Brother 5240-5250D-5270DN Service Manual

Confidential

Brother Laser Printer SERVICE MANUAL

MODEL: HL-5240/5250DN/5270DN/5280DW

Read this manual thoroughly before maintenance work.

Keep this manual in a convenient place for quick and easy reference at all times.

September 2005 SM-PRN057

Confidential

© Copyright Brother Industries, Ltd. 2005

Compilation and Publication: This manual has been complied and published, under the supervision of Brother Industries Ltd., covering the latest product descriptions and specifications. The contents of this manual and the specifications of this product are subject to change without notice. Brother reserves the right to make changes without notice in the specifications and materials contained herein and shall not be responsible for any damages (including consequential) caused by reliance on the materials presented, including but not limited to typographical and other errors relating to the publication. This product is designed for use in a professional environment.

Trademarks: The Brother logo is a registered trademark of Brother Industries, Ltd. Apple, the Apple Logo, Macintosh and TrueType are registered trademarks of Apple Computer, Inc in the United States and other countries. Epson is a registered trademark and FX-80 and FX-850 are trademarks of Seiko Epson Corporation. Hewlett Packard is a registered trademark and HP LaserJet 6P, 6L, 5P, 5L, 4, 4L 4P, III, IIIP, II, and IIP are trademarks of Hewlett-Packard Company. IBM, IBM PC, and Proprinter are registered trademarks of International Business Machines Corporation. Microsoft, MS-DOS, Windows and Windows NT are registered trademarks of Microsoft Corporation in the U.S. and other countries. ENERGY STAR is a U.S. registered mark. Citrix and MetaFrame are registered trademarks of Citrix Systems, Inc. in the United State. SuSE is a registered trademark of SuSE Linux AG. RED HAT is a registered trademark of Red Hat. Inc. Mandrake is a registered trademark of Mandrake Soft SA. All other terms and brand and product names mentioned in this Service Manual are registered trademarks of their respective companies.

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PREFACE This service manual contains basic information required for after-sales service of the laser printer (hereinafter referred to as "this machine" or "the printer"). This information is vital to the service technician to maintain the high printing quality and performance of the printer.

This service manual covers the HL-5240/5250DN/5270DN/5280DW printers.

This manual consists of the following chapters:

CHAPTER 1: GENERAL Features, specifications, etc.

CHAPTER 2: THEORY OF OPERATION Basic operation of the mechanical system, the electrical system and the electrical circuits.

CHAPTER 3: PERIODIC MAINTENANCE Periodical replacement parts, consumable parts, etc.

CHAPTER 4: TROUBLESHOOTING Reference values and adjustments, troubleshooting image defects, troubleshooting malfunctions, etc.

CHAPTER 5: DISASSEMBLY AND RE-ASSEMBLY Procedures for disassembling and re-assembling the mechanical system.

CHAPTER 6: ADJUSTMENTS AND UPDATING OF SETTING, REQUIRED AFTER PARTS REPLACEMENT

CHAPTER 7: SERVICE SUPPORT SOFTWARE Test print mode and Service menu mode, etc.

APPENDIX: Diagrams etc…

Information in this manual is subject to change due to improvement or redesign of the product. All relevant information in such cases will be supplied in service information bulletins (Technical Information).

A thorough understanding of this printer, based on information in this service manual and service information bulletins, is required for maintaining its print quality performance and for improving the practical ability to find the cause of problems.

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TABLE OF CONTENTS REGULATION............................................................................................. vii SAFETY INFORMATION ............................................................................. ix CHAPTER 1 GENERAL........................................................................... 1-1 1. FEATURES............................................................................................................. 1-1

2. PARTS NAMES AND FUNCTIONS ........................................................................ 1-3

2.1 Overview...........................................................................................................................1-3

2.2 Control Panel....................................................................................................................1-5

3. SPECIFICATIONS .................................................................................................. 1-7 3.1 Printing .............................................................................................................................1-7

3.2 Functions ..........................................................................................................................1-8

3.3 Electronics and Mechanics.............................................................................................1-11

3.4 Service Information.........................................................................................................1-12

3.5 Network Connectivity......................................................................................................1-13

3.6 Paper ..............................................................................................................................1-14 3.6.1 Paper handling ..................................................................................................................1-14

3.6.2 Media specifications..........................................................................................................1-14

3.7 Printable Area.................................................................................................................1-17 3.7.1 PCL5e/EPSON/IBM emulation..........................................................................................1-17

3.7.2 PCL6 emulation.................................................................................................................1-20

3.8 Print Speeds with Various Settings ................................................................................1-21

3.9 Toner Cartridge Weight Information...............................................................................1-22

4. SERIAL NO. DESCRIPTIONS .............................................................................. 1-23 CHAPTER 2 THEORY OF OPERATION................................................. 2-1 1. OVERALL ............................................................................................................... 2-1

1.1 General Block Diagram ....................................................................................................2-1

2. ELECTRONICS ...................................................................................................... 2-2 2.1 General Block Diagram ....................................................................................................2-2 2.2 Main PCB Block Diagram.................................................................................................2-3

2.3 Main PCB .........................................................................................................................2-4 2.3.1 CPU.....................................................................................................................................2-4

2.3.2 USB interface (2.0 High Speed) ..........................................................................................2-4

2.3.3 IEEE 1284 interface ............................................................................................................2-4

2.3.4 Network interface ................................................................................................................2-4

2.3.5 ROM....................................................................................................................................2-4

2.3.6 SDRAM ...............................................................................................................................2-4 2.3.7 Optional RAM......................................................................................................................2-4 2.3.8 EEPROM.............................................................................................................................2-4

HL-5240/5250DN/5270DN/5280DW SERVICE MANUAL

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2.3.9 Reset circuit ........................................................................................................................2-5

2.3.10 Panel I/O .............................................................................................................................2-5

2.3.11 Video I/O .............................................................................................................................2-5

2.3.12 Power supply.......................................................................................................................2-5

2.3.13 Wireless LAN ......................................................................................................................2-5

2.4 Power Supply....................................................................................................................2-6 2.4.1 Low-voltage power supply...................................................................................................2-6

2.4.2 High-voltage power supply ..................................................................................................2-6

3. MECHANICS .......................................................................................................... 2-7 3.1 Overview of Printing Mechanism ......................................................................................2-7

3.2 Overview of Gear..............................................................................................................2-8

3.3 Paper Transfer .................................................................................................................2-9 3.3.1 Paper supply .......................................................................................................................2-9

3.3.2 Paper registration..............................................................................................................2-11

3.3.3 Drum unit...........................................................................................................................2-11

3.3.4 Developing ........................................................................................................................2-12

3.3.5 Fixing stage.......................................................................................................................2-13

3.3.6 Paper eject ........................................................................................................................2-14

3.3.7 Duplex printing (HL-5250DN/5270DN/5280DW)...............................................................2-15

3.3.8 Paper feeding from the MP tray ........................................................................................2-16

3.3.9 LT tray ...............................................................................................................................2-16

3.4 Toner Cartridge ..............................................................................................................2-17 3.4.1 Toner life end mode ..........................................................................................................2-17

3.4.2 New toner detection mechanism.......................................................................................2-19

3.4.3 Counter reset during indication of “Toner Life End” ..........................................................2-20

3.5 Print Process ..................................................................................................................2-21 3.5.1 Charging............................................................................................................................2-21

3.5.2 Exposure stage .................................................................................................................2-21

3.5.3 Transfer .............................................................................................................................2-22

3.6 Sensors ..........................................................................................................................2-23

3.7 Heat Control of Fuser Unit..............................................................................................2-24 CHAPTER 3 PERIODIC MAINTENANCE ............................................... 3-1 1. CONSUMABLE PARTS .......................................................................................... 3-1

1.1 Toner Cartridge ................................................................................................................3-1

1.2 Drum Unit .........................................................................................................................3-7

2. PERIODICAL REPLACEMENT PARTS ................................................................ 3-12 2.1 Periodical Replacement Parts ........................................................................................3-12

2.2 Procedures to Replace Periodical Replacement Parts ..................................................3-13 2.2.1 Fuser unit and laser unit....................................................................................................3-13

2.2.2 Paper feeding kit for tray 1, 2, 3 ........................................................................................3-34

2.2.3 Paper feeding kit for MP tray.............................................................................................3-42

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3. PERIODICAL CLEANING ..................................................................................... 3-50 3.1 Cleaning the Inside of the Printer ...................................................................................3-50 3.2 Cleaning the Corona Wire ..............................................................................................3-53

CHAPTER 4 TROUBLESHOOTING ....................................................... 4-1 1. INTRODUCTION .................................................................................................... 4-1

1.1 Initial Check ......................................................................................................................4-1

1.2 Warnings for Maintenance Work......................................................................................4-2

1.3 Identify the Problem..........................................................................................................4-3

2. ERROR MESSAGE ................................................................................................ 4-4 2.1 Operator Calls ..................................................................................................................4-4

2.1.1 Operator calls for HL-5240/5250DN....................................................................................4-4

2.1.2 Operator calls for HL-5270DN/5280DW..............................................................................4-6

2.2 Service Calls.....................................................................................................................4-8 2.2.1 Service calls for HL-5240/5250DN......................................................................................4-8

2.2.2 Service calls for HL-5270DN/5280DW..............................................................................4-10

2.3 Error Message in the Status Monitor ..............................................................................4-12

2.4 Error Message Printouts.................................................................................................4-14

3. PAPER PROBLEMS ............................................................................................. 4-15 3.1 Paper Loading Problems................................................................................................4-15

3.2 Paper Jams ....................................................................................................................4-16 3.2.1 Paper jams and how to clear them for HL-5240/5250DN..................................................4-16

3.2.2 Paper jams and how to clear them for HL-5270DN/5280DW ..........................................4-18

3.2.3 Causes & countermeasures..............................................................................................4-26

3.3 Paper Feeding Problems................................................................................................4-27

4. SOFTWARE SETTING PROBLEMS .................................................................... 4-29 5. MALFUNCTIONS.................................................................................................. 4-32 6. IMAGE DEFECTS................................................................................................. 4-38

6.1 Image Defect Examples .................................................................................................4-38

6.2 Diameter of Rollers.........................................................................................................4-38

6.3 Troubleshooting Image Defect .......................................................................................4-39

6.4 Location of Grounding Contacts .....................................................................................4-57 6.4.1 Drum unit...........................................................................................................................4-57

6.4.2 Printer body & Paper tray ..................................................................................................4-57

7. INCORRECT PRINTOUT ..................................................................................... 4-58 8. NETWORK PROBLEM ......................................................................................... 4-60

8.1 Installation Problem ........................................................................................................4-60

8.2 Printing Problem .............................................................................................................4-63

8.3 Protocol-Specific Troubleshooting..................................................................................4-65


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CHAPTER 5 DISASSEMBLY AND RE-ASSEMBLY .............................. 5-1 1. SAFETY PRECAUTIONS ....................................................................................... 5-1

2. PACKING................................................................................................................ 5-2

3. SCREW TORQUE LIST.......................................................................................... 5-3

4. HARNESS ROUTING ............................................................................................. 5-4

5. LUBRICATION...................................................................................................... 5-13

6. DISASSEMBLY FLOW ......................................................................................... 5-14

7. DISASSEMBLY PROCEDURE ............................................................................. 5-15

7.1 AC Cord..........................................................................................................................5-15

7.2 Drum/Toner ASSY..........................................................................................................5-15

7.3 DX Feed ASSY...............................................................................................................5-16

7.4 Paper Tray......................................................................................................................5-16

7.5 Back Cover .....................................................................................................................5-19

7.6 Outer Chute ASSY .........................................................................................................5-20

7.7 Fuser Unit .......................................................................................................................5-21

7.8 Tray MP ASSY................................................................................................................5-23

7.9 MP Tray Cover ASSY/Process Cover ASSY..................................................................5-24

7.10 Access Cover/ Side Cover L...........................................................................................5-27

7.11 Main PCB .......................................................................................................................5-28

7.12 Gear Plate Calking ASSY AL/Develop Joint/Main Motor ASSY AL................................5-30

7.13 Main Shield Plate ASSY .................................................................................................5-31

7.14 Relay Rear PCB ASSY/Connector .................................................................................5-33

7.15 Relay Front PCB ASSY ..................................................................................................5-34

7.16 Drive Release Link .........................................................................................................5-35

7.17 MP Solenoid ASSY.........................................................................................................5-36

7.18 T1 Solenoid ASSY..........................................................................................................5-36

7.19 Register Solenoid ASSY.................................................................................................5-37

7.20 Ejector Solenoid ASSY...................................................................................................5-38

7.21 Toner Sensor PCB .........................................................................................................5-38

7.22 Interlock SW ASSY ........................................................................................................5-39

7.23 New Toner Actuator........................................................................................................5-39

7.24 Gear 17/20......................................................................................................................5-40

7.25 Side Cover R ..................................................................................................................5-42

7.26-1 Top Cover Printed ASSY (HL-5240/5250DN)...............................................................5-43

7.26-2 Panel PCB ASSY..........................................................................................................5-43

7.26-3 SW Key A/B..................................................................................................................5-44

7.26-4 Inner Chute/Pinch Roller Holder ...................................................................................5-45

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7.27-1 Top Cover 2 Printed ASSY (HL-5270DN/5280DW) .....................................................5-46

7.27-2 Inner Chute/Pinch Roller Holder ...................................................................................5-47

7.27-3 Panel PCB ASSY..........................................................................................................5-48

7.27-4 SW Key A/B/C/ SW Key Printed ASSY ........................................................................5-49

7.27-5 LCD Holder ASSY ........................................................................................................5-51

7.28 Filter................................................................................................................................5-53

7.29 Laser Unit .......................................................................................................................5-54

7.30 PS PCB Unit ...................................................................................................................5-55

7.31 High-Voltage PS PCB ASSY ..........................................................................................5-58

7.32 Toner LED PCB Unit ASSY............................................................................................5-60

7.33 Fan Motor 60 Unit...........................................................................................................5-61

7.34 Fan Motor 60 Unit LV .....................................................................................................5-61

7.35 Frame L ..........................................................................................................................5-62

7.36 Frame R..........................................................................................................................5-62

7.37 MP Unit ...........................................................................................................................5-63

7.38 Regist Actuator Rear/Regist Actuator Spring .................................................................5-68

7.39 Regist Actuator Front/Regist Actuator Spring.................................................................5-69

7.40 Roller Holder ASSY ........................................................................................................5-70

7.41 PE Actuator, Edge Actuator, Edge Actuator Spring .......................................................5-71

7.42 PE PG Sensor ASSY......................................................................................................5-73

8. DISASSEMBLY PROCEDURE (LT-5300)............................................................. 5-74

8.1 Paper Tray......................................................................................................................5-74

8.2 LT Front Cover ASSY.....................................................................................................5-77

8.3 LT Back Cover................................................................................................................5-78

8.4 LT Side Cover L..............................................................................................................5-78

8.5 LT Side Cover R .............................................................................................................5-79

8.6 LT PCB ASSY ................................................................................................................5-80

8.7 Connector: 55533-1219..................................................................................................5-81

8.8 Connector: 54702-1219..................................................................................................5-81

8.9 Gear 24LT ......................................................................................................................5-82

8.10 Collar 6 ...........................................................................................................................5-83

8.11 LT Solenoid ASSY..........................................................................................................5-87

8.12 Roller Holder ASSY ........................................................................................................5-88

8.13 Edge Actuator Spring .....................................................................................................5-89

8.14 PE Actuator, Edge Actuator............................................................................................5-90

8.15 LT Sensor PCB ASSY....................................................................................................5-91

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CHAPTER 6 ADJUSTMENTS AND UPDATING OF SETTINGS, REQUIRED AFTER PARTS REPLACEMENT.................. 6-1

1. IF YOU REPLACE THE MAIN PCB ..........................................................................6-1

2. IF YOU REPLACE THE PERIODICAL MAINTENANCE PARTS............................6-10

CHAPTER 7 SERVICE SUPPORT SOFTWARE.................................... 7-1 1. CONTROL PANEL ....................................................................................................7-1

1.1 Users Mode...................................................................................................................... 7-1

1.2 User Maintenance Mode.................................................................................................. 7-3

1.3 Service Mode ................................................................................................................... 7-5

2. HIDDEN FUNCTION MENUS .................................................................................7-15 2.1 Professional Menu ......................................................................................................... 7-16

2.2 Reset Parts Life Menu ................................................................................................... 7-22

2.3 Service Menu ................................................................................................................. 7-23

3. NVRAM DEFAULT VALUE......................................................................................7-27

APPENDIX 1. MAIN PCB CIRCUIT DIAGRAM............................................................................... A-1 2. LOW-VOLTAGE POWER SUPPLY PCB CIRCUIT DIAGRAM (100V, 200V).......... A-7 3. HIGH-VOLTAGE POWER SUPPLY PCB CIRCUIT DIAGRAM ............................... A-9 4. POINT TO POINT CONNECTION DIAGRAM........................................................ A-10 5. GEAR LAYOUT DRAWING.................................................................................... A-11

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REGULATION LASER SAFETY (100 - 120V MODEL ONLY) This printer is certified as a Class 1 laser product under the U.S. Department of Health and Human Services (DHHS) Radiation Performance Standard according to the Radiation Control for Health and Safety Act of 1968. This means that the printer does not produce hazardous laser radiation.

Since radiation emitted inside the printer is completely confined within protective housings and external covers, the laser beam cannot escape from the machine during any phase of user operation.

FDA REGULATIONS (100 - 120V MODEL ONLY) U.S. Food and Drug Administration (FDA) has implemented regulations for laser products manufactured on and after August 2, 1976. Compliance is mandatory for products marketed in the United States. One of the following labels on the back of the printer indicates compliance with the FDA regulations and must be attached to laser products marketed in the United States.

The label for Japanese manufactured products

MANUFACTURED: Brother Industries, Ltd.,

15-1 Naeshiro-cho Mizuho-ku Nagoya, 467-8561 Japan This product complies with FDA performance standards for laser products except for deviations pursuant to Laser Notice No.50, dated July 26, 2001.

The label for Chinese manufactured products

MANUFACTURED: Brother Corporation (Asia) Ltd. Brother Buji Nan Ling Factory

Gold Garden Ind., Nan Ling Village, Buji, Rong Gang, Shenzhen, CHINA This product complies with FDA performance standards for laser products except for deviations pursuant to Laser Notice No.50, dated July 26, 2001.

Caution Use of controls, adjustments or performance of procedures other than those specified in this User’s Guide may result in hazardous radiation exposure.

C


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IEC 60825 (220-240V MODEL ONLY) This printer is a Class 1 laser product as defined in IEC 60825 specifications. The label shown below is attached in countries where it is required.

This printer has a laser diode which emits invisible laser radiation in the Laser Unit. The Laser Unit should not be opened without disconnecting the two connectors connected with the AC power supply and laser unit. Since the variable resistor in the laser unit is adjusted in accordance with the standards, never touch it.

Caution Use of controls, adjustments or performance of procedures other than those specified in this manual may result in hazardous radiation exposure.

For Finland and Sweden LUOKAN 1 LASERLAITE KLASS 1 LASER APPARAT Varoitus! Laitteen käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saattaa altistaa käyttäjän turvallisuusluokan 1 ylittävälle näkymättömälle lasersäteilylle.

Varning – Om apparaten används på annat sätt än i denna Bruksanvisning specificerats, kan användaren utsättas för osynlig laserstrålning, som överskrider gränsen för laserklass 1.

Internal laser radiation Maximum radiation power: 5 mW

Wave length: 770 – 810 nm

Laser class: Class 3B

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SAFETY INFORMATION CAUTION FOR LASER PRODUCT (WARNHINWEIS FUR LASER DRUCKER) CAUTION: When the machine during servicing is operated with the cover open, the

regulations of VBG 93 and the performance instructions for VBG 93 are valid.

CAUTION: In case of any trouble with the laser unit, replace the laser unit itself. To prevent direct exposure to the laser beam, do not try to open the enclosure of the laser unit.

ACHTUNG: Im Falle von Störungen der Lasereinheit muß diese ersetzt werden. Das Gehäuse der Lasereinheit darf nicht geöffnet werden, da sonst Laserstrahlen austreten können.

<Location of the laser beam window>

ADDITIONAL INFORMATION When servicing the optical system of the printer, be careful not to place a screwdriver or other reflective object in the path of the laser beam. Be sure to take off any personal accessories such as watches and rings before working on the printer. A reflected beam, though invisible, can permanently damage the eyes.

Since the beam is invisible, the following caution label is attached on the laser unit.


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DEFINITIONS OF WARNINGS, CAUTIONS AND NOTES The following conventions are used in this service manual:

WARNING Indicates warnings that must be observed to prevent possible personal injury.

! CAUTION: Indicates cautions that must be observed to service the printer properly or prevent damage to the printer.

NOTE: Indicates notes and useful tips to remember when servicing the printer.

**Listed below are the various kinds of “WARNING” messages included in this manual.

WARNING Always turn off the power switch and unplug the power cord from the power outlet before accessing any parts inside the printer.

WARNING Some parts inside the printer are extremely hot immediately after the printer is used. When opening the front cover or back cover to access any parts inside the printer, never touch the shaded parts shown in the following figures.

WARNING If you analyze malfunctions with the power plug inserted into the power outlet, special caution should be exercised even if the power switch is OFF because it is a single pole switch.


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CHAPTER 1 GENERAL

1. FEATURES

This printer has the following features.

High Resolution and Fast Print Speed True 600 x 600 dots, true 300 x 300 dots per inch (dpi), HQ1200 and 1200 x 1200 dpi for graphics with microfine toner and up to 28 pages per minute (ppm) print speed for printing on A4 size paper, and up to 30 pages per minute (ppm) print speed for Letter- size paper.

Versatile Paper Handling The printer loads paper automatically from the paper tray. The paper tray can hold A4, letter, B5 (ISO), B5 (JIS), A5, B6 (ISO), A6, Executive, Folio and Legal* size of paper. You can use a variety of types and sizes of paper when printing from the Multi-purpose tray. Width: 69.9 to 215.9 mm (2.75 to 8.5 in) Length: 116 to 406.4 mm (4.57 to 16 in). A4, Letter, Legal sizes of paper can be held when automatic duplex print. *Legal paper is not available in some regions.

Front Operation Basic operation of the printer can be controlled from the control panel.

Enhanced Printing Performance and User-Friendly Operation for Windows The dedicated printer driver for Microsoft Windows 95/98/Me, Windows NT 4.0 and Windows 2000/XP Home Edition/XP Professional/XP Professional x64 Edition are available on the CD-ROM supplied with your printer. You can easily install them into your Windows system using our installer program. The driver supports our unique compression mode to enhance printing speed in Windows applications and allows you to choose various printer settings including toner save mode, custom paper size, sleep mode, gray scale adjustment, resolution, water mark and many layout functions. You can easily setup these print options through the Printer Setup Menu.

Printer Status Monitor with Bi-directional Parallel Interface The printer driver can monitor the status of your printer using bi-directional parallel communications. IEEE-1284 bi-directional parallel printer cable is recommended.

The printer status monitor program can show the current status of your printer. The animated dialog box appears on your computer screen to show the current printing process when printing. If an error occurs, a dialog box will appear to let you know what to correct. If you have turned on the Interactive Help (Windows only) you can get visual guidance on your PC screen on the actions in the event of certain printer errors. The default setting is OFF.

Quick Print Setup The Quick Print Setup is a convenient utility to allow you to make changes to frequently used driver settings easily without having to open the printer properties selection box every time. It is launched automatically when this printer driver is selected. You can change the settings by clicking on the icon with the right mouse button. The default setting is OFF.

Enhanced Memory Management The printer provides its own data compression technology in its printer hardware and the supplied printer driver software, which can automatically compress graphic data and font data efficiently into the printer’s memory. You can avoid memory errors and print most full pages 1200 dpi graphic and text data, including large fonts, with the standard printer memory.

CHAPTER 1 GENERAL

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USB Interface (for Windows 98/Me/2000/XP Home Edition/XP Professional/XP Professional X64 Edition, Mac OS 9.1-9.2/ Mac OS X 10.2.4 or greater) The printer can be connected using the Universal Serial Bus (USB) interface to a PC or Mac which has a USB interface. Drivers that allow you to use the USB port are provided on the CD-ROM supplied with the printer.

Popular Printer Emulation Support These printers support the following printer emulation modes. BR-Script 3, HP LaserJet (PCL6), Epson FX-850 and IBM Proprinter XL.

Environment-Friendly <Economy Printing Mode (Toner Save Mode)> This feature will cut your printing cost by saving toner. It is useful for obtaining draft copies for proof-reading. You can select the toner saving economy mode through the Windows printer driver supplied with your printer. <Sleep Mode (Power Save Mode)> Sleep mode automatically reduces power consumption when the printer is not in use for a certain period of time. The printer consumes less than 8.5W when in sleep mode. <Low Running Cost> Since the toner cartridge is separate from the drum unit, you need to replace only the toner cartridge after printing around 3,500 (Standard cartridge) pages or 7,000 (High yield cartridge) at 5% coverage for A4 paper for the standard cartridge, which is both cost effective and ecologically friendly.

Bar Code Print The printer can print the following 11 types of bar codes

• Code 39 • US-PostNet • EAN-8 • Code 128 • ISBN • EAN-13 • Interleaved 2 of 5 • UPC-A • EAN-128 • Codabar • UPC-E

Network Feature (for HL-5250DN/5270DN/5280DW) The Brother printer has built in multi protocol network capability as standard. This allows multiple host computers to share the printer on a 10/100Mbps Ethernet network. Any users can print their jobs as if the printer was directly connected to their computer. Users on Windows® 95/98/Me, Windows® NT4.0, Windows® 2000/XP Home Edition/XP Professional/XP Professional x64 Edition, Mac OS® 9.1 to 9.2, Mac OS® X 10.2.4 or greater simultaneously can access this printer. For further information, see the Network User’s Guide supplied with the printer.


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2. PARTS NAMES AND FUNCTIONS

2.1 Overview (HL-5240/5250DN)

<Front View>

Fig. 1-1

<Rear View>

*The printer illustration is based on HL-5250DN.

Fig. 1-2

Control panel

Face-down output tray support flap (support flap)

MP tray cover ASSY

Paper tray

Power switch

Multi-purpose tray (MP tray)

Front cover release button Face-down output tray

Back cover

Duplex tray (For HL-5250DN)

AC power connector

Network status LEDs (Light emitting diodes)(For HL-5250DN) 10/100BASE-TX port

(For HL-5250DN)

USB interface connector

DIMM cover

Parallel interface connector

Front cover

CHAPTER 1 GENERAL

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(HL-5270DN/5280DW)

<Front View>

Fig. 1-3

<Rear View>

Fig. 1-4

Front cover release button

Control panel

Face-down output tray support flap (support flap)

MP tray cover ASSY

Paper tray

Power switch

Face-down output tray

Multi-purpose tray (MP tray)

Back cover

Duplex tray

AC power connector

LEDs (Light emitting diodes)10/100BASE-TX port

USB interface connector

DIMM cover

Parallel interface connector

Front cover


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2.2 Control Panel (HL-5240/5250DN) There are the four Light Emitting Diodes (LEDs) (Toner, Drum, Paper and Status) and two control buttons (Go and Job Cancel) on the control panel.

Fig. 1-5

1. Toner LED indicates when the Toner is low or at the end of its life.

2. Drum LED indicates when the Drum is nearing the end of its life.

3. Paper LED indicates when the paper tray is empty or there is a paper jam.

4. Status LED will flash and change color depending on the printer status.

5. Job Cancel button will stops and cancels the print operation in progress.

6. Go button Wake-up / Error recovery / Form feed / Reprint

CHAPTER 1 GENERAL

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(HL-5270DN/5280DW)

Fig. 1-6

1. LCD • Off: The printer is off or in sleep status. • Green (General): Ready to print.

Printing Warming up Job canceling

• Red (Error): There is a problem with the peinter. • Orange (Setting): The printer is offline.

Choosing a menu Setting number of reprints. Pause

2. Data LED: Orange • On: Data is in the printer memory. • Blinking: Receiving or processing data. • Off: No remaining data in the memory.

3. Go button Exit from the control panel menu and reprint setting. Clear error messages. Pause and Continue printing.

4. Job Cancel button Stop and cancel the printing operation in progress.

5. Reprint button Choose the reprint menu and the number of extra copies (1-999). Please enhance the RAMDISK size when you want to use the Reprint functions.

6. Menu buttons • +: Move forward through menus.

Move forward through the available options. • -: Move backward through menus.

Move forward through the available options. • Set: Choose the control panel menu.

Set the chosen menus and settings. • Back: Go back one level in the menu structure.


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3. SPECIFICATIONS

3.1 Printing

Print method Electrophotography by semiconductor laser beam scanning

Laser Wavelength: 770 - 810nm Output: 5mW max Laser class: Class B

Resolution <Windows® 95, WindowsNT® 4.0, Windows® 98/Me, Windows® 2000, Windows® XP Home Edition/XP Professional/XP Professional x64 Edition and Mac OS®>

1200 dpi*/ HQ1200/ 600dpi/ 300dpi <DOS> 600dpi <Linux> 600dpi/ 300dpi

* When you choose the higher print quality setting, the print speed will be slower.

Print quality Normal printing mode Economy printing mode (Toner saving mode)

Print speed Normal Up to 28 pages/minute (A4 size paper) Up to 30 pages/minute (Letter-size paper)

Warm-up Less than 18 seconds at 23°C (73.4°F)

First print Less than 8.5 seconds when the printer is in the ready state. (when loading A4 or Letter-size paper from the standard paper tray)

Consumables <Toner cartridge> Life expectancy: Standard 3,500 pages / cartridge High yield 7,000 pages / cartridge * when printing A4 or Letter-size paper at 5% print coverage.

<Drum unit> Life expectancy: 25,000 pages/ drum unit (1 page/ job) * when printing A4 or Letter-size paper at 5% print coverage.

NOTE: Print speed varies depending on the paper size or media type. For details, refer to 3.8 ‘Print Speeds with Various Settings’ in this chapter.

CHAPTER 1 GENERAL

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3.2 Functions

<Controller> Processor 266MHz

Emulation BR-Script 3 (PostScript® 3TM), HP LaserJet (PCL6), Epson FX-850 and IBM Proprinter XL

Memory <Standard> 16 MB (HL-5240) 32MB (HL-5250DN/5270DN/5280DW)

<Option> DIMM (HL-5240) The HL-5240 printer has 16 MB of standard memory and one slot for optional memory expansion. You can expand the memory up to 528 MB by installing dual in-line memory modules (DIMMs). (HL-5250DN/5270DN/5280DW) The HL-5250DN/5270DN/5280DW printer has 32 MB of standard memory and one slot for optional memory expansion. You can expand the memory up to 544 MB by installing dual in-line memory modules (DIMMs).

“DIMM types” You can install the following DIMMs:

• 128 MB Buffalo Technology VN133-D128/ VN133-X128 • 256MB Buffalo Technology VN133-D256 • 512MB Buffalo Technology VN133-D512 • 64 MB TechWorks 12165-0004 • 128 MB TechWorks 12462-0001 • 256MB TechWorks 12485-0001 • 512MB TechWorks 12475-0001

In general, the DIMM must have the following specifications: Type: 144 pin and 64 bit output CAS latency: 2 Clock frequency: 100 MHz or more Capacity: 64, 128, 256 or 512 MB Height: 31.75 mm (1.25 in.) Dram Type: SDRAM 2 Bank SDRAM can be used.

NOTE: There might be some DIMMs that will not work with the printer.

Interface Standard:

HL-5240 HL-5250DN/5270DN HL-5280DW

Hi-Speed USB 2.0 IEEE 1284 Parallel

Hi-Speed USB 2.0 IEEE 1284 Parallel 10/100 BASE-TX

Hi-Speed USB 2.0 IEEE 1284 Parallel 10/100 BASE-TX Wireless LAN IEEE802.11 b/g

Option:

HL-5240 HL-5250DN/5270DN HL-5280DW

10/100 BASE-TX Ethernet (NC-2100p)

N/A N/A


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Resident Fonts (HL-5240/5250DN) 66 scalable fonts, 12 bitmap fonts, 11 bar codes; Code39, Interleaved 2 of 5, EAN-8, EAN-13, UPC-A, EAN-128, Codabar, FIM (US-PostNet), ISBN, Code128

(HL-5270DN/5280DW) <PCL>

66 scalable fonts, 12 bitmap fonts, 11 bar codes; Code39, Interleaved 2 of 5, EAN-8, EAN-13, UPC-A, EAN-128, Codabar, FIM (US-PostNet), ISBN, Code128

<PostScript® 3TM> 66 fonts

Option Font (HL-5240/5250DN/5270DN/5280DW) BT-1000 (Agfa Barcode Font)

<Software> Printer driver <Windows®>

• PCL Driver for Windows® 95/98/Me, Windows NT® 4.0, Windows® 2000 and Windows® XP Home Edition/XP Professional/XP Professional x64 Edition * * Download the printer driver for Windows® XP Professional x64

Edition from http://solutions.brother.com

• Generic PCL Driver for Windows NT® 4.0, Windows® 2000 and Windows® XP Home Edition/XP Professional/XP Professional x64 Edition

• BR-Script 3 (PPD file) for Windows® 95/98/Me, Windows NT® 4.0

<Macintosh®> • Brother Laser Driver for Mac OS® 9.1 to 9.2 and Mac OS® X

10.2.4 or greater • BR-Script 3 (PPD file) for Mac OS® 9.1 to 9.2 and Mac OS® X

10.2.4 or greater

<Linux*> • LPR Driver for Linux • CUPS driver for Linux

* Download the printer driver for Linux from http://solutions.brother.com

CHAPTER 1 GENERAL

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Utilities (HL-5240) Interactive Help*

(HL-5250DN/5270DN/5280DW) Interactive Help*, Driver Deployment Wizard** * Interactive Help: Instructional animations for problem solving. ** The Driver Deployment Wizard automates the installation of a

printer in a peer-to-peer network. System Requirements

Computer Platform & Operating System Version

Processor Speed Minimum RAM

Recom- mended RAM

Available Hard Disk Space

95*1, 98, 98SE 486/66 MHz 8 MB 16 MB 40 MB NTWorkstation 4.0 *1 Intel Pentium 75 MHz 16 MB 32 MB 50 MB 2000 Professional Intel Pentium 133 MHz 64 MB 128 MB 50 MB Me Intel Pentium 150 MHz 32 MB 64 MB 50 MB XP Home Edition XP Professional

Intel Pentium 300 MHz 128 MB 128 MB 50 MB

Windows

XP Professional x64 Edition *2

AMD OpteronTM

AMD AthlonTM 64 Intel XeonTM with Intel EM64T Intel X Pentium with 4 Intel EM64T

256 MB 256 MB 50 MB

OS 9.1-9.2 32 MB 64 MB 50 MB Apple Macintosh*3 Mac OS X10.2.4 or

greater

All base models meet minimum requirements 128 MB 160 MB 50 MB

*1 USB is not supported under Windows 95 or Windows NT 4.0. *2 Download the printer driver for Windows XP Professional x64 Edition from

http://solutions.brother.com *3 Power Macintosh with an Apple original pre-installed USB port.


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3.3 Electronics and Mechanics

Power source U.S.A. and Canada: AC 110 to 120V, 50 Hz/60 Hz Europe and Australia: AC 220 to 240V, 50 Hz/60 Hz

Power consumption Printing: Average 610 W at 25°C (77°F) Standing by: Average 80 W at 25°C (77°F) Sleep: Average 8 W (HL-5240)

Average 9 W (HL-5250DN/5270DN)

Noise level <Sound pressure> Printing: 53dB (A) Standing by: 27dB (A)

<Sound power> Printing: LWAd=6.4 Bell (A) Standing by: 4.0 Bell (A)

Temperature Operating: 10 to 32.5°C (50 to 90.5°F) Non operating: 0 to 40°C (38 to 104°F) Storage: -20 to 40°C (-4 to 104°F)

Humidity Operating: 20 to 80% (non condensing) Storage: 10 to 85% (non condensing)

Dimensions (HL-5240/5250DN) <W x D x H> 371 x 384 x 246 mm (14.6 x 15.1 x 9.7 inches) (HL-5270DN) <W x D x H> 393 x 384 x 259 mm (15.5 x 15.1 x 10.2 inches)

Weight (HL-5240) Approximately 8.3 kg (18.3 lb.), not including the drum unit and toner cartridge. Approximately 9.5 kg (20.9 lb.) including the drum unit and toner cartridge. (HL-5250DN) Approximately 8.6 kg (19.0 lb.), not including the drum unit and toner cartridge. Approximately 9.8 kg (21.6 lb.) including the drum unit and toner cartridge. (HL-5270DN/5280DW) Approximately 8.8 kg (19.4 lb.), not including the drum unit and toner cartridge. Approximately 10.0 kg (22.0 lb.) including the drum unit and toner cartridge

NOTE: The power consumption figure quoted for sleep mode is when the fan has stopped.

CHAPTER 1 GENERAL

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3.4 Service Information

These are key service information to maintain the product.

Machine life: 200,000 pages/ 5 years

MTBF (Meantime between failure): Up to 4000 hours

MTTR (Meantime to repair): Average 30 minutes

Monthly volume: 20,000 pages

Periodical replacement parts:

Parts Approximate Life

Fuser Unit 100,000 pages

Separator pad holder assembly 100,000 pages

Pick up roller assembly 100,000 pages

Laser Unit 100,000 pages

* As for periodical replacement parts, refer to CHAPTER 3.


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3.5 Network Connectivity <Print server>

• NC-6400h (HL-5250DN/5270DN/5280DW)

Operating system support

Windows 95/98/Me, Windows NT 4.0, Windows 2000/XP Home Edition/XP Professional/XP Professional x64 Edition, Mac OS 9.1 to 9.2, Mac OS X 10.2.4 or greater

TCP/IP: IPv4 APR, RARP, BOOTP, DHCP, APIPA (Auto IP), WINS, NetBIOS name resolution, DNS Resolver, mDNS. LPR/LPD, Custom Raw Port/Port9100, SMB Print, IPP, FTP Server, Telnet, SNMP, HTTP, TFTP, SMTP Client

Protocol support

TCP/IP: IPv6 NDP, DNS Resolver, mDNS, LPR/LPD, Custom Raw Port/Port9100, IPP, FTP Server, Telnet, SNMP, HTTP, TFTP, SMTP Client

Network type 10/100BASE-TX Ethernet network

Network printing Windows 95/98/Me Peer-to-Peer printing, Windows NT 4.0 and Windows 2000/XP Home Edition/XP Professional/XP Professional x64 Edition TCP/IP printing, Macintosh printing

BRAdmin Professional utility

Windows 95/98/Me, Windows NT 4.0, Windows 2000/XP Home Edition/XP Professional/XP Professional x64 Edition

BRAdmin Light Mac OS X 10.2.4 or greater

Management utilities

Web BRAdmin Windows 2000 Professional / Server / Advanced Server, Windows XP Home Edition/XP Professional/XP Professional x64 Edition Professional

NOTE: NC-6400h is a network controller of the printer built-in type.

• NC-2100p (HL-5240) (Option) An optional network print server (NC-2100p) allows you to connect to your network through the parallel interface.

Network interface 10/100BASE-TX Ethernet

Printer interface Parallel

Support protocol TCP/IP, NetBEUI

Embedded web server support

SNMP / MIB support

TELNET remote console

BRAdmin Professional compatible

Management features

Flash memory for easy updating of firmware

CHAPTER 1 GENERAL

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3.6 Paper 3.6.1 Paper handling

Paper Input* All models

Multi-purpose tray 50 sheets

Paper tray (Standard) 250 sheets

Lower tray (Option) 250 sheets

* Calculated with 80 g/m2 (21 lb) paper.

Paper Output* All models

Face-down 150 sheets

* Calculated with 80 g/m2 (21 lb) paper.

Duplex HL-5240 HL-5250DN/ 5270DN/ 5280DW

Manual Duplex Yes

Automatic Duplex N/A Yes 3.6.2 Media specifications

(1) Media types

The printer loads paper from the installed paper tray or the multi-purpose tray. The feedable media type and size are different depending on the paper tray installed. The names for the paper trays in the printer driver and this guides are as follows;

Paper tray Tray 1

Multi-purpose tray MP Tray

Optional lower tray unit Tray 2/ Tray 3

Duplex tray for automatic duplex printing (for HL-5250DN/5270DN/5280DW)

DX

The table in the next page shows the feedable media of each paper tray described above.


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Tray 1/2/3 MP Tray DX

Choose the media type from the printer driver

Plain paper 75 g/m2 to 105 g/m2

(20 to 28 lbs.)

Yes Yes Yes Plain paper

Recycled paper

Yes Yes Yes Recycled paper

Bond paper Rough paper- 60 g/m2 to 161 g/m2

(16 to 43 lbs.)

Yes 60 g/m2 to 105 g/m2

(16 to 28 lbs.)

Yes 60 g/m2 to 161 g/m2

(16 to 43 lbs.)

N/A Bond paper

Thin paper 60 g/m2 to 75 g/m2

(16 to 20 lbs.)

Yes Yes Yes Thin paper

Thick paper 105 g/m2 to 161 g/m2

(28 to 43 lbs.)

N/A Yes N/A Thick Paper or Thicker Paper

Transparency Yes

Up to 10 sheets A4 or Letter **

Yes Up to 10 sheets A4 or Letter

N/A Transparencies

Labels N/A Yes A4 or Letter

N/A Thicker Paper

Envelopes N/A Yes N/A Envelopes,

Env. Thin, Env. Thick

* Up to 10 sheets ** Not available for the optional Tray 2/3.

(2) Media size

MP Tray Tray 1 (Standard) Tray 2, Tray3 (Option)

DX

Width: 69.9 to 215.9 mm (2.75 to 8.5 in.) Length: 116 to 406.4 mm (4.57 to 16 in.)

A4, Letter, Legal*, B5 (ISO), Excutive, A5, A6, B6 (ISO)

A4, Letter, Legal*, B5 (ISO), Excutive, A5, B6 (ISO)

A4, Letter, Legal*

* Legal size paper is not available in some regions outside the USA and Canada.

