Xerox Phaser 5400

• Code: E4-3, E4-5
• Description: Jam at E - E4-3 Exit 2 Area Jam Paper did not pass the Exit 2 Exit Sensor located behind Door E on time. • Jam at E - E4-3 Exit 2 Area Jam • Jam at A - E4-5 Exit 2 Area Jam
• Causes: • Exit 2 Exit Sensor • Exit 2 Motor • Exit 2 OCT Roller • Exit 2 FU Roller • Exit 2 Inv Roller • Exit PWB • Engine Control Board • LVPS
• Remedy: 1 Check paper position at Door E. Is paper touching the Exit 2 Sensor? Remove the paper. Go to Step 2. 2 Check the FU Roller. Is the FU Roller worn or contaminated with paper dust? Clean or replace the FU Roller. Go to Step 3. 3 Check the drive transmission. Does the FU Roller and gears rotate smoothly? Go to Step 4. Restore proper operation. 4 Check the Inv Roller. Is the INV Roller worn or contaminated with paper dust? Clean or replace the INV Roller. Go to Step 5. 5 Check the drive transmission. Does the INV Roller and gears rotate smoothly? Go to Step 6. Restore proper operation. 6 Check the OCT Roller. Is the OCT Roller worn or contaminated with paper dust? Clean or replace the OCT Roller. Go to Step 7. 7 Check the drive transmission. Does the OCT Roller and gears rotate smoothly? For E4-5: Go to Step 8. For E4-3: Go to Step 9. Restore proper operation. 8 For E4-5 Only: Test Exit 2 Gate Solenoid. Run the Service Diagnostics Exit 2 Gate Solenoid test. Does the Solenoid operate the Gate? Go to Step 9. Go to Step 10. 9 Test the Exit 2 Sensor. 1. Open Door E. 2. Run the Service Diagnostics Exit Sensor test. Does the sensor change state? For E4-5: Go to Step 10. For E4-3: Go to Step 12. Go to Step12. 10 For E4-5 Only: Check Exit 2 Solenoid. Check continuity on each wire between P/ J209 to P/J433. Is there continuity on each wire between P/ J209 to P/J433. Go to Step 11. Repair the wiring. 11 For E4-5 Only: Check for +24 V to the Exit 2 Gate Solenoid. Is there +24 V across P/J433-11 (+) <=> ground? Replace the Exit 2 Gate Solenoid. Replace the Exit PWB. 12 Check the Exit Sensor connection. Are P/J112, P/J606B, and P/J434 connected? Go to Step 13. Connect the sensor. 13 Check continuity between the Exit Sensor and Exit PWB. Is there continuity on each wire between P/ J112 <=> P/J434? Go to Step 14. Repair the wiring. 14 Check for +5 V at the Exit Sensor. Is there +5 V across the sensor connector’s P/J112-3 <=> ground? Replace the Exit 2 Sensor. Go to Step 15. 15 Check the connection between the Exit PWB and Engine Control Board. Are P/J431 and P/J421 connected? Go to Step 16. Connect P/J431 and P/J421. 16 Check continuity between the Exit PWB and the Engine Control Board. Is there continuity on each wire between P/ J431 <=> P/J421? Go to Step 17. Repair the wiring. 17 Check the connection between the Exit PWB and the LVPS. Are P/J430 and P/J526 connected? Go to Step 18. Connect P/J430 and P/J526. 18 Check continuity between the Exit PWB and the LVPS. Is there continuity on each wire between P/ J430 <=> P/J526? Go to Step 19. Repair the wiring. 19 Check for +24 V to the Exit PWB. Is there +24 V across P/J430-1 (+) <=> ground? Replace the Exit PWB. Replace the LVPS. 20 Test the Exit 2 Motor operation. Run the Service Diagnostics Exit 2 Output Motor tests. Does the Exit 2 Motor operate properly? Replace the Engine Control Board. Go to Step 21. 21 Check the Exit 2 Motor connection. Are P/J208, P/J606A and P/J433 connected? Go to Step 22. Connect P/J208, P/J606A and P/ J433. 22 Check continuity between the Exit 2 Motor and Exit PWB. Is there continuity on each wire between P/ J208 <=> P/J433? Go to Step 23. Repair the wiring. 23 Check for +24 V to the Exit 2 Motor. Is there +24 V across P208-5 (+) <=> ground? Replace the Exit 2 Motor. Go to Step 24. 24 Check the connection between the Exit PWB and Engine Control Board. Are P/J431 and P/J421 connected? Go to Step 25. Connect P/J431 and P/J421. 25 Check continuity between the Exit PWB and Engine Control Board. Is there continuity on each wire between P/ J431 <=> P/J421? Go to Step 26. Repair the wiring. 26 Check the connection between the Exit PWB and the LVPS. Are P/J430 and P/J526 connected? Go to Step 27. Connect P/J430 and P/J526. 27 Check continuity between the Exit PWB and the LVPS. Is there continuity on each wire between P/ J430 <=> P/J526? Go to Step 28. Repair the wiring. 28 Check for +24 V to the Exit PWB. Is there +24 V across P/J430-1 (+) <=> ground? Replace the Exit PWB. Replace the LVPS.

