplex Jam Open Rear Cover . . . . . . . . . . . . . . . . . . . . . . . .67
RAP 14 Error Code E3-1: Paper Jam / Open Top Cover . . . . . . . . . . . . . . . . . . . . . . . . .69
RAP 15 Error Code E4-0: Exit Jam Open Rear and Top Cover . . . . . . . . . . . . . . . . . . . .72
RAP 16 Error Code E5: Close Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
RAP 17 Insert MBF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
RAP 18 Close Tray 2 Rear Door Close Tray 3 Rear Door . . . . . . . . . . . . . . . . . . . . . . . .78
RAP 19 Close Stacker Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
RAP 20 Error Code E7-1: Duplex Jam Open Rear Cover . . . . . . . . . . . . . . . . . . . . . . . .82
RAP 21 Error Code E8-1: Stacker Jam Open Rear Cover . . . . . . . . . . . . . . . . . . . . . . . .84
RAP 22 Error Code: E9-1 Duplex Unit Fail or Removed . . . . . . . . . . . . . . . . . . . . . . . . .86
RAP 23 Error Code E9-2: Stacker Bin Fail Power Off / On . . . . . . . . . . . . . . . . . . . . . . .88
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 ID Mismatch . . . . . . . . . . . . . . . . . . . . . .93
RAP 29 Error Code PSE-1: Paper Size Jam Open Rear Cover. . . . . . . . . . . . . . . . . . . .94
RAP 30 Error Code U1: Motor Failure Power Off / On . . . . . . . . . . . . . . . . . . . . . . . . . . .96
RAP 31 Error Code U2: Laser Failure Power Off / On . . . . . . . . . . . . . . . . . . . . . . . . . . .98
RAP 32 Error Code 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 37 Error Code U6: IOT NVM Fail Power Off / On . . . . . . . . . . . . . . . . . . . . . . . . .105

Introduction
The Control Panel displays error information when sensors report problems with trays
or consumables, open covers, jams, system failures or other operating problems. Error
codes are usually specific: the word string or code has a special meaning, which
makes it important that service and users record errors exactly. Error codes are listed
in this section with Repair Analysis Procedures (RAPs) that outline corrective actions
that should resolve the error or conflict.
If an error is not visible on the Control Panel, fault history may be accessed one of
three ways:
1. Print (if possible) the Fault History from the Control Panel’s Print Menu.
2. View fault history in the Control Panel using Print Menu, Display Faults. When
the [3] key is pressed, the first fault will be displayed. Continue to press the [3] key
to view the entire fault history. It will read as follows:
Log Entry #1
<error code> <page count>
3. If the printer has a TCP/IP address and is connected to a network, view the
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 (e.g. — failure to power up) and
print-quality problems, refer to Troubleshooting on page 107.
Error messages
The Control Panel displays error codes when it encounters certain system failures or
anomalies otherwise undetected by the user. These error codes are discussed in this
section. When an error code first occurs, cycle power on the printer to see if the error
recurs.

Measurements
Power and signal grounds are connected to frame ground, therefore all circuit
troubleshooting can be performed using the metal frame (chassis) as the grounding
point. If more information is needed to locate connectors or test points, refer to
Plug/Jack Connector Locations on page 433.
Unless otherwise specified, the following voltage tolerances are used within this
section:
Table 17 Voltage Measurements

Stated Measured
+3.3 VDC +3.0 to 3.6 VDC
+5.0 VDC +4.8 to +5.2 VDC
+24.0 VDC +21.6 to +26.4 VDC
0.0 VDC Less than +0.5 VDC
Service Flowchart
Note: A Service Flowchart that outlines one possible approach to
troubleshooting and repair of the printer has been provided.
The Service Flowchart is an overview of the path a service
technician could take, using this technical manual, to service
the printer engine and options.
To use the Service Flowchart, start at Block 1 to identify the problem. After you have
identified the problem, return to the Service Flowchart and proceed to Block 2 where
you inspect and clean the printer (a through cleaning frequently solves many printer
problems). You continue down the Flowchart in this manner, always returning to the
next block 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.

Identify the Problem
1. Verify that the reported problem does exist.
2. Check for any error codes and write them down.
1 3. Print three test prints.
4. Make note of any print quality problems in the test prints.
5. Make note of any mechanical or electrical abnormalities present.
6. Make note of any unusual noise or smell coming from the printer.
7. Print a Fault History (if the printer is able to print).
Inspect and Clean the Printer

1. Switch OFF printer power.
2. Disconnect the AC power cord from the wall outlet.
Print Cartridge and shield it from strong light.
3. Remove the Toner
4. Inspect the printer interior and remove any foreign matter such as paper clips, staples,
pieces of paper, paper dust, or toner.
5. Clean the printer interior with a lint-free cloth, dampened slightly with cold water.
2 Do not use solvents or chemical cleaners to clean the printer interior.
Do not use any type of oil or lubricant on printer parts.
6. Clean all rubber rollers with a lint-free cloth that is dampened slightly with isopropyl alcohol
or cold water. Use a clean, dry, lint-free cloth to dry the rollers.
7. While you are cleaning, inspect the interior of the printer for damaged wires, loose
connections, toner leakage, and damaged or obviously worn parts.
8. If the Toner Cartridge appears obviously damaged, replace it with a new one.
Find the Cause of the Problem

3 Use the Repair Analysis Procedure (RAP) Tables to find the cause of the problem.
Use Diagnostics to check printer and option components.
Use the Wiring Diagrams to locate Plugs/Jacks (P/Js) and test points.
Take voltage readings at various test points.
Correct the Problem

4 Use the Parts List to locate a part number.
Use the Removal and Replacement Procedures (RRPs) to replace a part.
Final Checkout
5 Test the printer to be sure you corrected the initial problem and there are no additional
problems present.
S5400-03
Figure 16 Service Flowchart

Repair Analysis Procedure Table
If you used the Service Flowchart, it may have directed you to this section. Follow the
Repair Analysis Procedure Table located in this section to help you analyze your
printer problem.
How to Use a Repair Analysis Procedure Table

1. If you have an error code or error message displayed, refer to the Repair Analysis
Procedure in this section and locate the ERROR CODE in the “Error Code”
column or the “Error Message” in the “Displayed Error Message” column, then
go to the Repair Analysis Procedure indicated in the “Go To...” cell to the right of
the ERROR CODE.
2. If you have a printer operation problem, go to the PRINTER PERFORMANCE
area in the Troubleshooting Section of this manual.
3. If you have a print image problem, go to the IMAGE QUALITY area in the
Troubleshooting section of this manual.
4. Follow the Repair Analysis Procedure Table leading from the “Problem” cell to
the individual Primary Repair Analysis Procedure that corresponds to your error
code, printer operation problem, or print image problem.
5. Follow the instructions presented in the Repair Analysis Procedure.
6. If the Repair Analysis Procedure instructs you to perform a diagnostic test, refer to
Diagnostics area in the Tests and Adjustments Section of 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.

How to Follow a Repair Analysis Procedure
See the RAP Table example below.
1. Each numbered step in a Repair Analysis Procedure instructs you to perform a
certain action or procedure.
2. The Actions and Questions box may contain additional information and
numbered procedure steps you must follow to perform the action.
3. The action is followed by a question.
4. If your response to the question is Yes, then follow the instructions for a Yes reply.
5. If your response to the question is No, then follow the instructions for a No reply.
6. Repair Analysis Procedures may ask you to take voltage readings at certain test
points within the printer. The Plug/Jack Connector Locations and Master Wiring
Diagram sections of this manual contain information on test point locations and
signal names.
7. Repair Analysis Procedures may ask you to run a specific diagnostic routine in
order to test a component or circuit. The Tests /Adjustments and Resetting NVRAM
sections of this manual contain information on printer diagnostics.
8. Repair Analysis Procedures often ask you to replace a printer component. The Key
FRU (Field Replaceable Unit) section of this manual provides detailed steps for
removing and replacing all major parts of the printer. If the component is not part
of the base engine, the Repair Analysis Procedure indicates which technical
manual contains the procedure.
RAP Table Example
Step Actions and Questions Yes No
2 NO PAPER SENSOR TEST Go to Step 3 Replace the No
1. Enter Diagnostics. Paper Sensor
2. From the Main Menu, select Component Assembly
Test / Sensor Input / press [4] to start, [0]
to stop.
3. Remove Tray 1 from the printer.
4. Manually actuate and deactuate Tray 1
No Paper Sensor.
Does the LCD counter increment each
time you press and release the
actuator?

General Notes on Using Repair Analysis
Procedures
1. Unless indicated otherwise, the instruction “switch ON printer main power” means
for you to switch ON printer power and let the printer proceed through power-on
diagnostics and warm-up until it is on-line and ready to print.
2. Conventions used to represent connectors:
■ P/J XX means a Plug and its corresponding Jack are connected.
■ PXX means a Plug is disconnected. (Unless this plug is soldered to a board).
■ JXX means a Jack is disconnected. (Unless this jack is soldered to a board).
3. When you are instructed to take a voltage reading between “P/J A–B and P/J
X–Y”, place the red probe (+) of your meter on pin B of P/J A, and place the black
probe (–) of your meter on pin Y of P/J X.
4. When you are instructed to take voltage readings between “P/J X and P/J Y”
(without specified pin numbers), check all voltage carrying pins. Refer to the
Wiring Diagrams for signals and pin numbers.
5. When you are instructed to take a voltage reading, the black probe (–) is generally
connected to a pin that is either RTN (Return) or SG (Signal Ground). You can
substitute any RTN pin or test point in the printer, and you can use frame ground
(frame ground) in place of any SG pin or test point.
6. Unless a Repair Analysis Procedure instructs you otherwise; before measuring
voltages make sure the printer is switched ON, the Xerographic Cartridge and the
paper trays are in place, and all of the interlock switches are actuated.
7. All voltage values given in the Repair Analysis Procedures are approximate
values. Actual measured voltages may vary more than 25% from the values stated
in the Repair Analysis Procedures. The main purpose of most voltage readings
taken in the Repair Analysis Procedures is to determine whether or not a
component is receiving the correct voltage value from the power supply and if
gating (a voltage drop) occurs during component actuation. Gating signals may be
nothing more than a pulse, resulting in a momentary drop in voltage that may be
difficult or impossible to read on the average multi-meter.
8. Repair Analysis Procedures may instruct you to remove or replace a component.
Refer to the Key FRU Removal and Replacement Procedures section for
information on how to remove and reinstall a component.
9. When a Repair Analysis Procedure instructs you to replace a non-spared
component, and that component is part of a larger assembly, you should replace
the entire assembly.
Note: Repair Analysis Procedures assume there is no malfunction
in the System Controller Board. If you are unable to fix a
problem using the Repair Analysis Procedures, it is
recommended that you replace the System Controller board.
In some instances, the Control Panel Display may not be
sufficiently functional to accurately show error codes and/or
messages. Before replacing the System Controller, please
refer to the System Controller Error Blink Code Table on
page 222 to check the LED blink codes for additional help in
troubleshooting.

Using Printer Diagnostics
Repair Analysis Procedures often ask you to enter Diagnostics and perform a specific
output test or input test. Diagnostics are built into the Print Engine Controller Board.
Use the Control Panel to access and run the various diagnostic routines that are
presented in this manual. Refer to Diagnostics, Test Prints, Service Tests and NVRAM
Adjustments on page 219 of this manual.
To Enter Diagnostics mode
When troubleshooting, you will encounter times when it is necessary to enter
Diagnostics mode. Please use the following procedure:
1. Make certain the printer is OFF.
2. Press and hold buttons [2] and [6] on the Control Panel while you switch printer
power ON. Continue holding until *IOT?* appears in the display (approximately
20 seconds).
3. When the Control Panel LCD displays *IOT?*, release buttons [2] and [6], then
press and hold button [4] until the LCD indicates you are in Diagnostics mode.
Note: You have 10 seconds to complete the transition from holding
[2] and [6] to pressing [4]. If you miss this 10 second window,
the printer will complete a normal boot sequence, requiring
you to switch printer power OFF and start over.
4. When attempting to enter certain areas of Diagnostics, a password is required.
When so requested for password, sequentially press [0], [7], [3], [4] to gain entry.
Note: To exit Diagnostics, you must switch printer power OFF, wait
20 - 30 seconds and switch printer power ON.

Error Codes with Repair Analysis
Procedure
Table 18 Error Code / Repair Analysis Procedure
Displayed Fault Diagnostic Message / Action

Error Message History Fault Description /
Log Comment
Insert Tray 1 C3: Tray 1 Error Install Tray 1
Tray 1 is not detected in printer. (All Go to RAP 1, page 42.
paper size switches not actuated.)

Tray 2 is not detected in printer. (All 500-Sheet Feeder
paper size switches not actuated.) Go to RAP 2, page 44.

Tray 3 is not detected in printer. (All 500-Sheet Feeder
paper size switches not actuated.) Go to RAP 2, page 44.
Tray 2 Failure C3-2E C3-E3: HCF Elevator Open and close

Power Off/On 1. 2000-Sheet Feeder elevator did not 2000-Sheet Feeder
reach home position within the paper tray.
prescribed time. Go to RAP 3, page 46.
2. Paper level sensor on when 2000-
Sheet Feeder Tray is opened.
Tray 3 Failure C3-3E C3-E3: HCF Elevator Open and close

Power Off/On 1. 2000-Sheet Feeder elevator did not 2000-Sheet Feeder
reach home position within the paper tray.
prescribed time. Go to RAP 3, page 46
2. Paper level sensor on when
2000-Sheet Feeder Tray is opened.
Load Tray 1 C5: Tray 1 Empty Load paper into Tray 1

Tray 1 is out of paper. Go to RAP 4, page 48
Load Tray 2 C5: Tray 2 Empty Load paper into Tray 2

500-Sheet Feeder
Go to RAP 5, page 50
2000-Sheet Feeder
Load Tray 3 C5: Tray 3 Empty 500-Sheet Feeder

2000-Sheet Feeder
Load MBF C5: MBF Empty Load paper into MBF

MBF is out of paper. Go to RAP 4, page 48

Table 18 Error Code / Repair Analysis Procedure (cont'd.)

Log Comment
Remove Output C5: Top Tray Full Empty Top Tray.
from Std. Bin Top Tray is declared full when 5 prints Go to RAP 6, page 52.
are delivered to the top tray after the
Full Stack sensor is actuated.
Remove Output C5: HCS Tray Full Empty HCS Tray.

from Stacker Bin Five prints are delivered to the top tray Go to RAP 7, page 55.
after the HCS Full Stack sensor is
actuated.
Disk Error D-1 Hard Drive error was detected. ■ Power Off/On.
■ Format Hard Drive -
Format Disk See Reset Menu
(RAP 68, page 172).
■ Replace Hard Drive.
■ Replace System
Controller Board
(RRP 8.1, page 305).
Init Failed D-2 Cannot format disk, disk locked via ■ Customer Unlock
PJL or SNMP Command. Disk.
Disk Locked ■ Replace Hard Disk.
Format Failed D-3 Cannot put disk in factory default ■ Customer Unlock
attempt to initialize disk after it is Disk.
Disk Locked ■ Replace Hard Disk.
locked.
Memory Failure ESS-M Controller memory has failed (32 MB ■ Power Off/On
on board). ■ Remove Options
Power Off/On ■ Replace System
Controller PWB
(RRP 8.1, page 305).
NV Memory Fail ESS-N Controller NVM Failure ■ Power Off/On

■ Replace System
Power Off/On Controller PWB
(RRP 8.1, page 305).
Paper Jam E1-1 E1: Reg. Jam Open Top Cover,

1. Registration Sensor did not remove EP Cartridge.
Open Top Cover
deactuate within time after actuation Open and Extend MBF
Open/Extend of Registration sensor. assembly and remove
MBF 2. Registration sensor is actuated at any paper.
power on.
Remove PrintCart 3. Registration is actuated during Go to RAP 9, page 60.
Clear Paper Path warm up cycle or an erase cycle.
Duplex Jam E2-D E2-2: Misfeed Jam Open Rear Cover and
Open Rear Cover Registration Sensor did not actuate remove any paper.
within time after the actuation of the Go to RAP 13,
Clear Paper Path Duplex Motor in reverse. page 67.


Log Comment
Paper Jam E2-1M E2-1 Misfeed Jam Open Top Cover or
Open Top Cover 1. Simplex printing: Reg. Sensor is Feeder and remove
OFF when the specified time has the sheets, then close
Open /Extend passed timing from Feed Roll ON. the cover.
MBF 2. Printing from 2000-Sheet Feeder:
Reg. Sensor is OFF when the timing Go to RAP 10,
Remove All Paper is after receiving Feed Run status. page 61.
Comment: MBF misfeed
Tray 1 Jam E2-11 E2-1 Misfeed Jam Open Top Cover of

1. Simplex printing: Reg. Sensor is Feeder and remove
Open Tray 1
Open/Extend passed timing from Feed Roll ON. the cover.
MBF 2. Printing from 2000-Sheet Feeder:
Open Top Cover is after receiving Feed Run status. page 61.
Remove Print
Comment: Tray 1 Misfeed
Cart.
Clear Paper Path
Tray 2 Jam E2-12 E2-1 Misfeed Jam Open Top Cover or

Simplex printing: Reg. Sensor is OFF Feeder and remove
Open Tray 2
when the specified time has passed the sheets, then close
Open/Extend timing from Feed Roll ON. the cover.
MBF
Comment: Tray 2 misfeed with Go to RAP 11,
Open Top Cover 500-Sheet Feeder installed as Tray 2. page 63.
Remove PrintCart
Clear Paper Path

Open Tray 2
Open Rear timing from Feed Roll ON. the cover.
TrayDr
Printing from 2000-Sheet Feeder: Go to RAP 12,
Clear Paper Path Reg. Sensor is OFF when the timing is page 65.
after receiving Feed_Run status.
Comment: Tray 2 misfeed with
2000-Sheet Feeder installed as
Tray 2.

Open Tray 3
Open/Extend timing from Feed Roll ON. the cover.
MBF
Comment: Tray 3 Misfeed with Go to RAP 11,
Open Top Cover 500-Sheet Feeder installed as Tray 3. page 63.
Remove PrintCart
Clear Paper Path


Log Comment
Open Tray 3 1. Simplex printing: Reg. Sensor is Feeder and remove
Open Rear passed timing from Feed Roll ON. the cover.
TrayDr 2. Printing from 2000-Sheet Feeder:
Clear Paper Path is after receiving Feed_Run status. page 65.
Comment: Tray 3 misfeed with

2000-Sheet Feeder installed as
Tray 3.
Paper Jam E3-1 E3: Reg. Jam Open Top Cover,

Exit Sensor did not actuate within time remove EP Cartridge
Open Top Cover
after the Registration clutch is and remove any paper.
Remove Print actuated. Go to RAP 14,
Cartridge
page 69.
Clear Paper Path
Exit Jam-Open E4-0 E-4: Exit Jam Open Top Cover,

Rear & Top Cover 1. Exit Sensor is not deactuated within remove EP Cartridge
time after it is actuated. and remove any paper.
Remove Print
Cartridge 2. Exit Sensor is being actuated at Go to RAP 15,
Power-Up.
3. Exit Sensor is ON when the interlock page 72.
Clear Paper Path
is closed.
4. Exit Sensor turns from OFF to ON at
Erase Cycle.
Close Stacker E5: HCS Rear Door Close HCS rear door.
Door HCS rear door interlock switch is Go to RAP 19,
open. page 80.
Close Tray 2 E5: HCF Cover Close 2000-Sheet

Rear Door 2000-Sheet Feeder rear cover feeder rear cover.
interlock switch is open. Go to RAP 18,
Comment: 2000-Sheet Feeder page 78.
installed as Tray 2.
Close Tray 3 E5: HCF Cover Close 2000-Sheet

2000-Sheet Feeder rear cover feeder rear cover.
Rear Door
interlock switch is open Go to RAP 18,
Comment: 2000-Sheet Feeder page 78.
Close Covers E5: Close Cover Close Top Cover.

1. Top cover interlock is open. Close Rear Cover.
2. Rear cover interlock is open.
Go to RAP 16,
page 74.
Insert MBF E5: MBF Extend Close MBF.

MBF Assy. is not closed. Go to RAP 17,
page 76.


Log Comment
Duplex Jam E7-1 E7: Duplex Jam Open the Rear Cover
Open Rear Cover 1. Duplex Sensor is not actuated within and remove any paper.
the time after the start of the Duplex Go to RAP 20,
Clear Paper Path drive motor in reverse. page 82.
2. Duplex Sensor is being actuated at
Power-Up.
3. Duplex Sensor is on when the
interlock is closed.
Stacker Jam E8-1 E8-1 HCS Jam Open HCS rear door
Open Rear Cover 1. HCS Sensor did not actuate within and remove any paper.
time after the actutation of the Exit Open Rear cover and
Open Stacker sensor. remove any paper.
Door 2. HCS Sensor is not deactuated
within time after actuation of HCS Go to RAP 21,
Clear Paper Path Sensor. page 84.
3. HCS Sensor is actuated at power
on.
Comment: Jam in the HCS
Duplex Unit Fail E9-1 E9: Duplex Fail Reinstall Duplex

or Removed Duplex module removed while power Module
is on. Go to RAP 22,
page 86.
Stacker Bin Fail E9-2 E-9: Reinstall HCS

Power Off/On HCS removed while power is on. Go to RAP 23,
page 88.
Tray 2 Failure E9-3 E-9: HCF Fail Reinstall HCF

Power Off/On 2000-Sheet Feeder removed while Go to RAP 24,
power is on. page 89.
Comment: 2000-Sheet Feeder
Tray 3 Failure E9-3 E-9: HCF Fail Reinstall HCF

Power Off/On 2000-Sheet Feeder removed while Go to RAP 24,
power is on. page 89.
Comment: 2000-Sheet Feeder
Install J3: EP Cartridge Install the Print

Print Cartridge is not installed. Cartridge, or replace
Print Cartridge
with the correct Print
Cartridge.
Go to RAP 27,
page 92.


Log Comment
Toner Low J5 J5: Toner Low Replace Print
Toner Low is detected after 10 prints Cartridge.
while toner sensor is on. Go to RAP 25,
page 90.
Go to RAP 26,
page 91.
Replace Print J6-1 Print Cartridge Life Expired Replace Print

Cartridge Cartridge.
Go to RAP 27,
page 92.
Print Cartridge J8-1 Print Cartridge ID Incorrect Install correct Print

OEM ID Cartridge.
Mismatch
Go to RAP 28,
page 93.
Paper Size Jam PSE-1 Paper Size Error Correct the mismatch.
Open Rear Cover There is a conflict between the size of Go to RAP 29,
the paper, which is detected by the page 94.
Size Switches, and the length of paper
the printer detects by the length of
time the Registration Sensor is
actuated.
Motor Failure U1 U1: Motor Fail Power Off/On.

Power Off/On Motor Fail signal is declared 0.75 Go to RAP 30,
seconds after start of Main Motor. page 96.
Laser Failure U2 U2: Laser Fail Power Off/On.

Power Off/On 1. Laser Signal intervals are longer Go to RAP 31,
than the Ready time interval 20 page 98.
seconds after the start of Laser
warm up.
2. The laser power does not reach the
value in NVM when the laser diode
is switched on after the start of Laser
warm up.
3. Laser signal intervals become
longer than the Fail time interval
after Laser warm up is completed.
Fuser Failure U4 U4: Fuser Fail Power Off/On.

Power Off/On 1. Fuser temperature drops below the Go to RAP 32,
set temperature after the Fuser page 100.
warm up is complete.
2. Fuser warm up does not complete
within 110 seconds.
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.


Log Comment
Fan Failure U5 U5: Fan Fail Check the Fuser Fan
Power Off Now 1. Fuser Fan has failed. and the LVPS Fan.
2. LVPS Fan has failed. Power Off/On.
Go to RAP 33,
page 101.
IOT NVM Fail U6 U6: NVM Fail Power Off/On.

Power Off/On 1. A read error is detected during Go to RAP 37,
power on. page 105.
2. A write error is detected during write
to the Nonvolatile Memory.
0101-DIMM 1 DIMM in slot J4 has failed. Go to RAP 34,

page 102.

page 103.

page 104.

RAP 1 Error Code C3: Insert Tray 1
The Tray 1 Assembly is not in place.
Table 19 Error Code C3: Insert Tray Troubleshooting Procedure

1 REMOVE & REINSTALL TRAY 1 Go to Problem
Completely remove and reinstall Tray. Step 2. solved.
Does the Insert Tray 1 message still appear?
2 PAPER STACK END GUIDE INSPECTION Go to Go to
Inspect the Paper Stack End Guide position in the tray. Step 4. Step 3.
Is the End Guide snug against the paper stack?
3 END GUIDE ADJUSTMENT Problem Go to
1. Adjust the End Guide to contact the paper stack. solved. Step 4.
2. Reinsert Tray and observe the Control Panel display.
Does adjusting the End Guide clear the Insert
Tray 1 message?
4 PAPER SIZE TEST Replace Go to
1. Enter Diagnostics Mode. Print Engine Step 5.
2. From the Main Menu, select Component Test / Tray 1 Controller
Size / press [4]. Board
Does the paper size indicated on the LCD match [RRP 8.5,
the paper size in Tray 1? page 310]. If
problem still
exists,
replace
System
Controller
Board
[RRP 8.1,
page 305].
5 TRAY SIZE SENSOR TEST Go to Go to

1. Remove Tray 1. Step 6. RAP 54,
2. Enter Diagnostics Mode. page 142.
3. From the Main Menu, select Component Test / Sensor
Input / press [4] to start the test.
4. Press and release each of the Tray 1 size sensor
actuators, while observing the LCD.
Does the LCD counter increment with each
actuation of a size sensor?
6 PAPER TRAY SIZE CAM INSPECTION Go to Replace
Inspect the size cam on the left side of the paper tray for Step 7. Tray 1
cracks or breakage and free rotation when the Paper [PL 2.1,
Tray End Guide is moved page 386 /
PL 2.2,
Is the cam in good condition and does it rotate page 388].
freely when the Paper Tray End Guide is moved?

Table 19 Error Code C3: Insert Tray Troubleshooting Procedure (cont'd.)

7 OBSERVING PAPER SIZE ACTUATORS Replace the Replace
1. Remove the Left Side Cover (RRP 1.1, page 250). Tray 1 Left Tray 1
2. As you insert Tray 1, observe the size actuators Guide [PL 2.1,
(visible under the Print Engine Controller Board metal Assembly page 386 /
cover) move depending on the setting of Tray 1 [see [RRP 3.5, PL 2.2,
Table 20below]. page 277]. page 388] If
Do the Tray 1 Size Cams contact the Paper Size still NO,
Actuators correctly for each size of paper? replace
Tray 1 Left
Guide
Assembly
[RRP 3.5,
page 277].
8 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.
■ Wiring and connectors linking the components
■ Paper Tray and components
■ Print Engine Controller Board [RRP 8.5, page 310]
■ System Controller Board [RRP 8.1, page 305]
Table 20 Paper Size Actuators
8.5” A4 B5 A5 14” 8.5” A4 B4

Actuator LEF LEF LEF LEF SEF SEF SEF SEF
4 Top X X X X X
3 X X X X X
2 X X X X
1 Bottom X X X X

RAP 2 Error Code C3: Insert Tray 2
Insert Tray 3
.
Troubleshooting Procedure

1 REMOVE & REINSTALL TRAY 2/3 Go to Problem
Remove and reinstall the paper tray. Step 2. solved.
Does the Insert Tray 2/3 still appear?
2 PAPER STACK END GUIDE INSPECTION Go to Adjust the
Inspect the Paper Stack End Guide position in the tray. Step 3. position of
the End
Is the End Guide snug against the paper stack? Guide.
3 PAPER SIZE CHECK Replace the Go to

1. Enter Diagnostics mode. Print Engine Step 4.
2. From the Main Menu, select Component Test / Tray 2 Controller
Size (or Tray 3 Size) / press [4]. Board
Does the paper size indicated on the LCD match [RRP 8.5,
the paper size actually in Tray 2 (or Tray 3)? page 310].
4 PAPER SIZE SENSOR TEST Go to Go to

1. Remove the paper tray. Step 5. RAP 54
2. Scroll to Sensor Input / press [4]. (Size
3. One at a time, press and release each of the size Switch),
actuators for the problem tray. page 142.
Does the LCD counter increment each time you
press and release one of the actuators?
5 SIZE CAM INSPECTION Go to Replace
Inspect the Size Cam on the left side of the Paper Tray. Step 6. Tray 1
[PL 2.1,
Are the cams in good condition (not broken or page 386 /
damaged) and rotate freely as the paper tray end PL 2.2,
guide is moved? page 388].
6 LEFT GUIDE ASSEMBLY Replace the Replace

1. Remove the 500-Sheet Feeder Left Cover [RRP 11.3, Tray 2/3 Left Tray 1
page 330]. Guide [PL 2.1,
2. As you insert the paper tray, watch the size actuators Assembly page 386 /
move depending on the setting of paper tray. See [RRP 11.13, PL 2.2,
Table 2 below. page 340]. page 388].
Do the Tray 2/3 size cams contact the Paper Size If problem
Actuators correctly for each size of paper? persists,
replace the
Tray 2/3 Left
Guide
Assembly
[RRP 11.13,
page 340].

Troubleshooting Procedure (cont'd.)

■ Tray 2/3 [PL 2.1, page 386; PL 2.2, page 388]
■ Left Guide Assembly [RRP 11.13, page 340]
8.5" A4 B5 A5 14" 8.5" A4 B4

4 Top X X X X X
3 X X X X X
2 X X X X
1 Bottom X X X X

RAP 3 Error Code C3-2E: Tray 2 Failure
Power Off / On
Error Code C3-3E: Tray 3 Failure
Power Off / On
The 2000-Sheet Feeder Tray Assembly has not been set.

1 PROCEDURE Go to Problem
Open and close the 2000-Sheet Feeder Tray Assembly. Step 2. solved.
Does the Insert Tray 2/3 message still appear?
2 STOPPER LINK Go to Replace the
1. Open the 2000-Sheet Feeder Tray Assembly. Step 3. Stopper Link
2. Manually push the actuator of the Stopper Link [RRP 12.17,
[RRP 12.17, page 369]. page 369].
3. Make certain the front side of the Nudger Support
Assembly lowers each time you press the Stopper
Link.
Does the Nudger Support Assembly lower each
time you press the Stopper Link?
3 STOPPER LINK Replace the Go to
2. From the Main Menu, select Component Test / Sensor Controller
Input / press [4] to start, [0] to stop. Board
3. Manually push the actuator of the Stopper Link [RRP 8.5,
[RRP 12.17, page 369]. page 310].
press the Stopper Link?
4 “NO” FROM STEP 3 ABOVE Go to Go to
1. Switch printer power OFF. Step 7. Step 5.
2. Open the 2000-Sheet Feeder Tray Assembly.
3. Remove the Lower Rear Cover.
4. Disconnect P/J603 form the 2000-Sheet Feeder
Board.
5. Switch printer power ON.
6. Measure the voltage between P/J603-3 and frame
ground.
Does the voltage measure +3.2 VDC?
5 “NO” FROM STEP 4 ABOVE Replace the Go to
Measure the voltage between P601-1 and frame 2000-Sheet Step 6.
ground. Feeder
Board
Does the voltage measure +3.2 VDC? [RRP 12.8,
page 360].


6 “NO” FROM STEP 5 ABOVE Replace the Replace the
Check for continuity between P/J13-1 and P601-1. Print Engine 2000-Sheet
Controller Feeder
Is there continuity between the pins? Board Harness
[RRP 8.5, [PL 12.2,
page 310]. page 420] or
Feeder
Harness
[PL 9.1,
page 404] as
necessary.
7 “YES” FROM STEP 4 ABOVE Replace the Replace the

1. Switch printer power OFF. Print Engine Paper
2. Reconnect P/J603 to the Feeder Board. Controller Height
3. Switch printer power ON. Board Sensor
4. Measure the voltage between P/J603-3 and frame [RRP 8.5, [RRP 12.15,
ground. page 310]. page 367].
5. Press and release the Stopper Link.
Does the voltage measure +3.2 VDC when the
link is released and 0.0 VDC when the link is
pressed?
■ Stopper Link [RRP 12.17, page 369]
■ 2000-Sheet Feeder Board [RRP 12.8, page 360]
■ 2000-Sheet Feeder Harness [PL 12.2, page 420]
■ Feeder Harness [PL 9.1, page 404]
■ Paper Height Sensor [RRP 12.15, page 367]

RAP 4 Load MBF / Load Tray 1 / Load Tray 2 /
Load Tray 3
Logic Control on the Print Engine Controller Board detected a problem where a false
message to add paper to the MBF or a Paper Tray appears on the LCD.
Table 24 Add Paper to MBF, Tray 1, 2 or 3 Message Troubleshooting

Procedure

1 Does this problem appear only when using Go to Go to
Tray 2 or Tray 3? RAP 5, Step 2.
page 50,
[500-Sheet
Feeder].
Go to
RAP 8,
page 58,
[2000-Sheet
Feeder].
2 TRAY 1 PAPER LEVEL Go to Load paper

Inspect the paper level in Tray. Step 3. into Tray 1.
Are there at least 100 sheets of paper in Tray 1?
3 MBF PAPER LEVEL Go to Load paper
Inspect the paper level in the MBF. Step 4. into the
MBF.
Is there paper in the MBF?
4 MBF TRAY TEST PRINT Go to Go to
1. Enter Diagnostics mode. Step 9. Step 5.
2. From the Main Menu, select Test Print / Input Tray /
MBF / press [4] to select MBF as Input Tray.
3. From the Main Menu, select Test Print / Print Pattern /
press [4] to generate a test print.
Does the Load MBF message appear when you
feed paper from the MBF?
5 TRAY 1 TEST PRINT Go to Return to
1. Enter Diagnostics mode. Step 6. Service Flow
2. From the Main Menu, select Test Print / Input Tray / Chart.
Tray 1 / press [4] to select Tray 1 as Input Tray.
Does the Load Tray 1 message appear when you
feed paper from Tray 1?
6 BOTTOM PLATE INSPECTION Go to Replace the
1. Remove Tray 1 from the printer. Step 7. Tray 1
2. Remove the Tray Cover, if installed, and all paper from Assembly
the tray. [PL 2.1,
3. Insert Tray into the printer and inspect the Bottom page 386;
Plate. PL 2.2,
Is the bottom plate raised fully and evenly? page 388].

Table 24 Add Paper to MBF, Tray 1, 2 or 3 Message Troubleshooting
Procedure (cont'd.)

7 TRAY 1 NO PAPER & LOW PAPER SENSOR Go to Replace the
ACTUATORS CHECK Step 8. Tray 1 No
1. Remove Tray 1. Paper
2. Manually actuate the Tray 1 No Paper and Low Paper Sensor
sensor actuators. Actuator
[RRP 2.6,
Note: When checking the Low Paper Sensor using
the Sensor Test, at least one Paper Size page 266] or
switch and the Low Paper Sensor must be Low Paper
actuated. Sensor
Actuator
Do the No Paper and Low Paper Sensor [PL 3.1,
Actuators move smoothly? page 390].
8 TRAY 1 NO PAPER & LOW PAPER SENSORS Replace the Go to

CHECK Print Engine RAP 43,
1. Enter Diagnostics mode. Controller page 119
2. From the Main Menu, select Component Test / Sensor Board [Low Paper]
Input / press [4] to start test, [0] to stop. [RRP 8.5, or RAP 53,
3. Manually actuate the Tray 1 No Paper and Low Paper page 310]. page 140
Sensors. [No Paper].
actuate one of the actuators?
9 MBF NO PAPER SENSOR ACTUATOR CHECK Go to Replace the
Insert, then remove a sheet of paper into the MBF. Step 10. actuator.
Does the MBF No Paper Actuator move smoothly
when paper is inserted, then removed?
10 MBF NO PAPER SENSOR CHECK Replace the Go to
1. Enter Diagnostics mode. Print Engine RAP 51,
2. From the Main Menu, select Component Test / Sensor Controller page 137.
Input / press [4] to start test, [0] to stop. Board
3. Insert, then remove a sheet of paper into the MBF [RRP 8.5,
while observing the LCD. page 310].
Does the LCD counter increment when you
insert, then remove the paper from the MBF?
■ MBF Tray and components

RAP 5 Load Tray 2 / Load Tray 3
Tray 2 or Tray 3 is out of paper.
Table 25 Add Paper To 500-Sheet Feeder


1 PAPER LEVEL Go to Load paper
Check the paper level in the indicated Tray Assembly. Step 2. into the Tray.
Is there paper in the indicated tray?
2 TRAY 2/3 BOTTOM PLATE Go to Replace the
1. Remove the tray from the 500-Sheet Feeder Step 3. Tray [PL 2.1,
Assembly. page 386 /
2. Remove the Tray Cover and all paper from the tray. PL 2.2,
3. Insert the Tray into the 500-Sheet Feeder Assembly page 388].
and inspect the Bottom Plate.
Is the bottom plate raised?
3 NO PAPER SENSOR ACTUATOR Go to Replace the
1. Remove the Paper Tray. Step 4. No Paper
2. Manually actuate the No Paper Sensor Actuator. Sensor
Actuator
Does the No Paper Sensor Actuator move [RRP 11.20,
smoothly?
page 350].
4 NO PAPER SENSOR Replace the Go to

3. Press and release the No Paper Sensor Actuator. [RRP 8.5,
Does the LCD counter increment when you press page 310].
and release the actuator?
5 “NO” FROM STEP 4 ABOVE Go to Check for
1. Switch printer power OFF. Step 6. continuity
2. Remove the 500-Sheet Feeder Left Cover [RRP 11.3, between
page 330]. P/J133 &
3. Disconnect P/J 133, and switch printer ON. P/J13A, then
4. Measure the voltage between P133-4 and frame between
ground, then between P133-6 and frame ground. P/J13A &
Do both voltages measure +3.2 VDC? P/J134.
Repair or
replace as
necessary. If
the harness
checks OK,
replace the
No Paper
Sensor
[RRP 11.19,
page 348].

Table 25 Add Paper To 500-Sheet Feeder

6 “YES” FROM STEP 5 ABOVE Go to Replace the
1. Switch printer power OFF. Step 7. Feeder
2. Reconnect P/J133. Board
3. Switch printer power ON. [RRP 11.7,
4. Measure the voltage between P/J133-6 and frame page 334].
ground as you actuate and deactuate the No Paper
Sensor.
Does the voltage measure +3.2 VDC when
deactuated and 0.0 VDC when actuated?
Measure the voltage between P/J132-7 and frame Step 8. Feeder
ground as you actuate and deactuate the No Paper Board
Sensor. [RRP 11.7,
page 334].
deactuated and +2.76 VDC when actuated?
8 “YES” FROM STEP 7 ABOVE Replace the Check for
1. Switch printer power OFF. Print Engine continuity
2. Remove the printer Left Side Cover [RRP 1.1, Controller between
page 250] and the Print Engine Controller Board Board P/J132 &
Cover [RRP 8.5, page 310]. [RRP 8.5, P/J131, then
3. Switch printer power ON. page 310]. between
4. Measure the voltage between P/J13-7 and frame P/J131 &
ground as you actuate and deactuate the No Paper P/J13.
Sensor.
Repair or
Does the voltage measure +0.9 VDC when replace as
deactuated and +2.76 VDC when actuated? necessary.
■ Feeder Board [RRP 11.7, page 334]
■ No Paper Sensor [RRP 11.19, page 348]
■ Paper Tray [PL 2.1, page 386 / PL 2.2, page 388]

RAP 6 Error Code C5: Remove Output
From Std. Bin
Error code indicates the Standard Bin is full.
Table 26 Error Code C5: Standard Bin Full


1 STACK FULL SENSOR TEST It appears Go to
1. Enter Diagnostics mode. the HCS Step 2.
2. From the Main Menu, select Component Test / Sensor Stack Full
Input / press [4] to start, [0] to stop. Sensor is
3. Actuate and deactuate the Stack Full Sensor Actuator. working
Does the LCD counter increment each time you correctly. If a
press and release the actuator? problem
persists,
replace the
Print Engine
Controller
Board
[RRP 8.5,
page 310].
2 STACK FULL SENSOR ACTUATOR INSPECTION Go to Replace the

Visually inspect the Stack Full Sensor Actuator. Step 3. Stack Full
Sensor
Does the actuator move freely and appear to be Actuator
in good condition (not broken or damaged)? [RRP 5.4,
page 294].
3 “YES” FROM STEP 2 ABOVE Go to Go to

2. Remove the Left Side Cover [RRP 1.1, page 250 and
the Print Engine Controller Board Cover [RRP 8.5,
page 310].
3. Disconnect P/J19 from the Print Engine Controller
Board.
ground, then between P/J19-13 and frame ground.
Do both voltages measure +3.3 VDC?
Measure the voltage between P/J16-4 and frame Print Engine LVPS
ground. Controller [RRP 8.6,
Board page 312].
page 310].


5 “YES” FROM STEP 3 ABOVE Replace the Go to
1. Switch printer power OFF. Print Engine Step 6.
2. Reconnect P/J19 to the Print Engine Controller Board. Controller
3. Enter Diagnostics mode. Board
4. From the Main Menu, select Component Test / Sensor [RRP 8.5,
Input / press [4] to start, [0] to stop. page 310].
5. On the Print Engine Controller Board, measure the
voltage between P/J19-13 and frame ground.
Does the voltage measure +3.3 VDC between
P19-13 and frame ground when the Stack Full
Sensor is deactuated and 0.0 V when actuated?
2. Open the Rear Cover.
3. Disconnect P/J527 (3-pin connector on HVPS Cover).
7 “NO” FROM STEP 6 ABOVE Go to Repair or
1. Switch printer power OFF. Step 8. replace the
2. Remove the HVPS Cover [RRP 8.2, page 307]. harness
3. Check for continuity between P/J502 and P/J527 as [PL 9.1,
follows: page 404] as
■ J527-1 and J502-1 necessary.
■ J527-2 and J502-2
■ J527-3 and J502-3
Is there continuity between each of the pins?

8 “YES” FROM STEP 7 ABOVE Replace the Repair or
1. Disconnect P/J501 from the Duplex Interface Board Duplex replace the
and P/J19 from the Print Engine Controller Board. Interface Duplex
2. Check for continuity between P/J501 and P/J19 as Board Interface
follows: [RRP 8.3, Harness, as
■ J501-1 and J19-13 page 308]. necessary
■ J501-2 and J19-12 [PL 9.1,
■ J501-3 and J19-11
page 404].
1. Switch printer power OFF. Full Stack replace the
2. Disconnect P/J507 from the Full Stack Sensor. Sensor Full Stack
3. Check for continuity between P/J507 and P/J527 as [RRP 5.2, Sensor
follows: page 289]. Harness
■ J507-1 and J527-3 [PL 6.1,
■ J507-2 and J527-2 page 398 as
■ J507-3 and J527-1
necessary.


■ Stack Full Sensor Actuator [RRP 5.4, page 294]
■ Stack Full Sensor [RRP 5.2, page 289]
■ LVPS [RRP 8.6, page 312]
■ Duplex Interface Board [RRP 8.3, page 308]
■ Duplex Interface Harness [PL 9.1, page 404]
■ Stack Full Sensor Harness [PL 6.1, page 398]

RAP 7 Error Code C5: Remove Output
From Stacker Bin
Error code indicates the Stacker Bin is full.
Table 27 Error Code C5: Stacker Bin Full

1 STACK FULL SENSOR TEST It appears Go to
1. Enter Diagnostics mode. the Stack Step 2.
2. From the Main Menu, select Component Test / Sensor Full Sensor
Input / press [4] to start, [0] to stop. is working
3. Actuate and deactuate the Stack Full Sensor Actuator. correctly. If a
Does the LCD counter increment each time you problem
press and release the actuator? persists,
replace the
Print Engine
Controller
Board
[RRP 8.5,
page 310].
2 STACK FULL SENSOR INSPECTION Go to Replace the

Visually inspect the Stack Full Sensor Actuator. Step 3. HCS Stack
Full Sensor
Does the actuator appear to be in good condition Actuator
(not broken or damaged) and does it move freely [RRP 10.7
when actuated? page 324].

2. Remove the Left Side Cover [RRP 1.1, page 250] and
page 310].
Board.
5. ON the Print Engine Controller Board, measure the
voltage P19-11 and frame ground, then between
P19-13 and frame ground.
Board page 312].
page 310].


5. ON the Print Engine Controller Board, measure the
voltage between P/J19-13 and frame ground while
actuating and deactuating the Stack Full Sensor
Actuator.
Stack Full Sensor is deactuated and 0.0 VDC
when actuated?
3. Disconnect P/J527 (3-pin connector on HVPS Cover).
7 “NO” FROM STEP 6 ABOVE Go to Repair or
1. Switch printer power OFF. Step 8. replace the
2. Remove the HVPS Cover [RRP 8.2, page 307]. HCS Stack
3. Check for continuity between P/J502 and P/J527 as Full Sensor
follows: Harness
■ J527-1 and J502-1 [PL 6.1,
■ J527-2 and J502-2 page 398],
■ J527-3 and J502-3
as
Is there continuity between the pins? necessary.

1. Disconnect P/J501 from the Duplex Interface Board Duplex replace the
and P/J19 form the Print Engine Controller Board. Interface Duplex
2. Check for continuity between P/J501 and P/J19 as Board Interface
follows: [RRP 8.3, Harness
■ J501-1 and J19-13 page 308]. [PL 9.1,
■ J501-2 and J19-12 page 404],
■ J502-3 and J19-11
as
Is there continuity between each of the pins? necessary.

