Brother 5240-5250D-5270DN Service Manual

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
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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. THEORY OF OPERATION Basic operation of the mechanical system, the electrical system and the electrical circuits. PERIODIC MAINTENANCE Periodical replacement parts, consumable parts, etc. TROUBLESHOOTING Reference values and adjustments, troubleshooting image defects, troubleshooting malfunctions, etc. DISASSEMBLY AND RE-ASSEMBLY Procedures for disassembling and re-assembling the mechanical system. ADJUSTMENTS AND UPDATING OF SETTING, REQUIRED AFTER PARTS REPLACEMENT SERVICE SUPPORT SOFTWARE Test print mode and Service menu mode, etc. Diagrams etc
CHAPTER 2:
CHAPTER 3:
CHAPTER 4:
CHAPTER 5:
CHAPTER 6:
CHAPTER 7:
APPENDIX:
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. 2. FEATURES............................................................................................................. 1-1 PARTS NAMES AND FUNCTIONS ........................................................................ 1-3
2.1 2.2 Overview........................................................................................................................... 1-3 Control Panel.................................................................................................................... 1-5 Printing ............................................................................................................................. 1-7 Functions .......................................................................................................................... 1-8 Electronics and Mechanics............................................................................................. 1-11 Service Information......................................................................................................... 1-12 Network Connectivity...................................................................................................... 1-13 Paper .............................................................................................................................. 1-14
3.6.1 Paper handling ..................................................................................................................1-14 3.6.2 Media specifications..........................................................................................................1-14
3.
SPECIFICATIONS .................................................................................................. 1-7

3.1 3.2 3.3 3.4 3.5 3.6
3.7
Printable Area................................................................................................................. 1-17

3.7.1 PCL5e/EPSON/IBM emulation ..........................................................................................1-17 3.7.2 PCL6 emulation.................................................................................................................1-20
3.8 3.9
Print Speeds with Various Settings ................................................................................ 1-21 Toner Cartridge Weight Information............................................................................... 1-22
4.
SERIAL NO. DESCRIPTIONS .............................................................................. 1-23
CHAPTER 2 THEORY OF OPERATION................................................. 2-1

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

2.1 2.2 2.3 General Block Diagram .................................................................................................... 2-2 Main PCB Block Diagram ................................................................................................. 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
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HL-5240/5250DN/5270DN/5280DW SERVICE MANUAL
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 3.2 3.3 Overview of Printing Mechanism ...................................................................................... 2-7 Overview of Gear.............................................................................................................. 2-8 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 3.7
Sensors .......................................................................................................................... 2-23 Heat Control of Fuser Unit.............................................................................................. 2-24
CHAPTER 3 PERIODIC MAINTENANCE ............................................... 3-1

1. CONSUMABLE PARTS .......................................................................................... 3-1
1.1 1.2 Toner Cartridge ................................................................................................................ 3-1 Drum Unit ......................................................................................................................... 3-7
2.
PERIODICAL REPLACEMENT PARTS ................................................................ 3-12

2.1 2.2 Periodical Replacement Parts ........................................................................................ 3-12 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 3.2 Cleaning the Inside of the Printer ................................................................................... 3-50 Cleaning the Corona Wire .............................................................................................. 3-53
CHAPTER 4 TROUBLESHOOTING ....................................................... 4-1

1. INTRODUCTION .................................................................................................... 4-1
1.1 1.2 1.3 Initial Check ...................................................................................................................... 4-1 Warnings for Maintenance Work...................................................................................... 4-2 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 2.4
Error Message in the Status Monitor .............................................................................. 4-12 Error Message Printouts................................................................................................. 4-14
3.
PAPER PROBLEMS ............................................................................................. 4-15

3.1 3.2 Paper Loading Problems ................................................................................................ 4-15 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. 5. 6.
SOFTWARE SETTING PROBLEMS .................................................................... 4-29 MALFUNCTIONS.................................................................................................. 4-32 IMAGE DEFECTS................................................................................................. 4-38
6.1 6.2 6.3 6.4 Image Defect Examples ................................................................................................. 4-38 Diameter of Rollers......................................................................................................... 4-38 Troubleshooting Image Defect ....................................................................................... 4-39 Location of Grounding Contacts ..................................................................................... 4-57
6.4.1 Drum unit...........................................................................................................................4-57 6.4.2 Printer body & Paper tray ..................................................................................................4-57
7. 8.
INCORRECT PRINTOUT ..................................................................................... 4-58 NETWORK PROBLEM ......................................................................................... 4-60

8.1 8.2 8.3 Installation Problem ........................................................................................................ 4-60 Printing Problem ............................................................................................................. 4-63 Protocol-Specific Troubleshooting.................................................................................. 4-65
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CHAPTER 5 DISASSEMBLY AND RE-ASSEMBLY .............................. 5-1

1. 2. 3. 4. 5. 6. 7. SAFETY PRECAUTIONS ....................................................................................... 5-1 PACKING................................................................................................................ 5-2 SCREW TORQUE LIST.......................................................................................... 5-3 HARNESS ROUTING ............................................................................................. 5-4 LUBRICATION...................................................................................................... 5-13 DISASSEMBLY FLOW ......................................................................................... 5-14 DISASSEMBLY PROCEDURE ............................................................................. 5-15
7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 AC Cord.......................................................................................................................... 5-15 Drum/Toner ASSY.......................................................................................................... 5-15 DX Feed ASSY............................................................................................................... 5-16 Paper Tray...................................................................................................................... 5-16 Back Cover ..................................................................................................................... 5-19 Outer Chute ASSY ......................................................................................................... 5-20 Fuser Unit ....................................................................................................................... 5-21 Tray MP ASSY................................................................................................................ 5-23 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 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 Paper Tray...................................................................................................................... 5-74 LT Front Cover ASSY..................................................................................................... 5-77 LT Back Cover................................................................................................................ 5-78 LT Side Cover L.............................................................................................................. 5-78 LT Side Cover R ............................................................................................................. 5-79 LT PCB ASSY ................................................................................................................ 5-80 Connector: 55533-1219.................................................................................................. 5-81 Connector: 54702-1219.................................................................................................. 5-81 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. 2. IF YOU REPLACE THE MAIN PCB ..........................................................................6-1 IF YOU REPLACE THE PERIODICAL MAINTENANCE PARTS ............................6-10
CHAPTER 7 SERVICE SUPPORT SOFTWARE.................................... 7-1