CHAPTER 1 GENERAL

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(3) Media weights

Tray 1 MP Tray DX Tray 2/3 Lower tray unit (Option) (LT-5300)

60 to 105 g/m2 (16 to 28 lb.)

60 to 161 g/m2 (16 to 43 lb.)

60 to 105 g/m2 (16 to 28 lb.)

60 to 105 g/m2 (16 to 28 lb.)

(4) Recommended paper

Europe USA

Plain paper Xerox Premier 80 g/m2

Xerox Business 80 g/m2

M-real DATACOPY 80 g/m2

Xerox 4200DP 20lb Hammermill Laser Paper 24lb

Recycled paper Xerox Recycled Supreme N/A

Transparency 3M CG3300 3M CG 3300

Label Avery laser label L7163 Avery laser label #5160

* This printer can use recycled paper that meets the DIN 19309 specification. (5) Moisture content

Moisture content 4% to 6% by weight

! CAUTION: When you are choosing print media, be sure to follow the information given below to prevent any paper jams, print quality problems or printer damage; • It is recommended to use long-grained paper for the best print quality. If short-grained

paper is being used, it might be the cause of paper jams. • Use neutral paper. Do not use acid paper to avoid any damage to the drum unit. • Avoid using coated paper such as vinyl coated paper. • Avoid using preprinted or highly textured paper. • It is recommended to use labels or transparencies which are designed for use in laser

printers. • Avoid feeding labels with the carrier sheet exposed, or the printer will be damaged. • Before loading paper with holes such as organizer sheets, be sure to fan the stack well. • Do not use organizer sheets that are stuck together. The glue that is used might caused

damaged to the printer. • When printing on the back of pre-printed paper, if the paper is curled, be sure to straighten

the paper as much as possible. Different types of paper should not be loaded at the same time in the paper tray to avoid any paper jams or misfeeds.


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3.7 Printable Area 3.7.1 PCL5e/EPSON/IBM emulation

When using PCL emulation, the edges of the paper that cannot be printed on are shown below.

Portrait

A

B

C

D

E

F

GF

G

E

G G

Physical page

Printable area

Logical page

B Physical page length

D Maximum logical page length

F Distance from edge of physical page toedge of logical page

NOTE:

• “Logical page” shows the printable area for a PCL driver. • “Printable area” shows mechanical printable area of the machine. • Therefore, the machine can only print within the shaded area when you use a PCL driver.

CHAPTER 1 GENERAL

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The table below shows the printable areas when printing on Portrait for each paper size.

Size A B C D E F G Letter

215.9 mm 8.5” (2,550 dots)

279.4 mm 11.0” (3,300 dots)

203.2 mm 8.0” (2,400 dots)

279.4 mm 11.0” (3,300 dots)

6.35 mm 0.25” (75 dots)

0 mm 4.2 mm 0.16” (50 dots)

Legal

215.9 mm 8.5” (2,550 dots)

355.6 mm 14.0” (4,200 dots)

203.2 mm 8.0” (2,400 dots)

355.6 mm 14.0” (4,200 dots)

0 mm

4.2 mm 0.16” (50 dots)

Folio

215.9 mm 8.5” (2,550 dots)

330.2mm 13.0” (3,900 dots)

203.2 mm 8.0” (2,400 dots)

330.2mm 13.0” (3,900 dots)

0 mm

4.2 mm 0.16” (50 dots)

Executive

184.15 mm 7.25” (2,175 dots)

266.7 mm 10.5” (3,150 dots)

175.7 mm 6.92” (2,025 dots)

266.7 mm 10.5” (3,150 dots)

6.35 mm 0.25” (75 dots)

0 mm 4.2 mm 0.16” (50 dots)

A 4

210.0 mm 8.27” (2,480 dots)

297.0 mm 11.69” (3,507 dots)

198.0 mm 7.79” (2,338 dots)

297.0 mm 11.69” (3,507 dots)

6.01 mm 0.24” (71 dots)

0 mm 4.2 mm 0.16” (50 dots)

A 5

148.5 mm 5.85” (1,754 dots)

210.0 mm 8.27” (2,480 dots)

136.5 mm 5.37” (1,612 dots)

210.0 mm 8.27” (2,480 dots)

0 mm

4.2 mm 0.16” (50 dots)

A 6

105.0 mm 4.13” (1,240 dots)

148.5 mm 5.85” (1,754 dots)

93.0 mm 3.66” (1,098 dots)

148.5 mm 5.85” (1,754 dots)

0 mm

4.2 mm 0.16” (50 dots)

B 5 (JIS)

182.0 mm 7.1” (2,130 dots)

257.0 mm 10.11” (3,033 dots)

170.0 mm 6.69” (2,007 dots)

257.0 mm 10.11” (3,033 dots)

0 mm

4.2 mm 0.16” (50 dots)

B 5 (ISO)

176.0 mm 6.93” (2,078 dots)

250.0 mm 9.84” (2,952 dots)

164.0 mm 6.46” (1,936 dots)

250.0 mm 9.84” (2,952 dots)

0 mm

4.2 mm 0.16” (50 dots)

B 6 (ISO)

125.0 mm 4.92” (1,476 dots)

176.0 mm 6.93” (2,078 dots)

164.0 mm 4.44” (1,334 dots)

176.0 mm 6.93” (2.078 dots)

0 mm

4.2 mm 0.16” (50 dots)

COM10

104.78 mm 4.125” (1,237 dots)

241.3 mm 9.5” (2,850 dots)

92.11 mm 3.63” (1,087 dots)

241.3 mm 9.5” (2,850 dots)

6.35 mm 0.25” (75 dots)

0 mm 4.2 mm 0.16” (50 dots)

MONARCH

98.43 mm 3.875” (1,162 dots)

190.5 mm 7.5” (2,250 dots)

85.7 mm 3.37” (1,012 dots)

190.5 mm 7.5” (2,250 dots)

0 mm

4.2 mm 0.16” (50 dots)

C 5

162.0 mm 6.38” (1,913 dots)

229.0 mm 9.01” (2,704 dots)

150.0 mm 5.9” (1,771 dots)

229.0 mm 9.01” (2,704 dots)

6.01 mm 0.24” (71 dots)

0 mm 4.2 mm 0.16” (50 dots)

DL

110.0 mm 4.33” (1,299 dots)

220.0 mm 8.66” (2,598 dots)

98.0 mm 3.86” (1,157 dots)

220.0 mm 8.66” (2,598 dots)

0 mm

4.2 mm 0.16” (50 dots)

DL L 220.0 mm 8.66” (2,598 dots)

110.0 mm 4.33” (1.299 dots)

207.4 mm 8.17” (2,450 dots)

110.0 mm 4.33” (1.299 dots)

6.27 mm 0.25” (74 dots)

0 mm 6.27 mm 0.25” (74 dots)

NOTE: • The paper sizes indicated here should confirm to the nominal dimensions specified by JIS

except B5 (ISO), B6 (ISO). • The dot size is based on 300 dpi resolution.


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Landscape

A

B

C

D

E

F

GF

G

E

G G

Physical page

Printable area

Logical page

B Physical page length

D Maximum logical page length

F Distance from edge of physical page to edge of logical page

NOTE:

• “Logical page” shows the printable area for a PCL driver. • “Printable area” shows mechanical printable area of the machine. • Therefore, the machine can only print within the shaded area when you use a PCL driver.

CHAPTER 1 GENERAL

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The table below shows the printable areas when printing on Landscape for each paper size.

Size A B C D E F G Letter

279.4 mm 11.0” (3,300 dots)

215.9 mm 8.5” (2,550 dots)

269.3 mm 10.6” (3,180 dots)

215.9 mm 8.5” (2,550 dots)

5.0 mm 0.2” (60 dots)

0 mm 4.2 mm 0.16” (50 dots)

Legal

355.6 mm 14.0” (4,200 dots)

215.9 mm 8.5” (2,550 dots)

345.5 mm 13.6” (4,080 dots)

215.9 mm 8.5” (2,550 dots)

0 mm

4.2 mm 0.16” (50 dots)

Folio

330.2mm 13.0” (3,900 dots)

215.9 mm 8.5” (2,550 dots)

320.0mm 12.6” (3,780 dots)

215.9 mm 8.5” (2,550 dots)

0 mm

4.2 mm 0.16” (50 dots)

Executive

266.7 mm 10.5” (3,150 dots)

184.15 mm 7.25” (2,175 dots)

256.6 mm 10.1” (3,030 dots)

184.15 mm 7.25” (2,175 dots)

5.0 mm 0.2” (60 dots)

0 mm 4.2 mm 0.16” (50 dots)

A 4

297.0 mm 11.69” (3,507 dots)

210.0 mm 8.27” (2,480 dots)

287.0 mm 11.2” (3,389 dots)

210.0 mm 8.27” (2,480 dots)

4.8 mm 0.19” (59 dots)

0 mm 4.2 mm 0.16” (50 dots)

A 5

210.0 mm 8.27” (2,480 dots)

148.5 mm 5.85” (1,754 dots)

200.0mm 7.87” (2,362 dots)

148.5 mm 5.85” (1,754 dots)

0 mm

4.2 mm 0.16” (50 dots)

A 6

148.5 mm 5.85” (1,754 dots)

105.0 mm 4.13” (1,240 dots)

138.5 mm 5.45” (1,636 dots)

105.0 mm 4.13” (1,240 dots)

0 mm

4.2 mm 0.16” (50 dots)

B 5 (JIS)

257.0 mm 10.11” (3,033 dots)

182.0 mm 7.1” (2,130 dots)

247.0 mm 9.72” (2,916 dots)

182.0 mm 7.1” (2,130 dots)

0 mm

4.2 mm 0.16” (50 dots)

B 5 (ISO)

250.0 mm 9.84” (2,952 dots)

176.0 mm 6.93” (2,078 dots)

240.0 mm 9.44” (2,834 dots)

176.0 mm 6.93” (2,078 dots)

0 mm

4.2 mm 0.16” (50 dots)

B 6 (ISO)

176.0 mm 6.93” (2,078 dots)

125.0 mm 4.92” (1,476 dots)

166.4 mm 6.55” (1,960 dots)

125.0 mm 4.92” (1,476 dots)

0 mm

4.2 mm 0.16” (50 dots)

COM10

241.3 mm 9.5” (2,850 dots)

104.78 mm 4.125” (1,237 dots)

231.1 mm 9.1” (2,730 dots)

104.78 mm 4.125” (1,237 dots)

5.0 mm 0.2” (60 dots)

0 mm 4.2 mm 0.16” (50 dots)

MONARCH

190.5 mm 7.5” (2,250 dots)

98.43 mm 3.875” (1,162 dots)

180.4 mm 7.1” (2,130 dots)

98.43 mm 3.875” (1,162 dots)

0 mm

4.2 mm 0.16” (50 dots)

C 5

229 mm 9.01” (2,704 dots)

162 mm 6.38” (1,913 dots)

219.0 mm 8.62” (2,586 dots)

162 mm 6.38” (1,913 dots)

4.8 mm 0.19” (59 dots)

0 mm 4.2 mm 0.16” (50 dots)

DL

220 mm 8.66” (2,598 dots)

110 mm 4.33” (1,299 dots)

210.0 mm 8.26” (2,480 dots)

110 mm 4.33” (1,299 dots)

0 mm

4.2 mm 0.16” (50 dots)

DL L

110 mm 4.33” (1,299 dots)

220 mm 8.66” (2,598 dots)

97.5 mm 3.84” (1,151 dots)

220 mm 8.66” (2,598 dots)

6.27 mm 0.25” (74 dots)

0 mm 6.27 mm 0.25” (74 dots)

NOTE: • The paper sizes indicated here should confirm to the nominal dimensions specified by JIS

except B5 (ISO), B6 (ISO). • The dot size is based on 300 dpi resolution.

3.7.2 PCL6 emulation You can not print within 4.2 mm (50dots in 300 dpi mode) on all four sides of the paper.


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3.8 Print Speeds with Various Settings Print speed is up to 28 ppm for A4 size and 30 ppm for Letter size when loading A4 or Letter size paper from the paper tray in the plain paper mode.

Actual print speed varies depending on the media type or paper size as shown in the tables below;

<A4 / Letter size>

Media type setting All models

Transparency 28/30 ppm

Thin Paper 28/30 ppm

Plain Paper 28/30 ppm

Recycled Paper 28/30 ppm

Thick Paper, Envelopes, Env.Thin

14 ppm

Thicker/Bond Paper, Env.Thick

3 ppm

<Smaller size than A4 or Letter>

Media type setting All models

Transparency 28/30 ppm

Thin Paper 28/30 ppm

Plain Paper 90 sec 28/30 ppm 14 ppm

Recycled Paper 90 sec 28/30 ppm 14 ppm

Env.Thin 14 ppm

Thick Paper, Envelopes

14 ppm

Thicker/Bond Paper, Env.Thick

3 ppm

NOTE: • The print speed may vary according to conditions, such as paper size and paper tray. • When a smaller size paper than A4 or Letter is printed, the temperature on both edges of

the fuser unit is much higher than the temperature on the center of the unit where the paper is fed depending on the setting or model. Therefore, the print speed is slowed in order to decrease the temperature on the edges after the specified time, it is maximum print speed when you first start printing.

• The actual print speed varies depending on the paper size.

CHAPTER 1 GENERAL

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3.9 Toner Cartridge Weight Information

Toner Cartridge Weight (approximate weight)

TN580 US TN-3170 EUR/EEU TN-3185 AP

Brand new Toner Cartridge Weight 727g

Toner Weight at Brand New Toner Cartridge 190g

Toner Cartridge Weight at Toner Near Empty 617g (± 13g)

Remain Toner Weight at Toner Near Empty 77g

Toner Cartridge Weight at Toner Life End 605g (± 10g)

Remain Toner Weight at Toner Life End 68g

TN-550 US TN-3130 EUR/EEU TN-3145 AP

Brand new Toner Cartridge Weight 663g

Toner Weight at Brand New Toner Cartridge 126g

Toner Cartridge Weight at Toner Near Empty 617g (± 13g)

Remain Toner Weight at Toner Near Empty 77g

Toner Cartridge Weight at Toner Life End 602g (± 10g)

Remain Toner Weight at Toner Life End 65g

You can print about 630 pages with 10g toner. (A4 size, 5% coverage, continuous printing)

NOTE:

The figure has varied quite a bit, for example from 590 pages to 720 pages, on a comparison of printing test results.

NOTE: • Without yellow protector, DR cover. • Toner cartridge weight may vary within 2 to 3g depending on the cartridge weight. • From the 10th of December 2005, 60g is over in the total weight of a toner cartridge

because of a different type of the Develop Roller.


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4. SERIAL NO. DESCRIPTIONS

The descriptions below show how to understand the meanings of the numbers printed on the labels or bag of the printer and printer parts.

< ID for production month >

A: January B: February C: March D: April E: May F: June G: July H: August J: September K: October L: November M: December

< ID for year >

5: 2005 6: 2006

< ID for factory > 9: Kariya Plant A: Mie Brother C: BIUK J: Buji Nan Ling Factory E: BITM D: BIUS F: BISZ

(1) Printer: Printed on the label attached on the rear of the main body

<Example>

U 5 2 6 8 2 A 5 J 1 1 1 1 0 1

(2) Process unit: Imprinted on the aluminum bag

(Drum unit with toner cartridge)

5 A 1 1 J A

(3) Drum unit: Printed on the bar code label attached inside the drum unit

A 5 J 5 1 0 0 1 0 4 A

<MODEL NO.>

MONTH

< SERIAL NO. >

DR/TN REUSE The first time: M The second time: N The third time: P

SEQUENTIAL NO. FACTORY ID NO.

YEAR

PRODUCTION LINE NO. FACTORY ID NO.

DATEMONTH

YEAR

PRODUCTION LINE NO. SERIAL NO.

TONER VOLUME

MONTH YEAR

FACTORY ID NO.

CHAPTER 1 GENERAL

Confidential 1-24

(4) Toner cartridge: Imprinted on the aluminum bag

5 A 3 0 J A

Printed on the bar code label attached on the toner cartridge

M 5 J L 0 0 0 1 9 9 A

(5) Laser unit: On the laser unit

X X XXXXXXX

CARTRIDGE PRODUCTION INFO.

DR/TN REUSE The first time: M The second time: N The third time: P

MOLD NUMBER

SERIAL NUMBER

YEAR

MONTH

DATE

FACTORY ID NO.

PRODUCTION LINE NO.

MONTHYEAR

FACTORY ID NO.

TONER VOLUMEL: 80g M: 100g

SERIAL NO. PRODUCTION LINE NO.

MANUFACTURE DISTINCTION


Confidential 2-1

CHAPTER 2 THEORY OF OPERATION

1. OVERALL

1.1 General Block Diagram Fig. 2-1 shows a general block diagram.

Ethernet10/100 Base TX

(HL-5250DN/5270DN/5280DW)

Video control block

Engine control blockOperation block

(Control panel)

Control system

Low

-vol

tage

pow

er s

uppl

y bl

ock

Hig

h-vo

ltage

pow

er s

uppl

y bl

ock

Laser unitDrive block(DC motor)

Drum unit

Transfer block

Exposuredrum

Charging block

Ext

erna

l dev

ice

Paper tray

Fuser unit

Paper eject tray

Paper feed system

Image generation system

Interface blockUSBParallel

USB host(HL-5280DW)

Wireless LAN(HL-5280DW)

RAM16MB: HL-524032MB: HL-5250DN/ 5270DN/ 5280DW

Extended RAMSODIMM 144pin

Paper dustcleaner block

Toner cartridge

Developing block

Developer unit

Fig. 2-1


Confidential 2-2

2. ELECTRONICS

2.1 General Block Diagram

High-voltage power supply

Low-voltage power supply

Fuser thermistor

Main PCB

Regist front sensor

Main fan

Sensor PCB(PE+PEDGE)

LT Sensor PCB(PE+PEDGE)

Regist rear sensor

Toner sensor PCB(Light reception)

Toner LED PCB(Light emission)

Power supply fan

Interlock switch(Cover sensor)

MP sensor PCB

Tray1 solenoid

Regist solenoid

Main motor

Panel PCB

DX solenoid(HL-5250DN/5270DN)

DX unit sensor PCB

MP solenoid LT solenoid

Front relay PCB

New tonersensor

Rear relay PCB

Paper ejectsensor

LT PCB

LT1

Wireless LAN(HL-5280DW)

Polygon motor

Laser diode PCB

LT Sensor PCB(PE+PEDGE)

LT solenoid

LT PCB

LT2

Fig. 2-2


Confidential 2-3

2.2 Main PCB Block Diagram Fig. 2-3 shows the block diagram of the main PCB.

SO

-DIM

M

SDRAM

HL-5240: 16MBHL-5250DN/5270DN/ 5280DW: 32MB

8MBInternal: 16MB

HL-5250DN: 2MBHL-5270DN/5280DW: 4MB

HL-5250DN: TCP/IPHL-5270DN: Full Protocol

MAX 512MB

CDCC GA

IEEE 1284

SPD

D16/A13

CPU Core

ASIC

(Sapphire 266MHz)

CLKINTDATA

REQn

RSTn

USB2.02.0 High Speed VBUS

D+/D-

Mask ROM Flash ROM

Network IC(LAN9115)

LAN

25.00MHz

Xtal

48.00MHz

Xtal(for Sysclk/USB)

23.4617MHz

Xtal(for Video)

D16/A24

D16/A24

(Laser Diode PCB)8 pin

CN (PANEL)10 pin

CN (DXSOL)2 pin

CN (TNRSEN)2 pin

CN (RELAY FRONT)9 pin

CN (RELAY REAR)6 pin

CN (LT)12 pin

CN (LVPS)8 pin

CN (HVPS)23 pin

CN (Laser Unit)14 pin

CN (MAIN MOTOR)19 pin

MotorDriver IC

Reset IC+3.3V

+3.3V

Par

arel

l IF

5 LED/2 SW (HL-5240/5250DN)

LCD16x1 1LED 7SW (HL-5270DN/5280DW)

DX solenoid

GRIDC

Toner LED

5 PWM_out (HVPS)

3 solenoid (T1/REG/MP)

2 FAN (MAIN/HVPS)

5 sensor (reg_f/reg_r/pedg/T1PE/MPPE)

Therm1/2

HeaterON

AI3:7

AI1:2

ComparatorHTLIMITN

+24V+8V +3.3V+24VRET

0V

4 sensor (pedgex2/PEx2)2 solenoid

Regulator

Regulator

5V 3.3V

3.3V 1.5V

+5V

SCAN_CTR/MAIN_CTR/MAIN_FR

CS

RO

M1/

RD

/WR

CS

RO

M0/

RD

/WR

EX

CS

0/R

D/W

RE

XC

S1/

Rb/

WR

INTn

RSTn

HL-5280DW

USB HOSTISP 1362

WirelessLAN

12.00MHz

Xtal

INTn

RSTn

2 sensor (PaperOut/DX tray)

3 sensor (Front_Cover/Toner sensor/Process NEW)

5 Analog_in (HVPS)

EEPROM16kbit

CN

Fig. 2-3


Confidential 2-4

2.3 Main PCB For the entire circuit diagram of the main PCB.

2.3.1 CPU A Sapphire – 266 MHz (Vr5500) is built into the CPU in the ASIC. It runs at a clock frequency of 266 MHz.

The functions of the interface block communication with external devices are described below;

2.3.2 USB interface (2.0 High Speed) Stores the data received from the PC into DRAM as controlled by the DMA controller. The transmission speed is 12Mbps.

2.3.3 IEEE1284 interface Stores the data received from the PC into DRAM by DMA using the Gate Array (UPD65421MC-11) exclusive for parallel I/F. It is for the normal reception and dual direction communication (nibble mode, byte mode, ECP mode).

2.3.4 Network interface It uses the National Semiconductor brand 10 Base-T/100 Base-TX network controller (LAN9115). The pulse transformer and the Link/Active LED are built in the RJ-45 connector.

2.3.5 ROM < ROM 0 >

64 Mbit ROM (8 MB) is fitted. The main program is written into the ROM.

< ROM 1: Demo Specification For US, Canada> 16 Mbit ROM (2 MB) is fitted. (HL-5240) 32 Mbit ROM (4 MB) is fitted. (HL-5250DN)

< ROM 1: Standard Specification > 16 Mbit ROM (2 MB) is fitted. (HL-5250DN) 32 Mbit ROM (4 MB) is fitted. (HL-5270DN/5280DW)

2.3.6 SDRAM 16 MB SDRAM (128 Mbits x 1) is used as the RAM. (HL-5240)

32 MB SDRAM (256 Mbits x 1) is used as the RAM. (HL-5250DN/5270DN/5280DW)

2.3.7 Optional RAM 1 DIMM (144pin) slot can be fitted as optional expansion RAM. The main PCB has one slot and the capacity of DIMM can be from 64MB to 512MB.

2.3.8 EEPROM The EEPROM is M24C16 type of two-wire method with a 16kbit configuration.


Confidential 2-5

2.3.9 Reset circuit The reset IC is a S-80928CLNB. The reset voltage is 2.8V (typ.) and the low period of reset is 260ms (typ.).

2.3.10 Panel I/O The interface with the panel board is connected to ASIC.

2.3.11 Video I/O The video signal is directly output from ASIC to laser unit.

2.3.12 Power supply +3.3V is supplied from LVPS. +3.3V is used by logic circuit.

In addition, +3.3V is generated by the voltage regulator from +8V supplied from the LVPS. +1.5V is used for the CPU within the ASIC and the logic circuit.

24V is used for the motors and solenoids and fan.

2.3.13 Wireless LAN The wireless LAN is conformable to 802.11 b/g. It is also conformable to WEP, WPA-PSK, LEAP and Secure Easy Setup.


Confidential 2-6

2.4 Power Supply 2.4.1 Low-voltage power supply

The power supply uses a switching regulation system to generate the regulated DC power (+5V and +24V), which are converted from the AC line.

The regulated output and the production code of each power supply are listed below; Regulated Output Production Code +3.3V / 1.5A +24V / 2.4A, +8V / 0.8A

100V: SRP1828UC 200V: SRP1829EK

2.4.2 High-voltage power supply

The high-voltage power supply generates and outputs the voltages and currents for the charging, development and transfer functions.


Confidential 2-7

3. MECHANICS

3.1 Overview of Printing Mechanism

Fig. 2-4

Laser unit Eject roller ASSY

Fuser unit

Back cover

Outer chute ASSY

Halogen heater

Heat roller

Pressure roller

Exposure drum

Duplex unit

Developer roller

Drum unit

Regist roller

Pinch roller

Transfer roller

Paper tray

Paper tray (LT unit)

LT unit

Separation roller

Feed roller

Separation roller MP

Feed roller

Regist actuator front Feed roller TR

Separation roller

Feed roller

Feed roller TR

Regist actuator rear

Pressure roller

Pressure roller


Confidential 2-8

3.2 Overview of Gears

Fig. 2-5

Eject solenoid

LT

DX

Main motor (Drive sub ASSY)

T1 solenoid

MP solenoid

Register solenoid

LT solenoid


Confidential 2-9

3.3 Paper Transfer

3.3.1 Paper supply The feed roller picks up a few sheets or one sheet of paper from the paper tray every time it is rotated and feeds it to the separation roller.

Fig. 2-6

The main motor drive is transmitted to the gears, and the gears are engaged. Then, the paper is gripped between the separation roller and separation pad and separated into individual sheets. The paper drawn out of the paper tray pushes against the regist front actuator, and the paper top position or absence of paper is detected by the actuator movement. The tail edge actuator detects the end of the paper fed.

Feed roller TR

Separation roller

Regist roller

Pinch roller

Feed roller

PE actuator Pressure roller

Paper

Plate


Confidential 2-10

The plate ASSY in the paper tray is pushed up with the motor drive and not with the spring in order to maintain the constant paper feeding performance regardless the number of sheet remained in the tray. When the paper tray (Tray1 cassette) is installed into the printer, the lift gear 46 is rotated, and the motor drive is transmitted to the plate ASSY so that it is pushed up.

Fig. 2-7

When the feed roller is pushed up, the hook is released by the lift arm, and the rotation of the clutch gear is stopped. Then, the pressure plate is stopped to push up.

Fig. 2-8

When a paper jam occurs, the nips between the pressure roller and feed roller TR and between the pinch roller and regist roller are released, which allows you to remove the jammed recording paper easily.

P/P clutch hook A2

P/P clutch hook A1

P/P gear 29 clutch cam

P/P clutch hook B

P/P differentioal

P/P gear 22/B23 tray drive

Gear 15

Gear 21-16 Lift gear 46 Plate ASSY

Plate up plate

Stop


Confidential 2-11

3.3.2 Paper registration After the paper top position is detected by the regist actuator front, the paper, separated into individual sheets by the separation roller, is fed further for a specified time, and the paper top position reaches the regist roller so that the paper skew is adjusted. Then, the register solenoid is turned off, the paper feed roller starts turning, and the paper is fed to the transfer roller in the drum/toner ASSY.

Fig. 2-9

The regist actuator rear in the path from the regist roller to the transfer roller controls the first print position on the paper. The printer starts transferring an image when a definite time passes after the paper is passed through the regist actuator rear.

3.3.3 Drum unit

Exposure drum Generates the latent electrostatic image and develops the image on the drum surface.

Primary charger

Forms a uniform charge on the drum surface.

(1) Corona wire Generates the ion charge on the drum.

(2) Grid Spreads the ion charge evenly over the drum surface.

Transfer roller

Transfers the toner image to the paper from the drum surface.

Cleaner Removes the paper dust or dirt on the surface of the exposure drum.


Transfer roller

Exposure drum

Drum/toner ASSY

Regist roller Regist actuator front


Confidential 2-12

3.3.4 Developing Developing causes the toner to be attracted to the electrostatic image on the drum so as to transform it into a visible image. The developer consists of a non-magnetic toner. The developer roller is made of conductive rubber and the supply roller (which is also made of conductive sponge) rotate against each other. The toner is charged and carried from the supply roller to the developer roller. The toner adheres to the developer roller and is conveyed to the exposure drum at an even thickness controlled by the blade. The toner is nipped between the developer roller and the drum and developed onto the latent image on the drum. The electrostatic field between the drum and the developer roller, which is DC-biased from the high-voltage power supply, creates the electrostatic potential to attract toner particles from the developer roller to the latent image area on the drum surface.

Fig. 2-10

Developer roller

Exposure drum

Transfer roller

Corona wire

Supply roller

Blade


Confidential 2-13

3.3.5 Fixing stage The image transferred to the paper by static electricity is fixed by heat and pressure when passing through the heat roller and the pressure roller in the fuser unit. The thermistor keeps the surface temperature of the heat roller constant by detecting the surface temperature of the heat roller and turning on or off the halogen heater lamp.

Fig. 2-11

Pressure roller

Halogen heater

Heat roller

Fuser unit


Confidential 2-14

3.3.6 Paper eject

After the printing image on the exposure drum is transferred onto the paper, the paper is fed to the fuser unit to fix unfixed toner onto the paper by the heat roller and the pressure roller in the fuser unit.

Afterwards, the paper is ejected from the fuser unit. The paper eject actuator detects whether the paper is ejected correctly or not.

After the paper exits from the heat roller, the paper is turned by the back cover and ejected face down into the top output tray through the eject roller ASSY.

Fig. 2-12

When a paper jam occurs, the roller in the eject roller ASSY is released to remove the jammed recording paper easily.

Paper eject actuator

Eject roller ASSY

Back cover

Heat roller

Pressure roller


Confidential 2-15

3.3.7 Duplex printing (HL-5250DN/5270DN/5280DW) After the paper exits from the eject roller ASSY with the front of sheet printed, the eject roller ASSY rotates conversely and feeds the paper to the duplex tray, where the paper skew is adjusted. Afterwards, the paper is ejected from the duplex tray to the path through the regist roller and the transfer roller to the transfer block in the drum unit again for process of printing on the back of sheet.

Fig. 2-13

Eject roller ASSY

Back cover

Outer chute ASSY

Pressure roller

Duplex unit Transfer roller

Exposure drum

Heat roller

Pinch roller

Regist roller

Regist actuator front



Confidential 2-16

3.3.8 Paper feeding from the MP tray The separation roller is connected with the feed roller through the gear in the MP roller holder ASSY. When the separation roller is driven, therefore, the feed roller is also driven. At this time, the recording paper is drawn out of the MP tray by rotation of the feed roller contacted with the recording paper. The drawn recording paper is separated into individual sheets by the separation roller.

Fig. 2-14 3.3.9 LT tray

The motor drive is transmitted to the gear to rotate the feed roller, then the recording paper is drawn out of the LT tray. The drawn recording paper is separated into individual sheet by the separation roller and fed to the printer.

Fig. 2-15

Separation roller MP

Feed roller

MP tray cover ASSY

Separation pad ASSY MP

Feed roller TR

Separation roller

Separation pad

Feed roller

Plate Paper


Confidential 2-17

3.4 Toner Cartridge Develops the electrostatic latent image on the exposure drum with toner and forms the visible image.

3.4.1 Toner life end mode

A new toner cartridge can print approximately 3,500 (standard toner) or approximately 7,000 (high yield toner) A4 or Letter size single-sided pages at 5% coverage. In the case of low-duty printing, “Toner Life End” is indicated by lighting Toner LED (HL-5240/5250DN) or “TONER LIFE END” message appears on the LCD panel (HL-5270DN/5280DW) before the toner runs out because the developer roller surface or other toner sealing is worn out due to a rotation of the rollers. The upper limit of the drum rotation is 44,000 = 4,000 sheets x 11 rotations (standard toner), 92,400 = 8,400 sheets x 11 rotations (high yield toner). The following graph shows the number of printable pages in the case of A4 printing.

HL-5240/5250DN/5270DN/5280DW(Standard (3.5K) toner)Page/job 1 2 3 4 5 6 7 8 9 10 11 12Cartridge life 4,200 6,329 7,615 8,477 9,094 9,559 9,920 10,210 10,447 10,645 10,813 10,957Cartridge life+ON/OFF 2,310 3,915 5,096 6,000 6,715 7,295 7,774 8,177 8,520 8,817 9,075 9,302Toner empty (5%) 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500Toner empty (4%) 4,375 4,375 4,375 4,375 4,375 4,375 4,375 4,375 4,375 4,375 4,375 4,375Toner empty (3%) 5,833 5,833 5,833 5,833 5,833 5,833 5,833 5,833 5,833 5,833 5,833 5,833Toner empty (2%) 8,750 8,750 8,750 8,750 8,750 8,750 8,750 8,750 8,750 8,750 8,750 8,750Toner empty (1%) 17,500 17,500 17,500 17,500 17,500 17,500 17,500 17,500 17,500 17,500 17,500 17,500

Cartridge life = 11a x 4200 / ( 3.6 x (a - 1) + 11 ) a : Page / job

Cartridge life+ON/OFF = ( 11a x 4200 ) / ( 3.6 x (a - 1) + 11 + 9 )

Cartridge life (Mechanical limit) : 4200 ( 1page / job )

02,0004,0006,0008,000

10,00012,00014,00016,00018,00020,000

1 2 3 4 5 6 7 8 9 10 11 12Page / Job

Prin

tabl

e pa

ges

Cartridge life

Cartridge life+ON/OFF

Toner empty (5%)

Toner empty (4%)

Toner empty (3%)

Toner empty (2%)

Toner empty (1%)


Confidential 2-18

• The number of rotation of the developer roller per page is as follows; 1. One printed page only or the first page of continuous printing = 11 rotations 2. The second page or later = 3.6 rotations

• Number of idling rotation when the printer is turned ON = 9 rotations

HL-5240/5250DN/5270DN/5280DW(High Capacity (7K) toner)Page/job 1 2 3 4 5 6 7 8 9 10 11 12Cartridge life 8,400 12,658 15,231 16,954 18,189 19,117 19,840 20,420 20,894 21,290 21,626 21,913Cartridge life+ON/OFF 4,620 7,831 10,191 12,000 13,430 14,589 15,548 16,354 17,041 17,634 18,150 18,604Toner empty (5%) 7,000 7,000 7,000 7,000 7,000 7,000 7,000 7,000 7,000 7,000 7,000 7,000Toner empty (4%) 8,750 8,750 8,750 8,750 8,750 8,750 8,750 8,750 8,750 8,750 8,750 8,750Toner empty (3%) 11,667 11,667 11,667 11,667 11,667 11,667 11,667 11,667 11,667 11,667 11,667 11,667Toner empty (2%) 17,500 17,500 17,500 17,500 17,500 17,500 17,500 17,500 17,500 17,500 17,500 17,500Toner empty (1%) 35,000 35,000 35,000 35,000 35,000 35,000 35,000 35,000 35,000 35,000 35,000 35,000

Cartridge life = 11a x 8400 / ( 3.6 x (a - 1) + 11 ) a : Page / job

Cartridge life+ON/OFF = ( 11a x 8400 ) / ( 3.6 x (a - 1) + 11 + 9 )

Cartridge life (Mechanical limit) : 8400 ( 1page / job )

0

5,000

10,000

15,000

20,000

25,000

30,000

35,000

40,000

1 2 3 4 5 6 7 8 9 10 11 12Page / Job

Prin

tabl

e pa

ges

Cartridge life

Cartridge life+ON/OFF

Toner empty (5%)

Toner empty (4%)

Toner empty (3%)

Toner empty (2%)

Toner empty (1%)


Confidential 2-19

3.4.2 New toner detection mechanism (1) The motor drive is transmitted to the gear (4) through a few gears.

(2) When the gear (4) is rotated, the rib A on the gear (4) pushes against a new toner actuator, and a new toner sensor detects the actuator motion. Then, the toner sensor detects that a new toner cartridge is installed.

(3) For the high yield toner cartridge, the rib B is provided on the gear (4) as shown in the figure below so that a new toner actuator is pushed against twice by both ribs A and B.

(4) When the toner actuator is pushed twice, the two signals are transmitted to a new toner sensor, and it is detected that the high yield toner cartridge is installed. For the standard toner cartridge, the rib B is not provided, and a new toner actuator is pushed only once by the rib A. In this case, the one signal is transmitted to a new toner sensor so that it is detected that the standard toner cartridge is installed.

<Printer side view when a new toner cartridge is installed>

Fig. 2-16

Gear (4)

Gear (3)

Gear (2) Gear (1)

Rib B

Rib A

New toner actuator

New toner sensor

Relay front PCB ASSY


Confidential 2-20

When the new toner detection switch detects that the toner cartridge is replaced with a new one, the developing bias voltage is initialized at the same time.

The toner used for the printer has a property that print density is light first and gradually darker in the course of usage. The developing bias controls the toner property so that the print density is constant from first to last.

Toner property Actual control

[Used toner amount] [Used toner amount]

Print density

Bias voltage Bias voltage

Print density

[Density]�[Voltage]

[Density]�[Voltage]

To obtain a print result of a constant density all the time, the printer counts the number of print pages immediately after the toner cartridge is replaced and changes the bias voltage according to the accumulated number of prints with the toner cartridge.

The bias voltage is changed with the steps described below:

(1) When the new toner sensor detects that the toner cartridge is replaced with a new (full) one, the developing bias is set to 400V (initialized).

(2) After that, the bias voltage is stepped down according to the number of prints. 3.4.3 Counter reset during indication of “Toner Life End”

The counter resetting method during indication of “Toner Life End” depends on the cause of toner life end and the condition of the inserted toner cartridge. Refer to the following table for details.

Toner Life End (Toner empty)

Toner Life End (Developer count full)

When a used toner is inserted (Reset gear is at the position of in use.)

Toner exchange count: +0 Page counter of each toner: Continued

Coverage of each toner: Continued

Development bias: Reset (Default)

Not used.

When a new toner is inserted (Reset gear is at the position of factory set.)

Toner exchange count: +1 Page counter of each toner: Reset (0)

Coverage of each toner: Reset (0)

Development bias: Reset (Default)


Confidential 2-21

3.5 Print Process 3.5.1 Charging

The drum is charged to approximately 900V by an ion charge which is generated by the primary charger. The charge is generated by ionization of the corona wire, which has a DC bias from the high-voltage power supply applied to it. The flow of the ion charge is controlled by the grid to ensure it is distributed evenly on the drum surface. The aluminum drum sleeve in the exposure drum is grounded.

+++

++ + + + +

++

+++

+++

+ + ++

------- - - - -

Fig. 2-17

The primary charge uses a corona wire, but since the drum is positively charged, only less than 1/10 of the usual quantity of ozone is generated compared with the negatively charged drum. The level of ozone expelled from the printer is therefore not harmful to the human body. Applicable safety standards have been complied with.

3.5.2 Exposure stage

After the drum is positively charged, it is exposed to the light emitted from the laser unit.

Fig. 2-18

< Laser exposure unit >

1. The laser beam radiated from a laser diode inside the laser unit are concentrated into a constant width by a slit in the CO lens cell and then reflected by a polygon mirror rotating at high speed.

2. The laser beam reflected by the polygon mirror are refracted by the f-theta lens and radiated from the right through to the left end of the reflection mirror as the polygon mirror rotates. At this time, blur of the vertical direction of the laser beam by inclination of a polygon mirror is corrected by passing a Toric lens.

Aluminum drum sleeve Organic photoconductor layer

Exposure drum

Voltage circuit

Grid

HVPS

Corona wire

Laser beam

Polygon mirror

Paper

Laser detector

Laser diode Motor

Laser beam

f θ lens

Drum

Toric Lens

CO Lens


Confidential 2-22

3. The laser beams reflected by the reflection mirror go straight toward the exposure drum below it, then expose the exposure drum.

The area exposed to the laser beam is the image to be printed. The surface potential of the exposed area is reduced, forming the electrostatic image to be printed.

Fig. 2-19 3.5.3 Transfer

(1) Transfer process

After the drum has been charged and exposed, and has received a developed image, the toner formed is transferred onto the paper by applying a negative charge to the back of the paper. The negative charge applied to the paper causes the positively charged toner to leave the drum, and adhere to the paper. As a result, the image is visible on the paper.

(2) Cleaning process of transfer roller

If the toner is not transferred onto the paper perfectly it is possible that there may be residual toner on the drum which will adhere to the transfer roller. The transfer roller voltage changes to a positive voltage during non-printing rotation of the drum. Therefore the transfer roller is cleaned by returning the positively charged toner adhering to the transfer roller onto the exposure drum.

3 Primary charging

Laser beam exposure and developing

(a) Unexposed area (Non image area)

(b) Exposed area (Image area)

Transfer the image to paper

Drum sleeve 0

2 1 1

2

3

(a)

(b) +100

+400

+900

Surface potential (V) 1 Cycle of drum

Time


Confidential 2-23

3.6 Sensors

Sensor name Type Located on

Regist front sensor Photo sensor High-voltage PS PCB

Regist rear sensor Photo sensor High-voltage PS PCB

Paper eject sensor Photo sensor Relay rear PCB

New toner sensor Photo sensor Relay front PCB

Toner LED PCB (Light emission)

Photo sensor Frame R

Toner sensor PCB (Light reception)

Photo sensor Frame L

Front cover sensor Mechanical switch Frame L

PE sensor Photo sensor PE EG sensor ASSY

Edge sensor Photo sensor PE EG sensor ASSY

MP PE sensor Photo sensor MP PE sensor ASSY

DX tray sensor Mechanical switch Relay rear PCB

Fig. 2-20

Frame R


Chute


New toner sensor (Relay front PCB)

High-voltage PS PCB

Regist rear sensor Regist front sensor

MP PE sensor

PE EG sensor

Edge sensor

PE sensor

Paper eject sensor (Relay rear PCB)

Frame L

Front cover sensor

DX tray sensor

Paper feed frame

Regist frame


Confidential 2-24

3.7 Heat Control of Fuser Unit The printer controls the temperature in the fuser unit in order to keep the constant image quality when printing on any type or size of paper.