1. Switch printer power OFF. HCS Stack replace the
2. Disconnect P/J507 from the Stack Full Sensor. Full Sensor HCS Stack
3. Check for continuity between P/J507 and P/J526 as [RRP 10.6, Full Sensor
follows: page 323]. [RRP 10.6]
■ J507-1 and J527-3 or the Stack
■ J507-2 and J527-2 Full Sensor
■ J507-3 and J527-1
Harness
Is there continuity between the pins? [PL 10.2,
page 410],
as
necessary.


■ HCS Stack Full Sensor Actuator [RRP 10.7, page 324]
■ HCS Stack Full Sensor [RRP 10.6, page 323]
■ Stack Full Sensor Harness [PL 10.2, page 410]

RAP 8 Load Tray 2 / Load Tray 3
The last sheet of paper was fed.
Table 28 Add Paper to 2000-Sheet Feeder

1 PROCEDURE Go to Add paper to
Open the 2000-Sheet Feeder paper tray. Step 2. the tray and
close.
Is there paper in the tray?
2 NO PAPER SENSOR ACTUATOR Go to Replace the
1. Open the 2000-Sheet Feeder Tray Assembly. Step 3. No Paper
2. Inspect the No Paper Sensor Actuator. Sensor
Actuator
Is the actuator in good condition and does it
[RRP 12.19,
move freely?
page 371].
3 NO PAPER SENSOR TEST Replace the Go to Step 4

1. Enter Diagnostics mode. Print Engine
3. Manually push the No Paper Sensor Actuator up and [RRP 8.5,
release. page 310].
press and release the No Paper Sensor
Actuator?
2. Open the 2000-Sheet Feeder Tray Assembly.
4. Disconnect P/J602 from the 2000-Sheet Feeder
Board.
ground.
Measure the voltage between P601-1 and frame 2000-Sheet Step 6.
ground. Feeder
Board
page 360].

2. Check for continuity between P/J13-1 and P601-1. Controller
Board
Is there continuity between the pins?
[RRP 8.5,
page 310].

Table 28 Add Paper to 2000-Sheet Feeder

1. Switch printer OFF. Print Engine No Paper
2. reconnect P/J602 to the Feeder Board. Controller Sensor
3. Switch printer power ON. Board [RRP 12.18,
4. Measure the voltage between P/J602-3 and frame [RRP 8.5, page 370].
ground. page 310].
5. Press and release the No Paper Sensor Actuator.
actuator is released and 0.0 VDC when the
actuator is pressed?
■ No Paper Sensor Actuator [RRP 12.19, page 371]
■ No Paper Sensor [RRP 12.18, page 370]

RAP 9 Error Code E1-1: Paper Jam
Open Top Cover
There is a paper jam between the Paper Tray / Paper Handler Assembly and the
Registration Sensor.
Table 29 Error Code E1-1: Paper Jam Tray to Registration

1 REGISTRATION SENSOR ACTUATOR Remove Go to
INSPECTION foreign Step 2.
Inspect the Registration Sensor Actuator. material.
Is there foreign material blocking the
Registration Sensor Actuator?
2 REGISTRATION SENSOR TEST Replace the Go to
Input / press [4] to start test, [0] to stop. Board
3. Manually actuate the Registration Sensor Actuator (RRP 8.5,
actuate the Registration Sensor Actuator?
3 REGISTRATION CLUTCH TEST Replace the Go to
1. From the Main Menu, select Component Test / Reg Print Engine RAP 39,
Clutch / press [4] to test. Controller page 112.
2. Listen for the Registration Clutch to actuate and Board
deactuate. (RRP 8.5,
Did the Registration Clutch actuate & deactuate? page 310].
Print Engine Controller Board [RRP 8.5,
page 310].

RAP 10 Error Code E2-1M: Paper Jam
Open Top Cover
Error Code E2-11: Tray 1 Jam
Open Tray 1
There is a paper jam between the Tray 1 or MBF and the Registration Sensor.
Table 30 Error Code E2-1: Paper Jam Troubleshooting Procedure

1 TEST PRINTS Go to Go to
MBF, Tray 1, 2 or 3 / press [4] to select as Input Tray.
4. Run 10 test prints.
5. Repeat sub-steps 1~4 above for all paper feed trays
and run 10 test prints from each tray.
Does the problem appear only when feeding
from Tray 1?
2 Is the paper curled, damaged or damp? Replace with Go to
fresh, dry Step 3.
paper.
3 Is the paper size within specifications? Go to Replace with

Step 4. paper within
size specs.
4 MBF FEED ROLLERS CHECK Go to Go to

1. Open the MBF door. Step 6. Step 5.
2. Enter Diagnostics mode.
MBF / press [4] to select MBF as Input Tray.
5. Observe the MBF Feed Rollers.
Do the MBF Feed Rollers rotate one complete
turn?
5 MBF GEAR AND SPRING INSPECTION Go to Replace
1. Remove the MBF Assembly [RRP 2.1, page 259]. RAP 57, defective
2. Remove MBF Gear Cover and inspect the gears for page 149. gears or
cracks, broken or missing teeth. Also, inspect the spring.
return spring for the MBF Feed Roller Shaft Gear.
Are the MBF gears and spring OK?
6 MBF TRAY INSPECTION Replace the
1. Remove the MBF Assembly [RRP 2.1, page 259]. MBF
2. Inspect the paper tray for a broken, bent or missing 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?

Table 30 Error Code E2-1: Paper Jam Troubleshooting Procedure (cont'd.)

7 BOTTOM PLATE INSPECTION Go to Replace the
1. Remove Tray 1 and remove all paper. Step 8. tray
2. Open the printer Top Cover, remove the Print assembly.
Cartridge and extend the MBF to the paper load
position.
3. Insert the Tray Assembly into the printer and observe
the bottom plate.
Is the bottom plate raised?
8 Tray 1 FEED ROLLER TEST Go to Go to
1. Close the MBF. Step 9. Step 10.
2. Reinstall the Print Cartridge.
3. Close the Top Cover.
4. Remove Tray 1.
6. From the Main Menu, select Component Test / Main
Motor / press [4] to start test.
7. While the Main Motor is running, select Component
Test / Tray 1 Feed Sol / press [4] to test.
Note: It may be necessary to press [4] several times
to observe the rollers.
8. Observe the Tray 1 Feed Rollers.
Do the Feed Rollers rotate one complete
revolution?
9 RETARD CHUTE ASSEMBLY INSPECTION Go to Go to
1. Remove the Retard Chute Assembly [RRP 3.1, RAP 55, Step 10.
page 273]. page 145.
2. Inspect the retard holder and retard arm for damage.
Is the Retard Chute Assembly OK?
10 RETARD CHUTE / RETARD HOLDER Go to Problem
REPLACEMENT RAP 56, solved.
Replace the Retard Chute Assembly [RRP 3.1, page 147.
page 273] or the Tray 1 Retard Holder Assembly
[RRP 2.11, page 272] as necessary.
Does the problem persist?

RAP 11 Error Code E2-12: Tray 2 Jam
Open Tray 2
Open Tray 3
There is a paper jam between a 500-Sheet Feeder Assembly and the Registration
Sensor.
Table 31 Paper Jam / Misfeed 500-Sheet Feeder


1 PROCEDURE Go to Go to
1. Remove all of the paper from the problem paper tray Step 2. RAP 5,
and reinstall the paper tray. page 50.
scroll to the empty paper tray / press [4] to select.
4. Scroll to Print Pattern / press [4] to begin test prints, [0]
to stop.
Does the LCD display a C5 error code?
fresh, dry Step 3.
paper.

Step 4. paper within
size specs.
4 PROBLEM TRAY REPLACEMENT Go to Replace the

1. Remove problem paper tray and install Tray 1 into the Step 5. defective
problem feeder. Tray
2. Enter Diagnostics mode. Assembly.
3. From the Main Menu, select Test Print / Print Pattern / [PL 2.1,
press [4] to start test prints, [0] to stop. page 386 /
4. Print approximately twenty prints from the problem PL 2.2,
feeder. page 388].
Does the LCD display an E2-1 error code?
5 PROBLEM TRAY FEED ROLLER Go to Go to
1. Remove Tray 1 from problem feeder. Step 7. Step 6.
Motor / press [4] to start motor, [0] to stop.
4. Scroll to Tray 2 or Tray 3 Feed Sol / press [4].
5. Observe the problem tray feed rollers.
Do the feed rollers rotate one complete turn?
1. Remove the Left Cover [RRP 11.3, page 330] of the Step 8. RAP 65,
500-Sheet Feeder. page 167.
3. From the Main Menu, select Component Test / Turn
Roll Clutch / press [4]
Is the Feeder Motor rotating?

Table 31 Paper Jam / Misfeed 500-Sheet Feeder

7 TURN ROLLER SHAFT TEST Go to Remove the
1. Open the rear door of the 500-Sheet Feeder. Step 9. 500-Sheet
2. Enter Diagnostics mode. Feeder Feed
3. From the Main Menu, select Component Test / Turn Head
Roll Clutch / press [4] to start. Assembly
Is the Turn Roller Shaft rotating? [RRP 11.8,
page 335]
and inspect
the gears.
Replace all
defective
parts
[PL 11.2,
page 414].
8 RETARD CHUTE ASSEMBLY Remove the Replace the

1. Remove the 500-Sheet Feeder Retard Chute Rear Chute Retard
Assembly [RRP 11.13, page 340]. Assembly Chute
2. Inspect the retard holder and retard arm for damage. [RRP 11.12, Assembly
Is the Retard Chute Assembly OK? page 339]. [RRP 11.12,
Inspect the page 339].
Rear Chute
Assembly for
damaged,
missing or
broken Idler
Rollers and
Springs.
■ Feed Tray Assembly [PL 2.1, page 386 / PL 2.2,
page 388]
■ 500-Sheet Feeder Feed Head [RRP 11.8, page 335]
■ Rear Chute Assembly [RRP 11.12, page 339]

RAP 12 Error Code E2-12: Tray 2 Jam
Open Tray 2
Open Tray 3
A paper jam has occurred in the 2000-Sheet Feeder.

1. Open the 2000-Sheet Feeder Upper Rear Cover Step 2. solved.
Assembly.
2. Remove the Jammed paper.
3. Run a test print.
Does the error message still appear?
2 PAPER INSPECTION Go to Replace with
1. Pull out the 2000-Sheet Feeder Tray Assembly. Step 3. fresh paper
2. Check the paper condition and size. of the proper
size from an
Is the paper dry, in good condition and is the size unopened
within specifications?
ream.
3 FEED MOTOR ASSEMBLY Go to Replace the

1. Switch printer power OFF. Step 4. 2000-Sheet
2. Remove the 2000-Sheet Feeder Right Side Cover Feeder Feed
[RRP 12-5]. Motor
3. Open the Upper Rear Cover. Assembly
4. Manually rotate the top gear clockwise. [RRP 12.16,
5. Inspect the rotation of the 2000-Sheet Feeder Motor page 368] or
Assembly. gears.
Does the Feed Motor Assembly rotate smoothly?
4 REPLACE FEED ROLLER [RRP 12.14, page 366] Go to Problem
Run Test prints. Step 5. solved.
Does the Error Code still appear?
5 TOP GEAR ROTATION Go to Replace the
Manually rotate the top gear counterclockwise. Step 6. Feeder
Assembly
Does the 2000-Sheet Feeder Assembly rotate [PL 12.3,
smoothly and feed a sheet of paper from the page 422], if
Feeder Tray Assembly? it does not
rotate
smoothly.
6 DRIVE ASSEMBLY GEARS Go to Replace the

1. Remove the 2000-Sheet Feeder Tray Assembly Step 7. Drive
[RRP 12.7, page 359]. Assembly
2. Rotate the gears of the Drive Assembly. [RRP 12.13,
Do the gears of the Drive Assembly rotate page 365].
smoothly?


7 TEST PRINT Problem Replace the
Run a test print. solved. 2000-Sheet
Feeder
Has the E2-1 Error Code cleared? Board
[RRP 12.8,
page 360].
■ Feed Motor Assembly [RRP 12.16, page 368]
■ Feed Roller Assembly [RRP 12.14, page 366]
■ Drive Assembly [RRP 12.13, page 365]

RAP 13 Error Code E2-D: Duplex Jam
Open Rear Cover
There is a paper jam between the Duplex Assembly and the Registration Sensor when
the paper is re-fed to print a 2nd page.
Table 33 Error Code E2-D: Duplex Jam Troubleshooting Procedure

fresh, dry Step 2.
paper.
2 Is the paper size within specification? Go to Replace with

Step 3. paper
meeting size
specs.
3 25 TEST PRINTS Go to Go to
2. From the Main Menu, select Test Print / Duplex / On /
press [4] to set Duplex.
press [4] to start printing test pages, [0] to stop.
4. Print approximately 25 pages, or until the above
Paper Jam message appears and printing stops.
5. Open the Top Cover.
6. Remove the Print Cartridge.
7. Inspect the position of the paper.
Is the paper touching the Registration Sensor
Actuator?
4 DUPLEX MOTOR TEST Go to Replace
1. Enter Diagnostics mode. Step 5. Duplex
2. From the Main Menu, select Component Test / Dup Assembly
Motor On / press [4] to start the Duplex Motor, [0] to [RRP 9.1,
stop. page 404]. If
Does the Duplex Motor run? problem still
exists,
replace the
Print Engine
Controller
Board
[RRP 8.5,
page 310].
5 DRIVE BELT INSPECTION Replace Replace

Inspect the Duplex Drive Belt for breakage, missing Duplex Duplex Drive
teeth, or wear. Assembly Belt
[RRP 9.1, [PL 13.1,
Is the Drive Belt in good condition? page 317]. If page 426].
problem still
exists,
replace the
Print Engine
Controller
Board
[RRP 8.5,
page 310].

Table 33 Error Code E2-D: Duplex Jam Troubleshooting Procedure (cont'd.)

6 REGISTRATION SENSOR TEST Replace the Go to
Input Test / press [4] to start test, [0] to stop. Board
3. Manually actuate the Registration Sensor Actuator [RRP 8.5,
press and release the actuator?
■ Duplex Unit [RRP 9.1, page 317]

RAP 14 Error Code E3-1: Paper Jam /
Open Top Cover
There is a paper jam between the Registration Sensor and the Exit Sensor.

1 Is the paper loaded in the paper tray wrinkled or Replace Go to Step 2.
damaged? with fresh,
dry paper.

Step 3. paper
meeting size
specifications.
3 PAPER PATH INSPECTION Go to Go to Step 4.

1. Open the Rear Cover. Step 11.
2. Open the Rear Fuser Cover.
3. Inspection the position of paper when the error code
E3 is displayed.
Is the paper touching the Exit Sensor Actuator?
4 DRIVE TRAIN TEST Go to Replace the
1. Open the Top Cover. Step 5. Main Gear
2. Remove the Print Cartridge. Drive
3. Enter Diagnostics mode. Assembly
4. From the Main Menu, select Component Test / Main [RRP 6.1,
Motor / cheat the Top Cover Interlock and press [4] to page 295]
start motor. and/or the
Note: If continuing to Step 5, allow motor to run MBF Gears
until you complete the next step. [PL 4.1,
page 392]
5. Observe Gear Assembly, H/R Idler Gear and the MBF [PL 4.2,
Assembly Drive Gears. page 394].
Do the gears rotate smoothly?
5 REGISTRATION ROLLER TEST Go to Replace the
1. Continuing from Step 4, sub-step 5 above, from the Step 6. Paper
Main Menu, select Component Test / Reg. Clutch / Transport
press [4]. Assy.
2. Observe the Metal and Rubber Registration Rollers. [RRP 4.1,
3. Press [0] to stop test. page 283].
Do the Metal and Rubber Registration Rollers
rotate smoothly?
6 PAPER POSITION AT REGISTRATION ROLLERS Go to Go to
Inspect the paper position when E3 is displayed. Step 7. RAP 39,
page 112.
Has the front edge of the paper passed between
the Metal Registration Roller and the Rubber
Registration Roller?


7 PAPER HOLDING AT BTR AND PRINT Go to Replace the
CARTRIDGE DRUM Step 8. Paper
1. Remove the Fuser Assembly [RRP 5.1, page 288]. Transport
2. Install the Print Cartridge by first inserting a sheet of Assembly
paper between the BTR Assembly and the Print [RRP 4.1,
Cartridge Drum. page 283].
Do the BTR Assembly and the Print Cartridge
Drum hold the paper evenly?
8 PAPER PASSAGE AT BTR AND PRINT Go to Replace the
CARTRIDGE DRUM Step 9. Paper
1. Remove the paper inserted in Step 7, sub-step 2, Transport
above and reinstall the Print Cartridge. Assembly
2. Run a test print. [RRP 4.1,
3. Inspect the position of the front edge of the paper. page 283].
Has the front edge of the paper passed between
the BTR and the Print Cartridge Drum?
9 DETACK SAW INSPECTION Go to Clean the
Inspect the Detack Saw. Step 10. Detack Saw
or replace the
Is the Detack Saw clean and free of Paper
contamination? Transport
Assembly
[RRP 4.1,
page 283].
10 HEAT ROLLER IDLER GEAR TEST Go to Replace the

Rotate the Heat Roller Idler Gear. Step 11. Fuser
Assembly
Does the Heat Roller Idler Gear rotate smoothly? [RRP 5.1,
page 288].
11 PAPER PASSAGE AT EXIT ROLLER AND PINCH Go to Replace the

ROLLER OF FUSER Step 12. Fuser
1. Run a test print. Assembly
2. Inspect the paper path between the Paper Transport [RRP 5.1,
Assembly and the pinch roller of the Fuser Assembly. page 288].
Does the paper pass through the Exit Roller
Assembly and the pinch roller of the Fuser
Assembly?
12 FUSER EXIT SENSOR TEST Replace the Go to
1. Enter Diagnostics mode. Print RAP 67,
2. From the Main Menu, select Component Test / Sensor Engine 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].


■ Main Gear Drive Assembly [RRP 6.1, page 295]
■ MBF Gears [PL 4.1, page 392]
■ Paper Transport Assembly [RRP 4.1, page 283]
■ Fuser Assembly [RRP 5.1, page 288]

RAP 15 Error Code E4-0: Exit Jam Open
Rear and Top Cover
There is a paper jam at the Exit Sensor.
Table 35 Error Code E4: Exit Jam Troubleshooting Procedure

1 PAPER PATH INSPECTION AND TEST PRINTS Go to Go to
1. Inspect the paper path for paper, debris or foreign Step 3. Step 2.
material causing an obstruction.
4. Run 25 test prints from Tray 1.
When the E4 Exit Jam error code is displayed, is
there paper on the Exit Sensor?
2 EXIT SENSOR TEST Replace the Go to
3. Actuate and deactuate the Exit Sensor while [RRP 8.5,
observing the LCD. page 310].
3 Does the printer have the Duplex option Go to Go to
installed? Step 8. Step 4.
4 REAR COVER EXIT & PINCH ROLLERS CHECK Go to Go to

Motor / press [4] to start motor, [0] to stop.
Do the Exit Rollers and Pinch Rollers on the Rear
Cover rotate smoothly?
5 EXIT & FUSER DRIVE GEAR CHECK Replace Replace the
1. Remove the Left Side Cover [RRP 1.1, page 250]. Rear Cover Fuser
2. Enter Diagnostics mode. Assembly Assembly
3. From the Main Menu, select Component Test / Main [RRP 1.9, [RRP 5.1,
Motor / press [4] to start motor, [0] to stop. page 258. page 288].
4. Observe the Exit and Fuser Drive Gears.
6 RERUN TEST PRINTS Go to Problem
1. Enter Diagnostics mode. Step 7. solved.
press [4] to start test pages, [0] to stop.
Does the Error Code reappear?
7 FUSER INSPECTION Check the Clean or
Inspect the Fuser Assembly for obstructions or Exit replace the
contamination. Assembly. Fuser
Clean or Assembly
Is the Fuser Assembly clean and fee of replace as [RRP 5.1,
obstructions? necessary. page 288].

Table 35 Error Code E4: Exit Jam Troubleshooting Procedure (cont'd.)

8 EXIT AND PINCH ROLLERS CHECK Clean, or Go to
1. Enter Diagnostics mode. replace, the Step 9.
2. From the Main Menu, select Component Test / Exit Fuser
Motor Fwd L / press [4] to start test, [0] to stop. Assembly as
3. Observe the Exit and Pinch Rollers on the Rear Cover necessary
Assembly. [RRP 5.1,
Do the Exit Rollers and Pinch Rollers on the Rear page 288].
Cover Assembly rotate smoothly?
9 EXIT DRIVE MOTOR AND EXIT DRIVE GEARS Go to Go to
TEST Step 12. Step 10.
1. Remove the Left Side Cover [RRP 1.1, page 250].
3. From the Main Menu, select Component Test / Exit
Motor Fwd L / press [4] to start, [0] to stop.
4. Observe the Exit Drive Gears and Exit Motor L.
10 Does the Exit Motor Fwd L rotate? Go to Replace
Step 11. Duplex
Assembly
[RRP 9.1,
page 317].
11 EXIT MOTOR TEST Replace the Replace the

1. Open the Rear Cover. Rear Cover Duplex
2. Cheat the Rear Cover Interlock Switch. Assembly Assembly
3. Enter Diagnostics mode. [RRP 1.9, [RRP 9.1,
4. From the Main Menu, select Component Test / Exit page 258]. page 317].
Motor Fwd L / press [4] to start motor.
5. After a few seconds, press [0] to stop motor.
6. From the Main Menu, select Component Test / Exit
Motor Rev L / press [4] to start motor, [0] to stop.
Does the Exit Motor rotate smoothly in both
directions?
12 EXIT ASSEMBLY INSPECTION Go to Problem
1. Inspect the Exit Assembly for obstructions. Step 13. solved.
2. Clean all rollers in the Exit Assembly.
3. Replace Rear Cover Assembly, if necessary.
Does the Error Code reappear?
■ Duplex Assembly [RRP 9.1, page 317]
■ Rear Cover Assembly [RRP 1.9, page 258]

RAP 16 Error Code E5: Close Covers
The Top Cover or Rear Cover is open.
Table 36 Error Code E5: Close Covers Troubleshooting Procedure

1 OPEN CLOSE TOP COVER AND REAR DOOR Go to Problem
Open and close the Rear Cover and the Top Cover. Step 2. solved.
Is the error message still displayed?
2 REAR COVER Go to Realign or
1. Open the Rear Cover. Step 3. replace the
2. Slowly close the Rear Cover checking to ensure the Rear Cover
cover is actuating the Rear Cover Interlock Switch. [RRP 1-9,
Does the Rear Cover actuate the Interlock page 258].
Switch?
3 TOP COVER Go to Replace the
1. Open the Top Cover. Step 4. Top Cover
2. Slowly close the Top Cover check to ensure the cover [RRP 1.3,
is actuating the Top Cover Interlock Switch. page 252].
Does the Top Cover actuate the Interlock
Switch?
4 REMOVE LOWER REAR COVER Go to Go to
1. Switch printer power OFF. Step 5. RAP 40,
2. Remove the Lower Rear Cover [RRP 1.7, page 256]. page 114.
ground.
Does the voltage measure +24 VDC?
Measure the voltage between P/J162-3 and frame Print Engine Step 6.
ground. Controller
Board
Does the voltage measure +24 VDC? [RRP 8.5,
page 310].
6 “NO” FROM STEP 4 ABOVE Go to Check the

1. Switch printer power OFF. Step 7. wiring
2. Remove the Right Side Cover [RRP 1.2, page 251]. between the
3. Switch printer power ON. Rear Cover
4. Measure the voltage between the Top Cover Interlock Interlock
Switch, both terminals, (P/J623) and frame ground. Switch. If the
Do both voltages measure +24 VDC? wiring is OK,
replace the
Top Cover
Interlock
Switch
[RRP 7.4,
page 302].

Table 36 Error Code E5: Close Covers Troubleshooting Procedure (cont'd.)

7 “YES” FROM STEP 6 ABOVE Replace the Check the
Measure the voltage between the Rear Cover Interlock Print Engine wiring
Switch, both terminals orange wires (P/J621 and Controller between the
P/J622) and frame ground. Board Top Cover
[RRP 8.5, Interlock
Do both voltages measure +24 VDC? page 310]. Switch. If the
wiring is OK,
replace the
Rear Cover
Interlock
Switch
[PL 9.2,
page 406].
■ Top Cover [RRP 1.3, page 252]
■ Rear Cover [RRP 1.9, page 258]

RAP 17 Insert MBF
The Multi-sheet Bypass Feeder (MBF) is extended and is not in the home position.
Table 37 Insert MBF Troubleshooting Procedure

Extend and close the MBF. Step 2. solved.
Does the error code still appear?
2 MBF HOME SWITCH INSPECTION Go to Replace the
1. Extend the MBF and inspect the MBF Home Switch. Step 3. MBF Home
2. Manipulate the MBF Home Switch Actuator. Switch
[RRP 3.8,
Is the MBF Home Switch in good condition and
page 282].
does the actuator move freely?
3 MBF HOME SWITCH TEST Replace the Go to Step 4
1. Enter Diagnostics mode. Print Engine
3. Actuate and deactuate the MBF Home Switch. [RRP 8.5,
Does the LCD counter increment each time you page 310].
4 “NO” FROM STEP 4 ABOVE Go to Replace the
1. Switch printer power OFF. Step 5. Print Engine
2. Remove the Left Side Cover [RRP 1.1, page 250] and Controller
the Print Engine Controller Cover [RRP 8.5, Board
page 310]. [RRP 8.5,
3. Disconnect P/J20 from the Print Engine Controller page 310].
Board.
5. Measure the voltage between P20-1 and frame
ground.
Does the voltage between P20-1 and frame
ground measure +3.2 VDC?
1. Switch print power OFF. Print Engine MBF Home
2. Reconnect P/J20 to the Print Engine Controller Board. Controller Switch
4. Measure the voltage between P20-2 and frame [RRP 8.5, page 282].
ground as you actuate and deactuate the switch. page 310].
switch is actuated and 0.0 VDC when the switch
is deactuated?

Table 37 Insert MBF Troubleshooting Procedure (cont'd.)

■ MBF Home Switch [RRP 3.8, page 282]

RAP 18 Close Tray 2 Rear Door
Close Tray 3 Rear Door
The 2000-Sheet Feeder Rear Door is open.
Table 38 2000-Sheet Feeder Cover Open Troubleshooting Procedure

1 UPPER REAR COVER INTERLOCK SWITCH Go to Reinstall the
1. Manually open and close the 2000-Sheet Feeder Step 2. Interlock
Upper Rear Cover Assembly. Switch. If the
2. Make certain the Upper Rear Cover actuates the bracket is
Interlock Switch. deformed,
Does the 2000-Sheet Feeder Upper Rear Cover reshape or
Assembly actuate the Interlock Switch? replace the
bracket.
2 UPPER REAR COVER INTERLOCK SWITCH Replace the Go to

INPUT TEST Print Engine Step 3.
1. Enter Diagnostics mode. Controller
2. From the Main Menu, select Component Test / Sensor Board
Input / press [4] to start, [0] to stop. [RRP 8.5,
3. Open and close the 2000-Sheet Feeder Upper Rear page 310].
Cover.
open and close the cover?
1. Switch printer power OFF. Step 4. Upper Rear
2. Remove the 2000-Sheet Feeder Lower Rear Cover Cover
[RRP 12.4, page 356]. Interlock
3. Switch printer power ON. Switch
4. Check the voltage between P/J604-3 and frame [PL 12.2,
ground as you open and close the Upper Rear Cover. page 420].
cover is open and 0.0 VDC when the cover is
closed?
4 CONTINUITY CHECK Replace the Replace the
1. Switch printer power OFF. Print Engine appropriate
2. Remove the Left Side Cover [RRP 1.1, page 250] and Controller harness.
the Print Engine Controller Board [RRP 8.5, Board
page 310]. [RRP 8.5,
3. Disconnect P/J13 from the Print Engine Controller page 310],
Board and P/J604 form the 2000-Sheet Feeder or the
Board. 2000-Sheet
4. Check for continuity between the pins as follows:
■ P601-1 and P13-1
Feeder
■ P601-2 and P13-2 Board
■ P601-3 and P13-3 [RRP 12.8,
■ P601-4 and P13-13 page 360].
■ P601-5 and P13-10
■ P601-6 and P13-14
■ P601-7 and P13-15
Is there continuity between all pins measured?

Table 38 2000-Sheet Feeder Cover Open Troubleshooting Procedure (cont'd.)

■ Upper Rear Cover Interlock Switch [PL 12.2,
page 420]
■ Wiring and connectors linking the components)

RAP 19 Close Stacker Door
The Rear Cover is open.
Table 39 Close Stacker Door Troubleshooting Procedure

1 OPEN/CLOSE REAR COVER Go to Problem
Open and close the HCS Rear Cover. Step 2. solved.
Does the error code still appear?
2 REAR COVER INTERLOCK SWITCH Go to Replace the
INSPECTION Step 3. HCS Rear
Open the HCS Rear Cover and check the Rear Cover Cover
Interlock Switch. Interlock
Switch
Is the Rear Cover Interlock Switch in good [RRP 10.9,
condition and does the actuator move freely? page 326].
3 REAR COVER INTERLOCK SWITCH TEST Replace the Go to

3. Actuate and deactuate the Rear Cover Interlock [RRP 8.5,
Switch. page 310].
2. Remove the HCS Front Cover [RRP 10.4, page 321].
3. Disconnect P/J524 from the HCS Board.
ground.
Measure the voltage between P/J514-6 and frame HCS Board Step 6.
ground. [PL 10.2,
page 410].
the Print Engine Controller Board Cover [RRP 8.5, Board
page 310]. [RRP 8.5,
3. Measure the voltage between P/J19-11 and frame page 310].
ground.
Check for continuity between P/J19-11 and P/J501-3, Duplex replace the
then between P/J504-6 and P/J514-6. Interface HCS
Board Harness
Is there continuity between both sets of pins? [RRP 8.3, [PL 10.2,
page 308]. page 410].

Table 39 Close Stacker Door Troubleshooting Procedure (cont'd.)

1. Switch printer power OFF. Print Engine HCS Rear
2. Reconnect P/J524 to the HCS Board. Controller Cover
3. Switch printer power ON. Board Interlock
4. Measure the voltage between P524-1 and frame [RRP 8.5, Switch
ground as you actuate and deactuate the Rear Cover page 310]. [RRP 10.9,
Interlock Switch. page 326].
switch is deactuated and 0.0 VDC when the
switch is actuated?
■ HCS Rear Cover Interlock Switch [RRP 10.9,
page 326]
■ HCS Board [PL 10.2, page 410]
■ HCS Harness [PL 10.2, page 410]

RAP 20 Error Code E7-1: Duplex Jam
Open Rear Cover
There is a paper jam between the Exit Assembly and the Duplex Sensor.
Table 40 Error Code E7: Duplex Jam Troubleshooting Procedure

1 PAPER PATH Go to Clear all
Open the printer and check for paper or other Step 2. jammed
obstructions in the paper path. paper, paper
scraps, and
Is the printer free of jammed paper, paper scraps, obstructions
or other obstructions? from the
printer.
2 DUPLEX TEST PRINTS Go to Problem

1. Enter Diagnostics mode. Step 3. solved.
2. From the Main Menu, select Test Print / Duplex / On /
press [4].
3. Scroll to Print Pattern / press [4] to start, [0] to stop.
4. Run approximately 20 Duplex test prints.
Does the error code reappear?
3 DUPLEX MOTOR LOW Go to Replace
1. Open the Rear Cover and cheat the Rear Cover Step 4. Duplex
Interlock. Assembly
2. Enter Diagnostics mode. [PL 13.1,
3. From the Main Menu, select Component Test / Dup page 426].
Motor On Low / press [4].
Do the Duplex Motor and rollers turn smoothly at
low speed?
4 DUPLEX MOTOR HIGH Go to Replace
Scroll to Dup Motor On Hi / press [4]. Step 5. Duplex
Assembly
Do the Duplex Motor and rollers turn smoothly at [PL 13.1,
high speed? page 426].
5 DUPLEX SENSOR TEST Go to Go to

2. From the Main Menu, select Sensor Input / press [4]
to start, [0] to stop.
4. Actuate and deactuate the Duplex Sensor Actuator.
2. Remove the Left Side Cover [RRP 1.1, page 250 and
page 310].
Board.
ground.

Table 40 Error Code E7: Duplex Jam Troubleshooting Procedure (cont'd.)

2. Reconnect P/J19 to the Print Engine Controller Board.
4. Measure the voltage between P/J19-5 and frame as
you actuate and deactuate the Duplex Sensor
Actuator.
sensor is deactuated and 0.0 VDC when the
sensor is actuated?
8 CONTINUITY CHECK Replace the Repair or
1. Switch printer power OFF. Duplex replace the
2. Disconnect P/J19 from the Print Engine Controller Assembly. Duplex
Board and P/J501 from the Duplex Interface Board. Interface
3. Check for continuity between the pins as follows: Harness
■ P501-1 and P19-13 [PL 9.1,
■ P501-2 and P19-12 page 404].
■ P501-3 and P19-11
■ P501-4 and P19-10
■ P501-5 and P19-9
■ P501-6 and P19-8
■ P501-7 and P19-7
■ P501-8 and P19-6
■ P501-9 and P19-5
■ P501-10 and P19-4
■ P501-11 and P19-3
■ P501-12 and P19-2
■ P501-13 and P19-1

9 DUPLEX ROLLERS Go to Clean the
1. Remove the Duplex Assembly. Step 10. rollers as
2. Inspect the Duplex Assembly rollers for contamination necessary.
and wear.
Are the rollers clean and in good condition?
10 TEST PRINTS Replace the Problem
1. Replace the Duplex Assembly. Print Engine solved.
2. Run Duplex Test Prints per Step 2 above. Controller
Board
[RRP 8.5,
page 310].
■ Duplex Assembly [PL 13.1, page 426]
■ Duplex Interface Harness Assembly [PL 9.1,
page 404]

RAP 21 Error Code E8-1: Stacker Jam
Open Rear Cover
There is a paper jam at the HCS Sensor.
Table 41 Error Code E8-1: Stacker Jam Troubleshooting Procedure

1 Is the lead edge of the paper located within the Go to Go to Step 4.
Exit Assembly? Step 2.
2 EXIT GATE SOLENOID INSPECTION Go to Reinstall

1. Open Rear Cover. Step 3. and/or
2. Inspect the Exit Gate Solenoid for proper/secure reconnect
installation and for proper connection. the solenoid.
Is the Exit Gate properly installed and Go to Step 3.
connected?
3 EXIT GATE SOLENOID TEST Go to Replace Exit
1. Enter Diagnostics Mode. Step 4. Gate
2. Open Rear Cover and defeat the Rear Cover Interlock Solenoid.
Switch. [RRP 10.5,
3. From the Main Menu, select Component Test / Exit page 322].
Gate Sol / press [4], while observing the Exit Gate
Solenoid.
4. Press [4] again while observing the Exit Gate to
reverse its exit position.
Does the Exit Gate Solenoid change position
each time [4] is pressed?
4 TEST PRINT Go to Problem
1. Remove and reinstall the HCS Assembly [RRP 10.1, Step 5. solved.
page 318].
2. Run a simplex Test Print.
Does the Error Code E8-1 still appear?
5 Is the paper discharged from the top of the HCS Go to Go to Step 6.
Assembly? Step 7.
6 “NO” FROM STEP 2 ABOVE Go to Replace any

1. Rotate the 14/33T Idler Gear counter-clockwise Step 7. defective
manually. parts as
2. Observe for correct contact between the 14/33T Idler necessary
Gear and the 29T Gear. [PL 13.1,
Do all of the gears rotate smoothly? page 426].
7 “YES” FROM STEP 5 ABOVE Go to Go to Step 8.

1. Run a Test Print. Step 7.
2. Observe the rotation of the Inlet Roller.
Do the Inlet and Output Rollers rotate in the
same direction smoothly?

Table 41 Error Code E8-1: Stacker Jam Troubleshooting Procedure (cont'd.)

■ HCS Motor Assembly [RRP 10.8, page 325]
■ HCS Sensor [RRP 10.10, page 327]
■ HCS Assembly [RRP 10.1, page 318]

RAP 22 Error Code: E9-1 Duplex Unit Fail
or Removed
.

1 PROCEDURE Go to Replace the
the Print Engine Controller Board Cover [RRP 8-5, Board
page 310]. [RRP 8.5,
Board.
5. Measure the voltage between P19-4 on the Print
Engine Controller Board and frame ground.
3. Remove the HCS, if installed. Board
5. Measure the voltage between P19-4 on the Print page 310].
1. Switch printer power OFF. Duplex Duplex
2. Open the Rear Cover and remove the Duplex Assembly Interface
Assembly [RRP 9.1, page 404]. [PL 13.1, Board
3. Remove the HVPS Cover [RRP 8.2, page 307]. page 426]. If Harness
4. Disconnect P/J501 from the Duplex Interface Board problem [PL 9.1,
and P/J19 from the Print Engine Controller Board. persists, page 404].
5. Check for continuity between the following pins: replace the
■ P501-1 and P19-13
■ P501-2 and P19-12
Duplex
■ P501-3 and P19-11 Interface
■ P501-4 and P19-10 Board
■ P501-5 and P19-9 [RRP 8.3,
■ P501-6 and P19-8 page 308].
■ P501-7 and P19-7
■ P501-8 and P19-6
■ P501-9 and P19-5
■ P501-10 and P19-4
■ P501-11 and P19-3
■ P501-12 and P19-2
■ P501-13 and P19-1


■ Duplex Assembly [PL 13.1, page 426]
■ Wiring and connectors linking the components)

RAP 23 Error Code E9-2: Stacker Bin Fail
Power Off / On
.
Table 43 Error Code E9-2: Stacker Bin Fail Troubleshooting Procedure

1 +3.2 VDC CHECK Go to Go to
1. Switch print power OFF. Step 3. Step 2.
the Print Engine Controller Board [RRP 8.5,
page 310].
Board.
ground.
Board page 312].
page 310].

1. Switch printer power OFF. HCS Board replace the
2. Remove the HCS Front Cover [RRP 10.4, page 321]. [PL 10.2, HCS
3. Disconnect P/J514 from the HCS Board. page 410]. Harness
4. Check for continuity between the following pins: [PL 10.2,
■ P514-2 and P19-2 page 410] or
■ P514-3 and P19-3 the Duplex
■ P514-4 and P19-4
Interface
■ P514-6 and P19-11
■ P514-7 and P19-12
Harness
[PL 9.2,
Is there continuity between all pins measured? page 406].
■ HCS Harness [PL 10.2, page 410]
■ Duplex Interface Harness [PL 9.2, page 406]

RAP 24 Error Code E9-3: Tray 2 Failure
Power Off / On
Tray 3 Failure
Power Off / On
The HCF has failed or disconnected with Power-On.
Table 44 Error Code E9-3: HCF Fail (2000-Sheet Feeder) Troubleshooting
Procedure

1 HARNESS CONNECTIONS Go to Secure the
1. Switch printer power OFF. Step 2. connections
2. Remove the Lower Rear Cover. of the
3. Inspect the connection at both ends of the 2000-Sheet 2000-Sheet
Feeder harness Assembly (P/J601 on the Feeder Feeder
Board and P/J131 feeder Interface Harness). Harness
Is the 2000-Sheet Feeder Interface Harness Assembly
properly connected to the 2000-Sheet Feeder [J131, J601].
Board?
2 2000-SHEET FEEDER BOARD REPLACEMENT Go to Problem
Replace the 2000-Sheet Feeder Board [PL 12.2, Step 3. solved.
page 420].
Does the problem still occur?
3 HARNESS CONTINUITY CHECK Replace the Repair or
1. Remove the 2000-Sheet Feeder Harness assembly. Print Engine replace the
2. Check for continuity between the pins as follows: Controller 2000-Sheet
■ J601-1 and J131-7 Board Feeder
■ J601-2 and J131-6 [RRP 8.5, Harness
■ J601-3 and J131-5 page 310]. Assembly
■ J601-4 and J131-10 [PL 12.2,
■ J601-5 and J131-13
page 420].
■ J601-6 and J131-9
■ J601-7 and J131-8

■ 2000-Sheet Feeder Board [PL 12.2]
■ 2000-Sheet Feeder Harness Assembly [PL 12.2]

RAP 25 Error Code J5: Toner Low
The Print Cartridge is nearing end-of-life and should be replaced.
Table 45 Error Code J5: Toner Low Troubleshooting Procedure

1 PRINT CARTRIDGE REPLACEMENT Go to Problem
Install a new Print Cartridge. Step 2. solved.
Does the J5 error code still appear?
2 CONTINUITY CHECK Go to Repair or
1. Remove the Left Side Cover [RRP 1.1, page 250]. Step 3. replace the
2. Remove the Print Engine Controller Board Cover Toner
[RRP 8.5, page 310]. Sensor
3. Disconnect P/J14 from the Print Engine Controller Harness
Board. Assembly as
4. Check for continuity between J14-1 and P141-1 / necessary
J14-2 and P141-2 / J14-3 and P141-3. [PL 8.1,
Does continuity check OK between J14-1 & page 402].
P141-1, J14-2 & P141-2, and J14-3 & P141-3?
3 TONER SENSOR ASSEMBLY REPLACEMENT Replace the Problem
Replace the Toner Sensor Assembly [RRP 7.3, Print Engine solved.
page 301]. Controller
Board
Does the problem continue to exist? [RRP 8.5,
page 310].
■ Print Cartridge [PL 8.1, page 402]

RAP 26 Error Code J5: Toner Low
Toner Low is not displayed when the Print Cartridge appears to be empty.
Table 46 Error Code J5: Toner Low Troubleshooting Procedure

1 TEST PRINT Go to Problem does
1. Run a test print or print a page from a file. Step 2. not exist.
2. Inspect the print quality.
Does the print appear light due to an empty Print
Cartridge?
2 PRINT CARTRIDGE Go to Go to
1. Replace the Print Cartridge [PL 8.1, page 402]. Step 3. Image-Quality
2. Run five test prints (Config Sheet or Demo Page). Defect
3. Inspect the print quality. Definitions,
Does the print quality meet specifications? page 177.
3 TONER SENSOR Replace Go to Step 4.

1. Remove Tray 1. the Print
2. Remove any paper from the MBF. Engine
3. Enter Diagnostics mode. Controller
4. From the Main Menu, select Component Test / Sensor Board
Input Test / press [4] to start test, [0] to stop. [RRP 8.5,
5. Open the MBF Cover and carefully pull down, then page 310].
release the Toner Sensor.
pull down and release the Toner Sensor?
■ Toner Sensor Assembly [RRP 7.3, page 301]

RAP 27 Error Code J6-1: Replace Print
Cartridge
Install Print Cartridge

Logic Control on the Print Engine Controller Board detected a problem where a
message to replace the Print Cartridge is generated.
Table 47 Error Code J6-1: Replace Print Cartridge Troubleshooting
Procedure

1 PRINT CARTRIDGE Go to Problem
1. Switch printer power OFF. Step 2. solved.
2. Replace the Print Cartridge.
2 CRUM ANTENNA TESTS Replace the Go to
2. On the Print Engine Controller Board, disconnect P/J Controller
21 and measure the resistance between pins 1 and 2 Board
of the connector just unplugged. [RRP 8.5,
Does the resistance measure less than 10 ohms? page 310].

Perform a continuity check of the harness to the CRUM CRUM harness
Board, specifically Antenna between the
Board CRUM
■ P/J 21-1 to P/J 211-4 [RRP 3.7, Antenna
■ P/J 21-2 to P/J 211-3. page 281]. Board P/J
Is there continuity between the connector pins? 211 and the
Print Engine
Controller
Board P/J
21.
■ Print Cartridge
■ CRUM Antenna [RRP 3.7, page 281]

RAP 28 Error Code J8-1: Print Cartridge
OEM ID Mismatch
A Print Cartridge for a different printer is detected.
Table 48 Error Code J8-1: Print Cartridge OEM ID Mismatch Troubleshooting
Procedure

1 PRINT CARTRIDGE Go to Problem
1. Switch printer power OFF. Step 2. solved.
2. Replace the Print Cartridge.
2 CRUM ANTENNA TESTS Replace the Go to
2. On the Print Engine Controller Board, disconnect Controller
P/J 21 and measure the resistance between pins 1 Board
and 2 of the connector just unplugged. [RRP 8.5,
Does the resistance measure less than 10 ohms? page 310].

Perform a continuity check of the harness to the CRUM CRUM harness
Board, specifically Antenna between the
Board CRUM
■ P/J 21-1 to P/J 211-4 [RRP 3.7, Antenna
■ P/J 21-2 to P/J 211-3. page 281]. Board
Is there continuity between the connector pins? P/J 211 and
the Print
Engine
Controller
Board
P/J 21.
■ Print Cartridge
■ CRUM Antenna [RRP 3.7, page 281]

RAP 29 Error Code PSE-1: Paper Size Jam
Open Rear Cover
There is a conflict between the size of paper the printer senses in the paper tray and/or
MBF and the size of paper that is actually loaded.
Table 49 Error Code PSE-1 Paper Size Jam

1 Does the problem appear when using Tray 1, 2 or Go to Go to
3? Step 3. Step 2.
2 MBF PAPER SIZE VERIFICATION Go to Enter User

1. Open the MBF and verify the size of paper currently in Step 9. Menu /
the MBF Tray. select MBF
2. Enter User Menus, select Tray Menu / MBF Size / then Size / then
scroll through the MBF Size sub-menus to find the select the
default paper size. size
Does the paper size displayed on the LCD match matching the
the size actually in the MBF? paper in the
MBF Tray.
3 Is the paper size in the problem tray within Go to Replace with

printer specifications? Step 4. paper that
meets
specs.
4 INSPECTING GUIDES Go to Properly set

Inspect the side guides and Paper Stack End Guide in Step 5. the guides.
the problem Tray.
Are all guides properly set for the size of paper
installed?
5 SIZE CAM INSPECTION Go to Replace the
Inspect the size cam on the left side of the paper tray. Step 6. paper tray
[PL 2.1,
Are the cams in good condition (not broken) and page 386 /
rotate freely as the paper tray end guide is PL 2.2,
moved? page 388].
6 TRAY SIZE TEST Replace the Go to

2. From the Main Menu, select Component Test / Tray Controller
(1, 2 or 3 - the problem tray) Size / press [4] to start, Board
[0] to stop. [RRP 8.5,
Does the paper size displayed on the LCD match page 310].
the size of the paper actually loaded?
7 SENSOR INPUT TEST Go to Go to
1. While still in Diagnostics mode from Step 6 above, Step 8. RAP 54,
select Component Test / Sensor Input Test / press [4] page 142.
start, [0] to stop.
2. One at a time, press and release each of the problem
tray size actuators.
press and release one of the actuators?