1. CONTROL PANEL ....................................................................................................7-1
1.1 1.2 1.3 Users Mode...................................................................................................................... 7-1 User Maintenance Mode.................................................................................................. 7-3 Service Mode ................................................................................................................... 7-5
2.
HIDDEN FUNCTION MENUS .................................................................................7-15

2.1 2.2 2.3 Professional Menu ......................................................................................................... 7-16 Reset Parts Life Menu ................................................................................................... 7-22 Service Menu ................................................................................................................. 7-23
3.
NVRAM DEFAULT VALUE......................................................................................7-27
APPENDIX
1. 2. 3. 4. 5. MAIN PCB CIRCUIT DIAGRAM ............................................................................... A-1 LOW-VOLTAGE POWER SUPPLY PCB CIRCUIT DIAGRAM (100V, 200V).......... A-7 HIGH-VOLTAGE POWER SUPPLY PCB CIRCUIT DIAGRAM ............................... A-9 POINT TO POINT CONNECTION DIAGRAM ........................................................ A-10 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 Users Guide may result in hazardous radiation exposure.
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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 kyttminen muulla kuin tss kyttohjeessa mainitulla tavalla saattaa altistaa kyttjn turvallisuusluokan 1 ylittvlle nkymttmlle lasersteilylle. Varning Om apparaten anvnds p annat stt n i denna Bruksanvisning specificerats, kan anvndaren utsttas fr osynlig laserstrlning, som verskrider grnsen fr 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. Im Falle von Strungen der Lasereinheit mu diese ersetzt werden. Das Gehuse der Lasereinheit darf nicht geffnet werden, da sonst Laserstrahlen austreten knnen.
ACHTUNG:
<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.
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.
CAUTION:
**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
1. FEATURES
GENERAL
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 printers 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.
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CHAPTER 1 GENERAL
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 CDROM 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 Code 128 Interleaved 2 of 5 Codabar
US-PostNet ISBN UPC-A UPC-E
EAN-8 EAN-13 EAN-128
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 Users Guide supplied with the printer.
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2.
PARTS NAMES AND FUNCTIONS
2.1 Overview
(HL-5240/5250DN) <Front View>
Front cover release button Control panel Face-down output tray Front cover
Face-down output tray support flap (support flap) MP tray cover ASSY
Power switch
Paper tray
Multi-purpose tray (MP tray)
Fig. 1-1
<Rear View>
Back cover DIMM cover
Duplex tray (For HL-5250DN) Parallel interface connector
AC power connector
USB interface connector Network status LEDs (Light emitting diodes) (For HL-5250DN)
10/100BASE-TX port (For HL-5250DN)
*The printer illustration is based on HL-5250DN.

Fig. 1-2
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CHAPTER 1 GENERAL
(HL-5270DN/5280DW) <Front View>

Front cover release button Control panel Face-down output tray Front cover
Face-down output tray support flap (support flap) MP tray cover ASSY
Power switch
Paper tray
Multi-purpose tray (MP tray)
Fig. 1-3
<Rear View>
Back cover
DIMM cover
Duplex tray
Parallel interface connector
AC power connector
USB interface connector LEDs (Light emitting diodes)
10/100BASE-TX port
Fig. 1-4
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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. 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
Fig. 1-5
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CHAPTER 1 GENERAL
(HL-5270DN/5280DW) 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.
Fig. 1-6
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 Laser Electrophotography by semiconductor laser beam scanning Wavelength: Output: Laser class: 770 - 810nm 5mW max 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. Normal printing mode Economy printing mode (Toner saving mode) Normal Up to 28 pages/minute (A4 size paper) Up to 30 pages/minute (Letter-size paper) Less than 18 seconds at 23C (73.4F) 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) <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.
Print quality Print speed
Warm-up First print Consumables
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.
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CHAPTER 1 GENERAL
3.2 Functions
<Controller> Processor Emulation Memory 266MHz BR-Script 3 (PostScript 3TM), HP LaserJet (PCL6), Epson FX-850 and IBM Proprinter XL <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 Hi-Speed USB 2.0 IEEE 1284 Parallel HL-5250DN/5270DN Hi-Speed USB 2.0 IEEE 1284 Parallel 10/100 BASE-TX HL-5280DW Hi-Speed USB 2.0 IEEE 1284 Parallel 10/100 BASE-TX Wireless LAN IEEE802.11 b/g
Option: HL-5240 10/100 BASE-TX Ethernet (NC-2100p) HL-5250DN/5270DN N/A HL-5280DW 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
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CHAPTER 1 GENERAL
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
*1
Processor Speed
Minimum RAM
Recommended RAM
Available Hard Disk Space
Windows
95 , 98, 98SE *1 NTWorkstation 4.0 2000 Professional Me XP Home Edition XP Professional XP Professional x64 *2 Edition
486/66 MHz Intel Pentium 75 MHz Intel Pentium 133 MHz Intel Pentium 150 MHz Intel Pentium 300 MHz AMD Opteron TM AMD Athlon 64 TM Intel Xeon with Intel EM64T Intel X Pentium with 4 Intel EM64T All base models meet minimum requirements
TM
8 MB 16 MB 64 MB 32 MB 128 MB 256 MB
16 MB 32 MB 128 MB 64 MB 128 MB 256 MB
40 MB 50 MB 50 MB 50 MB 50 MB 50 MB
Apple *3 Macintosh
OS 9.1-9.2 Mac OS X10.2.4 or greater
32 MB 128 MB
64 MB 160 MB
50 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: Europe and Australia: Printing: Standing by: Sleep: <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 32.5C (50 to 90.5F) Non operating: 0 to 40C (38 to 104F) Storage: -20 to 40C (-4 to 104F) Operating: Storage: 20 to 80% (non condensing) 10 to 85% (non condensing) AC 110 to 120V, 50 Hz/60 Hz AC 220 to 240V, 50 Hz/60 Hz Average 610 W at 25C (77F) Average 80 W at 25C (77F) Average 8 W (HL-5240) Average 9 W (HL-5250DN/5270DN)
Power consumption
Noise level
Humidity
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.
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CHAPTER 1 GENERAL
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 Fuser Unit Separator pad holder assembly Pick up roller assembly Laser Unit Approximate Life 100,000 pages 100,000 pages 100,000 pages 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 Protocol 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 NDP, DNS Resolver, mDNS, LPR/LPD, Custom Raw Port/Port9100, IPP, FTP Server, Telnet, SNMP, HTTP, TFTP, SMTP Client
TCP/IP: IPv6
Network type Network printing
10/100BASE-TX Ethernet network 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 BRAdmin Light Web BRAdmin Windows 95/98/Me, Windows NT 4.0, Windows 2000/XP Home Edition/XP Professional/XP Professional x64 Edition Mac OS X 10.2.4 or greater Windows 2000 Professional / Server / Advanced Server, Windows XP Home Edition/XP Professional/XP Professional x64 Edition Professional
Management utilities
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 Printer interface Support protocol Management features 10/100BASE-TX Ethernet Parallel TCP/IP, NetBEUI Embedded web server support SNMP / MIB support TELNET remote console BRAdmin Professional compatible Flash memory for easy updating of firmware
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CHAPTER 1 GENERAL
3.6
3.6.1
Paper
Paper handling Paper Input* Multi-purpose tray Paper tray (Standard) Lower tray (Option) * Calculated with 80 g/m (21 lb) paper. Paper Output* Face-down * Calculated with 80 g/m (21 lb) paper. Duplex Manual Duplex Automatic Duplex N/A HL-5240 HL-5250DN/ 5270DN/ 5280DW Yes Yes
2 2
All models 50 sheets 250 sheets 250 sheets
All models 150 sheets
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 Multi-purpose tray Optional lower tray unit Duplex tray for automatic duplex printing (for HL5250DN/5270DN/5280DW) Tray 1 MP Tray Tray 2/ Tray 3 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 Plain paper