< Fixing temperature of each media type >

Media type Fixing temperature (°C)

(approximately) [Full speed / Half speed]

Plain paper 213/185

Plain paper (Small size) 200/185

Plain paper (Duplex) 195/180

Recycled paper 195/180

Recycled paper (Small size) 189/170

Recycled paper (Duplex) 189170

OHP 185

OHP (Small size) 185

OHP (Duplex) 185

Thin paper 195

Thin paper (Small size) 195

Thin paper (Duplex) 181

Thick paper 200

Thick paper (Small size) 195

Thick paper (Duplex) 195

Envelope (Thin) 200

Envelope (Thin, small size) 200

Envelope (Thin, duplex) 195

Envelope (Others) 220

Envelope (Others, small size) 220

Envelope (Others, duplex) 205

NOTE: The values described in the table above are approximate and vary depending on the conditions such as the operation environment or the like.


Confidential 3-1

CHAPTER 3 PERIODIC MAINTENANCE

To avoid creating secondary problems by mishandling, follow the warnings below during maintenance work.

WARNING • If your clothes are smeared with toner, wipe the toner with a dry cloth immediately

and wash the clothes in cold water to avoid stains. • Be careful to inhale toner. • Always turn off the power switch and unplug the power cord from the power

outlet before accessing any parts inside the printer.

• Some parts inside the printer are extremely hot immediately after the printer is used. • When opening the front cover or back cover to access any parts inside the printer,

never touch the shaded parts shown in the following figures.

1. CONSUMABLE PARTS

The consumable parts described in this section are parts which are subject to deterioration or damage and should be replaced at least once during the period of warranty of the product if any printing quality problem appears.

1.1 Toner Cartridge A new toner cartridge can print up to 3,500 (standard cartridge) or up to 7,000 (high yield cartridge) A4 or Letter size single-sided pages at about 5% coverage.

NOTE: * The amount of toner used varies according to what is printed on the page and the print

density setting. * If the print density setting for lighter or darker printing is changed, the amount of toner

used will change. * Wait to unpack the toner cartridge until immediately before putting it into the printer. * There are many factors that determine the actual toner life, such as temperature, humidity,

type of paper used, the number of pages per print job, etc.


Confidential 3-2

<Toner Low Message> (HL-5240/5250DN)

The Toner LED alternates turning on for 2 seconds and off for 3 seconds.

Fig. 3-1

If the LED shows this message, the printer has nearly run out of toner. Buy a new toner cartridge and have it ready before you get a “Toner Life End” message. NOTE: The Toner LED will blink continuously if the toner cartridge is nearly empty.

(HL-5270DN/5280DW)

Appears at intervals.

TONER LOW

If the LCD shows “TONER LOW”, the printer has nearly run out of toner. Buy a new toner cartridge and have it ready before you get a “TONER LIFE END” message.

<Toner Life End Message> (HL-5240/5250DN)

If the LED shows the message below, the printer has run out of toner or the toner is not evenly distributed inside the cartridge.

Fig. 3-2

(HL-5270DN/5280DW)

Appears at intervals.

TONER LIFE END

If the LCD shows “TONER LIFE END”, the printer has run out of toner or the toner is not evenly distributed inside the cartridge.

In both situations, the printer will stop printing until a new toner cartridge has been put into the printer. “TONER LIFE END” can only be cleared by putting a new toner cartridge into the drum unit.


Confidential 3-3

<Replacement Procedure> NOTE: * To ensure high quality printing, make sure to use genuine Brother toner cartridges. * It is recommended to clean the printer when replacing the toner cartridge.

(1) Press the front cover release button and then open the front cover.

Fig. 3-3

(2) Take out the drum unit and toner cartridge assembly.

Fig. 3-4

! CAUTION: * We recommend that you put the drum unit and toner cartridge assembly on a piece of

disposable paper or cloth in case you accidentally spill or scatter toner. * To prevent damage to the printer from static electricity, DO NOT touch the electrodes shown

in the illustration.


Confidential 3-4

(3) Push down the blue lock lever and take the toner cartridge out of the drum unit.

Fig. 3-5

! CAUTION: * Handle the toner cartridge carefully. If toner scatters on your hands or clothes, wipe or wash

it off with cold water at once. * To avoid any degradation of the print quality, DO NOT touch the shaded parts shown in the

illustrations.

NOTE: * Be sure to seal up the toner cartridge tightly in a bag so that toner powder does not spill out

of the cartridge. * Discard the used toner cartridge according to local regulations, keeping it separate from

domestic waste. If you have questions, call your local waste disposal office.

(4) Unpack the new toner cartridge. Hold the cartridge level with both hands and gently rock it from side to side five or six times to spread the toner evenly inside the cartridge.

Fig. 3-6


Confidential 3-5

! CAUTION: * Wait to unpack the toner cartridge until immediately before you put it in the printer. If toner

cartridges are left unpacked for a long time the toner life will be shortened. * If an unpacked drum unit is put in direct sunlight or room light, the unit may be damaged. * Brother strongly recommends that you do not refill the toner cartridge provided with your

printer. We also strongly recommend that you continue to use only genuine Brother brand replacement toner cartridges. Using or trying to use potentially incompatible toner and/or toner cartridges in your printer may cause damage to the printer itself and/or may result in unsatisfactory print quality. Our warranty coverage does not apply to any problem that was caused by the use of unauthorized third party toner and toner cartridges. To protect your investment and guarantee print quality, continue to replace consumed toner cartridges with only genuine Brother branded supplies.

* Printing with a third-party toner or third-party toner cartridge may reduce not only the print quality but also the quality and life of the printer itself. It may also cause serious damage to the performance and life of the drum unit. Warranty coverage does not apply to problems caused by the use of third-party toner or third-party toner cartridges.

* Put the toner cartridge in the drum unit immediately after you have removed the protective cover. To prevent any degradation to the print quality, DO NOT touch the shaded parts shown in the illustrations.

(5) Pull off the protective cover.

Fig. 3-7

(6) Put the new toner cartridge firmly into the drum unit until you hear it lock into place. If you put it in properly, the lock lever will lift automatically.

Fig. 3-8


Confidential 3-6

! CAUTION: Make sure that you put in the toner cartridge properly or it may separate from the drum unit.

(7) Clean the primary corona wire inside the drum unit by gently sliding the blue tab from right to left and left to right several times.

Fig. 3-9

! CAUTION: Be sure to return the tab to the home position (▲). If you do not, printed pages may have a vertical stripe.

(8) Put the drum unit and toner cartridge assembly back in the printer. Close the front cover.

Fig. 3-10

Home position


Confidential 3-7

1.2 Drum Unit A new drum unit can print approximately 25,000 A4 or Letter size single-sided pages at 5% coverage. NOTE: * There are many factors that determine the actual drum life, such as the temperature,

humidity, type of paper, type of toner used, number of pages per print job and so on. Under ideal conditions, the average drum life is estimated at approximately 25,000 pages. The actual number of pages that your drum will print may be significantly less than this estimate. Because we have no control over the many factors that determine the actual drum life, we cannot guarantee a minimum number of pages that will be printed by your drum.

* For the best performance, use only genuine Brother toner. The printer should be used only in a clean, dust-free environment with adequate ventilation.

* Printing with a third-party drum unit may reduce not only the print quality but also the quality and life of the printer itself. Warranty coverage does not apply to problems caused by the use of a third-party drum unit.

<Change Drum Message> (HL-5240/5250DN)

If the LED shows the message below, it means the drum unit is near the end of its life. We recommend that you replace the drum unit with a new one before there is a noticeable deterioration in the print quality.

Fig. 3-11

(HL-5270DN/5280DW) Appears at intervals.

DRUM NEAR END

If the LCD shows “DRUM NEAR END”, it means the drum unit is near the end of its life. We recommend that you replace the drum unit with a new one before there is a noticeable deterioration in the print quality.


Confidential 3-8

<Replacement Procedure>

! CAUTION: * While removing the drum unit, handle it carefully as it may contain toner. * Every time you replace the drum unit, be sure to clean the inside of the printer.

When you replace the drum unit with a new one, you need to reset the drum counter by completing the following steps:

(HL-5240/5250DN) (1) Make sure that the printer is turned on and the Drum LED is blinking. Press the front

cover release button and then open the front cover.

(HL-5270DN/5280DW)

(1) Make sure that the LCD shows “DRUM NEAR END”. Press the front cover release button and then open the front cover.

Fig. 3-12

(HL-5240/5250DN) (2) Press and hold down Go for about 4 seconds until all the LEDs light up. Once all four

LEDs are lit, release Go.

Fig. 3-13


Confidential 3-9

(HL-5270DN/5280DW) (2) Hold down Go until the message “DRUM CLEAR” is displayed on the LCD, then release

Go.

Fig. 3-14

Improper Setup: Do not reset the drum counter when you only replace the toner cartridge.


Fig. 3-15





Confidential 3-10

(4) Push down the blue lock lever and take the toner cartridge out of the drum unit.

Fig. 3-16


it off with cold water at once. * To avoid any degradation of the print quality, DO NOT touch the shaded parts shown in the

illustrations.

NOTE: * Be sure to seal up the toner cartridge tightly in a bag so that toner powder does not spill out

of the cartridge. * Discard the used toner cartridge according to local regulations, keeping it separate from

domestic waste. If you have questions, call your local waste disposal office.

(5) Unpack the new drum unit.

! CAUTION: Wait to unpack a drum unit until immediately before you put it in the printer. Exposure to direct sunlight or room light may damage the drum unit.


Confidential 3-11

(6) Put the toner cartridge firmly into the new drum unit until you hear it lock into place. If you put the cartridge in properly, the blue locklever will lift automatically.

Fig. 3-17

! CAUTION: Make sure that you put in the toner cartridge properly, or it may separate from the drum unit.

(7) Put the drum unit and toner cartridge assembly back in the printer.

Fig. 3-18

(HL-5240/5250DN) (8) Close the front cover.

Make sure that the Drum LED is now off.

(HL-5270DN/5280DW) (8) Close the front cover. Make sure that the “DRUM NEAR END” message on the LCD in

now off.


Confidential 3-12

2. PERIODICAL REPLACEMENT PARTS

2.1 Periodical Replacement Parts Periodical replacement parts are the parts to be replaced periodically to maintain product quality. These parts would affect the product quality greatly if they lost their function even if they do not appear to be damaged or there is no change in their appearance.

The periodical replacement parts listed below should be replaced at the service center referring to the service life.

Parts Name LCD Message (HL-5270DN

/5280DW) Qty

Approximate Life *1 (number of prints)

Replacement Procedure

Fuser Unit REPLACE FUSER 1 100,000 pages

Laser Unit REPLACE LASER 1 100,000 pages

See subscription 2.2.1, Chapter 3

Paper feeding kit for Tray 1 *3 REPLACE PF KIT1 1 100,000 pages



See subscription 2.2.2, Chapter 3

Paper feeding kit for MP tray *2

REPLACE PF KITMP 1 100,000 pages See subscription

2.2.3, Chapter 3

NOTE: *1 At 5% print coverage (A4 or Letter size). The actual number of printed pages will vary depending on the print jobs and paper you use. *2 Paper feeding kit means the paper pick up roller and the separation pad. *3 Paper feeding kit for Tray 1, Tray 2 and Tray 3 means the paper feed roller, separation roller, separation pad and separation pad spring. Tray 1, Tray 2 and Tray 3 are the same kit. NOTE: *Always turn off the power switch of the printer and unplug the power cord from the power outlet before replacing the periodical replacement parts. *If the Fuser Unit is replaced after errors related to the Fuser Unit occur, it is necessary to leave the printer power ON for ten minutes after part replacement. This will make the printer to be released from errors. *To reset the count of each periodical replacement parts, refer to “2.IF YOU REPLACE THE PERIODICAL MAINTENANCE PARTS”, Chapter 6.


Confidential 3-13

2.2 Procedures to Replace Periodical Replacement Parts 2.2.1 Fuser unit and laser unit

< Uninstalling Procedure >

(1) Disconnect the AC cord from the Printer.

Fig. 3-19

(2) Pull out the Paper tray.

Fig. 3-20

Printer

AC cord

Paper tray


Confidential 3-14

(3) Open the Front cover.

(4) Remove the Drum/toner ASSY.

Fig. 3-21

(5) Remove the DX feed ASSY.

Fig. 3-22

NOTE: The DX feed tray is not provided for the HL-5240 printer.

Front cover

Drum/toner ASSY

Printer

DX feed ASSY

1

2

3


Confidential 3-15

(6) Remove the Back cover.

Fig. 3-23

(7) Remove the Outer chute ASSY.

Fig. 3-24

Back cover

Outer chute ASSY

Pin

Pin

Pin

1

2

3

Pin

1

2

3


Confidential 3-16

(8) Remove the two bind B M4x12 Taptite screws to remove the Side cover L.

Fig. 3-25

(9) Remove the four cup S M3x6 SR Taptite screws to remove the Shield cover and the FG harness.

Fig. 3-26

Taptite, bind B M4x12


Front cover

Side cover L

Hooks

Hooks

Hole

1

1 2

3

Taptite, cup S M3x6 SR

Shield cover

Taptite, cup S M3x6 SR FG harness


Confidential 3-17

(10) Remove the two bind B M4x12 Taptite screws to remove the Shield cover R.

Fig. 3-27

(11) Disconnect the Connector of the Panel PCB.

Fig. 3-28


Shield cover R


Hole

Hooks

Hooks

Hooks

Hole

1

1 2

3

Top cover printed ASSY

Main PCB

Connector

Panel PCB


Confidential 3-18

(12) Remove the two bind B M4x12 Taptite screws to remove the Top cover printed ASSY.

Fig. 3-29

(13) Remove the bind B M4x16 Taptite screw to remove the FU harness cover 1.

Fig. 3-30

Hooks

Hooks Hooks

Hooks


Hole

Hole



FU harness cover 1 Hooks

1

2

1

1

2 3


Confidential 3-19

(14) Remove the Heater terminal L and Heater terminal S from the Fuser unit.

Fig. 3-31

(15) Remove the FU harness cover 2.

Fig. 3-32

Fuser unit

Heater terminal L

Heater terminal S

FU harness cover 2

Hook

1

2


Confidential 3-20

(16) Disconnect the connectors of the Thermistor ASSY M and Thermistor ASSY S from the Relay rear PCB ASSY.

Fig. 3-33

(17) Remove the cup B M4x16 Taptite screw to remove the Fuser unit.

Fig. 3-34

Thermistor ASSY S

Relay rear PCB ASSY

Thermistor ASSY M

Fuser unit

Fuser unit

Taptite, cup B M4x16


Confidential 3-21

(18) Remove the Sub duct from the Air duct.

Fig. 3-35

(19) Remove the Filter from the Air duct.

Fig. 3-36

Air duct

Sub duct Hooks

Filter

Air duct

Filter

2 3

1


Confidential 3-22

(20) Remove the Air duct from the Laser unit.

Fig. 3-37

(21) Remove the two flat cable.

(22) Remove the six cup S M3x6 Taptite screw to remove the Laser unit.

Fig. 3-38

Laser unit

Air duct

Laser unit

Taptite, cup S M3x6

Taptite, cup S M3x6

1

2 3

Pin

Pin

Pin

Hook

Hook


Confidential 3-23

< Installing Procedure >

(1) Secure the Laser unit with the six cup S M3x6 Taptite screws.

(2) Install the two flat cable.

Fig. 3-39

(3) Install the Air duct into the Laser unit.

Fig. 3-40

Laser unit

Taptite, cup S M3x6

Taptite, cup S M3x6

Laser unit

Air duct

1 2

3

Pin

Pin

Hook

Hook

Pin


Confidential 3-24

(4) Install the Filter into the Air duct.

Fig. 3-41

(5) Install the Sub duct into the Air duct.

Fig. 3-42

Air duct

Filter

Air duct

Sub duct Hooks

Filter

1 2


Confidential 3-25

WARNING • DO NOT subject the fuser unit to strong physical shocks or vibrations. • DO NOT touch the rollers and the electrodes to prevent damage to the fuser unit In

the following figures.

! CAUTION:

To prevent the deformation of the pressure roller, the fuser unit spare part is shipped with its pressure roller at low nip pressure. Before installing the fuser unit, turn back the levers to the normal position by following instructions below. (1) Put the fuser unit on a flat, horizontal surface. Pull up each of the blue tab (a) on the right

side and left side.

(2) Make sure that the black lever (b) is in the position in the illustration below.

(a)

(a)

(b)

(b)


Confidential 3-26

(6) Secure the Fuser unit with the bind B M4x16 Taptite screw.

Fig. 3-43

(7) Connect the connectors of the Thermistor ASSY M and Thermistor ASSY S onto the relay

rear PCB ASSY.

Fig. 3-44

Fuser unit


Thermistor ASSY S

Relay rear PCB ASSY

Thermistor ASSY M

Fuser unit


Confidential 3-27

(8) Install the FU harness cover 2.

Fig. 3-45

(9) Install the Heater terminal L and Heater terminal S.

Fig. 3-46

FU harness cover 2

Hook

Fuser unit

Heater terminal L

Heater terminal S

1

2


Confidential 3-28

(10) Secure the FU harness cover 1 with the bind B M4x16 Taptite screw.

Fig. 3-47

(11) Secure the Top cover printed ASSY with the two bind B M4x12 Taptite screws.

Fig. 3-48


FU harness cover 1 Hooks

Hooks

Hooks Hooks

Hooks


Hole

Hole


1

2 3

1

2

2


Confidential 3-29

(12) Connect the Connector of the Panel PCB.

Fig. 3-49

(13) Secure the Side cover R with the two bind B M4x12 Taptite screws.

Fig. 3-50


Side cover R


Hole

Hooks

Hooks

Hooks

Hole

1

2

3

3


Main PCB

Connector

Panel PCB


Confidential 3-30

(14) Secure the Shield cover and FG harness with the four cup S M3x6 SR Taptite screws.

Fig. 3-51

(15) Secure the Side cover L with the two bind B M4x12 Taptite screws.

Fig. 3-52



Side cover L

Hooks

Hooks

Hole

1

2

3

3

Front cover

Shield cover



FG harness


Confidential 3-31

(16) Install the Outer chute ASSY.

Fig. 3-53

(17) Install the Back cover.

Fig. 3-54

Outer chute ASSY

Back cover

1

3

Pin

Pin

2

Pin

Pin

1

2

3


Confidential 3-32

(18) Install the DX feed ASSY.

NOTE: The DX feed tray is not provided for the HL-5240 printer.

Fig. 3-55

(19) Install the Drum/toner ASSY into the Printer.

(20) Close the Front cover.

Fig. 3-56

DX feed ASSY

Printer

Drum /toner ASSY

Front cover

2

1


Confidential 3-33

(21) Put the Paper tray into the Printer.

Fig. 3-57

(22) Connect the AC cord into the Printer.

Fig. 3-58

Paper tray

Printer

AC cord


Confidential 3-34

2.2.2 Paper feeding kit for tray 1, 2, 3 < Uninstalling Procedure >


Fig. 3-59

(2) Pull out the Paper tray and remove the paper from the Paper tray.

Fig. 3-60

Printer

AC cord

Paper tray


Confidential 3-35

(3) Remove the Separation pad ASSY.

(4) Remove the Separation pad spring.

Fig. 3-61




Fig. 3-62

Front cover

Drum/toner ASSY

Printer

1

2

3

4

Paper tray

Separation pad ASSY

Hook Hook

Hooks

2

2

1

3 Separation pad spring


Confidential 3-36

(8) Remove the DX feed ASSY. NOTE: The DX feed tray is not provided for the HL-5240 printer.

Fig. 3-63

(9) Turn over the Printer. NOTE: • Pull out and put into the paper tray so that the Roller holder ASSY is lowered. • If the Roller holder ASSY is remained up, it cannot be removed.

(10) Remove the Lift arm from the Pin of the Roller holder ASSY.

Fig. 3-64

DX feed ASSY

Lift arm

Roller holder ASSY

Printer

Pin

2

1


Confidential 3-37

(11) Remove the Roller holder ASSY.

Fig. 3-65

Roller holder ASSY

Printer 1

2

3


Confidential 3-38


(1) Install the Roller holder ASSY.

Fig. 3-66

(2) Assemble the Lift arm onto the Pin of the Roller holder ASSY.

(3) Place the Printer on its base.

Fig. 3-67

Roller holder ASSY

Printer

Lift arm

Roller holder ASSY

Printer

Pin

1

2

3

1

2


Confidential 3-39

(4) Install the DX feed ASSY. NOTE: The DX feed tray is not provided for the HL-5240 printer.

Fig. 3-68


(6) Install the Drum /toner ASSY, and close the Front cover.

Fig. 3-69

DX feed ASSY

Printer

Drum /toner ASSY

Front cover

3

4 2

1


Confidential 3-40

(7) Set the Separation pad spring.

(8) Fix the Separation pad ASSY.

Fig. 3-70

NOTE: Check that the Separation pad spring is assembled correctly.


Fig. 3-71

Paper tray

Separation pad ASSY

Hook

Paper tray

Hook

Hooks

Separation pad spring

1

2

2

3


Confidential 3-41


Fig. 3-72

Printer

AC cord


Confidential 3-42

2.2.3 Paper feeding kit for MP tray < Uninstalling Procedure >


Fig. 3-73

(2) Pull out the Paper tray.

Fig. 3-74

Printer

AC cord

Paper tray


Confidential 3-43



Fig. 3-75

(5) Open the MP feed frame cover.

Fig. 3-76

Front cover

Drum/toner ASSY

Printer

MP feed frame cover

Front cover

1

2

3

MP feed frame


Confidential 3-44

(6) Remove the Holder bearing MP.

Fig. 3-77

(7) Remove the MP roller holder ASSY.

Fig. 3-78

Holder bearing MP

Hook

MP roller holder ASSY

Pin

3

2

1

MP feed frame

MP feed frame

Lift arm MP 1

2 3

4


Confidential 3-45

(8) Remove the Separation pad ASSY MP.

Fig. 3-79


MP feed frame

MP frame


Confidential 3-46


(1) Fix the Separation pad ASSY MP.

Fig. 3-80

(2) Install the MP roller holder ASSY.

Fig. 3-81



Pin

MP feed frame

MP frame

3

2

1

4

MP feed frame

Lift arm MP


Confidential 3-47

(3) Install the Holder bearing MP.

Fig. 3-82

(4) Close the MP feed frame cover.

Fig. 3-83

Holder bearing MP

Hook

MP feed frame cover

Front cover

MP feed frame

1

2 3

MP feed frame


Confidential 3-48

(5) Install the Drum /toner ASSY.


Fig. 3-84


Fig. 3-85

Paper tray

Drum /toner ASSY

Front cover

1

2


Confidential 3-49


Fig. 3-86

Printer

AC cord


Confidential 3-50

3. PERIODICAL CLEANING

Clean the outside and inside of the printer regularly with a dry soft cloth. When you replace the toner cartridge or the drum unit, make sure you clean the inside of the printer. If printed pages are stained with toner, clean the inside of the printer with a dry soft cloth.

! CAUTION: While drum/toner ASSY and scanner window cleaning can be implemented by the end user, the electrical terminals inside the printer and on the drum/toner ASSY should be cleaned by a service technician. Instruct the users not to touch those terminals.

WARNING There are high voltage electrodes inside the printer. Before cleaning the printer, make sure that the power switch has been turned off and the power cord has been unplugged from the power outlet.

3.1 Cleaning the Inside of the Printer (1) Turn off the printer power switch and then unplug the printer.

Fig. 3-87


Fig. 3-88


Confidential 3-51


Fig. 3-89

HOT SURFACE: After you have just used the printer, some internal parts of the printer will be extremely hot. Wait for the printer to cool down before you touch the internal parts of the printer.


disposable paper or cloth in case you accidentally spill or scatter toner. * Handle the toner cartridge carefully. If toner scatters on your hands or clothes, wipe or wash

it off with cold water at once. * To prevent damage to the printer from static electricity, DO NOT touch the electrodes shown



Confidential 3-52

(4) Wipe the scanner window with a dry, lint-free cloth.

Fig. 3-90

(5) Put the drum unit and toner cartridge assembly back in the printer.

(6) Close the front cover.

(7) Plug the printer back in, and then turn on the power switch.


Confidential 3-53

3.2 Cleaning the Corona Wire

! CAUTION: It is recommended to place the drum/toner ASSY on a piece of disposable paper or cloth in case you accidentally spill or scatter toner.

If you have print quality problems, clean the corona wire as follows:


Fig. 3-91


Fig. 3-92


Confidential 3-54




(3) Clean the primary corona wire inside the drum unit by gently sliding the blue tab from right to left and left to right several times.

Fig. 3-93

! CAUTION: Be sure to return the tab to the home position. If you do not, printed pages may have a vertical stripe.

(4) Put the drum unit and toner cartridge assembly back in the printer. Close the front cover.

Fig. 3-94

Home position


Confidential 4-1

CHAPTER 4 TROUBLESHOOTING

1. INTRODUCTION

1.1 Initial Check (1) Operating environment

Check if :

• The source voltage stays within ±10% from the rated voltage shown on the rating plate.

• The printer is installed on a solid, level surface.

• The room temperature is maintained between 10°C and 32.5°C. The relative humidity is maintained between 20% and 80%.

• The printer is not located in a dusty place.

• The printer is not exposed to ammonia fumes or other harmful gases.

• The printer is not located in a hot or humid area (such as near water or a humidifier).

• The printer is not exposed to direct sunlight.

• The room is well-ventilated.

• The printer is not placed where the ventilation hole of the printer is blocked.

(2) Print paper

Check if :

• A recommended type of print paper is being used. [If the paper is too thick or too thin, or tends to curl, paper jams or paper feed problems may occur, or printed images may be blurred.]

• The print paper is damp. [If so, use fresh paper, and check whether the print quality improves or not.]

• The print paper is short-grained paper or acid paper. [If so, print quality problems may occur.]

For further information on paper, refer to 3.6 “Paper” in Chapter 1.

(3) Consumable parts

Check if :

(HL-5240/5250DN)

• The LEDs on the printer control panel indicate “Toner Life End”. If the LEDs indicate “Toner Life End”, replace the toner cartridge with a new one.

(HL-5270DN/5280DW)

• The LCD shows “TONER LIFE END” the printer has run out of the toner is not evenly distributed inside the cartridge.

For further information on consumable parts, refer to 1. “CONSUMABLE PARTS” in Chapter 3.


Confidential 4-2

(4) Others

Condensation: When the printer is moved from a cold room into a warm room in cold weather, condensation may occur inside the printer, causing various problems as listed below:

• Condensation on the optical surfaces such as the scanning mirror, lenses, the reflection mirror and the protection glass may cause the print image to be light.

• If the exposure drum is cold, the electrical resistance of the photosensitive layer is increased, making it impossible to obtain the correct contrast when printing.

• Condensation on the corona unit may cause corona charge leakage.

• Condensation on the pressure plate and separation pad may cause paper feed troubles.

If condensation has occurred, print several pages or leave the printer for 2 hours to allow it to reach room temperature.

If the drum unit is unpacked soon after it is moved from a cold room to a warm room, condensation may occur inside the unit, which may cause incorrect images. Instruct the user to allow the unit to come to room temperature before unpacking it. This will take one or two hours.

1.2 Warning for Maintenance Work To avoid creating secondary problems by mishandling, follow the warnings below during maintenance work.

WARNING • Always turn off the power switch and unplug the power cord from the power outlet

before accessing any parts inside the printer. • Some parts inside the printer are extremely hot immediately after the printer is used.

When opening the front cover or back cover to access any parts inside the printer, never touch the shaded parts shown in the following figures.


Confidential 4-3

1.3 Identify the Problem If you encounter any printer error or problem, first identify it referring to the chart below, then see the appropriate section.

NOTE: The following troubleshooting sections contain both the actions which users should take or check and the ones which service technicians should perform.


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2. ERROR MESSAGE

2.1 Operator Calls 2.1.1 Operator calls for HL-5240/5250DN

When an operator call occurs, the red Status LED is blinking to indicate. An ‘operator call’ which the printer indicates on the LEDs is user recoverable. Identify the error from the table below and take the corrective action described for each indication to correct it. The printer automatically recovers from most errors, but some of errors are necessary to reset the printer by holding down the Go button.

LED Type of error Error clearance by pressing the

Go button. Remedy

Toner low ---

The Toner LED will turn on for 2 seconds and off for 3 seconds. Replace the toner cartridge.

Toner life end N/A Replace the toner cartridge with a new one.

Cartridge position error

N/A

The drum unit ASSY is not installed correctry. Put the drum unit ASSY back in.

Drum near end

---

The drum unit is near the end of its life. We recommend that you get a new drum unit to replace the current one. The Drum LED will turn on for 2 seconds and off for 3 seconds.

No paper fed tray N/A Put paper in the tray. Press the Go button.

Paper jam N/A

Clear the paper jam. If the printer does not start printing, press the Go button.

Incorrect Paper size for Duplex (HL5250DN/5270DN/ 5280DW)

Yes

Press the Go or Job Cancel. Set the correct paper that you want to use, or load the same paper size paper that you selected in the current driver setting. The paper size you can use doe automatic duplex printing is A4, Letter or Legal.

Duplex disabled Yes

Close the back cover of the printer and put the duplex tray back in.


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LED Type of error Error clearance by pressing the

Go button. Remedy

Front cover is open N/A Close the front cover of the printer.

Fuser cover is open N/A Close the back cover of the printer.

Dust on drum N/A The corona wire needs to be cleaned.

Too many trays N/A

Maximum number of optional trays is two. Remove additional trays.

Buffer error Yes

Check the cable connection between the PC and the printer.

Memory full Yes

The printer memory is full and the printer cannot print full pages of a document.

Print overrun Yes

A print overrun occurred and the printer cannot print full pages of a document.

Download full Yes

The download buffer or the printer is full. Add more memory to the printer.

Font full Yes

The font memory area is full. Delete fonts or add more memory to the printer.


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2.1.2 Operator calls for HL-5270DN/5280DW An “Operator call” which the printer indicates on the LCD display is user recoverable. Identify the error from the table below and take the corrective action described for each indication to correct it. The printer automatically recovers from most errors, but it may also be necessary to reset the printer with the control panel. The LCD names for the paper trays are as follows.

• Upper paper tray: TRAY 1 • Multi-purpose tray: MP • Optional Lower tray: TRAY 2 or TRAY 3

Error message Remedy

BUFFER ERROR Check the Interface settings.

CARTRIDGE ERROR The drum unit ASSY is not installed in properly. Take out the drum unit ASSY and put it back into the printer again.

DIMM ERROR Re-installed the DIMM correctly. Turn off the printer. Wait a few seconds, and then turn it on again. If this error message appears again, replace the DIMM with a new one.

DOWNLOAD FULL Add more memory.

DUPLEX DISABLED Close the back cover of the printer and put the duplex tray back in.

DUST ON DRUM Open the front cover. Take out the drum unit and toner cartridge ASSY. Gently slide the blue tab of the drum unit across several times.

FONT FULL Add more memory.

FRONT COVER OPEN Close the front cover of the printer.

FUSER COVER OPEN

Close the fuser cover located behind the back cover of the printer.

Fig. 4-1

JAM XXX Carefully pull out the jammed paper from the area shown in the “Paper jams and how to clear them” refer to 3.2 “Paper Jams” in this chapter.

MANUAL FEED Put the same size of paper in the MP tray as is shown on the LCD. If the printer is “paused”, press the Go button.

MEMORY FULL Add more memory.

NO PAPER

Put paper in the empty tray. If the error was not cleared when you put paper in the tray, match the size of paper that you selected in the application with the TRAY SIZE or set the TRAY SIZE to ANY using the control panel.


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NO PAPER XXX Put paper in the empty tray.

NO TRAY XXX Put the paper tray in the printer.

PRINT OVERRUN Cut the resolution or add the optional memory. Set Page Protection to the correct size.

SIZE ERROR DX You can only use A4, Letter and Legal size for duplex printing. Check the printer driver setting and put the correct sized paper in the paper tray or MP tray that is selected in the printer driver.

SIZE MISMATCH Put the same size paper in the paper tray or MP tray that is selected in the printer driver, and then press Go, or set the size of paper you loaded in by using the control panel.

STORAGE FULL The RAMDISK size is set to 0 MB. Increase the RAMDISK size. Or there is no space to store jobs. Delete unnecessary macros or fonts.

TONER LIFE END Replace the toner cartridge with a new one.

TOO MANY TRAYS Maximum number of optional trays is two. Remove additional trays.

Maintenance message Remedy

DRUM NEAR END The drum unit is near the end of its life. Replace it with a new one.

TONER LOW Buy a new toner cartridge and have it ready before you get a TONER LIFE END message.

TONER LIFE END Replace the toner cartridge with a new one.

REPLACE PF KITMP Replace the paper feeding kit (paper pick up roller and separation plate) for MP tray.

REPLACE PF KIT 1

REPLACE PF KIT 2

REPLACE KIT 3

Replace the paper feeding kit. (Paper feed roller, separation roller, separation pad, and separation pad spring)

REPLACE FUSER Replace the fuser unit.

REPLACE LASER Replace the laser unit.


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2.2 Service Calls 2.2.1 Service calls for HL-5240/5250DN

If service calls occur, all four LEDs blink on and off to notice it. In this state execute the operation described on the top of Table 1 to notify a fault location from the specific combination of ON/OFF and status color of the LED. Instruct the user to turn off the power switch, wait a few seconds and then turn it on again and try to print again. If the error is not cleared and the same service call appears, refer to 5. “MALFUNCTIONS” to take the corrective action.

Refer to 5. "MALFUNCTION".

NO

YES

Error occurs.

Error occurs again.

Comfirm the LED indication.

Turn OFF/ON the power switch.

Temporary error.Use the printer with out corrective action.


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<To show the service call type> If Go and Job Cancel buttons are pressed together, the LEDs will be lighted up as shown in the table below to identify the error.

LED Type of service call LED Type of service call

Fuser unit failure*1

Main PCB failure

Laser unit failure

Main motor failure

High voltage error

DIMM error *2

<Table 1> *1: If this error occurs, turn off the printer power switch, wait a few seconds, and then turn it on

again. Leave the printer for 10 minutes with the power on. *2: If this error occurs, ensure that the DIMM is installed correctly.


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2.2.2 Service calls for HL-5270N/5280DW When each of the following messages appears alternately on the LCD, a user unrecoverable error may have occurred. Instruct the user to turn off the power switch, wait 5 seconds and then turn it on again. If the error is not cleared and the same service call appears, identify the error from the table on the next page and take the corrective action described for each indication to correct it.

Error occurs.

Confirm the LCDindication.

Turn OFF/ON the power switch.

Error occurs again.

See section 5.'MALFUNCTIONS'.

Temporary error.Use the printer with-

out corrective action.

NO

YES

Error message (Print Settings) Error descriptions Remedy

ERROR S01 FATAL ERROR EX Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB.

ERROR S02 ADRL ERROR EX Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB.

ERROR S03 ADRS ERROR EX Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB.

ERROR S04 BUS ERROR EX (INSTRUCT) Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB.

ERROR S05 BUS ERROR EX (DATA L/S) Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB.

ERROR S06 SYSCALL EX Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB.

ERROR S07 BREAKPOINT EX Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB.

ERROR S08 RESERVED INSTRUCT EX Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB.

ERROR ### * * ### indicates the error codes.


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Error message (Print Settings) Error descriptions Remedy

ERROR S09 COPROCESSOR UNUSAB EX Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB.

ERROR S10 ARITHMETIC OVERFLOW EX Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB.

ERROR S11 UNDEFINED INTERRUPT Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB.

ERROR S12 SOFTWARE1 INTERRUPT Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB.

ERROR S13 SOFTWARE2 INTERRUPT Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB.

ERROR E49 FUSER UNIT MALFUNCTION Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB.

ERROR E50 FUSER UNIT MALFUNCTION Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB.

ERROR E51 LASER BEAM DETECTION ERROR

Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB.

ERROR E52 SCANNER MOTOR MALFUNCTION


ERROR E54 MAIN MOTOR LOCK ERROR Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB.

ERROR E55 HIGH-VOLTAGE POWER SUPPLY MALFUNCTION


ERROR H61 ROM CHECKSUM ERROR Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB.

ERROR H63 DRAM ACCESS ERROR Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB.

ERROR H66 NVRAM WRITE ERROR Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB.

ERROR H67 NVRAM READ ERROR Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB.

ERROR H68 NVRAM BUS ERROR Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB.

<Recovering from the service call> Turn off the printer. Wait a few seconds, then turn it on again. For an unrecoverable error, however, the printer detects a service call again and indicates it.


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2.3 Error Message in the Status Monitor The Status Monitor will report problems with the printer. Take the corrective actions listed in the following table for the error message that the Status Monitor reports. The default setting for the Status Monitor is off. If you would like to turn the status monitor on, you can change the setting of the Status Monitor in the Device Options of the Advanced tab.


Toner Low • Purchase a new toner cartridge and have it ready for when the Toner Life End status is indicated.

Toner Life End • Refer to 1.1 “Toner Cartridge” in chapter 3.

Cartridge Error • Take out the toner cartridge and put it back into the printer again.

Drum Near End • The drum is near the end of it's life. Purchase a new drum unit to replace the current one. Refer to 1.2 “Drum Unit” in chapter 3.

No Paper Fed Tray No Paper Fed Manual No Paper Multi Purpose Tray No Paper Tray 1/2/3

• The paper tray may be out of paper or not properly installed. If it is empty, put a new stack of paper in the paper tray and then press the Go button.

• If there is paper in the paper tray, make sure it is straight. If the paper is curled, straighten it before printing. Sometimes it is helpful to remove the paper, turn the stack over and put it back in the paper tray.

• Reduce the amount of paper in the paper tray, and then try again.

• Make sure you use paper that meets Brother’s recommended paper specifications. Refer to 3.6 “Paper” in chapter 1.

Jam MP Tray Jam Tray 1/2/3 Jam Inside Jam Rear Jam Duplex

• Take out the jammed paper from the indicated area. Refer to 3.2 “Paper Jams” in this chapter.

Incorrect Paper Size for DX

• Press the Go button or Job Cancel button. Set the correct paper that you want to use, or load the same size paper that you selected in the current driver setting. The paper size you can use for automatic duplex printing is A4, Letter or Legal.

Duplex Disabled • Close the back cover of the printer and put the duplex tray back in.

Front cover open • Close the front cover of the printer.

Fuser cover open • Close the fuser cover located behind the back cover of the printer.

Fig. 4-2


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Dust On Drum • Refer to 3.2 “Cleaning the Corona Wire” in chapter 3.

Print Overrun • Press the Go button to print the data left in the printer. Cancel the print job if you want to delete the data remaining in the printer.

• If this does not clear the error, reduce the complexity of your document or reduce the print resolution.

• Set page protection to AUTO by using the supplied Windows®

driver or Remote Printer Console program. • Change the following settings in the supplied Windows®

driver and try again. The best combination of these settings will vary depending on your document:

• Graphics Mode • TrueType mode • Use Printer TrueType® Fonts

Service Call Error • Check the LED indication or the LCD message to identify the error. Refer to 2.2 “Service Calls” in this chapter.


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2.4 Error Message Printouts The printer will report problems by printing an error message as defined in the following table. Take the corrective actions for the error message.


MEMORY FULL

• Press the Go button to print the data left in the printer. Cancel the print job if you want to delete the data remaining in the printer.

• Reduce the print resolution or reduce the complexity of your document.

• Add more memory.

PRINT OVERRUN • Press the Go button to print the data left in the printer. Cancel the print job if you want to delete the data remaining in the printer.

• If this does not clear the error, reduce the complexity of your document or reduce the print resolution.

• Add more memory. • Set page protection to AUTO by using the supplied

Windows® driver or Remote Printer Console program.

• Change the following settings in the supplied Windows®

driver and try again. The best combination of these settings will vary depending on your document:

• Graphics Mode • TrueType mode • Use Printer TrueType® Fonts

RESOLUTION REDUCED TO ENABLE PRINTING (The printer has printed the document at a reduced resolution)

• Reduce the complexity of your document before you print to prevent automatic reduction in the resolution.

* NOTE: The communication parameter settings are printed on the Print Settings sheet. For details on how to print the Print Settings page, refer to “Print Settings” in Chapter 7.


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3. PAPER PROBLEMS

3.1 Paper Loading Problems First, make sure that you are using paper that meets Brother recommended paper specifications. Refer to 3.6 “Paper” in Chapter 1.

Problem Remedy

The printer does not feed paper.

• If there is paper in the paper tray, make sure it is straight. If the paper is curled, straighten it before printing. Sometimes it is helpful to remove the paper, turn the stack over and put it back in the paper tray.

• Reduce the amount of paper in the paper tray, and then try again.

• Check that manual feed mode is not selected in the printer driver.

The printer does not feed paper from the MP tray.

• Fan the paper well and put it back in firmly. • Make sure that you have chosen the MP Tray in the

Paper Source pf the printer driver.

The printer does not feed envelopes.

• The printer can feed envelopes from the multi-purpose tray. Your application software must be set up correctly to print on the envelope size you are using. This is usually done in the page setup or document setup menu of your software. Please see your software application manual.

A paper jam has occurred. • Clear the jammed paper. Refer to 3.2 “Paper Jams” in this Chapter.

When printing on normal paper, it creases.

• Change the printer driver setting in Media Type to a thin setting.

When printing on Legal size paper or longer sized paper, the paper slides off the top output tray.

• Pull out and lift up the output tray support flap.

Fig. 4-3


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3.2 Paper Jams NOTE: Refer to the Cautions described in the following pages.

3.2.1 Paper jams and how to clear them for HL-5240/5250DN If a paper jam occurs, the printer will flash the Paper LED as shown below.

Fig. 4-4

Clear the jammed paper as follows. If the jammed paper is removed completely by following the steps below, you can install the paper tray first, and then close the front cover. The printer will resume printing automatically. If the printer does not start printing automatically, press the Go button. If the printer still does not start printing, please check that all the remaining jammed paper has been removed from the printer. Then try printing again.

NOTE: Always remove all paper from the paper tray and straighten the stack when you add new paper. This helps to prevent multiple sheets of paper from feeding through the printer at one time and reduces paper jams.

(1) Press the cover release button and then open the front cover.

(2) Slowly take out the drum unit and toner cartridge ASSY. The jammed paper will be pulled out with them drum unit and toner cartridge ASSY.

(3) Pull the paper tray completely out of the printer.


(5) Pull the jammed paper up and out of the printer.

(6) Open the front cover again.