Table 49 Error Code PSE-1 Paper Size Jam

8 PAPER TRAY INSPECTION Replace the Replace
1. Switch printer power OFF. Print Engine paper tray
2. Remove the Left Side Cover [RRP 1.1, page 250]. Controller [PL 2.1,
3. Remove, then reinsert the problem paper tray while Board page 386 /
observing the size actuators move, depending on the [RRP 8.5, PL 2.2,
setting of the paper tray [see Table 50 below]. page 310]. page 388]. If
Do the Tray Size Cams contact the Paper Size problem
Actuators correctly for each size of paper? persists,
replace the
Tray 1 Left
Guide
Assembly
[RRP 3.6,
page 279].
■ Registration Sensor [RRP 4.4, page 287]
■ Registration Sensor Actuator [RRP 4.2, page 285]
■ Guide Assembly, CST L [RRP 3.6, page 279]
■ MBF Assembly [RRP 2.1, page 259
■ Cassette Assembly [PL 2.1, page 386; PL 2.2,
page 388]
■ Size Switch [PL 3.1, page 390]
■ Harness Assembly SNS [PL 3.1, page 390]
8.5” A4 B5 A5 14” 8.5” A4 B4

4 Top X X X X X
3 X X X X X
2 X X X X
1 Bottom X X X X

RAP 30 Error Code U1: Motor Failure
Power Off / On
There is a problem with the Main Motor.
Table 51 Error Code U1: Motor Failure Troubleshooting Procedure

1 MOTOR ROTATION CHECK Go to Go to
1. Open the Rear Cover. Step 4. Step 2.
2. If installed, remove the Duplex Assembly.
3. Rotate the rotor of the Main Motor counterclockwise
(as viewed from the right side of the printer) manually.
Does the rotor of the Main Motor rotate
smoothly?
2 PRINT CARTRIDGE ISOLATION Replace the Go to
1. Open the Top Cover and remove the Print Cartridge. Print Step 3.
2. Manually rotate the rotor of the Main Motor clockwise. Cartridge
[PL 8.1,
Does the rotor of the Main Motor rotate
page 402].
smoothly?
3 FUSER ISOLATION Go to Replace the
1. Remove the Fuser Assembly [RRP 5.1, page 288]. Step 4. Fuser.
2. Manually rotate the Fuser Assembly Drive Gear.
Does the Fuser rotate smoothly?
4 REGISTRATION ROLLERS ROTATION CHECK Go to Replace the
1. Open the Top Cover. Step 5. Paper
2. Remove the Print Cartridge. Transport
3. Manually rotate the Metal Registration Roller and the Assembly
Rubber Registration Roller. [RRP 4.1,
Do the Metal Registration Roller and the Rubber page 283].
Registration Roller rotate smoothly?
5 EXIT ASSEMBLY ROTATION CHECK Go to Replace
1. Open the Rear Cover. Step 6. components
2. Manually rotate the Exit Assembly that is attached to or the Exit
the Rear Cover. Assembly as
Does the Exit Assembly rotate smoothly? necessary
[PL 6.1,
page 398].
6 DRIVE GEARS ROTATION CHECK Go to Go to

1. Close the Rear Cover. Step 7. RAP 47,
2. With the Top Cover still open, cheat the Top Cover page 128.
Interlock.
Motor / press [4] to start, allow to continue running
through Step 8 below.
Do the Main Motor and drive gears run smoothly
and all drive gears are in good condition?

Table 51 Error Code U1: Motor Failure Troubleshooting Procedure (cont'd.)

7 MBF FEED ROLLER ROTATION CHECK Go to Replace the
1. Remove all paper from the MBF tray. Step 8. MBF Feed
2. With the Main Motor still running from Step 6, Roller
sub-step 4, above, select MBF Feed Sol / press [4] to components
test. as
Does the MBF Feed Roller Assembly rotate necessary
smoothly? [PL 4.1,
page 392].
8 TRAY 1 PICK UP GEAR ROTATION CHECK Go to Repair or

1. Remove Tray 1. RAP 47, replace the
2. With the Main Motor still running from Step 6, sub-step page 128. gears or
4 above, select Tray 1 Feed Sol / press [4] to rotate the assembly as
Tray 1 Pick Up Rollers one revolution. necessary
3. Observe the Tray 1 Pick Up Rollers through the Tray [PL 4.2,
1 opening. Press [4] as many times as necessary to page 394].
evaluate the rotation of the rollers.
Do the Tray 1 Pick Up Rollers rotate smoothly?
■ Main Motor and/or drive gears [PL 7.1, page 400
■ Exit Assembly [PL 6.1, page 398]
■ MBF Feed Roller Assembly [PL 4.1, page 392]

RAP 31 Error Code U2: Laser Failure
Power Off / On
There is a problem with the Laser Assembly.

1 RESOLUTION CHECK Go to Replace the
1. Enter Diagnostics mode. Step 2. Print Engine
2. From the Main Menu, select NVM Config / enter Controller
password [0734] / Resolution / press [3] or [7] for Board
reading. [RRP 8.5,
Is the Resolution reading “D”? page 310].
2 LASER DENSITY CHECK Go to Replace the

password [0734] / Laser Density / press [3] or [7] for Board
reading. [RRP 8.5,
Is the Laser Density reading “4”? page 310].
3 SCANNER MOTOR CHECK Go to Go to

1. Enter Diagnostics mode. Step 4. RAP 48,
2. From the Main Menu, select Component Test / ROS page 130.
Motor / press [4] to start the Laser Scanner Motor, [0]
to stop.
Can you hear the Laser Scanner Motor spin up?
4 VOLTAGE CHECK 1 Go to Go to
1. Switch the printer power OFF. RAP 27, Step 5.
2. Remove the Left Side Cover [RRP 1.1, page 250]. page 92.
3. Remove the Print Engine Controller Board Cover
[RRP 8.5, page 310].
Board.
6. Measure the voltage between P11-7 & P11-8 on the
Print Engine Controller Board.
Is this voltage +5.0 VDC between P11-7 & P11-8?
5 VOLTAGE CHECK 2 Go to Go to
With the printer still on from Step 4, sub-step 5, RAP 48, RAP 40,
measure the voltage between P21-4 & P/H21-1 on the page 130. page 114.
Print Engine Controller Board.
Is this voltage +5 VDC between P21-4 and
P/J21-1?



RAP 32 Error Code U4: Fuser Failure
Power Off / On
There is a problem with the Fuser Assembly.
Table 53 Error Code U4: Fuser Failure Troubleshooting Procedure

1 POWER OFF / ON Go to Go to
1. Switch the printer power OFF. RAP 49, Step 2.
2. Wait a few minutes, then switch the printer power ON. page 133.
2 TEST PRINT VERIFICATION Go to Problem
1. Enter Diagnostics mode. RAP 49, solved.
2. From the Main Menu, select Test Print / Print Pattern / page 133.
3. Run 20 to 30 test pages.
Does the Fuser Failure error code reappear?

RAP 33 Error Code U5: Fan Failure
Power Off Now
The printer is detecting incorrect fan rotation.
Table 54 Error Code U5: Fan Fail Troubleshooting Procedure

1 Do both fans rotate when printer power is Go to Go to
switched ON? Step 3. Step 2.
2 Are both of the fans stopped? Go to Replace the

Step 4. fan that is
not running
[RRP 8.4,
page 309 /
RRP 8-7,
page 313].
3 DIAGNOSTICS CHECK Replace the Go to

2. From the Main Menu, select Component Test / Fan Controller
Motor High / press [4] to start, [0] to stop. Board
Do the fans rotate at high speed? [RRP 8.5,
page 310].
4 VOLTAGE CHECK Replace the Replace the

1. Switch printer power OFF. Remove power cord from LVPS Print Engine
rear of printer. [RRP 8.6, Controller
2. Remove the Lower Rear Cover [RRP 1.7, page 256]. page 312]. Board
3. Reconnect power cord to printer. Switch printer power [RRP 8.5,
ON. page 310].
4. Check for +24 VDC between P/J161-13 and frame
ground.
5. Check for +0.6 VDC between P/J161-12 and frame
ground.
Are both voltages (+24 VDC and +0.6 VDC)
correct?
5 DIAGNOSTICS CHECK Replace the Go to
2. From the Main Menu, select Component Test / Fan Controller
Motor High / press [4] to start, [0] to stop. Board
Do the fans rotate at high speed? [RRP 8.5,
page 310].
■ Cooling Fans [RRP 8.4, page 309 / RRP 8-7,
page 313]
■ Low Voltage Power Supply (LVPS) [RRP 8.6,
page 312]
■ Wiring and connectors linking the components.

RAP 34 Error Code: 0101 - DIMM 1
DIMM in slot J4 has failed at Power-Up.
Table 55 0101 - DIMM 1 Troubleshooting Procedure

1 PROCEDURE Replace the Go to
1. Switch printer power OFF. System Step 2.
2. Remove the Left Side Cover [RRP 1.1, page 250]. Controller
3. Remove the DIMM installed in Slot 1 (J4). Board
Is the “0101 - DIMM 1” error message still page 305].
displayed on the Control Panel LCD?
2 DIMM TEST Replace the Go to
1. Switch printer power OFF. DIMM. Step 3.
2. Install the removed DIMM into Slot 2 (J5).
Is the “0102 - DIMM 2” error message displayed
on the Control Panel LCD?
3 DIMM RETEST / VERIFICATION Replace the Attribute the
1. Switch printer power OFF. System problem due
2. Remove the DIMM from Slot 2 (J5) and reinstall it into Controller to a poor
Slot 1 (J4). Board connection
3. Switch printer power on. [RRP 8.1, of the DIMM
Is the “0101 - DIMM 1” error message still page 305]. on the
displayed on the Control Panel LCD? System
Controller
Board.
■ LVPS Power Supply [RRP 8.6, page 312]
■ Harness Assembly [PL 9.1, page 404]


Controller
Board.


Controller
Board.

RAP 37 Error Code U6: IOT NVM Fail
Power Off / On
There is a problem with the Non-Volatile RAM on the Print Engine Controller Board.
Table 58 Error Code U6: IOT NVM Failure Troubleshooting Procedure

1 POWER CYCLING Go to Go to
Switch the printer power OFF, wait 20 - 30 seconds, Step 3. Step 2.
then switch printer power ON.
Does the IOT NVM Fail error code appear?
2 VERIFYING STEP 1 ABOVE Go to Problem
To ensure the problem is solved, switch the printer Step 3. solved.
power OFF and ON several times.
Does the IOT NVM Fail error code reappear?
3 ENTER DIAGNOSTICS Go to Replace the
password [0734] / Board
Was the password accepted and does [RRP 8.5,
“Resolution” now appear on the LCD? page 310].
4 NON-VOLATILE MEMORY CONFIGURATION Go to Replace the

CODES Step 5. Print Engine
Check the NVM Data one by one referring to the Controller
NVRAM Configuration Table of Non-Volatile Memory Board
Configuration Codes, page 233. [RRP 8.5,
page 310].
Is the data set properly?
5 POWER OFF/ON Replace the Problem
Switch printer power OFF, wait 10-20 seconds, then Print Engine solved.
switch power ON. Controller
Board
Does the IOT NVM Fail error message still [RRP 8.5,
appear? page 310].

Blank Page

Troubleshooting
This topic discusses troubleshooting the printer. Troubleshooting is discussed in the
following areas:
■ Printer Performance Problems: Refer to the Repair Analysis Procedure
(RAP) Table 59 “Print Performance Problems RAP Table,” on page 107.
■ Image-Quality Problems: Refer to the Repair Analysis Procedure (RAP)
Table 60 “Image-Quality Problems RAP Table,” on page 109.
■ Electrical Interference Problems: Refer to the Repair Analysis Procedure
(RAP) Table 61 “Electrical Interference RAP Table,” on page 109.
General Assumption:
When asked to run a “Test Print”, run any test print that is quick and easy for you,
including sending a simple print job to the printer. The object is merely to print
anything on a sheet of paper for evaluation. On other occasions, follow the procedure
as instructed.
Printer Performance Problems Repair

Analysis Procedure (RAP) Table
Table 59 Print Performance Problems RAP Table
Problem Go To
AC Power RAP 38 on page 110
Registration Clutch RAP 39 on page 112
DC Power RAP 40 on page 114
DC Power Loading RAP 41 on page 116
System Controller Isolation RAP 42 on page 118
Low Paper Tray 1/2/3 RAP 43 on page 119
Inoperative Printer RAP 44 on page 120
Malfunctioning LCD/LED RAP 45 on page 123
Inoperative Keypad RAP 46 on page 126
Main Motor Assembly RAP 47 on page 128
Laser Assembly RAP 48 on page 130
Fuser Assembly RAP 49 on page 133
Registration Sensor RAP 50 on page 135

Table 59 Print Performance Problems RAP Table (cont'd.)
Problem Go To
MBF No Paper Sensor RAP 51 on page 137
Laser Safety Switch RAP 52 on page 139
Tray 1 No Paper Sensor RAP 53 on page 140
Size Switch RAP 54 on page 142
Turn Roller Clutch Assembly RAP 55 on page 145
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 Paper Tray 2 (or Tray 3) / 500-Sheet Feeder RAP 61 on page 159
500-Sheet Feeder Feed Solenoid RAP 62 on page 161
500-Sheet Motor RAP 63 on page 163
500-Sheet Feeder Assembly Not Recognized RAP 64 on page 164
Exit Sensor RAP 65 on page 167
Pre-Registration Sensor RAP 66 on page 168
HCS Motor Assembly RAP 67 on page 170
Disk Error Format Hard Disk RAP 68 on page 172
Erratic Printer Operation RAP 69 on page 173

Image-Quality Problems Repair
Analysis Procedure (RAP) Table
Table 60 Image-Quality Problems RAP Table
Problem Go To RAP No.

Light (Undertoned) Prints RAP 70 on page 178
Blank Prints RAP 71 on page 181
Spots RAP 72 on page 183
Horizontal (Scan) Deletions RAP 73 on page 185
Vertical (Process) Deletions RAP 74 on page 188
Spot Deletions RAP 75 on page 190
Vertical (Process) Streaks RAP 76 on page 192
Horizontal (Scan) Streaks RAP 77 on page 194
Residual Image (Ghosting) RAP 78 on page 197
Black Prints RAP 79 on page 199
Background RAP 80 on page 200
Uneven Density RAP 81 on page 202
Skewed Image RAP 82 on page 204
Damaged Prints RAP 83 on page 210
Registration RAP 84 on page 212
Skips / Smears RAP 85 on page 214
Unfused Image RAP 86 on page 215
Resolution RAP 87 on page 217
Electrical Interference Repair 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.

Printer Performance Problems
RAP 38 AC Power
There is a possible problem with the AC power.
Initial Action
Disconnect the AC power cord from the wall outlet.
Warning: Improper connection of the grounding conductor can
result in the risk of electrical shock. The following must be
observed:
■ Never use a ground adapter plug to connect the machine to a
power source.
■ Never attempt any maintenance function which is not specifically
called out in the service procedures.
■ Never remove any covers which are fastened with screws, unless so
instructed in the service procedures.
Caution: If any of the voltage measurements are not as specified in
the following steps, the cause must be corrected. Caution
the customer NOT to connect the machine to the wall
outlet. Advise the customer that a licensed electrician must
correct the wiring. Do not attempt to correct the wiring
yourself. If you later find the condition has not been
corrected, inform your manager in writing of the improper
wiring.
Table 62 AC Power Testing Procedure

1 US, XCI and AO [110 VAC] Go to Inform
Step 4. customer of
insufficient
voltage or
improper
wiring.
1. Measure the AC voltage between AC Line and

Neutral, between AC Line and Ground, and between
AC Neutral and Ground.
2. The voltage between Line and Neutral and between
Line and Ground should range from 104 to 127 VAC
and the voltage between Neutral and Ground should
be less than 3 VAC.
Is the AC voltage within specification?

Table 62 AC Power Testing Procedure (cont'd.)

2 XL, UK AND AO [220 VAC] Go to Inform
Step 4. customer of
insufficient
voltage or
improper
wiring.
1. Measure the AC voltage between Line and Neutral,

between AC Line and Earth/Ground, and between
Neutral and Earth/Ground.
Line and Earth/Ground should range from 216 to
264 VAC and the voltage between Neutral and
Ground should be less than 3 VAC.
Is the AC line voltage within specification?
3 XL, EUROPE [220 VAC] Go to Inform
Step 4. customer of
insufficient
voltage or
improper
wiring.
1. Measure the AC voltage between Line and Neutral,

between AC Line and Earth/Ground, and between
Neutral and Earth/Ground.
Line and Earth/Ground should range from 196 to
244 VAC and the voltage between Neutral and
Ground should be less than 3 VAC.
Is the AC line voltage within specification?
4 CONTINUITY CHECK Perform DC Replace the
1. Check the continuity through all connections of the Power power cord.
power cord. Check
2. The measurement should be less than 10 ohms for [RAP 40,
each connection. page 114].
Does continuity test per specification?

RAP 39 Registration Clutch
.
Table 63 Registration Clutch Troubleshooting Procedure

2. From the Main Menu, select Component Test / Reg.
Clutch / press [4] to test, [0] to stop.
Can you hear the Registration Clutch energize?
2. Remove the Left Side Cover [RRP 1.1 on page 250]
and remove the Print Engine Controller Board Cover
[RRP 8.5 on page 310].
3. Disconnect P/J22 on the Print Engine Controller
Board.
4. Measure the resistance between pins 1 and 2 on the
disconnected plug.
Is the resistance approximately 170 to
185 ohms?
3 “NO” FROM STEP 2 ABOVE Replace the Repair or
1. Remove the Print Cartridge and the MBF Assembly Registration replace the
[RRP 2.1 on page 259]. Clutch Registration
2. Disconnect P/J222 from the Registration Clutch. [RRP 4.3 on Clutch
3. Check for pin to pin continuity between P22 and P222. page 286]. Harness as
Is there continuity between both pins? necessary
[PL 9.1,
page 404].

1. Switch printer power ON. Step 6. Step 5.
ground.
Does the voltage between P/J22-1 and frame
ground measure +24 VDC?
ground. Controller [RRP 8.6 on
Board page 312].
Does the voltage between P/J16-9 and frame [RRP 8.5 on
ground measure +24 VDC? page 286].

1. Switch printer power OFF. Step 7. Registration
2. Reconnect P/J22. Clutch
3. Enter Diagnostics mode. [RRP 4.3 on
4. From the Main Menu, select Component Test / Reg. page 286] or
Clutch. Paper
5. Measure the voltage between P/J22-2 and frame Transport
ground. Assy
6. While watching the voltmeter, press [4].
[RRP 4.1 on
Does the voltage drop from +24 VDC to 0.0 VDC? page 283].

Table 63 Registration Clutch Troubleshooting Procedure (cont'd.)

7 REGISTRATION CLUTCH TEST Problem Replace the
1. Switch printer power OFF. solved. Registration
2. Open the Top Cover and remove the Print Cartridge. Clutch
3. Enter Diagnostics mode. [RRP 4.3 on
4. From the Main Menu, select Component Test / Main page 286] or
Motor / press [4] to start motor. Paper
5. Scroll to Reg. Clutch / press [4] to energize clutch. Transport
Do the Registration Rollers rotate smoothly and Assy
without stalling or jerking? [RRP 4.1 on
page 283].
■ Registration Clutch [“RRP 4.3 Registration Clutch”]
■ Registration Clutch Harness [PL 9.1, page 404]
■ Paper Transport Assy [RRP 4.1, page 283]

RAP 40 DC Power (LVPS)
.
Table 64 DC (LVPS) Troubleshooting Procedure

1 1. Perform RAP 38 before starting this RAP. Go to Step 2. Replace the
2. If RAP 38 checks out OK, switch the main power OFF AC Input
and disconnect the printer power. Assembly
3. Remove the Lower Rear Cover (RRP 1.7, page 256). (RRP 8.8,
4. Connect printer power.
5. Switch the printer power ON. page 314).
6. Measure the voltage on the LVPS between P/ J167
pins 1 and 3.
Does the voltage match the line voltage?
2 Measure the voltage between the bottom of Fuse F101 Go to Step 4. Go to
and P/ J167 pin 3. Step 3.
3 1. Switch the main power OFF. Problem Replace the
2. Replace fuse F101. Solved. LVPS
3. Switch the main power ON. (RRP 8.6,
4. Measure the voltage between the bottom of Fuse page 312).
F101 and P/ J167 pin 3.
4 Measure the voltage between LVPS P/ J162 pin 3 and Go to Step 8. Go to
frame ground. Step 5.
Is the voltage +24 VDC?
5 On the LVPS, measure the voltage between P/ J162 Go to Step 6. Replace the
pin 1 and frame ground. LVPS
(RRP 8.6,
page 312).
6 Check the Top Cover and the printer Upper Rear Go to Step 7. Repair or
Cover. replace the
defective
Are both covers properly closed and actuating
the interlock switches? cover/
interlock
switch as
necessary.
7 Check the continuity through the interlock switches. Replace if Go to

necessary Step 8.
Do both switches exhibit continuity?
(RRP 7.4,
page 302/
RRP 10.9,
page 326).
8 Check the voltages listed in Table 65. Return to the Go to

procedure RAP 41.
Are the voltages correct as measured?
that sent you
here.

Table 65 LVPS Voltages
Red Lead Black Lead Voltage

P/J161 pin 10 Frame Ground +5.0 VDC
P/J161 pin 3 Frame Ground +24 VDC

RAP 41 DC Power Loading
Initial Actions
Perform RAP 40, DC Power (LVPS) Troubleshooting, before starting this RAP.
Warning: AC input voltages can be lethal. Use extreme care while
checking the voltages on the LVPS. Disconnect the power
cord while checking the continuity of fuses and removing
or reinstalling the components.
Table 66 DC Power Loading Troubleshooting Procedure

1 Switch the printer power OFF. Remove the Lower Rear Go to Step 2. Replace the
Cover (RRP 1.7 on page 256). Disconnect the LVPS
following from the LVPS: (RRP 8.6 on
■ P/J161 (Print Engine Controller PWB) page 312).
■ P/J163 (System Controller PWB)
■ P/J164 (Main Motor)
■ P/J165 (Main Fan)
■ P/J166 (LVPS Fan)
■ P/J168 (5VDC Power Supply)
Switch the printer power ON and measure the voltages
listed in Table 67 on the LVPS.
Are all the voltages correct?
2 1. Switch the printer power OFF. Go to Step 5. Go to Step 3.
2. Reconnect P/J161 to the LVPS.
3. Switch the printer power ON and measure the
voltages listed in Table 67.
3 1. Switch the printer power OFF. Go to Step 4. Replace the
2. Remove the Left Side Cover and the Print Engine Print Engine
Controller PWB Cover. Controller
3. Reconnect all the P/Js to the LVPS. PWB
4. Disconnect the following from the Print Engine
(RRP 8.5 on
Controller PWB:
■ P/J11 (Laser) page 310).
■ P/J21 (Print Cartridge Sensor)
■ P/J14 (Toner Sensor)
■ P/J12 (Tray 1 Feed head components/Tray 1 Low
Paper Sensor)
■ P/J22 (Registration Clutch)
■ P/J13 (Feeder 2/3)
■ P/J17 (Fuser Control PWB / Fuser)
■ P/J19 (Duplex Assembly/OCT)
■ P/J18 (HVPS/Registration Sensor)
■ P/J20 (Tray 1 Size Sensor/MBF Home Sensor)
5. Switch the printer power ON and measure the
voltages listed in Table 67.

Table 66 DC Power Loading Troubleshooting Procedure (cont'd.)

4 Switch the printer power OFF. Reconnect one of the Repeat the Replace the
disconnected plugs. Switch the printer power ON. step with the component
Measure the voltages listed in Table 67. next just
disconnected connected to
plug. the Print
Engine
Controller
PWB.
5 1. Switch the printer power OFF. Repeat the Replace the

2. Reconnect one of the disconnected plugs. step with the component
3. Switch the printer power ON. next just
4. Measure the voltages listed in Table 67. disconnected connected to
Are all the voltages correct? plug. the LVPS.
Table 67 LVPS Voltages

Red Lead Black Lead Voltage

RAP 42 System Controller Isolation
Table 68 System Controller Isolation Procedure

1 SYSTEM CONTROLLER ISOLATION Go to Go to
2. Disconnect all cables connected the rear of the
System Controller Board.
4. Remove all options from the System Controller Board.
Does the printer boot up correctly and “Ready”
is displayed on the Control Panel?
2 SYSTEM CONTROLLER RESEAT Problem Replace the
1. Switch printer power OFF. solved. System
2. Remove, then reinstall the System Controller Board Controller
[RRP 8.1, page 305] to reseat the connection with the Board
Print Engine Controller Board. [RRP 8.1,
3. Switch printer power ON. page 305].
Does the printer boot up correctly and “Ready”
is displayed on the Control Panel?
3 OPTIONS ISOLATION Repeat the Replace the
1. Switch printer power OFF. last step with option or
2. Reinstall one of the removed options or cables. the next cable just
3. Switch printer ON. option or installed.
Does the printer boot up correctly and “Ready” cable until
is displayed on the Control Panel? the problem
is found.
■ Print Engine Controller Board [RRP 8.5, page 310
■ Printer Options

RAP 43 Low Paper Tray 1/2/3
Paper stack in the Paper Tray Assembly is below 50 sheets.
Table 69 Low Paper Tray 1/2/3 Troubleshooting Procedure

1 LOAD PAPER Go to Problem
Insert a full Tray Assembly into the affected position. Step 2. solved.
Does the Error Message reappear?
2 LOW PAPER SENSOR ACTUATOR TEST Go to Repair or
1. Remove the affected Tray Assembly. Step 3. replace the
2. Push up the Low Paper Sensor Actuator [PL 3.1, Low Paper
page 390] manually, then release. Sensor
Does the Low Paper Sensor Actuator return to its Assembly
normal position when released? [RRP 3.4,
page 276] or
Low Paper
Sensor
Actuator
[PL 3.1,
page 390].
3 LOW PAPER SENSOR TEST Replace the Check wiring

Print Engine associated
Note: When checking the Low Paper Sensor using Controller with the Low
the Sensor Test, at least one Paper Size
switch and the Low Paper Sensor must be Board Paper
actuated. [RRP 8.5, Sensor. If
page 310]. OK, replace
1. Enter Diagnostics mode. the Low
2. From the Main Menu, select Component Test / Sensor Paper
Input / press [4] to start test, [0] to stop. Sensor.
3. Push up the Low Paper Sensor Actuator, then
release.
Does the LCD increment each time you push and
release the Actuator?
■ Low Paper Sensor Actuator [RRP 3.4, page 276]
■ Print Engine Controller Board [RRP 8.5, page 310

RAP 44 Inoperative Printer
Printer power cannot be switched ON.
Table 70 Inoperative Printer Troubleshooting

1 AC POWER CORD Go to Problem
Ensure the power cord is properly connected to the wall Step 2. solved.
outlet and to the back of the printer.
Does the problem still exist?
2 AC POWER Go to Notify
Perform RAP 38, AC Power, then return here. Step 3. customer
that power is
Did RAP 38 indicate the correct AC voltage is out of spec.
being supplied to the printer?
3 DC POWER Go to Go to
Perform RAP 40, DC Power (LVPS), then return here. Step 5. Step 4.
Did RAP 40 indicate the correct DC voltages are
being supplied throughout the printer?
4 Did RAP 40 instruct you to replace a Replace Perform
component? component RAP 41,
as page 116.
necessary.
5 SYSTEM CONTROLLER +3.3 VDC CHECK Go to Go to

1. Remove the Left Side Cover [RRP 1.1, page 250]. Step 8. Step 6.
2. On the System Controller Board, measure the voltage
between P/J3-1 and P/J3-2.
P/J3-1 and P/J3-2?
6 +3.3 VDC LOAD CHECK AT SYSTEM Go to Go to
CONTROLLER P/J3 Step 11. Step 7.
1. Switch printer power OFF.
2. Disconnect P/J3 from the System Controller Board.
4. Check the voltage between pins 1 and 2 on the
disconnected plug.
Is the voltage +3.3 VDC between pins 1 and 2 on
the disconnected plug?
7 LOW VOLTAGE POWER SUPPLY Repair or Replace the
1. Remove the Lower Rear Cover [RRP 1.7, page 256] replace the LVPS
to access the LVPS. harness [RRP 8.6,
2. Measure the voltage between P/J163-1 and P/J163-2. between the page 312].
LVPS and
Note: Do not reinstall the Lower Rear Cover until the System
this RAP is completed. You may need to make
additional tests on the LVPS. Controller
Board.
Does the voltage between P/J163-1 and P/J163-2
measure +3.3 VDC?

Table 70 Inoperative Printer Troubleshooting (cont'd.)

8 SYSTEM CONTROLLER +5 VDC CHECK Replace the Go to
Measure the voltage between pins 1 and 2 of P/J13 on System Step 9.
the System Controller Board. Controller
Board
Does the voltage between P/J13, pins 1 and 2 [RRP 1.1,
measure +5.0 VDC? page 250]. If
problem
persists,
replace the
Print Engine
Controller
Board
[RRP 8.5,
page 310].
9 SYSTEM CONTROLLER +5 VDC LOAD CHECK Go to Go to

3. Measure the voltage between pins 1 and 2 of the
disconnected plug.
Does the voltage between pins 1 and 2 of the
disconnected plug measure +5.0 VDC?
10 LVPS +24 VDC CHECK AT P/J168 Replace the Replace the
Measure the voltage between pins 1 and 2 of P/J168 on System LVPS
the LVPS. Controller [RRP 8.6,
Board +5 page 312].
Does the voltage between P/J168, pins 1 and 2 VDC Power
on the LVPS measure +24 VDC? Supply
[RRP 8.9,
page 315.
11 REMOVE OPTIONS Go to Replace the

1. Switch printer power OFF. Step 9. System
2. Remove any options connected to the System Controller
Controller Board. Board
3. Reconnect P/J3 to the System Controller Board. [RRP 8.1,
5. Check the voltage on P/J3 between pins 1 and 2.
Note: If there are no options installed, follow the NO
path.
measure +3.3 VDC?
12 INSTALL OPTIONS ONE AT A TIME Switch Replace the
1. Switch printer power OFF. printer defective
2. Reinstall any one of the removed options. power OFF. option just
3. Switch printer power ON. Install next installed.
4. Check the voltage on P/J3 between pins 1 and 2. option and Problem
Does the voltage between P/J3-1 and P/J3-2 repeat solved.
measure +3.3 VDC? Step 9 until
voltage fails.

Table 70 Inoperative Printer Troubleshooting (cont'd.)

■ AC Power
■ Power Supply [RRP 8.9, page 315]

RAP 45 Malfunctioning LCD/LED
The Control Panel LCD is erratic.
Table 71 Malfunctioning LCD/LED Troubleshooting Procedure

2. Remove any options connected to the System
Controller Board.
5. On the System Controller Board, measure the
following voltages between P/J18 and frame ground.
Note: Refer to Table 72 for what should be expected.
Do all the voltages listed in the column “With
P/J18 Disconnected” measure correctly?
2 +3.3 VDC AT P/J3 ON SYSTEM CONTROLLER Go to Go to
BOARD Step 5. Step 3.
Measure the voltage on P/J3-1 and P/J3-2.
Does the voltage at P/J3-1 and P/J3-2 measure
+3.3 VDC?
3 +3.3 VDC NO LOAD CHECK ON SYSTEM Replace the Go to
CONTROLLER BOARD System Step 4.
1. Switch printer power OFF. Controller
2. Disconnect P/J3 from the System Controller Board. Board
4. Measure the voltage between pins 1 and 2 on the page 305].
disconnected plug.
Does the voltage between pins 1 and 2 on the
4 LVPS P/J163 VOLTAGE CHECK Repair or Replace the
Measure the voltage between P/J163-1 and P/J163-2. replace the LVPS
harness [RRP 8.6,
Does the voltage between P/J163-1 and 163-2 between the page 312].
measure +3.3 VDC? LVPS and
the System
Controller
Board
[PL 9.2,
page 406].
5 SYSTEM CONTROLLER BOARD +5 VDC CHECK Go to Go to

On the System Controller Board, measure the voltage Step 8. Step 6.
on P/J13-1 and P/J13-2.
measure +5.0 VDC?

Table 71 Malfunctioning LCD/LED Troubleshooting Procedure (cont'd.)

6 SYSTEM CONTROLLER BOARD +5 VDC NO Replace the Go to
LOAD CHECK System Step 7.
2. Disconnect P/J13 from the System Controller Board. Board
4. Measure the voltage between pins 1 and 2 on the page 305].
disconnected plug.
Does the voltage between pins 1 and 2 on the
7 LVPS +24 VDC CHECK Replace the Replace the
On the LVPS, measure the voltage between P/J168-1 System LVPS
and P/J168-2. Controller [RRP 8.6,
+5.0 VDC page 312].
Does the voltage between P/J 168-1 and P/J168-2 Power
measure +24 VDC? Supply
[RRP 8.1,
page 305].
8 RECONNECT P/J18 TO SYSTEM CONTROLLER Go to Replace the

BOARD Step 9. Control
1. Switch printer power OFF. Panel
2. Reconnect P/J18 to the System Controller Board. [PL 1.1,
4. Measure the voltages in Table 72 between the pins
listed and frame ground.
Do all the voltages listed in the column “with
P/J18 connected” measure correctly?
9 REMOVE OPTIONS FROM SYSTEM Replace the Go to
CONTROLLER BOARD Control Step 10.
1. Switch printer power OFF. Panel
2. Remove all options, if any, from the System Controller Assembly
Board. [PL 1.1,
3. Switch printer power ON. page 384]. If
4. Observe the LCD. problem
Is the LCD still erratic? persists,
replace the
System
Controller
Board
[RRP 8.1,
page 305].
10 REINSTALL OPTIONS (ONE BY ONE) Repeat this Replace the

1. Switch printer power OFF. step until all last option
2. Reinstall the removed options on at a time, switching options have reinstalled.
printer power ON and checking the voltages in Table been
72 between the pins listed and frame ground. reinstalled. If
Do the voltages measure correctly and does the problem
display work correctly after reinstalling any persists,
option? return to
initial actions
and restart.

Table 71 Malfunctioning LCD/LED Troubleshooting Procedure (cont'd.)

■ Control Panel Assembly [PL 1.1, page 384]
■ Harness Assembly, System Controller Board to
Control Panel [PL 9.1, page 404]
■ Harness Assembly, 3.3V [PL 9.1, page 404]
■ Power Supply [PL 9.1, page 404]
Table 72 System Controller Board Voltages at P/J18

P18 With P/J18 With P/J18 Connected
Disconnected
Pin 1 3.3 VDC 3.3 VDC

RAP 46 Inoperative Keypad
Control Panel is not operative.
Table 73 Inoperative Keypad Troubleshooting Procedure

2. From the Main Menu, select Component Test / Sensor
Input / press [4] to start, [0] to stop.
Does the printer enter the Diagnostics mode to
the Sensor Input level?
2 SYSTEM CONTROLLER BOARD P/J18 VOLTAGE Go to Replace the
CHECK Step 3. System
1. Disconnect P/J18 on the System Controller Board. Controller
2. Measure the voltages listed in Table 74, between P18 Board
on the System Controller Board and frame ground. [RRP 8.1,
Are all voltages correct per Table 74? page 305].

1. Disconnect P/J421 from the Control Panel. Control Wiring
2. Perform a continuity check on all wires from P/J421 Panel Harness
and P/J18. Assembly [PL 9.1,
Do all wires check OK for continuity? [PL 1.1, page 404].
page 384].
4 KEYPAD TEST Replace the Replace the

Press keypad buttons (1-3 and 5-7) while observing the System Control
LCD. Controller Panel
Board Assembly
Note: Keypad numbers increment the LCD counter. [RRP 8.1, [PL 1.1,
Keypad [4] enters the test and [0] stops the page 305]. page 384].
test.
press Keypad numbers (1-3 and 5-7)?
■ Control Panel Assembly [PL 1.1, page 384]
■ Wiring Harness Assembly, System Controller Board to
Control Panel [PL 9.1, page 404]
■ Wiring Harness Assembly, System Controller Board
3.3 V [PL 9.1, page 404]
■ Power Supply [PL 9.1, page 404]

Table 74 Keypad
Pin Voltage Pin Voltage
1 +3.3 VDC 5 +3.3 VDC
2 0 VDC 6 +1.3 VDC
3 +1.3 VDC 7 +3.3 VDC
4 0 VDC 8 0 VDC

RAP 47 Main Motor Assembly
.
Table 75 Main Motor Assembly Troubleshooting Procedure

1 PROCEDURE Problem Go to
1. Open the Top Cover. solved. Step 2.
2. Remove the Print Cartridge.
3. Cheat the Top Cover Interlock.
Motor / press [4] to start test, [0] to stop.
Does the Main Motor rotate?
2 LVPS VOLTAGES Go to Go to
1. Switch print power OFF. Step 7. Step 3.
2. Remove the Lower Rear Cover [RRP 1.7, page 256].
4. Measure the voltages listed in the table [see Table 76
below] on the LVPS.
Are all voltages correct?
3 Are the voltages on pins 1 and 2 correct? Go to Replace the
Step 4. LVPS
[RRP 8.6,
page 312].
4 Is the voltage on pin 6 correct? Go to Replace the

Step 5. Print Engine
Controller
Board
[RRP 8.5,
page 310].
5 Is the voltage on pin 5 correct Replace the Go to

LVPS Step 6.
[RRP 8.6,
page 312].

Check the voltage between P/J161-11 and frame Print Engine LVPS
Board page 312].
Does the voltage on P/J161-11 measure [RRP 8.5,
+3.3 VDC? page 310].

1. With the Top Cover Interlock still cheated, enter Step 9. Step 8.
Diagnostics mode.
Motor.
ground. Note this voltage, then continue with
sub-step 4.
4. Press [4] to start test, [0] to stop.
5. Measure (again) the voltage between P/J164-6 and
frame ground.
Does the voltage drop from +4.7 VDC (measured
in sub-step 3) to 0 VDC (measured in
sub-step 5)?

Table 75 Main Motor Assembly Troubleshooting Procedure (cont'd.)

1. Remove the cheater from the Top Cover Interlock, LVPS Print Engine
then reinstall the cheater. [RRP 8.6, Controller
2. With Main Motor still selected, measure the voltage on page 312]. Board
the LVPS between P/J161-7 and frame ground. [RRP 8.5,
3. Press [4] while watching the voltmeter. page 310].
Does the voltage drop from +4.7 VDC to 0 VDC?
■ Main Motor Assembly [RRP 6.1, page 295
■ LVPS Power Supply [RRP, page 312]
Table 76 Main Motor Harness
From To Voltage
P/J164-1 Frame Ground +24 VDC
P/J164-2 Frame Ground +24 VDC
P/J164-5 Frame Ground +3.2 VDC

This voltage is
valid if printer is
set for 1200 DPI.

RAP 48 Laser Assembly
.
Table 77 Laser Assembly Troubleshooting Procedure

1 LASER SCANNER MOTOR Go to Go to
2. From the Main Menu, select Component Test / ROS
Motor / press [4] to start, [0] to stop.
Do you hear the Laser Scanner motor spin up?
4. Measure the voltage between P/J11-11 on the Print
Measure the voltage between P/J16-9 on the Print Print Engine LVPS
Engine Controller Board and frame ground. Controller [RRP 8.6,
Board page 312].
Does the voltage between P/J16-9 on the Print [RRP 8.5,
Engine Controller Board and frame ground page 310].
measure +24.0 VDC?
1. Enter Diagnostics mode. Laser Print Engine
2. From the Main Menu, select Component Test / ROS Assembly Controller
Motor. [RRP 7.1, Board
3. Measure the voltage between P/J11-13 and frame page 297]. [RRP 8.5,
ground. page 310].
4. Press [4] and observe the voltmeter.
Does the voltage drop from +5.8 VDC to 0.6
VDC?
3. Remove the Print Engine Controller Board Cover
[RRP 8.5, page 310].
ground.
Does the voltage between P11 and frame ground
measure +5.0 VDC?
Measure the voltage between P/J21-4 and frame Step 9. Step 7.
ground.

Table 77 Laser Assembly Troubleshooting Procedure (cont'd.)

ground. Controller
Board
Does the voltage P/J21-3 and frame ground [RRP 8.5,
measure +5.0 VDC. page 310].

1. Switch printer power OFF. LVPS Print Engine
2. Remove the Lower Rear Cover [RRP 1.7, page 256]. [RRP 8.6, Controller
3. Disconnect P/J16 from the Print Engine Controller page 312]. Harness
Board. [PL 9.2,
4. Measure the resistance between pin 5 of the page 406].
disconnected plug and P/J161-10 on the LVPS.
Is there continuity between P16-5 and
P/J161-10?
ground. Controller
Board
Does the voltage between P/J21-3 and frame [RRP 8.5,
ground measure +5.0 VDC? page 310].
10 PRINT CARTRIDGE TAB Go to Replace the

1. Open the Top Cover and remove the Print Cartridge. Step 11. Print
2. Inspect the tab on the left side of the Print Cartridge Cartridge
that actuates the Print Cartridge Switch. [PL 8.1,
Is the tab on the Print Cartridge intact? page 402].
11 LASER SAFETY SWITCH ACTUATOR Go to Replace the

Press and release the Laser Safety Switch Actuator. Step 12. CRUM PWB
[RRP 3.7,
Does the Laser Safety Switch Actuator lever page 281].
move smoothly?
1. Switch printer power OFF. Print Engine CRUM PWB
2. Install the Print Cartridge. Controller [RRP 3.7,
3. Leave the Top Cover open. Board page 281].
4. Disconnect P/J21 from the Print Engine Controller [RRP 8.5,
Board. page 310].
5. Check for continuity between J21-4 and J21-3 as you
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?
1. Run a test print while measuring the voltage between Step 14. Print Engine
P/J11-5 and frame ground. Controller
2. Run a test print while measuring the voltage between Board
P/J11-6 and frame ground. [RRP 8.5,
Does the voltage on both pins change from page 310].
0.0 VDC to +1.1 VDC and back to 0.0 VDC?

Table 77 Laser Assembly Troubleshooting Procedure (cont'd.)

14 LASER ASSEMBLY REPLACEMENT Go to Problem
Replace the Laser Assembly [RRP 7.1, page 297]. Electrical solved.
Noise,
Does the problem still appear? page 157.
■ Laser Assembly [RRP 7.1, page 297]
■ CRUM PWB [RRP 3.7, page 281]

RAP 49 Fuser Assembly
Warning: If the printer has been switched on, the fuser may be very
hot.
Table 78 Fuser Assembly Troubleshooting Procedure

1 RESISTANCE MEASUREMENTS Go to Replace the
1. Switch printer power OFF. Step 2. Fuser
2. Remove the Fuser Assembly [RRP 5.1, page 288]. Assembly
3. Measure the resistance between pins A1 and A2, and [RRP 5.1,
between pins 1 and 4 or 2 and 4 on P174 on the Fuser page 288].
Assembly [see Figure 17 on page 134].
Does the resistance between A1 and A2 measure
between 10K and 350K ohms (depending on the
temperature of the fuser) and the resistance
between pins 1 and 4 or 2 and 4 measure less
than 5 ohms?
1. Reinstall the Fuser Assembly. Step 4. Step 3.
2. Remove the Lower Rear Cover [RRP 1.7, page 256].
3. Disconnect P/J172 from the Fuser Board.
4. Ensure the Rear Cover is closed.
5. Check for continuity between P172-1 and P172-3.
Is there continuity between P172-1 and P172-3?
1. Remove the Right Side Cover [RRP 1.2, page 251]. Fuser Rear Cover
2. Ensure the Rear Cover is closed. Harness Interlock
3. Check for continuity between P/J172-1 and both sides Assembly Switch
of the Rear Cover Interlock Switch. [PL 9.2, [PL 9.2,
Is there continuity between P/J172-3 and both page 406]. page 406] or
sides of the Rear Cover Interlock Switch? the Fuser
Wiring
Harness
[PL 9.2,
page 406] as
necessary.

1. Remove the Left Side Cover [RRP 1.1, page 250] and Step 5. Fuser
the Print Engine Controller Board Cover [RRP 8.5, Harness
page 310]. Assembly
2. Disconnect P/J17 from the Print Engine Controller [PL 9.2,
Board. page 406].
3. Check for continuity between P17-7 and P17-8.
Is there continuity between P17-7 and P17-8?
1. Disconnect P/J171 from the Fuser Board. Step 6. Fuser
2. Check for continuity between P17-3 and P171-1, Harness
P17-2 and P171-2 and P17-1 and P171-3. Assembly
Is there continuity between all pins measured? [PL 9.2,
page 406].