75 g/m to 105 2 g/m (20 to 28 lbs.)
2
MP Tray Yes
DX Yes
Choose the media type from the printer driver Plain paper
Yes
Recycled paper Bond paper Rough paper60 g/m to 161 2 g/m (16 to 43 lbs.)
2
Yes Yes
60 g/m to 105 2 g/m (16 to 28 lbs.)
2
Yes Yes
60 g/m to 161 2 g/m (16 to 43 lbs.)
2
Yes N/A
Recycled paper Bond paper
Thin paper
60 g/m to 75 2 g/m (16 to 20 lbs.)
2
Yes
Yes
Yes
Thin paper
Thick paper
105 g/m to 161 2 g/m (28 to 43 lbs.)
2
N/A
Yes
N/A
Thick Paper or Thicker Paper
Yes Transparency Labels Envelopes * Up to 10 sheets ** Not available for the optional Tray 2/3.
Up to 10 sheets A4 or Letter **
Yes
Up to 10 sheets A4 or Letter
N/A
Transparencies
N/A N/A
Yes
A4 or Letter
N/A N/A
Thicker Paper Envelopes, Env. Thin, Env. Thick
Yes
(2) Media size MP 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.) Tray 1 (Standard) A4, Letter, Legal*, B5 (ISO), Excutive, A5, A6, B6 (ISO) Tray 2, Tray3 (Option) A4, Letter, Legal*, B5 (ISO), Excutive, A5, B6 (ISO) DX A4, Letter, Legal*
* Legal size paper is not available in some regions outside the USA and Canada.
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CHAPTER 1 GENERAL
(3) Media weights Tray 1 60 to 105 g/m (16 to 28 lb.)

2
MP Tray 60 to 161 g/m (16 to 43 lb.)

2
DX 60 to 105 g/m (16 to 28 lb.)

2
Tray 2/3 Lower tray unit (Option) (LT-5300) 60 to 105 g/m (16 to 28 lb.)
2
(4) Recommended paper Europe Plain paper Xerox Premier 80 g/m 2 Xerox Business 80 g/m 2 M-real DATACOPY 80 g/m Xerox Recycled Supreme 3M CG3300 Avery laser label L7163
2
USA Xerox 4200DP 20lb Hammermill Laser Paper 24lb N/A 3M CG 3300 Avery laser label #5160
Recycled paper Transparency Label
* This printer can use recycled paper that meets the DIN 19309 specification. (5) Moisture content Moisture content 4% to 6% by weight
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.
CAUTION:
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3.7
3.7.1
Printable Area
PCL5e/EPSON/IBM emulation When using PCL emulation, the edges of the paper that cannot be printed on are shown below.
Portrait
G F
Physical page Printable area Logical page
E G
E D G B B D F Physical page length Maximum logical page length Distance from edge of physical page to edge of logical page
F
G C A
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.
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CHAPTER 1 GENERAL
The table below shows the printable areas when printing on Portrait for each paper size.
Size Letter Legal Folio Executive A4 A5 A6 B 5 (JIS) B 5 (ISO) B 6 (ISO) COM10 MONARCH C5 DL DL L A 215.9 mm 8.5 (2,550 dots) 215.9 mm 8.5 (2,550 dots) 215.9 mm 8.5 (2,550 dots) 184.15 mm 7.25 (2,175 dots) 210.0 mm 8.27 (2,480 dots) 148.5 mm 5.85 (1,754 dots) 105.0 mm 4.13 (1,240 dots) 182.0 mm 7.1 (2,130 dots) 176.0 mm 6.93 (2,078 dots) 125.0 mm 4.92 (1,476 dots) 104.78 mm 4.125 (1,237 dots) 98.43 mm 3.875 (1,162 dots) 162.0 mm 6.38 (1,913 dots) 110.0 mm 4.33 (1,299 dots) 220.0 mm 8.66 (2,598 dots) B 279.4 mm 11.0 (3,300 dots) 355.6 mm 14.0 (4,200 dots) 330.2mm 13.0 (3,900 dots) 266.7 mm 10.5 (3,150 dots) 297.0 mm 11.69 (3,507 dots) 210.0 mm 8.27 (2,480 dots) 148.5 mm 5.85 (1,754 dots) 257.0 mm 10.11 (3,033 dots) 250.0 mm 9.84 (2,952 dots) 176.0 mm 6.93 (2,078 dots) 241.3 mm 9.5 (2,850 dots) 190.5 mm 7.5 (2,250 dots) 229.0 mm 9.01 (2,704 dots) 220.0 mm 8.66 (2,598 dots) 110.0 mm 4.33 (1.299 dots) C 203.2 mm 8.0 (2,400 dots) 203.2 mm 8.0 (2,400 dots) 203.2 mm 8.0 (2,400 dots) 175.7 mm 6.92 (2,025 dots) 198.0 mm 7.79 (2,338 dots) 136.5 mm 5.37 (1,612 dots) 93.0 mm 3.66 (1,098 dots) 170.0 mm 6.69 (2,007 dots) 164.0 mm 6.46 (1,936 dots) 164.0 mm 4.44 (1,334 dots) 92.11 mm 3.63 (1,087 dots) 85.7 mm 3.37 (1,012 dots) 150.0 mm 5.9 (1,771 dots) 98.0 mm 3.86 (1,157 dots) 207.4 mm 8.17 (2,450 dots) D 279.4 mm 11.0 (3,300 dots) 355.6 mm 14.0 (4,200 dots) 330.2mm 13.0 (3,900 dots) 266.7 mm 10.5 (3,150 dots) 297.0 mm 11.69 (3,507 dots) 210.0 mm 8.27 (2,480 dots) 148.5 mm 5.85 (1,754 dots) 257.0 mm 10.11 (3,033 dots) 250.0 mm 9.84 (2,952 dots) 176.0 mm 6.93 (2.078 dots) 241.3 mm 9.5 (2,850 dots) 190.5 mm 7.5 (2,250 dots) 229.0 mm 9.01 (2,704 dots) 220.0 mm 8.66 (2,598 dots) 110.0 mm 4.33 (1.299 dots) E 6.35 mm 0.25 (75 dots) 6.35 mm 0.25 (75 dots) 6.01 mm 0.24 (71 dots) 6.35 mm 0.25 (75 dots) 6.01 mm 0.24 (71 dots) 6.27 mm 0.25 (74 dots) F 0 mm 0 mm 0 mm 0 mm 0 mm 0 mm 0 mm 0 mm 0 mm 0 mm 0 mm 0 mm 0 mm 0 mm 0 mm G 4.2 mm 0.16 (50 dots) 4.2 mm 0.16 (50 dots) 4.2 mm 0.16 (50 dots) 4.2 mm 0.16 (50 dots) 4.2 mm 0.16 (50 dots) 4.2 mm 0.16 (50 dots) 4.2 mm 0.16 (50 dots) 4.2 mm 0.16 (50 dots) 4.2 mm 0.16 (50 dots) 4.2 mm 0.16 (50 dots) 4.2 mm 0.16 (50 dots) 4.2 mm 0.16 (50 dots) 4.2 mm 0.16 (50 dots) 4.2 mm 0.16 (50 dots) 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
Physical page Printable area E G E