(7) Open the back cover.

(8) Pull the tabs at the left and right hand sides toward you to open the fuser cover.

(9) Pull the jammed paper out of the fuser unit. If the jammed paper cannot be pulled out easily, push down the blue tab with one hand as you gently pull the paper out with the other.

(10) Close the back cover.

(11) Pull the duplex tray completely out of the printer.

(12) Pull the jammed paper out of the printer or the duplex tray. Put the duplex tray back in the printer.


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(13) Push down the blue lock lever and take the toner cartridge out of the drum unit. Clear the jammed paper if there is any inside the drum unit.

(14) Put the toner cartridge back into the drum unit until you hear it lock into place. If you put the cartridge in properly, the blue lock lever will lift automatically.

(15) Pull the drum unit and toner cartridge ASSY back in the printer.

(16) Put the paper tray firmly back in the printer.


(18) Make sure that the Paper LED is now off and the printer is ready.


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3.2.2 Paper jams and how to clear them for HL-5270DN/5280DW If paper jams inside the printer, the printer will stop. One of the following LCD messages will appear to tell you where to find the jammed paper.

5

1

2

3

4

6

7

Fig. 4-5

1. JAM MP TRAY : Paper jam in the MP tray.

2. JAM TRAY1 : Paper jam in the upper paper tray (TRAY 1).

3. JAM TRAY2 : Paper jam in the lower tray (TRAY 2).

4. JAM TRAY3 : Paper jam in the lower tray (TRAY 3).

5. JAM INSIDE : Paper jam inside the printer.

6. JAM REAR : Paper jam where the paper comes out of the printer.

7. JAM DUPLEX : Paper jam in the duplex tray.

Check where the jam is and clear the jammed paper as follows.

If the error message still appears on the LCD after you remove the jammed paper, there may be more paper jammed somewhere else. Check the printer thoroughly.

After you have removed all the jammed paper, open the front cover and then close it again to start printing.

NOTE: Always remove all paper from the paper tray and straighten the stack when you add new paper. This helps prevent multiple sheets of paper from feeding through the printer at one time and prevents paper jams.


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1. JAM MP TRAY (Paper jam in the MP tray)

JAM MP TRAY

If a paper jam occurs inside the MP tray, follow these steps:

(1) Press the cover release button and then open the front cover. (2) Take out the drum unit and toner cartridge ASSY. (3) Remove the paper from the MP tray. (4) Fan the paper stack, then put it back in the MP tray.

Fig. 4-6

(5) When loading paper in the MP tray, make sure that it touches the back of the tray and stays under the maximum paper height guides on both sides of the tray.

(6) Open the front cover and close it, or press Go button to start printing.

2. JAM TRAY 1 / TRAY 2 / TRAY 3 (Paper jam inside the paper tray) NOTE: The LCD names for the paper trays are as follows. • Upper paper tray: TRAY1 • Optional Lower tray: TRAY2 or TRAY3

JAM TRAY1

JAM TRAY2

JAM TRAY3

If a paper jam occurs inside the paper tray, follow these steps:

(1) Pull the paper tray completely out of the printer.

Fig. 4-7


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(2) Use both hands to slowly pull out the jammed paper.

Fig. 4-8

(3) Put paper below the maximum paper mark ( ). While pressing the blue paper-guide release lever, slide the paper guides to fit the paper size. Make sure that the guides are firmly in the slots.

(4) Put the paper tray firmly back in the printer. (5) Open the front cover and close it to resume printing.

! CAUTION: DO NOT take out the upper paper tray while paper is feeding from a lower paper tray because this may cause a paper jam.

3. JAM INSIDE (Paper jam inside the printer)

JAM INSIDE

HOT SURFACE: After you have just used the printer, some internal parts of the printer will be extremely hot. When you open the front cover or back cover of the printer, DO NOT touch the shaded parts shown in the illustrations.


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If a paper jam occurs inside the MP tray, follow these steps:


Fig. 4-9

(2) Slowly take out the drum unit and toner cartridge ASSY. The jammed paper will be pulled out with the drum unit and toner cartridge ASSY.

Fig. 4-10

! CAUTION: * After you have removed the jammed paper, print a few test pages. This is to make sure that

the printed pages have no toner stains on them before you restart the print job. * Remove the jammed paper carefully so you do not spread toner. * Take care not to stain your hands and clothes with toner. Wash toner stains at once with

cold water. * We recommend that you put the drum unit and toner cartridge ASSY on a piece of

disposable paper orcloth in case you accidentally spill the toner. * To prevent damage to the printer caused by static electricity, DO NOT touch the electrodes

shown in the illustration.


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(3) Push down the blue lock lever and take the toner cartridge out of the drum unit. Clear the jammed paper if there is any inside the drum unit.

Fig. 4-11


it off with cold water at once. * To avoid print quality problems, DO NOT touch the shaded parts shown in the illustrations.

(4) Put the toner cartridge back into the drum unit until you hear it lock into place. If you put the cartridge in properly, the blue lock lever will lift automatically.

Fig. 4-12



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4. JAM REAR (Paper jam behind the back cover)

JAM REAR

HOT SURFACE: After you have just used the printer, some internal parts of the printer will be extremely hot. When you open the front cover or back cover of the printer, DO NOT touch the shaded parts shown in the illustrations.

If a paper jam occurs behind the face-up output tray, follow these steps:

(1) Press the cover release button and then open the front cover.

Fig. 4-13

(2) Slowly take out the drum unit and toner cartridge ASSY. The jammed paper will be pulled out with the drum unit and toner cartridge ASSY.

Fig. 4-14


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! CAUTION: * We recommend that you put the drum unit and toner cartridge ASSY on a piece of



(3) Open the back cover.

Fig. 4-15

(4) Pull the tabs at the left and right hand sides toward you to open the fuser cover (1).

1 Fig. 4-16

(5) Using both hands, gently pull the jammed paper out of the fuser unit.

HOT SURFACE: After you have just used the printer, some internal parts of the printer will be extremely hot. Wait for the printer to cool down before you touch the internal parts of the printer.


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(6) Close the back cover. (7) Put the drum unit and toner cartridge ASSY back in the printer (press firmly). (8) Close the front cover.

5. JAM DUPLEX (Paper jam in the duplex tray)

JAM DUPLEX

If a paper jam occurs inside the duplex tray, follow these steps:

(1) Pull the duplex tray completely out of the printer.

Fig. 4-17

(2) Pull the jammed paper out of the printer or the duplex tray.

Fig. 4-18

(3) Put the duplex tray back in the printer.


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3.2.3 Causes & countermeasures The causes for paper jam problems vary depending on the location of the paper jam. When a paper jam occurs inside the printer, you have to find the location of the paper jam first, remove the jammed paper and then take the appropriate countermeasure referring to the table below;

Problem Type of Jam Cause Remedy

Jam when the printer is turned on.

Paper stuck The regist front sensor or paper eject sensor is turned on.

Remove the paper inside the printer. If there is no paper, check the suspect sensors refer to “Factory Inspection Mode” in Chapter 7.

Paper stopped in the middle of feeding.

Jam caused by paper length detected as longer than 410mm (16 in).

The regist front sensor is not returning properly and is not turning off.

Check front registration sensor motion refer to “Factory Inspection Mode” in Chapter 7.

Bottom of paper stopped around the transfer roller.

Jam caused by paper length detected as shorter than 80mm.

The regist front sensor was turned off early. Malfunction of actuator or hardware noise.

Check the front registration sensor refer to “Factory Inspection Mode” in Chapter 7.

Top of paper stopped between the paper feed roller and the pick-up roller.

Jam caused by a paper feed delay.

Paper was not fed in at the proper timing due to paper dust or wear of the rubber pick-up roller.

Remove the paper dust attached to the pick-up roller. If the rubber is worn out, replace it with a new one.

Top of paper stopped at 60mm from the contact point of the heat roller and pressure roller.

Jam caused by the paper not being sensed when ejected from the paper eject sensor.

The paper eject sensor is not working properly and has not turned off. (single printing)

Check sensor motion refer to “Factory Inspection Mode” in Chapter 7.

Jam after paper is ejected.

Jam caused by the paper not being sensed when ejected from the paper eject sensor.

The paper eject sensor or front registration sensor is not working properly and has not turned off. (continuous printing)

Check sensor motion refer to “Factory Inspection Mode” in Chapter 7.


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3.3 Paper Feeding Problems Even if the paper is printed and ejected without any problems such as paper jams, paper feeding problems below may appear.

Users can clear these problems by following the ‘User Check’ items for each problem. Even if the same problem occurs again, follow the procedures in the table below.

(1) Double feeding

User Check Check the paper used meets the recommended paper specifications. (Refer to 3.6 “Paper” in Chapter 1.)

Possible cause Step Check Result Remedy

Separation pad 1 Is the surface of the separation pad worn out?

Yes Replace the separation pad.

(2) Wrinkles or creases

User Check (1) Check that paper is loaded into the paper tray correctly.

(2) Check the paper used meets the recommended paper specifications. (Refer to 3.6 “Paper” in Chapter 1.)

(3) Try printing using the straight-through output path.

(4) Turn over the stack of paper in the tray or try rotating the paper 180° in the tray.

(5) For the envelope, check the setting of the nip action in the fuser unit.


Paper 1 Is the problem solved if new paper is used?

Yes Instruct the user how to store paper so that it does not absorb moisture.

Fuser unit entrance guide

2 Is the entrance guide dirty? Yes Clean the entrance guide.

Fuser unit 3 Is the pressure roller dirty? Yes Clean the pressure roller. No Replace the fuser unit.

(3) Page skew

User Check (1) Check that the paper or other media is loaded into the paper tray correctly and that the paper

guides are not too tight or too loose against the paper stack.

(2) If using the manual feed slot, check how to load paper into the manual feed slot correctly.

(3) The paper tray may be too full. Load paper below mark in depth.

(4) Check the paper used meets the recommended paper specifications. (Refer to 3.6 “Paper” in Chapter 1.)

(5) Check that the levers on the left and right hand sides for the nip action in the fuser unit are nipped equally.


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(4) Curl or Wave

User Check (1) Check the paper used meets the recommended paper specifications. Both high temperature and humidity will cause paper to curl.

(2) If the printer is used infrequently, the paper may have sat for too long in the paper tray. Turn over the stack of paper in the paper tray. Also, try rotating the paper 180° in the paper tray.

(3) Check that the paper used meets the Media Type setting in the driver.

NOTE: For no paper supplied as the cause of a malfunction, refer to 5. “MALFUNCTIONS” in this chapter.

(6) Prints only single side of the paper when duplex-printing

User Check Check the size of the paper used meets the recommended paper specifications (A4 or Letter, Legal).

(6) Paper pickup


Disconnection of the pickup solenoid harness

1 Is the harness of the pickup solenoid disconnected?

Yes Reconnect the harness.

Pickup solenoid harness failure

2 Does the harness of the pickup solenoid work correctly?

No Replace the pickup solenoid.

Pressure plate gear damage

3 Is the pressure plate gear damaged?

Yes Replace the pressure plate gear.

Clutch gear damage

4 Is the clutch gear damaged? Yes Replace the gear unit.


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4. SOFTWARE SETTING PROBLEMS

The printer may not print the data correctly if there are incorrect software settings.

(1) “There was an error writing to LPT1: (or BRUSB) for the printer” error message appears.

User Check (1) Check that the printer cable is not damaged or broken. Check also that the cable is connected

to the correct interface connectors of both the printer and PC.

(2) Check that the correct printer is selected if you have an interface switching device.

(3) Check that the appropriate printer driver is selected as ‘Set as Default’. Check also that the correct print port is set for the selected printer driver.

(4) Check that the printer is not connected to the same port which is also connected to a mass storage device or scanner. Remove all other devices and connect the port to the printer only. Turn off the printer status monitor in the device options tab in the printer driver.

(5) If the print port is set as an ECP port, change it to a normal port.

(6) Try printing the test page refer to ‘Test Sample Page’ in Chapter 7.

(7) Try resetting the factory settings.


Failure inside the printer

1 Is it possible to print the test page with the method of ‘Test Sample Page’ in Chapter 7.?

No Identify the error type, then refer to the specified section of this chapter.

Main PCB failure

2 Is it possible to print with another PC and printer cable?

No Replace the main PCB.

Yes This problem may appear under the specified system environment. Check the environment which the user used.


Confidential 4-30

(2) Although the USB driver is installed, it is unable to find the BRUSB: port. (Windows98/Me only)

User Check (1) Re-install the USB driver by following the steps below;

i) Turn the printer off. ii) Double-click the file “Deins USB.exe” in the USB directory of the CD-ROM. iii) Re-boot the PC. iv) Turn the printer on. v) “Add New Hardware Wizard” is launched again, follow the instructions in the Wizard to

re-install the driver. (2) Try to connect the printer directly to the computer if it is connected through a USB hub.


Computer Operating System

1 Windows 95 or Windows NT4.0?

Yes The operating system does not support USB.

Computer settings

2 Does ‘Universal Serial Bus Controllers’ appear in the Device Manager tab of ‘System Properties’ in Control Panel?

No This problem can be caused by your computer settings. See the computer manual.

USB cable/ printer damage

3 Does “Add New Hardware Wizard” appear on the screen or Does test print complete?

No The USB cable is damaged. Replace the cable. If the same problem appears, the printer will be damaged.

(3) The print speed slows down under BR-Script 3

User Check

Add optional memory.

(4) Unable to print EPS data under BR-Script 3.

User Check Follow the steps below;

(1) In the printer folder, choose the printer you use.

(2) Press the Advanced button on the Post Script® tab.

(3) Choose Tagged binary communication protocol in data format.

! CAUTION: Not following the instructions for using the printer may cause you to be responsible for all repairs.


Confidential 4-31

(5) This printer does not appear in Chooser (Mac OS® 9.1 to 9.2), Print center (Mac OS® X 10.2) or Printer Setup Utility (Mac OS® X 10.3 or greater).

User Check (4) Check the printer is turned on.

(5) Check the USB cable is connected correctly.

(6) Check the printer driver is installed correctly.


Printer connection

1 Select ‘Apple System Profiler’ in Apple Menu. Are the following items indicated in the USB box of the Device and Volumes tab? • Product ID: 002A (HL-5240),

002B (HL-5250DN), 002C (HL-5270DN), 002D (HL-5280DW)

• Vender: Brother International Corporation (or 0x4f9)

No Check the printer is turned on and the USB cable is connected correctly. Check that the USB cable used is the shielded twisted pair type and 5 m or less. Try to connect the printer and PC with the USB cable directly.

Driver installation

2 Are there the following files in the Extensions Folder of System Folder?

No Try to re-install the printer driver.

<For System 9.1 – 9.2> • BR_PrintMoniter (laser) • Brother Laser

Yes Turn off the printer and PC power switch, and check all connections between them. Then, turn them on again.

(6) Unable to print from the application when using Macintosh with USB

User Check Make sure that the supplied Macintosh® printer driver is installed in the Hard Disk and that it is selected with Chooser (Mac OS® 9.1 to 9.2), Print Center (Mac OS® X 10.2.4 or greater) or Print Setup Utility (Mac OS® X 10.3 or greater).

(7) Unable to print from the application software under DOS.

User Check (1) Make sure that the DOS application interface settings match those of your printer. For example, if you are using a parallel printer cable, you would set your DOS application printer port to LPT1.

(2) Check if the printer has any printer alarms.

(3) Make sure that you have chosen the proper printer in your application.


Confidential 4-32

5. MALFUNCTIONS

When taking countermeasures for malfunctions as described in this section, check connectors for contact failure before measuring the voltage at the specified connector pins.

(1) No AC power supplied


Supply voltage 1 Is the correct voltage present at the outlet?

No Inform the user that the correct voltage is not supplied at the outlet.

Power plug 2 Is the power cord securely plugged into the outlet?

No Plug the power cord securely into the outlet.

Fuse (F1, F2) 3 Is the fuse blown? Yes If the fuse blows again immediately after replacing the low-voltage power supply PCB, check that there is not a short circuit somewhere in the AC power supply line.

Wiring 4 Unplug the power supply plug. Is there a broken wire between the AC input connector of the low-voltage power supply and the power plug?

Yes Replace the AC power cord.

(2) No DC power supplied


AC power supply

1 Is AC power supplied between connectors CN1-L and CN1-N when the power plug is plugged into the outlet?

No Follow the same check procedure of (1) “No AC power supplied”.

Wiring, DC load 2 Turn on the power switch. Measure the voltages between the terminals. Do the measured voltage satisfy the prescribed valued in the table below?

Yes Turn off the power switch, reconnect the connector and turn the power switch on again. If the protector circuit is activated, check the connector, the wiring from the connector, and the DC load.

Low-voltage power supply PCB

3 Refer to the chart *1 below. No Replace the low-voltage power supply PCB.

*1 PCB +lead pin - lead pin Voltage

Main CN8-4 CN8-5 CN8-6 CN8-7

CN8-2, CN8-3 CN8-2, CN8-3 CN8-8 CN8-8

Approx. 24V Approx. 24V Approx. 6.5V to 13V Approx. 3.3V


Confidential 4-33

WARNING If you analyze malfunctions with the power plug inserted into the power outlet, special caution should be exercised even if the power switch is OFF because it is a single pole switch.

(3) Main motor failure


Failure of connector

1 Is the connection of connector CN4 on the main PCB correct?

No Reconnect the connector.

Main motor 2 Is the problem solved by replacing the main motor?

Yes Replace the main motor.

Main PCB 3 Is the problem solved by replacing the main PCB?

Yes Replace the main PCB.

(4) No paper supplied


Separation pad / pickup roller failure

1 Is the surface of the separation pad or the pickup roller dirty or worn out?

Yes 1) Clean the surface of the separation pad or pickup roller.

2) Replace the separation pad or pickup roller.

Failure of connector

2 Is the contact of the solenoid connector on the relay front PCB good?


HVPS circuit Set paper in the manual feed slot and make a test print by pressing the Go button.

Yes Replace the relay front PCB.

Paper pickup clutch solenoid

3

Does the voltage between pins 1(SOLENOID) and 2 (24V) of the CN1 TRAY1, CN3 MP connector on the relay front PCB change from approx. 24V DC to 0V within the specified time?

No Replace the paper pickup clutch solenoid.

Main PCB 4 Is the problem solved by replacing the main PCB?



Confidential 4-34

(5) Insufficient output from high-voltage power supply unit


High-voltage contact

1 Do any of the terminals on the high-voltage contacts have dirt or contact burns?

Yes Clean the terminals.

Yes Replace the high-voltage power supply PCB.

High-voltage power supply PCB

2 Check the connections of the connector between the high-voltage power supply and the main PCB are secured correctly?

No Reconnect the connector between the high-voltage power supply and the main PCB.

(6) Fixing heater temperature failure


1 Is the contact of connector CN1 and CN2 on the relay rear PCB good?

No Reconnect the connector. Poor thermistor harness contact

2 Is the contact of connector CN3 on the main PCB good?


Blown thermostat

3 Remove the fuser unit and measure the resistance of the thermostat. Is it open circuit?

Yes Replace the fuser unit.

Halogen heater lamp failure

4 Remove the fuser unit and measure the resistance of the halogen heater lamp. Is it open circuit?


(7) Laser Unit failure


No Reconnect the connector securely.

Harness connection failure (1)

1 Is connector CN18 on the main PCB secured correctly?

Yes Replace the laser unit. No Reconnect the connector

securely. Harness connection failure (2)

2 Is the connection of the scanner motor connector CN10 on the main PCB secure? Yes Replace the laser unit.


Confidential 4-35

(8) Fuser unit failure


1 Is the contact of connector CN1 and CN2 on the relay rear PCB good?

No Reconnect the connector. Poor thermistor harness contact

2 Is the contact of connector CN3 on the main PCB good?


Yes Replace the fuser unit. Thermistor assembling failure

3 Is the thermistor installed properly? No Reinstall the thermistor

properly.

Halogen heater lamp failure

4 Remove the fuser unit and measure the resistance of the halogen heater lamp. Is it open circuit?


Heater harness connection failure

5 Is the heater harness connector connected to the low-voltage power supply PCB and fuser unit secure?

No Reconnect the connectors securely.

NOTE: • This problem will be cleared if leaving the printer power ON for ten minutes. • If the heater is cooled down sufficiently, this problem may be cleared by turning on the

printer power switch while pressing the Go button. Be warned, however, that this operation will melt the fuser unit if the heater is hot.

(9) Main PCB failure


Main PCB 1 Is it possible to print the test page with the method of ‘Test Sample Page’ in Chapter 7?


Software bug 2 Does this problem appear when printing specific data or printing under a specific environment?

Yes Inform the Brother office of the used specific data, printer condition and system environment.


Confidential 4-36

(10) Pickup function of paper tray does not work


Link lever does not move smoothly.

1 Does the link lever work? Isn't the link lever bent?

Yes Remove the cause of non-smooth operation of the link lever. Replace the link lever.

Pickup roller holder ASSY does not move smoothly.

2 Does the pickup roller holder ASSY move up and down?

No Replace the pickup roller holder ASSY.

Main motor failure

3 Does the main motor work? No Replace the main motor.

Pressure plate drive cam failure

4 Does the pressure plate drive cam rotate?

No Replace the main frame L ASSY.

(11) The new toner is not sensed


The toner cartridge is not set to the main body correctly.

1 The toner cartridge is not inserted completely.

Yes Reset the cartridge.

New toner detection switch failure

2 Isn't the toner sensed even if the switch is held?

Yes Replace the switch.

Main PCB failure

3 Is the problem solved by replaceing the main PCB?


(12) Maximum speed is slow


Two or more sheets of the paper in the tray are pulled to feed.

1 Does paper double feeding occur?

Yes Replace the separation pad.

Foreign body attached to the tail edge actuator

2 Is a foreign body caught on the tail edge actuator?

Yes Remove a foreign body.

Tail edge actuator failure

3 Is the tail edge actuator deformed?

Yes Replace the tail edge actuator.

Tail edge sensor malfunction

4 Is the tail edge sensor turned ON?

Yes Replace the tail edge sensor.


Confidential 4-37

(13) LED failure


Three LEDs light up after turning the power ON.

A1 Is the printer in the service mode?

Yes Check that the Go button has been pressed or not.

Panel PCB failure

A2 Does any LED light up when pressing the Go button?

No Replace the panel PCB.

Disconnection of the panel PCB harness

B1 Is the harness connected securely?

No Reconnect the harness securely.

Regist front sensor failure

B2 Does the regist front sensor work correctly?

No Replace the regist front sensor.

Regist rear sensor failure

B3 Does the regist rear sensor work correctly?

No Replace the regist rear sensor.

Paper eject sensor failure

B4 Does the paper eject sensor work correctly?

No Replace the paper eject sensor.

Main cover switch malfunction

B5 Is the main cover switch closed securely?

Yes Check the switch.

(14) Service error indication when turning the power ON


Disconnection of the main motor harness

1 Is the harness of the main motor connected?


Disconnection of the scanner motor harness

2 Is the harness of the scanner motor connected?


Fuser unit failure 3 Does the printer resume after opening the cover, turning the power ON and leaving the printer for ten minutes?

No Replace the thermistor.

(15) The printer stops while idling


Front cover failure

1 Is the cover opened by vibration during idling?

Yes Replace the front cover.

New toner detection switch failure

2 Does the new toner detection switch work correctly?

No Replace the new toner detection switch.

Process unit terminal failure

3 Are the terminals of the process unit dirty?

Yes Clean the terminals.

Laser unit failure 4 Does the laser unit work correctly?

No Replace the laser unit.


Confidential 4-38

6. IMAGE DEFECTS

6.1 Image Defect Examples

I-2 DarkI-1 Light I-2 Dark I-3 Completely blank I-4 All black I-5 Dirt on back of paper

I-6 Black vertical streaks

I-6 Black verticalstreaks

I-7 Black horizontalstripes

I-12 Poor fixing I-13 Image distortion I-14 Faint print

Print out test print out test print out test Print out test print o


Print out test print o












































































I-19 Hollow printI-15 White spots I-16 Black spots I-18 Gray backgroundI-17 Black band

I-20 Downward fogging

of solid blackI-21 Horizontal lines

I-11 Faulty registration

I-10 White horizontalstreaks

I-8 Black verticalstreaks

I-9 White verticalstreaks

I-23 GhostI-22 Light rain I-24 Toner specks

Fig. 4-19

6.2 Diameter of Rollers

The diameter of each roller and the pitch which appears in the image are listed below.

No. Parts Name Diameter (The pitch which appears in the image)

1 Paper Feed Roller Ø 14.0 mm (44.0 mm)

2 Transfer Roller Ø 15.2 mm (48.2 mm)

3 Exposure Drum Ø 30.0 mm (94.2 mm)

4 Heat Roller Ø 25.0 mm (78.5 mm)

5 Pressure Roller Ø 25.0 mm (78.5 mm)

6 Developer Roller Ø 20.0 mm (42.7 mm)


Confidential 4-39

6.3 Troubleshooting Image Defect Several types of the image defects can be cleared by end users. For those defects, instruct the user to check the ‘User Check’ items described in each table. Even if the same image defect appears, the following procedures should be followed in the event of specific image defects.

See also 6.4 “Location of Ground Contacts” in this Chapter for information about the location of the grounding contacts.

! CAUTION: When using the printer for a special job, such as printing of name cards, print quality cannot be guaranteed.

(I-1) Light

Possible cause Step Check Result Remedy Ground contacts

Toner sensor failure (printer side)

1 Can printing be started with the drum unit and toner cartridge removed?

Yes Check if the toner sensor is dirty and check the toner sensor connection.

Toner sensor failure (toner cartridge side)

2 Is the problem solved when 4 or 5 pages are printed after the toner cartridge is replaced with a full one?

Yes The wiper of the toner cartridge is defective. Replace the toner cartridge.

Drum connection failure

3 Are all the contacts between the drum unit and printer body connected correctly?

No Clean contact electrodes both on the drum unit and in the printer body.

(1), (4),

(5), (6)

HVPS / Main PCB failure

4 Is the harness connection between the HVPS and the main PCB correct?

Yes Replace the HVPS or the main PCB.

Dirt on the scanner window

5 Is there any dirt on the scanner window?

Yes Wipe it off with a soft clean paper.

Laser unit failure 6 Is the problem solved after replacing the laser unit?

Yes Replace the laser unit.

User Check (1) Check the printer’s environment. Conditions such as humidity, high

temperatures, etc. may cause this situation to occur.

(2) If the whole page is light, toner save mode may be on. Disable toner save mode within Printer Properties tab of the driver.

(3) Try installing a new toner cartridge or drum unit.


Confidential 4-40

(I-2) Dark


Corona failure (contact failure)

1 Are the charge electrodes between the printer body and the drum unit dirty?

Yes Clean both electrodes. (3)

Drum unit failure 2 Is the problem solved after replacing the drum unit?

Yes Replace the drum unit with a new one.

Toner cartridge failure

3 Is the problem solved after replacing the toner cartridge?

Yes Replace the toner cartridge with a new one.

High-voltage power supply PCB failure

4 Is the connections of the connector between the high-voltage power supply PCB and the main PCB secured correctly?


Main PCB failure

5 Are there any disconnected connectors?


User Check (1) Check the paper used meets the recommended paper specifications.

(2) Check the printer’s environment. High temperature and high humidity conditions can increase the amount of background shading.

(3) Clean the corona wire with the wire cleaner.

(4) Try installing a new toner cartridge or drum unit.


Confidential 4-41

(I-3) Completely blank


Developing bias contact failure

1 Are the developing bias contacts between the printer body and drum unit dirty?

Yes Clean the electrodes at both sides. (4)

Yes Clean the shaft and the electrode. (1) Drum unit 2 Are the drum shaft and drum

electrode of the printer body connected correctly? No Check the connection

between the shaft and the electrode.

(1)


Yes Replace the drum unit.




Scanner harness connection failure

5 Is the scanner harness connected securely? (Check if there is any play in the connection.)

No Reconnect the connector correctly.

Main PCB failure

6 Are printing signals being input to the laser unit?

Is the problem solved after replacing the main PCB?


Yes Replace the laser unit. Laser unit failure 7 Is the scanner interlock lever damaged? Is the scanner mirror broken or loose?

No Replace the high-voltage power supply PCB.


Confidential 4-42

(I-4) All black


1 Is the corona wire dirty? Yes Clean the corona wire with the wire cleaner. (2)

2 Is the corona wire broken? Yes Replace the drum unit.

Corona failure



Harness connection

4 Is the laser unit connected to the main PCB correctly?

No Connect the harness between the laser unit and the main PCB correctly.


5 Is the problem solved after replacing the high-voltage power supply PCB?


Main PCB failure

6 Is the problem solved after replacing the main PCB?


Laser unit failure 7 Is the problem solved after replacing the laser unit?


User Check (1) Clean the corona wire of the drum unit. (2) The drum unit may be damaged. Install a new drum unit.


Confidential 4-43

(I-5) Dirt on the back of paper


Fuser unit dirty 1 Is the pressure roller dirty?

Is any other area in the printer dirty?

Yes Clean the pressure roller referring to the following procedure.

Yes Replace the drum unit Dirt in the drum unit

2 Is the transfer roller dirty?

Is the problem solved after replacing the drum unit?


NOTE: This problem may disappear after printing approximately 10 pages of completely blank sheets.

How to clean the pressure roller Clean the pressure roller as follows;

(HL-5240/5250DN)

(1) Set five or more sheets of paper in the paper tray.

(2) Open the front cover, and turn on the power switch while holding down the Go button.

(3) All LEDs light up, and keep the Go button pressed down until the Status LED goes off. Then, release the Go button and make sure that all LEDs are off.

(4) Press the Go button once and make sure that Toner, Drum and Paper LEDs light up.

(5) Press the Go button twice and wait for two seconds. Then, the printer starts printing the grid pattern continuously.

(6) Close the front cover, and print approximately five pages.

(7) Press the Job Cancel button after printing.

(HL-5270DN/5280DW)

(1) Set five or more sheets of paper in the paper tray.

(2) Open the front cover, and turn on the power switch while holding down the Go button.

(3) “USERS MODE” message appears on the LCD panel.

(4) Release the Go button and make sure that all LEDs are off.

(5) Press the Go button once and make sure that “USERS MODE” message appears on the LCD panel with the orange backlight.

(6) Press the Go button twice and wait for two seconds. Then, the printer starts printing the grid pattern continuously.

(7) Close the front cover, and print approximately five pages.

(8) Press the Job Cancel button after printing.


Confidential 4-44

(I-6) Black and blurred vertical streaks


Corona failure 1 Is the corona wire dirty? Yes Clean the corona wire with the wire cleaner.

Corona failure 2 Is the vertical block streak about 10mm wide? (Check if the wire cleaner is at its home position.)

Yes Return the wire cleaner to its home position.

Dirt in the paper feed system

3 Is the paper tray or feed system on the drum unit dirty with toner?

Yes Clean the toner off.

Scratch on the drum

4 Is the surface of the drum scratched?


Cleaning failure 5 Is the surface of the drum dirty with toner in streaks?


Scratch on the heat roller

6 Is the surface of the heat roller scratched?


NOTE: • If you print the same pattern (especially vertical streaks) continuously, electrostatic charge

performance of the drum will decrease temporarily and black vertical streaks may appear on the paper.

• This problem may occur with noise due to the corona wire being dirty. In that case, clean the corona wire with the wire cleaner.

User Check (1) Clean the corona wire in the drum unit.

(2) Check that the wire cleaner is at the home position.

(3) Check that the toner cartridge is not empty.

(4) The drum unit may be damaged. Install a new drum unit.

(5) The toner cartridge may be damaged. Install a new toner cartridge.


Confidential 4-45

(I-7) Black and blurred horizontal stripes


Scratch on the drum

1 Are the horizontal stripes at 74mm (exposure drum) intervals?

Yes The exposure drum was scratched. Replace the drum unit.

Toner stuck on the developer roller

2 Are the horizontal stripes at 42.7mm (developer roller) intervals?

Yes After printing several pages, the problem will disappear. If not, replace the toner cartridge.

Scratch on the heat roller

3 Are the horizontal stripes at 79mm (heat roller) intervals?

Yes Replace the heat roller.

Corona contact failure






(I-8) Black vertical streaks (in a gray background)


Translucent stain on the scanner window


Yes 1) Clean the scanner window.

2) If it is not effective, replace the laser unit.

Corona failure 2 Is the corona wire dirty? Yes Clean the corona wire with the wire cleaner. (2)

User Check (1) The drum unit may be damaged. Install a new drum unit.

(2) Check the paper used meets the recommended paper specifications.

(3) Clean inside of the printer and the corona wire in the drum unit.


Confidential 4-46

(I-9) White vertical streaks


Translucent stain on the scanner window


Yes 1) Clean the scanner window.

2) If it is not effective, replace the laser unit.

Transfer failure 2 Is the transfer roller scratched? Yes Replace the drum unit.

Condensation 3 Has condensation occurred inside the printer?

Yes Try to print several pages or leave the printer 2 hours to allow it to reach room temperature.

(I-10) White horizontal streaks


Developing bias contact failure

1 Are the developing bias contacts between the printer body and toner cartridge dirty?

Yes Clean the electrodes at both sides. (4)

User Check (1) Try to wipe the scanner window with a soft cloth.


(3) Check the printer’s environment. High temperature and high humidity conditions can cause this problem.

(4) Damp (wet) paper might be used. Try to change to freshly unpacked paper.

User Check (1) Check the paper used meets the recommended paper specifications. A rough

surfaced paper, damp paper or thick media can cause the problem.

(2) Check that the appropriate media type is selected in the printer driver.

(3) The problem may disappear by itself. Try printing about 10 pages to clear this problem especially if the printer has not been used for a long time.



Confidential 4-47

(I-11) Faulty registration


Excessive paper load

1 Is the paper loaded in the paper tray more than 27mm high?

Yes Instruct the user to keep paper loads below 27mm in depth.

2 Is the specified weight of the recommended paper being used?

No Recommend to use the specified types of paper.

Print paper

3 Is the first printing position within ±1mm of the tolerance specification?

Yes Adjust the Y offset by using the utility software supplied.

Regist rear sensor position incorrect

4 Is the regist rear sensor off from the correct position?

Yes Reposition the sensor to the correct position.

Drum unit failure 5 Is the rotation torque of the drum unit heavy?



Confidential 4-48

(I-12) Poor fixation


Print paper 1 Is thick paper of more than 43lb being used?

Yes Recommend to use the specified types of paper.

Nip release lever

2 Does the position of the nip release levers in the fuser unit decompress the nip pressure?

Yes Return the nip release levers to the original position.

Toner sensor failure (When printing is faint.)

3 Is the problem solved by replacing the drum unit or the toner cartridge?

Yes 1) Toner is empty. 2) The toner sensor is defective.

Clean the toner sensor. 3) If the wiper in the toner

cartridge is broken, replace the toner cartridge with a new one.

Fuser unit thermistor failure

4 Is the thermistor fitted correctly?

No Fit the thermistor correctly.

Low-voltage power supply PCB failure

5 Is the problem solved by replacing the low-voltage power supply PCB?

Yes Replace the low-voltage power supply PCB.

• Open the back cover and fuser cover. Push down the blue tab (1). Repeat this process on the

other side. Make sure that the top of the tab and the white lever (2) are not level with each other. Close the back cover and try printing again.

1

2

2

1

Fig. 4-20


Confidential 4-49

(I-13) Image distortion


Laser unit installation

1 Is the laser unit secured to the frame incorrectly? (Check if there is any play.)

Yes Secure the unit correctly and tighten the screws.

Scanner LD emission failure

Scanner motor rotation failure

2 Is the laser diode or the scanner motor defective?


Scanner connection failure

3 Is the scanner harness connected properly? (Check if it is coming loose.)

No Connect the harness correctly.

(I-14) Faint print

Print out test print out test print out test Print out test print o Print out test print o













Print out test print out test print out test Print out test print oPrint out test print o














Printer installation

1 Is the printer placed horizontally?

No Place the printer on a flat surface.

Toner cartridge 2 Does the problem happen immediately after replacing the toner cartridge with a new one?

Yes Remove and carefully shake the toner cartridge horizontally.

Scanner window dirty

3 Is the scanner window dirty? Yes Clean the scanner window with a soft dry cloth.

Laser unit failure 4 Is the problem solved by replacing the laser unit?



Confidential 4-50

(I-15) White spots


1 Are the white spot at 94.2mm intervals?

Yes 1) If toner or glue remains stuck, wipe it off gently with a cotton swab. (Refer to NOTE in the next page.)

2) If the drum surface is scratched, replace the drum unit.

Drum unit failure

2 Is the problem solved after replacing the drum unit?


No toner 3 Is the toner in the toner cartridge almost empty?


Print paper 4 Is the problem solved after changing to specified freshly unpacked paper?

Yes Damp (wet) paper might be used. Recommend to change freshly unpacked paper.

Environment 5 Does the problem still appear after the printer has warmed up?

Yes 1) Replace the drum unit. 2) Advise the user of the

specified print environment.

User Check (1) If the problem is not solved after printing a few pages, the drum unit may have

glue from label stock on the exposure drum surface. Refer to Step 1 in the table below and NOTE in the next page.



Confidential 4-51

NOTE: Clean the drum unit as follows. (1) Put the print sample in front of the drum unit, and find the exact position of the poor print.

Fig. 4-21

< Examples of poor print quality >

94 mm(3.7 in.)

94 mm(3.7 in.)

94 mm(3.7 in.)

94 mm(3.7 in.)

Fig. 4-22

(2) Turn the drum unit gear by hand while looking at the surface of the OPC drum.

Fig. 4-23

(3) When you have found the mark on the drum that matches the print sample, wipe the surface of the OPC drum with a cotton swab until the dust or paper powder on the surface comes off.

Fig. 4-24

! CAUTION: DO NOT clean the surface of the photosensitive drum with a sharp object.

White Spots on black text and graphics at 94 mm (3.7 in.) intervals

Black Spots at 94 mm (3.7 in.) intervals


Confidential 4-52

(I-16) Black spots


Drum unit 1 Are the spots at 94.2mm intervals? (The problem is not solved after printing a few pages.)

Yes 1) If toner or glue remains stuck, wipe it off gently with a cotton swab. (Refer to NOTE in the previous page.)

2) If the exposure drum is scratched or deteriorated (exposed), replace the drum unit.


2 Is the contact between the drum unit and printer body connected correctly?

No Clean contact electrode both on the drum unit and in the printer body.

(7)

Fuser unit 3 Are the spots at 79mm intervals? (The problem is not solved after printing a few pages.)

Yes 1) Check and clean the heat roller with a cloth dampened with alcohol.

2) Replace the fuser unit.




User Check (1) If the problem is not solved after printing a few pages, the drum unit may have

glue from label stock on the exposure drum surface. Refer to Step 1 in the table below and NOTE in the previous page.



Confidential 4-53

(I-17) Black band


Corona failure 1 Is the wire cleaner at its home position?

No Return the wire cleaner to its home position. (2)

Corona dirty 2 Is the corona wire dirty? Yes 1) Clean the corona wire.

2) If the problem still appears after cleaning, replace the drum unit.

(2)

(I-18) Gray background


No Recommend to use the specified types of paper.

Print paper 1 Does the paper being used meet the paper specification (weight, etc.). Yes Recommend to change to

freshly unpacked paper.

Toner sensor failure (printer side)

2 Is Ready LED still lighted after the toner cartridge and drum unit are taken out? (The front cover is closed.)

Yes Toner sensor failure. Clean the toner sensor and check the toner sensor connection.



Yes Replace the toner cartridge.

Yes Replace the drum unit. Drum unit failure 4 Is the problem solved after replacing the drum unit?


NOTE: The following cases increase the possibility of this problem. • Acid paper is being used. • The drum unit is at the end of its life. • There is dust or paper powder.


Confidential 4-54

(I-19) Hollow print


Yes Recommend to use the specified types of paper.

Print paper 1 Is thick paper of more than 43lb being used or extremely rough surface paper? No Refer and compare with I-15.

(I-20) Downward fogging of solid black




Yes Replace the toner cartridge.




(I-21) Horizontal lines


Paper tray contacts

1 Are the ground contacts on the right side of the paper tray connecting correctly?

No Clean the contacts.

Drum unit 2 Are the high-voltage power supply and drum unit contacted correctly?

No Clean the contacts.

User Check (1) Check the paper used meets the recommended paper specifications.

(2) Select the ‘Thick paper mode’ in the printer driver, or use thinner paper than you are currently using.

(3) Check the printer’s environment, conditions such as high humidity may cause this situation to occur.


Confidential 4-55

(I-22) Light rain

Possible cause Step Check Result Remedy Ground contact




2 Is the contact between the drum unit and printer body connected correctly?

No Clean contact electrode both on the drum unit and in the printer body.

(7)




(I-23) Ghost


Driver setting 1 Is thin paper such as 64g/m2 used under the thick paper mode?

Yes 1) Change the current mode to the normal mode from the driver setting.

2) Print 5 or 6 blank pages if this problem occurs.






User Check (1) Check the paper used meets the recommended paper specifications. Damp

paper, thick media or rough surfaced paper can cause the problem.

(2) Check the printer’s environment. High temperature and high humidity conditions can cause the problem.

(3) Check that the appropriate media type is selected in the printer driver.

(4) Try installing a new drum unit.


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(I-24) Toner specks

User Check (1) Check the paper used meets the recommended paper specifications. A rough

surfaced paper may cause the problem.


(3) The drum unit may be damaged, or may be nearly at the end of life. Install a new drum unit.


Confidential 4-57

6.4 Location of Grounding Contacts 6.4.1 Drum unit

Fig. 4-25 6.4.2 Printer body & paper tray

Fig. 4-26

Toner cartridge

Drum Unit

(4) Developer roller

(1) Exposure drum

(6) Transfer roller

(5) Grid

(7) Cleaner

(3) Charge

(2) Wire cleaner

(4) Developer roller

(3) Charge

(7) Cleaner

(5) Grid

(1) Exposure drum

(6) Transfer roller


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7. INCORRECT PRINTOUT

When the data is not printed correctly as it is seen on the PC screen, follow the procedures below in the event of a specific error.