Table 78 Fuser Assembly Troubleshooting Procedure (cont'd.)

1. Reconnect P/J171, P/J172 and P/J17. Fuser Board Step 7.
2. Switch printer power ON. [RRP 8-8,
3. Measure the voltage between J17-2 on the Print page 314]. If
Engine Controller Board and frame ground. problem
Does the voltage measure +3.3 VDC? persists,
replace the
Print Engine
Controller
Board
[RRP 8.5,
page 310].

Board page 312].
Does this voltage measure +3.3 VDC? [RRP 8.5,
page 310.
■ Fuser Board [RRP 8-8, page 314]
■ Fuser Interlock Switch [PL 9.2, page 406]
Figure 17 Fuser Connector P174

RAP 50 Registration Sensor
.
Table 79 Registration Sensor Troubleshooting Procedure

1 PROCEDURE It appears Go to
1. Open the Top Cover and remove the Print Cartridge. the Step 2.
2. Extend the MBF by lifting, then pulling toward you. Registration
3. Enter Diagnostics mode. Sensor is
4. From the Main Menu, select Component Test / Sensor working
Input / press [4] to start, [0] to stop. correctly. If
5. Actuate and deactuate the Registration Sensor. problem
Does the LCD counter increment each time you persists,
press and release the actuator? replace the
Print Engine
Controller
Board
[RRP 8.5,
page 310].
2 REGISTRATION SENSOR ACTUATOR Go to Replace the

INSPECTION Step 3. Registration
1. Visually inspect the Registration Sensor Actuator Sensor
through the open MBF door. Actuator
2. Manually actuate the Registration Sensor Actuator. [RRP 4.2,
Does the actuator move freely and appear to be page 285].
in good condition (not broken or damaged)?
page 310]. [RRP 8.5,
3. Disconnect P/J18 from the Print engine Controller page 310].
Board.
voltage between P18-11 and frame ground, then
between P18-13 and frame ground.
both pins and frame ground?
1. Switch printer power OFF. Print Engine Registration
2. Reconnect P/J18 to the Print Engine Controller Board. Controller Sensor
3. Enter Diagnostics mode. Board Actuator
4. From the Main Menu, select Component Test / Sensor [RRP 8.5, [RRP 4.4,
Input / press [4] to start, [0] to stop. page 310]. page 287].
Registration Sensor is deactuated and 0.1 VDC
when actuated?

Table 79 Registration Sensor Troubleshooting Procedure (cont'd.)

■ Registration Sensor Actuator [RRP 4.2, page 285]

RAP 51 MBF No Paper Sensor
.
Table 80 MBF No Paper Sensor Troubleshooting Procedure

1. Open the MBF Door and remove all paper from the the MBF No Step 2.
MBF. Paper
2. Enter Diagnostics mode Sensor is
3. From the Main Menu, select Component Test / Sensor working
Input / press [4] to start, [0] to stop. correctly. If a
4. Actuate and deactuate the MBF No Paper Sensor problem
Actuator. persists,
Does the LCD counter increment each time you replace the
press and release the actuator? Print Engine
Controller
Board
[RRP 8.5,
page 310].
2 MBF NO PAPER SENSOR ACTUATOR Go to Replace the

INSPECTION Step 3. MBF No
1. Manually move the MBF No Paper Sensor Actuator. Paper
2. Visually inspect the MBF No Paper Sensor Actuator. Sensor Actor
[RRP 2.7,
Does the actuator move freely and appear to be
in good condition (not broken or damaged)? page 267].

page 310]. [RRP 8.5,
Board.
CAUTION! In the next step you will be very close to
P12-10, which is the +24 VDC supply. If accidently
shorted to pin 9, the Print Engine Controller Board will
be immediately destroyed. Use extreme caution in
making this measurement.
between P12-9 and frame ground.
Are both voltage readings +3.28 VDC?
P12-9 and frame ground when the MBF No Paper
Sensor is deactuated and 0.0 VDC when
actuated?

Table 80 MBF No Paper Sensor Troubleshooting Procedure (cont'd.)

5 MBF COMBO HARNESS CONTINUITY CHECK Go to Replace the
1. Switch printer power OFF. Step 6. MBF Combo
2. Disconnect P/J121 from the MBF Assembly and Harness
P/J12 from the Print Engine Controller Board. [PL 4.2,
3. Check for continuity between P/J121 and P/J12 as page 394].
follows:
■ J121-9 and J12-7
■ J121-8 and J12-8
■ J121-7 and J12-9
Is there continuity between each of the wires?

1. Remove the MBF Assembly and disconnect P/J125 MBF No MBF Combo
from the MBF No Paper Sensor. Paper Harness
2. Check for continuity between P/J125 and P/J121 as Sensor [PL 4.2,
follows: Assembly page 394].
■ J125-3 and J121-4 [RRP 2.7,
■ J125-2 and J121-5 page 267].
■ J125-1 and J121-6

■ MBF No Paper Sensor Assy [PL 4.2, page 394]

RAP 52 Laser Safety Switch
The Print Cartridge is not in place or is installed incorrectly.
Table 81 Error Code J3: Laser Safety Switch Open Troubleshooting

1 PRINT CARTRIDGE INSPECTION Go to Replace the
1. Open the Top Cover. Step 2. Print
2. Remove the Print Cartridge. Cartridge
3. Inspect the tab on the left side of the Print Cartridge [PL 8.1,
that actuates the Print Cartridge Switch. page 402].
Is the tab on the Print Cartridge intact?
2 PRINT CARTRIDGE SWITCH ACTUATOR Go to Replace the
INSPECTION Step 3. CRUM
Press and release the Print Cartridge Switch Actuator. board
[RRP 3.7,
Does the Print Cartridge Switch Actuator move page 281].
smoothly?
3 CONTINUITY CHECKS Replace the Replace the
1. Switch the printer power OFF. Print Engine CRUM
2. Install the Print Cartridge and leave the Top Cover Controller board
open. board [RRP 3.7,
3. Remove the Left Side Cover [RRP 1.1, page 250]. [RRP 8.5, page 281].
4. Remove the Print Engine Controller Board Cover page 310]
[RRP 8.5, page 310]. and retest. If
5. Disconnect P/J21 from the Print Engine Controller problem still
Board.
6. Check for continuity between J21-4 and J21-3 as you exists, go to
lift and lower the Print Cartridge. Step 4.
Is there continuity between J21-4 and J21-3
when you lower the cartridge and no continuity
when you lift the cartridge?
■ CRUM Board Assembly [RRP 3.7, page 281]

RAP 53 Tray 1 No Paper Sensor
Table 82 Tray 1 No Paper Sensor Troubleshooting Procedure

1. Remove Tray 1. the Tray 1 Step 2.
2. Enter Diagnostics mode. No Paper
3. From the Main Menu, select Component Test / Sensor Sensor is
Input / press [4] to start, [0] to stop. working
4. Actuate the Tray No Paper Sensor Actuator. correctly. If a
Does the LCD counter increment each time you problem
press and release the actuator? persists,
replace the
Print Engine
Controller
Board
[RRP 8.5,
page 310].
2 TRAY 1 NO PAPER SENSOR ACTUATOR Go to Replace the

INSPECTION Step 3. Tray 1 No
1. Manipulate the Tray 1 No Paper Sensor Actuator. Paper
2. Visually inspect the Tray 1 No Paper Sensor Actuator. Sensor
Actuator
Does the actuator move freely and appear to be
in good condition (not broken or damaged)? [RRP 2.6,
page 266].

page 310]. [RRP 8.5,
Board.
measure the voltage between P12-6 and frame
ground.
page 310]. [RRP 8.5,
Board.
voltage between P12-6 and frame ground.
ground measure +3.28 VDC when the Tray 1 No
Paper Sensor is deactuated and 0.0 VDC when
actuated?

Table 82 Tray 1 No Paper Sensor Troubleshooting Procedure (cont'd.)

5 “NO” FROM STEP 4 ABOVE Go to Replace
1. Switch printer power OFF. Step 6. MBF
2. Disconnect P/J121 from the MBF Assembly and Harness
P/J12 from the Print Engine Controller Board. [PL 4.2,
3. Check for continuity between P/J121 and P/J12 as page 394].
follows:
■ J121-12 and J12-4
■ J121-11 and J12-5
■ J121-10 and J12-6

1. Remove the MBF Assembly and disconnect P/J126 Tray 1 No MBF Combo
from the MBF No Paper Sensor. Paper Harness
2. Check for continuity between P/J126 and P/J121 as Sensor [PL 4.2,
follows: [RRP 2.6, page 394]
■ J126-3 and J121-1 page 266].
■ J126-2 and J121-2
■ J126-1 and J121-3

■ Tray 1 No Paper Sensor [RRP 2.6, page 266]

RAP 54 Size Switch
The error message indicates a problem with the standard feeder, the 500-Sheet Feeder
or the 2000-Sheet Feeder.
Table 83 Size Switch Troubleshooting Procedure

1 Is the problem with the 2000-Sheet Feeder? Go to Go to
Step 10. Step 2.
2 500-SHEET FEEDER TROUBLESHOOTING Go to Replace the

1. Remove the tray from the problem feeder. Step 3. Paper Tray
2. Inspect the Size Cams on the left side of the paper [PL 2.1,
tray. page 386 /
Are the Size Cams intact and in good condition PL 2.2,
(no broken surfaces)? page 388].
3 SIZE SWITCH ACTUATOR INSPECTION Go to Replace the

Visually inspect the Size Switch Actuators for damage Step 4. Left Guide
or wear. Assembly
[RRP 3.6,
Do the actuators move freely and appear to be in page 279 /
good condition (not broken or damaged)? RRP 11.13,
page 340].
4 SIZE SENSORS TEST The Size Go to

1. Enter Diagnostics mode. Sensors Step 5.
2. From the Main Menu, select Component Test / Sensor appear to be
Input / press [4] to start, [0] to stop. working
3. One at a time, press each of the Size Actuators, while correctly. If
observing the display. the problem
Does the LCD counter increment each time you persists,
press and release one of the actuators? replace the
Print Engine
Controller
Board
[RRP 8.5,
page 310].
5 Is the problem with the Tray 1 Size Sensor? Go to Go to

Step 9. Step 6.
6 “NO” FROM STEP 5 ABOVE Go to Check for

1. Switch printer power OFF. Step 7. pin-to-pin
2. Remove the Left Cover from the 500-Sheet Feeder continuity of
[RRP 11.3, page 330]. the Size
3. Disconnect P/J138 from the Feeder Board. Sensor
4. Check for continuity between the following pins, while Harness.
pressing the switches indicated: Repair or
■ P138-1 and P138-3 when pressing SW1 Bottom
replace as
■ P138-2 and P138-3 when pressing SW2
necessary. If
■ P138-5 and P138-3 when pressing SW4 Top the harness
is OK,
Is there continuity in each case? replace the
Size Sensor
Switch
[PL 11.3,
page 416].

Table 83 Size Switch Troubleshooting Procedure (cont'd.)

1. Reconnect P/J138 to the Feeder Board. Step 8. Feeder
2. Switch printer power ON. Board
3. Measure the voltages in Table 84 on P/J132-5 (Tray 2) [RRP 11.7,
or P/J132-6 (Tray 3) as you actuate the switches. page 334].
page 310]. [RRP 8.5,
4. Measure the voltages on P/J13-5 (Tray 2) or P/J132-6
(Tray 3) as you actuate the switches (see Table 84).
1. Switch printer power OFF. Print Engine pin-to-pin
2. Remove the Left Side Cover [RRP 1.1, page 250]. Controller continuity of
3. Disconnect P/J20 from the Print Engine Controller Board the Size
Board. [RRP 8.5, Sensor
4. Check for continuity between the following pins, of the page 310]. Harness.
disconnected plug, while pressing the switches: Repair or
■ P20-7 and P20-5 when pressing SW1(Top)
replace as
necessary. If
■ P20-3 and P20-5 when pressing SW4 (Bottom) the harness
OK, replace
Is there continuity in each case? the Size
Sensor
Switch
[PL 3.1,
page 390].

3. Press and release the 2000-Sheet Feeder A4 Paper [RRP 8.5,
Sensor. page 310].
press and release the sensor actuator?
1. Switch printer power OFF. 2000-Sheet 2000-Sheet
2. Disconnect P/J604 from the 2000-Sheet Feeder Feeder Feeder A4
Board. Board Paper
3. Check for continuity between pins 5 and 6 as you [RRP 12.8, Sensor
actuate and deactuate the Paper Size Sensor. page 360]. [RRP 12.10,
Does the ohmmeter measure continuity when page 362].
the sensor is actuated and infinity when
deactuated?

Table 83 Size Switch Troubleshooting Procedure (cont'd.)

12 “NO” FROM STEP 8 ABOVE. Replace the Repair or
Check for continuity between P/J13-5 (Print Engine Print Engine replace the
Controller Board) and P/J131-5 (Tray 2) or P/J13-6 and Controller harness as
P/J131-6 (Tray 3), then between P/J131-5 and P/J132-5 Board necessary.
(Feeder Board) (Tray 2) or P/J131-6 and P/J132-6 (Tray [RRP 8.5,
3). [P/J131 is the connector between the printer and the page 310].
500-Sheet Feeder.]
Is there continuity between each of the sets of
test points checked?
■ Left Guide Assy [RRP 3.6, page 279 or RRP 11.13,
page 340]
■ Paper Tray [PL 2.1, page 386 / PL 2.2, page 388]
■ Size Sensor Switch [PL 3.1, page 390]
■ 2000-Sheet Feeder Board [RRP 12.8, page 360].
Table 84 Size Switch Voltages
Press Press Press

Actuator Voltage Actuators Voltage Actuators Voltage
4 (top) +1.4 VDC 4&3 +0.4 VDC 4, 3 & 2 0.0 VDC
3 +2.3 VDC 4&2 +0.9 VDC None +3.3 VDC
2 +2.8 VDC 3&2 +1.8 VDC

RAP 55 Turn Roller Clutch Assembly
.
Table 85 Turn Roller Clutch Assembly Troubleshooting Procedure

2. From the Main Menu, select Component Test / Turn
Roll Clutch / press [4] to test, [0] to stop.
Can you hear the Turn Roller Clutch energize?
remove the Print Engine Controller Board Cover
[RRP 8.5, page 310].
Board.
4. Measure the resistance between pins 10 and 11 on
the disconnected plug.
Is the resistance approximately 170 to
185 ohms?
3 “NO” FROM STEP 2 ABOVE Repair or Go to
1. Remove the MBF Assembly. replace the Step 4.
2. On the MBF Assembly, measure the resistance MBF
between P121-7 and P121-8. Harness
Is the resistance approximately 170 to [PL 9.1,
185 ohms? page 404].
4 TURN ROLLER CLUTCH RESISTANCE Repair or Replace the

1. Remove the MBF Gear Cover. replace the Turn Roller
2. Disconnect the Turn Roller Clutch Assembly in-line MBF Combo Clutch
connector (P/J124). Harness Assembly
3. Measure the resistance of the clutch. [PL 4.2, [RRP 2.3,
Is the resistance approximately 170 to page 394]. page 262].
185 ohms?
5 “YES” FROM STEP 2 ABOVE Go to So to Step 6.
1. Switch printer power ON. Step 7.
Board page 312].
Is the voltage +24 VDC? [RRP 8.5,
page 310].

Table 85 Turn Roller Clutch Assembly Troubleshooting Procedure (cont'd.)

2. Reconnect P/J12. Controller
4. From the Main Menu, select Component Test / Turn [RRP 8.5,
Roll Clutch. page 310].
ground.
Does the voltage drop from +24 VDC to 0.0 VDC?
8 “YES” FROM STEP 7 ABOVE Problem Replace the
1. Switch printer power OFF. solved. Turn Roller
2. Open the Top Cover and remove the Print Cartridge. Clutch
3. With the Top Cover open, cheat the Top Cover [RRP 2.3,
Interlock. page 262] or
4. Enter Diagnostics mode. Turn Roller
5. From the Main Menu, select Component Test / Main Assembly
Motor / press [4]. [RRP 2.1,
6. Scroll to Turn Roll Clutch / press [4].
page 259] as
Do the Turn Rollers rotate smoothly without necessary.
stalling or jerking?
■ Turn Roller Clutch Assembly [RRP 2.3, page 262]
■ Harness Assembly, MBF Combo [PL 4.2, page 394]
■ Harness Assembly, Paper Handling [PL 9.1, page 404]
■ MBF Assy [RRP 2.1, page 259]

RAP 56 Tray 1 Feed Solenoid
.
Table 86 Tray 1 Feed Solenoid Troubleshooting Procedure

2. From the Main Menu, select Component Test / Tray 1
Feed Sol / press [4], [0] to stop.
Can you hear the solenoid energize?
page 310].
Board.
Is the resistance approximately 90 ohms?
2. On the MBF Assembly, measure the resistance MBF
Is the resistance approximately 90 ohms? [PL 9.1,
page 404].
4 “NO” FROM STEP 3 ABOVE Repair or Replace the

1. Remove the MBF Gear Cover. replace the Tray 1 Feed
2. Disconnect the Tray 1 Feed Solenoid in-line MBF Combo Solenoid
connector (P/J123). Harness [RRP 2.9,
3. Measure the resistance of the solenoid. [PL 4.2, page 270].
Is the resistance approximately 90 ohms? page 394].

Board page 312].
page 310].

Table 86 Tray 1 Feed Solenoid Troubleshooting Procedure (cont'd.)

7 “YES” FROM STEP 6 ABOVE Check for Replace the
1. Switch printer power OFF. mechanical Print Engine
2. Reconnect P/J12. binding of Controller
3. Enter Diagnostics mode. the solenoid Board
4. From the Main Menu, select Component Test / Tray 1 or a [RRP 8.5,
Feed Sol. defective page 310].
5. Measure the voltage between P/J12-13 and frame spring. If
ground. problem
persists,
Does the voltage drop from +24 VDC to 0.0 VDC? replace the
Tray 1 Feed
Solenoid
[RRP 2.9,
page 270].
8 TRAY 1 FEED SOLENOID TEST Problem Replace the

1. Enter Diagnostics mode. solved. Tray 1 Feed
2. From the Main Menu, select Component Test / Main Solenoid
Motor / press [4] to start, [0] to stop. [RRP 2.9,
3. Scroll to Turn Roll Clutch / press [4] to energize clutch. page 270].
4. Scroll to Tray 1 Feed Sol / press [4].
Was a sheet of paper fed from Tray 1 to the
Registration Rollers?
■ Feed Solenoid [RRP 2.9, page 270]

RAP 57 MBF Feed Solenoid
.
Table 87 MBF Feed Solenoid Troubleshooting Procedure

2. From the Main Menu, select Component Test / MBF
Feed Sol / press [4], [0] to stop.
page 310].
Board.
Is the resistance approximately 90 ohms?
2. On the MBF Assembly, measure the resistance MBF Combo
Is the resistance approximately 90 ohms? [PL 4.2,
page 394].

1. Remove the MBF Gear Cover. replace the MBF Feed
2. Disconnect the MBF Feed Solenoid in-line connector MBF Combo Solenoid
(P/J122). Harness [RRP 2.8,
3. Measure the resistance of the solenoid. [PL 4.2, page 269].
Is the resistance approximately 90 ohms? page 394].

Board page 312].
page 310].

Table 87 MBF Feed Solenoid Troubleshooting Procedure (cont'd.)

7 “YES” FROM STEP 5 ABOVE Check for Replace the
1. Switch printer power OFF. mechanical Print Engine
2. Reconnect P/J12. binding of Controller
3. Enter Diagnostics mode. the solenoid Board
4. From the Main Menu, select Component Test / MBF or a [RRP 8.5,
Sol. defective page 310].
5. Measure the voltage between P/J12-15 and frame spring. If the
ground. problem
persists,
MBF Feed
Solenoid
[RRP 2.8,
page 269].
8 MBF SOLENOID TEST Problem Replace the

1. Open the Top Cover and cheat the Top Cover solved. MBF Feed
Interlock. Solenoid
2. Remove the Print Cartridge. [RRP 2.8,
3. Add paper to the MBF. page 269].
5. From the Main Menu, select Component Test / MBF
Feed Sol / press [4] to start, [0] to stop.
6. Scroll to Main Motor / press [4] to start motor.
Was a sheet of paper fed from the MBF to the
Registration Rollers?
■ MBF Feed Solenoid [RRP 2.8, page 269]

RAP 58 Toner Sensor Assembly
.
Table 88 Toner Sensor Assembly Troubleshooting Procedure

page 310].
3. Open the Top Cover and remove the Print Cartridge.
4. Cheat the Top Cover Interlock.
Board.
Board page 312].
Does the voltage measure + 24.0 VDC? [RRP 8.5,
page 310].

Measure the voltage between P14-3 and frame ground. Step 4. Print Engine
Controller
Does the voltage measure +5.0 VDC? Board
[RRP 8.5,
page 310].
4 “YES” FROM STEP 3 ABOVE Problem Go to

1. Switch printer power OFF. solved. Step 5.
2. Reconnect P/J14.
4. Raise and lower the Print Cartridge approximately 2
inches (50.8 mm) while measuring the voltage
between P/J14-3 and frame ground.
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. Switch printer power OFF. Sensor Toner
2. Disconnect P/J14 from the Print Engine Controller Assembly 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 page 301]. [PL 8.1,
P/J141. page 402],
Is there continuity between all the pins tested? as
necessary.

Table 88 Toner Sensor Assembly Troubleshooting Procedure (cont'd.)

■ Toner Sensor Assembly [RRP 7.3, page 301]
■ Harness Assembly, Toner Sensor [PL 8.1, page 402]

RAP 59 HVPS Assembly
.
Table 89 HVPS Assembly Troubleshooting Procedure

1 PRINT CARTRIDGE RIGHT GUIDE ASSEMBLY Go to Replace the
INSPECTION Step 2. Right Print
1. Open the Top Cover and remove the Print Cartridge. Cartridge
2. Inspect all contacts on the right Print Cartridge Guide Guide
Assembly and the terminals on the Print Cartridge. Assembly
Are the contacts and terminals in good condition [RRP 7.2,
and contacting properly when the cartridge is page 299] or
installed? the Print
Cartridge
[PL 8.1,
page 402].
2 SEAL GUIDE INSPECTION Go to Replace the

Inspect the Seal Guide on the rear end of the Right Print Step 3. Right Print
Cartridge Guide Assembly. Cartridge
Guide
Is the Seal Guide intact, free of contamination, Assembly
deformation or damage? [RRP 7.2,
page 299].
3 CHARGE ROLLER AC TEST Go to Go to

2. From the Main Menu, select Component Test / Charge
Roll AC.
3. Cheat the Top Cover Interlock switch.
4. Measure the AC voltage between the Right Side
Guide Charge Terminal (connector nearest the front of
the machine) and frame ground.
Warning: The next step will result in very high
voltage being placed on an exposed
contact. Use all standard high-voltage
safety practices and avoid getting in
close proximity of the contact or meter
probe.
5. Press [4] to read, [0] to stop.
Does the voltage read approximately
1125 ±25 VAC?
4 “DEV BIAS AC” VOLTAGE CHECK Go to Go to
1. Scroll to “Dev Bias AC-”. Step 9. Step 5.
2. Measure the voltage between the Right Side Guide
Charge Terminal (connector nearest the back of the
machine) and frame ground.
contact. Use all standard high voltage
probe.
Does the voltage measure approximately
620 ±25 VAC?

Table 89 HVPS Assembly Troubleshooting Procedure (cont'd.)

5 “BTR -” VOLTAGE CHECK Replace the Go to
1. Scroll to “BTR -”. HVPS Step 6.
2. Measure the voltage between the left end of the BTR [RRP 8.2,
shaft and frame ground. page 307].
probe.
770 ±25 VDC?
6 +24 VDC CHECK Replace the Go to
1. Switch printer power OFF. HVPS Step 7.
2. Remove the Lower Rear Cover [RRP 1.7, page 256], [RRP 8.2,
Duplex Assembly [RRP 9.1, page 404] if installed, page 307].
and the HVPS Cover [RRP 1.6, page 255].
ground.
7 “NO” FROM STEP 6 ABOVE Check the Go to
1. Switch printer power OFF. wires for Step 8.
2. Remove the Left Side Cover [RRP 1.1, page 250] and continuity
the Print Engine Controller Board Cover [RRP 8.5, between
page 310]. P/J181 and
3. Switch printer power ON. P/J18.
4. Measure the voltage between P/J18-1 on the Print Repair or
Engine Controller Board and frame ground. replace as
Is the voltage +24 VDC? necessary.

Board page 312].
page 310].

1. Check the wiring connections and continuity between HVPS replace wire
the charge contact on the Right Side Guide and P186 [RRP 8.2, harness as
on the HVPS. page 307]. necessary.
2. Repair or replace as necessary.
Does wiring check OK?


1. Scroll to Charge Roll DC. Step 11. HVPS
2. Measure the voltage between the Right Side Guide [RRP 8.2,
Charge Terminal and frame ground. page 307].
probe.
3. Press [4] to test, [0] to stop.
390 ±25 VDC?
1. Scroll to Dev Bias AC. Step 12. HVPS
2. Measure the voltage between the Right Side Guide [RRP 8.2,
Developer Bias Terminal (connector nearest the back page 307].
of the machine) and frame ground.
probe.
3. Press [4] to test, [0] to stop.
620 ±25 VAC?
1. Remove the Right Print Cartridge Guide Assembly Step 13. Developer
[RRP 7.2, page 299]. Wire
2. Remove the screws that secure the Developer Wire Assembly
Assembly [PL 8.1, page 402] and P/J 186 of the Xero and/or Xero
Wire Assembly [PL 8.1, page 402]. Wire
3. Disconnect P/J187 and P/J186 from the HVPS Assembly
Assembly. [PL 8.1,
4. Check for continuity between both ends of the
developer Wire Assembly and Xero Wire Assembly. page 402].
Is there continuity respectively through the
Developer Wire Assembly and Xero Wire
Assembly?
13 “YES” FROM STEP 12 ABOVE Replace the Problem
Replace the Print Engine Controller Board [RRP 8.5, HVPS solved.
page 310]. [RRP 8.2,
page 307].
Does the problem still appear?


■ HVPS Assembly [RRP 8.2, page 307]
■ Print Cartridge Right Guide Assembly [RRP 7.2,
page 299]
■ Harness Assembly, HVPS [PL 9.1, page 404

RAP 60 Electrical Noise
.
Table 90 Electrical Noise Troubleshooting Procedure

1. Check to see if there is other electrical equipment, Step 2. solved.
such as electrical generators, radio transmitters, or
devices using electrical motors, within ten feet of the
printer.
2. Shut off the other electrical equipment, or relocate the
printer at least twenty feet away from other devices.
Is the electrical noise problem still present?
2 AC POWER Go to Inform the
Check the AC wall outlet and power cord [RAP 38, Step 3. customer of
page 110]. insufficient
voltage
Is the wall outlet correctly wired and is the power supply or
cord in good condition (not damaged in any improper
way)? wiring.
3 RIGHT PRINT CARTRIDGE GUIDE ASSEMBLY Go to Replace the

INSPECTION Step 4. Right Print
1. Open the Top Cover and remove the Print Cartridge. Cartridge
2. Inspect all contacts on the Right Print Cartridge Guide Guide
Assembly and the terminals on the Print Cartridge. Assembly
Are the terminals in good condition and [RRP 7.2,
contacting properly when the cartridge is page 299] or
installed? the Print
Cartridge
[PL 8.1,
page 402].
4 POWER SWITCH GROUNDING Go to Secure the

1. Remove the Lower Rear Cover [RRP 1.7, page 256]. Step 5. grounding
2. Inspect the grounding screw for the cable connected screw
to the printer power switch. properly.
Is the cable grounded properly?
Replace the Print Cartridge [PL 8.1, page 402]. Step 6. solved.
Is the electrical noise problem still present?
6 “YES” FROM STEP 5 ABOVE Go to Clean the
1. Remove the Print Cartridge. Step 7. Seal Guide
2. Remove the Right Print Cartridge guide Assembly or replace
[RRP 7.2, page 299]. the Right
3. Inspect the Seal Guide on the rear end of the Right Print
Print Cartridge Guide Assembly. Cartridge
Is the Seal Guide intact, free of contamination, Guide
obstructions and deformities? Assembly
[RRP 7.2,
page 299].

Table 90 Electrical Noise Troubleshooting Procedure (cont'd.)

7 PAPER TRANSPORT ASSEMBLY Go to Replace the
1. Remove the Paper Transport Assembly [RRP 4.1, Step 8. Paper
page 283]. Transport
2. Check all the wires in the Paper Transport Assembly Assembly
for continuity. [RRP 4.1,
Do all the wires check OK for continuity? page 283].
8 DEVELOPER WIRE ASSEMBLY Go to Secure /

Inspect the Developer Wire Assembly. Step 9. connect the
wires
Are all the wires connected properly? properly.
9 FUSER ASSEMBLY Go to Secure /

Inspect the cables of P174-1 and P174-4 and the right Step 10. connect the
end of the Heat Rod. cables
properly or
Are the cables attached properly? replace the
Fuser
Assembly
[RRP 5.1,
page 288].

1. Disconnect the HVPS (P/J18) from the Print Engine HVPS Board Step 11.
Controller Board [RRP 8.5, page 310]. Assembly
2. Print a continuous test run of approximately twenty [RRP 8.2,
sheets. page 307].
Does the printer complete the test run without
shutting down?
11 PRINT ENGINE CONTROLLER BOARD Go to Problem
REPLACEMENT Step 12. solved.
Replace the Print Engine Controller Board [RRP 8.5,
page 310].
Is the problem still present?
12 GROUND CONNECTIONS Go to Repair all
Inspect all of the grounds in the printer. Step 13. poor ground
connections.
Are all the grounds securely connected?
13 ASSEMBLY REPLACEMENT Problem Review
Replace the following components, one at a time, until solved. Step 13. If
the cause of the problems is found. problem
persists, call
■ HVPS Board Assembly [RRP 8.2, page 307] Technical
■ Right Print Cartridge Guide Assembly [RRP 7.2, Support.
page 299]
■ Inlet Assembly [PL 9.2]
■ Harness Assembly, HVPS [PL 9.2]
Does the problem disappear after replacing one

of the above assemblies?

RAP 61 Low Paper Tray 2 (or Tray 3) /
500-Sheet Feeder
Tray 2 and/or Tray 3 have low paper.
Table 91 Low Paper Tray 2 (or Tray 3) / 500-Sheet Feeder Troubleshooting
Procedure

Fill the affected paper tray with fresh paper. Step 2. solved.
Is the error code still displayed?
2 LOW PAPER SENSOR ACTUATOR TEST Go to Replace the
1. Remove the paper tray from the 500-Sheet Feeder Step 3. Low Paper
Assembly. Sensor
2. Manually push up and release the low paper actuator. Actuator
Does the low paper sensor actuator move [RRP 11.18,
smoothly up and down? page 347] or
the Tray 2/3
Left Guide
Assembly
[RRP 11.13,
page 340].
3 LOW PAPER SENSOR ACTUATOR Replace the Go to

3. Press and release the Low Paper Sensor Actuator. [RRP 8.5,
Does the LCD counter increment each time you page 310].
4 FEEDER BOARD Go to Replace the
2. Remove the 500-Sheet Feeder Left Cover [RRP 11.3, Board
page 330]. [RRP 11-7,
3. Disconnect P/J133 from the Feeder Board. page 334].
ground, then measure the voltage between P133-3
and frame ground.
Are both measurements +3.3 VDC?
2. Reconnect P/J133.
ground as you actuate and deactuate the Low Paper
Sensor.

Table 91 Low Paper Tray 2 (or Tray 3) / 500-Sheet Feeder Troubleshooting
Procedure (cont'd.)

1. Switch printer power OFF. Low Paper replace the
2. Remove the 500-Sheet Feeder Left Tray Guide. Sensor harness as
3. Check for continuity between all pins of P/J133 and [RRP 11.18, necessary.
P/J137. page 347].
Do all pins check OK for continuity?
Measure the voltage between P/J132-7 (Tray 2) or Step 8. Feeder
P/J132-8 (Tray 3) and frame ground as you actuate and Board
deactuate the Low Paper Sensor. [RRP 11-7,
page 334].
deactuated and 0.0 VDC when actuated?
page 250] and the Print Engine Controller Board Board P/J132 and
Cover [RRP 8.5, page 310]. [RRP 8.5, P/J131, then
4. Measure the voltage between P/J13-7 (Tray 2) or P/J131 and
P/J132-8 (Tray 3) and frame ground as you actuate P/J13, all
and deactuate the Low Paper Sensor.
pins. Repair
Does the voltage measure +0.9 VDC when or replace as
deactuated and 0.0 VDC when actuated? necessary.
■ Low Paper Sensor Actuator [RRP 11.18, page 347]
■ Tray Left Guide Assembly [RRP 11.13, page 340]
■ Feeder Board [RRP 11-7, page 334]

RAP 62 500-Sheet Feeder Feed Solenoid
The 500-Sheet Feeder is not feeding paper or not feeding paper at the correct time.
Table 92 500-Sheet Feeder Feed Solenoid

2. From the Main Menu, select Component Test / Tray 2
Feed Sol (or Tray 3 Feed Sol) / press [4] to start.
2. Remove the 500-Sheet Feeder Left Cover [RRP 11.3,
page 330].
3. Disconnect P/J133 on the Feeder Board.
Does the resistance measure approximately
90 ohms?
1. Disconnect P/J135 from the Feed Head Assembly. replace the Tray 2/3
2. Measure the resistance between P135-1 and P135-2. Feed Head Feed
Harness Solenoid
Does the resistance measure approximately [PL 11.3, [RRP11.10,
90 ohms?
page 416]. page 337].

2. Measure the voltage between P/J133-10 on the
Feeder Board and frame ground.
Measure the voltage between P/J132-3 and frame Feeder Step 6.
ground. Board
[RRP 11-7,
Does the voltage measure +24 VDC. page 334].
6 “NO” FROM STEP 5 ABOVE Check the Replace the

1. Switch printer power OFF. continuity of Print Engine
2. Remove the print Left Side Cover [RRP 1.1, the Feeder Controller
page 250] and the Print Engine Controller Board Harnesses Board
Cover [RRP 8.5, page 310]. [P/J132 to [RRP 8.5,
3. Switch printer power ON. P/J131 and page 310].
4. Measure the voltage between P/J13-3 and frame P/J131 to
ground. P/J13].
Does the voltage measure +24 VDC? Repair or
replace as
necessary.

Table 92 500-Sheet Feeder Feed Solenoid

7 “YES” FROM STEP 4 ABOVE Check for Go to
1. Switch printer power OFF. mechanical Step 8.
2. Reconnect P/J133. binding of
3. Enter Diagnostics mode. the solenoid
4. From the Main Menu, select Component Test / Tray 2 or a
Feed Sol (or Tray 3 Feed Sol). defective
5. Measure the voltage between P/J133-11 and frame spring. If the
ground. problem
6. Press [4].
persists,
Tray 2/3
Feed
Solenoid
[RRP 11.10,
page 337].

1. Measure the voltage between P/J132-4 and frame Tray 2/3 Step 9.
ground. Feeder
2. Press [4]. Board
Does the voltage change from 0.0 VDC to +3.2 [RRP 11-7,
VDC? page 334].
9 “NO” FROM STEP 8 ABOVE Check the Replace the

1. Switch printer power OFF. continuity of Print Engine
2. Remove the printer Left Side Cover [RRP 1.1, the Feeder Controller
page 250] and the Print Engine Controller Board Harnesses Board
[RRP 8.5, page 310]. (P/J132 to [RRP 8.5,
3. Switch printer power ON. P/H131 and page 310].
4. Measure the voltage between P/J13-4 and frame P/J131 to
ground. P/J13).
Does the voltage measure +3.2 VDC? Repair or
replace as
necessary
[PL 11.3,
page 416].
10 “YES” FROM STEP 1 ABOVE Problem Replace the

1. Scroll to Main Motor / press [4]. solved. Tray 2/3
2. Scroll to Turn Roll Clutch / press [4]. Feed
3. Scroll to Tray 2 (or Tray 3) Feed Sol / press [4]. Solenoid
Has a sheet of paper been fed from Tray 2/3 to [RRP 11.10,
the Registration Rollers? page 337].
■ Tray 2 (or Tray 3) Feed Solenoid [RRP 11.10,
page 337]
■ Feed Head Harness [PL 11.3, page 416]

RAP 63 500-Sheet Motor
Logic Control on the Print Engine Controller Board detects a problem with the
500-Sheet Feeder Main Motor.
Table 93 500-Sheet Feeder Motor Troubleshooting Procedure

1 +24 V CHECK AT P/J 140 ON 500-SHEET Replace the Go to
FEEDER BOARD 500-Sheet Step 2.
1. Remove the 500-Sheet Feeder Left Cover [RRP 11.6, Feeder
page 333]. Motor
2. Disconnect P/J 140 on the 500-Sheet Feeder Board. [RRP 11.6,
3. Measure the voltage at P/J 140-1 to frame ground. page 333]
2 +24 V CHECK AT P/J 132 ON 500-SHEET Replace the Go to
FEEDER BOARD 500-Sheet Step 3.
Measure the voltage at P/J 132-3 on the 500-Sheet Feeder
Feeder Board to frame ground. Board
[RRP 11.7,
Does the voltage measure +24 VDC? page 334].
3 +24 V CHECK AT P/J 13 ON THE PRINT ENGINE Perform Replace the

CONTROLLER BOARD continuity Print Engine
Measure the voltage at P/J 13-3 on the Print Engine check on the Controller
Controller Board to frame ground. harness Board
from P/J 13 [RRP 8.5,
Does the voltage measure +24 VDC? to P/J 132 page 310
on the Print
Engine
Controller
Board.
Repair /
replace as
necessary.

RAP 64 500-Sheet Feeder Assembly Not
Recognized
Print Engine Controller Board does not recognize the Feeder Assembly.

1 PROCEDURE Go to Reseat the
1. Check the alignment of the printer to the 500-Sheet Step 2. Feeder and
Feeder and the alignment of the top 500-Sheet printer to
Feeder to the second 500-Sheet Feeder, if installed. obtain
2. Ensure the connectors are properly aligned and proper
properly connected. alignment
Are the connectors properly aligned and and
secured? connection.
2 DISCONNECT P/J13 FROM PRINT ENGINE Go to Replace the

CONTROLLER BOARD Step 3. Print Engine
2. Remove the Left Side Cover [RRP 1.1, page 250] and Board
the Print Engine Controller Board Cover [RRP 8.5, [RRP 8.5,
page 310]. page 310].
Board.
3 Is the printer equipped with only one 500-Sheet Go to Go to
Feeder? Step 8. Step 4.
4 DISCONNECT P/J136 FROM FEEDER BOARD Go to Go to

2. Remove the Left Side Cover [RRP 11.3, page 330]
from the top 500-Sheet Feeder.
3. Disconnect P/J136 from the Feeder Board.
4. Reconnect P/J13 to the Print Engine Controller Board.


1. Switch printer power OFF. Feeder replace the
2. Disconnect P/J13 from the Print Engine Controller Board harness
Board and P/J132 from the Feeder Board. [RRP 11-7, between
3. Check for continuity between of the pins on P13 and page 334] in P/J13 and
P132 as follows: the top P/J131
■ P13-1 and P132-1 500-Sheet [PL 9.1,
■ P13-2 and P132-2
Feeder. page 404] or
■ P13-3 and P132-3
■ P13-4 and P132-4
between
■ P13-5 and P132-5 P/J131 and
■ P13-6 and P132-6 P/J132
■ P13-7 and P132-7 [PL 1.2].
■ P13-9 and P132-8
■ P13-10 and P132-9
■ P13-11 and P132-10
■ P13-12 and P132-11
■ P13-13 and P132-12
■ P13-14 and P132-13
■ P13-15 and P132-14
Is continuity measured between all pins?

6 RECONNECT P/J136 TO FEEDER BOARD Replace the Go to
2. Reconnect P/J136 to the top 500-Sheet Feeder. 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].
7 P136 TO P132 CONTINUITY Replace the Repair or
2. Remove the Left Cover [RRP 11.3, page 330] from the Board harness
top 500-Sheet Feeder Board and P/J132 from the [RRP 11-7, between
lower Feeder Board. page 334]. P/J13 and
3. Check for continuity between each of the Pins on P/J131
P136 and P132 as follows: [PL 9.1,
■ P136-1 and P132-1
page 404] or
■ P136-2 and P132-2
■ P136-3 and P132-3
between
■ P136-4 and P132-4 P/J131 and
■ P136-5 and P132-5 P/J132
■ P136-6 and P132-6 [PL 11.2].
■ P136-7 and P132-7
■ P136-8 and P132-9
■ P136-9 and P132-10
■ P136-10 and P132-11
■ P136-11 and P132-12
■ P136-12 and P132-13
■ P136-13 and P132-14

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].


9 P/J13 and P/J132 CONTINUITY CHECK Replace the Repair or
2. Remove the 500-Sheet Feeder Left Cover [RRP 11.3, Board harness
page 330]. [RRP 11-7, between
3. Disconnect P/J13 from the Print Engine Controller page 334]. P/J13 and
Board and P/J132 from the Feeder Board and frame P/J131
ground. [PL 9.1,
4. Check for continuity between each of the pins on P13 page 404] or
and P132 as follows:
■ P13-1 and P132-1
between
■ P13-2 and P132-2 P/J131 and
■ P13-3 and P132-3 P/J132
■ P13-4 and P132-4 [PL 11.2].
■ P13-5 and P132-5
■ P13-6 and P132-6
■ P13-7 and P132-7
■ P13-9 and P132-8
■ P13-10 and P132-9
■ P13-11 and P132-10
■ P13-12 and P132-11
■ P13-13 and P132-12
■ P13-14 and P132-13
■ P13-15 and P132-14

■ Feeder Board [RRP 11-7, page 334]
■ Harness, Wiring [PL 9.1, page 404]
■ Harness, Wiring [PL 11.2, page 414]

RAP 65 Exit Sensor
.
Table 95 Exit Sensor Troubleshooting Procedure

Input / press [4], to start, [0] to stop. Board
3. Open the rear cover. [RRP 8.5,
4. Open the Fuser Exit door. page 310].
5. Actuate and deactuate the Fuser Exit Sensor.
actuate and deactuate the sensor?
Board.
ground.
Measure the voltage between JP/J16-4 and frame Print Engine LVPS
Board page 312].
page 310].
4 FUSER EXIT SENSOR Replace the Replace the

1. Switch printer power OFF. Print Engine Fuser
2. Reconnect P/J17 to the Print Engine Controller Board. Controller Assembly
4. Measure the voltage between P/J17-6 and frame [RRP 8.5, page 288].
ground as you actuate and deactuate the Fuser Exit page 310].
Sensor.
Fuser Exit Sensor is deactuated and 0.0 VDC
when actuated?

RAP 66 Pre-Registration Sensor
.
Table 96 Pre-Registration Sensor Troubleshooting Procedure

1 PRE-REGISTRATION SENSOR ACTUATOR Go to Replace the
1. Open the 500-Sheet Feeder Rear Cover. Step 2. Pre-
2. Manually actuate and deactuate the Pre-Registration Registration
Sensor Actuator. Sensor
Does the Pre-Registration Sensor Actuator move Actuator
smoothly? [RRP 11.21,
page 351].
2 PRE-REGISTRATION SENSOR Replace the Go to

3. Press and release the Pre-Registration Sensor [RRP 8.5,
Actuator. page 310].
3 P133-7 and P133-9 VOLTAGE MEASUREMENT Go to Replace the
2. Remove the 500-Sheet Feeder Left Cover [RRP 11.3, Board
page 330]. [RRP 11-7,
3. Disconnect P/J133 from the Feeder Board. page 334].
ground, the between P133-9 and frame ground.
4 “YES” FROM STEP 4 ABOVE Go to Check for
1. Switch printer power OFF. Step 5. continuity
2. Reconnect P/J133. between
3. Switch printer power ON. P/J133 and
4. Measure the voltage between P/J133-9 and frame P/J13P, then
ground as you actuate and deactuate the between
Pre-Registration Sensor Actuator. P/J13P and
Does the voltage measure +3.2 VDC when P/J13C.
deactuated and 0.0 VDC when actuated? Repair or
replace as
necessary. If
harness
checks OK,
replace the
Pre-Regis-
tration
Sensor
[RRP 11.21,
page 351].

With Paper in the tray and the tray inserted into the Step 6. Feeder
500-Sheet Feeder, measure the voltage between Board
P/J132-7 and frame ground as you actuate and [RRP 11-7,
deactuate the Pre-Registration Sensor. page 334].

Table 96 Pre-Registration Sensor Troubleshooting Procedure (cont'd.)

page 250] and the Print Engine Controller Board Board P/J132 and
Cover [RRP 8.5, page 310]. [RRP 8.5, P/J131, the
4. Measure the voltage between P/J13-7 and frame P/J131 and
ground as you actuate and deactuate the P/J13.
Pre-Registration Sensor.
Repair /
Does the voltage measure +2.76 VDC when replace as
deactuated and +3.2 VDC when actuated? necessary.
■ Pre-Registration Sensor [RRP 11.21, page 351]
■ Feeder Board [RRP 11.7, page 334]

RAP 67 HCS Motor Assembly
.
Table 97 HCS Motor Assembly Message Troubleshooting Procedure

1 +24 VDC MEASUREMENT Go to Replace the
1. Switch printer power OFF. Step 2. LVPS
2. Remove the HVPS Cover [RRP 1.6, page 255]. [RRP 8.6,
3. Disconnect P/J506 from the Duplex Interface Board. page 312].
5. Measure the voltage between J506-2 and frame
ground.
2. Reconnect P/J506.
3. Remove the HCS Front Cover [RRP 10.4, page 321].
4. Disconnect P/J514 on the HCS Board.
5. Measure the voltage between J514-8 and frame
ground.
3 CONTINUITY CHECK Replace the Repair or
1. Switch printer power OFF. Duplex replace the
2. Check for continuity between P/J504 and P/J514 as Board STK-O
follows: [RRP 8.3, Harness
■ J504-1 and J514-1 page 308] Assembly
■ J504-2 and J514-2 [PL 10.2]
■ J504-3 and J514-3 and the
■ J504-4 and J514-4
SK-1
■ J504-5 No Connection
■ J504-6 and J514-6
Harness
■ J504-7 and J514-7 Assembly
■ J504-8 and J514-8 [PL 9.1,
■ J504-9 and J514-9 page 404].
Is there continuity between the pins?
1. Switch printer power OFF. HCS Motor HCS Board
2. Reconnect P/J514. 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?