D
Logical page B B D F Physical page length Maximum logical page length Distance from edge of physical page to edge of logical page
C
A
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.
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CHAPTER 1 GENERAL
The table below shows the printable areas when printing on Landscape for each paper size.
Size Letter Legal Folio Executive A4 A5 A6 B 5 (JIS) B 5 (ISO) B 6 (ISO) COM10 MONARCH C5 DL DL L A 279.4 mm 11.0 (3,300 dots) 355.6 mm 14.0 (4,200 dots) 330.2mm 13.0 (3,900 dots) 266.7 mm 10.5 (3,150 dots) 297.0 mm 11.69 (3,507 dots) 210.0 mm 8.27 (2,480 dots) 148.5 mm 5.85 (1,754 dots) 257.0 mm 10.11 (3,033 dots) 250.0 mm 9.84 (2,952 dots) 176.0 mm 6.93 (2,078 dots) 241.3 mm 9.5 (2,850 dots) 190.5 mm 7.5 (2,250 dots) 229 mm 9.01 (2,704 dots) 220 mm 8.66 (2,598 dots) 110 mm 4.33 (1,299 dots) B 215.9 mm 8.5 (2,550 dots) 215.9 mm 8.5 (2,550 dots) 215.9 mm 8.5 (2,550 dots) 184.15 mm 7.25 (2,175 dots) 210.0 mm 8.27 (2,480 dots) 148.5 mm 5.85 (1,754 dots) 105.0 mm 4.13 (1,240 dots) 182.0 mm 7.1 (2,130 dots) 176.0 mm 6.93 (2,078 dots) 125.0 mm 4.92 (1,476 dots) 104.78 mm 4.125 (1,237 dots) 98.43 mm 3.875 (1,162 dots) 162 mm 6.38 (1,913 dots) 110 mm 4.33 (1,299 dots) 220 mm 8.66 (2,598 dots) C 269.3 mm 10.6 (3,180 dots) 345.5 mm 13.6 (4,080 dots) 320.0mm 12.6 (3,780 dots) 256.6 mm 10.1 (3,030 dots) 287.0 mm 11.2 (3,389 dots) 200.0mm 7.87 (2,362 dots) 138.5 mm 5.45 (1,636 dots) 247.0 mm 9.72 (2,916 dots) 240.0 mm 9.44 (2,834 dots) 166.4 mm 6.55 (1,960 dots) 231.1 mm 9.1 (2,730 dots) 180.4 mm 7.1 (2,130 dots) 219.0 mm 8.62 (2,586 dots) 210.0 mm 8.26 (2,480 dots) 97.5 mm 3.84 (1,151 dots) D 215.9 mm 8.5 (2,550 dots) 215.9 mm 8.5 (2,550 dots) 215.9 mm 8.5 (2,550 dots) 184.15 mm 7.25 (2,175 dots) 210.0 mm 8.27 (2,480 dots) 148.5 mm 5.85 (1,754 dots) 105.0 mm 4.13 (1,240 dots) 182.0 mm 7.1 (2,130 dots) 176.0 mm 6.93 (2,078 dots) 125.0 mm 4.92 (1,476 dots) 104.78 mm 4.125 (1,237 dots) 98.43 mm 3.875 (1,162 dots) 162 mm 6.38 (1,913 dots) 110 mm 4.33 (1,299 dots) 220 mm 8.66 (2,598 dots) E 5.0 mm 0.2 (60 dots) 5.0 mm 0.2 (60 dots) 4.8 mm 0.19 (59 dots) 5.0 mm 0.2 (60 dots) 4.8 mm 0.19 (59 dots) 6.27 mm 0.25 (74 dots) F 0 mm 0 mm 0 mm 0 mm 0 mm 0 mm 0 mm 0 mm 0 mm 0 mm 0 mm 0 mm 0 mm 0 mm 0 mm G 4.2 mm 0.16 (50 dots) 4.2 mm 0.16 (50 dots) 4.2 mm 0.16 (50 dots) 4.2 mm 0.16 (50 dots) 4.2 mm 0.16 (50 dots) 4.2 mm 0.16 (50 dots) 4.2 mm 0.16 (50 dots) 4.2 mm 0.16 (50 dots) 4.2 mm 0.16 (50 dots) 4.2 mm 0.16 (50 dots) 4.2 mm 0.16 (50 dots) 4.2 mm 0.16 (50 dots) 4.2 mm 0.16 (50 dots) 4.2 mm 0.16 (50 dots) 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 Transparency Thin Paper Plain Paper Recycled Paper Thick Paper, Envelopes, Env.Thin Thicker/Bond Paper, Env.Thick 28/30 ppm 28/30 ppm 28/30 ppm 28/30 ppm 14 ppm 3 ppm All models
<Smaller size than A4 or Letter> Media type setting Transparency Thin Paper Plain Paper Recycled Paper Env.Thin Thick Paper, Envelopes Thicker/Bond Paper, Env.Thick 28/30 ppm 28/30 ppm 90 sec 28/30 ppm 14 ppm 90 sec 28/30 ppm 14 ppm 14 ppm 14 ppm 3 ppm All models
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.
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CHAPTER 1 GENERAL
3.9
Toner Cartridge Weight Information
Toner Cartridge Weight (approximate weight)