(P-1) The prints unexpectedly or it prints garbage.

User Check (1) Check if the printer cable is not too long. It is recommended to use a parallel cable of less than 2

meters (6.6 feet) in length.

(2) Check that the printer cable is not damaged or broken. Check also that the printer cable is connected to the correct interface connectors of both the printer and PC.

(3) If an interface switching device is used, remove it and connect the computer directly to the printer and try again.

(4) Check that the appropriate printer driver is selected as ‘Set as Default’. Check also that the correct print port is set for the selected printer driver.

(5) Check that the printer is not connected to the same port which is also connected to a mass storage device or scanner. Remove all other devices and connect the port to the printer only. Turn off the printer status monitor in the device options tab in the printer driver.

(6) If the print port is set as an ECP port, change it to a normal port.

(7) Try printing the test page referring to ‘Test Sample Page’ in Chapter 7.

(8) Try resetting the factory settings.


Failure inside the printer

1 Is it possible to print the test page with the method of ‘Test Sample Page’ in Chapter 7?

No Identify the error type, then refer to the specified section of this chapter.

(P-2) Unable to print full pages of a document with the “PRINT OVERRUN” message.

User Check (1) Press the Go button on the control panel to print the data remaining in the printer.

(2) If this does not clear the error, reduce the complexity of your document or reduce the printer resolution.

(3) Change the following setting in the printer driver and try again. The best combination of settings below will vary depending on your document.

Graphic Mode / TrueTypeTM mode / Use Printer TrueTypeTM Fonts

NOTE: This problem may appear if the data is too complex. If it is not cleared by taking the actions above, it will be impossible to print such data under the printer specifications.


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(P-3) Unable to print full pages of a document with the “MEMORY FULL” message.

User Check (1) Press the Go button on the control panel to print the data remaining in the printer.

(2) Reduce the complexity of your document or reduce the printer resolution.

NOTE: This problem may appear if the data is too complex.


Main PCB failure

1 Is it possible to print after reducing the data of a document?


(P-4) Headers or footers are not printed out even though they are viewed on PC screen.

User Check Most laser printers have a restricted area that cannot be printed on. Usually the first two lines and last two lines of text cannot print (leaving 62 printable lines). Adjust the top and bottom margins in your document to allow for this.

(P-5) The printer sometimes prints a couple of characters and then ejects the page.

User Check (For DOS environment only) The application printer emulation setting and the printer’s emulation do not match. Check in the application software which printer you have selected to make sure the printer is set up correctly. Remember that the printer emulates widely used printer selections:

HP Laser Jet 6P, HP Laser Jet 6P, Epson FX-850, IBM Proprinter XL Try setting the printer into HP emulation and then select the HP LaserJet 6P printer in the application software.


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8. NETWORK PROBLEM

If the error related to network occurs, refer to the following sections;

8.1 Installation Problem The Brother print server is not found during setup of the network print software installation or from the printer driver of the Brother printer in Windows®.

The Brother print server is not found using the Simple Network Configuration capabilities of Mac OS® X.

Make sure you have completed the IP address setting of the Brother print server according to Chapter 2 of this User’s Guide before installing the network print software or printer driver. Check the following:

1. Make sure that the printer is powered on, is on-line and ready to print.

2. Check to see if there is any LED activity. Brother print servers have two LEDs on the back panel of the printer.

Fig. 4-27

Both LEDs are off: the print server is not connected to the network. The upper LED is on: Link status The upper LED is blinking: Activity status The lower side LED is on: Link speed is 100M. The lower side LED is off: Link speed is 10M.

3. Print the Printer Settings Page and check if the settings such as IP address settings are correct for your network. The problem may be the result of mismatched or duplicate IP address. Verify that the IP address is correctly loaded into the print server. And make sure that no other nodes on the network have this IP address. For information on how to print the Printer Settings Page, see Printing the Printer Settings Page on page 7-6.

4. Verify that the print server is on your network as follows:

For Windows®

Try pinging the print server from the host operating system command prompt with the command:

ping ipaddress

Where ipaddress is the print server IP address (note that in some instances it can take up to two minutes for the print server to load its IP address after setting the IP address).

Network status LEDs (Light emitting diodes) (For HL-5250DN)


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For Macintosh®

For Mac OS® 9.1 to 9.2

(1) From the Apple menu, open the Chooser.

(2) Click the Brother Laser (IP) icon, and make sure that your print server name appears in the right frame. If it is visible, then the connection is good. Otherwise, go to Step 5.

For Mac OS® X 10.2.4 or greater

(1) From the Go menu, select Applications.

(2) Open the Utilities folder.

(3) Double-click the Printer Setup Utility icon.

(4) Click Add. (For Mac OS® X 10.2.4 to 10.3) Go to (5). (For Mac OS® X 10.4) Go to (6).

(5) (For Mac OS® X 10.2.4 to 10.3) Make the following selection.

(6) Make sure that your print server appears. If it is visible, then the connection is good.

Otherwise, go to Step 5. 5. If you have tried 1 to 4 above and it does not work, then reset the print server back to the

default factory settings and try from the initial setup again. For information how to reset to the default factory settings, see Restoring the network settings to factory default on page 7-7.

6. (For Windows®) Firewall setting on your PC may be rejecting the necessary network connection. Follow the instructions below to disable the Firewall. If you are using a personal Firewall software, see the User’s Guide for your software or contact the software manufacturer.

Windows XP SP2 users

(1) Click the Start button, Settings, and then Control Panel.

(2) Double click Windows Firewall.

(3) Click the General tab. Verify that Off (not recommended) is selected.

(4) Click OK.


Confidential 4-62

Windows® XP SP1 users

(1) Locate the “Windows” key on your keyboard. These are the keys with the Windows logo on it.

(2) Press the “Windows” key plus the “E” key to open My Computer.

(3) On the left, right click My Network Places, click Properties, then right click Local Area Connection and click Properties.

(4) Click the Advanced tab. Under Internet Connection Firewall, verify that the box next to Protect my computer... is unchecked. If the box is selected, click the box to remove the check. Then, click OK.

(5) Once your firewall is disabled, try reinstalling the Brother software package. For instructions on how to install from the CD-ROM, use the Quick Setup Guide we have provided with the machine.

(6) If the installation completed successfully, the Firewall on your computer is rejecting the necessary network connection. In this case, you will need to disable the Firewall on your computer whenever you install the network drivers.

NOTE: After the Brother software package is installed, enable again your Firewall. For instructions on how to re-enable your Firewall software, refer to your User’s Guide or contact the Firewall software manufacturer.


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8.2 Printing Problem <Print job is not printed> Make sure the status and configuration of the print server. Check following:

1. Make sure that the printer is powered on, is on-line and ready to print.

2. Print the Printer Settings Page of the printer and check if the settings such as IP address settings are correct for your network. The problem may be the result of mismatched or duplicate IP address. Verify that the IP address is correctly loaded into the print server. And make sure that no other nodes on the network have this IP address.

3. Verify that the print server is on your network as follows:

For Windows®

(1) Try pinging the print server from the host operating system command prompt with the command:

ping ipaddress

Where ipaddress is the print server IP address (note that in some instances it can take up to two minutes for the print server to load its IP address after setting the IP address).

(2) If a successful response is received, then proceed to Windows® 95/98/Me and Windows NT® 4.0 Peer-to-Peer print (LPR) troubleshooting, and Windows® 2000/XP IPP troubleshooting. Otherwise, proceed to Step 4.

For Macintosh®

For Mac OS® 9.1 to 9.2

(1) From the Apple menu, open the Chooser. (2) Click the Brother Laser (IP) icon, and make sure that your print server name appears

in the right frame. If it is visible, then the connection is good. Otherwise, go to Step (4).

For Mac OS® X 10.2.4 or greater

(1) From the Go menu, select Applications. (2) Open the Utilities folder. (3) Double-click the Printer Setup Utility icon. (4) Click Add.

(For Mac OS® X 10.2.4 to 10.3) Go to (5). (For Mac OS® X 10.4) Go to (6).

(5) (For Mac OS® X 10.2.4 to 10.3) Make the following selection.


Confidential 4-64

(6) Make sure that your print server appears. If it is visible, then the connection is good. Otherwise, go to Step 4.

4. If you have tried 1 to 4 above and it does not work, then reset the print server back to the default factory settings and try from the initial setup again. For information how to reset to the default factory settings, see Restoring the network settings to factory default on page 7-7.

<Error during printing> If you try to print while other users are printing large amounts of data (e.g. many pages or color pages with high resolution), the printer is unable to accept your print job until the ongoing printing is finished. If the waiting time of your print job exceeds a certain limit, a time out situation occurs, which causes the error message. In such situations, execute the print job again after the other jobs are completed.


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8.3 Protocol-Specific Troubleshooting <Windows® 95/98/Me and Windows NT® 4.0 Peer-to-Peer print (LPR) troubleshooting>

If you are having trouble printing on a Windows® 95/98/Me, Windows NT® 4.0 or later Peer-to-Peer network (LPR method), check the following:

1. Make sure that the Brother LPR Port driver is correctly installed and configured according to the Windows® 95/98/Me or Windows NT® 4.0 Peer-to-Peer chapters.

2. Try to turn the Byte Count on in the Configure port area of printer driver properties.

You may find that during the installation of BLP software, the screen that prompts you for a Port name is not displayed. This may happen on some Windows® 95/98/Me and Windows NT® 4.0 computers. Press the ALT and TAB keys to make it appear. <Windows® 95/98/Me and Windows NT® 4.0 Peer-to-Peer print (NetBIOS)

troubleshooting>

If you are having trouble printing on a Windows® 95/98/Me, Windows NT® 4.0 or later Peer-to-Peer network (NetBIOS), check the following:

1. Make sure that the Brother NetBIOS Port driver is correctly installed and configured according to the Windows® 95/98/Me or Windows NT® 4.0 Peer-to-Peer (NetBIOS) chapters. You may find that during the installation of the port driver, the screen that prompts you for a Port name is not displayed. This happens on some Windows® 95/98/Me and Windows NT® 4.0 computers. Press the ALT and TAB keys to make it appear.

2. Make sure that the print server is configured to be in the same workgroup or domain as the rest of your computers. It may take several minutes for the print server to appear in the network neighborhood.

<Windows® 2000/XP IPP troubleshooting>

Want to use a different Port number other than 631. If you are using Port 631 for IPP printing, you may find that your firewall may not let the print data through. If this is the case, use a different port number (port 80), or configure your Firewall to allow Port 631 data through.

To send a print job using IPP to a printer using Port 80 (the standard HTTP port) enter the following when configuring your Windows® 2000/XP system. http://ip_address/ipp

Get More Info option in Windows® 2000 not working

If you are using a URL of: http://ip_address:631 or http://ip_address:631/ipp ,

the Get More Info option in Windows® 2000 will not function. If you wish to use the Get More Info option, use the following URL: http://ip_address

This will then force Windows® 2000/XP to use Port 80 to communicate with the Brother print server.

<Web browser troubleshooting (TCP/IP)>

1. If you can not connect to the print server using your web browser it may be worth checking the Proxy Settings of your browser. Look in the Exceptions setting and if necessary, type in the IP address of the print server. This will stop your PC from trying to connect to your ISP or proxy server every time you wish to look at the printer server.

2. Make sure that you are using the proper web browser, we recommend Microsoft Internet Explorer version 6.0 (or higher) or Netscape® version 7.1 (or higher).


Confidential 5-1

CHAPTER 5 DISASSEMBLY AND RE-ASSEMBLY

1. SAFETY PRECAUTIONS

To avoid creating secondary problems by mishandling, follow the warnings and precautions below during maintenance work.

WARNING • Always turn off the power switch and unplug the power cord from the power outlet

before accessing any parts inside the printer. • Some parts inside the printer are extremely hot immediately after the printer is used.

When opening the front cover or back cover to access any parts inside the printer, never touch the red colored parts shown in the following figures.

! CAUTION: (1) Be careful not to lose screws, washers, or other parts removed.

(2) Be sure to apply grease to the gears and applicable positions specified in this chapter.

(3) When using soldering irons or other heat-generating tools, take care not to accidentally damage parts such as wires, PCBs and covers.

(4) Before handling any PCBs, touch a metal portion of the equipment to discharge any static electricity charge on your body, or the electronic parts or components may be damaged.

(5) When transporting PCBs, be sure to wrap them in the correct protective packaging.

(6) Be sure to replace self-tapping screws correctly, if removed. Unless otherwise specified, tighten screws to the following torque values.

TAPTITE, BIND or CUP B M3: 0.5N m M4: 0.8N m TAPTITE, CUP S M3: 0.5N m

(7) When connecting or disconnecting cable connectors, hold the connector body, not the cables. If the connector has a lock, release the connector lock first to release it.

(8) After a repair, check not only the repaired portion but also all connectors. Also check that other related portions are functioning properly before operational checks.


Confidential 5-2

2. PACKING

Fig. 5-1

Accessory bag

AC power cord

Option carton

Pad

Printer

Carton

Pad

Pad

Drum/toner ASSY


Confidential 5-3

3. SCREW TORQUE LIST

1 Frame L/Drive Unit No. Parts code Parts name Location Pcs. Tightening torque

N m (kgf • cm) 1 085311016 Taptite, bind B M3 x 10 Paper eject solenoid 1 0.5 ±0.1(5±1)2 087320616 Taptite, cup S M3 x 6 Main motor 4 0.7 ±0.1(7±1) 3 085311016 Taptite, bind B M3 x 10 T1, MP Regist

solenoid 3 0.5 ±0.1(5±1)

4 085411216 Taptite, bind B M4 x 12 Gear plate 8 0.9 ±0.1(9±1) 5 085411216 Taptite, bind B M4 x 12 Main shield 3 0.9 ±0.1(9±1)

2 Frame Unit No. Parts code Parts name Location Pcs. Tightening torque

N m (kgf • cm)

1 LM2048001 Screw, pan (S/P washer) M3.5 x 6

Ground wire 1 0.5 ±0.05 (5±0.5)

2 085411216 Taptite, bind B M4 x 12 SW holder 1 0.8 ±0.1(8±1) 3 085411216 Taptite, bind B M4 x 12 Under bar 4 0.7 ±0.1(7±1) 4 085411216 Taptite, bind B M4 x 12 Paper feed unit 8 0.8 ±0.1(8±1) 5 085411216 Taptite, bind B M4 x 12 HVPS 2 0.8 ±0.1(8±1) 6 085411216 Taptite, bind B M4 x 12 LVPS 2 0.8 ±0.1(8±1) 7 085411216 Taptite, bind B M4 x 12 Base plate 9 0.8 ±0.1(8±1) 8 LM5867001 Taptite, cup S M3 x 6 SR Main PCB 4 0.75 ±0.1(7.5±1)9 LM5867001 Taptite, cup S M3 x 6 SR Shield cover 4 0.75 ±0.1(7.5±1)10 087320616 Taptite, cup S M3 x 6 Scanner plate 6 0.7 ±0.1(7±1)

3 Paper Feeder No. Parts code Parts name Location Pcs. Tightening torque

N m (kgf • cm) 1 085310816 Taptite, bind B M3 x 8 PE, EG sensor 1 0.5 ±0.1(5±1)2 085310816 Taptite, bind B M3 x 8 MP, PE sensor 1 0.5 ±0.1(5±1) 3

085310816 Taptite, bind B M3 x 8 MP paper feed frame

2 0.5 ±0.1(5±1)

4 085411216 Taptite, bind B M4 x 12

Regist frame (2), MP tray unit (2), Chute 2 (2)

6 0.7 ±0.1(7±1)

4 Cover No. Parts code Parts name Location Pcs. Tightening torque

N m (kgf • cm) 1 085411216 Taptite, bind B M4 x 12 Inner chute 6 (7) 0.8 ±0.1(8±1) 2 087310816 Taptite, cup B M3 x 8 Panel PCB 3 0.5 ±0.1(5±1) 3 085411216 Taptite, bind B M4 x 12 Cover 6 0.8 ±0.1(8±1)


Confidential 5-4

4. HARNESS ROUTING

MP PE sensor ASSY1

High-voltage PS PCB ASSY

Hook "A"

Hook "B"

MP feed frame

MP feed frame

Hole

Hook "A"

Printer top side(Printer body upside down)

MP PE sensor ASSY


Confidential 5-5

Interlock SW ASSY3

Interlock SW ASSY


Hooks

Frame L

Pin

HookPin


PE EG sensor ASSY

PE EG sensor ASSY

Paper feed frame

Paper feed frame

Hook "A"

Hook "B"

Hook "B"

Hole "A"

Hole "A"


PE EG sensor ASSY2


Confidential 5-6

Register solenoid ASSY5

Register solenoid ASSY


Hooks

Hook

Hook

HookHook

Frame L

HookPin

Pin

Toner sensor PCB unit ASSY4

Toner sensor PCB unit ASSY


Hooks

Hook

Hook

Frame L

HookPin

Pin


Confidential 5-7

7 T1 solenoid ASSY


Hooks

HookPin

Pin

Hooks

T1 solenoid ASSY

Frame L

6 MP solenoid ASSY

Relay front PCB ASSYHooks

Hooks

MP solenoid ASSY

Frame L

HookPin

Pin


Confidential 5-8

9 Laser unit

Laser unitFrame L

HolesCore

Hook

Gear cover

Main PCB

Polygon motor connector

Protective film

LD harnessconnector

8 Relay front PCB ASSY


Main PCB

Hook

Frame L


Confidential 5-9

11 Fan motor 60 unit

Frame L

Hooks

Hook

Hook

Hook

Fan motor 60 unit

Toner LED PCB unit ASSY

Fan motor 60 unit LV

Frame L

Hooks



10


Confidential 5-10

Frame L

Hooks

Hook

Hook

Hole



High-voltage PS PCB ASSYHook

Hooks

Hole

Toner LED PCB unit ASSY12


Confidential 5-11

Shield cover

Shield cover

FG harness FG harness

Main PCB

Main PCB

PS PCB unit 13

FG harness14

PS PCB unit

Inlet harness ASSY

Power supply switch

Hook

HooksCore

<A view>

<A view>PS PCB unitterminal


Base plate LV

SW holder ASSY


Confidential 5-12

High-Voltage PS PCB ASSY15

High-VoltagePS PCB ASSY

HoleInsulation sheet

Printer top side(Printer body upside down)HVPS PCB harness

(Flat cable)

HVPS PCB harness(Flat cable)

Main PCB


Confidential 5-13

5. LUBRICATION

BG2

* BG2: KANTO KASEI BG- MU (2 mm dia. Ball)

BG2

* BG2: KANTO KASEI BG- MU (2 mm dia. Ball)

Gear 82R

Drive sub ASSY

Apply grease on the cogs of the motor side

DEV gear 37R joint drive

Gear cover


Confidential 5-14

6. DISASSEMBLY FLOW

7.1 7.2 7.3AC Cord Drum/ Toner ASSY DX Feed ASSY

7.5Back Cover

7.6Outer Chute ASSY 7.8

Tray MP ASSY

Access Cover/ Side Cover L

7.10

7.4Paper Tray

7.34Fan Motor 60 Unit LV

7.18T1 Solenoid ASSY

7.21Ejector Solenoid ASSY

7.35Frame L

7.20Register Solenoid ASSY

7.9MP Tray Cover ASSY/Process Cover ASSY

7.7Fuser Unit

7.11Main PCB

7.33Fan Motor 60 Unit

Basic Operation

7.15Relay Front PCB ASSY

7.19Toner Sensor PCB

7.36Frame R

7.14Relay Rear PCB ASSY/

Connector

7.12Gear Plate Calking ASSY AL/�

Develop Joint/Main Motor ASSY AL

7.17Drive Release Link

7.16MP Solenoid ASSY

7.22Interlock SW ASSY

7.23New Toner Actuator

7.24Gear 17/20

7.26-1 Top Cover Printed ASSY

7.27-1 Top Cover2 Printed ASSY

7.28Filter

7.29Laser Unit

7.26-4Inner Chute/

Pinch Roller Holder

7.26-2Panel PCB ASSY

7.26-3SW Key A/ B

7.27-4SW Key A/ B/ C

SW Key Printed ASSY

7.27-3Panel PCB ASSY

7.27-2Inner Chute/

Pinch Roller Holder

7.27-5LCD Holder ASSY

7.30PS PCB Unit

7.31High-Voltage PS PCB ASSY

7.32Toner LED PCB Unit ASSY

7.13Main Shield Plate ASSY

7.25Side Cover R

7.41PE Actuator/

Edge Actuator/Edge Actuator Spring

7.42PE EG Sensor ASSY

7.40Roller Holder ASSY

7.38Regist Actuator Rear/Regist Actuator Spring

7.37MP Unit

7.39Regist Actuator Front/Regist Actuator Spring

(HL-5240/5250DN)

(HL-5270DN/5280DW)

40s / 40s

Disassembly / Re-Assembly (sec.)

5s / 5s 5s / 5s 5s / 5s

5s / 5s

10s / 10s 40s / 50s

15s / 20s15s / 15s 30s / 30s

35s / 40s 50s / 50s

20s / 20s

55s / 60s

25s / 25s

35s / 45s

20s / 30s 20s / 30s

45s / 50s

70s / 70s

15s / 20s 15s / 20s 15s / 15s

15s / 20s

15s / 20s

20s / 25s

20s / 30s

10s / 20s 5s / 10s

10s / 10s

25s / 40s

20s / 20s

30s / 35s 20s / 20s

15s / 15s

10s / 10s

10s / 10s

25s / 10s 10s / 10s 10s / 10s 45s / 50s

25s / 10s 45s / 50s 15s / 15s 15s / 20s 20s / 20s

10s / 15s 40s / 40s

70s / 70s


Confidential 5-15

7. DISASSEMBLY PROCEDURE

7.1 AC Cord (1) Disconnect the AC cord from the Printer.

Fig. 5-2

7.2 Drum/Toner ASSY



Fig. 5-3

AC cord

Front cover

Drum/toner ASSY

1

2

3

Printer


Confidential 5-16

7.3 DX Feed ASSY (1) Remove the DX feed ASSY.

Fig. 5-4

7.4 Paper Tray (1) Close the Front cover and pull out the Paper tray.

(2) Remove the paper from the Paper tray.

Fig. 5-5

Front cover

Paper tray

DX feed ASSY

2

1


Confidential 5-17


Fig. 5-6


Fig. 5-7

Hook

Paper tray


Paper tray

Separation pad ASSY

2

1

2

3

Hook

Hooks


Confidential 5-18

(5) Remove the Lift gear 46.

Fig. 5-8

(6) Remove the Gear 21-16.

Fig. 5-9

Paper tray

Lift gear 46

Hooks

Gear 21-16 Paper tray


Confidential 5-19

(7) Remove the Gear 15.

Fig. 5-10

7.5 Back Cover (1) Remove the Back cover.

Fig. 5-11

Back cover

Paper tray Gear 15

Pin

Pin

1

2

3


Confidential 5-20

7.6 Outer Chute ASSY (1) Pull the tabs of the Outer chute ASSY at the left and right hand sides open.

Remove the Outer chute ASSY.

Fig. 5-12

(2) Release the Hook.

(3) Remove the Eject actuator and the Eject actuator spring from the Outer chute ASSY. Remove the Eject actuator spring from the Eject actuator.

Fig. 5-13

Eject actuator spring

Outer chute ASSY

Eject actuator

Outer chute ASSY

Rib

1

3

Pin

Pin

2

3

1

2

4

Hook

1

1


Confidential 5-21

7.7 Fuser Unit (1) Remove the bind B M4x16 Taptite screw, and then remove the FU harness cover 1.

Fig. 5-14

(2) Remove the Heater terminal L and Heater terminal S from the Fuser unit.

Fig. 5-15

FU harness cover 1


Hooks

1 2

3

Heater terminal L

Heater terminal S

Fuser unit


Confidential 5-22

(3) Remove the FU harness cover 2.

Fig. 5-16

(4) Disconnect the connectors of the Thermistor ASSY M and Thermistor ASSY S from the Relay rear PCB ASSY.

Fig. 5-17

Hook

FU harness cover 2

1

2

Thermistor ASSY S

Thermistor ASSY M

Fuser unit

Relay rear PCB ASSY


Confidential 5-23

(5) Remove the cup B M4x16 Taptite screw, and then remove Fuser unit.

Fig. 5-18

7.8 Tray MP ASSY (1) Open the MP tray cover ASSY.

(2) Remove the Tray MP ASSY.

Fig. 5-19

Fuser unit


Process cover ASSY

Tray MP ASSY

1 2

3 MP tray cover ASSY


Confidential 5-24

7.9 MP Tray Cover ASSY/Process Cover ASSY (1) Open the Process cover ASSY.

(2) Remove the Process cover stopper from the Drive release link.

Fig. 5-20

(3) Remove the MP tray cover ASSY and the Process cover.

Fig. 5-21

Hook

Process cover stopper

MP tray cover ASSY

Drive release link

1 Process cover ASSY

2

3

Process cover

MP tray cover ASSY

1

2

3


Confidential 5-25

(4) Remove the Process cover ASSY from the MP tray cover ASSY.

Fig. 5-22

(5) Remove the cup B M4x10 Taptite screw, and then remove the Process cover stopper.

Fig. 5-23

Process cover ASSY

MP tray cover ASSY

Process cover stopper


Process cover


Confidential 5-26

(6) Remove the Support flap from the Process cover.

Fig. 5-24

Support flap

Process cover


Confidential 5-27

7.10 Access Cover/Side Cover L (1) Remove the Access cover.

Fig. 5-25

(2) Remove the two bind B M4x12 Taptite screws, and then remove the Side cover L.

Fig. 5-26

Access cover

5

1


Hooks

2

Side cover L


Hooks

Hook

1

2

3 4


Confidential 5-28

7.11 Main PCB (1) Remove the four cup S M3x6 SR Taptite screws, remove the FG harness and then

remove the Shield cover.

Fig. 5-27

(2) Disconnect the four connectors and six flat cables from the Main PCB.

Fig. 5-28

Shield cover



LD harness connector (Flat cable)

DXsolenoid connector

Panel PCB connector

Relay front connector (Flat cable)

Main PCB

Polygon motor connector (Flat cable)

LVPS PCB connector

Main motor connector (Flat cable)

HVPS PCB connector (Flat cable) LT connector

Relay rear connector (Flat cable)

FG harness


Confidential 5-29

(3) Remove the four cup S M3x6 SR Taptite screws and two Screws to remove the Main PCB.

Fig. 5-29

Screws Main PCB

Taptite, cup S M3x6 SR FG harness


Confidential 5-30

7.12 Gear Plate Calking ASSY AL/Develop Joint/ Main Motor ASSY AL (1) Place the printer body so that the Frame L is at the top.

(2) Remove the eight bind B M4x12 Taptite screws and one cup S M3x6 taptite screw.

(3) Remove the Gear plate calking ASSY AL from the Frame L.

Fig. 5-30

NOTE: Be careful not to drop the gear.

(4) Remove the four cup S M3x6 Taptite screws, and then remove the Main motor ASSY AL.

Fig. 5-31

Taptite, bind B M4x12 Taptite, bind B M4x12

Taptite, cup S M3x6

Frame L

Gear plate calking ASSY AL

Taptite, cup S M3x6

Taptite, cup S M3x6 Main motor ASSY AL


Taptite, cup S M3x6


Confidential 5-31

(5) Remove the Develop joint from the Gear plate calking ASSY AL.

Fig. 5-32

7.13 Main Shield Plate ASSY

(1) Remove the Insulation sheet.

Fig. 5-33


Develop joint

Insulation sheet

Frame L


Confidential 5-32

(2) Remove the bind B M4x12 Taptite screw.

(3) Remove the bind B M4x12 Taptite screw, and then remove the Plate.

Fig. 5-34

(4) Remove the three bind B M4x12 Taptite screws and cup S M3x6 Taptite screw, and then remove the Main shield plate ASSY.

Fig. 5-35

Plate

Frame L


Pin

Pin


Taptite, cup S M3x6 Main shield plate ASSY

Frame L



Confidential 5-33

7.14 Relay Rear PCB ASSY/Connector (1) Remove the Relay rear PCB ASSY.

Fig. 5-36

(2) Remove the Connector harness.

(3) Disconnect the LT connector.

Fig. 5-37

Relay rear PCB ASSY

Frame L

Hook

LT connector

Hook

Hook Frame L

Connector harness


Confidential 5-34

7.15 Relay Front PCB ASSY (1) Remove the Relay front PCB ASSY.

(2) Disconnect the five connectors from the Relay front PCB ASSY.

Fig. 5-38

Fig. 5-39

Frame L


Hook Pin

Hook

Pin


Toner sensor PCB connector

Inter lock SW connector MP solenoid connector T1 solenoid connector

Register solenoid connector


Confidential 5-35

7.16 MP Solenoid ASSY (1) Remove the cup B M3x8 Taptite screw, and then remove the Spring.

Fig. 5-40


(3) Remove the MP solenoid ASSY, Solenoid release spring P/R and MP solenoid lever.

Fig. 5-41

MP solenoid ASSY

Solenoid release spring P/R

MP solenoid lever

Frame L


Taptite, cup B M3x8

Spring

Frame L


Confidential 5-36

7.17 Drive Release Link (1) Remove the Drive release cam and the Drive release link.

Fig. 5-42

7.18 T1 Solenoid ASSY


(2) Remove the T1 solenoid ASSY and the Solenoid release spring.

Fig. 5-43

Drive release cam Drive release link

Frame L 1

2

3


Solenoid release spring

T1 solenoid ASSY

Frame L

T1 solenoid lever


Confidential 5-37

7.19 Toner Sensor PCB (1) Remove the Toner sensor PCB unit ASSY from the Frame L.

Fig. 5-44

(2) Remove the PT sensor holder from the Toner sensor PCB ASSY AL.

Fig. 5-45

Frame L

Hooks

Toner sensor PCB unit ASSY

Hook

PT sensor holder

Toner sensor PCB ASSY AL


Confidential 5-38

7.20 Register Solenoid ASSY (1) Remove the bind B M3x10 Taptite screw.

(2) Remove the Register solenoid ASSY and the Solenoid release spring.

Fig. 5-46 7.21 Ejector Solenoid ASSY


(2) Remove the Ejector solenoid and the Solenoid release spring.

Fig. 5-47

Frame L

Solenoid release spring


Register solenoid ASSY Register solenoid lever

Solenoid release spring Taptite, bind B M3x10

Ejector solenoid

Frame L

Ejector solenoid lever


Confidential 5-39

7.22 Interlock SW ASSY (1) Remove the Interlock SW ASSY from the Frame L.

Fig. 5-48 7.23 New Toner Actuator

(1) Remove the New toner actuator and the New toner actuator spring.

Fig. 5-49

Frame L

Interlock SW ASSY

Hooks

Hook

New toner actuator

Frame L

New toner actuator spring


Confidential 5-40

7.24 Gear 17/20 (1) Remove the Gear 17.

Fig. 5-50


Fig. 5-51

Gear 17 Hook

Frame L

Frame L

Gear 20

Hook


Confidential 5-41

(3) Remove the Gear 17 (black).

Fig. 5-52

(4) Remove the Gear 17 (white).

Fig. 5-53

Gear 17 (black)

Hook

Frame L

Gear 17 (white)

Hook

Frame L


Confidential 5-42

7.25 Side Cover R (1) Remove the two bind B Taptite screws, and then remove the Side cover R.

Fig. 5-54



Side cover R

Hooks

Hooks

Hook

4

3 2

1

Hook

Hooks


Confidential 5-43

7.26-1 Top Cover Printed ASSY (HL-5240/5250DN) (1) Remove the two bind B M4x12 Taptite screws, and then remove the Top cover printed

ASSY.

Fig. 5-55

7.26-2 Panel PCB ASSY

(1) Turn the Top cover printed ASSY.

(2) Remove the three cup B M3x8 Taptite screws, and then remove the Panel PCB ASSY.

Fig. 5-56


Hook

Hook

Hook

Hook

Hooks

Hooks


1

2

1

Taptite, cup B M3x8

Panel PCB ASSY



Confidential 5-44

7.26-3 SW Key A/B (1) Remove the SW key A from the Top cover printed ASSY.

Fig. 5-57

(2) Remove the SW key B from the Top cover printed ASSY.

Fig. 5-58


SW key A


SW key B


Confidential 5-45

7.26-4 Inner Chute/Pinch Roller Holder (1) Remove the six bind B M4x12 Taptite screws, and then remove the Inner chute.

Fig. 5-59

(2) Turn the Inner chute.

(3) Remove the Pinch roller holder from the Inner chute.

Fig. 5-60




Hooks

Hooks

Inner chute


Inner chute

Pinch roller holder

Pinch roller holder


Confidential 5-46

7.27-1 Top Cover 2 Printed ASSY (HL-5270DN/5280DW) (1) Remove the two bind B M4x12 Taptite screws, and then remove the Top cover 2 printed

ASSY.

Fig. 5-61


Hook

Hook

Hook

Hook

Hooks

Hooks

Top cover 2 printed ASSY

1

2

1


Confidential 5-47

7.27-2 Inner Chute/Pinch Roller Holder (1) Remove the seven bind B M4x12 Taptite screws, and then remove the Inner chute.

Fig. 5-62

NOTE: When re-assembling the Inner chute, secure the screws according to the order of the numbers described in the figure above.

(2) Turn the Inner chute.

(3) Remove the Pinch roller holder from the Inner chute.

Fig. 5-63




Hooks

Hooks

Inner chute


1

2

3 4

5

6

7

Inner chute

Pinch roller holder

Pinch roller holder


Confidential 5-48

7.27-3 Panel PCB ASSY (1) Disconnect the LCD panel PCB harness and Back light PCB harness from the LCD panel

PCB ASSY.

Fig. 5-64

(2) Remove the three cup B M3x8 Taptite screws, and then remove the LCD panel PCB ASSY.

Fig. 5-65

NOTE: When re-assembling the LCD panel PCB ASSY, secure the screws according to the order of the numbers described in the figure above.

Taptite, cup B M3x8

LCD panel PCB ASSY


LCD panel PCB ASSY

Back light PCB harness

LCD panel PCB harness


1 3

2


Confidential 5-49

7.27-4 SW Key A/B/C /SW Key Printed ASSY (1) Remove the SW key A from the Top cover 2 printed ASSY.

Fig. 5-66

(2) Remove the SW key B from the Top cover 2 printed ASSY.

Fig. 5-67

(3) Remove the SW key C from the Top cover 2 printed ASSY.

Fig. 5-68


SW key A

SW key B


SW key C



Confidential 5-50

(4) Remove the Set key film.

Fig. 5-69

(5) Remove the Set key printed ASSY from the Top cover 2 printed ASSY.

Fig. 5-70

(6) Remove the Key top from the Set key printed ASSY.

Fig. 5-71


Set key printed ASSY

Key top




Set key film


Confidential 5-51

7.27-5 LCD Holder ASSY (1) Remove the LCD holder from the Top cover 2 printed ASSY.

Fig. 5-72

(2) Remove the Back light PCB ASSY from the LCD holder.

Fig. 5-73


LCD holder

LCD holder

Back light PCB ASSY


Confidential 5-52

(3) Remove the LCD panel PCB ASSY from the LCD holder.

Fig. 5-74

(4) Remove the Back light film from the LCD holder.

Fig. 5-75

LCD holder

LCD panel PCB ASSY

LCD holder

Back light film


Confidential 5-53

7.28 Filter (1) Remove the Sub duct from the Air duct.

Fig. 5-76

(2) Remove the Filter from the Air duct.

Fig. 5-77

Sub duct

Air duct

Hooks

Filter

Air duct

Filter

1

23


Confidential 5-54

7.29 Laser Unit (1) Remove the Air duct from the Laser unit.

Fig. 5-78

(2) Remove the six cup S M3x6 Taptite screws

(3) Pull out the flat cable from the Core, the Protective film.

(4) Remove the Laser unit.

Fig. 5-79

NOTE: • Before re-assembling the Laser unit, always assemble the Core. • Be careful not to lose the Protective film attached on the flat cable.

Taptite, cup S M3x6

Laser unit

Hook

Air duct

Hook

Hook

Hook

Hook

Taptite, cup S M3x6

Laser unit

1 2

Core

Protective film


Confidential 5-55

7.30 PS PCB Unit (1) Turn the Printer.

(2) Remove the five bind B M4x12 Taptite screws, and then remove the Base plate LV.

(3) Remove the one Screw pan (S/P washer) M3.5x6 from the Base plate LV to remove the PS PCB unit terminal.

Fig. 5-80

(4) Remove the two bind B M4x12 Taptite screws, and then remove the LV insulation sheet.

Fig. 5-81

Base plate LV

Taptite bind B M4x12

Screw pan (S/P washer) M3.5x6

PS PCB unit terminal

Taptite, bind B M4x12 LV insulation sheet

Taptite bind B M4x12


Confidential 5-56

(5) Remove the bind B M4x12 Taptite screw, and then remove the SW holder ASSY.

(6) Float the Fan motor 60 unit LV from the Frame R.

NOTE: Do not remove the Fan motor 60 unit at the above step.

Fig. 5-82

(7) Remove the Power supply switch and Inlet harness ASSY from the SW holder.

NOTE: When re-assembling the power supply switch onto the SW holder, give attention to the direction of the switch.

Fig. 5-83

SW holder ASSY Fan motor 60 unit LV


SW holder

Power supply switch

Inlet harness ASSY

Frame R

1

2

1

2


Confidential 5-57

(8) Remove the PS PCB unit.

(9) Remove the harness from the PS PCB unit.

Fig. 5-84

PS PCB unit

1

2


Confidential 5-58

7.31 High-Voltage PS PCB ASSY (1) Remove the four bind B M4x12 Taptite screws, and then remove the Base plate HV.

Fig. 5-85

(2) Remove the bind B M4x12 Taptite screw, and then remove the HV insulation sheet.

Fig. 5-86


Base plate HV


HV insulation sheet

Pin

Pin

Pin

Pin



Confidential 5-59

(3) Remove the bind B M4x12 Taptite screw, and then remove the High-voltage PS PCB ASSY.

(4) Disconnect the three connectors from the High-voltage PS PCB ASSY.

Fig. 5-87

Fig. 5-88

Taptite, bind B M4x12 High-voltage PS PCB ASSY

Toner LED PCB connector


PE EG sensor connector

MP PE sensor connector

Pins


Confidential 5-60

7.32 Toner LED PCB Unit ASSY (1) Remove the Toner LED PCB unit ASSY from the Frame R. (2) Disconnect the two connectors from the Toner LED PCB.

Fig. 5-89

(3) Remove the LED holder from the Toner LED PCB.

Fig. 5-90


Frame R

Hook

Hook

Pins

Hook Toner LED PCB

LED holder

Toner LED PCB

Fan motor 60 unit LV connector

Fan motor 60 unit connector


Confidential 5-61

7.33 Fan Motor 60 Unit (1) Remove the Fan motor 60 unit from the Frame R.

Fig. 5-91

7.34 Fan Motor 60 Unit LV

(1) Remove the Fan motor 60 unit LV from the Frame R.

Fig. 5-92

Fan motor 60 unit

Frame R


Frame R


Confidential 5-62

7.35 Frame L (1) Remove the six bind B M4x12 Taptite screws from the Frame L.

(2) Remove the Frame L.

Fig. 5-93

7.36 Frame R

(1) Remove the five bind B 4x12 Taptite screws from the Frame R.

(2) Remove the Frame R.

Fig. 5-94



Frame L



Under bar

Under bar


Frame R


Confidential 5-63

7.37 MP Unit (1) Cut the Binder.

Fig. 5-95

(2) Remove the two bind B M3x8 Taptite screws, and then remove the MP feed frame.

Fig. 5-96

NOTE: When removing the MP feed frame, cut the binder bundling the harnesses with nippers or the like.


Hook

Hook

MP feed frame

1

2

Paper feed frame


Binder Paper feed frame

Cut

PE EG sensor connector

MP PE sensor connector


Confidential 5-64

(3) Open the MP feed frame cover.

Fig. 5-97

(4) Remove the Holder bearing MP from the MP feed frame.

Fig. 5-98

1 2

Holder bearing MP

Hook

MP feed frame

3

MP feed frame cover

MP feed frame


Confidential 5-65

(5) Remove the MP roller holder ASSY from the MP feed frame.

Fig. 5-99

(6) Remove the PE actuator MP B from the MP feed frame.

Fig. 5-100

MP feed frame

Lift arm MP


Hook

1

2

3

MP feed frame

PE actuator MP B

PE actuator MP B

Hook

1

2

3


Confidential 5-66

(7) Remove the PE actuator MP from the MP feed frame.

Fig. 5-101

(8) Remove the bind B M3x8 Taptite screw, and then remove the MP PE sensor ASSY.

Fig. 5-102

MP feed frame

PE actuator MP

MP feed frame

MP PE sensor ASSY


1

2


Confidential 5-67

(9) Remove the Separation pad ASSY MP from the MP frame.

Fig. 5-103

(10) Remove the MP separation spring from the MP frame.

Fig. 5-104


MP frame

MP frame

MP separation spring


Confidential 5-68

7.38 Regist Actuator Rear/Regist Actuator Spring (1) Turn the Paper feed unit.

(2) Remove the Actuator cover from the Paper feed unit.

Fig. 5-105

(3) Remove the Regist actuator rear and the Regist actuator spring from the Paper feed unit.

Fig. 5-106

Actuator cover

Paper feed unit

Hook

Hook

Paper feed unit


Hook

1

2

3

Regist actuator spring 4


Confidential 5-69

7.39 Regist Actuator Front/Regist Actuator Spring (1) Remove the Regist actuator front and the Regist actuator spring from the Paper feed unit.

Fig. 5-107

Regist actuator front

Hook

Paper feed unit

2

1

3

Regist actuator spring 4


Confidential 5-70

7.40 Roller Holder ASSY (1) Release the Pin of the Roller holder ASSY from the Lift arm.

Fig. 5-108


NOTE: When re-assembling the roller holder ASSY, align the section “A” on the shaft of the roller holder ASSY with the hole on the paper feed frame.