Table 97 HCS Motor Assembly Message Troubleshooting Procedure (cont'd.)

■ Duplex Board [RRP 8.3, page 308]
■ HCS Motor Assembly [RRP 10.8, page 325]

RAP 68 Disk Error Format Hard Disk
Logic Control on the Print Engine Controller Board has sensed a problem with the
hard disk and requires reformatting.
Table 98 Hard Disk Formatting Troubleshooting Procedure

1 POWER OFF
1. Switch printer OFF and wait 20 - 30 seconds before
proceeding with sub-step 2.
2. Press and hold [0] and [4] as you switch printer power
ON.
3. You may release [0] and [4] after observing
“initializing” on the display.
4. Press [1] or [5] to scroll to “Reset Menu”.
5. Press [2] or [6] to scroll to “Format Disk”.
6. Press [4].
Disk formatting is automatic. When complete,
the display will say “Ready” without the error
message.

RAP 69 Erratic Printer Operation
The printer has a variety of problems that are not identified by displayed error codes
or messages. Problems may range from incomplete or garbled display text to
intermittent power shutdowns.
Table 99 Erratic Printer Operation Troubleshooting Procedure

1 PRINTER OPERATING ENVIRONMENT CHECK Go to Move the
Compare the printer room environment, such as Step 2. printer to an
temperature, humidity, and space requirements, with environment
the specifications listed in General Information section that meets
of this manual. printer
specs.
Does the printer room environment meet printer
specifications as listed in the General
Information Section?
2 AC POWER CHECK Go to Have an
1. Unplug the printer AC power cord from the AC wall Step 3. electrician
outlet. troubleshoot
2. Use a digital multimeter to monitor the voltage at the the AC line.
AC wall outlet.
3. Monitor the AC voltage for 30 minutes or longer.
Does the voltage at the AC wall outlet meet
printer specifications as listed in the General
Information Section and does the voltage remain
relatively stable without wide fluctuations?
3 AC POWER CORD REPLACEMENT Go to Problem
1. Replace the AC Power Cord. Step 4. solved.
2. Monitor printer operation.
Does the printer display erratic operation?
press [4] to start printing, [0] to stop.
Does the printer generate test prints?
5 LVPS +5 VDC CHECK Go to Go to
2. Disconnect P/J168 from the LVPS Assembly.
ground.

Table 99 Erratic Printer Operation Troubleshooting Procedure (cont'd.)

6 RETEST Go to Go to
2. Reconnect P/J168 to the LVPS Assembly.
3. Switch printer power ON, entering Diagnostics mode.
press [4] to start, [0] to stop.
Does the printer RESET while generating test
prints?
7 NVRAM SETTINGS CHECK Go to Return all
If applicable to your printer configuration, check the Step 8. settings to
NVRAM settings to make sure they are all set to the factory
recommended factory default values. default
values and
Are the NVRAM settings set to the factory default retest. If
values? problem still
exists, go to
Step 8.
8 SOFTWARE RELOAD Go to Problem

1. Reload print driver software in the host computer. Step 9. solved.
(Refer to the Printer Installer and Utilities CD-ROM.)
9 INTERFACE CABLE REPLACEMENT Go to Problem
1. Replace the Interface Cable connecting the host Step 10. solved.
computer to the printer, if applicable. IF NOT
APPLICABLE, GO TO STEP 10.
2. Run test prints from the host computer.
Does the problem still appear?
10 SYSTEM CONTROLLER BOARD REPLACEMENT Go to Problem
1. Replace the System Controller Board with a new one Step 11. solved.
(“RRP 8.1 System Controller PWB”).
11 LOW-VOLTAGE POWER SUPPLY Go to Problem
1. Reinstall the System Controller Board (“RRP 8.1
System Controller PWB”)
2. Replace the Low Voltage Power Supply (“RRP 8.6
Low-Voltage Power Supply [LVPS] Assembly”).
12 PRINT ENGINE CONTROLLER BOARD Go to Problem
1. Replace the Print Engine Controller Board (“RRP 8.5
Print Engine Controller Board”).

Table 99 Erratic Printer Operation Troubleshooting Procedure (cont'd.)

13 ELECTRICAL NOISE CHECK Go to Problem
1. Go to RAP 60 (Electrical Interference) and Step 14. solved.
troubleshoot for a possible internal or external
interference problem.
2. After you finish with RAP 60, return to this step and
monitor printer operation.
14 CUSTOMER NOTIFICATION
1. Notify customer the cause of the problem seems to be
a communication problem between the host computer
and the printer.
2. The customer should contact support for help with the
communication problem.
15 The following printer components and areas are

steps in this Fault Isolation Procedure, replace each
■ Interlock switches and circuits
■ Xerographic components and High Voltage Power
Supply (RRP 8.2, page 307)
■ Computer Interface Cable
■ Control Panel (RRP 8.9, page 315)
■ AC Driver Board (RRP 8.8, page 314)

Image-Quality Troubleshooting
Introduction
This section contains image-quality repair procedures to assist in correcting
image-quality defects. These procedures provide defect samples, definitions and
specifications to help identify the type of defect that exists, the test pattern to use, and
actions required to correct the defects.
Throughout these procedures, the term “vertical” refers to the process direction (the
direction paper travels through the printer); the term “horizontal” refers to the
scanning direction (the direction the laser beam scans across the page).
Be sure to check the paper tray to determine whether paper is being fed long edge or
short edge first. This determines “vertical” and “horizontal” for paper fed from that
particular tray.
Cleaning procedures should always be performed before beginning any Print-Quality
Repair procedure.
Be sure that the paper meets printer specifications. Changing the paper, or using paper
from a previously unopened ream, will resolve many print-quality issues.
After resolving an image-quality problem, return to Image-Quality Checkout to verify
that no other image-quality defects exist.
Sample reproductions of the various image-quality patterns are included under
Image-Quality Specifications.
Use the Image-Quality RAPS to further diagnose machine problems.
In the Y/N (Yes/No) steps of the RAPs, a “Yes” response will lead you to the next
step. A “No” response will indicate a corrective action, or will direct you to another
step. When the indicated corrective action has been completed, go to Section 1 and
restart the Initial Actions to verify that the problem has been corrected.

Image-Quality Defect Definitions
The System Controller Test Print is used to evaluate each of the print-quality
parameters. Each area of the test pattern is used for a print-quality parameter. The
areas and the print-quality parameters are listed in Image-Quality Checkout.
Table 100 Image-Quality Defect Definitions

Defect Definitions Go To: Page
LIGHT PRINTS: The overall image density is too light. Light page 178
(Undertoned)
Prints
BLANK PRINTS: Prints with no visible image. Blank Prints page 181
SPOTS: There are spots of toner on the page. Spots page 183
HORIZONTAL DELETIONS: There are areas of the image that Horizontal page 185
are extremely light or missing entirely. These areas run (Scan)
horizontally across the in the direction of scanning. Deletions
VERTICAL DELETIONS: There are areas of the image that are Vertical page 188
extremely light or missing entirely. These areas run vertically (Process)
along the page in the direction of paper movement. Deletions
SPOT DELETIONS: Solid areas are marked with irregular white Spot page 190
areas. Deletions
VERTICAL STREAKS: Extraneous dark lines/bands in the Vertical page 192
process direction. (Process)
Streaks
HORIZONTAL STREAKS: Extraneous dark lines/bands in the Horizontal page 194
direction of scan. (Scan)
Streaks
RESIDUAL IMAGES: The image from a previous print, which Residual page 197
was not removed during the cleaning process, has been Image
developed on the current print.
BLACK PRINTS: The print is completely covered with toner and Black Prints page 199
has no visible image.
BACKGROUND: Uniform toner contamination in non image Background page 200
areas. Refer to the Background specification.
UNEVEN DENSITY: The text/line darkness and solid area Uneven page 202
density image varies across the print. Density
SKEWED IMAGE: Angular displacement of the image from its Skewed page 204
intended position on the print. Refer to the specification. Image
DAMAGED PRINTS: Creases, wrinkles, excessive curl, cuts, Damaged page 210
folds or embossed marks. Print
REGISTRATION (Lead Edge to Trail Edge): Displacement of the Registration page 212
image, in the process direction, from its intended position on the
print.
(Inboard to Outboard): Displacement of the image, in the
direction of scan, from its intended position on the print.
SKIPS / SMEARS: Skip - Loss or stretching of the image in Skips / page 214
bands across the process direction. Smear - The distortion of the Smears
image in bands across the process direction that cause it to
appear to be blurred or compressed.
UNFUSED IMAGE: Part of or all of the image is unfused. Refer to Unfused page 215
the specification. Image
RESOLUTION: At 600 dpi, the two-pixel lines and halftone Resolution page 217
patches cannot be reproduced clearly on the print.

RAP 70 Light (Undertoned) Prints
The overall image density is too light.
Figure 18 Light Prints
Table 101 Light (Undertoned) Prints Troubleshooting Procedure

1 INITIAL ACTIONS
■ Inspect the printer paper path for items such as
staples, paper clips, paper scraps and/or other debris.
■ Check the installation of the Print Cartridge.
■ Check that the Print Cartridge ground contact points
are clean.
■ Ensure there are no obstructions in the Laser path.
2 PAPER REPLACEMENT Problem Go to

1. Load fresh, dry paper. solved. Step 3.
Does the image density meet specifications?
3 PRINT CARTRIDGE REPLACEMENT Problem Go to
1. Install a new Print Cartridge. solved. Step 4.
Does the image density meet specifications?

Table 101 Light (Undertoned) Prints Troubleshooting Procedure (cont'd.)

4 METAL GROUNDING CONTACT INSPECTION Go to Reform or
1. Remove the Print Cartridge. Step 5. clean the
2. Inspect the metal contacts on the Right Print Cartridge metal
Guide. contacts so
Are the metal contacts intact and free of that they
contamination? make better
contact with
the Print
Cartridge, or
replace the
Right Print
Cartridge
Guide
[RRP 7.2,
page 299].
5 “YES” FROM STEP 4 Go to Replace the

Check for continuity between the Metal Grounding Step 6. Right Print
Contact and the printer body frame. Cartridge
Guide
Is there continuity between the Metal Grounding [RRP 7.2,
Contact and the printer frame? page 299].
6 LASER BEAM PATH INSPECTION Go to Clean the

Inspect the Laser Beam path between the Laser Step 7. laser window
Assembly and the Drum for obstructions. and remove
any
Is the laser beam path free obstructions? obstructions
from the
laser beam
path.
7 BIAS TRANSFER ROLLER INSPECTION Go to Replace the

Inspect the Bias Transfer Roller (BTR). Step 8. BTR
[RRP 7.6,
Is the BTR intact and free of contamination? page 304].

1. Generate a Test Print and switch printer power OFF Step 9. RAP 59,
halfway through the print cycle. page 153
2. Carefully remove the Print Cartridge and inspect the
toner image on the drum just before the transfer area
(BTR).
Is the image on the drum completely developed
with sharp, black, easily read areas?
Inspect the toner image on the drum immediately after Step 10. RAP 59,
the transfer area (BTR). page 153
Has the toner image on the drum transferred
completely to the paper?

Table 101 Light (Undertoned) Prints Troubleshooting Procedure (cont'd.)

■ BTR Assembly [RRP 7.6, page 304]
■ HVPS Board [RRP 8.2, page 307]
■ Laser Assembly [RRP 7.1, page 297, page 297]
■ LVPS Assembly [RRP 8.6, page 312]
■ Right Print Cartridge Guide [RRP 7.2, page 299]

RAP 71 Blank Prints
No visible image anywhere on the output print.
Figure 19 Blank Prints
Table 102 Blank Prints Troubleshooting Procedure

1 INITIAL ACTIONS
are clean.
■ Ensure there are no obstructions in the Laser path.
■ Ensure the blank prints are not the result of multi-sheet
feeds.
press [4] to start, [0] to stop.
3. Run at least five test prints.
Are the test prints blank?
3 “NO” FROM STEP 2 ABOVE Remove and The problem
1. Switch printer power OFF to exit Diagnostics mode. reseat the appears to
2. Switch printer power ON to enter normal operational System be with the
mode. Controller host
3. Press [1] or [5] to scroll to Menus / Print Menu, then Board. If the computer or
press [2] or [6] to scroll to Print Menu / Config Sheet, problem the cables. If
press [4]. persists, 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].

Table 102 Blank Prints Troubleshooting Procedure (cont'd.)

Is there a normal image on the paper?
5 METAL CONTACT INSPECTION Go to Reform or
1. Remove the Print Cartridge. Step 6. clean the
2. Inspect the metal contacts on the rear end of the Right metal
Print Cartridge Guide. contacts so
Are the metal contacts intact and free of that they
contamination? make better
contact with
the Print
Cartridge, or
replace the
Right Print
Cartridge
Guide
[RRP 7.2,
page 299].

Check for continuity between the metal contacts and the Step 7. Right Print
printer frame. Cartridge
Guide
Is there continuity between the metal contact and [RRP 7.2,
the printer frame? page 299].

Inspect the Bias Transfer Roller (BTR). Step 8. BTR
Assembly
Is the BTR intact and free of contamination? [RRP 7.6,
page 304].

halfway through the print cycle. page 153.
(BTR).
Is the image remaining on the drum completely
developed, with sharp, black easily read area?
■ LVPS Assembly [RRP 8.6, page 312]

RAP 72 Spots
There are spots of toner randomly scatter on the

page.
Figure 20 Spots
Table 103 Spots Troubleshooting Procedure

1 INITIAL ACTIONS
■ Check that the paper supply is clean, dry and fresh
(recycled paper may have spots).
■ Check the installation of the Print Cartridge
are clean.
■ Check that rollers and other components in the paper
path are clean and unobstructed.

2. Run a Test Print.
Are the spots gone?
3 BIAS TRANSFER ROLLER (BTR) INSPECTION Go to Replace the
Inspect the BTR Assembly for contamination and wear. Step 4. BTR
Assembly
Is the BTR free of contamination and wear? [RRP 7.6,
page 304].

halfway through the print cycle. page 153.
(BTR).
developed, with sharp, black easily read area,
and free from spots?

Table 103 Spots Troubleshooting Procedure (cont'd.)

5 FUSER INSPECTION Go to Replace the
1. Open the Exit Assembly. Step 6. Fuser
Assembly
Warning: If the printer has been powered ON, [RRP 5.1,
the Fuser will be hot. Use extreme care page 288].
when handling the Fuser.
2. Remove the Fuser Assembly.
3. Turn the Fuser Assembly upside down.
4. Rotate the fuser idler gear manually and inspect the
Heat Roller.
5. Turn the Fuser Assembly right side up.
6. Open the fuse jam access cover.
Pressure Roller.
Are the Heat and Pressure Rollers free of
scratches (damage) and contamination?

RAP 73 Horizontal (Scan) Deletions
A deletion is an area of the print where the image is

missing or extreme light. Horizontal deletions
extend across the page in the scan direction.
Figure 21 Horizontal (Scan) Deletions
Table 104 Horizontal (Scan) Deletions Troubleshooting Procedure

1 INITIAL ACTIONS
■ Check that the Print Cartridge contact points are clean.
2 PRINT ENGINE CONTROLLER TEST PRINTS Go to Go to

press [4] to start.
3. Run approximately five test prints, then press [0] to
stop.
Do the test prints exhibit horizontal deletions?
3 SYSTEM CONTROLLER TEST PRINT Remove and The problem
2. Switch printer power ON to enter Ready mode. System be the host
3. From the Ready menu, press [1] or [5] to scroll to Test Controller computer or
Print, press [2] or [6] to scroll to Config Sheet, then Board. If the the cables. If
press [4] to print a Configuration Sheet. problem the problem
Does the Configuration Sheet exhibit horizontal persists, persists,
deletions? replace the replace the
System System
Controller Controller
Board Board
[RRP 8.1, [RRP 8.1,
page 305]. page 305].
4 PAPER REPLACEMENT Go to Problem

1. Load fresh, dry paper. Step 5. solved.
Are horizontal deletions still present?

Table 104 Horizontal (Scan) Deletions Troubleshooting Procedure (cont'd.)

1. Install a new Print Cartridge. Step 6. solved.
Are horizontal deletions still present?
Assembly
page 304]

(BTR).
developed, with sharp, black easily read area,
and free from deletions?
Inspect the toner image on the drum immediately after Step 9. RAP 59,
the transfer area (BTR). page 153
Was the toner image on the drum transferred to
the paper?
Assembly
Heat Roller.
Pressure Roller.

Table 104 Horizontal (Scan) Deletions Troubleshooting Procedure (cont'd.)

■ MBF Assembly [RRP 2.1, page 259]
■ Registration Clutch [RRP 4.3, page 286]
■ Turn Roller Assembly [RRP 2-4, page 263]

RAP 74 Vertical (Process) Deletions
A deletion is an area of the print where the image is

missing or extremely light. Vertical band deletions
are deletions which extend across the page in the
process direction.
Figure 22 Vertical (Process) Deletions
Table 105 Vertical (Process) Deletions Troubleshooting Procedure

1 INITIAL ACTIONS
■ Check that the paper supply is dry and fresh.
staples, paper clips, paper scraps and/or debris.
■ Ensure there are no obstructions in the Laser Beam
path.
■ Check that the rollers and other components in the
paper path are clean and unobstructed.

Are vertical deletions still present?
Are vertical deletions still present?
4 LASER BEAM PATH INSPECTION Go to Remove any
Inspect the laser beam path between the Laser Step 5. obstructions
Assembly and the Drum. from the laser
beam path.
Is the laser beam path free of obstructions?
5 PAPER PATH INSPECTION Go to Remove
Inspect the paper path, between feed and exit, for Step 6. obstructions
contamination or obstructions. or
contamination
Is the paper path free of contamination and from the
obstructions? paper path.

Table 105 Vertical (Process) Deletions Troubleshooting Procedure (cont'd.)

Assembly
page 304].

Assembly
Heat Roller.
Pressure Roller.

RAP 75 Spot Deletions
Solid areas are marked with irregular white areas.
Figure 23 Spot Deletions
Table 106 Spot Deletions Troubleshooting Procedure

1 INITIAL ACTIONS
1. Check that the paper supply is dry and fresh.
2. Inspect the printer paper path for items such as
staples, paper clip, paper scraps and/or debris.
3. Check the installation of the Print Cartridge.
4. Check that the Print Cartridge contact points are
clean.

Are spot deletions still present?
Are spot deletions still present?
1. Generate a Test Print and switch printer power OFF Step 5. BTR
halfway through the print cycle. Assembly
2. Carefully remove the Print Cartridge and inspect the [RRP 7.6,
toner image on the drum just after the transfer area page 304].
(BTR).
Was the toner image on the drum transferred to
the paper?

Table 106 Spot Deletions Troubleshooting Procedure (cont'd.)

Assembly
Heat Roller.
Pressure Roller.

RAP 76 Vertical (Process) Streaks
Extraneous dark lines/bands in the process direction

(in the direction of paper travel).
Figure 24 Vertical (Process) Streaks
Table 107 Vertical (Process) Streaks Troubleshooting Procedure

1 INITIAL ACTIONS
■ Check that the paper is within specifications.
■ Inspect the paper path, between feed and exit, for
contamination or obstructions.
2 PRINT ENGINE CONTROLLER TEST PRINTS Go to Go to

press [4] to start.
3. After approximately five prints have run, press [0] to
stop.
Do the test prints have vertical streaks?
2. Switch printer power ON to enter Ready mode. System be with the
3. From the Ready menu, press [1] or [5] to scroll to Test Controller host
Print, then press [2] or [6] to scroll to Config Sheet. Board. If the computer or
4. Press [4] to print a Configuration Sheet. problem the cables. If
Does the Configuration Sheet exhibit vertical persists, the problem
streaks? replace the persists,
System replace the
Controller System
Board Controller
[RRP 8.1, Board
page 305]. [RRP 8.1,
page 305].

Table 107 Vertical (Process) Streaks Troubleshooting Procedure (cont'd.)

Are the vertical streaks gone?
5 LASER BEAM PATH INSPECTION Go to Remove any
Inspect the laser beam path between the Laser Step 6. obstructions
Assembly and the Drum. form the
laser beam
Is the laser beam path free of obstructions? path.

Assembly
page 304].

1. Open the Exit Assembly. RAP 60, Fuser
page 157. Assembly
Heat Roller.
Pressure Roller.

RAP 77 Horizontal (Scan) Streaks
There are black lines running horizontally across the

page (at a right angle to the direction of paper
travel).
Figure 25 Horizontal (Scan) Streaks
Table 108 Horizontal (Scan) Streaks Troubleshooting Procedure

1 INITIAL ACTIONS
■ Check that the Print Cartridge contact points are
clean.
2 PRINT ENGINE CONTROLLER TEST PRINTS Go to Step 4. Go to Step 3.

2. From the Main Menu, select Test Print / Print Pattern
/ press [4] to start.
3. After approximately 5 prints have run, press [0] to
stop.
Do the test prints have horizontal streaks?
2. Switch printer power ON to enter Ready mode. System be with the
3. From the Ready menu, press [1] or [5] to scroll to Test Controller host
Print, then press [2] or [6] to scroll to Config Sheet. Board. If the computer or
4. Press [4] to print a Configuration Sheet. problem the cables. If
Does the Configuration Sheet exhibit horizontal persists, the problem
streaks? replace the persists,
System replace the
Controller System
Board Controller
[RRP 8.1, Board
page 305]. [RRP 8.1,
page 305].
4 PRINT CARTRIDGE REPLACEMENT Problem Go to Step 5.

1. Install a new Print Cartridge. solved.
Are the horizontal streaks gone?

Table 108 Horizontal (Scan) Streaks Troubleshooting Procedure (cont'd.)

5 METAL CONTACT INSPECTION Go to Step 6. Reform or
1. Remove the Print Cartridge. clean the
2. Inspect the metal contact on the Right Print Cartridge metal contact
Guide. so that it
Is the metal contact intact and free of makes better
contamination? contact with
the Toner
Cartridge, or
replace the
Right Print
Cartridge
Guide
[RRP 7.2,
page 299].
6 “YES” FROM STEP 5 ABOVE Go to Step 7. Replace the

Check for continuity between the Metal Grounding Right Print
Contact and the printer Body frame. Cartridge
Guide
Is there continuity between the Ground Contact [RRP 7.2,
and the printer frame? page 299].
7 BIAS TRANSFER ROLLER INSPECTION Go to Step 8. Replace the

Inspect the BTR Assembly for contamination and wear. BTR
Assembly
page 304].
8 “YES” FROM STEP 7 ABOVE Go to Step 9. Go to

1. Generate a Test Print and switch printer power OFF RAP 59,
(BTR).
developed, with sharp, black easily read area
free of streaks?
Inspect the toner image on the drum immediately after Step 10. BTR
the transfer area (BTR). Assembly
[RRP 7.6,
Was the toner image on the drum transferred to page 304].
the paper?

Table 108 Horizontal (Scan) Streaks Troubleshooting Procedure (cont'd.)

1. Open the Exit Assembly. RAP 60, Fuser
page 157 Assembly
the Fuser will be hot. Use extreme page 288].
care when handling the Fuser.
Heat Roller.
Pressure Roller.

RAP 78 Residual Image
The image from a previous print, which was not

removed during the cleaning process, has been
developed on the current print.
Figure 26 Residual Image
Table 109 Residual Image Troubleshooting Procedure

1 INITIAL ACTIONS
are clean.
■ Verify the fuser temperature (NVM).

Do residual images still appear?
Do residual images still appear?
Assembly
page 304].

Table 109 Residual Image Troubleshooting Procedure (cont'd.)

Assembly
Heat Roller.
Pressure Roller.

RAP 79 Black Prints
A totally black output print. There is toner on the

paper with no visible image.
s5400-038
Figure 27 Black Prints
Table 110 Black Prints Troubleshooting Procedure

1 INITIAL ACTIONS Replace the Go to
1. Power OFF the printer for 20 seconds. system Step 2.
2. Clear all paper from the paper path. controller
3. Power ON the printer. board
Does the printer print black prints within 15 [RRP 8.1,
seconds after Power On? page 305].
2 INSPECTIONS and Checks

are clean.
■ Ensure the machine covers are in place and fit well so
no outside light can enter.

Is the print normal?
1. Shield half of the window of the Laser Assembly. RAP 48, RAP 59,
2. Run a Test Print. page 130. page 153.
Is the print half white and half black?

RAP 80 Background
There is toner contamination on all or part of the

page. The contamination appears as a very light gray
dusting.
Figure 28 Background
Table 111 Background Troubleshooting Procedure

1 INITIAL ACTIONS
are clean.
■ Ensure the machine covers are in place and fit well so
no outside light can enter.

Is the background gone?
(BTR).
Are the undeveloped areas of the drum clean
and without background?

Table 111 Background Troubleshooting Procedure (cont'd.)

4 PAPER TRANSPORT ASSEMBLY BAFFLE Go to Remove and
GROUNDING Step 5. clean the
1. Remove the Print Cartridge. contact
2. Check for continuity from the front opening, between areas of the
metal parts of the Paper Transport Assembly and the Paper
printer frame. Transport
Is the Paper Transport Assembly Baffle Assembly
grounded? [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].
5 FUSER Problem Go to
Clean or replace the Fuser Assembly. solved. Step 6.
Is the background gone?

RAP 81 Uneven Density
Image Density varies within the page in either

direction.
s5400_363
Figure 29 Uneven Density
Table 112 Uneven Density Troubleshooting Procedure

1 INITIAL ACTIONS
■ Load fresh, dry paper.
■ Check that the correct Print Cartridge is properly
installed and not empty.
■ Ensure that the machine is reasonably level.
■ Check to make sure the laser path is clean and
unobstructed.
■ Remove the Print Cartridge and check the Left and
Right Guide for wear, contamination, obstructions, etc.
■ Clean the laser window.
2 TEST PRINT Go to There is no

Run a Test Print. Step 3. problem with
the printer.
Does the Test Print image contain uneven print? Check the
customer’s
application.

Does the Test Print image contain uneven print?
Assembly
page 304].

Table 112 Uneven Density Troubleshooting Procedure (cont'd.)

Assembly
Heat Roller.
Pressure Roller.
1. Generate a Test Print and switch printer power OFF Step 7. Laser
halfway through the print cycle. Assembly
2. Carefully remove the Print Cartridge and inspect the [RRP 7.1,
image on the drum. page 297].
Does the image on the drum have even density?
7 UNFUSED DENSITY Replace the Replace the
Examine the print on the paper before the Fuser. Fuser BTR
Assembly [RRP 7.6,
Does the unfused image on the paper display [RRP 5.1, page 304].
even density? page 288].

RAP 82 Skewed Image
The image is not parallel to the edges of the print

sheet.
Figure 30 Skewed Image
Table 113 Skewed Image Troubleshooting Procedure

1 INITIAL ACTIONS
■ Check the paper tray(s) installation and the paper in
the tray(s).
■ Load fresh, dry paper meeting specification.
■ Check the paper path for staples, paper clips, paper
scraps and/or debris causing obstructions.
■ Ensure the Print Cartridge is properly installed.
2 DUPLEX TEST PRINTS Go to Go to Step 7.

Run five Test Prints from each paper tray, duplexed if Step 3.
the printer is so equipped. If not equipped with a Duplex
Module, skip to Step 4 below.
Does the skewed image appear only on duplexed
prints?
3 FUSER INSPECTION Clean, Go to Step 4.
1. Inspect the Fuser Assembly for work parts or rollers. repair or
2. Inspect for obstructions or contamination. replace the
Fuser
Were any worn parts or rollers, or were any
Assembly
obstructions found in the Fuser Assembly?
[RRP 5.1,
page 288].
4 EXIT ASSEMBLY INSPECTION Clean, Go to Step 5.

1. Inspect all rollers, drives and gears in the Exit repair or
Assembly for contamination and/or wear. replace the
2. Check for any obstructions in the Exit Assembly paper Rear Cover
path. Assembly
Were any obstructions or worn/damaged parts [RRP 1-9].
found in the Exit Assembly?

Table 113 Skewed Image Troubleshooting Procedure (cont'd.)

5 DUPLEX ASSEMBLY INSPECTION Clean, Go to Step 6.
1. Inspect the Duplex Assembly for worn or repair or
contaminated parts or rollers. replace the
2. Inspect the Duplex Assembly paper path for Duplex
obstructions. Assembly
Were there any worn or contaminated parts or [PL 13.1,
rollers found, or were there any obstructions in page 426].
the paper path?
6 REAR CHUTE INSPECTION Go to Clean or
1. Inspect the Rear Chute between the Duplex Assembly Step 7. replace any
and the Registration Rollers for worn parts and rollers. worn or
2. Also inspect for obstructions and contamination. contaminated
Is the Rear Chute free of obstructions and parts as
contamination as well as free of worn parts and necessary.
rollers? Remove any
obstructions.
7 Does the skewed image occur on prints fed from Go to Go to

all trays? Step 8. Step 13.
8 REGISTRATION SENSOR ACTUATOR Go to Clean, repair

INSPECTION Step 9. or replace
1. Inspect the Registration Sensor for damage, secure the
mounting and/or obstructions. Registration
2. Check the Registration Sensor Actuator for damage, Sensor
freedom of operation, obstructions or contamination. and/or the
Does the Registration Sensor Actuator move Actuator, as
freely and is the Sensor and Actuator free of necessary
damage, contamination and obstructions? [RRP 4.2,
page 285 /
RRP 4.4,
page 287].
9 REGISTRATION ROLLERS Go to Clean or

Inspect the Registration Rollers for cleanliness, wear, Step 10. replace the
obstructions and/or contamination. Paper
Transport, if
Are the registrations rollers clean and free of necessary
obstructions and contamination? [RRP 4.1,
page 283].
10 BTR INSPECTION Go to Clean or

Inspect the BTR and bearings for wear, damage or Step 11. replace the
contamination. BTR as
necessary
Is the BTR free of wear, damage or [RRP 7.6,
contamination? page 304].
11 PRINT CARTRIDGE Go to Replace the

Inspect the Print Cartridge for wear, obstructions or Step 12. Print
damage. Cartridge.
Is the Print Cartridge free of wear, damage or
obstructions?


12 PAPER TRANSPORT ASSEMBLY INSPECTION Go to Clean, repair
Inspect the Paper Transport Assembly for wear, Step 34 or replace
obstructions or contamination. the Paper
Transport
Is the Paper Transport Assembly free of wear, Assembly
page 283].
13 Does the skewed image occur on printed from Go to Go to

the MBF Tray? Step 14. Step 18.
14 MBF FEED ROLLERS INSPECTION Go to Replace the

Inspect the MBF Feed Rollers for contamination and/or Step 15. MBF Feed
wear. Rollers
[RRP 2.2,
Are the MBF Feed Rollers free of contamination page 261].
and wear?
15 MBF RETARD PAD INSPECTION Go to Clean or
Inspect the MBF Retard Pad for wear, damage or Step 16. replace the
contamination. MBF Pad
[RRP 2-5].
Is the MBF Pad free of wear, damage or
contamination?
16 MBF CHUTE INSPECTION Go to Clean the
Inspect the MBF Chute for obstructions and Step 17. MBF Chute
contamination. as
necessary.
Is the MBF Chute free of obstructions and
contamination?
17 REGISTRATION SENSOR INSPECTION Go to Clean or
1. Inspect the Registration Sensor obstructions or Step 34. replace the
contamination. Registration
2. Inspect the Registration Sensor Actuator for freedom Sensor or
of operation, damage, obstructions and Actuator as
contamination. necessary
Is the Registration Sensor (and Actuator) free of [RRP 4.2,
obstructions and contamination and does the page 285 /
Registration Sensor Actuator move freely? RRP 4.4,
page 287].
18 Does the skewed image occur on prints fed from Go to Go to

Tray 1? Step 19. Step 24.
19 TRAY 1 FEED ROLLERS INSPECTION Go to Clean or

Inspect the Tray 1 Feed Rollers for wear or Step 20. replace the
contamination. Tray 1 Feed
Rollers as
Are the Tray 1 Feed Rollers free of wear and necessary
contamination? [RRP 2.10,
page 271].


20 TRAY 1 ENVELOPE FEED ROLLERS Go to Clean or
INSPECTION Step 21. replace the
Inspect the Tray 1 Envelope Feed Rollers for wear or Tray 1
contamination. Envelope
Feed Rollers
Are the Tray 1 Envelope Feed Rollers free of as necessary
wear and contamination? [RRP 2.10,
page 271].
21 TRAY 1 RETARD PAD INSPECTION Go to Clean or

Inspect the Tray 1 Retard Pad for wear and Step 22. replace the
contamination. Tray 1 Retard
Pad
Is the Retard Pad free of wear and [RRP 3.1,
22 TRAY 1 TURN ROLLER INSPECTION Go to Clean or

Inspect the Tray 1 Turn Roller Assembly for obstructions Step 23. replace the
or contamination. Tray 1 Turn
Roller as
Is the Tray 1 Turn Roller Assembly free of necessary.
obstructions and contamination?
23 TRAY 1 FEED CHUTE INSPECTION Go to Clean or
Inspect the Feed Chute between Tray 1 and the Step 34. replace the
Registrations Rollers for obstructions or contamination. Tray 1 Feed
Chute
Is the Feed Chute free of obstructions and [RRP 3.1,
24 Does the skew occur on prints fed from Tray 2? Go to Go to

Step 25. Step 31
25 TRAY 2 FEED ROLLER INSPECTION Go to Clean or

Inspect the Tray Feed Roller Assembly for wear and Step 26. replace the
Rollers as
Are the Tray 2 Feed Rollers free of wear and necessary
page 336].
26 TRAY 2 RETARD PAD/RETARD ROLLER Go to Clean or

Inspect the Tray 2 Retard Pad/Retard Roller for wear Tray 2 Retard
and contamination. Pad/Retard
Roller
Is the Tray 2 Retard Pad/Retard Roller free of [RRP 11.12,
wear and contamination? page 339].
27 2000-SHEET FEEDER PICK ROLLER Go to Clean or

If a 2000-Sheet Feeder is installed, inspect the Pick 2000-Sheet
Roller for wear and contamination. Feeder Pick
Roller
Is the 2000-Sheet Feeder Pick Roller free of wear [RRP 12.14,
and contamination? page 366].


28 FEED CHUTE INSPECTION Go to Clean or
Inspect the Feed Chute between Tray 2 and Tray 1 for Step 29. replace the
obstructions and contamination. Feed Chute
as necessary
Is the Feed Chute free of obstructions and [RRP 3.1,
contamination? page 273 /
RRP 11.12,
page 339].
29 TRAY 1 LOWER TURN ROLLER INSPECTION Go to Clean or

Inspect the Tray 1 Lower Turn Roller Assembly for Step 30. replace the
obstructions and contamination. Tray 1 Lower
Turn Roller
Is the Tray 1 Lower Turn Roller Assembly free of as necessary
page 275].
30 TRAY 1 REAR CHUTE INSPECTION Go to Clean or

Inspect the Tray 1 Rear Chute for obstructions and Step 34. replace the
contamination. Tray 1 Rear
Chute as
Is the Tray 1 Rear Chute free of obstructions and necessary
page 273].
31 TRAY 3 FEED ROLLERS INSPECTION Go to Clean or

Inspect the Tray 3 Feed Rollers for wear or Step 32. replace the
Rollers as
Are the Tray 3 Feed Roller free of wear or necessary
page 336].
32 TRAY 3 RETARD PAD/RETARD ROLLER Go to Clean or

INSPECTION Step 27, replace the
Inspect the Tray 3 Retard Pad/Retard Roller Assembly then go to Tray 3 Retard
for wear or contamination. Step 33. Pad/Retard
Roller
Is the Tray 3 Retard Pad/Retard Roller free of [RRP 11.12,
wear and contamination? page 339]
33 TRAY 3 FEED CHUTE INSPECTION Go to Clean or

Inspect the Feed chute between Tray 3 and Tray 2 for Step 34. replace the
obstructions and contamination. Feed Chute
[RRP 11.12,
Is the Feed Chute free of obstructions and page 339].
contamination?


■ Fuser Assembly
■ Exit Assembly
■ Duplex Assembly
■ Registration Sensor
■ Registration Sensor Actuator
■ Registration Rollers
■ Bias Transfer Roller / Bearings
■ Print Cartridge
■ Paper Transport Assembly
■ MBF Feed Rollers
■ MBF Retard Pad
■ MBF Chute
■ Tray 1/2/3 Feed Rollers
■ Tray 1/2/3 Envelope Feed Rollers
■ Tray 1/2/3 Retard Pad/Retard Rollers
■ Tray 1 Turn Rollers
■ Tray 1 Feed Chute
■ Tray 1 Lower Turn Roller
■ Tray 1 Rear Chute

RAP 83 Damaged Print
The printed page comes out of the printer either

wrinkled, creased, or torn.
Figure 31 Damaged Print
Table 114 Damaged Print Troubleshooting Procedure

1 INITIAL ACTIONS
■ Ensure that the paper is within specification.
2 OBSERVE PAPER FEED Go to Go to Step 3.

Observe paper feed as you run a Test Print. RAP 82,
page 204
Is the paper fed crooked?
1. Replace paper with fresh, dry standard paper. Step 4. solved.
Is the paper still damaged?
Assembly
Heat Roller.
Pressure Roller.

Table 114 Damaged Print Troubleshooting Procedure (cont'd.)

5 PAPER PATH INSPECTION Go to Remove
Inspect the paper path between the feed tray and the Step 6. obstructions
exit tray for contamination or obstructions. or
contamination
Is the paper path free of obstructions and from the
contamination? paper path.
6 ROLLER INSPECTION Go to Replace the

Inspect all of the roller along the paper path, between Step 7. damaged or
the feed tray and the exit tray, for contamination, wear contaminated
or damage. roller.
Are the paper path roller free of contamination,
wear or damage?
Is the print still damaged?
■ BTR Assembly [RRP 7.6, pagepage 304]
■ MBF Feed Roller Assembly [RRP 2.2, page 261]
■ Retard Holder Assembly [RRP 2-5]
■ Turn Roller Assembly [RRP 2-4]
■ Feed Roller [RRP 2.10, page 271]
■ Tray Assembly [PL 2.1 / PL 2.2]

RAP 84 Registration
The image is not positioned correctly on the paper. It

may be off in either the process direction or in the scan
direction.
s5400_364
Figure 32 Registration
Table 115 Registration Troubleshooting Procedure

1 INITIAL ACTIONS
■ Check to ensure that the paper is within specification.
■ Check that the paper supply is dry and fresh and
loaded correctly.
■ Check that the Paper Tray guides are set correctly.
2 TEST PRINT Go to Go to
Run a Test Print. Step 4. Step 3.
Is the Test Print output properly registered?
3 REGISTRATION CHECK Go to Perform the
Perform the registration check (page 231). Step 5. registration
adjustment
Is the printer registration set correctly? procedure
[page 231].
4 NEW PRINT JOB Problem Contact

Have the customer send another print job. solved. Xerox
Customer
Is the print image properly registered? Support.

Table 115 Registration Troubleshooting Procedure (cont'd.)

5 “YES” FROM STEP 3 ABOVE
completely.
If misregistration occurs in the process direction,

replace in sequence as necessary:
■ Registration Clutch [RRP 4.3, page 286]
■ Main Gear Drive [RRP 6.1, page 295]
■ System Controller Board [RRP 8.1, page 305].
■ Paper Transport [RRP 4-1, page 283]
If misregistration occurs across the process direction,
replace in sequence as necessary:

RAP 85 Skips / Smears
A skip is a disturbance of the image that lengthens or

shortens the image in the process direction. A smear
is a darkening across the process direction or a
repeat of the image in the process direction.
Figure 33 Skips / Smears
Table 116 Skips / Smears Troubleshooting Procedure

1 INITIAL ACTIONS
■ Check that the paper path for any obstructions or
debris.
2 TEST PRINT Go to Problem

Run a Test Print. Step 3. solved.
Does the image display skips or smears?
3 SEQUENTIAL REPLACEMENT Replace the Problem
Check, clean or replace as necessary in the following Print solved.
sequence: Cartridge
[PL 8.1,
■ Paper Transport [RRP 4.1, page 283]. page 402].
■ Main Drive components [RRP 6.1, page 295].
■ Fuser Assembly [RRP 5.1, page 288].
Does the defect still occur?

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

1 INITIAL ACTIONS

1. Replace paper with fresh, dry standard paper. Step 3. solved.
3 CHECK FUSER SETTING Go to Go to
Refer to Non-Volatile Memory Setup Mode and check Step 5. Step 4.
the Fuser Setting.
Is the NV code set to factory default value?
4 RESET TO FACTORY DEFAULT Increase the Problem
1. Set NV code to the factory default value. fuser solved.
2. Run 25 Test Prints. temperature
by one
increment
and run 25
test prints.
Recheck /
repeat as
necessary.
5 Is the overall print density within specification? Go to Go to

Step 6. RAP 70,
page 178.

Table 117 Unfused Image Troubleshooting Procedure (cont'd.)

Assembly
Heat Roller.
Pressure Roller.
1. Open the fuser jam access cover. Step 8. Fuser
2. Rotate the fuser idler gear manually and inspect the Assembly
contact between the Heat Roller and the Pressure [RRP 5.1,
Roller along the rotation. page 288].
Do the Heat and Pressure Rollers contact each
other uniformly?

RAP 87 Resolution
The two pixel lines and halftone patches cannot be reproduced clearly on the print.
Table 118 Resolution Troubleshooting Procedure

1 INITIAL ACTIONS
■ Check that the print density is set to the default value.

1. Install a new Print Cartridge [PL 8.1, page 402]. solved. Step 3.
2. From the Ready Menu, press [1] or [5] to scroll to
Menus / Print Menu, then press [2] or [6] to scroll to
Print Menu / Test Print, press [4] to run the
Print-Quality Test Print.
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:
■ Laser Assembly [RRP 7.1, page 297
■ HVPS [RRP 8.2, page 307]

Blank Page

Diagnostics, Test Prints,
Service Tests and NVRAM
Adjustments
The printer has four modes of operation:
■ On-Line Mode
■ Power Saver Mode
■ Diagnostics Mode
■ Menu Mode
On-Line Mode
On-Line is the printer’s normal operating mode. In this mode, the printer is on line,
under the control of the System Controller Board, and ready to generate output. The
On-Line Mode occurs automatically when the printer is powered ON.
If the printer goes out of the On-Line Mode during operation, it may be restored to on
line by pressing the On-Line button [0] on the Control Panel.
When the printer is on line, the “On Line” LED is illuminated steadily, indicating data
reception, transmission, analysis and printing are allowed. When the “On Line” LED
is blinking, the printer is receiving or processing data, or printing.
Power Saver
The printer employs a Power Saver Mode to reduce power consumption by lowering
the temperature of the fuser. If no data is received, or no Control Panel operation is
performed within a period of time (either printer default or set by the user), the printer
enters the power saving state.
The Power Saver Mode interval can be set from 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.

Diagnostics
Diagnostics available to the technician are built into the System Controller Board.
Test prints are available from the System Controller (in normal or On-Line Mode) and
the Print Engine Controller Board (in Diagnostics mode) to test functionality and
make adjustments.
You can use Diagnostics to:
■ Test the operation of printer switches and sensors.
■ Test the operation of printer motors, solenoids, and electric clutches.
■ Generate a test pattern to check printer operation and xerographic functions.
■ Read component usage logs.
■ Read and change operational parameters.
■ Analyze and adjust registration both overall and for each paper feed tray.
Menu Mode
Menu Mode utilizes the Control Panel to select various printer operations, print
configuration 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.

Entering Diagnostics Mode
2. Press and hold buttons [2] and [6] on the Control Panel while you switch ON
printer main power. Continue holding until *IOT?* appears in the display
(approximately 20 seconds).
Xerox Phaser™ 5400
On Line Form Feed ! Fault Data
0 1 2 3
On Line Menu Up Item Up Value Up
4 5 6 7
Enter Menu Down Item Down Value Down
s5400-348
3. When the Control Display shows *IOT?*, release buttons [2] and [6] and press
button [4]. The Control Panel first reads “Entering IOT Diagnostics Mode” then
changes to “Main Menu, Component Test.” The printer is now in Diagnostics
Mode.
Note: You must press button [4] within 10 seconds after *IOT?*
appears in the display to enter Diagnostics Mode, or the
printer will default to a normal power-up sequence.
*IOT?*
0 1 2 3
4 5 6 7
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Note: If you miss the 10-second window, the printer will reenter its
normal boot sequence. To try again, power down the printer,
wait 20 - 30 seconds, and begin at step 1 above again.
4. Diagnostics Mode menus are navigated like On Line Mode menus. Use buttons [1]
and [5] to display the three top level menus, Component Test, Test Print and NVM
Config. When “NVM Config” is displayed and you push buttons [2] or [6] to reach
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.