TN580 US
Brand new Toner Cartridge Weight Toner Weight at Brand New Toner Cartridge Toner Cartridge Weight at Toner Near Empty Remain Toner Weight at Toner Near Empty Toner Cartridge Weight at Toner Life End Remain Toner Weight at Toner Life End
TN-3170 EUR/EEU
727g 190g 617g ( 13g) 77g 605g ( 10g) 68g
TN-3185 AP
TN-550 US
Brand new Toner Cartridge Weight Toner Weight at Brand New Toner Cartridge Toner Cartridge Weight at Toner Near Empty Remain Toner Weight at Toner Near Empty Toner Cartridge Weight at Toner Life End Remain Toner Weight at Toner Life End
TN-3130 EUR/EEU
663g 126g 617g ( 13g) 77g 602g ( 10g) 65g
TN-3145 AP
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: E: J: January May September B: F: K: February June October C: G: L: March July November D: H: M: April August December
< ID for year > 5: 2005 6: 2006
< ID for factory > 9: J: F: Kariya Plant A: Buji Nan Ling Factory BISZ Mie Brother E: BITM C: BIUK D: BIUS
(1) Printer: Printed on the label attached on the rear of the main body <Example>
<MODEL NO.> < SERIAL NO. >
U52682A5J111101
SEQUENTIAL NO. FACTORY ID NO. YEAR MONTH
(2) Process unit: Imprinted on the aluminum bag (Drum unit with toner cartridge)
5A11
YEAR MONTH DATE
JA
PRODUCTION LINE NO. FACTORY ID NO.
(3) Drum unit: Printed on the bar code label attached inside the drum unit
A5J5100104A
MONTH SERIAL NO. PRODUCTION LINE NO. YEAR FACTORY ID NO. TONER VOLUME
DR/TN REUSE The first time: M The second time: N The third time: P
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CHAPTER 1 GENERAL
(4) Toner cartridge: Imprinted on the aluminum bag
5A30
YEAR MONTH DATE
JA
PRODUCTION LINE NO. FACTORY ID NO.
Printed on the bar code label attached on the toner cartridge

CARTRIDGE PRODUCTION INFO.
M5JL000199A
MONTH YEAR SERIAL NO. PRODUCTION LINE NO. TONER VOLUME L: 80g M: 100g FACTORY ID NO.
DR/TN REUSE The first time: M The second time: N The third time: P
(5) Laser unit: On the laser unit
X X XXXXXXX
SERIAL NUMBER MOLD NUMBER MANUFACTURE DISTINCTION
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CHAPTER 2
1.
1.1
THEORY OF OPERATION
OVERALL
General Block Diagram
Fig. 2-1 shows a general block diagram.
Control system
Extended RAM SODIMM 144pin
USB host (HL-5280DW)
Wireless LAN (HL-5280DW)
RAM 16MB: HL-5240 32MB: HL-5250DN/ 5270DN/ 5280DW
Low-voltage power supply block
Video control block

Interface block USB Parallel
Engine control block
Operation block (Control panel)
High-voltage power supply block
Laser unit
Drive block (DC motor)
Paper tray
Drum unit
Transfer block
Charging block
Fuser unit
Exposure drum
Developer unit Developing block
Paper dust cleaner block
Paper eject tray Paper feed system
Toner cartridge
Image generation system
Fig. 2-1
2-1
External device
Ethernet 10/100 Base TX (HL-5250DN/ 5270DN/5280DW)
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CHAPTER 2 THEORY OF OPERATION
2.
2.1
ELECTRONICS
General Block Diagram
Toner sensor PCB (Light reception)
Main fan
Power supply fan
High-voltage power supply

Regist front sensor Regist rear sensor
Low-voltage power supply

Rear relay PCB Paper eject sensor
Fuser thermistor
DX unit sensor PCB
Sensor PCB (PE+PEDGE)

MP sensor PCB
Tray1 solenoid
DX solenoid (HL-5250DN/5270DN)
Main PCB
Regist solenoid
MP solenoid
Front relay PCB
LT PCB
LT Sensor PCB (PE+PEDGE)

LT solenoid
Interlock switch (Cover sensor)
New toner sensor

LT PCB
LT1
LT Sensor PCB (PE+PEDGE) LT solenoid
LT2
Toner LED PCB (Light emission)

Wireless LAN (HL-5280DW)
Polygon motor
Laser diode PCB
Main motor
Panel PCB
Fig. 2-2
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2.2
Main PCB Block Diagram

Fig. 2-3 shows the block diagram of the main PCB.
MAX 512MB
SDRAM
HL-5240: 16MB HL-5250DN/5270DN/ 5280DW: 32MB
Mask ROM
Flash ROM
HL-5250DN: 2MB HL-5270DN/5280DW: 4MB
CSROM1/ RD/WR
ASIC
8MB Internal: 16MB

CSROM0/ RD/WR
SO-DIMM
CPU Core (Sapphire 266MHz)