• Code: E4-6
• Description: Jam at E - E4-6 Exit 2 Area Jam Paper remains at the Exit 2 Exit Sensor located behind Door E.
• Causes: • Exit 2 Exit Sensor • Exit PWB • Engine Control Board • LVPS
• Remedy: 1 Check paper position at Door A. Is paper touching the Fuser Exit Sensor? Remove the paper. Go to Step 2. 2 Test the Exit Sensor. Run the Service Diagnostics Exit Sensor test. Does the sensor change state? Replace the Engine Control Board. Go to Step 3. 3 Check the Exit Sensor connection. Are P/J112, P/J606B and P/J434 connected? Go to Step 4. Connect the sensor. 4 Check continuity between the Exit Sensor and Exit PWB. Is there continuity on each wire between P/ J112<=> P/J434? Go to Step 5. Repair the wiring. 5 Check for +5 V at the Exit Sensor. Is there +5 V across the sensor connector’s P/J112-3 <=> ground? Replace the Exit Sensor. Go to Step 6. 6 Check the connection between the Exit PWB and Engine Control Board. Are P/J431 and P/J421 connected? Go to Step 7. Connect P/J431 and P/J421. 7 Check continuity between the Exit PWB and Engine Control Board. Is there continuity on each wire between P/ J431 <=> P/J421? Go to Step 8. Repair the wiring. 8 Check the connection between Exit PWB and LVPS. Are P/J430 and P/J526 connected? Go to Step 9. Connect P/J430 and P/J526. 9 Check continuity between the Exit PWB and LVPS. Is there continuity on each wire between P/ J430 <=> P/J526? Go to Step 10. Repair the wiring. 10 Check for +24 V to the Exit PWB. Is there +24 V across P/J430-1 (+) <=> ground? Replace the Exit PWB. Replace the LVPS.

• Code: E8-2
• Description: Jam at E - E8-2 Duplex Area Jam Paper being fed into the Duplex Unit did not reach the Wait Sensor on time.
• Causes: • Duplex Wait Sensor • Exit 2 Motor • Exit 2 OCT Roller • Exit 2 FU Roller • Exit 2 Inv Roller • Exit PWB • Duplex Unit PWB • Engine Control Board • LVPS
• Remedy: 1 Check paper position at Door E. Does paper remain in Exit 2? Remove the paper. Go to Step 2. 2 Check the FU Roller. Is the FU Roller worn or contaminated with paper dust? Clean or replace the FU Roller. Go to Step 3. 3 Check the drive transmission. Does the FU Roller and gears rotate smoothly? Go to Step 4. Restore proper operation. 4 Check the Inv Roller. Is the INV Roller worn or contaminated with paper dust? Clean or replace the INV Roller. Go to Step 5. 5 Check the drive transmission. Does the INV Roller and gears rotate smoothly? Go to Step 6. Restore proper operation. 6 Check the OCT Roller. Is the OCT Roller worn or contaminated with paper dust? Clean or replace the OCT Roller. Go to Step 7. 7 Check the drive transmission. Does the OCT Roller and gears rotate smoothly? Go to Step 8. Restore proper operation. 8 Test the Exit 2 Motor. Run the Service Diagnostics Exit 2 Motor tests. Does the Exit 2 Motor operate properly? Go to Step 17. Go to Step 9. 9 Check the Exit 2 Motor connections. Are P/J208, P/J606A and P/J433 connected? Go to Step 10. Connect P/J208, P/J606A and P/ J433. 10 Check continuity between the Exit Motor and Exit PWB. Is there continuity on each wire between P/ J208 <=> P/J433? Go to Step 11. Repair the wiring. 11 Check for +24 V to the Exit 2 Motor. Is there +24 V across P208-5 (+) <=> ground? Replace the Exit 2 Motor. Go to Step 12. 12 Check the connection between the Exit PWB and Engine Control Board. Are P/J431 and P/J421 connected? Go to Step 13. Connect P/J431 and P/J421. 13 Check continuity between the Exit PWB and the Engine Control Board. Is there continuity on each wire between P/ J431 <=> P/J421? Go to Step 14. Repair the wiring. 14 Check the connection between the Exit PWB and the LVPS. Are P/J430 and P/J526 connected? Go to Step 15. Connect P/J430 and P/J526. 15 Check continuity between the Exit PWB and the LVPS. Is there continuity on each wire between P/ J430 <=> P/J526? Go to Step 16. Repair the wiring. 16 Check for +24 V to the Exit PWB. Is there +24 V across P/J430-1 (+) <=> ground? Replace the Exit PWB. Replace the LVPS. 17 Test the Wait Sensor. Run the Service Diagnostics Duplex Wait Sensor test. Does the Wait Sensor operate properly? Replace the Engine Control Board. Go to Step 18. 18 Check the Wait Sensor connection. Are P/J123 and P/J541 connected? Go to Step 19. Connect P/J123 and P/J541. 