System Controller Board Error (Blink)
Codes
The System Controller Board Error Code Table below
identifies error conditions and error (blink) codes
during the Power On Diagnostics Sequence. The Blink CR1
codes can be observed under all powered ON
conditions. CR1 View Port
LEFT
R
A
E
R
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Table 119 System Controller Board Error (Blink) Codes

Failure Condition Error Control Panel Number Comment
Code Message of CR1
blinks
(Followed
by 1 sec.
off)
System Controller 0001 0001 - 1 System Controller PWB major
CONTROLLER failures
System Controller 0001 ESS - Base RAM 2 System Controller PWB on
Base RAM board RAM failure
System Controller 0001 0001 - BASE 3 System Controller PWB boot
ROM ROM ROM failure
ASIC 0001 0001 - ASIC 4 System Controller PWB ASIC
controller failure
Timer 0001 0001 - TIMER 4 System Controller Timer failure
PWPM 0001 0001 - PWPM 5 System Controller PWPM failure
DMA Controller 0001 0001 - DMA 5 System Controller PWB ASIC
DMA failure
Communication 0001 0001 - PARALLEL 6 Parallel Port failure
Interfaces
001 - USB 6 USB port failure
0001 - ENET 6 1/100 Base-TX failure
IOT Communication 1000 1000 - IOT 8 System Controller PWB - IOT
handshake failure
Hard Disk 0010 0010 - DISK 9 Hard disk failure
DIMM 1 0101 0101 - DIMM1 10 DIMM board 1 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

Recommended Corrective Action
For most of the blink code errors, the System Controller Board should be replaced.
For Hard Disk and DIMM slot errors, the cause of the error could be either the
System Controller Board or the plugged-in accessory. If the blink error points to a
(HD or RAM) component that is not even installed, the System Controller is to blame.
Otherwise, be prepared to replace either component (DIMM or HD and the System
Controller).
Power On LED Sequence

The following LEDs on the System Controller Board aid in identifying faults during
the Power On sequence. The LEDs provide status information in all powered ON
operating modes.
Table 120 System Controller LEDs

LED Location Color Description
Power - CR 6 Red Indicates power to the controller. Should stay on when power is
CR6 turned on.
Test - CR1 CR 1 Red Indicates that a power on diagnostics failure has occurred when
flashing.
Speed CR 4 Red ON: 10 Mbit Ethernet
OFF: 100 Mbit Ethernet
Link CR 3 Green OFF: Indicates 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

Diagnostics Menu Map
The table below summarizes the operation of the Control Panel keys in Diagnostics
Mode.
Note: An asterisk (*) indicates a factory default setting.
Table 121 Diagnostics Menu Map
Press [1] or [5] to display: ⇒ Main Menu
Test Print
Press [2] or [6] to display: ⇓ Press [3] or [7] to display: ⇓
Print Pattern
Input Tray Input Tray / Tray 1*
Input Tray / Tray 2
Input Tray / Tray 3
Input Tray / MBF
Output Tray Output Tray / Standard*
Output Tray / HCS
Duplex Duplex / Off*
Duplex / On

NVM Config
Note: When prompted for password, press [0], [7], [3] & [4] to gain entry.
NVM Config
Resolution (R) Read-only
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

Table 121 Diagnostics Menu Map (cont'd.)

Component Test
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 Feed Sol
Turn Roll Clutch
Reg Clutch
Main Motor
Detack Saw
Fan Motor High
DUP Motor On Low
DUP Motor On Hi
Exit Motor Fwd L
Exit Motor Rev L
Exit Motor Rev H
ROS Motor
HCS Motor
Exit Gate Sol
Charge Roll AC
Charge Roll DC
Dev Bias AC
Dev Bias DC
BTR-
BTR+
MBF Tray Size
Tray 1 Size
Tray 2 Size
Tray 3 Size

System Controller Board Test Prints
Note: System Controller Board Test Prints are available from the
Main Menu without entering Diagnostics Mode.
A variety of test prints are available to aid in determining the quality of output from
the printer and to assist in troubleshooting problems. Most test prints are available
from the Main Menu (in Menu Mode). One test print “Print Pattern” page 229 is
available in Diagnostics Mode.
Note: For assistance in analyzing print-quality problems, please
refer to the Troubleshooting section of this manual,
Image-Quality Troubleshooting, page 176.
Main Menu Test Prints

The test prints available from the Main Menu consist of a “Test Print” for helping to
evaluate print quality and alignment/registration. Other available prints provide a
printer configuration sheet, fault history, menu map, PS and PCL font lists, and a PCL
Demo page. Some of these test prints serve a twofold purpose by providing
information germane to the printer and an indicator of measurable print quality.
Test prints from the Print Menu are PCL or PostScript files, processed and printed like
a file from a host computer. These files test image processing as well as the printer’s
mechanical function. Printer default settings in the System Menu, such as Paper Size,
Paper Type, Print Quantity, Duplex, Resolution and Output Destination may be set as
needed to exercise the desired part of the printer.
Note: If multiple test prints are desired, enter the System Menu and
change “Print Quantity” value from 1 to the desired number.
Remember to reset the value back to 1 after
checking/adjusting registration.
Note: It is not necessary to take the printer “Off Line” to run the
following test prints. The [0] key takes the printer Off Line, if
needed and returns all modes, except Diagnostics, to
“Ready.”
Configuration Sheet
A printer configuration sheet can be used as an indicator of print quality, as well as
providing the user/technician with pertinent information regarding the printer’s
configuration. It is a good idea to print a configuration sheet and keep it close 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 “Config Sheet” is displayed.
3. Press [4] and a printer configuration sheet is printed.

System Controller Board Test Print
The “Test Print” is a multi-purpose print displaying a wide
variety of objects including text, multi-positional thin/thick
lines, black painted areas, gray scale, fine alignment
graduations to facilitate checking registration, lead edge and
side edge alignment, etc. Normally, running this test print
delivers two identical pages.
1. From the Ready menu, press [1] or [5] until “Print
Menu” is displayed.
2. Press [2] or [6] until “Test Print” is displayed.
3. Press [4] and the System Controller test page is printed.
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Fault History
The fault history is a printed list consisting of two columns. The first column is the
page count when the fault occurred; the second column is the fault or error code,
which may be found in Error Codes and Messages on page 27. If the printer is not
functional and a Fault History cannot be printed, see Display Faults.
2. Press [2] or [6] until “Display Faults” is displayed.
3. Press [3] to view the most recent fault. Continuing to press [3] will display earlier
faults, in order with page count and fault code.
Note: It is advisable to obtain a list of fault codes for reference
before calling for technical assistance.
Display Faults
Display Faults provides fault history for the case where a page cannot be printed. It is
recommended that you write down the fault history, or at least recent faults that may
be pertinent to resolving a problem.
2. Press [2] or [6] until “Config Sheet” is displayed.
3. Press [4] and a printer configuration sheet is printed.
Menu Map
The menu map helps the user/technician navigate the multitudes of menus and
sub-menus available. It is a good idea to print a menu map and keep it close to the
printer for reference by users, technicians, and/or system administrators.
2. Press [2] or [6] until “Menu Map” is displayed.
3. Press [4] and the menu map is printed.

PS Font List
The PS Font List produces a list of internally available PostScript fonts. Use this
single test page for a print quality check.
1. While in the menu mode, press [1] or [5] until “Print Menu” is displayed.
2. Press [2] or [6] until “PS Font List” is displayed.
3. Press [4] and the PS font list is printed.
PCL Font List:

Several pages of internal PCL fonts is provided with this test. This is another useful
print with which to gauge print quality.
2. Press [2] until “PCL Font List” is displayed.
3. Press [4] and the PCL font list is printed.
PCL Demo:
The PCL Demo print shows 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.

Print Engine Controller Board Test 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 Print is used to bypass the System Controller
Board. The “Print Pattern” test print is an excellent tool for isolating and diagnosing
printer feed, paper path, registration and image-quality problems. Refer to the
Registration section page 231 for information on using test prints to help adjust print
image registration.
The Control Panel Test Legend to the right will aid in 0
0 11 22 33
navigating through the variety of test prints available. On Line Menu Up Item Up Value Up
4 5 6 7
Upon entering Diagnostics Mode, the Control Panel LCD Enter Menu
Down
Item
Down
Value
Down
will momentarily display “Entering IOT Diagnostics

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Mode.” Then the LCD will display “Main Menu / Component Test.
Note: An asterisk (*) indicates a factory default setting.
Table 122 Test Print Menu
Test Print
Press [2] or [6] to display: ⇓ Press [3] or [7] to display: ⇓ Comment
Test Print Press [4] to start the test
Print Pattern print selected.
Note: Print Pattern
generates
continuous test
prints.
Press [0] to stop.
Input Tray Input Tray Press [4] to select the
Tray 1* paper feed tray desired.
Input Tray Press [4] to select the
Tray 2 paper feed tray desired.
Tray 3 paper feed tray desired.
MBF paper feed tray desired.
(Multi-sheet Bypass Feeder)
Output Tray Output Tray Press [4] to select the
Standard* output Tray desired.
Output Tray Outputs to the High
HCS Capacity Stacker
Test Print Duplex Single side printing
Duplex Off*
Duplex Both sides of page
On printed
By selecting various combinations of Input Tray, Output Tray and Duplex ON/OFF,
you can test most of the printer’s functional areas as well as print quality.

Analyzing Test Prints
Test prints provide several uses in troubleshooting printer problems.
■ Isolating problems to either the Print Engine Controller Board or to the
System Controller Board and host software.
■ Locating feed and paper transport problems.
■ Detecting print-quality and image registration problems.
Note: Always check Fault History and appropriate RAPs before
initiating additional tests or investigations.
Using Test Prints to Isolate a Problem to the Print Engine
Controller Board or the System Controller Board
1. Print a sample image from the host computer.
2. Enter Printer Diagnostics and generate a Print Engine Controller Board test print.
3. Compare both prints.
4. If the problem occurs when you print from the host computer but does not occur
when you print from Diagnostics, the problem may be in the System Controller
Board, in the print driver software, or in the application software on the host
computer.
5. If the problem occurs when you print a test print, then the problem is in the print
engine.
Note: If a Test Print image is not centered on the page or has
uneven borders, refer to Registration on page 231. If the Test
print is centered but the host computer’s image is not
centered properly, a software correction must be made at the
host computer by adjusting margins, page size, etc.
Using Test Prints to Locate a Feed or Paper Transport Problem
Test prints may help you locate a problem with paper feed or with paper
transportation 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.

Registration
Purpose
To adjust the registration in the scan direction and the process direction.
To Set Default Tray
1. Enter Diagnostics Mode and press [1] or [5] to scroll to “Main Menu / Test Print”.
2. Ensure the paper guides are properly set to match the paper size.
3. Press [2] or [6] to scroll to “Input Tray”.
4. Press [3] or [7] to scroll to the tray that you wish to be the Default Tray.
5. Press [4] to set.
Check
1. Set the Default Tray per the above procedure.
2. Ensure paper is loaded correctly and the side paper guides are properly set.
3. Press [1] or [5] to scroll to “Main Menu / Test Print”.
4. Press [2] or [6] to scroll to “Print Pattern” and press [4].
5. After at least two prints complete, press the [0] key for one second to stop the
printing.
6. The measurement should be made on two consecutive test patterns from each tray.
■ Measure the distance from the top edge of the paper to the top edge of the
image (C) and measure the distance from the bottom edge of the paper to the
bottom edge of the image (D). These two measurements should be equal (see
Figure 35).
■ Measure the distance from the lead edge of the paper to the lead edge of the
image (A) and measure the distance from the trail edge of the paper to the
trail edge of the image (B). These 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
1. Press [1] or [5] to scroll to “NVM Config.”
2. Enter the NVM Password in this sequence: [0], [7], [3] and [4].
3. Press [2] or [6] to scroll to “Process Tray ‘X’” or “Scan Tray ‘X’” adjustment for
the desired tray.
■ Process Tray X shifts the image from the Leading Edge to Trailing Edge (A
to B).
■ Scan Tray X shifts the image from top to bottom (C to D).
4. Press [3] or [7] one time to display the current setting.
5. Press [3] or [7] again to scroll to a new setting / value.

Note: Each increment of change equals approximately one-half
millimeter. In the scan direction increasing the value moves
the image to the right and decreasing the value moves the
image to the left. In the process direction increasing the
value moves the image toward the trail edge and decreasing
the value moves the image towards the lead edge.
6. Press [4] to save the setting.
7. Press [1] or [5] 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 left edge of the paper to the left edge of the image
and measure the distance from the right edge of the paper to the right edge of the
image. These two measurements should be equal.
10.Measure the distance from the lead edge of the paper to the lead edge of the image
and measure the distance from the trail edge of the paper to the trail edge of the
image. These two measurements should be equal.
11.Repeat steps 1 through 10 until equal side-to-side and lead edge to trail edge
measurements are achieved.
Figure 35 Registration Test Pattern

NVRAM Configuration (NVM Config)
The Non-Volatile RAM (NVRAM, or NVM) stores critical control parameters of the
mechanical and electromagnetic components of the printer. The following allows
service personnel to view status and/or change NVM settings.
Notes: Information displayed here requires entering Diagnostics
Mode. Refer to Entering Diagnostics Mode on page 221 for
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 0
0 1 2 3
through the NVRAM Configuration Menu. On Line Menu Up Item Up Value Up
4 5 6 7
Note: “(R)” displayed on the LCD means Read-Only. Enter Menu

Down
Item
Down
Value
Down
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Table 123 NVRAM Configuration Menu

NVM Config
Then, press [2] or (6) to display: ⇓ To view, Range / To Adjust
press Default
Note: When password is requested, * = default
sequentially press [0], [7], [3],
[4] to gain entry.
Resolution (R) [3] or [7] N/A / D* N/A - press [0] to exit
Laser Density (R) [3] or [7] N/A / 4* N/A - press [0] to exit
Fuser Stdby Temp (R) [3] or [7] N/A / 8* N/A - press [0] to exit
Fuser Run Temp (See Table 124 on [3] or [7] 0 ~ F / 8* Press [3] or [7] to scroll to
page 234) desired setting.
Press [4] to set and exit.
Front Tray Size [3] or [7] 0 ~ F / 8* Press [3] or [7] to scroll to
desired setting.
Front Tray Opt (R) [3] or [7] N/A / 4* N/A - press [0] to exit
Process Tray 1 [3] or [7] 0 ~ F Press [3] or [7] to scroll to
desired setting.
desired setting.
desired setting.
Process MBF [3] or [7] 0 ~ F Press [3] or [7] to scroll to
desired setting. Press [4] to set
and exit.
Scan Tray 1 [3] or [7] 0 ~ 7 Press [3] or [7] to scroll to
desired setting.

Table 123 NVRAM Configuration Menu (cont'd.)
desired setting.
desired setting.
Scan MBF [3] or [7] 0 ~ 7 Press [3] or [7] to scroll to
desired setting.
Full Stack Count [3] or [7] 0 ~ A Press [3] or [7] to scroll to
desired setting.
Table 124 Phaser 5400 Fuser Run Temp Conversion Table

NVM Fuser Component Heat Roll Temp Heat Roll Temp
Run Temp Test Fuser Centigrade (°C) Fahrenheit (°F)
Temp Read
0 3E 156° 312.8°
1 41 159° 318.2°
2 43 162° 323.6°
3 46 165° 329.0°
4 49 168° 334.4°
5 4C 171° 339.8°
6 4F 174° 345.2°
7 52 177° 350.6°
8a 55 180° 356.0°
9 58 183° 361.4°
A 5B 186° 366.8°
B 5E 189° 372.2°
C 61 192° 377.6°
D 64 195° 383.0°
E 67 198° 388.4°
F 6A 201° 393.8°
a. Shaded Cells = Default

Component Tests
Note: Before entering Diagnostics Mode, it is recommended to
print a Configuration Sheet for reference.
Component Control Output tests are used to aid in verifying proper component
operation, identifying problems and isolating faulty components. Access the
Component Test sequence from Diagnostics Mode. Refer to Entering Diagnostics
Mode on page 221 for how to enter Diagnostics Mode.
Use the Control Panel legend below to help navigate through the Component Test
menu.
Caution: It may be necessary to bypass or activate door interlocks in
order to observe the Component Tests. Mechanisms may
move that are not anticipated! Bypass the interlock
switches with care. Remove any loose jewelry, neckties, or
loose clothing that might be caught in the printer.
Control Panel Test Legend: Nomenclature Legend:

IOT: Print Engine - the printer not including the
0
0 1 2 3
System Controller Board or options.
HCF: High Capacity Feeder Option
4 5 6 7
Enter Menu Item Value MBF (or MSI): Multi-sheet Bypass Feeder
Down Down Down
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Table 125 Component Tests

Press [1] or [5] to display: Main Menu
Component Test
Press [2] or [6] Displayed Turn -On
to display: ⇓ Result: ⇓ Duration Procedure / Comment
Print Counter Print Counter 3 sec. 1. Press [4] to display for duration.
Prints = nnnnnnnn 2. Displays total pages passed the Fuser
Exit Sensor for duration.
Note: This number will differ from the
same number on the
Configuration sheet.
Sensor Input Sensor Input N/A 1. Press [4] to start the test.
Input Counts nn 2. Actuate sensors and interlocks.
3. Observe display for Input Counts to
increment with each sensor / interlock
actuation.
4. Press [0] to stop.
Fuser Temp Set Fuser Temp Set 3 sec. 1. Press [4] to display for duration.
Standby Temp = nn 2. Displays Fuser temperature setting
value for duration.
Fuser Temp Read Fuser Temp Read N/A 1. Press [4] to start test.
Current Temp = nn 2. Displays current Fuser temperature.

Table 125 Component Tests (cont'd.)
Component Test
IOT ROM IOT ROM 3 sec. 1. Press [4] to display for duration.
Checksum Checksum 2. Displays a ROM checksum for
CheckSum = duration to compare against current
nnnn Engine Software Version checksum on
configuration sheet.
MBF Feed Sol 3 sec. 1. Press [4] to start test.
2. Actuates the MBF Feel Solenoid for
duration.
3. Listen for clicks when pressing [4].
Tray 1 Feed Sol 2 sec. 1. Press [4] to start test.
2. Actuates Tray 1 Feed Solenoid for
duration.
3. Listen for click when pressing [4].
duration.
duration.
3. Listen for click and short duration
motor run when pressing [4].
Turn Roll Clutch 5 min. 1. Press [4] to actuate Tray 1 Feed
Clutch.
Note: Actuating this test may feed
one or more sheets of paper to
the Registration Roller. If this
happens you may get a paper
jam message, or the printer may
eject one or more sheets of
paper before it comes on line
again. If you get a paper jam
message, the jam is likely to be
most visible by removing
Tray 1, then lifting and pulling
the MBF outward to its limit.
You are then able to access the
paper at the Registration Roller.
Reg. Clutch 2 sec. 1. Press [4] to start test.
2. Actuates the Registration Clutch for
duration.
Main Motor 5 min. 1. Press [4] to start test.
2. Main Motor runs for duration.

Component Test
Detack Saw 5 min. 1. Press [4] to start test.
2. Detack Saw is electrically charged for
duration.
Fan Motor High 5 min. 1. Press [4] to start test.
2. Operates the Fan Motor at high speed
for duration.
Dup Motor On Low 5 min. 1. Press [4] to start test.
2. Operates the Duplex Motor at low
speed for duration.
Dup Motor On Hi 5 min. 1. Press [4] to start test.
2. Operates the Duplex Motor at high
speed for duration.
Exit Motor Fwd L 5 min. 1. Press [4] to start test.
2. Operates the Exit Motor Forward at
low speed or Press [0] to stop.
Exit Motor Rev L 5 min. 1. Press [4] to start test.
2. Operates the Exit Motor Reverse at
low speed or Press [0] to stop.
Exit Motor Rev H 5 min. 1. Press [4] to start test.
2. Operates the Exit Motor Reverse at
high speed.
ROS Motor 5 min. 1. Press [4] to start test.
2. Operates the Laser Scanner Motor for
duration.
Note: Print Cartridge must be
installed to conduct this test.
HCS Motor 5 min. 1. Press [4] to start test.
2. Operates the HCS Motor for duration
or Press [0] to stop.
Exit Gate Sol 2 sec. 1. Press [4] to start test.
2. Actuates the Exit Gate Solenoid for
duration.
Charge Roll AC 5 min. 1. Press [4] to start test.
2. The Charge Roller is AC charged for
duration.
Charge Roll DC 5 min. 1. Press [4] to start test.
2. The Charge Roller is DC charged for
duration.

Component Test
Dev Bias AC 5 min. 1. Press [4] to start test.
2. Developer Bias is charged with AC for
duration.
Dev Bias DC 5 min. 1. Press [4] to start test.
2. Developer Bias is charged with DC for
duration.
BTR — 5 min. 1. Press [4] to start test.
2. The Bias Transfer Roller is negatively
charged for duration.
BTR + 5 min. 1. Press [4] to start test.
2. The Bias Transfer Roller is positively
charged for duration.
MBF Tray Size 4 sec. Press [4] to display MBF tray size for
duration.
Tray 1 Size 4 sec. Press [4] to start test to display Tray 1
size for duration.
Tray 2 Size 4 min. Press [4] to start test display Tray 2 size
for duration.
Tray 3 Size 4 min. Press [4] to start display Tray 3 size for
duration.

Reset Menu
The Reset Menu provides functions not normally encountered or needed during
routine service of the printer. Thus, a special action step is required to gain access to
the Reset Menu. Once in the Reset Menu, the following operations can be performed:
■ Restore Factory Defaults (resets front panel menu defaults, except
networking).
■ Restore Network Defaults (resets only the front panel networking defaults).
■ Enter Demo Mode (pressing any front panel key causes the PCL Demo page
to print).
■ Delete all spooled print jobs on an internal Hard Drive (if installed).
■ Initializes the internal Hard Drive (if installed).
■ Formats the Hard Drive (if installed).
Entering Reset Menu
1. To enter the Reset Menu, make certain the printer is switched OFF.
2. Press and hold [0] and [4] while switching printer power ON. Continue pressing
[0] and [4] until asterisks begin appearing across the Control Panel display (LCD).
0 1 2 3
4 55 6 7
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3. Release [0] and [4].

4. When “Ready” is displayed, press [1] or [5] until “Menus / Reset Menu” appears.
5. Press [2] or [6] to access the six tasks listed above. Each task is actuated using the
same following steps:
■ Press [2] or [6] to scroll to the desired task.
■ Press [3] or [7] to select the desired “Yes / No” choice.
■ Press [4] to enter that choice and make it happen.

Maintenance Kit Counter Reset
Procedure
The Control Panel informs the user when it is time to install a Maintenance Kit by
displaying “Maintenance Kit - Replace.” Printing is not inhibited. After a new BTR
and fuser are installed, the Maintenance Kit Counter must be manually reset.
Wordless reset instructions are included in the kit. The procedure below is provided
for when those instructions are unavailable.
Note: The Maintenance Kit Counter should only be reset when a
complete kit has been installed.
2. Press and hold buttons [2] and [6] on the Control Panel while you switch ON
printer power. Continue holding until *IOT?* appears in the display
(approximately 20 seconds).
0 1 2 3
4 5 6 7
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3. When the Control Display shows *IOT?*, release buttons [2] and [6], then press
and hold button [0] and [5]. You have 10 seconds to release [2] and [6] and press
[0] and [5]. Hold [0] and [5] until “Reset Complete Please Reboot” is displayed.
This message confirms the counter has been reset.
0 1 2 3
4
4 5
5
5
5 6 7
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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.

Maintenance and Cleaning
Scheduled Maintenance
The Phaser 5400 Laser Printer is designed and tested to require little maintenance. A
User Maintenance Kit (P/N 109R00521 for 110 volt printers and 109R00522 for
220 volt printers) contains:
■ Replacement Fuser
■ Bias Transfer Roller
■ Cleaning Cloth
The printer will tell the user when to install the User Maintenance Kit
(200,000 prints). Normally, it is not necessary for a trained technician to install the
kit. Following installation, it is necessary to reset the maintenance counter.
Note: See NVRAM Adjustments in the Diagnostics, Test Prints,
Services Tests and NVRAM Adjustments section of this
manual for this procedure.
Recommended Tools
■ Standard service tools used in printer repair
■ Toner vacuum, such as the 3M Toner Vac
Caution: Do NOT use a standard vacuum to clean up a toner spill.
■ Suction bulb to use as an air puff blower
■ Toner rags (specially treated fibrous paper cleaning “rags” that attract and
pick up toner and dust particles
■ Cotton swabs (for those hard to get at places)
■ Cleaning cloth
■ Isopropyl alcohol
■ Simple Green or equivalent cleaner
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.

Areas to inspect and clean while in the printer:
■ Feed rollers for wear, dirt/grime/dust
■ Paper Bins for dust, lint, debris
■ Paper paths for debris
■ Laser print cartridge area for spilled toner
■ Cabinet interior
■ Multi-sheet Bypass Feeder roller and retard pad
■ Duplex Unit rollers and paper path
■ All exit rollers
■ General overall appearance for signs of abuse, wear, unfriendly environment
damage, etc.
■ Clean as necessary
General Cleaning (if needed)

Whenever you check, service, or repair a printer, you should perform the following
procedures. Cleaning the printer, as outlined in the following steps, assures proper
operation of the printer and reduces the probability of having to service the printer in
the future.
The frequency of use and the type of paper a customer prints on determines how
critical cleaning the machine is. Users of ordinary Bond paper (copier paper) should
have very few problems since this paper is smooth and relatively dust-free.
Ask each printer customer about the type of paper he or she uses so that you can be
sure to clean the parts of the printer that particular paper may affect. If a customer is
printing on the more unusual or dustier papers, then you should pay particular
attention to these printer parts:
1. Turn off the printer.
2. Remove the Print Cartridge and immediately cover it to protect 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.

6. Clean the laser window with puffs of air from the suction bulb. Alternately, you
can vacuum the window clean.
7. Vacuum out the interior of the printer.
8. Carefully clean the area around the Bias Transfer Roller for impacted toner.
a. Remove the Bias Transfer Roller.
b. Vacuum any toner visible.
c. Reinstall the Bias Transfer Roller.

Blank Page

FRU Removal /
Replacement Procedures
(RRPs)
This section contains the removal and replacement procedures that enables the
Service Representative to restore the product to within specification after fault
isolation. Not all Replacement Procedures are included in this Quick Reference
Guide. In most cases, to reinstall a part, simply reverse the Removal Procedure
shown. In some instances the Replacement Procedure is included, because it may
contain special steps.
Contents - Removal and Replacement

Procedures
Introduction ................................................................................................................................248
Work Notes ................................................................................................................................248
Preparation.................................................................................................................................249
Notations in the RRP text...........................................................................................................249
Adjustment .................................................................................................................................249
Repair Procedures .....................................................................................................................250
RRP 1.1 Left Side Cover........................................................................................................250
RRP 1.2 Right Side Cover .....................................................................................................251
RRP 1.3 Top Cover Assembly ...............................................................................................252
RRP 1.4 Front Cover .............................................................................................................253
RRP 1.5 Lower Left Cover .....................................................................................................254
RRP 1.6 HVPS Cover ............................................................................................................255
RRP 1.7 Lower Rear Cover ...................................................................................................256
RRP 1.8 MBF Gear Cover .....................................................................................................257
RRP 1.9 Rear Cover ..............................................................................................................258
RRP 2.1 Multi-sheet Bypass Feeder (MBF) Assembly ..........................................................259
RRP 2.2 MBF Feed Rollers....................................................................................................261
RRP 2.3 MBF Tray 1 Turn Roller Clutch Assembly ...............................................................262
RRP 2.4 Tray 1 Turn Roller Assembly ...................................................................................263
RRP 2.5 MBF Retard Holder Assembly .................................................................................264
RRP 2.6 Tray 1 No Paper Sensor Assembly .........................................................................266
RRP 2.7 MBF No Paper Sensor Assembly............................................................................267
RRP 2.8 MBF Feed Solenoid.................................................................................................269
RRP 2.9 Tray 1 Feed Solenoid ..............................................................................................270
RRP 2.10 Tray 1 Feed Roller.................................................................................................271
RRP 2.11 Tray 1 Retard Holder Assembly ............................................................................272
RRP 3.1 Retard Chute Assembly...........................................................................................273
RRP 3.2 Rear Chute Assembly..............................................................................................274
RRP 3.3 Lower Turn Roller Assembly ...................................................................................275
RRP 3.4 Tray 1 Low Paper Sensor........................................................................................276
RRP 3.5 Tray 1 Right Guide Assembly..................................................................................277

RRP 3.6 Tray 1 Left Guide Assembly ................................................................................... 279
RRP 3.7 CRUM Board .......................................................................................................... 281
RRP 3.8 MBF Assembly Position Sensor ............................................................................. 282
RRP 4.1 Paper Transport Assembly ..................................................................................... 283
RRP 4.2 Registration Actuator .............................................................................................. 285
RRP 4.3 Registration Clutch ................................................................................................. 286
RRP 4.4 Registration Sensor ................................................................................................ 287
RRP 5.1 Fuser Assembly ...................................................................................................... 288
RRP 5.2 Stack Full Sensor.................................................................................................... 289
RRP 5.3 Exit Roller Assembly............................................................................................... 291
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 [BTR] Assembly ..................................................................... 304
RRP 8.1 System Controller PWB .......................................................................................... 305
RRP 8.2 High-Voltage Power Supply [HVPS] Board ............................................................ 307
RRP 8.3 Duplex Interface Board ........................................................................................... 308
RRP 8.4 Main Fan................................................................................................................. 309
RRP 8.5 Print Engine Controller Board ................................................................................. 310
RRP 8.6 Low-Voltage Power Supply [LVPS] Assembly........................................................ 312
RRP 8.7 LVPS FAN .............................................................................................................. 313
RRP 8.8 AC Input Assembly ................................................................................................. 314
RRP 8.9 Control Panel +5 VDC Power Supply ..................................................................... 315
RRP 9.1 Duplex Assembly .................................................................................................... 317
RRP 10.1 1000-Sheet High Capacity Stacker [HCS] ............................................................ 318
RRP 10.2 HCS Top Cover .................................................................................................... 319
RRP 10.3 HCS Rear Cover Assembly .................................................................................. 320
RRP 10.4 HCS Front Cover .................................................................................................. 321
RRP 10.5 HCS Exit Gate Solenoid ....................................................................................... 322
RRP 10.6 HCS Stack Full Sensor ......................................................................................... 323
RRP 10.7 HCS Stack Full Sensor Actuator........................................................................... 324
RRP 10.8 HCS Drive Motor Assembly .................................................................................. 325
RRP 10.9 HCS Rear Cover Interlock Switch......................................................................... 326
RRP 10.10 HCS Paper 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
RRP 11.5 Rear Cover ........................................................................................................... 332
RRP 11.6 Drive Assembly..................................................................................................... 333
RRP 11.7 Feeder Board........................................................................................................ 334
RRP 11.8 Feed Head Assembly ........................................................................................... 335
RRP 11.9 Feed Rollers ......................................................................................................... 336
RRP 11.10 Feed Solenoid..................................................................................................... 337
RRP 11.11 Turn Roller Assembly ......................................................................................... 338
RRP 11.12 Retard Chute Assembly...................................................................................... 339
RRP 11.13 Left Tray Guide ................................................................................................... 340
RRP 11.14 Right Tray Guide................................................................................................. 342
RRP 11.15 Retard Holder Assembly..................................................................................... 344
RRP 11.16 Retard Turn Roller Assembly.............................................................................. 345
RRP 11.17 Paper Size Sensor.............................................................................................. 346
RRP 11.18 Paper Tray Sensor.............................................................................................. 347

RRP 11.19 No Paper Sensor .................................................................................................348
RRP 11.20 No Paper Sensor Actuator ..................................................................................350
RRP 11.21 Preregistration Sensor.........................................................................................351
RRP 12.1 Removing the 2000-Sheet Feeder ........................................................................352
RRP 12.2 Left Side Cover......................................................................................................354
RRP 12.3 Upper Rear Cover .................................................................................................355
RRP 12.4 Lower Rear Cover .................................................................................................356
RRP 12.5 Right Side Cover ...................................................................................................357
RRP 12.6 Front Cover ...........................................................................................................358
RRP 12.7 Tray Assembly.......................................................................................................359
RRP 12.8 2000-Sheet Feeder PWB ......................................................................................360
RRP 12.9 Tray Lift Motor Assembly.......................................................................................361
RRP 12.10 A4 Paper Size Sensor .........................................................................................362
RRP 12.11 Casters ................................................................................................................363
RRP 12.12 Harness Assembly ..............................................................................................364
RRP 12.13 Drive Assembly ...................................................................................................365
RRP 12.14 Feed, Nudger, and Retard Roller ........................................................................366
RRP 12.15 Paper Height Sensor ...........................................................................................367
RRP 12.16 Paper Feed Motor Assembly ...............................................................................368
RRP 12.17 Link Stopper ........................................................................................................369
RRP 12.18 No Paper Sensor .................................................................................................370
RRP 12.19 No Paper Sensor Actuator ..................................................................................371
RRP 12.20 Left and Right Wire Cover ...................................................................................372
RRP 12.21 Shaft Cover Assembly .........................................................................................373
RRP 12.22 Drive Shaft Assembly ..........................................................................................374
RRP 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

Introduction
This repair subsection contains instructions for removal and replacement tasks. A
removal and/or replacement task is included when it is not obvious how components
are removed and replaced, or when special conditions (such as an adjustment) must
be met during these tasks.
Step-by-step removal procedures for a specific component or assembly are provided.
Numbers in the illustrations refer to steps in the procedure. For example: if step 3 in a
procedure instructed you to remove a screw, the screw in the illustration would be
labeled 3.
Illustrations are used to assist you with the procedures. You should refer to the
specific Parts List illustration (listed under the repair title) for locating most
components within a procedure.
Cautions: Always reinstall the correct type and size screws. Using the
wrong screw can damage tapped holes.
Do not use excessive force to either remove or install a part.
Locations, such as left, right, front, or rear, given in the repairs assume you are facing
the printer Control Panel.
Work Notes
Note: Names of parts that appear in the RRPs may not be exactly
the same as the names appear in the Section 12 Parts List.
For example, a part called the Metal Registration Roller in
an RRP may appear on the Parts List as Registration Metal
Roller. When working on an RRP, ignore any prerequisite
RRP if you have already performed that removal procedure.
Caution: Always use the correct 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.

Preparation
Before you begin any Removal and Replacement Procedure:
1. Switch OFF the printer power and disconnect the power cord from the AC wall
outlet.
2. Remove the Laser Print (EP) Cartridge and protect it from exposure to light by
covering it with a piece of opaque plastic sheeting or by placing it in a light-tight
container.
3. Disconnect all computer interface cables from the printer.
4. Wear an electrostatic discharge wrist strap to help prevent damage to the sensitive
electronics of the printer circuit boards.
5. Wait at least 30 minutes after you have switched OFF printer power for the Fuser
to cool before you work on or around the Fuser.
Notations in the RRP text

■ The notation “rear” of a component, in place or removed, refers to the
surface of the component that is, when installed, facing the rear of the print
engine.
■ The notation “front” of a component refers to the surface of the component
that is, if installed, facing the front of the print engine.
■ The notation “(RRP X.Y)” in an RRP step directs you to another RRP for
information on how to perform a related or prerequisite procedure.
■ Bold arrows in an illustration show direction of movement when 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.

Repair Procedures
RRP 1.1 Left Side Cover
(See PL 1.1 Covers)
Figure 36 Removing the Left Side Cover
Removal
Warning: Switch off the power and disconnect the Power Cord.
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.

RRP 1.2 Right Side Cover
(See PL 1.1 Covers)
Figure 37 Right Side Cover
Removal
2. Remove the HCS, if installed (RRP 10.1 1000-Sheet High Capacity
Stacker [HCS]).
3. Open the Top Cover and remove the Print Cartridge. Cover the cartridge to protect
it from light.
Note: Place paper inside the Print Cartridge cavity to catch any
dropped hardware.
4. Remove the Left Side Cover (RRP 1.1 Left Side Cover).
5. Remove the Top Cover Assembly (RRP 1.3 Top Cover Assembly).
6. Remove the five screws that secure the Right Side Cover to the printer.
7. Remove the Right Side Cover.
Replacement

RRP 1.3 Top Cover Assembly
(See PL 1.1 Covers)
Figure 38 Top Cover Assembly
Removal
Stacker [HCS]).
4. Cover the cartridge to protect it from light.
Note: The top is secured by three types of screws. Note the type and
position of each of the screws as they are removed. This
information will be required for replacement of the screws.
6. Remove the eight screws that secure the Top Cover Assembly to the printer.
7. Remove the two screws that secure the Right and Left Print Cartridge Latches to
the Top Cover.
8. Disconnect P/J421 from the rear of the Control Panel.
9. Remove the Top Cover Assembly. A small flat blade screwdriver may be used to
release the two latches (one at each front) from the sides.
Replacement

RRP 1.4 Front Cover
(See PL 1.1 Covers)
Figure 39 Front Cover
Removal
Stacker [HCS]).
Note: Place paper inside the Print Cartridge cavity to catch any
dropped hardware.
7. Open the MBF Assembly Door, lift slightly, and pull the assembly out
approximately 2 inches (51 mm).
8. Pull out the Paper Tray approximately 2 inches.
9. 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.

RRP 1.5 Lower Left Cover
(See PL 1.1 Covers)
Figure 40 Lower Left Cover
Removal
2. Remove the two screws that secure the Lower Left Cover to the printer.
3. Remove the Lower Left Cover.
Replacement

RRP 1.6 HVPS Cover
(See PL 7.1 Frame & Drives)
Figure 41 HVPS Cover
Removal
1. Remove the Rear Cover (RRP 1.9 Rear Cover).
2. Remove the Duplex Assembly, if installed (RRP 9.1 Duplex Assembly).
3. Remove the screw that secures the Left Duplex Stopper to the printer. Remove the
Stopper.
4. Remove the screw that secures the Right Duplex Stopper to the printer. Remove
the Stopper.
5. 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

RRP 1.7 Lower Rear Cover
Figure 42 Lower Rear Cover
Removal
1. Remove the four screws that secure the Lower Rear Cover to the printer.
Replacement

RRP 1.8 MBF Gear Cover
(See PL 4.2 Paper Handler)
Figure 43 MBF Gear Cover
Removal
1. Remove the MBF Assembly (RRP 2.1 Multi-sheet Bypass Feeder (MBF)
Assembly).
2. Remove the screw that secures the Left MBF Gear Cover to the left side of the
Paper Handler.
3. Release the three locking tabs and remove the MBF Gear Cover.
4. The MBF 2 Idler Gear may come off with the cover.
5. Release the locking tabs and remove the harness from the MBF Cover.
Replacement

RRP 1.9 Rear Cover
(See PL 6.1 Rear Cover Assembly With Fuser)
Figure 44 Rear Cover
Removal
2. Disconnect P/J527 and P/J528 and release clamp.
3. Remove the two screws that secure the Rear Cover support straps to the Rear
Cover. Support Rear Cover with one hand while removing the straps from the
posts.
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

RRP 2.1 Multi-sheet Bypass Feeder (MBF)
Assembly
Figure 45 MBF Paper Handler Assembly
Removal
1. Remove Tray 1.
2. Open and extend the MBF Assembly to the paper load position.
3. Remove the screw that secures the cover to the left side of the MBF Assembly.
4. To release the locking tab, push in slightly on the left front of the cover and rotate
the cover clockwise to remove with the left hand, while pulling the rear ‘piece’
toward you to release the alignment pin with the right hand.
5. Release the harness from the underside of the cover.
6. Disconnect the in-line connector P/J121.
7. Critical: Push the MBF into the home position.
8. Push down and hold onto the left tray stop, pull out to remove.
9. Push down on the right tray stop, pull out to remove.
10.Extend 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.

Figure 46 MBF Left Tray Stop
Figure 47 MBF Right Tray Stop
Replacement

RRP 2.2 MBF Feed Rollers
(See PL 4.1 Multi-sheet Bypass Feeder (MBF) Assembly)
Figure 48 MBF Feed Roller Assembly
Removal
Assembly).
2. For the Left Feed Roller, lift the locking tab on the Left MBF Roller Core and slide
the core to the left. Slide the MBF Feed Roller to the left and remove.
3. For the Right Feed Roller, lift the locking tab on the Right MBF Roller Core and
slide the core to the right. Slide the MBF Feed Roller to the right and remove.
Replacement
Note: Arrows of the back side of the Feed Rollers indicate direction
of rotation.

RRP 2.3 MBF Tray 1 Turn Roller Clutch Assembly
Figure 49 MBF Tray 1 Turn Roller Clutch Assembly
Removal
Assembly).
2. Remove MBF Gear Cover (RRP 1.8 MBF Gear Cover).
3. Disconnect in-line connector P/J124.
4. Remove the screw that secures the Tray 1 No Paper Sensor Assembly Bracket to
the bottom of the Paper handler.
5. Note the harness path, then remove the Turn Roller Clutch harness from the cable
clamps.
6. Remove the E-Ring that secures the Turn Clutch Assembly to the Paper Handler.
7. Remove the Turn Roller Clutch Assembly from the Turn Roller Assembly.
Replacement
2. Ensure that the tab on the clutch is positioned on the pin on the Paper Handler.

RRP 2.4 Tray 1 Turn Roller Assembly
Figure 50 Tray 1 Turn Roller Assembly
Removal
Assembly).
2. Remove the MBF Gear Cover (RRP 1.8 MBF Gear Cover).
3. Remove the Turn Roller Clutch (RRP 2.3 MBF Tray 1 Turn Roller Clutch
Assembly).
4. Remove the bearing located behind the Turn Roller Clutch.
5. Remove the E-Ring from the right end of the Turn Roller Assembly.
6. Remove the bearing from the right end of the Turn Roller Assembly Shaft.
7. Remove the Turn Roller Assembly.
Replacement

RRP 2.5 MBF Retard Holder Assembly
Figure 51 MBF Pick Up Shaft
Removal
Assembly).
3. Remove the Pick-up Spring from the MBF Pick-up Gear.
4. Release the two locking tabs on the MBF Pick-up Gear and remove the gear.
5. Move the MBF Pick-up Shaft to the right and remove the shaft from the MBF.
6. Remove the screw that secures the support bracket to the MBF. Remove the
bracket.
7. Insert a screwdriver between the left side of the MBF and the MBF Tray Assembly
near the tray pivot point. Carefully spread the two assemblies until the tray
disengages from the MBF.
8. Release the two locking tabs on the back of the retard holder and rotate the retard
holder forward.
9. Continue to rotate the holder forward until it can be lifted out of the MBF base.

Figure 52 MBF Tray Assembly
Figure 53 MBF Retard Holder Assembly
Replacement

RRP 2.6 Tray 1 No Paper Sensor Assembly
Figure 54 Tray 1 No Paper Sensor Assembly
Removal
Assembly).
3. Disconnect P/J126 from the sensor assembly.
4. Remove the screw that secures the Tray 1 No Paper Sensor Assembly Bracket to
the MBF.
5. Use a small screwdriver to carefully release the two locking tabs that secure the
sensor to the sensor assembly bracket.
6. Release the sensor harness from the harness clamps and remove the sensor.
Replacement

RRP 2.7 MBF No Paper Sensor Assembly
Figure 55 MBF No Paper Sensor Assembly
Removal
Assembly).
3. Remove the Pick Up Spring from the MBF Pick Up Gear.
4. Release the two locking tabs on the MBF Pick Up Gear and remove the gear.
5. Move the MBF Pick Up Shaft to the right and remove the shaft from the MBF.
6. Remove the screw that secures the support bracket to the MBF and remove the
bracket.
7. Insert a screwdriver between the left side of the MBF and the MBF Tray Assembly
near the tray pivot point. Carefully spread the two assemblies until the tray
disengages from the MBF.
8. Disconnect P/J125 from the MBF No Paper Sensor Assembly.
9. Release the two locking tabs on the bottom of the Sensor Assembly and remove
the sensor.

Figure 56 MBF Tray Assembly
Figure 57 MBF No Paper Sensor Assembly
Replacement

RRP 2.8 MBF Feed Solenoid
Figure 58 MBF Feed Solenoid
Removal
Assembly).
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

RRP 2.9 Tray 1 Feed Solenoid
Figure 59 Tray 1 Feed Solenoid
Removal
Assembly).
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

RRP 2.10 Tray 1 Feed Roller
Figure 60 Tray 1 Feed Roller
Removal
Assembly).
2. Turn the MBF upside down.
3. Release the Tray 1 Feed Solenoid.
4. Rotate the Feed Rollers up.
5. Press locking tab that secures the Left Roller Core.
6. Slide the Left Roller Core to the left.
7. Slide the Feed Roller to the left and remove.
8. If replacing the Envelope Feed Rollers, press the locking tabs and remove the two
Envelope Feed Rollers.
Replacement
Note: The arrows on the side of the Envelope Feed Rollers indicate
the direction of rotation.