D16/A13
D16/A24
EXCS0/ RD/WR
SPD
INTn RSTn
Network IC (LAN9115)
HL-5250DN: TCP/IP HL-5270DN: Full Protocol Xtal
LAN
25.00MHz
EEPROM
16kbit
D16/A24
EXCS1/ Rb/WR
Pararell I F
CDCC GA IEEE 1284
CLK INT DATA REQn RSTn
INTn RSTn
USB HOST ISP 1362 HL-5280DW
Wireless LAN
Xtal 12.00MHz
5 LED/2 SW (HL-5240/5250DN)
2.0 High Speed
VBUS D+/D-
LCD16x1 1LED 7SW (HL-5270DN/5280DW)
CN (PANEL) 10 pin
USB2.0
DX solenoid Xtal(for Sysclk/USB) 48.00MHz
CN (DXSOL) 2 pin
CN (TNRSEN) 2 pin
Xtal(for Video)
23.4617MHz
3 solenoid (T1/REG/MP)
3 sensor (Front_Cover/Toner sensor/Process NEW)
CN (RELAY FRONT) 9 pin
CN (Laser Diode PCB) 8 pin
HTLIMITN
Comparator
Therm1/2 2 sensor (PaperOut/DX tray) 5 Analog_in (HVPS) GRIDC 5 PWM_out (HVPS) 2 FAN (MAIN/HVPS) 5 sensor (reg_f/reg_r/pedg/T1PE/MPPE) Toner LED CN (HVPS) 23 pin CN (RELAY REAR) 6 pin
AI1:2 SCAN_CTR/ MAIN_CTR/ MAIN_FR
CN (Laser Unit) 14 pin
CN (MAIN MOTOR) 19 pin
Motor Driver IC
AI3:7
+3.3V
Reset IC HeaterON +24V +8V +3.3V +24VRET 0V 4 sensor (pedgex2/PEx2) 2 solenoid CN (LVPS) 8 pin
+5V
Regulator 5V 3.3V
+3.3V
Regulator 3.3V 1.5V
CN (LT) 12 pin
Fig. 2-3
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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.
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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.
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2.4
2.4.1
Power Supply
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 +3.3V / 1.5A +24V / 2.4A, +8V / 0.8A Production Code 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.
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3.
3.1
MECHANICS
Overview of Printing Mechanism
Laser unit Eject roller ASSY Developer roller Fuser unit Back cover Drum unit Outer chute ASSY Pinch roller
Halogen heater Heat roller Pressure roller Exposure drum Duplex unit Transfer roller
Separation roller MP Feed roller Regist roller Regist actuator front Feed roller TR Pressure roller Regist actuator rear Separation roller Feed roller
Paper tray
Feed roller TR Pressure roller Separation roller
Paper tray (LT unit) Feed roller LT unit
Fig. 2-4
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3.2
Overview of Gears
Register solenoid Eject solenoid
MP solenoid
DX
Main motor (Drive sub ASSY) T1 solenoid
LT
LT solenoid
Fig. 2-5
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3.3 3.3.1
Paper Transfer 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.
Pinch roller
Feed roller TR Regist roller
Pressure roller PE actuator Separation roller
Feed roller
Paper Plate 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.
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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.
P/P clutch hook A2 P/P gear 29 clutch cam P/P clutch hook B
P/P differentioal P/P clutch hook A1
P/P gear 22/B23 tray drive
Gear 15
Lift gear 46 Plate ASSY Plate up plate
Gear 21-16
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.
Stop
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.
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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.
Drum/toner ASSY
Exposure drum
Transfer roller
Regist actuator rear
Regist roller Fig. 2-9
Regist actuator front
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 Generates the latent electrostatic image and develops the image on the drum surface.
Exposure drum
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.
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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.
Supply roller Corona wire Developer roller Blade
Exposure drum
Transfer roller
Fig. 2-10
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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.
Fuser unit
Heat roller
Halogen heater
Pressure roller
Fig. 2-11
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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.
Eject roller ASSY
Back cover
Heat roller Paper eject actuator
Pressure roller
Fig. 2-12
When a paper jam occurs, the roller in the eject roller ASSY is released to remove the jammed recording paper easily.
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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.
Eject roller ASSY
Heat roller Exposure drum Back cover
Outer chute ASSY
Pinch roller
Pressure roller Regist actuator front
Duplex unit
Transfer roller Regist actuator rear Fig. 2-13
Regist roller
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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.
Separation roller MP
Feed roller
MP tray cover ASSY Separation pad ASSY MP
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.
Feed roller TR
Separation roller
Separation pad
Feed roller
Paper Fig. 2-15
Plate
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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 12 4,200 6,329 7,615 8,477 9,094 9,559 9,920 10,210 10,447 10,645 10,813 10,957 Cartridge life 2,310 3,915 5,096 6,000 6,715 7,295 7,774 8,177 8,520 8,817 9,075 9,302 Cartridge life+ON/OFF 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 Toner empty (5%) 4,375 4,375 4,375 4,375 4,375 4,375 4,375 4,375 4,375 4,375 4,375 4,375 Toner empty (4%) 5,833 5,833 5,833 5,833 5,833 5,833 5,833 5,833 5,833 5,833 5,833 5,833 Toner empty (3%) 8,750 8,750 8,750 8,750 8,750 8,750 8,750 8,750 8,750 8,750 8,750 8,750 Toner empty (2%) 17,500 17,500 17,500 17,500 17,500 17,500 17,500 17,500 17,500 17,500 17,500 17,500 Toner empty (1%) Cartridge life = 11a x 4200 / ( 3.6 x (a - 1) + 11 ) Cartridge life+ON/OFF = ( 11a x 4200 ) / ( 3.6 x (a - 1) + 11 + 9 ) Cartridge life (Mechanical limit) :
Cartridge life
a : Page / job
4200 ( 1page / job )
20,000 18,000 16,000 Printable pages 14,000 12,000 10,000 8,000 6,000 4,000 2,000 0 1
Cartridge life+ON/OFF Toner empty (5%) Toner empty (4%) Toner empty (3%) Toner empty (2%) Toner empty (1%)
10
11
12
Page / Job
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HL-5240/5250DN/5270DN/5280DW(High Capacity (7K) toner) Page/job 1 2 3 4 5 6 8,400 12,658 15,231 16,954 18,189 19,117 Cartridge life 4,620 7,831 10,191 12,000 13,430 14,589 Cartridge life+ON/OFF 7,000 7,000 7,000 7,000 7,000 7,000 Toner empty (5%) 8,750 8,750 8,750 8,750 8,750 8,750 Toner empty (4%) 11,667 11,667 11,667 11,667 11,667 11,667 Toner empty (3%) 17,500 17,500 17,500 17,500 17,500 17,500 Toner empty (2%) 35,000 35,000 35,000 35,000 35,000 35,000 Toner empty (1%) Cartridge life = 11a x 8400 / ( 3.6 x (a - 1) + 11 ) Cartridge life+ON/OFF = ( 11a x 8400 ) / ( 3.6 x (a - 1) + 11 + 9 ) Cartridge life (Mechanical limit) :
Cartridge life
7 19,840 15,548 7,000 8,750 11,667 17,500 35,000
8 20,420 16,354 7,000 8,750 11,667 17,500 35,000
9 20,894 17,041 7,000 8,750 11,667 17,500 35,000
10 21,290 17,634 7,000 8,750 11,667 17,500 35,000
11 21,626 18,150 7,000 8,750 11,667 17,500 35,000
12 21,913 18,604 7,000 8,750 11,667 17,500 35,000
a : Page / job
8400 ( 1page / job )
40,000 35,000 30,000 Printable pages 25,000 20,000 15,000 10,000 5,000 0 1
Cartridge life+ON/OFF Toner empty (5%) Toner empty (4%) Toner empty (3%) Toner empty (2%) Toner empty (1%)
10
11
12
Page / Job
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
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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>
Relay front PCB ASSY New toner actuator Gear (4)
New toner sensor
Rib B
Rib A
Gear (3) Gear (2)
Gear (1)
Fig. 2-16
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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 [Density] [Voltage] Print density [Density] [Voltage] Print density Bias voltage Bias voltage Actual control
[Used toner amount]
[Used toner amount]
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) When a used toner is inserted (Reset gear is at the position of in use.) When a new toner is inserted (Reset gear is at the position of factory set.) Toner exchange count: +0 Page counter of each toner: Continued Coverage of each toner: Continued Development bias: Reset (Default) Toner exchange count: +1 Page counter of each toner: Reset (0) Coverage of each toner: Reset (0) Development bias: Reset (Default) Not used. Toner Life End (Developer count full)
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3.5
3.5.1
Print Process
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.
Voltage circuit
+ + + -- + ++ - - - ++ + + + + + + + + + + + ++
Corona wire
Aluminum drum sleeve Organic photoconductor layer
Exposure drum
Grid
HVPS
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.
Drum Laser beam Paper Laser beam f lens
Laser detector Toric Lens Laser diode CO Lens
Polygon mirror
Motor 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.
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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.
Surface potential (V) 1 Cycle of drum
1
+900
2
(a)
3
1 2
Primary charging Laser beam exposure and developing (a) Unexposed area (Non image area)
+400 (b) +100
(b) Exposed area (Image area)