Fig. 5-109

Roller holder ASSY

Paper feed frame

Lift arm

Roller holder ASSY Paper feed frame

2

3

1

Pin

2

1

“A”


Confidential 5-71

7.41 PE Actuator/Edge Actuator/Edge Actuator Spring (1) Remove the Edge actuator spring.

Fig. 5-110

(2) Remove the Separation R shaft bearing.

Fig. 5-111

Edge actuator

Hooks

Edge actuator spring

Paper feed frame

Separation R shaft bearing

Paper feed frame


Confidential 5-72

(3) Remove the Separation roller drive shaft, then remove the Edge actuator and PE actuator.

Fig. 5-112

Edge actuator

PE actuator

Paper feed frame

Separation roller drive shaft

1

2

3


Confidential 5-73

7.42 PE EG Sensor ASSY (1) Remove the two bind B M3x8 Taptite screws, and then remove the MP frame.

Fig. 5-113

(2) Remove the bind B M3x8 Taptite screw, and then remove the PE EG sensor ASSY.

Fig. 5-114

PE EG sensor ASSY

Taptite bind B M3x8

Paper feed frame

Paper feed frame

Taptite bind B M3x8

Taptite bind B M3x8

MP frame


Confidential 5-74

8. DISASSEMBLY PROCEDURE (LT-5300)

8.1 Paper Tray (1) Pull out the Paper tray from the LT-5300.

Fig. 5-115


Fig. 5-116

Paper tray

Separation pad ASSY

Paper tray

Hooks 2

2

1

3 Hook Hook


Confidential 5-75


Fig. 5-117

(4) Remove the Lift gear 46.

Fig. 5-118


Paper tray

Paper tray

Lift gear 46

Hook


Confidential 5-76

(5) Remove the Gear 21-16.

Fig. 5-119


Fig. 5-120

Paper tray Gear 21-16

Paper tray Gear 15


Confidential 5-77

8.2 LT Front Cover ASSY (1) Remove the two bind B M4x12 Taptite screws.

(2) Remove the LT front cover ASSY.

Fig. 5-121

(3) Remove the LT front paper guide from the LT front cover ASSY.

Fig. 5-122

LT front cover ASSY


LT front cover ASSY

LT front paper guide

Hooks


Confidential 5-78

8.3 LT Back Cover (1) Remove the two cup S M3x6 Taptite SR screws.

(2) Remove the LT back cover.

Fig. 5-123

8.4 LT Side Cover L


(2) Remove the cup S M3x6 Taptite SR screw.

(3) Remove the LT side cover L.

Fig. 5-124

Taptite, cup S M3x6 SR LT back cover



LT side cover L

Hooks

Hooks

4

1

2

3

5

Boss


Confidential 5-79

8.5 LT Side Cover R (1) Remove the bind B M4x12 Taptite screw.

(2) Remove the cup S M3x6 Taptite SR screw.

(3) Remove the LT side cover R.

Fig. 5-125



LT side cover R

Hooks

Boss

4

2

1

5

3


Confidential 5-80

8.6 LT PCB ASSY (1) Disconnect the connectors from the LT PCB ASSY.

(2) Remove the bind B M4x12 Taptite screw, and then remove the LT PCB ASSY.

Fig. 5-126

Hook


LT PCB ASSY

LT sensor PCB connector LT sensor harness ASSY 1 connector

LT PCB ASSY

LT solenoid connector LT sensor harness ASSY 2 connector

LT frame L


Confidential 5-81

8.7 Connector: 55533-1219 (1) Remove the LT sensor harness ASSY 1 from the Connector: 55533-1219.

(2) Remove the Connector: 55533-1219 from the LT frame L.

Fig. 5-127

8.8 Connector: 54702-1219

(1) Remove the LT sensor harness ASSY 2 from the Connector: 54702-1219.

(2) Remove the Connector: 54702-1219 from the LT frame L.

Fig. 5-128

Connector: 55533-1219

Hook Hook

LT sensor harness ASSY 1

LT frame L

LT sensor harness ASSY 2

LT frame L

Connector: 54702-1219

Hook

Hook


Confidential 5-82

8.9 Gear 24 LT (1) Place the LT so that the LT frame L is at the top.

(2) Remove the Gear 20 T1 roller drive from the LT frame L.

Fig. 5-129

(3) Remove the Retaining ring E4.

(4) Remove the Gear 24 LT from the LT frame L.

Fig. 5-130

LT frame L

LT frame L

Gear 20 T1 roller drive

Hook

Retaining ring E4

Gear 24 LT


Confidential 5-83

8.10 Collar 6 (1) Remove the Gear plate ground spring from the LT frame L.

Fig. 5-131

(2) Remove the cup S M3x6 Taptite SR screw, and then remove the Feed roller ground plate.

Fig. 5-132

LT frame L

Gear plate ground spring

Taptite, cup S M3x6 SR LT frame L

Feed roller ground plate


Confidential 5-84

(3) Remove the T1 sector gear spring LT from the LT frame L.

Fig. 5-133

(4) Remove the LT solenoid harness from the hooks of the LT drive unit.

Fig. 5-134

LT frame L T1 sector gear spring LT

LT drive unit

LT solenoid harness

Hooks Hooks

LT solenoid ASSY


Confidential 5-85

(5) Remove the cup S M3x6 Taptite screw.

(6) Remove the four bind B M4x12 Taptite screws, and then remove the LT drive unit.

Fig. 5-135

(7) Remove the Clutch spring from the LT drive unit.

Fig. 5-136

LT frame L


Taptite, cup S M3x6


LT drive unit

Ground wire top

LT drive unit

Clutch spring


Confidential 5-86

(8) Remove the Collar 6.

(9) Remove the Clutch arm ASSY from the LT drive unit.

Fig. 5-137

(10) Remove the Collar 6 from the Clutch arm ASSY.

Fig. 5-138

LT drive unit

Collar 6

Clutch arm ASSY

Collar 6

Clutch arm ASSY


Confidential 5-87

8.11 LT Solenoid ASSY (1) Remove the bind B M3x10 Taptite screw, and then remove the LT solenoid ASSY.

(2) Remove the Solenoid release spring P/R from the LT solenoid ASSY.

Fig. 5-139

Taptite, bind B M3x10 LT frame L Solenoid release spring P/R

LT solenoid ASSY


Confidential 5-88

8.12 Roller Holder ASSY (1) Remove the Lift arm from the Pin of the Roller holder ASSY.

Fig. 5-140


NOTE: When re-assembling the roller holder ASSY, align the section “A” on the shaft of the roller holder ASSY with the hole on the paper feed frame.

Fig. 5-141

Lift arm

LT paper feed frame

Pin

Roller holder ASSY

2

1

Roller holder ASSY Paper feed frame

2

3

1

“A”


Confidential 5-89

8.13 Edge Actuator Spring (1) Remove the Edge actuator spring.

Fig. 5-142

LT paper feed frame

Edge actuator spring

Hooks

Edge actuator


Confidential 5-90

8.14 PE Actuator , Edge Actuator (1) Remove the Separation R shaft bearing.

Fig. 5-143

(2) Remove the Separation roller drive shaft, then remove the Edge actuator and PE actuator.

Fig. 5-144

PE actuator

Edge actuator

Separation roller drive shaft

LT paper feed frame

Separation R shaft bearing

LT paper feed frame

Hook


Confidential 5-91

8.15 LT Sensor PCB ASSY (1) Remove the two bind B M4x12 Taptite screws.

(2) Remove the four cup S M3x6 Taptite SR screws, and then remove the LT frame L.

Fig. 5-145

(3) Remove the two cup S M3x6 Taptite SR screws, and then remove the LT paper feed frame.

Fig. 5-146


LT frame R

LT frame L





Under bar

Under bar

LT paper feed frame


Confidential 5-92

(4) Remove the two cup B M3x12 Taptite screws, and then remove the LT front beam.

Fig. 5-147

(5) Remove the bind B M3x8 Taptite screw, and then remove the LT sensor PCB ASSY.

Fig. 5-148


LT paper feed frame

LT front beam


LT paper feed frame

LT sensor PCB ASSY


Confidential 6-1

CHAPTER 6 ADJUSTMENTS AND UPDATING OF SETTINGS, REQUIRED AFTER PARTS REPLACEMENT

1. IF YOU REPLACE THE MAIN PCB

The table below shows the ROM type of each main PCB.

Main PCB (For a supplied part) Model

ROM 0 ROM 1 HL-5240 8 Mbyte Flash ROM x 1 N/A

HL-5250DN 8 Mbyte Flash ROM x 1 2 Mbyte Flash ROM x 1

HL-5270DN 8 Mbyte Flash ROM x 1 4 Mbyte Flash ROM x 1

HL-5280DW 8 Mbyte Flash ROM x 1 4 Mbyte Flash ROM x 1

<What to do when replacing the main PCB>

Rewriting the firmware (ROM) of the printer Setting the default paper size. Setting the serial number.

<Which part to use for the operation>

HL-5240 LM9076001 MAIN PCB ASSY 5240 LZ0683001 FW: MAIN CONTROLLER AL

HL-5250DN LM9077001 MAIN PCB ASSY 5250 LZ0683001 FW: MAIN CONTROLLER AL

HL-5270DN LM9110001 MAIN PCB ASSY 5270 LZ0683001 FW: MAIN CONTROLLER AL

HL-5280DW LM9064001 MAIN PCB ASSY 5280DW US LM9138001 MAIN PCB ASSY 5280DW EU LZ0683001 FW: MAIN CONTROLLER AL


Confidential 6-2

<What you should prepare>

1) Computer (Windows® XP/2000 or later) Create the “hl5200” folder in the C drive, for example.

2) HL-5240/5250DN/5270DN/5280DW target printer

3) USB cable (one piece)

4) FILEDG32.EXE file Download the ”FILEDG32.EXE”(PrUt030003) file from the databank, and install it into the PC. Then, copy the installed program into the “hl5200” folder that has been created in the C drive.

5) Target firmware: LZXXXX_$.BLF (firmware of the printer)

LZXXXX_$.BLF LZXXXX: First six digits of the part number of the firmware $: Alphabet representing the revision of the firmware.

Download the required firmware from the databank, extract it and copy the extracted files into the “hl5200” folder that has been created in the C drive.

6) Setting file of the default paper size:

Download the “5200setup.zip” file from “PrUt050007” in the databank. Then, extract this file.

S5200E (A4 size), s5200U (Letter size), s5200I (A4 size, Israeli font setting for Israel), AL_CHN.pjl (A4 size, Thin paper setting for China)

7) BR_DEVELOP.zip file Download the above file from “PrUt050009” in the databank and copy it into the “hl5200” folder that has been created in the C drive. Extract the copied file.

8) MAINTE.EXE file Download the above files from the databank and copy it into the “hl5200” folder that has been created in the C drive. Extract the copied file and run the bramainte.exe file by double-clicking.

Refer to the following steps for installing the printer driver.


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Installing the printer driver

To identify terminals connected via USB interface, the PC requires the corresponding virtual USB devices to be implemented by driver. If you connect any number of printers to your PC, therefore, the same number of virtual USB devices will be automatically configured on your PC. To prevent virtual USB devices from being configured limitlessly, use the unique driver installation procedure described below that enables your PC to identify terminals via single virtual USB device. NOTE: Once this installation procedure is carried out for the PC, no more driver installation will be required for that PC to identify machines.

1. Unplug the USB cable, if the printer is connected to the PC. 2. (HL-5240/5250DN) Turn the power supply of the printer on while holding down the Go

button and the Job Cancel button. Make sure that all LEDs are on. The Status LED lights up when releasing the Go button and the Job Cancel button. Press the Go button for five times (ROM 0). A few seconds later, the printer goes into the ROM rewriting mode. (HL-5270DN/5280DW) Turn the power supply of the printer on while holding down the Set key and the Back key. Select the appropriate mode by pressing the ◄ ►keys. Make sure that “PRL->ROM0 W” on the LCD panel and press the Set Key to be set. “Send BLF file..” message appears on the LCD panel. A few seconds later, the printer goes into the ROM rewriting mode.

3. Connect the USB cable with the printer. The following screen appears, indicating the detection of new hardware device by the system.


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4. Select “Search for a suitable driver for my device (recommended)” and click Next.

5. Select “Specify a location” and click Next.

6. Select the “BR_DEVELOP” folder in the C drive, then click OK.


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7. Click Next.

8. To proceed, click Yes.

9. If the driver is successfully installed, the following message window appears. Click Finish to return Windows.


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<Procedures>

After the installation procedure of the printer driver, refer to the following steps for the detailed procedures to rewrite the firmware.

Rewriting the firmware (ROM) of the printer

(HL-5240/5250DN)

1) Connect the PC and printer with the USB cable.

2) Turn the power supply of the printer on while holding down the Go button and the Job Cancel button. Make sure that all LEDs are on. The Status LED lights up when releasing the Go button and the Job Cancel button. Press the Go button for five times (ROM 0) or six times (ROM 1). A few seconds later, the printer goes into the ROM rewriting mode.

3) Start the PC.

4) Open the “hl5200” folder and double-click the FILEDG32 icon to start. Make sure that there is the “kensa” icon, and that no error occurs.

Fig. 6-1

5) Click the “kensa” icon in FILEDG32 to select.

6) Drag the firmware (LZ………) in the same folder and drop it onto the icon of the applicable model in FILEDG32. The files in the firmware are sent to the printer so that they are started to write into the flash ROM automatically. After finishing receiving the files, the printer starts to rewrite the firmware.

7) The Status LED blinks irregularly while the firmware being written. Then, be sure not to disconnect the USB cable or to turn off the power supply of the PC before this firmware rewriting is done.

8) Turn the power supply of the printer off.

NOTE:

If the error related to the BLF file or the printer occurs, the red Status LED lights up.


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(HL-5270DN/5280DW)

1) Connect the PC and printer with the USB cable.

2) Turn the power supply of the printer on while holding down the Set key and the Back key. Select the appropriate mode by pressing the ◄ ►keys. “PRL->ROM0 W” (For rewriting the ROM 0) “PRL->ROM1 W” (For rewriting the ROM 1) Press the Set Key to be set. Make sure that “Send BLF file..” message appears on the LCD panel.

3) Start the PC.

4) Open the “hl5200” folder and double-click the FILEDG32 icon to start. Make sure that there is the “kensa” icon, and that no error occurs.

Fig. 6-2

5) Click the “kensa” icon in FILEDG32 to select.

6) Drag the firmware (LZ………) in the same folder and drop it onto the icon of the applicable model in FILEDG32. The files in the firmware are sent to the printer so that they are started to write into the flash ROM automatically. After finishing receiving the files, the printer starts to rewrite the firmware.

7) The address messages appear on the LCD panel while the firmware being written. Then, be sure not to disconnect the USB cable or to turn off the power supply of the PC before this firmware rewriting is done. The “….Complete….” message appears on the LCD panel when the firmware rewriting is done properly.

8) Turn the power supply of the printer off.

NOTE:

If the error related to the BLF file or the printer occurs, the red backlight of the LCD panel lights up and the error message appears.


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Setting the default paper size

1) Open the “hl5200” folder and double-click the FILEDG32 icon to start. Select the applicable printer and click it. (Make sure that there is the icon of the connected printer and that no error occurs.)

2) Drag “s5200E” (A4 size), “s5200U” (Letter size), “s5200I” (A4 size, Israeli font for Israel) or “AL_CHN.pjl” (A4 size, Thin paper for China) in the same folder and drop it onto the icon of the applicable model in FILEDG32. When the Status LED (HL-5240/ 5250DN) or the Data LED (HL-5270DN/5280DW) of the printer lights up for an instant and goes off immediately after dropping it, the setting is completed. Then, set the serial number following the steps described in the next section.

Refer to the following step to set the serial number.

Setting the serial number

Operation of printer

(HL-5240/5250DN) 1) Check that the front cover is open. 2) Turn ON the power switch while the Go button is held. 3) After all LEDs on the panel are lit, only the Status LED goes out. 4) Release the Go button and check that all LEDs are out. 5) Press the Go button for a while. Make sure that the Paper LED lights up. 6) Close the front cover of the printer.

(HL-5270DN/5280DW)

1) Check that the front cover is open. 2) Turn ON the power switch while the Go button is held. 3) The message “USERS MODE” is shown on the LCD panel. 4) Release the Go button. 5) Press the Go button for a while. Make sure that the Data LED lights up. 6) Close the front cover of the printer.

Operation of computer

7) Connect the computer to the printer with the USB cable. 8) Double-click the brmainte.EXE file (maintenance utility) which has been copied in the

“hl5200” folder to start. 9) Select “Input Information” from Menu. Select the applicable model name.


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10) Check the port (USB) that the printer is connected through and click “Serial No.” in the lower box.

Fig. 6-3

Enter the serial number (the last nine digits) of the printer into the box at the right hand side. The serial number is shown in the window, and check that it is correct. Follow the next step without clicking the OK button.


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2. IF YOU REPLACE THE PERIODICAL MAINTENANCE PARTS

If any of periodical replacement parts are replaced, it is necessary to change the count of total pages on each periodical maintenance parts to zero, and to modify a number of times for replacing each periodical maintenance parts according to the procedures below.

NOTE:

As for HL-5270DN/5280DW models, it is possible to reset the count of each periodical maintenance parts by operating the LCD panel. Refer to “2.2 Reset Parts Life Menu” on Chapter 7.

<What you should prepare>

1) Computer (Windows® XP/2000 or later) Create the “hl5200” folder in the C drive, for example.

2) HL-5240/5250DN/5270DN/5280DW target printer 3) MAINTE.EXE

Download the above files from the databank and copy it into the “hl5200” folder that has been created in the C drive. Extract the copied file and run the “brmainte.exe” file by double-clicking.

<Procedures>

Operation of printer

(HL-5240/5250DN) 1) Check that the front cover is open. 2) Turn ON the power switch while the Go button is held. 3) After all LEDs on the panel are lit, only the Status LED goes out. 4) Release the Go button and check that all LEDs are out. 5) Press the Go button for a while. Make sure that the Paper LED lights up. 6) Close the front cover of the printer.

(HL-5270DN/5280DW)

1) Check that the front cover is open. 2) Turn ON the power switch while the Go button is held. 3) The message “USERS MODE” is shown on the LCD panel. 4) Release the Go button. 5) Press the Go button for a while. Make sure that the Data LED lights up. 6) Close the front cover of the printer.

Operation of computer 7) Connect the computer to the printer with the USB cable. 8) Double-click the “brmainte.EXE” (maintenance utility) which has been copied in the

“hl5200” folder to start.


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9) Select “Input Information” from Menu.

10) Select the applicable model name. And check the port (USB) that the printer is connected through.

11) Select the item of each periodical maintenance parts and check “ON” and click OK.


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Periodical Maintenance Parts Name Item

Fuser Unit Reset Fuser Counter

Laser Unit Reset Laser Counter

Paper feeding kit for Tray 1 Reset PF Kit 1 Counter



Paper feeding kit for MP tray Reset PF Kit MP Counter

After resetting any of counts, print the Print Settings to make sure a bar graph indicating the remaining life of each periodical maintenance parts full up.


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CHAPTER 7 SERVICE SUPPORT SOFTWARE

1. CONTROL PANEL

Various modes can be used if the power switch is set to ON while the Go button is held. There are two types of modes: Users Mode and Service Mode.

1.1 Users Mode

Operation procedure of Users Mode is shown below. The function change depends on number of times the Go button is pressed.

<HL-5240/5250DN> 1. Check that the front cover is closed. 2. Turn ON the power switch while holding down the Go button. 3. After all LEDs on the panel are lit, only the Status LED goes out. 4. Release the Go button and check that all LEDs are off. 5. Press the Go button. (If the Go button is pressed, the Status LED is lighted. If the Go

button is released, the LED is out.)

<HL-5270DN/5280DW> 1. Check that the front cover is closed. 2. Turn ON the power switch while holding down the Go button. 3. The message “USERS MODE” is shown on the LCD panel with the orange backlight. 4. Release the Go button and check that all LEDs are off. 5. Press the Go button. (If the Go button is pressed, the Data LED is lighted. If the Go

button is released, the LED is out.)

Press the Go button Each mode starts after 2 seconds.

Once (1) Test Sample Page

Twice (2) Print Fonts

Three times (3) Hex Dump Mode

Four times (4) PCB ONLY Mode

Five times (5) 1push Printing Recovery Mode * All LEDs are lit for 1 second and the printer returns to

the ready status.

Six times (6) Network Factory Reset 1 (APIPA: ON) * All LEDs are lit for 1 second and the printer returns to

the ready status.

Seven times (7) Network Factory Reset 2 (APIPA: OFF) * All LEDs are lit for 1 second and the printer returns to

the ready status.

Eight times (8) NV-RAM Factory Reset * All LEDs are lit for 1 second and the printer returns to

the ready status.

More than nine times (1) Test Sample Page


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NOTE: * Each mode starts 2 seconds after pressing the Go button. * Both “Network Factory Reset 1” and “Network Factory Reset 2” functions are not

available for HL-5240. Explanation of functions of each Users Mode is shown below.

< Functions of each “Users Mode” >

(1) Test Sample Page The printer prints a demo page. The printer returns to the ready status after printing.

(2) Print Fonts The printer prints a list of the internal fonts. The printer returns to the ready status after printing.

(3) Hex Dump Mode You can print data as hexadecimal code. To exit from this mode, you have to turn off the printer.

(4) PCB ONLY Mode Even when the engine error occurs and PCB exchange is required for recovery, the printer can be started, ignoring the engine error if this mode is used. NVRAM data can be obtained.

(5) 1push Printing Recovery Mode Demo page print is possible by pressing Go button after the power supply is turned on.

(6) Network Factory Reset 1 (APIPA: ON) The network setting is reset to its factory setting. (APIPA is ON)

(7) Network Factory Reset 2 (APIPA: OFF) The network setting is reset to its factory setting. (APIPA is OFF)

(8) NV-RAM Factory Reset The printer is restored to the factory setting and permanent fonts and macros are cleared. The printer returns to the ready status after printing.


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1.2 User Maintenance Mode This section describes what the user should do when replacing the consumable parts.

<Resetting the drum counter> The printed image may deteriorate when using the drum unit to a certain degree. The printer detects how much the drum unit is used with the drum counter and lights up the Drum LED when the drum unit life is nearly at the end of its life to indicate to the user that the drum unit life reaches the end of its life soon, in order to prevent the printed image defects due to drum unit deterioration. The printer does not provide the function which resets the drum counter automatically when the drum unit is replaced with a new one. If replacing the drum unit with a new one without resetting the drum counter, the counted value of the old drum unit is used continuously so that the Drum LED is not off. When replacing the drum unit with a new one, it is required to reset the drum counter following the steps below:

<HL-5240/5250DN> (1) Make sure that the printer is turned on and the Drum LED is blinking. Press the front

cover release button and then open the front cover.

(2) Press and hold down the Go button for about four seconds until all the LEDs light up. Once all four LEDs are lit, release the Go button.

(3) Take out the drum unit and toner cartridge ASSY.

(4) Put the new drum unit and toner cartridge ASSY back into the printer.


<HL-5270DN/5280DW> (1) Press the front cover release button and then open the front cover.

(2) Press and hold down the Go button for about four seconds. When the message of finishing resetting the drum counter, release the Go button.

(3) Take out the drum unit and toner cartridge ASSY.

(4) Put the new drum unit and toner cartridge ASSY back into the printer.



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<Initializing the developing bias> When replacing the toner cartridge with a new one, the new toner sensor detects that the toner cartridge is replaced, and the developing bias is initialized automatically. Therefore, the user is not necessary to initialize the developing bias. If replacing the toner cartridge which contains enough toner with a used one, the new toner sensor cannot detect that the toner cartridge is replaced so that the developing bias is not initialized. In this case, the print density may be lighter than usual.

Density transition

Bias voltage

Print density

Toner empty [Used toner amount]

Dark

Light

Bias voltage when replacing with a new toner cartridge

Density when replacing with a new toner cartridge

Bias voltage when replacing with a used toner cartridge

Density when replacing with a used toner cartridge

In such a case, follow the steps below in order to initialize the developing bias forcedly.

<Standard Cartridge> (1) Open the front cover.

(2) Take the drum unit out of the printer.

(3) Press the Go button.

(4) Install the drum unit into the printer.



<High Yield Cartridge> (1) Open the front cover.

(2) Take the drum unit out of the printer.


(4) Install the drum unit into the printer.

(5) Press the Go button twice.



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1.3 Service Mode Operation procedure of Service Mode is shown below. The function change depends on number of times the Go button is pressed.

<HL-5240/5250DN> 1. Check that the front cover is open. 2. Turn ON the power switch while the Go button is held. 3. After all LEDs on the panel are lit, only the Status LED goes out. 4. Release the Go button and check that all LEDs are out. 5. (1st step) Press the Go button once or twice. (If the Go button is pressed, the Status LED

is lit. If the Go button is released, the LED is out.) 6. Check that Toner/Drum/Paper LEDs are lighted. 7. (2nd step) Press the Go button. Each mode starts after 2 seconds. (If the Go button is

pressed, the Status LED is lit. If the Go button is released, the LED is out.)

<HL-5270DN/5280DW>

1. Check that the front cover is open. 2. Turn ON the power switch while the Go button is held. 3. The message “USERS MODE” is shown on the LCD panel. 4. Release the Go button and check that all LEDs are out. 5. (1st step) Press the Go button once or twice. (If the Go button is pressed, the Data LED is

lit. If the Go button is released, the LED is out.) 6. Check that the message “USERS MODE” is shown on the LCD panel with orange

backlight. 7. (2nd step) Press the Go button. Each mode starts after 2 seconds. (If the Go button is

pressed, the Data LED is lit. If the Go button is released, the LED is out.)


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1st step 2nd step Each mode starts after 2 seconds.

Once (1) Factory Inspection Mode

Twice (2) Continuous Grid Pattern Print Mode

Three times (3) Fuser Unit Test Print

Four times (4) NV-RAM Value Dump Mode

Five times (5) RAM Check

Press the Go button once.

Six times Printing of the internal data for the factory inspection.

* Factory use.

Once (6) Printing for Maintenance * The machine starts printing after closing

the front cover. Twice (7) Print Settings

* The machine starts printing after closing the front cover.

Three times (8) Sleep Mode Indication (OFF/Dimmed)

Four times (9) Sleep Mode Setting (ON/OFF) * All LEDs are lit for 1 second and the

printer returns to the ready status.

Five times (10) Developer Roller Counter Reset 1 (For the standard toner)

* All LEDs are lit for 1 second and the printer returns to the ready status.

Six times (11) Developer Roller Counter Reset 2 (For the high capacity toner)

* All LEDs are lit for 1 second and the printer returns to the ready status.

Seven times (12) Fixed USB Speed * All LEDs are lit for 1 second and the

printer returns to the ready status.

Press the Go button twice.

Eight times (13) USB Speed Indication (ON/OFF) * All LEDs are lit for 1 second and the

printer returns to the ready status. The procedure from 1 to 4 is the same as the above.

Number of times of pressing the Go button

Press the Go button for 2 seconds (long push). (Check that Paper LED is lighted.)

PIT3 Inspection Mode * Factory use.

NOTE: * Each mode starts 2 seconds after pressing the Go button.


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< Functions of each “Service Mode” >

(1) Factory Inspection Mode This mode is to check each sensor at the assembly line.

< Sensor Inspection Check Procedure >

(1) Print “Print Settings” by clicking the Go button three times. If a failure such as paper jams occurs, activate each sensor manually when the machine goes into the inspection mode.

(2) Procedures to go into the factory inspection mode are as follows.

< HL-5240/5250DN >

1. Check that the front cover is open.

2. Turn ON the power switch while the Go button is held.

3. After all LEDs on the panel are lit, only the Status LED goes out.

4. Release the Go button and check that all LEDs are out.

5. Press the Go button once. (If the Go button is pressed, the Status LED is lit. If the Go button is released, the LED is out.)

6. Check that Toner/Drum/Paper LEDs are lighted.

7. Press the Go button once. Each mode starts after 2 seconds. (If the Go button is pressed, the Status LED is lit. If the Go button is released, the LED is out.)

< HL-5270DN/5280DW >

1. Check that the front cover is open.

2. Turn ON the power switch while the Go button is held.

3. The message “USERS MODE” is shown on the LCD panel.

4. Release the Go button and check that all LEDs are out.

5. Press the Go button once. (If the Go button is pressed, the Data LED is lit. If the Go button is released, the LED is out.)

6. Check that the message “USERS MODE” is shown on the LCD panel with orange backlight.

7. Press the Go button once. Each mode starts after 2 seconds. (If the Go button is pressed, the Data LED is lit. If the Go button is released, the LED is out.)


Confidential 7-8

(3) Activate each sensor listed below manually and verify that the Status LED (HL-5240/5250DN) or the Data LED (HL-5270DN/5280DW) is lit. In the inspection mode, the LED blinks once when the state of a sensor of a switch is changed from ON to OFF, or from OFF to on. When the state is changed continuously, the LED keeps blinking. ( Regist front sensor, Regist rear sensor, Paper eject sensor, New toner sensor,

Toner sensor, Front cover sensor, PE sensor, Edge sensor, MP PE sensor, DX tray sensor )

Fig. 7-1

(4) When the verification of all the sensors is completed, them the power off.

(2) Continuous Grid Pattern Print Mode

This mode is to print a grid pattern continuously with a serial number on it. The number of grid pattern prints is displayed at the same time. The machine does not go back to the ready state unless the power is turned off and on. To finish the continuous grid pattern print mode, press the Job Cancel button.

(3) Fuser unit Test Print This is to print the following three patterns to check the fuser unit. ・ Grid pattern with a serial number on it ・ Gray pattern ・ Black pattern

When this operation is completed, the machine automatically goes back to the ready state.

(4) NV-RAM Value Dump Mode This is to collectively print the present state of the NV-RAM of all printers. When this operation is completed, the machine automatically goes back to the ready state.

Frame R



New toner sensor (Relay front PCB)

High-voltage PS PCB

Regist rear sensor Regist front sensor

MP PE sensor

PE EG sensor

Edge sensor

PE sensor

Paper eject sensor (Relay rear PCB)

Frame L

Front cover sensor

DX tray sensor

Chute


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(5) RAM Check This is to execute a stricter RAM check than a standard one. If the result turns out unaccepted, it considers an error, and all the LEDs blink. If it turns out accepted, the Ready LED keeps blinking. The machine does not go back to the ready state unless the power is turned off and on.

(6) Printing for Maintenance This is to print a list of all maintenance information including printer coverage information.

• Series name • Serial Number: • Cont. ROM VERSION • RAM SIZE • Remaining life of periodical replacement parts • <Device Status>

Page Count: Average Coverage:

• <Total Pages Printed> MP TRAY: TRAY 1: TRAY2: TRAY3: DUPLEX:

• <Total Pages Printed> A4/LETTER: LGL/A4LONG/FOLIO: B5/EXECUTIVE: ENVELOPE: A5: OTHERS:

• <Error History (last 10 errors)> The page counter when each error occurred is also indicated.

• <Replace count> PF KITMP: PF KIT 1: PF KIT 2: PF KIT 3: FUSER: LASER: DRUM: TONER:

• <Total Pages Printed> Previously Used Toner: Current Toner:

• <Developing Bias>

NOTE: * Some margin of error must be taken into consideration because coverage for the printable area of A4-size paper is calculated using video signals

* If the firmware version is 1.02 or before, the maintenance information gives out false information on the remaining life of Drum. To know the accurate information of Drum, print the Print Settings or upgrade the firmware version.


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(7) Print Settings If you want to know the drum unit life or the number of printed pages, you should print out the Print Settings. 1. Contents overview

The “Print Settings” is configured with two pages for HL-5240 and more than three pages for HL-5250DN/5270DN/5280DW. All pages have following terms in common: * Title * Model name * Serial number The setting indication is the same as the panel setting information, supporting 17 languages. (ENG / FRE / GER / DUT / ITA / SPA / NOR / FIN / DAN / POR / SWE / CZE / POL / HUN / RUS / BUL / RUM) The descriptions on the third page or later are indicated in English only.

NOTE: • The descriptions printed in Print Settings vary depending on the countries. • It is also allowed you to print the print settings by pressing the Go button three times

continuously when the front cover is closed and when the printer is in the ready mode.

• Select Information, then Print Settings by pressing the Set button three times. (HL-5270DN/5280DW)


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< Page 1 > This page includes various setting information of the printer. Each term is indicated when it fulfills the condition.

< Page 2 >

This page includes the printer and maintenance information in the following order.

(1) Printer information The following terms are indicated in the order. • Controller version (CONT.ROM VERSION) • RAM SIZE (Mbyte) • Device information (RAMDISK)

(2) Maintenance information (i) Consumable information

The printable pages remained for the consumable part is indicated. Also, the percentage of life remained over the total printable pages is indicated in numerical value and band graph. A sample (PF KIT MP) is as follows: From the top left, the consumable part name, number of printable pages remained, and percentage of life remained are indicated. The right column is a band graph separated into 50 scale marks.

The consumable part indicated is as follows: • PF KIT MP • PF KIT 1 • PF KIT 2 (indicated only when the Tray2 is installed.) • PF KIT 3 (indicated only when the Tray3 is installed.) • FUSER • LASER • DRUM

< How to Read the Drum Unit Life >

The drum unit life is shown by the band graph at the center of Print Settings; • It initially indicates 100% and gradually decreases. • It indicates 0% when the Drum LED is blinking. • It stays at 0% even if further printing is done.

< The difference of the Drum Unit Life and the Drum Counter >

The drum unit life is based on the page counter. If the average number of drum rotations is more than the number of drum rotations in non-continuous printing, however, the drum unit life is counted by the number of drum rotations. Since the drum counter printed in Print Settings is an actual page counter after a new drum unit is replaced, the drum unit life may be different from the drum counter. For details on the difference between the drum unit life and drum counter, refer to the drum unit life calculation below;


Confidential 7-13

< How to calculate Drum Unit Life >

The number of drum rotations per one page printing is about 11 rotations. (Page counter reduced by the number of drum rotations) = (the number of drum rotations) ÷ 11 - The number of drum rotations per one page printing continuously = 3.6

rotations. - The number of drum rotations while warming-up = 9 rotations Example:

The number of pages calculated from drum rotations Cold start (page) Hot start (page)

1 page/job (9 + 11) / 11 = 1.82 11 / 11 = 1 2 pages/job (9 + 11 + 3.6) / 11 = 2.15 (11 + 3.6) / 11 = 1.33 18 pages/job (9 + 11 + 3.6 x 17) / 11 = 7.38 (11 + 3.6 x 17) / 11 = 6.56 If printing 1 page per job with cold start, the drum unit life is decreased earlier.

(ii) Counter information, history information The counter and history information related to the following term are included. When it reaches the maximum count, each term is no longer counted. • Page counter

The total number of pages printed. The maximum count is 1 million pages.

• Coverage on the Letter-size paper Average printing rate. The average of the total printed area against the printable are on the Letter-size paper. The coverage is calculated when up to 1 million pages are printed, and it is not updated after this. It is not printed on the Print Settings by default. (It is printed on the maintenance sheet by default.)

• Total pages printed (TRAY) The number of times that each of the Tray1, Tray2, Tray3, MP tray and Duplex tray is used. (For the Duplex tray, the number of times is printed only for the models supporting the Duplex tray, and it is not printed for HL-5240.) The maximum count for each item is 1 million times. The information above is not cleared when replacing the PF kit.

• Total pages printed (PAPER) The number of A4/Letter, A4Long/Legal/Folio, B5/Excutine, Envelope, A5 and other paper types used. The maximum count for each item is 1 million times.

• Total paper jams The number of paper jam occurrence in each of the Tray1, Tray2, Tray3, MP tray and Duplex tray. (For the Duplex tray, the number of occurrence is printed only for the models supporting the Duplex tray, and it is not printed for HL-5240.) The paper jam which occurs when the printer is turned ON is not counted. The maximum count for each item is 255 times.

• Replace count The number of replacement of each of the drum unit, toner cartridge, PF Kit, Tray 1/2/3, MP tray, fuser unit and laser unit. The maximum count for each item is 65535 times.


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• Error history The error history including the 10 latest errors and the number of pages when these errors occur are indicated. The errors such as Cover Open, Manual Feed, No Paper XX and No Tray XX are not included. The list is updated until the 1 millionth error occurs, and it is not even when more than 1 million errors occur. The page counter when each error occurred is also indicated.

• Developing bias The current developing bias is indicated. It is not printed on the Print Settings by default. (It is printed on the maintenance sheet by default.)

• Number of prints for each toner cartridge The number of printed pages for each of the toner cartridges used currently and last. (It is printed only in the maintenance sheet.) The maximum count is 65535 pages.

< Page 3 ~ > This page includes various network settings information of the printer.

(8) Sleep Mode Indication (OFF/Dimmed) This is to select whether the Ready LED is turned off completely or lit in green with low light intensity during the Sleep mode. Whenever you switch this mode, the setting is changed over from the present one to the other. When you take your finger off from this switch, the Ready LED is lit in 100% light intensity or low light intensity according to the setting so that you can verify the present setting.

(9) Sleep Mode Setting (ON/OFF) This is to allow you to turn on and off the sleep mode of the printer. The default setting is ON. The machine automatically goes back to the ready state after the operation is completed.

(10) Developer Roller Counter Reset 1 (For the standard toner) (11) Developer Roller Counter Reset 2 (For the high yield toner)

Since print density is likely to become darker as toner is getting older, the developing bias is lowered by degrees according to the number of prints so that an almost fixed density can be maintained from the start of the use of brand-new toner to the end of it. The value of the developing bias is printed on the maintenance sheet. The developing bias is a parameter which depends on the developing assembly, so it needs to be reset when the developing assembly is replaced. At that time, the developing roller counter reading is also reset. This mode is to enable to execute these operations (equivalent to those done when the developing assembly is replaced) manually from the service mode.

(12) Fixed USB Speed This allows you to switch the setting of Full fixed / Auto switching (HIGH/FULL) of the USB speed. Whenever switching, the current setting is changed to the other one. The default setting is Auto switching. It also allows you to check the selected setting by the TONER or DRUM LED being lit for 1 second when releasing the button. The former shows that the setting is Full fixed, and the latter shows Auto switching.

(13) USB Speed Indication (ON/OFF) This allows you to switch whether the current USB speed is indicated with the LED or not. Whenever switching, the current setting is changed to the other one. The USB speed is not indicated by default. It also allows you to check the selected setting by the TONER and DRUM LEDs being lit for 1 second or all LEDs being lit for 1 second when releasing the button. The former shows that the USB speed indication is ON, and the latter shows OFF.


Confidential 7-15

2. HIDDEN FUNCTION MENUS

The three hidden function menus are provided for the HL-5270DN/5280DW printer with the LCD.

• (by pressing the Go and Set buttons at the same time.) • (by pressing the Go and + buttons at the same time.) • (by pressing the + and Set buttons in this order while holding down the Go button.)

The method to enter the special mode by the button operation is as follows:

<Pressing the 1 button when the printer is turned ON>

Panel Function

Go To Users Mode Reprint Continuous test printing + Hex Dump Mode - Version Check Set Initializing the NVRAM

<Pressing the 2 button when the printer is turned ON>

Panel Function

Set & Back Rewriting the Flash ROM Go & + Checking the hardware (DRAM check, etc.) Go & Back - & + Factory Line Inspection Mode Go & Set Clearing the E50 (FUSERMULF)

<Pressing the 2 button in the normal status>

Panel Function

Go & + RESET PARTS LIFE (Clearing the counters of the periodical replacement parts)

Go & Set Professional Menu - & Set Indicating the error descriptions (The details of the service call or

paper jam occurrence section are indicated in English.)

<Others in the normal status>

Panel Function

Go & (+, Set) Service Menu (Acquiring the service information such as the number of replacement or paper jam occurrence, error, etc.)

Go & (-, +, Set) Developer Menu (Setting the specific function for the engineers)


Confidential 7-16

2.1 Professional Menu The main purpose of the professional menu is to customize the printer function which is opened to the users as per request. To enter the professional menu, press the Go and Set buttons at the same time.

< Function Table >

Title & Subtitle Item to be Set Description

TRAY SETTING MANUAL FEED PAPER IN=CONT* Feeds paper automatically when

printing using the manual feed function.

PAPER IN=STOP Feeds paper by pressing the Go button when printing using the manual feed function.

RESET SETTINGS RESET SETTING1 Selects the “User setting 1” as the current printer setting.

SAVE SETTINGS SAVE SETTING1 Saves the current printer setting as the “User setting 1”.

SAVE FONT PRIMARY FONT SET ID=#### Saves the current primary fonts in

LaserJet Emulation into the storage devices (ROM Disk). After fixing the first three digits with the Set button, set the last two digits.

SECONDARY FONT SET ID=#### Saves the current secondary fonts in LaserJet emulation into the storage devices (ROM Disk). After fixing the first three digits with the Set button, set the last two digits.

DOWNLOAD FONT DOWNLOAD=#### Saves the downloaded fonts in LaserJet emulation into the storage devices (ROM Disk). After fixing the first three digits with the Set button, set the last two digits.

SAVE MACRO (When a macro is registered if the LaserJet emulation is selected.)

SET ID=#### Saves the macro in LaserJet emulation into the storage devices (ROM Disk). After fixing the first three digits with the Set button, set the last two digits.

TRAY COM.=NORM.* HP LaserJet 4 compatible. TRAYCOMMAND MODE TRAY COM.=SPEC. HP LaserJet 3 compatible. READOUT=ON When receiving DC3 in FX

emulation, ignores the data received before DC1.

READOUT SELECT

READOUT=OFF* Not ignore the data even DC3 is received.


Confidential 7-17


FONT SELECT FONT=ALL* Enables all scalable fonts when

selecting PCL font setting. SCALABLE FONT (Only when the LaserJet emulation is selected.)

FONT=LJ4 Disables the fonts below when selecting PCL font setting. Atlanta, Bermuda Script, PC Brussels, Copenhagen, Germany, Portugal, Calgary, San Diego, US Roman

PRIMARY FONT Selects primary fonts in LaserJet emulation.

FONT SELECT

SECONDARY FONT Selects secondary fonts in LaserJet emulation.

IBM E1H=Esszet* Places “Esszet” on E1h of IBM character set.