RRP 2.11 Tray 1 Retard Holder Assembly
(See PL 3.1 Paper Feeder)
Figure 61 Tray 1 Retard Holder Assembly
Removal
it from light.
2. Remove Tray 1.
Assembly).
4. Remove the Retard Chute Assembly (RRP 3.1 Retard Chute Assembly).
5. From the rear, release the two locking tabs.
6. Remove the Retard Holder Assembly from the front.
Replacement

RRP 3.1 Retard Chute Assembly
Figure 62 Rear Chute Assembly
Removal
it from light.
2. Remove Tray 1.
Assembly).
4. Tilt the top of the Retard Chute Assembly toward the front of the printer.
5. Lift up on the right end of the chute.
6. Pull the right end forward and remove.
Replacement

RRP 3.2 Rear Chute Assembly
Figure 63 Rear Chute Assembly
Removal
it from light.
2. Remove Tray 1.
Assembly).
5. Remove the two screws that secure the Rear Chute Assembly to the 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

RRP 3.3 Lower Turn Roller Assembly
Figure 64 Lower Turn Roller Assembly
Removal
it from light.
2. Remove Tray 1.
Assembly).
5. Remove the E-ring from the right end of the Lower Turn Roller.
6. Remove the right bearing.
7. Release the locking tab on the Lower Turn Roller Gear and remove the gear.
8. Remove the left bearing.
9. Move the Lower Turn Roller Assembly to the left until the right end is free of the
assembly.
10.Lift and remove the Lower Turn Roller Assembly.
Replacement

RRP 3.4 Tray 1 Low Paper Sensor
Figure 65 Tray 1 Low Paper Sensor
Removal
it from light.
2. Remove Tray 1.
Assembly).
5. Remove Tray 1 Left 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

RRP 3.5 Tray 1 Right Guide Assembly
Figure 66 Paper Level Indicator Arm
Removal
it from light.
3. Remove Tray 1.
6. Remove the Right Side Cover (RRP 1.2 Right Side Cover).
Assembly).
9. Remove Front Cover (RRP 1.4 Front Cover).
10.Carefully push down on the locking tab that secures the rod to the paper level
actuator.
11.Remove the paper level assembly from the stud on the frame.
12.Move the paper level forward to unlatch then remove from the printer.

13.Remove the four screws that secure the Tray 1 Right Guide Assembly to the
printer.
14.Use a small screwdriver to pry up on the locking tab that locks the guide assembly
to the bottom of the printer.
15.Remove the Tray 1 Right Guide Assembly.
Figure 67 Tray 1 Right Guide Assembly
Replacement

RRP 3.6 Tray 1 Left Guide Assembly
Figure 68 Tray Left Guide Assembly
Removal
it from light.
2. Remove Tray 1.
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.

8. Use a small screwdriver to pry up on the locking tab that locks the guide assembly
to the bottom of the printer.
9. Disconnect P/J202 and P/J127 from the guide assembly.
10.Remove the Tray 1 Left Guide Assembly.
Replacement
Note: Ensure that all alignment pins are properly inserted in the
frame holes before replacing the six screws.

RRP 3.7 CRUM Board
(See PL 8.1 Xerographics)
Left CRU Guide
CRUM Board
Laser Safety Switch
CRUM Antenna
s5400-361
Figure 69 Removing the CRUM Board
Removal
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

RRP 3.8 MBF Assembly Position Sensor
Figure 70 MBF Assembly Position Sensor
Removal
it from light.
2. Remove Tray 1.
Assembly).
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

RRP 4.1 Paper Transport Assembly
(See PL 5.1 Paper Transport)
Figure 71 Paper Transport Assembly
Removal
2. Remove the Fuser Assembly (RRP 5.1 Fuser Assembly).
it from light.
4. Remove Tray 1.
Assembly).
8. Remove the HVPS Cover (RRP 1.6 HVPS Cover).
9. Disconnect plug P185 (R) from the top of transformer T503 on the HVPS PWB.
10.Remove the screw that secures the Detack Saw Wire to the assembly.
11.Remove the wires from cable clamps.

12.Disconnect P/J222 from the bottom of the Registration Clutch.
13.Remove the four screws that secure the Paper Transport Assembly to the printer.
Note: When removing the Paper Transport Assembly, do not touch
the BTR Roller with your hands. Oil from your hands can
cause copy quality problems.
14.Guide the high voltage leads through the holes in the printer frame as you remove
the Paper Transport Assembly.
Replacement

RRP 4.2 Registration Actuator
Figure 72 Registration Actuator
Removal
it from light.
4. Remove Tray 1.
Assembly).
9. Remove the Paper Transport Assembly (RRP 4.1 Paper Transport Assembly)
10.Note the position and tension force of the actuator spring.
11.Move the Registration Actuator to its full actuated position.
12.Slide the Registration Actuator to the left to disengage the right end of the actuator.
Pull the actuator up and out of the Paper Transport Assembly.
13.Remove the spring from the Registration Actuator.
Replacement

RRP 4.3 Registration Clutch
Figure 73 Registration Clutch
Removal
it from light.
4. Remove Tray 1.
Assembly).
9. Remove the Paper Transport Assembly (RRP 4.1 Paper Transport Assembly)
10.Remove the E-ring that secures the Registration Clutch to the Rubber Registration
Roller.
11.Remove the Registration Clutch.
Replacement

RRP 4.4 Registration Sensor
Figure 74 Registration Sensor
Removal
it from light.
4. Remove Tray 1.
Assembly).
9. Remove the Paper Transport Assembly (RRP 4.1 Paper Transport Assembly).
10.Remove the HVPS PWB (RRP 8.2 High-Voltage Power Supply [HVPS] Board).
11.Disconnect P/J183 from the Registration Sensor.
12.Release the three locking tabs and remove the sensor.
Replacement

RRP 5.1 Fuser Assembly
Figure 75 Fuser Assembly
Removal
Warnings: Switch off the power and disconnect the Power Cord.
If the printer has been in operation, the Fuser may be hot.
Caution: When handling the fuser, use care to prevent damage to the
entrance guide.
2. Move 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
Note: Install the locating pins first.

RRP 5.2 Stack Full Sensor
Figure 76 Lower Exit Chute
Removal
1. Open and remove the Rear Cover (RRP 1.9 Rear Cover).
2. Remove the four screws that secure the Lower Exit Chute Assembly. Remove the
assembly.
3. Remove the four screws that secure the Upper Exit Chute. Remove the top of the
Rear Cover.
4. Release the two locking tabs that secure the Stack Full Sensor Holder to the Rear
Cover.
5. Remove the Stack Full Sensor Holder and Actuator from the Rear Cover.

6. Release the three locking tabs and remove the sensor from the holder.
7. Disconnect P/J507 from the Stack Full Sensor.
Figure 77 Upper Exit Chute
Figure 78 Stack Full Sensor
Replacement
Note: The two shoulder screws go in the right end of the Lower
Exit Chute Assembly (see Figure 76).

RRP 5.3 Exit Roller Assembly
Figure 79 Lower Exit Chute
Removal
3. Remove the four screws that secure the Lower Exit Chute Assembly. Remove the
assembly.
4. Remove the four screws that secure the Upper Exit Chute. Remove the chute.
5. Remove the E-ring that secures the right end of the Upper Exit Roller Assembly.
6. Release the three locking tabs and remove the Gear Z15 from Upper Exit Roller
Assembly.
7. Remove the left and right bearings from the Exit Roller.
8. Remove the two paper tabs from the shaft.
9. Move the Exit Roller Shaft to the left until the right end is free of the Rear Cover.
Remove the Exit Roller.
10.Remove the E-ring that secures the right end of the Lower Exit Roller Assembly.
11.Release the three locking tabs and remove the Gear Z22 from Lower Exit Roller
Assembly.
12.Remove the left and right bearings from the Exit Roller.
13.Move the Exit Roller Shaft to the left until the right end is free of the Rear Cover.
Remove the Exit Roller.

Figure 80 Upper Exit Chute
Figure 81 Upper Exit Roller Assembly

Figure 82 Lower Exit Roller Assembly
Replacement

RRP 5.4 Stack Full Sensor Actuator
Figure 83 Stack Full Sensor Actuator
Removal
3. Remove the Stack Full Sensor (RRP 5.2 Stack Full Sensor).
4. Carefully pull the actuator out of the holder.
Replacement

RRP 6.1 Main Drive Gear Assembly
Figure 84 Shield Cover
Removal
Note: The Drive Gear Assembly includes both the Main Drive
Motor Gear Assembly and Motor Assembly.
1. Remove the Lower Rear Cover (RRP 1.7 Lower Rear Cover).
6. Remove Tray 1.
7. Extend the MBF Assembly.
9. Loosen the two thumb screws and remove the System Controller PWB Shield
Cover.
10.Remove the System Controller PWB (RRP 8.1 System Controller PWB).

11.Disconnect CN2 from the Motor Drive PWB.
12.In the next step, there are arrows stamped into the metal indicating the eight
screws to remove.
13.Remove the eight screws that secure the Gear Assembly to the printer.
14.Remove the Gear Assembly and Motor from the printer.
11
13
14
Figure 85 Gear Drive Assembly
Replacement

RRP 7.1 Laser Assembly
Figure 86 Laser Cover
Removal
Caution: These components are susceptible to electrostatic
discharge. Observe all ESD procedures to avoid damage.
it from light.
5. Remove 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.

8. Disconnect 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

RRP 7.2 Right Print Cartridge Guide Assembly
Figure 88 Right Print Cartridge Guide
Removal
2. Open and remove the Rear Cover (RRP 1.9 Rear Cover).
3. Remove the Fuser Assembly (RRP 5.1 Fuser Assembly)
it from light.

8. Remove the BTR Assembly
(RRP 7.6 Bias Transfer Roller [BTR] Assembly).
9. Disconnect P/J186 (R) and P/J187 (W) from the HVPS PWB.
10.Disconnect P/J177 and P/J178 from the Fuser Interlock Switch.
11.Disconnect P/J162 from the LVPS PWB.
12.Remove all disconnected harnesses from cable clamps.
13.Remove the two screws that secure the right guide assembly.
14.Guide harnesses through the printer frame as you remove the Right Print Cartridge
guide Assembly from the printer.
Note: The Pin 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

RRP 7.3 Toner Sensor Assembly
Figure 89 Toner Sensor Assembly
Removal
it from 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

RRP 7.4 Top Cover Interlock Switch
6
Figure 90 Top Cover Interlock Switch
Removal
2. Open the Top 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

RRP 7.5 Left Print Cartridge Guide Assembly
Figure 91 Left Print Cartridge Guide Assembly
Removal
it from light.
5. Remove the BTR Assembly (RRP 7.6 Bias Transfer Roller [BTR] Assembly).
6. Remove the two screws 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

RRP 7.6 Bias Transfer Roller [BTR] Assembly
Figure 92 Bias Transfer Roller [BTR] Assembly
Removal
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 handle on the left end of the BTR Assembly. Pull up on the handle
to free the left end of the BTR.
3. Use your finger to lift the right end of the BTR Assembly.
4. Place the BTR Roller on a sheet of clean paper and cover it with another sheet of
paper.
Replacement

RRP 8.1 System Controller PWB
(See PL 9.1 Electrical (1 of 2))
Removal
Warning: Turn the power off and disconnect the Power Cord.
2. Loosen the two thumb screws that secure the Shield Cover and remove the cover.
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 screws that secure the System Controller PWB to the printer.
6. Slide the System Controller PWB toward the rear of the printer to disconnect P/J14
from the Print Engine Controller PWB.
7. Remove the System Controller PWB Assembly.
Note: If replacing the System Controller PWB, continue with
step 8.
8. Remove any DIMMs from slots J5, J4, or J6 and install them on the new System
Controller PWB.
9. If installed, remove the Hard Disk Drive.

10.Remove the two screws that secure the parallel connector to the frame assembly.
11.Remove the three screws that secures the System Controller PWB to the frame
assembly. Remove the System Controller PWB.
Figure 94 System Controller Board Assembly
11
10
Figure 95 System Controller Board
Replacement

RRP 8.2 High-Voltage Power Supply [HVPS] Board
Figure 96 High-Voltage Power Supply [HVPS] Board
Removal
Warning: Turn the power off and disconnect the Power Cord.
3. Disconnect P/J181, P/J182, P/J186, P/J187, P/J188, P/J185 from the HVPS PWB.
Caution: When reconnecting the 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

RRP 8.3 Duplex Interface Board
(See PL 11.1 500-Sheet Feeder (1 of 3))
Figure 97 Duplex Interface Board
Removal
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

RRP 8.4 Main Fan
Figure 98 Main Fan
Removal
3. Remove the HCS if installed (RRP 10.1 1000-Sheet High Capacity
Stacker [HCS]).
it from light.
7. Remove the screw that secures the left edge of the HVPS Cover.
8. Disconnect P/J165 from the LVPS PWB.
9. Remove the three screws that secure the Fan Guard to the printer.
10.Remove Fan Harness from all clamps.
11.Remove the screw that secures the Main Fan to the printer. Remove the fan.
Replacement

RRP 8.5 Print Engine Controller Board
Removal
1. Remove the Left Side Cover (RRP 1.1 Left Side Cover)
2. Loosen the two thumb screws that secure the System Controller PWB Shield
Cover and remove the cover.
3. Remove the four screws that secure the Print Engine Controller PWB Cover.
Remove the cover.
4. Disconnect P/J11, P/J12, P/J13, P/J14, P/J16, P/J17, 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.

Figure 100 Print Engine Controller Board Cover
Figure 101 Print Engine Controller Board
Replacement

RRP 8.6 Low-Voltage Power Supply [LVPS]
Assembly
Figure 102 Low-Voltage Power Supply [LVPS]
Removal
2. Disconnect P/J168, P/J167, P/J166, P/J165, P/J164, P/J163, P/J162, and P/J161
from the LVPS Assembly.
Caution: In the next step, when removing the four LVPS mounting
screws, take note of the color. Two are silver colored and
two have a slight gold tint. The gold screws secure the
circuit board the frame. The silver screws secure the heat
sink to the frame.
3. Remove the four screws that secure the LVPS Assembly to the printer.
4. Remove the LVPS Assembly.
Replacement
Note: Reinstall the silver and gold screws in the correct position
noted in step 3 or the threads can be stripped.

RRP 8.7 LVPS FAN
2
Figure 103 LVPS Fan
Removal
3. Remove the Fan Harness from all clamps.
4. Remove the two screws that secure the LVPS Fan to the LVPS Assembly.
5. Remove the LVPS Fan.
Replacement

RRP 8.8 AC Input Assembly
Figure 104 AC Input Assembly
Removal
2. Remove the LVPS Fan (RRP 8.7 LVPS FAN).
Note: In the next step, when disconnecting the green wire (ground)
from the frame, take note there are two star washers. One
washer is under the wire terminal, and the other is under the
screw head. Be certain to reinstall properly.
3. Remove the screw that secures the grounding wire to the printer.
5. Remove the two screws that secure the AC Input Connector to the printer.
6. Disconnect P/J171 and P/J172 from the AC Input PWB.
7. Remove the two screws that secure the AC Input PWB to the LVPS Assembly.
8. Flex the Right Cover out as you remove the AC Input Assembly.
Replacement

RRP 8.9 Control Panel +5 VDC Power Supply
Figure 105 Print Engine Controller Board Cover
Removal
1. Remove the Left Cover (RRP 1.1 Left Side Cover).
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.

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

RRP 9.1 Duplex Assembly
(See PL 13.1 Duplex Assembly)
Figure 107 Duplex Assembly
Removal
2. Remove Left Cover (RRP 1.1 Left Side Cover).
3. Pull the top of the Duplex Assembly away from the printer to disengage the two
hooks securing the unit.
4. Pull the Duplex Assembly out and up to remove.
Replacement

RRP 10.1 1000-Sheet High Capacity Stacker [HCS]
(See PL 10.1 High Capacity Stacker [HCS] (1 of 2))
Figure 108 High Capacity Stacker [HCS] Assembly
Removal
1. Open the printer Rear Cover.
2. Loosen the thumb screw located on the inside of the right frame.
3. Lift the High Capacity Stacker (HCS) straight up and remove.
4. Remove HCS Solenoid Assembly (RRP 10.5 HCS Exit Gate Solenoid) if removal
is permanent.
Replacement

RRP 10.2 HCS Top Cover
Figure 109 HCS Top Cover
Removal
1. Open the HCS Rear Cover.
2. Remove the HCS Output Bin.
3. Remove the four screws that secure the Top Cover.
4. Lift the cover up to remove.
Replacement

RRP 10.3 HCS Rear Cover Assembly
Figure 110 HCS Rear Cover
Removal
2. Carefully press in on the right bracket to disengage the cover from the frame.
3. Remove the cover.
Replacement

RRP 10.4 HCS Front Cover
Figure 111 HCS Front Cover
Removal
2. Remove the HCS Top Cover (RRP 10.2 HCS Top Cover).
3. Remove the four screws that secure the Front Cover. Remove the cover.
Replacement

RRP 10.5 HCS Exit Gate Solenoid
Figure 112 Exit Gate Solenoid
Removal
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

RRP 10.6 HCS Stack Full Sensor
Figure 113 HCS Stack Full Sensor
Removal
3. Disconnect P/J521 from the Stack Full Sensor.
4. Release the three locking tabs and remove the sensor.
Replacement

RRP 10.7 HCS Stack Full Sensor Actuator
Figure 114 HCS Stack Full Sensor Actuator
Removal
3. Remove the Stack Full Sensor (RRP 10.6 HCS Stack Full Sensor).
4. Move the actuator to the left. Carefully flex the center of the actuator until the right
end is free of the assembly.
5. Remove the actuator.
Replacement

RRP 10.8 HCS Drive Motor Assembly
Figure 115 HCS Drive Motor Assembly
Removal
3. Disconnect P/J518 from the Drive Motor.
4. Remove the two screws that secure the Motor Bracket to the HCS.
5. Remove the Drive Motor and bracket.
Replacement

RRP 10.9 HCS Rear Cover Interlock Switch
Figure 116 HCS Rear Cover Interlock Switch
Removal
3. Disconnect P/J525 from the interlock switch.
4. Release the two locking tabs and remove the switch.
Replacement

RRP 10.10 HCS Paper Sensor
Figure 117 HCS Paper Sensor
Removal
3. Remove the HCS Front Cover (RRP 10.4 HCS Front Cover).
4. Disconnect P/J523 from the Paper Sensor.
5. Release the two locking tabs that secure the sensor and remove the sensor.
Replacement

RRP 11.1 500-Sheet Feeder Removal
Figure 118 Feeder Removal
Removal
1. Remove the HCS, if installed
(RRP 10.1 1000-Sheet High Capacity Stacker [HCS]).
3. Remove the two screws that secure the printer to the Optional Paper 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

RRP 11.2 Front Cover
Removal
1. Remove the paper tray from the feeder.
2. Loosen the two screws that secure the front cover.
3. Pull out on the top of the Front Cover and lift slightly to remove the cover.
Replacement

RRP 11.3 Left Cover
Figure 120 Left Cover
Removal
3. Remove the five screws that secure the Left Cover. Remove the cover.
Replacement

RRP 11.4 Right Cover
Figure 121 Right Cover
Removal
3. Remove the five screws that secure the Right Cover. Remove the cover.
Replacement

RRP 11.5 Rear Cover
Figure 122 Rear Cover
Removal
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

RRP 11.6 Drive Assembly
Figure 123 Feeder Drive Assembly
Removal
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

RRP 11.7 Feeder Board
Figure 124 Feeder Board
Removal
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

RRP 11.8 Feed Head Assembly
Figure 125 Feed Head Assembly
Removal
1. Remove the printer from the 500-Sheet Feeder (RRP 11.1 500-Sheet Feeder
Removal).
5. Disconnect P/J13A, P/J13P, and P/J135 from the Feed Head Assembly.
6. Remove the screw that secures the Feed Head to the feeder frame.
7. Push the right locking pin down and slide the right end of the Feed Head forward.
8. Push the left locking pin down and slide the left end of the Feed Head forward.
9. Slide the Feed Head forward and remove.
Replacement

RRP 11.9 Feed Rollers
Figure 126 Feed Rollers
Removal
Removal).
4. Remove the Left Cover (RRP 11.3 Left Cover).
5. Remove the 500-Sheet Feed Head Assembly (RRP 11.8 Feed Head Assembly).
6. Release the Feed Solenoid.
7. Rotate the Feed Rollers up.
8. Press the left locking tab and slide the Roller core to the left.
9. Slide the Roller core to the left.
10.Slide the Feed Roller to the left and remove.
11.If replacing the envelope Feed Rollers, rotate the Feed Roller Shaft to access the
locking tabs, press the locking tabs and remove the Rollers.
Replacement
Note: The arrows on the side of the Envelope Feed Rollers indicate
the direction of rotation.

RRP 11.10 Feed Solenoid
Figure 127 Feed Solenoid
Removal
Removal).
6. Disconnect P/J135.
7. Remove the screw that secures the feed solenoid.
8. Remove the solenoid.
Replacement

RRP 11.11 Turn Roller Assembly
Figure 128 Turn Roller Assembly
Removal
Removal).
6. Remove the two screws that secure the Gear Cover and remove the cover.
7. Release the locking tab and remove the turn gear.
8. Remove the E-rings and bearings from the left end of the turn shaft.
9. Remove the Turn Roller Assembly.
Replacement

RRP 11.12 Retard Chute Assembly
Figure 129 Retard Chute Assembly
Removal
Removal).
6. Tilt the retard chute forward.
7. Use a screwdriver to pry up the right end of the chute.
8. Slide the chute to the right and remove.
Replacement

RRP 11.13 Left Tray Guide
Figure 130 Left Tray Guide

Removal
Removal).
6. Remove the Retard Chute (RRP 11.12 Retard Chute Assembly).
7. Disconnect P/J133 and P/J138 and 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

RRP 11.14 Right Tray Guide
Figure 131 Paper Level Indicator Actuator
Removal
Removal).
4. Remove the Right Cover (RRP 11.4 Right Cover).
7. Carefully push down on the locking tab that secures the rod to the paper level
actuator.
8. Remove the paper level assembly from the 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.

Figure 132 Right Tray Guide
Replacement

RRP 11.15 Retard Holder Assembly
Figure 133 Retard Holder Assembly
Removal
Removal).
7. From the back of the Retard Chute Assembly, release the two locking tabs.
8. Remove the Retard Roller from the front of the chute.
Replacement

RRP 11.16 Retard Turn Roller Assembly
Figure 134 Turn Roller Assembly
Removal
Removal).
7. Press the locking tab and remove the Turn Gear from the left end of the shaft.
8. Remove the E-ring from the right end of the shaft.
9. Remove both the right and left bearings.
10.Remove the shaft.
Replacement

RRP 11.17 Paper Size Sensor
Figure 135 Paper Size Sensor
Removal
Removal).
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

RRP 11.18 Paper Tray Sensor
Figure 136 Paper Tray Sensor
Removal
Removal).
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

RRP 11.19 No Paper Sensor
Figure 137 No Paper Sensor Cover
Removal
Removal).
6. Remove the screw that secures the sensor cover and remove the cover.

7. Remove the No Paper Actuator (RRP 11.20 No Paper Sensor Actuator).
8. Release the Paper Feed Solenoid and rotate feed Rollers to allow access to the
sensor.
9. Disconnect P/J134 from the No Paper Sensor
10.Release the three locking tabs and remove the sensor.
Figure 138 Feed Solenoid
Figure 139 No Paper Sensor
Replacement

RRP 11.20 No Paper Sensor Actuator
Figure 140 No Paper Sensor Actuator
Removal
Removal).
6. Remove the actuator from the Feeder Chute. (A small screwdriver may be used to
pry the actuator free of the retaining clips.
Replacement

RRP 11.21 Preregistration Sensor
Removal
Figure 141 Sensor Cover

Removal).
5. Remove the Feed Head Assembly (RRP 11.8 Feed Head Assembly).
6. Remove the screw that secures the sensor cover and remove the cover.
7. Disconnect the P/J13C from the Preregistration Sensor.
8. Release the four locking tabs and remove the sensor.
Figure 142 Preregistration Sensor

Replacement

RRP 12.1 Removing the 2000-Sheet Feeder
Figure 143 Removing the Printer

Removal
1. Lock the front casters on the 2000-Sheet Feeder.
2. Remove the HCS, if installed
(RRP 10.1 1000-Sheet High Capacity Stacker [HCS]).
4. Remove the two screws that secure the printer.
Note: For safety reasons, have someone assist you in removing the
printer and setting it in a safe place.
5. Remove the 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

RRP 12.2 Left Side Cover
Figure 144 Left Side Cover
Removal
1. Remove the two screws that secure the Left Side Cover.
2. Pull the top of the cover out and up to remove.
Replacement

RRP 12.3 Upper Rear Cover
Figure 145 Upper Rear Cover
Removal
1. Open the Upper Rear Cover.
2. Carefully push in on the left or right bracket to disengage the end of the cover.
Replacement

RRP 12.4 Lower Rear Cover
Figure 146 Lower Rear Cover
Removal
1. Remove the two screws that secure the top of the Lower Rear Cover.
2. Loosen three screws that secure the Lower Rear Cover.
Replacement

RRP 12.5 Right Side Cover
Figure 147 Right Side Cover
Removal
1. Remove the two screws that secure the Right Side Cover.
Replacement

RRP 12.6 Front Cover
Removal
1. Open the 2000-Sheet Feeder Tray.
2. Remove the two screws that secure the front cover.
Replacement

RRP 12.7 Tray Assembly
Figure 149 Tray Assembly
Removal
1. Pull the 2000-Sheet Feeder Tray out until it stops.
2. Remove all paper from the tray.
3. Push and hold the button on the Left Rail to release the latch.
4. Remove the Tray Assembly.
Replacement

RRP 12.8 2000-Sheet Feeder PWB
Figure 150 2000-Sheet Feeder Board
Removal
2. Disconnect P/J601, P/J602, P/J603, P/J604, P/J605, P/J606, and P/J607.
3. Remove the four screws that secure the PWB.
4. Remove the PWB.
Replacement

RRP 12.9 Tray Lift Motor Assembly
Figure 151 Tray Lift Motor Assembly
Removal
2. Open the 2000-Sheet Feeder tray.
3. Disconnect P/J605 from the PWB.
4. Remove the three screws that secure the Lift Motor Assembly.
5. Remove the Tray Lift Motor Assembly.
Replacement

RRP 12.10 A4 Paper Size Sensor
Figure 152 Paper Size Sensor
Removal
1. Remove the 2000-Sheet Feeder Tray Assembly (RRP 12.7 Tray Assembly).
2. Disconnect P/J612 from the Paper Size Sensor.
3. Release the two locking tabs and remove the Sensor.
Replacement

RRP 12.11 Casters
Figure 153 Casters
Removal
1. Remove the Printer / 500-Sheet Feeder (RRP 11.1 500-Sheet Feeder Removal).
2. Remove the Left Foot.
4. Remove all paper from the 2000-Sheet Feeder tray.
5. Tilt the 2000-Sheet Feeder onto its left side.
Note: The front casters are locking casters and rear are not.
6. Remove the three screws that secure the defective caster.
Replacement

RRP 12.12 Harness Assembly
Figure 154 Harness Assembly
Removal
1. Remove the Printer / 500-Sheet Feeder (RRP 11.1 500-Sheet Feeder Removal).
4. Disconnect P/J601 from the 2000-Sheet Feeder 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

RRP 12.13 Drive Assembly
Figure 155 Drive Assembly
Removal
2. Remove the screw that secures the back of the Drive Assembly.
3. Remove the Tray Assembly (RRP 12.7 Tray Assembly).
4. Disconnect P/J615 from the Drive Assembly.
5. Remove the screw that secures the front of the Drive Assembly.
6. Remove the Drive Assembly.
Replacement

RRP 12.14 Feed, Nudger, and Retard Roller
Figure 156 Pick, Feed and Retard Rollers
Removal
1. Open the 2000-Sheet Feeder tray.
3. From the rear loosen the two thumb screws and remove the paper baffle.
4. From the rear of the feeder, carefully lift the locking tab on the Roller you wish to
change.
5. Slide the Roller off the end of the shaft.
Replacement

RRP 12.15 Paper Height Sensor
Figure 157 Paper Height Sensor
Removal
2. Hold the Nudger Assembly down as you release the three locking tabs that secure
the Paper Height Sensor.
3. Disconnect P/J611 from the sensor.
Replacement

RRP 12.16 Paper Feed Motor Assembly
Figure 158 Paper Feed Motor Assembly
Removal
2. Remove the E-ring that secures the 47T gear. Remove the gear.
3. Remove the two screws that secure the motor to the Feeder Frame.
4. Remove the Paper Feed Motor Assembly.
5. Disconnect P/J609 from the Feed Motor Assembly.
Replacement

RRP 12.17 Link Stopper
4
3
Figure 159 Link Stopper
Removal
1. Remove the Retard Assembly (RRP 12.26 Retard 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

RRP 12.18 No Paper Sensor
Figure 160 No Paper Sensor
Removal
2. Disconnect P/J610 from the No Paper Sensor.
3. Release the three locking tabs that secure the sensor
4. Remove the sensor.
Replacement

RRP 12.19 No Paper Sensor Actuator
Figure 161 No Paper Sensor Actuator
Removal
2. Release the four locking tabs that secure the actuator and support.
3. Remove the actuator from the Actuator Support.
Replacement

RRP 12.20 Left and Right Wire Cover
Figure 162 Tray Assembly Wire Covers
Removal
1. Open the 2000-Sheet Feeder Tray Assembly until it stops.
2. Remove the two screws that secure the Wire Cover to the Tray Assembly.
Replacement

RRP 12.21 Shaft Cover Assembly
Figure 163 Shaft Cover Assembly
Removal
2. Remove the four screws that secure the Shaft Cover Assembly to the Tray
Assembly.
Replacement

RRP 12.22 Drive Shaft Assembly
Figure 164 Drive Shaft Assembly
Removal
2. Remove the Shaft Cover Assembly (RRP 12.21 Shaft Cover Assembly).
3. Align the Drive Shaft Assembly with the hole in the Shaft Cover Assembly.
4. Remove the two screws that secure the Drive Shaft Bracket to the shaft cover.
5. Remove the Drive Shaft Assembly.
Replacement

RRP 12.23 Brake Assembly
Figure 165 Brake Assembly
Removal
2. Remove the two screws that secure the Brake Assembly to the Tray Assembly.
3. Remove the Brake Assembly.
Replacement

RRP 12.24 Left Tray Wires
Figure 166 Left Tray Wires
Removal
3. Remove the Brake Assembly (RRP 12.23 Brake Assembly).
4. Remove the Left Wire Cover (RRP 12.20 Left and Right Wire Cover).
5. Remove the E-ring that secures the 33 Gear and remove the gear.
6. Remove the Cable Pulley from the shaft.
7. Remove the E-rings and pulleys from the two shafts on the tray assembly.
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.
3. The longer wire goes to the front of the tray.

RRP 12.25 Right Tray Wires
Figure 167 Right Tray Wires
Removal
3. Remove the Right Wire Cover (RRP 12.20 Left and Right Wire Cover).
4. Remove the E-ring that secures the Cable Pulley. Remove the pulley.
5. Remove the E-rings and pulleys from the two shafts on the tray assembly.
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.
3. The longer wire goes to the front of the tray.

RRP 12.26 Retard Assembly
Figure 168 Feed Gears
Removal
3. Remove the E-ring that secures the 50T Gear to the Feeder Shaft, then remove the
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.

7. Release the spring from the left end (as viewed from the rear) of the Retard
Support.
8. Remove the two screws that secure the Retard Support Assembly to the feeder.
9. Lift the Retard Support Assembly, slide it to the right and remove.
Figure 169 Retard Assembly
Replacement

Blank Page

FRU Parts List
Introduction
The Parts List section provides exploded-view illustrations of all spared subsystem
components and a listing of the corresponding part numbers. The illustrations show
the relationships between parts.
Changes to the printer may be made to accommodate improved components as they
become available. When ordering parts and/or supplies, it is important to include the
following information:
■ Component’s part number,
■ Printer type or model number,
■ Printer serial number,
■ Modification number, if any.
Organization of this Section

The following elements make up the Parts List section: Parts Lists (PL), each item
number in the part numbers listing corresponds to an item number in the illustration.
All the parts in a given subsystem of the machine will be located in the same
illustration or in a series of associated illustrations. The parts which are spared are
indicated by a part number in the Part Number column. Conversely, the lack of a part
number for any given part indicates that part is not spared and is only available on its
parent assembly.
Exploded-View Illustrations: an item that is called out on an illustration has a
corresponding listing within this section. Components are given item numbers that
correspond to the part number listings. Hardware items are lettered. All hardware
dimensions are in millimeters unless otherwise noted.
Assemblies and kits are a combination of several separate components. A bracket is
used on the illustration when an assembly or kit is spared but is not shown. The item
number of the assembly 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.

Using the Parts List
1. The numbers shown in each illustration correspond to the parts list number for that
illustration.
2. Throughout this manual, parts are identified by the prefix “PL”, followed by a
number, a decimal point, and another number. For example, PL3.1.12 means the
part is item 12 of parts list 3.1.
3. The capital letters “C”, “E”, and “S” shown in an illustration stand for C-ring,
E-ring, and Screw, respectively.
4. A shaded triangle t in an illustration indicates the item is part of an assembly.
5. The notation “with X~Y” following an part name indicates an assembly that is
made up of components X through Y. For example, “1 (with 2~4)” means part 1
consists of part 2, part 3, and part 4.
6. The notation “RS” means that the part is a requested spare. Part numbers for these
parts will be provided as soon as they are available.
7. An asterisk * following a part name indicates the page contains a note about this
part.
8. The notation “J1<>J2 and P2” is attached to a wire harness. It indicates that
connector jack 1 is attached to one end of the wire harness and connector jack 2 is
attached to the other end that is plugged into plug 2.

9. A notation “(part of item 1.1)” indicates that the part is included with item 1.2.1
(PL1.2, line item 1).
Note: Only parts showing part numbers are available for support.
Parts not showing part numbers are available on the parent
assembly.
Table 126 Legend:
Identifier Meaning
C C-ring
E E-ring
KL E-clip
S Screw

Parts Lists
PL 1.1 Covers
25
24
27
26
22
23 (with 18, 22)
s5400-202
Figure 170 Covers

Table 127 PL 1.1 Covers
ID No. Part Number Qty Name / Description
1 802K29441 1 Cover Assembly, Top [includes 2~5, 7-15, 26, 29, 30,
32]
2 1 Door, Top Access [P/O item 1]
3 1 Stopper, Left [P/O item 1]
4 1 Bracket, Left [P/O item 1]
5 048E64291 1 Cap, Top Cover
6
7 1 Bracket, Right [P/O item 1]
8 1 Stopper, Right [P/O item 1]
9 1 Cover, Top [P/O item 1]
10 1 Latch, Right [P/O item 1]
11 1 Latch, Left [P/O item 1]
12 1 Tray Guide, Right [P/O item 1]
13 1 Tray Guide, Left [P/O item 1]
14 1 Tray Extension [P/O item 1]
15 050E88420 1 Tray Stopper
16 101K37901 1 Control Panel Assembly
17 048E64122 1 Cover, Right
18 1 Cover, Front [P/O item 23]
19 048E64102 1 Cover, Left Lower
20 048E64082 1 Left Cover
21
22 Label Front [P/O Item 23]
23 802K04213 1 Cover Assy, Front [with 18, 22]
24 1 Label, Access Cover 3 [P/O item 1]
25 1 Stand Cover, Pop Up
26 892E08500 1 Badge
27 042K92000 1 Cleaning Brush
28
S 600K76430 Kit, Hardware (includes screws and E-rings)

PL 2.1 Paper Tray [A3/Ledger]
Figure 171 Paper Tray (A3/Ledger)

Table 128 PL 2.1 Paper Tray [A3/Ledger]
1 109R00523 1 Tray Assembly, [A3/Ledger (includes 2~37)]
2 1 Bottom [P/O item 1]
3 1 Sprint, Latch [P/O item 1]
4 1 Plate, Side Guide [left] [P/O item 1]
5 1 Plate, Side Guide [right] [P/O item 1]
6 1 Lever, Side [right] [P/O item 1]
7 1 Latch Assembly [right] [P/O item 1]
8 2 Spring, Long [P/O item 1]
9 1 Spring, Ground [P/O item 1]
10 1 Guide, End [P/O item 1]
11 1 Spring, End Guide Plate [P/O item 1]
12 1 Guide, End Plate [P/O item 1]
13 1 Tray, Long Housing 1 [P/O item 1]
14 1 Rack [P/O item 1]
15 1 Pinion [P/O item 1]
16 1 Cover, Bottom [long] [P/O item 1]
17 1 Gear, Sector [long] [P/O item 1]
18 1 Gear, Idler [P/O item 1]
19 1 Lock, End Guide [P/O item 1]
20 1 Cover, Tray 1 [P/O item 1]
21 1 Cam, Size [long] [P/O item 1]
22 1 Lock, Pin [P/O item 1]
23 1 Label, Long Side [P/O item 1]
24 1 Label, Max Paper [P/O item 1]
25 2 Label, Hold Here [P/O item 1]
26 1 Label, Paper Set [P/O item 1]
27 1 Latch [P/O item 1]
28 1 Label, Tray Set [P/O item 1]
29 1 Cap, Side [right] [P/O item 1]
30 1 Cover, Latch [right] [P/O item 1]
31 1 Cover, Latch [left] [P/O item 1]
32 1 Latch Assembly [left] [P/O item 1]
33 802K05701 1 Cover Assembly, Tray [with 20, 28] [P/O item 1]
34 1 Plate, Mini Bottom [P/O item 1]
35 1 Rack [left] [P/O item 1]
36 1 Spring, N/F Center [P/O item 1]
37 1 Plate, Tray [P/O item 1]
S 600K76430 Hardware Kit (includes screws and E-rings)

PL 2.2 Paper Tray [A4/Letter]
Figure 172 Paper Tray [A4/Letter]

Table 129 PL 2.2 Paper Tray [A4/Letter]
1 109R00524 1 Tray Assembly, A4/Letter [includes 2~33]
2 1 Plate Assembly, Bottom
3 1 Spring, Latch
4 1 Plate, Side Guide [left]
5 1 Plate, Side Guide [right]
6 1 Lever, Side [right]
7 1 Latch Assembly [right]
8 2 Spring
9 1 Spring, Ground
10 1 End Guide
11 1 End Guide, Spring Plate
12 1 Guide, End Plate
13 1 Housing, Tray 1 [short]
14 1 Rack
15 1 Pinion
16 1 Cover, Bottom [short]
17 1 Gear, Sector [short]
18 1 Gear, Idler
19 1 Lock, End Guide
20 1 Cam, Size [A4/Letter]
21 1 Lock, Pin
22 1 Label, Side [short]
23 1 Label, Max Paper
24 1 Label, Set Paper
25 1 Latch
26 1 Cover, Latch [right]
27 1 Cover, Latch [left]
28 1 Latch Assembly [left]
29 1 Cap, Side [right]
30 1 Cover, Handle
31 1 Plate, Mini Bottom
32 1 Rack [left]
33 1 Spring, N/F Center
34 1 Plate, Tray
S 600K76430 Hardware Kit (includes screws and E-rings)

PL 3.1 Paper Feeder
Figure 173 Paper Feeder

Table 130 PL 3.1 Paper Feeder
1 054K13043 1 Chute Assembly, Rear [includes 2~4]
2 1 Chute, Rear [P/O item 1]
3 8 Roller, Pinch [P/O item 1]
4 8 Spring, Pinch [P/O item 1]
5 1 Rod, Paper Level Indicator [P/O item 16]
6 1 Collar, Paper Level Indicator [P/O item 16]
7 1 Guide Assembly, Tray 1 [with 5, 6 & 16] [P/O item 16]
8 054K13055 1 Chute Assembly, Retard [includes 9~‘5, 31 & 32]
9 1 Chute, Retard [P/O item 8]
10 1 Roller Assembly, Turn [left] [P/O item 8]
11 2 Support, Bearing [P/O item 8]
12 2 Bearing, ES8 [P/O item 8]
13 019K94613 1 Holder Assembly, Retard [P/O item 8]
14 1 Arm, Retard [P/O item 8]
15 1 Gear, Turn [P/O item 8]
16 604K01890 1 Guide Assembly, Tray 1 [right] [includes 5, 6 & 17~19]
17 1 Guide, Tray 1 [right] [P/O item 16]
18 1 Actuator, GG [P/O Item 16]
19 1 Spring, Paper Level Indicator [P/O item 16]
20 032K93788 1 Guide Assembly, Tray 1 [left] [includes 21~30]
21 1 Guide, Tray 1 [left] [P/O item 20]
22 4 Actuator, Size [P/O item 20]
23 110E98320 1 Switch, Paper Size
24 162K42630 1 Harness Assembly, Sensor [J20~J201, J202]
25 1 Harness Assembly, Low Paper Sensor [J127~P128]
[P/O item 20]
26 130E82030 1 Switch, MBF Home
27 1 Actuator, MBF [P/O item 20]
28 130E81970 1 Sensor, Tray 1 Low Paper
29 1 Sensor Actuator, Tray 1 Low Paper [P/O item 20]
30 1 Spring, Tray 1 Low Paper Sensor Actuator [P/O item
20]
31 1 Lever, Retard [P/O item 8]
32 1 Spring, Release [P/O item 8]
33 1 Clip, Ground [P/O item 16]

PL 4.1 Multi-sheet Bypass Feeder (MBF) Assembly
Figure 174 Multi-sheet Bypass Feeder (MBF) Assembly

Table 131 PL 4.1 MBF Assembly
1 059K19206 1 MBF Assembly [includes 2, 5~11, 13~24 (PL 4.2 items
2~5, 7~11, 13~16 & 18~27, 29~31)]
2 1 Tray Assembly [P/O item 1]
3 003K85592 1 Latch Assembly [left]
4 2 Guide, Upper
5 809E35460 1 Spring, MBF 1 [P/O item 1]
6 1 Gear, Pick Up [P/O item 1 & 25]
7 2 Cam, Pick Up [P/O item 1]
8 2 Roller, Core [P/O item 1]
9 2 Roller, MBF Feed [P/O item 26]
10 1 Shaft, Pick Up [P/O item 1]
11 5 Bearing #8 [P/O item 1]
12 003K85941 1 Latch Assembly [right]
13 121K20060 1 Clutch, Tray 1 Turn Roller
14 059K13064 1 Roller Assembly, Tray 1 Turn
15 1 Bracket [P/O item 1]
16 1 Gear, Tray 1 Pick Up [P/O item 1 & 25]
17 1 Gear, MBF Idler 1 [P/O item 1 & 25]
18 1 Roller, Tray 1 Core [P/O item 1]
19 2 Roller, Envelope Feed [P/O item 27]
20 2 Bearing, Core #8 [P/O item 1]
21 809E35460 1 Spring
22 059K14641 1 Roller, Tray 1 Feed
23 1 Shaft, MBF Turn Roller [P/O item 1]
24 1 Label [P/O item 1]
25 600K72223 Kit, Gear [includes 6, 16, 17 & PL 4.1B items 23 & 24]
26 600K 73123 Kit, Feed Roller [2 pieces]
27 604K10040 Kit, Envelope Feed Roller [2 pieces]

PL 4.2 Paper Handler
(includes 9, 18-20)
Figure 175 Paper Handler

Table 132 PL 4.2 Paper Handler
1 600K72192 1 Holder Assembly, Retard [includes 2~4]
2 2 Spring, NIP [P/O item 1]
3 1 Holder, Retard [P/O item 1]
4 1 Pad, Retard [P/O item 1]
5 2 Spring N/F
6 600K72223 1 Kit, Gear [includes 23, 24 & PL 4.1 (items 6, 16 & 17)]
7 1 Clamp [P/O PL 4.1 item 1]
8 1 Pin, Idler [P/O PL 4.1 item 1]
9 1 Sensor, No/Low Paper
10 1 Chute
11 1 Cover, Lower [P/O PL 4.1 item 1]
12 019K94931 1 Sensor Assembly, Tray 1 Sensor [includes 13~15]
13 1 Actuator, Tray 1 No Paper Sensor [P/O item 12]
14 1 Sensor, No Paper [P/O item 12]
15 1 Holder, Tray 1 Sensor [P/O item 12]
16 050K43611 1 Door, MBF
17 019K94921 1 Sensor, MBF No/Low Paper [includes 9 & 18~20]
18 1 Spring, MBF No/Low Paper Sensor [P/O item 17]
19 1 Actuator, MBF No/Low Paper Sensor [P/O item 17]
20 1 Holder, Sensor [P/O item 17]
21 121K27230 1 Solenoid, MBF Feed
22 121K18810 1 Solenoid, Tray 1 Feed
23 1 Gear, MBF In [P/O item 6]
24 1 Gear, MBF Idler 2 [P/O item 6]
25 1 Cover, MBF Gear
26 1 Chute, Lower [P/O PL 4.1 item 1]
27 162K42620 1 Harness, MBF Combo [P121~P122, P123, P124, J125
& J126]
28 048E64172 1 Cover
29 1 Plate, Lower Ground [P/O PL 4.1 item 1]
30 1 Plate, Ground [P/O PL 4.1 item 1]
31 2 Holder, Retard Pad [P/O PL 4.1 item 1]

PL 5.1 Paper Transport
Figure 176 Paper Transport

Table 133 PL 5.1 Paper Transport
1 054K18572 1 Transport Assembly, Paper [includes 2~15]
2 1 Transport, Chute [P/O item 1]
3 2 Bearing, BTR [P/O item 1]
4 2 Spring BTR [P/O item 1]
5 1 Actuator, Registration [P/O item 17]
6 1 Spring, Sensor [P/O item 17]
7 2 Spring, Registration [P/O item 1]
8 1 Gear, Registration [rubber roller shaft] [P/O Item 1]
9 1 Bearing, Right [rubber roller shaft] [P/O Item 1]
10 1 Gear, Registration [metal shaft] [P/O Item 1]
11 2 Bearing [metal shaft] [P/O Item 1]
12 1 Roller, Registration [rubber roller shaft] [P/O Item 1]
13 1 Roller, Registration [metal shaft] [P/O Item 1]
14 1 Bearing, Left [rubber roller shaft] [P/O Item 1]
15 121E84300 1 Clutch, Registration
16 130E82740 1 Sensor, Registration
17 600K72231 1 Kit, Actuator
18 022K62410 1 Roller, Bias Transfer [BTR]