3
Transfer the image to paper
Drum sleeve
0
Time
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.
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3.6
Sensors
Sensor name Regist front sensor Regist rear sensor Paper eject sensor New toner sensor Toner LED PCB (Light emission) Toner sensor PCB (Light reception) Front cover sensor PE sensor Edge sensor MP PE sensor DX tray sensor Type Photo sensor Photo sensor Photo sensor Photo sensor Photo sensor Photo sensor Mechanical switch Photo sensor Photo sensor Photo sensor Mechanical switch Located on High-voltage PS PCB High-voltage PS PCB Relay rear PCB Relay front PCB Frame R Frame L Frame L PE EG sensor ASSY PE EG sensor ASSY MP PE sensor ASSY Relay rear PCB
Chute Front cover sensor Frame R Toner LED PCB (Light emission)
Frame L Paper eject sensor (Relay rear PCB)
Regist frame Paper feed frame MP PE sensor PE EG sensor
DX tray sensor New toner sensor (Relay front PCB) Toner sensor PCB (Light reception) Regist rear sensor High-voltage PS PCB Fig. 2-20 Regist front sensor PE sensor
Edge sensor
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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 Plain paper Plain paper (Small size) Plain paper (Duplex) Recycled paper Recycled paper (Small size) Recycled paper (Duplex) OHP OHP (Small size) OHP (Duplex) Thin paper Thin paper (Small size) Thin paper (Duplex) Thick paper Thick paper (Small size) Thick paper (Duplex) Envelope (Thin) Envelope (Thin, small size) Envelope (Thin, duplex) Envelope (Others) Envelope (Others, small size) Envelope (Others, duplex) Fixing temperature (C) (approximately) [Full speed / Half speed] 213/185 200/185 195/180 195/180 189/170 189170 185 185 185 195 195 181 200 195 195 200 200 195 220 220 205
NOTE: The values described in the table above are approximate and vary depending on the conditions such as the operation environment or the like.
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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.
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CHAPTER 3 PERIODIC MAINTENANCE
<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.
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<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.
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(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
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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
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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.
Home position
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
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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.
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<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
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(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. (3) Take out the drum unit and toner cartridge assembly.
Fig. 3-15
CAUTION:
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(4) Push down the blue lock lever and take the toner cartridge out of the drum unit.
Fig. 3-16
CAUTION:
* 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.
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(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.
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2.
2.1
PERIODICAL REPLACEMENT PARTS

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. LCD Message (HL-5270DN /5280DW) REPLACE FUSER REPLACE LASER REPLACE PF KIT1 REPLACE PF KIT2 REPLACE PF KIT3 REPLACE PF KITMP
Parts Name
Qty
Approximate Life *1 (number of prints) 100,000 pages 100,000 pages 100,000 pages
Replacement Procedure
Fuser Unit Laser Unit Paper feeding kit for Tray 1 *3 Paper feeding kit for Tray 2 *3 Paper feeding kit for Tray 3 *3 Paper feeding kit for MP tray *2
1 1 1
See subscription 2.2.1, Chapter 3
100,000 pages
See subscription 2.2.2, Chapter 3
100,000 pages See subscription 2.2.3, Chapter 3
100,000 pages
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.
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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.
Printer
AC cord
Fig. 3-19
(2) Pull out the Paper tray.
Paper tray
Fig. 3-20
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(3) Open the Front cover. (4) Remove the Drum/toner ASSY.
Printer
1 2
Drum/toner ASSY
Front cover
Fig. 3-21
(5) Remove the DX feed ASSY.
DX feed ASSY
Fig. 3-22
NOTE: The DX feed tray is not provided for the HL-5240 printer.
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(6) Remove the Back cover.
Pin
2 1 3
Pin
Fig. 3-23
Back cover
(7) Remove the Outer chute ASSY.