IBM CHR SET MODE

IBM E1H=Beta Places “Beta” on E1h of IBM character set.

W BOLD=OFF* Does not convert into bold even if the same character is entered into the same position in the FX or XL emulation.

W BOLD ON/OFF

W BOLD=ON Converts into bold if the same character is entered into the same position in the FX or XL emulation. (The print speed is lowered.)

DLFNT Bd/It=NO* Creates the bold and italic letters from the download font.

DLFNT Bd/It

DLFNT Bd/It=YES Does not create the bold and italic letters from the download font.

B PROD=ON* Creates the bold and italic letters from the bitmap font.

B PROD ON/OFF

B PROD=OFF Does not create the bold and italic letters from the bitmap font.

CONDENC=16.66p* Sets the pitch of the condense letter in the EPSON/IBM emulation to 16.66 pitches.

CONDENCE SELECT

CONDENC=17.14p Sets the pitch of the condense letter in the EPSON/IBM emulation to 17.14 pitches.

OEMFONT=DISABLE* Disables the European Parliament fonts.

OEM FONT SELECT

OEMFONT=ENABLE Enables the European Parliament fonts.

DARKFONT=DISABLE* Disables the bold brougham font.

DARKFONT SELECT DARKFONT=ENABLE Enables the fold brougham font.


Confidential 7-18


FONT SELECT BROBITM=DISABLE* Disables the internal brougham

bitmap fonts of 10 and 12 pitches.

BRO FONT SELECT

BROBITM=ENABLE Enables the internal brougham bitmap fonts of 10 and 12 pitches.

ISRFONT=DISABLE Normal mode

ISR FONT SELECT ISRFONT=ENABLE Israel Mode

3B PRIO=LOW* The priority of selection for 300dpi bitmap fonts is standard (=low). Command <ESC><CR>!1T

300DPI PRIORITY

3B PRIO=HIGH The priority of selection for 300dpi bitmap fonts is high. Command <ESC><CR>!2T

SCAL.F=NORMAL* Only similar size fonts are selectable as scalable is selected.

FX/XL SCALE FONT (Setting related to the default font and font selected on the panel in the EPSON/IBM emulation.)

SCAL.F=ALL SIZE All size fonts are selectable as scalable font is selected.

ITA=OBLIQUE* Makes upright font oblique to have italic as scalable font is selected.

FX/XL SCALE ITA. (Setting related to italic of scalable font when the EPSON/IBM emulation.)

ITA=ITALIC SEL Uses the upright font to have italic as scalable font is selected.

DEF PAPER=A4 Printers to be shipped to the other area than USA and Canada have the A4 size setting by default.

PAPER&TRAY SIZE

DEF PAPER=LT Printers to be shipped to USA and Canada have the Letter size setting by default.

PARALLEL MENU CDCC BSSL=L* ACK signal is sent out before BUSY

signal goes down. STB/ACK DELAY

CDCC BSSL=H ACK signal is sent out when BUSY signal goes down.

REPRINT=ON* The ON/OFF setting of the reprint function follows the setting of the user menu.

REPRINT ON/OFF

REPRINT=OFF Turns the reprint function OFF forcedly.

PS BINARY=ASCII* Default setting. A problem may occur when printing the binary data though Ctrl-T, Ctrl-C and the like are enabled.

PS BINARY SELECT

PS BINARY=BIN Allows you to print the binary data though Ctrl-T and the like are disabled.


Confidential 7-19


PS QUOTEBIN=OFF* Not accept the binary data even with special codes.

PS QUOTE BINARY

PS QUOTEBIN=ON Accepts the binary data with special codes.

PS IMAGEMSK=OFF* Does not rewrite the IMAGEMSK procedure.

PS IMAGE MASK

PS IMAGEMSK=ON Rewrites the IMAGEMSK procedure. PS CEIL=FLOOR* PS CELL MODE PS CEIL=CEIL STATUS ECHO=ON* PS STATUS ECHO STATUS ECHO=OFF PRO.OFF=AUTO* Carries out the page protect if it is

turned OFF. (Memory full, Print overrun)

PROTECT OFF MODE

PRO.OFF=NORMAL Specification up to the fourth Mask ROM.

HP ESC E=RESET* Normal resetting. HP ESC E COMMAND HP ESC E=F/F Form feeds a printable page only. DPX SUP. =NOMAL* Deletes all white pages having no

data. DPX FF SUP. MODE

DPX SUP. =SPEC. Deletes only the page that both sides of paper is white.

PS300RESO=NO* Does not reduce the resolution automatically.

PS300RESO=IF 2M Reduces the resolution to 300dpi when the total memory is 2Mbytes.

PS300RESO

PS300RESO=FORCE Reduces the resolution to 300dpi. COPY PAGES=ON* COPY PAGES COPY PAGES=OFF

OFF: 1 page is fixed for the copy page number.

TIMEOUT=ON* PJL JOB TIMEOUT is effective. JOB TIMEOUT SEL TIMEOUT=OFF PJL JOB TIMEOUT does not carry

out. PICKUP RETRY SET PICKUP RETRY=2*

(0-7)

JOB CANCEL TIME TIME OUT=???sec PSCOPYPAGE=L3* PSCOPYPAGE PSCOPYPAGE=L2

Changes the PS copypage operator from Level3 to Level2.

1JOB1PAGE=SX* 1JOB1PAGE SEL 1JOB1PAGE=DX

Duplex=ON makes the printing speed of 1 page of data faster. Sets up the printing mode. (Simplex/Duplex)

BINARY=OFF* APPLEUSBPS BINARY=ON

Enables to print PS Pure Binary data via Mac USB.


Confidential 7-20


MPTRAY YADJUST PCTRAY YADJUST DUPLEX YADJUST

Adjusts the position of starting scanning in each paper tray. -50 to 50 dot (300dpi)

MPTRAY XADJUST TRAY1 XADJUST TRAY2 XADJUST TRAY3 XADJUST

MP CAS ADJUST

DUPLEX XADJUST

Adjusts the position of starting scanning in each paper tray. -100 to 750 dot (300dpi)

NET HEAP SIZE HEAPSIZE=xxxxK* Changes the size of the beep area used on Web. Allows you to change the size by 15 degrees. (The value from 0 to 14 is stored in the NVRAM internally.)

CLEAR CACHE=OFF* PS FONT CACHE CLEAR CACHE=ON

Controls whether the font cache is cleared or not when finishing a job in the PS emulation. When setting to OFF, the font cache is not cleared and is enabled for the next job. When setting to ON, the font cache is cleared and disabled for the next job.

POWER SAVE=ON* POWER SAVE POWER SAVE=OFF

Implements the power save setting. It is not allowed to set the power save setting to OFF on the panel. When the setting to OFF, the power save time is not displayed on the panel.

TONERLOW=ON* Checks toner with the duty level of 2%. (Default)

TONERLOW=DELAY Checks toner with the duty level of 8%.

TONER LOW Changes the timing when the toner low error is detected.

TONERLOW=OFF Does not detect the toner low error. T1 FIX=OFF* The media type of Tray1 follows the

one set in the print data. T1 FIX=PLAIN Fixes the media of Tray1 to plain

paper. T1 FIX=TRANS. Fixes the media of Tray1 to

transparencies. T1 FIX=THIN Fixes the media of Tray1 to thin

paper. T1 FIX=BOND Fixes the media of Tray1 to bond

paper.

T1 MEDIA FIX Selects the media type of Tray1. The default setting is OFF. When fixing the media to any type of setting, the printer ignores the media type set in the print data (driver) and prints with the media type set in the printer.

T1 FIX=RECYCLED Fixes the media of Tray1 to recycled paper.


Confidential 7-21


T2 FIX=OFF* The media type of Tray2 follows the one set in the print data.

T2 FIX=PLAIN Fixes the media of Tray2 to plain paper.

T2 FIX=TRANS. Fixes the media of Tray2 to transparencies.

T2 FIX=THIN Fixes the media of Tray2 to thin paper.

T2 FIX=BOND Fixes the media of Tray2 to bond paper.



T3 FIX=OFF* The media type of Tray3 follows the one set in the print data.

T3 FIX=PLAIN Fixes the media of Tray3 to plain paper.

T3 FIX=TRANS. Fixes the media of Tray3 to transparencies.

T3 FIX=THIN Fixes the media of Tray3 to thin paper.

T3 FIX=BOND Fixes the media of Tray3 to bond paper.



DEF ERRPRT=AUTO* Identifies the model and determines the default value automatically. HL-5240/5250DN: ON HL-5270DN/5280W: OFF

DEF ERRPRT=OFF Sets the default value of PCL error print to OFF.

DEF PCL ERRPRT Sets the default value of PCL error print. The setting value is reflected on the setting value of PCL error print when implementing PJL initialization or factory reset.

DEF ERRPRT=ON Sets the default value of PCL error print to ON.


Confidential 7-22

2.2 Reset Parts Life Menu The reset parts life menu is used when the service personnel replace the periodical replacement parts. This menu is divided into the service menu described in the next section since it is supposed that a user replaces such parts if the replacement operation is easy. To enter the reset parts life menu, press the Go and + buttons at the same time.

< Function Table >

Title Item to be Set Description

DRUM UNIT Initializes the drum unit remaining life.

PF KITMP Initializes the paper feeding kit MP remaining life.

PF KIT 1 Initializes the paper feeding kit 1 remaining life.



FUSER UNIT Initializes the fuser unit remaining life.

Reset Parts Life Menu

LASER UNIT Initializes the laser unit remaining life.


Confidential 7-23

2.3 Service Menu The main purpose of the service menu is to provide the service personnel with the printer information. To enter the service menu, press the + and Set buttons in this order while holding down the Go button.

< Function Table >

Title Subtitle Description

PAGE COUNT Displays the number of printing pages. JAM COUNT

JAM MP TRAY JAM TRAY1 JAM TRAY2 JAM TRAY3 JAM INSIDE JAM REAR JAM DUPLEX

Displays the number of jam occurrence.

REPLACE COUNT TONER Displays the number of the toner cartridge unit

replacement. DRUM UNIT Displays the number of the drum unit

replacement. PF KIT MP PF KIT 1 PF KIT 2 PF KIT 3

Displays the number of the PF kit replacement. PF kit MP/1/2/3 = PF kit for MP Tray / Tray1 / Tray2 / Tray3.

FUSER UNIT Displays the number of the fuser unit replacement.

LASER UNIT

Displays the number of the laser unit replacement.

COVERAGE Displays the average coverage (when printing Letter size paper at 100% print coverage).

PRINT PAGES A4/LTR PAGE LGL/A4LONG PAGE B5/EXE PAGE ENVELOPE PAGE A5 PAGE

SERVICE INFO

OTHER PAGE

Displays the number of pages when printing each paper size. PRINT PAGES counter will be effective until it counts up to 100,000 pages for each paper size. A4/LTR: A4, Letter LGL/A4LONG: Legal, A4 long, FOLIO B5/EXE: ISO B5, JIS B5, Executive ENVELOPE: C5, COM10, DL, DLL, MONARCH A5: A5 OTHER: Other paper than the ones described

above. ERROR HISTORY

1:####### 2:####### 3:####### …… 10:#######

Displays the 10 latest errors in order of newest to the oldest.


Confidential 7-24


DRUM UNIT Displays the drum unit life period. (page) PF KIT Displays the PF kit life period. (page) FUSER UNIT Displays the fuser unit life period. (page)

LIFE PERIOD

LASER UNIT Displays the laser unit life period. (image) DRUM LIFE CHK %

Sets up the timing of showing “CHANGE DRUM SOON” message. Default setting: 90%, Setting range: 1 to100%

JAM COUNT Displays the total number of paper jam occurrence.

JAM MP TRAY JAM TRAY1 JAM TRAY2 JAM TRAY3 JAM INSIDE JAM REAR JAM DUPLEX

The number of paper jam occurrence can be changed only to 0. (Reset only)

REPLACE COUNT TONER Displays the number of the toner cartridge

replacement. DRUM UNIT Displays the number of the drum unit

replacement. PF KIT MP PF KIT 1 PF KIT 2 PF KIT 3

Displays the number of the PF kit replacement. PF kit MP/1/2/3 = PF kit for MP Tray / Tray1 / Tray 2 / Tray 3.

FUSER UNIT Displays the number of the fuser unit replacement.

LASER UNIT Displays the number of the laser unit replacement.

REMAIN LIFE DRUM UNIT Displays the drum unit remaining life counters.

(page) DRUM UNIT2 Displays the drum unit remaining life counters.

(rotation) PF KIT MP PF KIT 1 PF KIT 2 PF KIT 3

Displays the PF kit remaining life counters. PF kit MP/1/2/3 = PF kit for MP Tray / Tray1 / Tray 2 / Tray 3.

FUSER UNIT Displays the fuser unit remaining life counters.

MODIFY COUNT (When setting the number of remaining life, the cursor moves to upper digits every time the Set button is pressed. The counter is set by pressing the Set button when the cursor is placed at the top digit.)

LASER UNIT Displays the laser unit remaining life counters.


Confidential 7-27


CLEAR COVERAGE Initialize average coverage counter. RESET COUNT CLEAR ERROR HIST Initialize error history.

NV-RAM DEBUG NV-RAM HEX PRINT Prints NV-RAM HEX dump. PPDS SUBSET ON/OFF Supports the PPDS Subset command in the FX

Emulation mode. FAN TEST Carries out movement test of FANs. TEST MENU FAN 1=ON/OFF* Carries out movement test of main fan, LVPS

fan. MOTOR TEST

MAIN MOTOR=ON/OFF*

Carries out movement test of main motor.

SCAN MOTOR=ON/OFF*

Carries out movement test of scanner motor.

SENSOR TEST FRONT COVER=ON/OFF

Front cover sensor (ON: Close)

T1 KOUTAN=ON/OFF

T1 tail edge sensor

T2 KOUTAN=ON/OFF

T2 tail edge sensor

T3 KOUTAN=ON/OFF

T3 tail edge sensor

REGI-MAE=ON/OFF Regist front sensor REGI-ATO=ON/OFF Regist rear sensor EJECT=ON/OFF Paper eject sensor T1 PAPER=ON/OFF Tray 1 paper sensor T2 PAPER=ON/OFF Tray 2 paper sensor T3 PAPER=ON/OFF Tray 3 paper sensor MP PAPER=ON/OFF

MP Tray paper sensor

DX UNIT=ON/OFF The DX unit is closed. (ON: Close) REAR COVER=ON/OFF

Back cover sensor (ON: Close)

NEW TONER=ON/OFF

New toner sensor

T2 CONNECT=ON/OFF

Tray 2 connect sensor

T3 CONNECT=ON/OFF


T4 CONNECT=ON/OFF



Confidential 7-26


MAINTENANCE PRINT

Always prints the maintenance and consumable parts information on the second page of the Print Settings. <Developing Bias: xxx V> is added to the end of the page. The xxx characters show 400 V when the developer counter is 0 page, and it is designed that they are changed gradually from 400V to 300V at 4,000 pages (for standard cartridge) or 7,000 pages (for high yield cartridge). They remain 300V after 4,000 pages (for standard cartridge) or 7,000 pages (for high yield cartridge).


Confidential 7-27

3. NVRAM DEFAULT VALUE

The default values for the main items to be set in NVRAM are as follows;

Items Descriptions

Timing of Drum LED ON 25,000 pages

(Counted from the drum unit life.)

Development switching timing

The developing bias is switched from 400V to 300V gradually when 4,000 pages (Standard cartridge), 7,000 pages (High yield cartridge) are printed. It is switched to 400V again when the toner cartridge is replaced with the new one.

(Counted from the number of the drum rotation in non-continuous printing)

Fixing temperature • Transparency: 185°C • Thin paper: 195°C • Plain paper: 213°C • Thick paper: 200°C • Thicker/Bond paper: 200°C (in non-continuous printing)

Smaller size mode Refer to 3.8 ‘PRINT SPEEDS WITH VARIOUS SETTINGS’ in Chapter 1.

Paper size The default paper size is "A4". The paper size needs to be changed in US and other countries.


A-1 Confidential

45MHz

22.5MHz

22.5MHz

100kHz

DATA[0]

DATA[1]

DATA[2]

DATA[3]

DATA[7]

DATA[6]

DATA[5]

DATA[4]

DATA[11]

DATA[12]

DATA[14]

DATA[15]

DATA[10]

DATA[9]

DATA[8]

DATA[13]

45MHz

SD_D[15-0]

45MHz

SD_ADR[0]

SD_ADR[1]

SD_ADR[3]

SD_ADR[2]

SD_ADR[5]

SD_ADR[6]

SD_ADR[4]

SD_ADR[7]

SD_ADR[9]

SD_ADR[10]

SD_ADR[8]

SD_ADR[11]

SD_ADR[12]

45MHz

45MHz

45MHz

45MHz

45MHz

90MHz

90MHz

90MHz

45MHz

45MHz

45MHz

45MHz

45MHz

45MHz

45MHz

45MHz

45MHz

45MHz

45MHz

ADR[1]

ADR[2]

ADR[4]

ADR[3]

ADR[8]

ADR[6]

ADR[5]

ADR[7]

ADR[12]

ADR[16]

ADR[10]

ADR[9]

ADR[15]

ADR[14]

ADR[11]

ADR[13]

ADR[24]

ADR[18]

ADR[17]

ADR[23]

ADR[22]

ADR[19]

ADR[20]

ADR[21]

SD_D[0]

SD_D[1]

SD_D[2]

SD_D[3]

SD_D[4]

SD_D[5]

SD_D[6]

SD_D[7]

SD_D[8]

SD_D[9]

SD_D[10]

SD_D[11]

SD_D[12]

SD_D[13]

SD_D[14]

SD_D[15]

22.5MHz

150MHz

C103C5P

R1344.7k

SGND

C102C5P

X2

SMD-49 48.00MHz

1

2

3-2A/3-3A/4-1AIO_WR_N

3-2A/3-3A/4-1AIO_RD_N

3-3AROM0_CS_N

3-2AROM1_CS_N

4-1ALAN_CS_N

+3.3VC87

C103SGND

+3.3V

SGND

C101C103

+1.5VC246

C103

SGND

R2661.5k1%(F)

R15410 4-8B

CDCC_CLK4-8B

CDCC_DATA4-8B

CDCC_RST_N4-8B

CDCC_INT_N4-8B

CDCC_REQ_N

4-7FPHOTO_RXD

4-7EDEBUG_RXD

4-6EDEBUG_TXD

4-6FPHOTO_TXD

2-6EEEPROM_CLK

R263100

TP2872-6E

EEPROM_DATA

5-1AHEATERON1

C208C22P

R2441M

C209C22P

X3

SMD-4923.46178MHz

1

2

SGND

5-4AVBDN

3-2A/3-5A/3-6ERESET_N

R1061k

C68

C101

3-1D/4-1EDATA[15-0]

R105 47

R272 47

R269 33

R271 33

@R273 33

3-1D/4-1DADR[24-1]

2-1CSD_D[15-0]

R24647

2-1ASD_ADR[12-0]

R247 47

R124 47

R123 47

R248 47

R151 82

R121 47

R150 33

R149 33

R122 33

R260 68

R133 33

R262 47

R251 47

R250 10

R259 47

R258 10

R249 47

R120 47

R116 47

2-3B/2-7CSD_BA0

2-3B/2-7CSD_BA1

2-3B/2-7DSD_RAS_N

2-3B/2-7DSD_CAS_N

2-3B/2-7DSD_WE_N

2-3B SD_CLK0

2-3BSD_CKE

2-3BSD_CS0_N

2-3B/2-7BSD_DQM0

2-7D SD_CLK1

2-7D SD_CLK2

2-7DSD_CS1_N

2-7DSD_CS2_N

2-3B/2-7BSD_DQM1

2-7BSD_DQM2

2-7BSD_DQM3

2-7BSD_DQM6

2-7BSD_DQM4

2-7BSD_DQM7

2-7BSD_DQM5

4-1BLAN_INT

R1251.6k1%(F)

R25439

R26539

4-8EUSB_VCC

6-5BDCCTL

C247C103

SGND

SGND

4-8DUSB_DATA_P

4-8DUSB_DATA_M

TP343

TP258 TP220

TP323

TP328

TP318

TP320

TP319

TP317

TP326

TP322

TP325

TP324

TP327

TP237

TP235

TP236

TP234

TP238

TP275

TP273

TP241

TP272

TP243

TP214

TP213

TP240

TP280

TP278

TP281

TP283

TP276

TP274

TP277

TP279

TP284

TP244

TP271

TP224

TP288

TP251

TP291

TP333

TP374

SGND

5-4CPNLLED0

5-4CPNLLED2

5-4CPNLSW0

6-5DSCNFGS

L7

BLM18PG300SN1B

(1608)

L6 (1608)

0

C88C106

(2012)

C86

C103

C82

C104

C81

C104

5-2B/5-7DTHM_CENTER

TP290

SGND

SGND

SGND

+3.3VC207

C103

C231

C103

C232C106

(2012)SGND

L17

BLM11P300SPB(1608)

TP254R2451 (1608)

L9

BLM11P300SPB(1608) R156

1 (1608)

C120

C103SGND

TP223

C119C106

(2012)

5-4CPNLLED1

SGND

C67

C103

TP315

C66C106

(2012)

R1041 (1608)

L5BLM18PG300SN1B

(1608)

TP330

TP331

TP329

TP332

TP218

TP22

TP245

TP6

TP340

TP249

TP29

TP215

TP30

TP250

SGND

SGND

SGND

+1.5V

SGND

C222C103

SGND

C225C103

+3.3V

+1.5V

SGND

C227C103

+1.5V

SGND

C248C103

SGND

+1.5VC241

C103

SGND

+1.5VC238

C103

+1.5VC237

C103

SGND

SGND

+3.3VC228

C103C226

C103

SGND

+3.3VC243

C103C244

C103

C230C103

C245C103

SGND

+3.3VC239

C103C240

C103

SGND

+3.3VC242

C103C223

C103

C221C103

UGND

+1.5V

+1.5V+1.5V

+1.5VC233

C103

R2561 (1608)

C234C106

(2012)

L18

BLM11P300SPB(1608)

TP253

TP259

UGND

TP256

SGND

C249C101

CH2TMODEN

6-7CDCFGS

R253 10k

(ASIC def )

TP209

R237 1

TP217

TP210

TP316

SGND

5-5BLD_MON

+3.3VTP226

4-5EJTAG_RST

4-5EJTAG_CK

4-5EJTAG_MS

4-5EJTAG_RMODE/BKTGIO

4-5EJTAG_DI

4-5ENTRC_CLK

4-5FNTRC_DATA0

4-5FNTRC_DATA1

4-5FNTRC_DATA3

4-5FNTRC_DATA2

4-5ENTRC_END

4-5EJTAG_DO

+1.5V

SGND

C229C103

C236C103

SGND

6 3

RA15335 4

8 1

7 2

7 2

8 1

RA14

335 4

6 3

8 1

7 2

RA13

335 4

6 3

7 2

RA12

335 4

6 3

8 1

6 3

5 4

RA8

338 1

7 2

6 3

5 4

RA7

338 1

7 2

RA4

338 1

6 3

7 2

6 3

5 4

5 4

RA5

338 1

7 2

5 4

RA3

338 1

7 2

RA2

338 1

5 4

6 3

7 2

6 3

5 4

7 2

5 4

7 2

6 3

RA38

478 1

6 3

RA36

478 1

5 4

6 3

7 2

RA37

478 1

TP219

TP247

TP41

TP407

TP25

TP187

TP242

R23533

TP221

+3.3V

R268 10k

ASIC def )SGND

R238 5.6k

TP216

5-4AVDON

UGND

UGND

+3.3V

5-2DPEDG_SEN

5-2DREG_F_SEN

5-2DREG_R_SEN

5-7EPO_SEN

5-7BPNEW_SEN

5-7CFRONT_COVER_SEN

5-2DT1_PE_SEN

5-2EMP_PE_SEN

5-7EDX_UNIT_SEN

5-4ELT1_PE_SEN

5-4ELT1_PEDG_SEN

5-4FLT_DET1

5-4FLT_DET2

5-4ELT2_PE_SEN

5-4ELT2_PEDG_SEN

5-1AHEATERON2

TP24

TP23

5-2DHVVCLN

5-1EFAN_MAIN_12V

5-1EFAN_MAIN_24V

5-1FFAN_PS_12V

5-1FFAN_PS_24V

5-4CPNLSW1

6-5BDCFR

6-5DSCNCTL

5-1ARLYOFFN

5-3BHTLIMITN

TP252

TP222

TP20

R255 1

R242 0

C113

C102

C116

C102

C117

C102

C114

C104

10%

SGND

5-2DHVPWMTRCC

5-2DHVPWMTRCV

5-2DHVPWMCHG

5-2DHVPWMDEV

5-2B/5-7DTHM_EDGE

5-2CFB_VCLN

5-2CFB_DEV

5-2CFB_GRID

5-2DFB_TRCCV

5-2DFB_TR

5-4BVENBN

5-4FLT_DET3

5-6CTNR_SEN

5-5ELT2_SOL

5-7EDX_SOL

5-7AT1_SOL

5-7BMP_SOL

5-7BREG_SOL

5-5DLT1_SOL

R240 100

5-4CPNLLED3

5-4CPNLLED4

5-2CGRIDC

5-6CPWM_TNRSEN

U6

UPD800268F1-011-MN9-A

AI0/BD_SMPW18

AI1Y18

AI2Y17

AI3/FB_VCLNW17

AI4/FB_DEVW16

AI5/FB_GRIDY16

AI6W15

AI7/FB_TRY15

TSTMODENW5

TSTCLKY5

TMC1Y7

TMC2W7

TENT18

TAPC_NWIRE_SELV13

THMODEW14

NOTAP_TEST_SELW13

BUNRIL16

GND_J9J9

GND_K9K9

GND_L9L9

GND_M9M9

GND_M10M10

GND_M11M11

GND_M12M12

GND_L12L12

GND_K12K12

GND_J12J12

GND_J11J11

GND_J10J10

GND_K10K10

GND_L10L10

GND_L11L11

GND_K11K11

GND_W9W9

GND_V9V9

GND_U9U9

GND_Y10Y10

GND_V10V10

GND_U10U10

AD_AVDDV17

AD_AGNDV14

AD_AVREFPV16

AD_AVREFMU14

VDD_E5E5

VDD_E7E7

VDD_G5G5

VDD_U2U2

VDD_P5P5

VDD_P4P4

VDD_T5T5

VDD_T4T4

VDD_U7U7

VDD_T7T7

VDD_Y13Y13

VDD_T14T14

VDD_T16T16

VDD_P16P16

VDD_K16K16

VDD_G16G16

VDD_E16E16

VDD_E14E14

VDD_E11E11

VDD_E10E10

VDD3_J5J5

VDD3_K5K5

VDD3_M5M5

VDD3_T3T3

VDD3_V6V6

VDD3_U13U13

VDD3_T13T13

VDD3_U15U15

VDD3_M16M16

VDD3_J16J16

VDD3_D17D17

VDD3_E12E12

VDD3_E9E9

GND_E6E6

GND_F5F5

GND_H5H5

GND_L5L5

GND_N5N5

GND_R3R3

GND_R5R5

GND_T6T6

GND_V7V7

GND_W12W12

GND_V12V12

GND_U12U12

GND_T12T12

GND_V15V15

GND_T15T15

GND_R16R16

GND_N16N16

GND_H16H16

GND_F16F16

GND_E15E15

GND_E13E13

GND_E8E8

U6

UPD800268F1-011-MN9-A

SXOUTY6

SXINW6

RSTICNV20

EXINTN0D20

EXINTN1F17

EXINTN2/PD01E17

DREQN/PD00E18

DATA00U19

DATA01R18

DATA02U20

DATA03T19

DATA04T20

DATA05R19

DATA06P17

DATA07P18

DATA08R20

DATA09P19

DATA10N18

DATA11N17

DATA12P20

DATA13M17

DATA14N19

DATA15N20

SDBKUPNB16

DIMMD00D2

DIMMD01C1

DIMMD02C2

DIMMD03E3

DIMMD04D3

DIMMD05F4

DIMMD06B1

DIMMD07C3

DIMMD08A1

DIMMD09E4

DIMMD10D4

DIMMD11B2

DIMMD12D5

DIMMD13A2

DIMMD14D6

DIMMD15B3

DIMMD16/PE00C4

DIMMD17/PE01C5

DIMMD18/PE02A3

DIMMD19/PE03A4

DIMMD20/PE04B4

DIMMD21/PE05C6

DIMMD22/PE06B5

DIMMD23/PE07A5

DIMMD24/PE08B6

DIMMD25/PE09D7

DIMMD26/PE10C7

DIMMD27/PE11A6

DIMMD28/PE12B7

DIMMD29/PE13C8

DIMMD30/PE14D8

DIMMD31/PE15A7

SDAV18

SSCG_AVDDY4

SSCG_AGNDY3

IORDNE20

IOWRNF19

CSROMN0E19

CSROMN1F18

EXCSN0D19

EXCSN1/PA01D18

EXCSN2/PA02C19

DACKN/PA00C20

ADR01M18

ADR02M19

ADR03M20

ADR04L18

ADR05L19

ADR06L20

ADR07L17

ADR08K17

ADR09K19

ADR10K20

ADR11K18

ADR12J20

ADR13J19

ADR14J18

ADR15H20

ADR16H19

ADR17J17

ADR18G20

ADR19H17

ADR20H18

ADR21G19

ADR22F20

ADR23G18

ADR24G17

DIMM_VDDE1

DIMMD_GNDG3

GND_D1D1

SDCLK0G4

SDCLK1F2

SDCLK2E2

SDCKEF3

SDCSN0B12

SDCSN1C12

SDCSN2A13

SDRASNB13

SDCASND12

SDWENA14

SDBA0C11

SDBA1A12

SDDQM0D13

SDDQM1C13

SDDQM2B14

SDDQM3A15

SDDQM4C14

SDDQM5D14

SDDQM6B15

SDDQM7A16

MA00D9

MA01B8

MA02A8

MA03C9

MA04B9

MA05A9

MA06C10

MA07A10

MA08B10

MA09D10

MA10D11

MA11A11

MA12B11

SCLT17

U6

UPD800268F1-011-MN9-A

VXOUTP1

VXINR1

VBDNW1

IDADC0/PWMA1/PB00G1

IDADC1/PWMA2/PB01J4

IDADC2/PWMA3/PB02H2

IDADC3/PWMA4/PB03H1

IDADC4/PWMA5/PB04J3

IDADC5/PB05J2

IDADC6/PB06J1

IDADC7/PB07K3

IDADC8/PF04K2

IDINT/PB14M1

IDBGNT/PB09K4

IDRACK/PB13L3

IDDREQ/PB10L4

HS1RXD/HEAT2G2

HS2RXD/PDIP2

HS3RXD/PC03W20

HS3CTS/PC05U18

DBGRXDY19

PHRXDW19

CDCC_DATAV3

CDCC_INTNY2

CDCC_REQNU6

VBUS/PC14Y14

USB_RPUV11

USB_DPT10

USB_DMT9

USB_RSDPT11

USB_RSDMT8

USB_RREFY11

DCFGS/PC08R2

SCNFGS/PC10N3

HTLMTN/PC13N2

JTRSTB18

JTCKA18

JTMSB17

RMODE_BKTGIOA17

JTDIC15

APLL_AGNDV1

APLL_AVDDU1

VDON0/PA08W2

VDON1/PA09U4

CAL0/PA10/VIB0M4

CAL1/PA11/VIB1N4

ENB0/PA12/VIOP0V2

ENB1/PA13/VIOP1R4

LDHALF/PA14/TLEDU3

IDCLKH3

IDRSTN/PWMA0H4

IDBREQ/PB08K1

IDRREQ/PB12L1

IDDACK/PB11L2

HS1TXD/HEAT1F1

PCLK/PC11V4

HS2TXD/PDOU5

HS3TXD/PWMA7Y20

HS3RTS/PWMA8R17

DBGTXDU16

PHTXDU17

CDCC_CLKY1

CDCC_RSTNV5

USB_PVDDV8

USB_PVSSW8

USB_AVDDW11

USB_AVSSY12

USB_VDD331Y8

USB_GND1Y9

USB_VDD151U11

USB_GND2W10

USB_COMU8

DCFR/VS/PC06T2

DCCTL/PC07T1

SCNCTL/PC09P3

RLYOFFN/PC12N1

REV0/PWMDEVM3

REV1/PWMCHGW4

REV2/PWMVCLNW3

REV3/PWMTRCCM2

REV4/EXCSN2BNV19

PLL_AVDDB20

PLL_AGNDB19

NTRC_CLKD16

NTRC_DATA0C18

NTRC_DATA1A20

NTRC_DATA2A19

NTRC_DATA3D15

NTRC_ENDC17

JTDOC16

A3.3V

A3.3V

R241 33 4-1BLAN_RST

5-4BLDHALF

5-1ETNRLED

R23410k

(ASIC def )SGND

TP21

R252 10k

(ASIC def )

TP18

R236 100

TP257

TP314

TP255 TP191

5-4CPNLLED5

R135100

2-6EDIMM_SPD_CLK

R500 33

TP501

TP500TP502

TP503

R243100

+3.3V

R14810k

R152

10k

+3.3V

R153 1k

R147 6.8k

SGND

R239 10k+3.3V

TP615

Main Asic (Valkyrie)

High Speed UART2/PIO

Debug UART

CDCC I/F

USB

DC MOTOR CTL / PIO

Low Speed AD/C

High Speed UART1

High Speed UART3/PIO

SCANER MOTOR CTL/PIO

HEATER CTL/PIO

POWER

MAIN ASIC(1/3)MAIN ASIC(2/3)

MAIN ASIC(3/3)

Laser/PO

ID_BUS

CPU/JTAG

Test

( )

(Analog )

(PLL )

(Digital )

System PLL1.35V 1.65V

sys_clkPLL

EEPROM

SDRAM

Local BUS

(Digital )

(VIDEO PLL )

HVPS/PIO

(SDRAM CLK )

(+3.3V input)

D

B

A

C

E

F

E

D

B

A

C

F

1

1 2 3 4 6 7 8

2 3 4 5 6 7 8

5

Appendix 1. Main PCB Circuit Diagram, HL-5240/5250DN/5270DN/5280DW (1/6)

NAME

CODE

B512210CIR (1/6)

APPENDIX

Confidential

A-2

IMA[9]

IMA[3]

IMA[8]

IMA[2]

IMA[7]

IMA[1]

IMA[12]

IMA[6]

IMA[11]

IMA[5]

IMA[10]

IMA[4]

SD_ADR[6]

SD_ADR[12]

SD_ADR[7]

SD_ADR[2]

SD_ADR[4]

SD_ADR[1]

SD_ADR[5]

SD_ADR[3]

SD_ADR[10]

SD_ADR[0]

SD_ADR[8]

SD_ADR[11]

SD_ADR[9]

45MHz

90MHz

90MHz

45MHz

45MHz

45MHz

45MHz

45MHz

IMA[0]

45MHz

45MHz

45MHz

IMA[12]

45MHz

SD_ADR[12]

IMA[12-0]45MHz

DMD[15-0]DMD[15-0]

45MHz

DMD[0]

DMD[1]

DMD[2]

DMD[3]

DMD[4]

DMD[5]

DMD[6]

DMD[7]

DMD[8]

DMD[15]

DMD[9]

DMD[13]

DMD[10]

DMD[12]

DMD[11]

DMD[14]

45MHz

45MHz

DMD[15-0]

DMD[0]

DMD[1]

DMD[3]

DMD[2]

DMD[5]

DMD[6]

DMD[4]

DMD[7]

DMD[1]

DMD[2]

DMD[0]

DMD[3]

DMD[4]

DMD[6]

DMD[5]

DMD[1]

DMD[0]

DMD[2]

DMD[0]

DMD[4]

DMD[1]

DMD[7]

DMD[6]

DMD[3]

DMD[3]

DMD[4]

DMD[6]

DMD[5]

DMD[5]

DMD[7]

DMD[2]

90MHz

45MHz

45MHz

45MHz

45MHz

45MHz

SD_ADR[0]

SD_ADR[1]

SD_ADR[2]

SD_ADR[3]

SD_ADR[8]

SD_ADR[9]

SD_ADR[10]

SD_ADR[11]

IMA[0]

IMA[1]

IMA[2]

IMA[3]

IMA[4]

IMA[5]

IMA[6]

IMA[7]

IMA[8]

IMA[9]

IMA[10]

IMA[11]

45MHz

DMD[0]

DMD[1]

DMD[3]

DMD[2]

DMD[6]

DMD[7]

DMD[5]

DMD[4]

DMD[14]

DMD[10]

DMD[11]

DMD[9]

DMD[8]

DMD[13]

DMD[15]

DMD[12]

0.5

DMD[7]

DMD[9]

DMD[10]

DMD[11]

DMD[12]

DMD[13]

DMD[14]

DMD[15]

DMD[8]

DMD[9]

DMD[8]

DMD[11]

DMD[12]

DMD[13]

DMD[14]

DMD[15]

DMD[10]

DMD[9]

DMD[8]

DMD[14]

DMD[13]

DMD[15]

DMD[12]

DMD[15]

DMD[8]

DMD[12]

DMD[11]

DMD[11]

DMD[9]

DMD[13]

DMD[14]

DMD[10]

DMD[10]

SD_D[0]

SD_D[1]

SD_D[2]

SD_D[3]

SD_D[4]

SD_D[5]

SD_D[6]

SD_D[7]

SD_D[8]

SD_D[9]

SD_D[10]

SD_D[11]

SD_D[12]

SD_D[13]

SD_D[14]

SD_D[15]

45MHz

45MHz

45MHz

45MHz

SD_ADR[7]

SD_ADR[6]

SD_ADR[5]

SD_ADR[4]

C145

C103

C189

C103

C146

C103

C190

C103

C188

C103

C187

C103

1 VSS

2 VSS

CN12

144PIN SO-DIMM

3 DQ0

4 DQ32

5 DQ1

6 DQ33

7 DQ2

8 DQ34

9 DQ3

10 DQ35

CN12144PIN SO-DIMM

11 VDD

12 VDD

13 DQ4

14 DQ36

15 DQ5

16 DQ37

17 DQ6

18 DQ38

19 DQ7

20 DQ39

21 VSS

22 VSS

CN12144PIN SO-DIMM

23 DQMB0

24 DQMB4

25 DQMB1

26 DQMB5

27 VDD

28 VDD

29 A0

30 A3

31 A1

32 A4

33 A2

34 A5

35 VSS

36 VSS

37 DQ8

38 DQ40

39 DQ9

40 DQ41

41 DQ10

42 DQ42

43 DQ11

44 DQ43

45 VDD

46 VDD

47 DQ12

48 DQ44

49 DQ13

50 DQ45

51 DQ14

52 DQ46

53 DQ15

54 DQ47

55 VSS

56 VSS

57 NC/CB0

58 NC/CB4

59 NC/CB1

60 NC/CB5

61 CK0

62 CKE0

63 VDD

64 VDD

65 nRAS

66 nCAS

67 nWE

68 CKE1

69 nCS0

70 A12

71 nCS1

72 A13,DSP

73 NC

74 CK1

75 VSS

76 VSS

77 NC,nMWAIT/CB2,nMWAIT

78 NC,nMIRQ/CB6,nMIRQ

79 NC/CB3

80 NC/CB7

81 VDD

82 VDD

83 DQ16

84 DQ48

85 DQ17

86 DQ49

87 DQ18

88 DQ50

89 DQ19

90 DQ51

91 VSS

92 VSS

93 DQ20

94 DQ52

95 DQ21

96 DQ53

97 DQ22

98 DQ54

99 DQ23

100 DQ55

101 VDD

102 VDD

103 A6

104 A7

105 A8

106 BA0

107 VSS

108 VSS

109 A9

110 BA1

111 A10/AP

112 A11

113 VDD

114 VDD

115 DQMB2

116 DQMB6

117 DQMB3

118 DQMB7

119 VSS

120 VSS

121 DQ24

122 DQ56

123 DQ25

124 DQ57

125 DQ26

126 DQ58

127 DQ27

128 DQ59

129 VDD

130 VDD

131 DQ28

132 DQ60

133 DQ29

134 DQ61

135 DQ30

136 DQ62

137 DQ31

138 DQ63

139 VSS

140 VSS

141 SDA

DMM3-RS144A2B-13

142 SCL

143 VDD

144 VDD

145 FG

DMM3-RS144A2B-13

146 FG

C130C104

C128C104

C141C104

C127C104

C137C104

C136C104

C126C104

C125C104

C140C104

C123C104

C135C104

C122C104

C134C104

C121C104

C133C104

1-3D/3BSD_BA0

1-3E/3BSD_BA1

1-3DSD_CS1_N

1-3DSD_CS2_N

1-3D/3BSD_RAS_N

1-3D/3BSD_CAS_N

1-3D/3BSD_WE_N

1-3DSD_CLK1

1-3DSD_CLK2

TP84

R230 47

R224 47

SGND

+3.3V

+3.3V

SGND

SGND

+3.3V

SGND

+3.3V

SGND

+3.3V

SGND

+3.3V

SGND

+3.3V

SGND

+3.3V

+3.3V

+3.3V

SGND

SGND

+3.3V

SGND

+3.3V

SGND

+3.3V

SGND

SGND

+3.3V

SGND

+3.3V1-3E/3BSD_DQM0

1-3E/3BSD_DQM1

1-3ESD_DQM2

1-3ESD_DQM3

1-3ESD_DQM7

1-3ESD_DQM4

1-3ESD_DQM6

1-3ESD_DQM5

+3.3V

1-3E/7BSD_DQM0

1-3E/7BSD_DQM1

@R21747

1-3ESD_ADR[12-0]

1-1CSD_D[15-0]