19 Check continuity between the Wait Sensor and Duplex PWB. Is there continuity on each wire between P/ J123 <=> P/J541? Go to Step 20. Repair the wiring. 20 Check for +5 V to the Wait Sensor. Is there +5 V across P123-3 (+) <=> ground? Replace the Wait Sensor. Go to Step 21. 21 Check the Duplex PWB connection. Are P/J540 and P/J417 connected? Go to Step 22. Connect P/J540 and P/J417 surely. 22 Check continuity between the Duplex PWB and Engine Control Board. Is there continuity on each wire between P/ J540 <=> P/J417? Go to Step 23. Repair the wiring. 23 Check for +5 V to the Duplex PWB. Is there +5 V across P/J540-1 (+) <=> ground? Replace the Duplex PWB. Replace the Engine Control Board.

• Code: H1-1 ... H1-4
• Description: Tray n Failure - H1 -1/2/3/4 Tray n Fail Detected lift failure. Paper size detection inoperative. • Tray 2 Failure - H1-1 Tray 2 Fail • Tray 3 Failure - H1-2 Tray 3 Fail • Tray 4 Failure - H1-3 Tray 4 Fail • Tray 5 Failure - H1-4 Tray 5 Fail
• Causes: • Tray • Feeder • Feed/Lift Motor • Level Sensor • Paper Size Switch • Tray 4-5 PWB • Engine Control Board
• Remedy: 1 Check paper supply. Is paper loaded in the affected tray? Go to Step 2. Load paper and go to Step 2. 2 Check the tray. Replace the tray with one from another position. Does the replaced tray lift? Go to Step 3. Go to Step 4. 3 Check lift components. Is the Sector Gear or surrounding parts damaged? Replace the tray. Go to Step 4. 4 Test the Feed/Lift Motor. Run the Service Diagnostics Lift Motor test for the affected tray. Does the motor operate properly? Go to Step 9. Go to Step 5. 5 Check the Feed/Lift Motor connections. Is the affected Feed/Lift motor properly connected to the harness? Go to Step 6. Connect the motor. If error continues, go to Step 6. 6 Test the Feed/Lift Motor. 1. Exchange the Feed/Lift Motor with one from an operational feeder. 2. Run the Service Diagnostics Lift Motor test on the replacement motor. Does the motor operate properly? Replace the Feed/ Lift motor. Go to Step 7. 7 Check for continuity on the connections. Reinstall the motors in the original feeders. Is there continuity on each wire between P/ J409 (Trays 2-3) or P/J549 (Trays 4-5) and the Feeder Harness? Go to Step 8. Repair the wiring. 8 Check for +24 V to the affected Feed/Lift Motor. Is there +24 V across the motor connector’s Pin 4(+) <=> ground? Replace the motor. Replace the Engine Control Board. If the error persists, replace the Tray 4-5 PWB. 9 Test the affected Level Sensor. Run the Service Diagnostics Level Sensor test for the affected tray. Does the sensor state change? Go to Step 13. Go to Step 10. 10 Check the Level Sensor connection. Is the sensor connected to the harness? Go to Step 11. Connect the sensor. If error persists, go to Step 11. 11 Check harness continuity between the Level Sensor and Engine Control Board. Is there continuity on each wire between the Level Sensor <=> P/J409 (Trays 2-3) or P/ J549 (Trays 4-5)? Go to Step 12. Repair the wiring. 12 Check for +5 V to the affected Level Sensor. Is there +5 V across Pin-3 (+) <=> ground? Replace the sensor. Replace the Engine Control Board. If the error persists, replace the Tray 4-5 PWB. 13 Test the affected Paper Size Switch. Run the Service Diagnostics Paper Size Sensor test for the affected tray. Is the paper size detected correctly when the tray, loaded with paper, is moved in and out? Replace the Engine Control Board. If the error persists replace Tray 4-5 PWB. Go to Step 14. 14 Check the affected Paper Size Switch connection. Is the switch connected to the harness? Go to Step 15. Connect the switch. If problem persists, go to Step 15. 15 Check continuity between the Paper Size Switch and the Engine Control Board (Tray 2-3) or Tray 4-5 PWB (Tray 4-5). Is there continuity on each wire between the switch <=> P/J412 (Tray 2-3) or P/J548 (Tray 4-5)? Go to Step 16. Repair the wiring. 16 Check for +3.3 V to the Paper Size Switch. Is there +5 V across P/J412-1 (+) <=> ground? for Tray 2-3 or 3.3 V across P/J548- 1 for Tray 4-5. Replace the switch. Replace the Engine Control Board. If the error persists, replace the Tray 4-5 PWB.