PL 6.1 Rear Cover Assembly With Fuser
1 (with 2~31,
2~28,33,
30,35~37)
32, 37~52, 55)
24 31
25
36
37
35
35
33 23
33 28
38
97 (with 28, 30x2 ea.)
26
27
99 (with 33)
32
30 29
30
28
30
28
27
98 (with 27x2 ea.)
94 (with
94 (with 2~10,
2~10, 13~22,
13~22,26)
37~41)
s5400-209
Figure 177 Rear Cover Assembly

Table 134 PL 6.1 Rear Cover Assembly with Fuser
ID No. Part Qty Name / Description
Number
14, 38 ID Numbers not used
1 802K04577 1 Cover Assembly, Rear [includes 2-31, 33, 35-37]
2 1 Gear Assembly, Cover Gate [P/O item 1]
3 1 Gear, Z20/20 [P/O item 1]
4 1 Spring, Cover Gate Gear [P/O item 1]
5 1 Gear, Z37 [P/O item 1]
7 4 Bearing, Exit [P/O item 1]
9 1 Gear, Z22/15 [P/O item 1]
10 1 Plate Assembly, Exit Drive [P/O item 1]
11 1 Cover, Top Exit [P/O item 1]
12 1 Cover, Gate [P/O item 1]
13 162K43690 1 Harness, Direction Solenoid [P/O item 1]
15 1 Holder, Full Stack Sensor [P/O item 31]
16 1 Sensor, Full Stack [P/O item 31]
17 1 Actuator, Full Stack Sensor [P/O item 31]
18 162K43700 1 Harness, Full Stack Sensor [P/O item 1]
19 1 Spring, Exit Gate [P/O item 1]
20 1 Gate, Exit [P/O item 1]
21 059K11893 1 Shaft, Rear Cover Roller [P/O item 1]
22 1 Chute, Upper Exit [P/O item 1]
23 1 Roller Assembly, Pre-Exit
24 1 Latch, Left Exit
25 1 Latch, Right Exit
26 1 Lower Exit Chute
27 001K68072 2 Kit, Exit Strap
28 1 Cover, Rear Exit
29 1 Plate, Earth
30 2 Spring, Earth Exit
31 600K72254 1 Sensor Assembly, Full Stack (with 15-17)
32 1 Fuser Assembly (P/O Item #99)
33 2 Flapper, Exit
34 011E07992 1 Handle, Fuser Latch
35 2 Cloth, Anti-Static [P/O Item 1]
36 1 Clip, Ground L [P/O Item 1]
37 4 Clip, Ground R [P/O Item 1]
94 1 Kit Assembly, Exit (with 2-10, 13-22, 26)
97 1 Kit Assembly, Rear, Exit Cover (with 28, 30x2 pcs)
98 1 Kit, Exit Strap (with 27x2pcs)
99 109R00521 1 Kit, Usage, (Fuser 110V~BTR) with 33, (PL5.1.18))
99 109R00522 1 Kit, Usage, (Fuser 220V~BTR) with 33, (PL5.1.18))

PL 7.1 Frame & Drives
Figure 178 Frame and Drives

Table 135 PL 7.1 Frame and Drives
1 1 Cover, Laser
2 1 Bracket, HCS [left]
3 1 Cover, Lower Rear
4 809E10940 1 Kit, Main Drive Motor Spring [2 pieces] [P/O item 11]
5 8 Clamp
6 2 Clamp, Laser
7 6 Clamp
8 1 Clamp
9 3 Clamp
10 007K86761 1 Gear Assembly, Drive [includes 4, 11 & 12]
11 1 Motor Assembly [includes 19 & 20] [P/O item 10]
12 1 Gear Assembly, Main Drive Motor [P/O item 10]
13 1 Harness, HCS Bush
14 1 Bush, High Voltage
15 1 Bracket, HCS [right]
16 003E46230 1 Stopper, Duplex [left]
17 003E46240 1 Stopper, Duplex [right]
18 048E65002 1 Cover, HVPS
19 1 Motor [P/O item 10]
20 1 Controller Board, Main Drive Motor [P/O item 10]
21 1 Cover, Drawer

PL 8.1 Xerographics
2 (with 3, 4, 18)
18
99 (with 14, 19)
13
22
s5400-212
Figure 179 Xerographics

Table 136 PL 8.1 Xerographics
1 113R00495 1 Cartridge, Print
2 062K10803 1 Laser Scanner Assembly, (with 3, 4, 18)
3 1 Harness Assembly, Laser Scanner [J115-1~J115-2]
4 1 Scanner, Laser (Reference only) [P/O Item 2]
5 032K93933 1 Guide Assembly, Print Cartridge [right] (with 6~12,15)
6 1 Harness Assembly, Interlock (J162~J621, J622, J623)
[P/O item 5]
7 1 Wire Assembly, Developer [P/O item 5]
8 1 Wire Assembly, Xerographic [P/O item 5]
9 1 Seal, Guide [P/O item 5]
10 1 Plate, Developer [P/O item 5]
11 1 Plate, Xerographic [P/O item 5]
12 1 Guide, Print Cartridge [right] [P/O item 5]
13 160K75680 1 Antenna, CRUM
14 1 Link Assembly, Right [P/O Item 99]
15 1 Interlock Switch (P/O Item 5)
16 130K57891 1 Sensor Assembly, Toner
17 1 Sensor Assembly, Print Cartridge
18 1 Laser label
19 Link Assembly, Left [P/O Item 99]
20 032E16202 1 Guide, Print Cartridge [left]
21
22 1 Wire Harness, Interlock
99 600K72262 1 Kit, Link (with 14, 19)

PL 9.1 Electrical (1 of 2)
Figure 180 Electrical (1 of 2)

Table 137 PL 9.1 Electrical (1 of 2)
1 160K83452 1 Board, System Controller
2 1 Kit, Cover Assembly [includes 3~6]
3 1 Cover, Shield
4 2 Screw, Thumb
5 1 Cover, Print Engine Controller Board (MCU)
6 802K35520 1 Panel, Rear
7 105K19330 1 Board, 5 VDC Power Supply
8 105K19091 1 Board, High Voltage Power Supply (HVPS)
9 160K74360 1 Board, Duplex Interface
10 162K43530 1 Harness, Full DUP-1 [J502-J527]
11 162K43550 1 Harness, Flap-1 [J505-J528]
12 127K32011 1 Fan, Fuser Cooling
13 055E33041 1 Cover, Fuser Fan
14 162K43542 1 Harness, STK-1 [J504-J526]
15 162K42610 1 Harness, P/H [J12-J121, J128]
16 162K42640 1 Harness, Tray 2/3 Feeder [J13-P131]
17 162K42821 1 Harness, System Controller Board to User Interface
[J18-J421]
18 162K42880 1 Harness, Laser NS [J11-J112, J114]
19 1 Harness
20 162K42740 1 Harness, Reg [J22-J222]
21 162K43521 1 Harness, Duplex Interface [J19-J501]
22 162K42720 1 Harness, HVPS [J18-J181, J183]
23 160K83415 1 Board, Print Engine Controller [110 VAC] [US]
160K83425 Board, Print Engine Controller 220 VAC] [EU]
24 733W14695 As 16 MB DIMM
733W14696 required 16 MB DIMM
733W14697 16 MB DIMM
160K71940 8 MB Flash DIMM
25 650-4238-00 Drive, Hard Disk (20 GB)

PL 9.2 Electrical (2 of 2)
Figure 181 Electrical (2 of 2)

Table 138 PL 9.2 Electrical (2 of 2)
1 162K42681 1 Harness, Low Voltage Power Supply (LVPS)
[J161-J16, J506]
2 105K19080 1 Power Supply, Low Voltage [110 VAC]
105K19170 Power Supply, Low Voltage [220 VAC]
3 962K05780 1 Harness, System Controller [3.3V] [J163-J3]
4 162K42800 1 Harness, System Controller [5V] [J169-J168, J13]
5 127E81781 1 Fan, LVPS Exhaust
6 1 Inlet Assembly [includes 11~13] [P/O Item 2]
7 1 Cord, Power [US]
8 1 Fuse [P/O Item 2]
9 110E98300 1 Switch, Rear Cover Fuser Interlock
10 162K62621 1 Harness, Fuser [115 VAC [J174, J17, J171, J177, J178
& J182]
162K62641 Harness, Fuser [220 VAC] [J174, J17, J171, J177,
J178 & J182]
11 1 Inlet [reference only] [P/O Item 2]
12 1 Board [reference only] [P/O Item 2]
13 Cover, Inlet
14 103K80930 1 Resistor, Flicker (220V only)

PL 10.1 High Capacity Stacker [HCS] (1 of 2)
s5400-215
Figure 182 High Capacity Stacker (1 of 2)

Table 139 PL 10.1 High Capacity Stacker (1 of 2)
1 097S02715 1 Stacker Assembly, High Capacity (HCS) (with 2-8,
10-19)
2 802E24491 1 Cover, Top [P/O Item 1]
3 036E91371 1 Weight, Paper [P/O Item 1]
4 802K26211 1 Cover Assembly, Rear (with 5~8) [P/O Item 1]
5 1 Cover, Rear [P/O Item 4]
6 1 Holder, Magnet [P/O Item 4]
7 4 Roller, Turn Pinch [P/O Item 4]
8 4 Spring, HCS Pinch [P/O Item 4]
9
10 001K74192 1 P/H, Assembly, HCS [same as PL 14.2, item 1]
11 802K24531 1 Cover, Front
12 050K43412 1 Tray Assembly, HCS (with 16-19)
13 048E64831 1 Cover, Gate
14 121K18871 1 Solenoid Assembly, Exit Gate
15 2 Flapper, HCS
16 1 Tray, Bottom [P/O Item 12]
17 1 Tray, Top [P/O Item 12]
18 3 Spring [P/O Item 12]
19 4 Cap [P/O Item 12]

PL 10.2 High Capacity Stacker [HCS] (2 of 2)
2 (with 4)
38
35
35
36
9
16
9
34
s5400-216
Figure 183 High Capacity Stacker (2 of 2)

Table 140 PL 10.2 High Capacity Stacker (2 of 2)
8, 16-17, 34-36 ID Numbers not used
1 001K74193 1 Paper Handling, HCS Assembly (with 2-7, 10-15,
18-33, 37-41) [same PL 14.1.10]
2 1 Eliminator Assembly, Static [with 3, 4, 6, 7]
3 1 Bracket, Stack Full
4 2 Eliminator
5 162K63540 1 Harness, Stack Full Sensor [J520-J521, J523]
6 130E82740 1 Sensor, HCS Stack Full
7 120E16941 1 Actuator, Stack Full Sensor
9 130K61650 2 Sensor, Jam
10 1 Chute Assembly, HCS Exit (with 11-14)
11 1 Chute Assembly
12 10 Bearing, Exit
13 1 Roller
14 1 Shaft
15 1 Chute, HCS
18 1 Screw, Spring
19 1 Frame, Side [right]
20 1 Support [right]
21 2 Roller, Inlet
22 162K63530 1 Harness, STK-0 [J514-P526]
23 1 Support [left]
24 127K31970 1 Motor Assembly, HCS
25 3 Gear
26 3 Gear, 29T
27 2 Gear, Idler 14/23
28 1 Frame Assembly, Left Side, HCS
29 162K63550 1 Harness, OP STK COV [J524-J525]
30 110E93440 1 Switch, Rear Cover Interlock
31 3 Clamp
32 1 Board, HCS
33 2 Sensor
37 162K63560 1 Harness Assembly, Stacker Motor (J517-J518)
38 1 Gear, Z49
39 1 Harness, Collar
40 2 Clamp
41 1 Label, SP HCS

PL 11.1 500-Sheet Feeder (1 of 3)
Figure 184 500-Sheet Feeder (1 of 3)

Table 141 PL 11.1 500-Sheet Feeder (1 of 3)
1 097S02712 1 Feeder Assembly, Complete [w/A4 CST]
097S02711 Feeder Assembly, Complete [w/A3 CST]
[customer purchased item]
2 802K11761 1 Cover Assembly, Rear [includes 3, 6 & 8~10]
3 2 Latch [P/O item 2]
4 802E03103 1 Cover, Front
5 802E28501 1 Cover, Left
6 1 Cover, Rear [P/O item 2]
7 019K94731 1 Roller Assembly, Pinch [includes 8~10]
8 4 Holder [P/O item 2] [P/O item 7]
9 3 Spring Torsion [P/O item 2] [P/O item 7]
10 3 Roller, Pinch [P/O item 2] [P/O item 7]
11 802E03091 1 Cover, Right
12 1 Label


Table 142 PL 11.2 500-Sheet Feeder
1 1 Feeder Assembly, Complete [P/O PL 11.1, item 1]
[customer purchased item]
2 015K39481 1 Bracket Assembly, Gear 28
3 1 Sub-Assembly, Feeder [same as PL 11.3, item1]
4 054K14729 1 Head Assembly, Feed [includes 5~22]
5 1 Gear, Turn
6 4 Bearing
7 1 Roller Assembly, Turn
8 130K60371 1 Sensor, Pre-Registration
9 1 Chute, Feeder
10 1 Sensor, No Paper [P/O item 34]
11 1 Actuator, No Paper Sensor [P/O item 34]
12 1 Plate, Ground
13 1 Roller Assembly, Feed [includes 14~17]
14 600K73132 2 Roller Assembly, Envelope Feed
15 059K14641 1 Roller, Feed
16 2 Roller, Core
17 1 Shaft, Pick Up
18 1 Gear, Pick Up
19 809E35460 1 Spring, Pick Up 300
20 121K18810 1 Solenoid, Feed
21 1 Gear, 17T
22 1 Shaft, Gear
23 162k47400 1 Harness, Tray 2/3 J134 [J13A-J134]
24 162K47410 1 Harness, J136 [P131-J136]
25 1 Gear [P/O item 32]
26 160K74332 1 Board, Feeder
27 1 Gear [P/O item 32]
28 162K47380 1 Harness J131 [J131-J132]
29 1 Bracket Assembly, Drive [P/O item 32]
30 913W01204 1 Connector
31 1 Plate, Shaft
32 015K50131 1 Drive Assembly [includes 25, 27, 29 & 33]
33 1 Motor Assembly [P/O item 32]
34 019K94931 Kit, No Paper Sensor


1 1 Feeder Assembly, Complete [customer purchased
item]
2 1 Frame Assembly
3 1 Rod, Paper Level Indicator [P/O Item 15]
4 1 Collar Assembly, Paper Level Indicator [P/O Item 15]
5 1 Lever, Retard [P/O item 7]
6 1 Spring, Release [P/O item 7]
7 054K13055 1 Chute Assembly, Retard [includes 8~14]
8 1 Chute, Retard [P/O item 7]
9 1 Roller Assembly, Turn [P/O item 7]
10 2 Support, Bearing [P/O item 7]
11 2 Bearing, 8T [P/O item 7]
12 019K94613 1 Holder Assembly, Retard [P/O item 7]
13 1 Arm, Retard [P/O item 7]
14 1 Gear, Turn [left] [P/O item 7]
15 604K01890 1 Guide Assembly [right] [includes 3,4,16~18]
16 1 Guide [right]
17 1 Actuator, Paper Level
18 1 Spring, Paper Level
19 032K93788 1 Guide Assembly [left] [includes 20~28]
20 1 Guide [left]
21 4 Actuator, Size
22 110E98320 1 Switch, Paper Size
23 1 Sensor, Low Paper
24 1 Actuator, Low Paper Sensor
25 1 Spring
26 1 Harness, J138 [J138-J139]
27 1 Harness, J133 [J133-J13A, P135, J137]
28 2 Spring, Tray 1
29 1 Arm, Tray 1 [right]
30 1 Arm, Tray 1 [left]
31 1 Cap, Tray 1
32 1 Edge, Saddle


1 097S02714 1 2000-Sheet Feeder Complete
2 048K77441 1 Cover Assembly, Side [left]
3 048K77533 1 Cover Assembly, Rear [includes 4 & 5]
4 2 Holder, Magnetic
5 1 Cover/Door, Rear
6 802K05400 1 Cover, Rear Bottom
7 048K77451 1 Cover Assembly, Side [right]
8 048K69591 1 Cover, Front
9 1 Assembly, Frame & Drive [reference only]
10 1 Tray Assembly, 2000-Sheet Feeder
11 2 Screw
12 2 Foot


1 1 Assembly, Frame & Drive [includes 2~20]
2 1 Bushing
3 160K74350 1 Board, 2000-Sheet Feeder
4 162K47560 1 Harness, 2000-Sheet Feeder SW [J604-J612, J613,
J614]
5 1 Clamp
6 127K24971 1 Motor Assembly, Tray Lift
7 1 Bracket, 2000-Sheet Feeder Board
8 2 Guide, Tray
9 110E93440 1 Sensor, A4 Paper
10 9 Clamp
11 017E91980 2 Caster
12 017E91970 2 Caster, Locking
13 600K78420 1 Kit, Roller [2 pieces]
14 162K43610 1 Harness, 2000-Sheet Feeder-1 [J131, J601]
15 162K43590 1 Harness, 2000-Sheet Feeder Tray Feed Motor [J607,
J615]
16 007K86830 1 Drive Assembly, 2000-Sheet Feeder
17 1 Assembly, Chute Feed Out
18 2 Edge, Saddle
19 110E93440 1 Switch, Tray Interlock
20 110E93440 1 Switch, Rear Cover Interlock
21 110K10600 1 Switch, Limit


1 050K38810 1 Retard Assembly, 2000-Sheet Feeder [includes 2~7]
2 600K78460 1 Feed Roller Kit, [3 pieces]
3 1 Spacer [P/O item 1]
4 1 Clutch Assembly, Friction [P/O item 1]
5 1 Shaft Assembly, Retard [P/O item 1]
6 3 Bearing, S6 [P/O item 1]
7 1 Support, Retard [P/O item 1]
8 809E20551 1 Spring, Retard
9 1 Support Assembly, Retard
10 130E82740 1 Sensor, Paper Height
11 162K47550 1 Harness, 2000-Sheet Feeder FRDY [J603-J611]
12 1 Gear, Stopper
13 1 Bearing
14 1 Gear, 50T [P/O item 35]
15 1 Gear, 22T [P/O item 35]
16 1 Gear, 47T [P/O item 35]
17 007K86890 1 Motor Assembly, Feed
18 162K47530 1 Harness, 2000-Sheet Feeder Feed Motor [J606-J609]
19 600K78440 Kit, Link Stopper / Spring
20 1 Stopper, Link [P/O item 19]
21 1 Support, Actuator [P/O item 34
22 1 Actuator [P/O item 34]
23 162K47540 1 Harness, 2000-Sheet Feeder No Paper Sensor
[J602-J610]
24 130E82740 1 Sensor, No Paper
25 054K08820 1 Chute Assembly, Front
26 050K36761 1 Feed Roller Assembly, [includes 2, 6 & 27~33]
27 1 Shaft, 2000-Sheet Feeder
28 1 Support Assembly, Nudger
29 1 Gear, 25T
30 1 Gear, 31T
31 1 Clutch Assembly, One-Way
32 1 Gear, 25T Clutch
33 1 Bearing
34 600K78450 Kit, No Paper Actuator [includes 21 &22]
35 604K02070 Kit, 2000-Sheet Feeder Gear [includes 14~16]


1 1 Tray Assembly, 2000-Sheet Feeder [includes 2~25]
2 1 Housing Assembly, 2000-Sheet Feeder
3 1 Guide, Side [left] [P/O item 26]
4 019K94630 1 Brake Assembly
5 1 Guide, Side [right] [P/O item 26]
6 4 Pulley [P/O item 27]
7 4 Guide, Wire [P/O item 27]
8 2 Wire 2 [P/O item 28]
9 2 Wire 1 [P/O item 28]
10 1 Plate Assembly, Bottom [includes 11 & 12]
11 1 Plate, Bottom
12 019E19780 1 Pad, Bottom
13 1 Cover Assembly, Shaft
14 1 Shaft Assembly, Drive [P/O item 30]
15 007E55100 1 Gear, Bevel [P/O item 30]
16 1 Bearing [P/O item 30]
17 1 Bracket, Gear
18 1 Shaft Assembly, Elevator [P/O item 29]
19 1 Pulley, Cable [P/O item 29]
20 1 Gear, 33T [P/O item 29]
21 003E48202 2 Latch, Side Guide
22 2 Cover, Wire
23 600K78500 1 Kit, Spacer [4 pieces]
24 003E23672 1 Latch, Tray
25 017K92370 1 Caster Assembly, Tray
26 600K78470 Kit, 2000-Sheet Feeder Tray Side Guide [includes 3 & 5]
27 600K78480 Kit, Elevator Wire Guide [includes 6 & 7]
28 600K78490 Kit, Elevator Wire [includes 8 & 9]
29 600K78520 Kit, 2000-Sheet Feeder Elevator Shaft [includes 18~20]
30 600K78510 Kit, Drive Gear [includes 14~16]

PL 13.1 Duplex Assembly
23
13
15
15
15 13
23 12
23
30
29
31
98 (with 37, 38)
98 (with 12x6 ea., 14, 24)
13
13
13 s5400-224
31
Figure 191 Duplex Assembly

Table 148 PL 13.1 Duplex
4, 13, 15, 23, 31 ID Numbers not used
1 097S02713 1 Duplex Assembly (with 2, 3, 5-12, 14, 16-22,
24-30, 32-40)
2 1 Motor Assembly, Exit
3 1 Cover, Duplex Motor
5 1 Gear, Z18/37
6 1 Clamp
7 1 Bracket Assembly, Duplex Left
8 1 Gear, Z15
9 2 Bearing, Duplex
10 1 Gear, Z16
11 1 Gear. Z45/17
12 3 Roller, Duplex, Pinch
14 1 Roller Assembly, Upper Duplex [P/O item 28]
16 1 Bracket, Duplex, Right
17 2 Bearing, Exit
18 2 Pulley, 16T Duplex
19 2 Collar
20 023E15680 1 Belt 160 S2M
21 1 Frame, Duplex
22 130K59671 1 Sensor Assembly, Duplex
24 Roller Assembly [lower] [P/O item 28]
25 1 Holder, Duplex Pinch
26 1 Board, Duplex
27 1 Motor Assembly, Duplex
28 3 Spring, Duplex Pinch Lower
29 1 Spacer, Motor
30 1 Damper, Motor Case
32 2 Spring, Upper Pinch
33 3 Roller, Duplex Pinch Upper
34 1 Shaft, Duplex Pinch
35 1 Label, Handle Left
36 1 Label, Handle Right
37 1 Case, Duplex Motor
38 2 Damper, Exit Motor
39 1 Plate, Reinforcement
40 1 Label, SP Duplex
98 1 Kit, Duplex Motor Case Assembly (with 37,38)
99 600K72271 1 Kit, Roller (with item 12x3 pcs), 14, 24

Xerox Supplies and Accessories
The following are the printer’s Customer-Replaceable Consumables (CRCs):
1. Laser Print Cartridge (accessed through the top cover)
2. Maintenance Kit (Fuser and Bias Transfer Roll)
2
1
S5400-224A
Figure 192 CRC Locations
Your printer displays messages on the control panel when user intervention is
required. Attention messages do not result in printer shutdown, but warn of an action
that should be taken to avert a shutdown.
An empty Laser Print Cartridge or expended maintenance item may reduce print
quality and/or prevent printing.
■ Keep consumables and maintenance items in supply.
■ Add or replace when prompted by the printer.
To order supplies and accessories, contact your local dealer, or visit the Xerox web
site: www.xerox.com/officeprinting

Table 149 Customer-Replaceable Consumables
Item Average Life Part Number

Laser Print Cartridge 20,000 prints* 113R00495
Maintenance Kit 200,000 prints 109R00521

Contains: a Fuser Cartridge, Bias for 110 V (60 Hz)
Transfer Roll, cleaning cloth, and 109R00522
instructions. for 220 V (50 Hz)
* Average life of a Laser Print Cartridge is based on page coverage of 5 percent using Letter-
or A4-size paper. The printer displays a message on the control panel when the toner is
low and when you need to replace the Laser Print Cartridge.
Table 150 Xerox Professional Printing Paper
Item Size Description Part Number

Standard Papers
Xerox 4024 DP Letter (U. S.) 20 lbs. 3R721
8.5 x 11 in. (75 g/m2)
Xerox Business Letter (U. S.) 20 lbs. 3R2047

Multi-purpose 4200 8.5 x 11 in. (75 g/m2)
Xerox 4024 DP 3-hole Letter (U. S.) 20 lbs. 3R2193

punch 8.5 x 11 in. (75 g/m2)
Xerox 4024 DP Legal 20 lbs. 3R727

8.5 x 14 in. (75 g/m2)
Xerox 4024 DP Ledger 20 lbs. 3R729

11 x 17 in. (75 g/m2)
Xerox Premier Paper A4 (Metric Letter) 80 g/m2 3R91805

210 x 297 mm
Xerox Business Paper A4 (Metric Letter) 80 g/m2 3R91820

210 x 297 mm
Xerox Cover Stock Letter (U. S.) 65 lbs. 3R3041

8.5 x 11 in. (243 g/m2)
Alternative Paper
Xerox Image Series Letter (U. S.) 20 lbs. 3R54
Smooth 8.5 x 11 in. (75 g/m2)
Recycled Paper
Xerox Planet Plus A4 (Metric Letter) 80 g/m2 3R90652
210 x 297 mm
Table 151 Xerox Transparency Film
Item Size Part Number

Xerox Clear Letter (U. S.) 3R3117
8.5 x 11 in.

Table 151 Xerox Transparency Film (cont'd.)
Item Size Part Number

Xerox Paperback, Clear Letter (U. S.) 3R3028
8.5 x 11 in.
Xerox Type C, Plain A4 (Metric Letter) 3R96002

210 x 297 mm
Table 152 Xerox Labels
Size Description Part Number

A4 (Metric Letter) 24 labels per sheet 3R96178
210 x 297 mm
Letter (U.S.) 30 labels per sheet 3R4469

8.5 x 11 in.
Table 153 Options
Option and Features Part Number

Hard Disk Drive 097S02965
■ 2+ Gbyte hard drive
■ Store resources, fonts, forms, and macros; enables
uninterrupted large-job collation
A3-/Ledger-/Legal-size Cassette 109R00523

■ Additional/Replacement - Tray only
A4-/Letter-size Cassette 109R00524

■ Additional/Replacement - Tray only
500-Sheet Feeder with A3-/Ledger-size tray 097S02711

■ Additional media tray and feeder
■ A3-/Ledger-size tray is interchangeable with Tray 1 or any
500-Sheet Feeder
500-Sheet Feeder with A4-/Letter-size tray 097S02712

■ Additional media tray and feeder
■ A4-/Letter-size tray is interchangeable with Tray 1 or any
500-Sheet Feeder
2,000-Sheet Feeder 097S02714

■ Enables loading of up to 2,000 sheets of paper of A4- or
Letter-size
■ Increased paper-printing capacity
■ Increased printing versatility and convenience
1,000-Sheet Stacker Bin 097S02715

■ Enables stacking of up to 1,000 sheets of paper
■ Supplements the standard output bin
Duplex Module 097S02713

■ Enables automatic duplex capability

Table 153 Options (cont'd.)
Option and Features Part Number

Memory (DIMMs)
■ Increases the font capability and enhances the speed of data
transfer and complex page processing
■ Memory kits available in three configurations, packaged in
single units each:
■ 16 Mbytes
■ 32 Mbytes
097S02356
■ 64 Mbytes
097S02357
097S02358
Flash Memory (DIMMS) 097S02360

■ Provides 8 Mbytes of memory for storage of downloaded fonts
and overlays

Blank Page

Plug/Jack Connector
Locations
Contents
P/J Tables
Plug/Jack Location Table 154 - Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .434
Plug/Jack Location Table 155 - 500-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .440
Plug/Jack Location Table 156- Duplex Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .442
Plug/Jack Location Table 157- High Capacity Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . .444
Plug/Jack Location Table 158- 2000-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .446
P/J Maps
Plug/Jack Location Map 1 - Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .437
Plug/Jack Location Map 4 - 500-Sheet 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

Plug/Jack (P/J) Locations for the Engine
Use the table and maps in this section to locate specific plug/jack (P/J) connectors
within the printer.
To find the location of a P/J within the printer;
1. Locate the P/J connector number in the first column of the table.
2. Locate the corresponding coordinates in the second column, such as I7 or J7.
3. Go to the map.
4. Cross-reference the letter and number of the P/J coordinates with the letters and
numbers on the map.
5. The P/J connector is located within the area where the coordinates cross.
Contents
Plug/Jack (P/J) Connector Location Table 1
Plug/Jack (P/J) Connector Location Maps
Table 154Plug/Jack Connector Locations - Engine

Map &
P/J Number Connect to... Other and connected to...
11 H-18 Print Engine Controller P/J 112 Laser Assembly
P/J 114 Laser Assembly
12 I-17 Print Engine Controller P/J 121 MBF Assembly
P/J 128 - P/J 127 Tray 1 Low Paper
Sensor
13 I-18 Printer Engine COntroller P/J 131 Second Feeder
14 I-18 Print Engine Controller P/J 141 Toner Sensor
15 H-19 Empty Not Used
16 I-19 Print Engine Controller P/J 161 LVPS
17 I-18 Print Engine Controller P/J 171 Fuser PWB
18 H-19 Print Engine Controller P/J 183 Reg Sensor
P/J 181 HVPS
19 I-19 Print Engine Controller P/J 501 Duplex Interface PWB
20 H-20 Print Engine Controller P/J 202 MBF Home Switch
P/J 201 Paper Size Switch
21 H-18 Print Engine Controller P/J211 CRUM PWB
22 I-18 Print Engine Controller P/J 222 Reg Clutch
31 H-24 System Controller PWB Connects Print Engine Controller PWB
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

Table 154Plug/Jack Connector Locations - Engine (cont'd.)
Map &
121 C-8 MBF Assembly P/J 12 Print Engine Controller
P/J 122 MBF Solenoid
P/J 123 Tray 1 Solenoid
P/J 124 Turn Roll Clutch
P/J 125 MBF No Paper Sensor
P/J 126 Tray 1 No Paper Sensor
122 D-9 MBF Solenoid P/J 121 MBF Assembly
123 D-9 Tray 1 Solenoid P/J 121 MBF Assembly
124 D-9 Turn Roll Clutch P/J 121 MBF Assembly
125 E-9 MBF No Paper Sensor P/J 121 MBF Assembly
126 F-9 Tray 1 No Paper Sensor P/J 121 MBF Assembly
127 G-26 Tray 1 Low Paper Sensor P/J 128
128 I-25 In Line Connector P/J 127 Tray 1 Low paper Sensor
P/J 12 Print Engine Controller
131 B-10 Second Feeder P/J 13 Print Engine Controller
141 C-7 Toner Sensor P/J 14 Print Engine Controller
161 E-41 LVPS P/J 16 Print Engine Controller
P/J 506 Duplex Interface PWB
162 F-42 LVPS P/J 621 Rear Cover Interlock SW
P/J 622 Rear Cover Interlock SW
P/J 623 Top Cover Interlock SW
163 F-42 LVPS P/J 311 System Controller
164 F-42 LVPS Main Motor Control PWB
165 E-41 LVPS Fuser Fan
166 E-41 LVPS LVPS Fan
167 D-41 LVPS Power Cord Connector
168 F-41 LVPS P/J 169 5v Power Supply
P/J 312 System Controller
169 H-26 5 V Power Supply P/J 312 System Controller
P/J 168 LVPS
171 C-41 Fuser PWB P/J 17 Print Engine Controller
172 C-41 Fuser PWB P/J 176 Rear Cover Interlock SW
174 J-7 Fuser Assembly P/J 17 Print Engine Controller
P/J 177 Rear Cover Interlock
P/J 182 HVPS
177 J-8 Rear Cover Interlock SW P/J 174 Fuser Assembly
178 J-8 Rear Cover Interlock SW P/J 172 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

Table 154Plug/Jack Connector Locations - Engine (cont'd.)
Map &
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 Engine Controller
202 H-26 MBF Home Sw P/J 20 Print Engine Controller
212 C-7 CRUM PWB P/J 21 Print Engine Controller
222 E-7 Reg Clutch P/J 22 Print Engine Controller
311 F-27 System Controller P/J 163 LVPS
312 H-26 System Controller P/J 169 5V Power Supply
P/J 168 LVPS
411 G-24 System Controller P/J 421 Control Panel
421 B-6 Control Panel P/J 411 System Controller
501 I-34 Duplex Interface PWB P/J 19 Print Engine Controller
502 I-34 Duplex Interface PWB P/J 527-P/J 507 Full Stack Sensor
503 I-34 Duplex Interface PWB Duplex PWB
504 I-34 Duplex Interface PWB P/J 526
505 I-34 Duplex Interface PWB P/J 528-P/J 519 Exit Gate Solenoid
506 J-34 Duplex Interface PWB LVPS
507 G-5 Full Stack Sensor P/J 527
519 J-6 Exit Gate Solenoid P/J 528
526 D-5 Stacker Duplex I/F PWB.
527 E-26 Full Stack Sensor P/J 507 Full Stack Sensor
528 E-26 Exit Gate Solenoid P/J 519 Exit Gate Solenoid
621 J-8 Rear Cover Interlock SW P/J 162 LVPS
622 J-8 Rear Cover Interlock SW P/J 162 LVPS
623 H-7 Top Cover Interlock SW P/J 162 LVPS

Plug/Jack Location Map 1 - Engine
S5400-321
Figure 193 P/J Location Map 1 - Engine

S5400-322
S5400-322

S5400-323

Plug/Jack Location Map 4 - 500-Sheet
Feeder
Table 155Map 4 - 500-Sheet Feeder
Map &
P/J Number Connect to... Other and connected...
13A D8 In Line Connector P/J 134 No Paper Sensor
P/J 133 Feeder PWB
13C H-8 Pre Reg Sensor P/J 13P - P/J 133 Feeder PWB
13P D-8 In Line Connector P/J 13C Pre Reg Sensor
P/J 133 Feeder PWB
131 B8 Printer or Second Feeder P/J 136 Feeder PWB
131 B10 Third Feeder P/J 132 Feeder PWB
132 D4 Feeder PWB P/J 131 Third Feeder
133 B4 Feeder PWB P/J 135 Feed Solenoid
P/J 13A - P/J 134 No Paper Senor
P/J 137 Low Paper Sensor
P/J 13P - P/J 13C Pre Reg Sensor
134 F8 No Paper Sensor P/J 13A - P/J 133 Feeder PWB
135 D8 Feed Solenoid P/J 133 Feeder PWB
136 D5 Feeder PWB P/J 131 Printer or Second Feeder
137 C9 Low Paper Sensor P/J 133 Feeder PWB
138 C4 Feeder PWB P/J 139 Size Switch
139 B10 Size Switch P/J 138 Feeder PWB
140 B-4 Feeder PWB Motor

S5400-324
Figure 196 P/J Location Map 4 - 500-Sheet Feeder

Plug/Jack Location Map 5 - Duplex
Assembly
Table 156Plug/Jack Connector Locations
Map &
P/J Number 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 Duplex PWB
510 C7 Duplex PWB. P/J 511 Exit Motor
511 B5 Exit Motor P/J 510 Duplex PWB
512 E8 Duplex PWB. P/J 513 Duplex Jam Sensor
513 F8 Duplex Jam Sensor. P/J 512 Duplex PWB

Figure 197 P/J Location Map 5 - Duplex Assembly

Plug/Jack Location - 1000-Sheet (High
Capacity) Stacker
Table 157Plug/Jack Connector Locations - 1000-Sheet (High Capacity) Stacker
Map &
514 E6 Feeder PWB P/J 526 - P/J 504 Duplex Interface Pwb
517 F6 Stacker PWB P/J 518 Stacker Motor
518 C6 Stacker Motor P/J 517 Stacker PWB
519 J9 Exit Gate Solenoid. P/J 528 - P/J 505 Duplex Interface
PWB
520 E6 Stacker PWB P/J 521 Stack Full Sensor
P/J 523 Jam Sensor 1
P/J 524 Jam Sensor 2
521 D5 Stack Full Sensor P/J 520 Stacker PWB
523 G7 Jam Sensor 1 P/J 520 Stacker PWB
524 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

s5400-332
Figure 198 P/J Location Map 6 - 1000-Sheet High Capacity Stacker

Plug/Jack Location - 2000-Sheet Feeder
Table 158Plug/Jack Connector Locations - 2000-Sheet Feeder
Map &
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 Paper Sensor P/J 602 HCF PWB
601 I5 HCF PWB P/J 131
602 J5 HCF PWB P/J 513B No Paper Sensor
603 J5 HCF PWB P/J P/J 513A Stack Height Sensor
604 J4 HCF PWB P/J 614 Tray in Switch
P/J 613 Rear Cover Interlock
P/J 612 Paper Size Switch
605 I5 HCF PWB
606 I4 HCF PWB P/J 609 Feed Motor
607 J4 HCF PWB P/J 608 Lift Motor
608 H9 Lift Motor P/J 607 HCF PWB
609 H9 Feed Motor P/J 606 HCF PWB
612 G10 Paper Size Switch P/J 604 HCF PWB
613 H8 Rear Cover Interlock P/J 604 HCF PWB
614 F9 Tray in Switch P/J 614 HCF PWB
615 C8 Drive Motor P/J 607 HCF PWB

Plug/Jack Location Map 7 - 2000-Sheet
Feeder
S5400-335
Figure 199 P/J Location Map 7 - 2000-Sheet Feeder

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Wiring Diagrams
Wiring Diagram Notations

This section of the manual contains a Master Wiring Diagram for the printer. The
Master Wiring Diagram shows the interconnections of the major subsystems. More
detailed wiring diagrams are contained in the CD Service Manual.
For more detailed information, refer to the On-Line CD version which contains
complete wiring information.
The following circuit notations are used to describe components and signal paths
throughout the Master Wiring Diagram.

Organization
Base Engine
■ Master Wiring Diagram - Figure 200 and Figure 201
■ Wiring Diagrams and Signal Description between Components
■ Figure 202 Print Engine Controller PWB <–> LVPS <–> Interlock Switch
and Fans (page 454)
■ Figure 203 Print Engine Controller PWB <–> Fuser Assembly, Fuser PWB
(page 455)
■ Figure 204 Print Engine Controller PWB-Laser and CRUM PWB (page 456)
■ Figure 205 Print Engine Controller PWB, HVPS and Print Cartridge (page
457)
■ Figure 206 Print Engine Controller PWB <–> Registration Clutch and
Registration Sensor (page 458)
■ Figure 207 Print Engine Controller PWB <–> Feed Solenoid, Turn Clutch,
No-Paper Sensor (page 459)
■ Figure 208 Print Engine Controller PWB, Low Paper Sensor, MBF Home
Switch, and Tray 1 Paper Size Switch (page 460)
■ Figure 209 Print Engine Controller PWB <–> Main Motor (page 461)
■ Figure 210 Print Engine Controller PWB <–> Toner Sensor (page 462)
■ Figure 211 Print Engine Controller PWB <–> Duplex Interface PWB <–>
Full Stack Sensor (page 463)
■ Figure 212 Controller and Control Panel (page 464)
Options
■ 500-Sheet Feeder
■ Figure 213 500-Sheet Feeder - Tray 2 Wiring Diagram and Signal
Information Between Components (page 465)
■ Figure 214 500-Sheet Feeder - Tray 3 Wiring Diagram and Signal
Information Between Components (page 466)
■ Duplex Assembly
■ Figure 215 Duplex Assembly - Wiring Diagrams and Signal Information
Between Components (page 467)
■ 1000-Sheet (High Capacity Stacker)
■ Figure 216 Master Wiring Diagram, High Capacity Stacker (page 468)
■ 2000-Sheet Feeder
■ Figure 217 2000-Sheet Feeder - Wiring Diagram and Signal Information
Between Components (page 469)
■ Figure 218 2000-Sheet Feeder PWB <–> No Paper Sensor (page 470)
■ Figure 219 2000-Sheet Feeder PWB <–> Low Paper Sensor (page 470)
■ Figure 220 2000-Sheet Feeder PWB <–> Switches (page 471)

Master Connection and Wiring Diagram
Figure 200 Master Wiring Diagram 1 of 2

Figure 201 Master Wiring Diagram 2 of 2

Table 159 Legend:
CCW Counter-Clockwise NOP No Paper
CL Clutch NUT Neutral - associated with electrical power to

the printer
CONN Connector HCS Offset
CW Clockwise REGI Registration
GFI Ground Fault Indicator SNR Sensor
HVPS High Voltage Power Supply SOL Solenoid
INTLK Interlock SOS Start Of Scan - associated with the Laser

Scanner timing
LVPS Low Voltage Power Supply SW Switch
MBF Multi-sheet Bypass Feeder TA Take Away
MOT Motor
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.

Base Engine Wiring Diagrams
Figure 202 Print Engine Controller PWB <–> LVPS <–> Interlock Switch
and Fans

Figure 203 Print Engine Controller PWB <–> Fuser Assembly, Fuser PWB

Figure 204 Print Engine Controller PWB-Laser and CRUM PWB

White
Red
White
Red
Yellow
P/J 181
Figure 205 Print Engine Controller PWB, HVPS and Print Cartridge

Figure 206 Print Engine Controller PWB <–> Registration Clutch and
Registration Sensor

Figure 207 Print Engine Controller PWB <–> Feed Solenoid, Turn Clutch,
No-Paper Sensor

Figure 208 Print Engine Controller PWB, Low Paper Sensor, MBF Home
Switch, and Tray 1 Paper Size Switch

Figure 209 Print Engine Controller PWB <–> Main Motor

Figure 210 Print Engine Controller PWB <–> Toner Sensor

Figure 211 Print Engine Controller PWB <–> Duplex Interface PWB <–>
Full Stack Sensor

Figure 212 Controller and Control Panel

500-Sheet Feeder
P/J134
P/J13C
Figure 213 500-Sheet Feeder - Tray 2 Wiring Diagram and Signal

Information Between Components

Figure 214 500-Sheet Feeder - Tray 3 Wiring Diagram and Signal
Information Between Components

Duplex Assembly
Figure 215 Duplex Assembly - Wiring Diagrams and Signal Information

Between Components

1000-Sheet (High Capacity Stacker)
Figure 216 Master Wiring Diagram, High Capacity Stacker

2000-Sheet Feeder
Figure 217 2000-Sheet Feeder - Wiring Diagram and Signal Information

Between Components

Figure 218 2000-Sheet Feeder PWB <–> No Paper Sensor
Figure 219 2000-Sheet Feeder PWB <–> Low Paper Sensor

Figure 220 2000-Sheet Feeder PWB <–> Switches

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PHASER™ 5400

This printing: August 2002

Apple®, LaserWriter®, LocalTalk®, Macintosh®, Mac® OS, and AppleTalk®are

PCL® and HP-GL® are registered trademarks of Hewlett-Packard Corporation.

MS-DOS® and Windows® are registered trademarks of Microsoft Corporation.

Novell® and NetWare® are registered trademarks of Novell, Incorporated.

Sun® and Sun Microsystems® are registered trademarks of Sun Microsystems,

UNIX® is a registered trademark in the US and other countries, licensed exclusively

ii Phaser 5400 Laser Printer Service Guide

Note: A Note may indicate an operating or maintenance procedure,

Warning: If the product loses the ground connection, usage of knobs

Phaser 5400 Laser Printer Service Guide iii

Mechanical Components: Manually rotate drive assemblies to inspect sprockets and

iv Phaser 5400 Laser Printer Service Guide

Disconnect the power plug:

■ If the power cord or plug is frayed or otherwise damaged,

Phaser 5400 Laser Printer Service Guide v

This product is certified under IEC 825 as a Class 1 Laser Product.

CLASS 1 LASER PRODUCT

vi Phaser 5400 Laser Printer Service Guide

KLASS 1 LASER APPARAT

Phaser 5400 Laser Printer Service Guide vii

■ Either re–orient or relocate the radio/television receiving antenna.

viii Phaser 5400 Laser Printer Service Guide

Phaser 5400 Laser Printer Service Guide ix

x Phaser 5400 Laser Printer Service Guide

List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix

List of Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxv

Phaser 5400 Laser Printer Service Guide xi

Diagnostics, Test Prints, Service Tests and

xii Phaser 5400 Laser Printer Service Guide

Maintenance and Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

FRU Removal / Replacement Procedures (RRPs) . . . . . . . . . . . 245

Phaser 5400 Laser Printer Service Guide xiii

xiv Phaser 5400 Laser Printer Service Guide

Phaser 5400 Laser Printer Service Guide xv

Plug/Jack Connector Locations. . . . . . . . . . . . . . . . . . . . . . . . . . 433

xvi Phaser 5400 Laser Printer Service Guide

Phaser 5400 Laser Printer Service Guide xvii

xviii Phaser 5400 Laser Printer Service Guide

Phaser 5400 Laser Printer Service Guide xix

xx Phaser 5400 Laser Printer Service Guide

Phaser 5400 Laser Printer Service Guide xxi

xxii Phaser 5400 Laser Printer Service Guide

Phaser 5400 Laser Printer Service Guide xxiii

xxiv Phaser 5400 Laser Printer Service Guide

Phaser 5400 Laser Printer Service Guide xxv

xxvi Phaser 5400 Laser Printer Service Guide

Phaser 5400 Laser Printer Service Guide xxvii

xxviii Phaser 5400 Laser Printer Service Guide

Figure 1 Machine Orientation

Process Direction = paper path

Phaser 5400 Laser Printer Service Guide 1

2 Phaser 5400 Laser Printer Service Guide

Phaser 5400 Laser Printer Service Guide 3

Figure 2 Front View

Figure 3 Rear View

4 Phaser 5400 Laser Printer Service Guide

Figure 4 View from Right Front

Figure 5 View from Left Rear