SGND

SGND

SGND

SGND

TP179

TP182

TP119

TP177

+3.3V

R223100

TP58

TP76

TP145

TP80

TP196

TP173

TP198

TP167

TP147

TP116

SGND

+3.3V

C129C104

TP78

TP82

TP129

TP43

TP113

TP146

TP81

TP83

TP79

R215 47

1-3E/7CSD_BA1

TP211

R216 0

TP133

TP178

1-3DSD_CLK0

1-3DSD_CKE

1-3D/7CSD_BA0R214 47

TP122

TP131

TP42R228 47

1-3D/7DSD_CAS_N

1-3D/7DSD_WE_N

1-3DSD_CS0_N

1-3D/7DSD_RAS_NR227 47

R229 47

TP181

TP132

+3.3V

SGND

+3.3V

C203C103

+3.3V

C139C104

SGND

C138C104

SGND

+3.3V

@U13

M24C16-WMN6TP

16kbits EEPROM

8 VCC 4VSS

1A0

2A1

3A2

5 SDA

7 TEST

6 SCL

R222100

SGND

TP109

TP124

TP185

TP134

TP186

TP92

TP128

TP125

TP127

TP126

TP141

TP140

TP139

TP138

TP94

TP135

TP137

TP136

TP112

TP169

TP114

TP172

TP115

TP166

TP111

TP163

1-1FEEPROM_DATA

1-3FEEPROM_CLK

TP110

TP143

TP188

TP144

TP189

TP120

TP121

TP118

TP176

TP117

TP285

TP108

R2204.7k

+3.3V

6 3

5 4

RA3533

8 1

7 2

5 4

6 3

7 2

RA34

338 1

6 3

RA33

338 1

7 2

5 4

5 4

7 2

RA32

338 1

6 3

6 3

5 4

5 4

6 3

7 2

7 2

RA3047

8 1

RA29

478 1

R207 0

TP286

TP246

TP174

TP175

TP130

TP180

TP184

TP183

6 3

RA2322

8 1

7 2

5 4

RA2222

8 1

5 4

6 3

7 2

7 2

RA2522

8 1

5 4

6 3

7 2

5 4

6 3

RA2622

8 1

TP51

TP47

TP85

TP89

TP268

TP248

@U11

K4S281632F-UC75

SDRAM(128Mbit/256Mbit)

CS19

RAS18

CAS17

WE16

LDQM15

UDQM39

CLK38

CKE37

BA020

BA121

A023

A124

A225

A326

A429

A530

A631

A732

A833

A934

A10/AP22

A1135

A12/NC3636

NC40

VDD11

VDD1414

VDD2727

VDDQ33

VDDQ99

VDDQ4343

VDDQ4949

VSS2828

VSS4141

VSS5454

A12/NC66

VSSQ1212

VSSQ4646

VSSQ5252

DQ02

DQ14

DQ25

DQ37

DQ48

DQ510

DQ611

DQ713

DQ842

DQ944

DQ1045

DQ1147

DQ1248

DQ1350

DQ1451

DQ1553

R219 47

R218 47

R226 47

R225 47

TP59

TP55

TP77

TP56

TP57

TP142

TP54

TP75

TP74

TP195

TP192

TP197

TP194

TP193

TP190

TP171

TP170

TP168

TP165

TP164

TP162

TP50

TP49

TP48

TP46

TP45

TP44

TP86

TP87

TP88

TP90

TP91

TP93

1-6ADIMM_SPD_CLK

TP616

SDRAM,SODIMM,EEPROM

54pin TSOPII

D

B

A

C

E

F

E

D

B

A

C

F

1

1 2 3 4 6 7 8

2 3 4 5 6 7 8

5


NAME

CODE

B512210CIR (2/6)


A-3Confidential

DATA[13]

DATA[5]

DATA[11]

DATA[0]

DATA[14]

DATA[6]

DATA[10]

DATA[2]

DATA[15]

DATA[12]

DATA[7]

DATA[4]

DATA[1]

DATA[8]

DATA[9]

DATA[3]

ADR[3]

ADR[4]

ADR[5]

ADR[6]

ADR[7]

ADR[8]

ADR[13]

ADR[9]

ADR[10]

ADR[16]

ADR[11]

ADR[12]

ADR[17]

ADR[20]

ADR[21]

ADR[1]

ADR[2]

ADR[4]

ADR[3]

ADR[7]

ADR[8]

ADR[6]

ADR[5]

ADR[11]

ADR[12]

ADR[13]

ADR[16]

ADR[15]

ADR[10]

ADR[14]

ADR[9]

ADR[21]

ADR[17]

ADR[23]

ADR[18]

ADR[24]

ADR[20]

ADR[23]

ADR[1]

ADR[2]

ADR[3]

ADR[4]

ADR[5]

ADR[6]

ADR[7]

ADR[8]

ADR[9]

ADR[10]

ADR[16]

ADR[14]

ADR[11]

ADR[13]

ADR[12]

ADR[15]

ADR[18]

ADR[17]

ADR[19]

ADR[22]

ADR[20]

ADR[21]

ADR[23]

ADR[22]

ADR[1]

ADR[2]

ADR[3]

ADR[6]

ADR[5]

ADR[4]

ADR[9]

ADR[8]

ADR[11]

ADR[12]

ADR[10]

ADR[7]

ADR[14]

ADR[18]

ADR[16]

ADR[17]

ADR[13]

ADR[15]

ADR[23]

ADR[19]

ADR[21]

ADR[20]

ADR[22]

DATA[0]

DATA[1]

DATA[3]

DATA[2]

DATA[5]

DATA[4]

DATA[7]

DATA[6]

DATA[9]

DATA[14]

DATA[15]

DATA[12]

DATA[8]

DATA[11]

DATA[10]

DATA[13]

ADR[19]

ADR[17]

DATA[14]

ADR[6] DATA[1]

DATA[4]

ADR[21]

DATA[0]

ADR[19]

ADR[10]

DATA[11]

ADR[1]

ADR[5]

DATA[9]

ADR[15] DATA[10]

ADR[9]

ADR[3]

DATA[7]

ADR[16]

ADR[8]

DATA[15]

DATA[8]

DATA[3]

DATA[12]

DATA[5]

DATA[6]ADR[11]

ADR[4]

ADR[7]

ADR[14]

ADR[12]

ADR[13]

ADR[2]

DATA[13]ADR[18]

DATA[2]

ADR[14]

ADR[22]

ADR[20]

@U15

MBM29PL64LM-10PCM

CE32

WE13

OE34

RY/BY17

BYTE53

RESET14

A031

A126

A225

A324

A423

A522

A621

A720

A810

A99

A108

A117

A126

A135

A144

A153

A1654

A1719

A1818

A1911

A2012

A2115

A222

A231

A2456

A2555

VCC43

VSS5252

VSS3333

VI/0(VCCQ)29

NC2727

NC2828

NC3030

WP/ACC16

DQ035

DQ137

DQ239

DQ341

DQ444

DQ546

DQ648

DQ750

DQ836

DQ938

DQ1040

DQ1142

DQ1245

DQ1347

DQ1449

DQ15/A-151

TP424

@C251C104

@C254

C104

+3.3V

+3.3V

+3.3V

SGND

SGND

+3.3V

SGND

+3.3V

TP321

TP380

TP379

R28210k

R30010k

R29710k

R30110k

R29810k

R29910k

R29510k

R29410k

R29110k

R29310k

R29210k

SGND

+3.3V

R29610k

R4210k

R27610k

R8010k

R28910k

R7510k

R7910k

R3510k

R3810k

R7410k

R4310k

R9310k

R3910k

R8510k

@R30510k

R4010k

R7610k

R4410k

R8710k

R4610k

R3610k

R3710k

R4810k

R27710k

R30410k

@R8110k

R8610k

R8810k

@R30610k

C54C103

C55C103

TP3011-1A/2A/5A

RESET_NTP356

TP414

TP431

TP402

TP426

TP421

TP398

TP420

TP423

TP418

TP427

TP401

TP429

TP415

TP430

TP400

TP425

TP417

TP422

TP408

TP375

TP416

TP419

TP428

TP310

TP305

TP304

TP348

TP344

TP303

TP309

TP350

TP308

TP349

TP302

TP345

TP306

TP307

TP342

TP346

@U16

MR27V12850J-034TN

CE24

OE27

BYTE1

A023

A122

A221

A320

A419

A518

A617

A716

A810

A99

A108

A117

A126

A135

A144

A153

A162

A1715

A1814

A1911

A2013

A2112

A2236

VCC3737

VCC3838

VSS2525

VSS2626

VSS4747

VSS4848

D028

D130

D232

D334

D439

D541

D643

D745

D829

D931

D1033

D1135

D1240

D1342

D1444

D15/A-146

SGND

SGND

+3.3V

U4

S-80928CLNB

VDD2

CD3

VSS1

OUT4

1-3A/2A/4-1AIO_WR_N

1-3AROM0_CS_N

1-3B/4-1DADR[24-1]

1-1B/4-1EDATA[15-0]

1-3A/2A/4-1AIO_RD_N

@C253C104

+3.3V

TP405

+3.3V

@R267 1k

1-3AROM1_CS_N

SGND

1-1A/5A/6ERESET_N

1-3A/3A/4-1AIO_RD_N

1-3A/3A/4-1AIO_WR_N

TP404

+3.3V

1-1A/2A/6ERESET_N

@R56 1k

@U14

MBM29PL32BM90TN-K-E1

11WE

12RESET

27VSS27

37VCC

6A10

5A11

25A0

4A12

14WR/ACC

13NC

46VSS46

23A2

24A1

22A3

20A5

29DQ0

44DQ7

31DQ1

33DQ2

21A4

19A6

18A7

26CE

15RY/BY

8A8

7A9

1A15

2A14

3A13

48A16

38DQ4

35DQ3

40DQ5

42DQ6

28OE

47BYTE

17A17

16A18

9A19

10A20

30DQ8

32DQ9

34DQ10

36DQ11

39DQ12

41DQ13

43DQ14

45DQ15/A-1

@R8310k

R29010k

TP312

TP455

+3.3V

+3.3V

TP413

ROM, Reset IC, Board id

56pin TSOP1

MASK ROM(128/64Mbit)

MIRROR FLASH (128/64Mbit)

RESET IC

ROM0

48pin TSOP1

ByteByte

NCWP/ACC

NC

64M

A21

FUJITSU

RY/BY

NC

RY/BY

A19

A21

ROM1

DL

WP/ACC

Mirror

OKI

type

OKI

Byte

NC

P2ROM

64M

Vccq

A21

32M

A19

48PIN TSOP1

64M

A19

NCNC

Byte

32M

*NC pin Vss Vcc

P2ROM

FUJITSU

A19

47

TOSHIBA

NC

13

NC14

PIN16M

FLASH PIN

ACC

WP

FLASH (64/32Mbit)

15

A19

A19

type

RY/BY

Byte

LV

9

D

B

A

C

E

F

E

D

B

A

C

F

1

1 2 3 4 6 7 8

2 3 4 5 6 7 8

5


NAME

CODE

B512210CIR (3/6)

APPENDIX

Confidential

A-4

CDCC_GA

LAN I/F, CDCC I/F, USB I/F, Debug Serial I/F

30pin TSOP

8:not use

5:not use

green

7:not use

3:RX+

yellow

2:TX-

1:TX+

4:not use

orange

6:RX-

0.5mm pitch 100pin TQFP

Speed

Link&Activ

Full Duplex

(SMD 16x3.6)

22.5MHz

22.5MHz

22.5MHz

45MHz

ADR[3]

ADR[7]

ADR[4]

ADR[2]

ADR[5]

ADR[1]

ADR[6]

DATA[8]

DATA[9]

DATA[10]

DATA[11]

DATA[12]

DATA[13]

DATA[14]

DATA[15]

DATA[0]

DATA[1]

DATA[2]

DATA[3]

DATA[4]

DATA[5]

DATA[6]

DATA[7]

0.5

C152

C101

C195

C101

1-4CCDCC_DATA

1-4DUSB_DATA_P

1-6DCDCC_RST_N

C147

C101

TP61

C194

C101

@DA3

DF5A6.8FU(F)

C3

C1

C2

AC4

R2081k

R2121.5k

@DA2

DF5A6.8FU(F)

C3

C1

C2

AC4

C191C101

@DA1DF5A6.8FU(F)

C3

C1

C2

AC4

C148

C101

C196C103

C200

C103

C201

C101

C149

C101

1-4DUSB_DATA_M

C193

C101

1-4DCDCC_INT_N

C143

C101

1-4DUSB_VCC

1-6CCDCC_CLK

R10715k

R210

33

C151

C101

C153

C101

C154

C101

@DA4

DF5A6.8FU(F)

C3

C1

C2

AC4

1-4DCDCC_REQ_N

C142

C101

C198

C101

R21333

R211

33

SGND

C150

C101

C199

C101

C197

C101

R209

33

1-4C DEBUG_RXD

B2B-PH-K-Y(LF)

2DBTXD1-6C

DEBUG_TXD

B2B-PH-K-M(LF)

2PHRXD

CN19PHOTO-DEBUG

1PHTXD1-6C PHOTO_TXD

1-4CPHOTO_RXD

U8

1B

4Y

5VCC

2A

3GND

@CN20DEBUG

1DBRXD

@CN15

1 5V

B2B-PH-K-PK(LF)(SN)

2 GNDSGND

+3.3V

SGND

+5.0V

+5.0V

+5.0V

SGND

+3.3V

SGND

SGND

SGND

TP32

TP8

TP60

TP95

TP225

TP148

U12

CDCC-GA

RSTN/SIN21

INTN24

REQN/SOUT22

CLK/SCK25

DATA23

AMC13

SMC20

VDD511

VDD577

VDD51616

GND2626

VDD330

GND1515

ACKN6

BUSY5

PE4

SELECT3

FLTN28

AFN2

SELINN29

INITN27

STBN17

D018

D119

D214

D312

D411

D510

D69

D78

TP69

@U9

TC7SH08FU(F)

(SSOP5)5V->3.3V Level

1B

4Y

5VCC

2A

3GND

TP33

SGND

+3.3V

R18310k

SGND

@R18410k

+3.3V

R1090

R1860

SGND

R1360

SGND

+5.0V

SGND

+5.0V

SGND

SGND

+5.0V

R10810k

TP334

TP63

TP62

TP65

SGND

TP64

SGND

SGND

@R58

330

@C29

C103

TP382

@R6249.9

(2012)

TP386

@C27C8P

@R9149.9

(2012)

@C60C104

TP435

@C25

C103

@C59C104

4BLAN_LEDB_N

2BLAN_LEDB_N

TP376

@C37

C103

@C39

C103

TP433

@C51

C103

TP354

@R8949.9

(2012)

@C255

C102

@C33C104

4ALAN_LEDA_N

2BLAN_LEDA_N

@X1SMD-49 25.00MHz

@R571M

TP377

@C38

C103

@R283100

@C50

C103

@R96100

@C30C10P

@R9049.9

(2012)

@C32C104

@L2

BLM18PG300SN1B

(1608)

@R98 100

(1608)

@CN5

08B0-1X1T-03-F

LAN

1 TCT

2 TD+

3 TD-

4 RD+

5 RD-

6 RCT

7 LED1_C

8 LED1_A

9 LED2

10 LED2

11 FG

12 FG

@C257C103

(1005)25VDC10%(B)

@C26

C103

@R308100

(1608)

@C256

C103

TP378

+3.3V

SGND

+3.3V

SGND

1-6BLAN_RST

1-3A/3-2A/3-3AIO_RD_N

1-3A/3-2A/3-3AIO_WR_N

1-3ALAN_CS_N

1-1ALAN_INT

1-3B/3-1DADR[24-1]

1-1B/3-1DDATA[15-0]

TP353

TP351

SGND

SGND

SGND

TP385

TP388

TP390

TP391

+3.3V

+3.3V

SGND

SGND

TP150

TP99

TP68

TP72

TP53

C192C103

FG2

SGND

C202C103

SGND

1-4FJTAG_CK

1-4FJTAG_MS

1-4FJTAG_RST

1-4FJTAG_DI

1-5FJTAG_DO

1-5FNTRC_CLK

1-5FNTRC_END

+3.3V

R270

4.7k

R13210k

+3.3V

SGND

1-4FJTAG_RMODE/BKTGIO

+3.3V

R11910k

@ZD3

UDZS6.8B

R1880

FG1

R1260

SGND

7 2

@RA10

08 1

5 4

6 3

6 3

7 2

@RA9

08 1

5 4

@RA6

08 1

7 2

6 3

5 4

5 4

6 3

7 2

@RA1

08 1

RA2733

8 1

7 2

6 3

5 4

RA24100

8 1

7 2

6 3

5 4

6 3

5 4

RA31100

8 1

7 2

7 2

RA28100

8 1

5 4

6 3

RA201.5k

81

72

63

54

RA211.5k

81

72

54

63

RA182.2k

81

72

63

54

54

72

RA192.2k

81

63

TP384

TP7

TP282

TP270

1-5FNTRC_DATA3

1-5FNTRC_DATA2

1-5FNTRC_DATA1

TP3131-5F

NTRC_DATA0

@R9710k

@U1

LAN9115

XTAL16

XTAL25

nCS94

nRD92

nWR93

IRQ72

nRESET95

SPEED_SEL74

FIFO_SEL76

ATEST9

RESERVE7171

RESERVE7373

RESERVE7575

RESERVE8484

A118

A217

A316

A415

A514

A613

A712

D064

D163

D262

D359

D458

D557

D656

D753

D852

D951

D1050

D1149

D1246

D1345

D1444

D1543

VDD(D16)40

VDD(D17)39

VDD(D18)38

VDD(D19)37

VDD(D20)36

VDD(D21)33

VDD(D22)32

VDD(D23)31

VDD(D24)30

VDD(D25)29

VDD(D26)26

VDD(D27)25

VDD(D28)24

VDD(D29)23

VDD(D30)22

VDD(D31)21

PME70

EXRES187

RBIAS10

TPO+79

TPO-78

TPI+83

TPI-82

GPIO0/nLED198

GPIO1/nLED299

GPIO2/nLED3100

EED/GPO3/nD16BUS67

EECLK69

EECS/GPO468

VDD_REF8

VSS_REF11

VDD_PLL7

GND_PLL4

VDD_CORE33

VDD_CORE6565

GND_CORE11

GND_CORE6666

AVDD8181

AVDD8585

AVDD8989

AVDD9191

AGND7777

AGND8080

AGND8686

AGND8888

AGND9090

VREG2

VDD2020

VDD2828

VDD3535

VDD4242

VDD4848

VDD5555

VDD6161

VDD9797

GND1919

GND2727

GND3434

GND4141

GND4747

GND5454

GND6060

GND9696

@C261

C103

@C52

C106

@C260C106

SGND

SGND

@C28C103

TP383

TP352

TP436

SGND

+3.3V

TP387

TP355

TP389

TP357

@C42

C103

@C40

C106

L3.3V

LGND

+3.3V

@C259

C103

@C53

C103

@R95 10k+3.3V

@R284 12.4k

@C43

C10P

L3.3V

@C44C682

@C45C682

@R60 10(2012) 1%(F)

LGND

SGNDOT1

LGND

@C31

C223

(1005)16VDC10%(B)

LGND

TP311

TP149

TP269

TP151

TP101

TP73

TP100

TP71

TP97

TP52

TP70

TP67

TP96

TP98

TP66

TP434

TP381

TP438

TP359

@R307 12k1%(F)

TP504

TP505

35NC

7DI6

15NC

260V

33NC

210V

12PE

9DI8

32FLTn

240V

14ATFEEDn

31INPRIMn

36SELINn

2DI1

3DI2

170V

34NC

11BUSY

190V

220V

300V

8DI7

6DI5

1STBn

37FG

280V

13SELECT

10ACKn

290V

38FG

200V

270V

4DI3

250V

CN13CDCC

160V

5DI4

230V

18+5V

1PC_+5V

6FG

3DP

4GND

CN7USB

2DM

CONNECTOR:UBR24-4K2300LG5459001

5FG

SGND

SGND

TP602

TP605

TP603

TP604

SGND

TP600

TP601

TP606

C612

C103

R600 10k

TP607SGND

R601

10kSGND

R501 1.5k

TP611

TP610

TP609

TP608

TP613

TP612

TP614

11NTRC_DATA0

6JTAG_DI

9NTRC_CLK

7JTAG_DO

2VDD3

10NTRC_END

CN6

1S0V

4JTAG_MS

5JTAG_RST

3JTAG_CK

13NTRC_DATA2

8JTAG_RMODE

BM14B-SRSS-TB

14NTRC_DATA3

12NTRC_DATA1

NC

NC

NC

NC

D

B

A

C

E

F

E

D

B

A

C

F

1

1 2 3 4 6 7 8

2 3 4 5 6 7 8

5


NAME

CODE

B512210CIR (4/6)


A-5 Confidential

+

ANALOG

ANALOG

ANALOG

180mA0.5

ANALOG

ANALOG

(200mA)

(200mA)

450mA0.5

0.4

110mA

0.4 110mA

625mA

450mA

ANALOG

1-4CHEATERON2

R141

18k

1%(F)

TP450

C105C102

C235

C104(1608)

TP157

1-6ERLYOFFN

TP267

TP295TP451

C210

C103

Q13

DTC143ZUA

C

B

E

C206C103

C205C102

L8

TP156

R142

680

1%(F)

TP260

C3

R8 100

1-7BFB_DEV

10 PWM_TRCC

19 GRIDC

23 PWM_VCLN

C85

R13 100

1-7BFB_GRID 20 FB_GRID

14 /TRCV

TP448

C8

TP444

C70

12 FB_TRCCVR12 100

1-7EHVPWMTRCC

1-7BFB_VCLN

1-1EREG_F_SEN

1-7EHVPWMTRCV

C6C102

CN1

22 VCC24

13 FB_TR

R14 100

1-7EHVPWMDEV

1-7CFB_TRCCV

R15

1k

TP446

11 24RET

8 REG_FRONT_SEN

C5

TP447

C73

C102

R16 100

16 PWM_DEV

21 FB_VCLN

C1C103

17 S0V

TP397

1-7CFB_TR

TP449R17 100

R11 100

C84

1-7EHVPWMCHG

C72

C102

R10

68k

C83

C102

C9C104

1-4BHVVCLN

15 PWM_CHG

18 FB_DEV

1 VCC3.3V

TP399

C4

C101

1-6CGRIDC

C2

C7

C102

1-6CPNLLED1

1-4CPNLLED0

R179 1k

1-6CPNLLED2

1-6BPNLLED3

1-4CPNLSW0

TP26

L13 0

L14 0

L15 0

L16 0

R178 4.7k

C184

1-4BFAN_MAIN_24V

C19

C102(1608)

R2801k

ZD2

BZX85-C11(PITCH=15)

3 FAN_MAIN

TP3691-4B

FAN_MAIN_12V

TP370

R71

10k

R28810k

TP368 TP395

R721k

1-4CPNLSW1

TP27

C115

C102

C252

C102

C183

C182

C101

C181

R181 1k

R180 1k

1-4BTNR_SEN

TP16

C161

C102

R168470k

R170 10k

C144

C102

@D61SS355

TP36 @Q7

2SD1484K

C

B

E

R163 820 TP35

R16210k

1-4BDX_SOL

4 TNRLED

1-6BTNRLED

TP161

1-6CHEATERON1

Q12

DTC143ZUA

C

B

E

C204C102

R64

10k

R30

18k

1%(F)

1-7B/2BTHM_EDGE

CN3

4 VDD3

TP441

C15C101

C69

C103

1-7A/2BTHM_CENTER

6 THM_EDGE

C71C103

TP440

L1(1608)

0

5 THM_CENTER

R63

10k

R29

18k

1%(F)

C16

C101

1 S0VSGND

1-1EPO_SEN

R2868k

R61 100

R59 100

1-1EDX_UNIT_SEN

C14

C101

TP439

C224

C102

3 PO_SEN

C13C101

TP437

R2768k

C216C102 IMSA-9615S-06A-PP-A

2 DX_UNIT_SEN

L12 0

1-6CPNLLED4

C180

1-4BLT1_SOL

1-4BLT2_SOL

C10C104

TP410

TP409

1-1ELT1_PEDG_SEN

C98

1-1ELT1_PE_SEN

C214

TP454

1-1ELT2_PE_SEN

1-1ELT2_PEDG_SEN

C21

TP456

C215

C102

C100

C99

TP452

TP411

C217

C102

1-1ELT_DET1

1-1FLT_DET2

Q9

2SC5865

C

B

E

C157

C102

1-4BT1_SOL

TP10

R199

10k

D71SS355

R200 470TP37

TP38

1-4BREG_SOL

TP12Q10

2SC5865

C

B

E

C158

TP39

1-4BMP_SOL

R204 470

Q11

2SC5865

C

B

E

TP13

C159

SGND

1-7A/7DTHM_CENTER

1-7B/7DTHM_EDGE

R201

10k

R203

10k

C168

C101

1-1EPNEW_SEN

TP14

1-1EFRONT_COVER_SEN

C160

C102

R166 100

R16768k

TP4451-1EREG_R_SEN

R9 100 9 REG_REAR_SEN

R7

68k

C212

C102

TP4421-1EPEDG_SEN

R4 100 6 PEDG_SEN

TP3721-1ET1_PE_SEN

R1 100 5 T1_PE_SEN

C211 C219

C218

C213

R5 100 7 MP_PE_SEN1-1E

MP_PE_SENTP443

R3

68k

R2

68k

R6

68k

R197

10k

C176

C102

2 GND

R1901k

C166

C27P

R1964.7k

R189

0

R182

680

3 DATA

6 PWMENB

TP288 BD

1-4AVBDN

R191

(1608)BLM18RK221SN1D

5 LDHALF

C174

C104 10%

R192

68k

C172

C101

C175C103

CN18

1 5VI

R27410k

TP338

R275 820Q14

A1577

C

B

E

1-6AVENBN

1-6AVDON

1-6ALDHALF

IMSA-9615S-08A-PP-A

7 LD_MON

C185

C102

R194 100

1-7ALD_MON

TP31

R67 33

1/2W

(10mm pitch)

R2781k

R28610k

ZD1

BZX85-C11(PITCH=15)

TP365

TP364

TP3661-6B

FAN_PS_12V

TP394

R68

10k

R691k

1-6BFAN_PS_24V IMSA-9615S-23A-PP

2 FAN_PS

C18

C102(1608)

TP412

1-1FLT_DET3

C220

C169C103

C12C103

5ACOVER/VDD5I

C163C103

TP3 L100

(1608)

TP123

Q8

DTC114YUA

C

B

E

R16968k

+3.3V

+3.3V

+3.3V

+3.3V

+3.3V

+3.3V

+3.3V

+3.3V

+3.3V

+3.3V

+3.3V

+3.3V

+5.0V

+8.0V

+5.0V

+24V_2

+24V_2

+24V

+24V_2

+24V

+24V

PGND

PGND

PGND

PGND

PGND

PGND

PGND PGND

PGNDPGND

SGND

SGND

SGND SGND SGND

SGND

SGND

SGND SGND SGND

SGND

SGND

SGND

SGND

SGND

SGND

SGND

SGND

SGND

SGND SGND

SGNDSGND

SGND

SGND

SGND

SGND

SGND

SGND

SGND

SGND

SGND

SGND

SGND

SGND

SGND

SGND

SGND

SGND

SGND

PGND

@CN14

1+24V

S2B-PH-K-S(LF)

2DX_SOL

+5.0V

C165C103

7B

COVER/VDD5I

4 5V+5.0V

C173C103

8 SW1

3 LED3

2 LED4

6 LED0/PNLRST

CN17

7 SW0 /PNLDI

4 LED2/PNLDO

5 LED1/PNLCLK

9 GND

S10B-PH-K-S(LF)

10 +5V

R198

10k

R193

0

SGND

R173

100k

R1611.2k

1%(F)

R16018k

1%(F)

TP106

SGND

SGND

TP40

R19568k

+3.3V

SGND

C186C103

R171 10k

SGND

1-4BPWM_TNRSEN

+5.0V

R205 10k

SGND

SGND

C164C10310%

C162C10310%

+3.3V

C89C103

TP347TP373

+5.0V

CN81 RELAYOFFN

CN89 HEATERONN1

CN810 HEATERONN2

CN84 +24V

CN85 +24V

CN82 24VRET

CN83 24VRET

CN88 S0V

CN87 +3.3V

CN8

B10B-EH

6 +8V

Q15

DTC114YUA

C

B

E

SGND

R54

68k

R45

68k

SGND

R140 10k+3.3V

SGNDR139 10k

+3.3V

TP1

TP11

TP4

TP228TP15

TP453

TP229 TP396

TP227 TP153R285

1k

+3.3V

R287

1k

+3.3V

R20668k

SGND

R70

1k

R73

1k

TP17

TP19

TP339

L11 0

1-5EPNLLED5 1 LED5

R172

100k

C179

ZD5UDZS36B

+24V_2

R281

1k

R279

1kZD4UDZS36B

+24V_2

TP367

TP371

+5.0V

C501

C100

10V( 6.3)

EEE1AA101SP

QA1

IMX17

1

5

6

QA1

IMX17

4

2

3

QA2

IMX17

1

5

6

QA2

IMX17

4

2

3

1 F_COV_SEN

2 S0V

IMSA-9615S-09A-PP-A

3 TNR_SEN

4 PNEW_SEN

5 +5V

6 MP_SOL

7 REG_SOL

8 T1_SOL

CN16

9 +24V

A3.3V

A3.3V

A3.3V

RA40 10081

72

63

RA40 10054

SGND

RA39

100k

27

18

36

45

R202 390

1-4EHTLIMITN

+3.3V

R606

10kU7

LM393PT6

57

U7

LM393PT2

31

U7

LM393PT

8V+

4V-

SGND

R607

10k

U10

LM393PT

8V+

4V-

U10

LM393PT6

57

U10

LM393PT 2

31

DA5

SDS2838

A1 C A2

DA6

SDS2838

A1 C A2

SGND

C617C103

C24

C101

SGND

C23

C22

C616

SGND

C615

C614

C101

L600(1608)

0

1 24RET

CN2

2 24V

3 LT1_SOL

4 3V

5 LT1_PE

6 LT1_PEDG

7 LT_DET1

8 LT_DET2

B12B-PH-K-S(LF)

9 LT_DET3

10 LT2_SOL

11 LT2_PE

12 LT2_PEDG

RA41 10081

72

63

54

RA42 68k

81

72

63

54

RA43 68k

81

72

63

RA43 68k54

C705

C101

C704

SGND

+24V_2

C711

C101

C702

C101

C700

SGND

SGND

C701

C703

C101SGND

C712

C713

C101

C716

C101

C717

C101

SGND

SGND

SGND

C714

C715

TP701TP702TP700

C708

SGND

C707

C101

C710

C709

C706

C724

R47

BLM15AG601SN1D

R55

BLM15AG601SN1D

Other PCB I/F Conector (LVPS HVPS LD PANEL RELAY_F RELAY_R TNR_SEN DX_SOL LT(opt.) )

4.7k

LVPS

47k

HEATER HARD-LIMIT295

3.3V0V HARD LIMIT ON

HVPS

PANEL

LED PORTL (RESET)H

4.7k

47k

RELAY_REAR

DX_SOL

LT(opt)

RELAY_FRONT

LD

(to LD POWER)

47k

10k

10k

47k

PWM

PWM

PWM

PWM

HEATER HARD-LIMIT308

3.3V0V HARD LIMIT ON

+

-

+

-

+

-

+

-

D

B

A

C

E

F

E

D

B

A

C

F

1

1 2 3 4 6 7 8

2 3 4 5 6 7 8

5


NAME

CODE

B512210CIR (5/6)

APPENDIX

Confidential

A-6

++

1.0

TP207

TP239

C110C104

CH11.5V

R146

1k 1%(F)

SGND

C111

C104

+3.3V

R145

200

1%(F)

+1.5V

D5RB751V-40

SGND

L4 0

L3 0

TP360

D4 RB751V-40

TP341

C58C104

TP2

C57C104

5BMAIN_UOUT

5BMAIN_VOUT

5BMAIN_WOUT

C79

C103

C78

C103

C77

C103

C90

C103

C91

C103

C92

C103

7AMAIN_UOUT

7BMAIN_VOUT

7B

MAIN_WOUT

7CSCANNER_UOUT

7CSCANNER_VOUT

7CSCANNER_WOUT

7CFG+

7CFG-

1-6EDCFR

C104

C103

C76C104

C61

C10050V

R100 1k

R99 1k

R138 1k

R137 1k

C34

C103

R114

0.47

(PITCH=12.5)1W

TP296C63

C104

R102

1.5k1%(F)

R10310k

1%(F)

C64

C104R11310k1%(F)

TP299

TP264

TP298

TP294

TP265

TP293

TP292

SGND SGND

5DSCANNER_VOUT

5DSCANNER_WOUT

5DSCANNER_UOUT

C62

C471

R101 150k

1%(F)1-4E

DCFGS

C106

C104

C94

C102

SGND

TP233

1-6ESCNCTL

R128

100k1%(F)

R127

100k1%(F)

TP230

C95

C102

TP231

1-4ESCNFGS

C75C102

R111

56k1%(F)

R112

56k1%(F)

1-6EDCCTL

TP261 C74

C102

+24V_2

A3.3V

SGND

SGND

PGND

PGND

SGND

SGND

+5.0V

TP232

TP266

+5.0V

CN4

19HU+

18HU-

17HV+

16HV-

15HW+

14HW-

12S0V

13+5V

11U

10U

9U

8V

7V

6V

5W

4W

3W

2FG+

IMSA-9615S-19A-PP-A

1FG-

+5.0V

IMSA-9615S-14A-PP-A

1COILW

2COILW

3COILV

4COILV

5COILU

6COILU

7S0V

8+5V

9HW-

10HW+

11HV-

12HV+

13HU-

CN10

14HU+

C47C104

SGND

+8.0V

C46C104

D3 RB751V-40

SGND

+5.0V

+5.0V

R144 10k+3.3V

U2

RQ5RW33B

VDD2

CE4

VOUT3

GND1

R129

100k

SGND

R110

100k

SGND

TP206

TP204

TP200

TP203

TP199

TP201

TP202

TP5

TP363

TP362

TP361

TP336

TP337

TP335

TP152

TP154

TP103

TP105

TP102

TP104

TP297

TP263

TP262

TP212

U5

TB6577FG

HA1+13

HA1-12

HB1+15

HB1-14

HC1+17

HC1-16

CW/CCW25

LP1_121

LP1_222

HA2+31

HA2-30

HB2+33

HB2-32

HC2+35

HC2-34

FG22

LP2_14

LP2_25

VDD11

VDD3636

S-GND1818

S-GND1919

OUT1_A29

OUT1_B28

OUT1_C26

RS127

FGO23

FGS124

OUT2_A7

OUT2_B9

OUT2_C10

RS28

NC66

NC1111

VCC120

VCC23

P-GND3737

P-GND3838

R92 0.33

(PITCH=15)

2W 2%(G)

C65C103

4CFG+

4CFG-

SGND

TP208

C93C104

C96

C10050V

+5.0V

SGND

PGND

+24V

R25710k+3.3V

+5.0V

81

RA17 1k72

63

54

81

RA11 1k72

63

54

C503

C10010V( 6.3)

EEE1AA101SP

C505

C10010V( 6.3)

EEE1AA101SP

C502C10010V

( 6.3)

EEE1AA101SP

C504

C10010V( 6.3)

EEE1AA101SP

C506

C221

U3

TA75S01F1

34

U3

TA75S01F

5V+

2V-

C507

C221

Q5

LD1117S50OUTIN

GND

Q6LD1117DT-R

OUTINADJ

C613

C106

(2125)

C608

C103

C606

C103

C611

C103

C609

C103

C610

C103

C607

C103

C722

C101

C720

C718

C719

C723

C101

C721

PGND

PGND

REGURATOR, MOTOR DRIVER

(TO Main ASIC Logic)

SCANNER MOTOR DRIVER

MAIN MOTOR DRIVER

3.3V(Analog 3.3V) REGULATOR

5.0V REGULATOR

1.5V(FOR ASIC) REGULATOR

(TO Main ASIC A/D )

+

+

+

+

D

B

A

C

E

F

E

D

B

A

C

F

1

1 2 3 4 6 7 8

2 3 4 5 6 7 8

5


NAME

CODE

B512210CIR (6/6)


A-7 Confidential

Low-voltage PS Circuit (100V)

D

B

A

C

E

F

E

D

B

A

C

F

1

1 2 3 4 6 7 8

2 3 4 5 6 7 8

5

Appendix 2. Low-voltage Power Supply PCB Circuit Diagram (100V)

NAME

APPENDIX

Confidential

A-8

Low-voltage PS Circuit (200V)

D

B

A

C

E

F

E

D

B

A

C

F

1

1 2 3 4 6 7 8

2 3 4 5 6 7 8

5

Appendix 2. Low-voltage Power Supply PCB Circuit Diagram (200V)

NAME


A-9 Confidential

D

B

A

C

E

F

E

D

B

A

C

F

1

1 2 3 4 6 7 8

2 3 4 5 6 7 8

5

Appendix 3. High-Voltage Power Supply Circuit Diagram

NAME High-Voltage PS Circuit


A-10 Confidential

APPENDIX 4 POINT TO POINT CONNECTION DIAGRAM

Main PCB

LANParallelInterface

CN5

LT_DET1

LT2_PEDG

+24V

+24V

24VRET

+24V

VCC24FB_VCLN

LT1_PE+3V

LT1_SOL

24VRET

S0V+3.3V

+8V

PWM_DEV

T1_PE_SEN

GRIDCFB_DEV

S0V

/TRCV

FB_TRCCV

PWN_TRCC

PWM_CHG

FB_TR

24RET

+24V-8

CN16-9

RELAY_FRONT REG_SOL

MP_SOL+5V

PNEW_SEN

-6-5

-4

-4-3

-7

+24V

DX_SOLCN14-2

-1

T1_SOL

TNR_SENS0V

F_COV_SEN

-3-2

-1

CN3-6-5

THM_EDGETHM_CENTERVDD3PO_SEN

-2-1

DX_UNIT_SENS0V

BD-7

CN18-8

LD LD_MONPWNENBLDFALF+5VDATAGND+5VI

FB_GRID

LT_DET2

FAN_MAIN

MP_PE_SENPEDG_SEN

TNRLED

HU+

REG_REAR_SEN

HV+HU-

HV-

+5VS0V

UU

V

W

HU+HU-

HV+HV-

HW-HW+

+5VS0V

UUVV

WW

FG+FG-

HL5280DW only

USBCN7

DIMM

RELAY_REAR

-4-3

-6-5

-2-1

SWIGND

LED0/ PNLRST

+5VI

-8-7

CN17-10-9

-6-5

DX_SOL

PANEL

FGGNDDATA-DATA++5VFG

-4-3

CN800-6-5

-2-1

WIRELESSLAN

CN2-12

-6-5-4

-7

-3-2-1

LT(OPTION)

CN8-8

-6-5-4

-7

-3-2-1

-22

-18-17-16

-19

-15-14-13

-21-20

-12

-8-7-6

-9

-5-4-3

-11

-2-1

-10

-18-17-16

CN4-19

-15-14-13-12

-8-7-6

-9

-5-4-3

-11

-2-1

-10

LVPSHEATERONN1

24VRET

HVPS

REG_FRONT_SEN

FAN_PSVCC3.3V

MAIN MOTORDRIVERHW+

HW-

U

VV

WW

CN10-14-13-12

-8-7-6

-9

-5-4-3

-11

-2-1

-10

SCANNER MOTORDRIVER

-4-3

-2-1

SW0/ PNLDI

LED1/ PNLCLKLED2/ PNLDO

LED3LED4LED5

-10-9

-11

-8

LT2_PE

LT1_PEDG

LT_DET3LT2_SOL

CN1-23PWM_VCLN

CN13 CN12


A-11 Confidential

APPENDIX 5 GEAR LAYOUT DRAWING

1. HL-5240

LM5016001EJECTOR GEAR 16

LM5475001 EJECTOR GEAR 44SX

LM5055001 REGISTER GEAR 159/43 INTERNAL

LM5461001 REGISTER DIFFENTIAL

LM5065001 MP GEAR 55/60 SECTOR

LM5019001 EJECTOR GEAR 22

LM5048001 FUSER GEAR 39R H/R DRIVE

LM5042001 FUSER GEAR 17/63R PENDULUM

LM5054001 REGISTOR GEAR 19 PLANETARY

LM5056001 FEEDER GEAR 21/31 PENDULUM

LM5057001 FEEDER GEAR 48

LM5050001 DX GEAR 27/68 L

LM5023001 P/P GEAR 29 CLUTCH CAM

LM5071001 T1 GEAR 50/45 SECTOR

LM5070001 T1 GEAR 31/47 LM5460001

P/P DIFFERENTIAL

LM5028001 P/P GEAR 147/37 INTERNAL

LM5027001 P/P GEAR 15 PLANETARY

LM5026001P/P GEAR 32CARRIER

LM5025001 P/P GEAR 17CENTER

LM5053001 REGISTER GEAR 48 CARRIER

LM5052001 REGISTER GEAR 21 CENTER

APPENDIX

Confidential

A-12

2. HL-5250DN/ 5270DN/ 5280DW

LM5015001EJECTOR SWITCH ARM LM5056001

FEEDER GEAR 21/31 PENDULUM

LM5057001 FEEDER GEAR 48

LM5050001 DX GEAR 27/68 L


LM5071001 T1 GEAR 50/45 SECTOR LM5070001

T1 GEAR 31/47

LM5460001 P/P DIFFERENTIAL


LM5042001 FUSER GEAR 17/63R PENDULUM

LM5048001 FUSER GEAR 39R H/R DRIVE

LM5019001 EJECTOR GEAR 22



LM5013001GEAR 28 SECTOR

LM5461001 REGISTER DIFFERENTIAL

LM5025001 P/P GEAR 17CENTER

LM5026001P/P GEAR 32CARRIER

LM5027001 P/P GEAR 15PLANETARY

LM5028001 P/P GEAR 147/37 INTERNAL

LM5055001 REGISTER GEAR 159/43 INTERNAL

LM5054001 REGISTOR GEAR 19 PLANETARY

LM5052001 REGISTER GEAR 21 CENTER

LM5053001 REGISTER GEAR 48 CARRIER

Brother 5240-5250D-5270DN Service Manual

Documents

Transcript of Brother 5240-5250D-5270DN Service Manual