• Code: H1-5
• Description: Tray 6 Failure - H1-5 Tray 6 Fail Detected lift failure or paper size detection inoperative.
• Causes: • Tray In Sensor • Tray 6 Main Harness • Tray 6 Feeder Harness • Tray 6 PWB • Lift Cables • Feed/Lift Motor • Nudger Solenoid • Level Sensor • Engine Control Board
• Remedy: 1 Check Tray In Sensor alignment. Pull the Tray out. Does the actuator enter the sensing area of the Tray Set Sensor, or is it deformed or damaged? Go to Step 2. Repair the damage and go to Step 2. 2 Check the Tray installation. Is the Tray installed correctly? Go to Step 3. Correct and go to Step 3. 3 Check the repairs. Does the error reoccur? Go to Step 4. Problem solved. 4 Test the Tray In Sensor. Run the Service Diagnostics Tray In Sensor test. Does the sensor status change when the tray is moved in and out? Go to Step 10. Go to Step 5. 5 Check the Tray In Sensor Main Harness connection. Are PF53 and JF01 connected? Go to Step 7. Connect and go to Step 6. 6 Check the repairs. Does the error reoccur? Go to Step 7. Problem solved. 7 Check Tray In Sensor Main Harness continuity. 1. Disconnect PF53 and JF01. 2. Check for continuity at the following: • PF53-1 <=> JF01-6 • PF53-2 <=> JF01-5 • PF53-3 <=> JF01-4 Are these conductive? Go to Step 8. Repair the Tray 6 Tray Set Sensor harness. 8 Check for +5 V to the Tray In Sensor. Is there +5 V across PF01-6 <=> PF04-2 on the Tray 6 PWB? Go to Step 9. Replace the Tray 6 PWB. 9 Check Tray In Sensor signal. Does the voltage across JF01-5 <=> PF04-2 on the Tray 6 PWB change when the sensor is blocked? Go to Step 36. Replace the sensor. 10 Check the Tray cables. Remove the Tray from the HCF. Are the two cables installed correctly? Go to Step 11. Correct and go to Step 11. 11 Test the Level Sensor. Run the Service Diagnostics Tray 6 Level Sensor test. Does the sensor state change? Go to Step 19. Go to Step 12. 12 Check the Level Sensor Harness connections. Are PF62 and PF56B connected? Go to Step 13. Connect and go to Step 13. 13 Check the Level Sensor Harness connections. Are PF56B and JF02 connected? Go to Step 15. Connect and go to Step 14. 14 Check the repair. Does the error still occur? Go to Step 15. Problem solved. 15 Check Level Sensor Harness continuity. 1. Disconnect PF62 and JF56B. 2. Check for continuity at the following: • PF62-1 <=> JF56B-6 • PF62-2 <=> JF56B-5 • PF62-3 <=> JF56B-4 Are these conductive? Go to Step 16. Repair the Tray 6 Feeder Harness.

• Code: H2-7
• Description: Duplex Unit Failure - H2-7 Duplex Comm Failure Communications failure between the Engine Control Board and the Duplex Unit.
• Causes: • Duplex Unit PWB • Engine Control Board
• Remedy: 1 Check Duplex Unit installation. Reinstall the Duplex Unit. Does the error still occur? Go to Step 2. Problem solved. 2 Check the Duplex PWB connection. Are P/J540 and P/J417 connected? Go to Step 3. Connect P/J540 and P/J417. 3 Check Duplex Harness continuity between the Duplex PWB and the Engine Control Board. 1. Disconnect P/J540 and P/J417. 2. Check for continuity at the following: • P/J540-1 <=> P/J417-A1 • P/J540-2 <=> P/J417-B1 • P/J540-3 <=> P/J417-A2 • P/J540-4 <=> P/J417-B2 • P/J540-5 <=> P/J417-A3 • P/J540-6 <=> P/J417-B3 • P/J540-7 <=> P/J417-A4 • P/J540-8 <=> P/J417-B4 Are these conductive? Go to Step 4. Repair the wiring. 4 Check for +24 V to the Duplex PWB. Is there +24 V across P/J540-2 (+) <=> ground? Replace the Duplex PWB. Replace the Engine Control Board.