Pin
1 3
Outer chute ASSY Pin
Fig. 3-24
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(8) Remove the two bind B M4x12 Taptite screws to remove the Side cover L.
Taptite, bind B M4x12 Hole
Side cover L
3 1
Front cover Hooks Taptite, bind B M4x12
2 1
Fig. 3-25
Hooks
(9) Remove the four cup S M3x6 SR Taptite screws to remove the Shield cover and the FG harness.
Taptite, cup S M3x6 SR
Shield cover
FG harness
Fig. 3-26
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(10) Remove the two bind B M4x12 Taptite screws to remove the Shield cover R.
Shield cover R
Hole
1
Taptite, bind B M4x12
Hooks
Hooks
Hooks
Fig. 3-27
(11) Disconnect the Connector of the Panel PCB.
Top cover printed ASSY
Panel PCB
Connector
Main PCB
Fig. 3-28
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(12) Remove the two bind B M4x12 Taptite screws to remove the Top cover printed ASSY.
Hooks Top cover printed ASSY Hooks Hooks
1 2
Hole
Hooks
Hole
Fig. 3-29
(13) Remove the bind B M4x16 Taptite screw to remove the FU harness cover 1.
2 1
Hooks
FU harness cover 1
Fig. 3-30
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(14) Remove the Heater terminal L and Heater terminal S from the Fuser unit.
Heater terminal L Fuser unit
Heater terminal S
Fig. 3-31
(15) Remove the FU harness cover 2.
FU harness cover 2
1
Hook
Fig. 3-32
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(16) Disconnect the connectors of the Thermistor ASSY M and Thermistor ASSY S from the Relay rear PCB ASSY.
Thermistor ASSY M Fuser unit
Thermistor ASSY S
Relay rear PCB ASSY Fig. 3-33
(17) Remove the cup B M4x16 Taptite screw to remove the Fuser unit.
Taptite, cup B M4x16
Fuser unit
Fig. 3-34
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(18) Remove the Sub duct from the Air duct.

Air duct
Filter
3 2
Hooks Sub duct
Fig. 3-35
(19) Remove the Filter from the Air duct.

Air duct
Filter
Fig. 3-36
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(20) Remove the Air duct from the Laser unit.
Pin
Laser unit
Hook
Hook
Air duct
Pin Pin
Fig. 3-37
(21) Remove the two flat cable. (22) Remove the six cup S M3x6 Taptite screw to remove the Laser unit.
Laser unit
Taptite, cup S M3x6
Taptite, cup S M3x6
Fig. 3-38
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< Installing Procedure > (1) Secure the Laser unit with the six cup S M3x6 Taptite screws. (2) Install the two flat cable.
Laser unit
Taptite, cup S M3x6
Taptite, cup S M3x6
Fig. 3-39
(3) Install the Air duct into the Laser unit.
Pin
Laser unit
Hook
1 2
Hook
Air duct
Pin Pin
Fig. 3-40
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(4) Install the Filter into the Air duct.

Air duct
Filter
Fig. 3-41
(5) Install the Sub duct into the Air duct.

Air duct
Filter
1 2
Hooks Sub duct Fig. 3-42
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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.
(a)
(b)
(2) Make sure that the black lever (b) is in the position in the illustration below.
(a)
(b)
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(6) Secure the Fuser unit with the bind B M4x16 Taptite screw.
Fuser unit
Fig. 3-43
(7) Connect the connectors of the Thermistor ASSY M and Thermistor ASSY S onto the relay rear PCB ASSY.
Thermistor ASSY S
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(8) Install the FU harness cover 2.
FU harness cover 2
2
Hook
Fig. 3-45
(9) Install the Heater terminal L and Heater terminal S.
Heater terminal S Fig. 3-46
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(10)Secure the FU harness cover 1 with the bind B M4x16 Taptite screw.
2
Hooks
FU harness cover 1
Fig. 3-47
(11) Secure the Top cover printed ASSY with the two bind B M4x12 Taptite screws.
Hooks Top cover printed ASSY Hooks Hooks
2 1
Hole
Hooks
Hole
Fig. 3-48
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(12) Connect the Connector of the Panel PCB.
Top cover printed ASSY Panel PCB
Connector
Main PCB
Fig. 3-49
(13) Secure the Side cover R with the two bind B M4x12 Taptite screws.
Side cover R
Hole
Hooks
2
Hooks
Hooks
Fig. 3-50
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(14)Secure the Shield cover and FG harness with the four cup S M3x6 SR Taptite screws.
Shield cover
FG harness
Fig. 3-51
(15) Secure the Side cover L with the two bind B M4x12 Taptite screws.
Side cover L
1 3
Front cover Hooks Taptite, bind B M4x12
2 3
Fig. 3-52 Hooks
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(16) Install the Outer chute ASSY.

Pin
3 1
Fig. 3-53
(17) Install the Back cover.
Pin
2 3 1
Pin Back cover Fig. 3-54
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(18) Install the DX feed ASSY. NOTE: The DX feed tray is not provided for the HL-5240 printer.
DX feed ASSY
Fig. 3-55
(19) Install the Drum/toner ASSY into the Printer. (20) Close the Front cover.
Printer
Drum /toner ASSY
Front cover Fig. 3-56
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(21) Put the Paper tray into the Printer.
Paper tray
Fig. 3-57
(22) Connect the AC cord into the Printer.
Printer
AC cord
Fig. 3-58
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2.2.2 Paper feeding kit for tray 1, 2, 3

Printer
AC cord
Fig. 3-59
(2) Pull out the Paper tray and remove the paper from the Paper tray.
Paper tray
Fig. 3-60
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(3) Remove the Separation pad ASSY. (4) Remove the Separation pad spring.
Hooks Separation pad ASSY
2
Hook Hook
2
Separation pad spring
Paper tray
Fig. 3-61
(5) Open the Front cover. (6) Remove the Drum/toner ASSY. (7) Close the Front cover.
Printer
1
Drum/toner ASSY
4 2
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(8) Remove the DX feed ASSY. NOTE: The DX feed tray is not provided for the HL-5240 printer.
DX feed ASSY
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.
Lift arm Pin Roller holder ASSY
Printer
Fig. 3-64
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(11) Remove the Roller holder ASSY.
Roller holder ASSY
2
Printer
Fig. 3-65
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< Installing Procedure > (1) Install the Roller holder ASSY.
Roller holder ASSY
2
Printer
Fig. 3-66
(2) Assemble the Lift arm onto the Pin of the Roller holder ASSY. (3) Place the Printer on its base.
Lift arm Pin Roller holder ASSY
Printer
Fig. 3-67
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(4) Install the DX feed ASSY. NOTE: The DX feed tray is not provided for the HL-5240 printer.
DX feed ASSY
Fig. 3-68
(5) Open the Front cover. (6) Install the Drum /toner ASSY, and close the Front cover.
Printer
1 2 4
Drum /toner ASSY
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(7) Set the Separation pad spring. (8) Fix the Separation pad ASSY.
Hooks Hook Separation pad ASSY
2
Hook
2
Paper tray
Fig. 3-70
NOTE: Check that the Separation pad spring is assembled correctly. (9) Put the Paper tray into the Printer.
Paper tray
Fig. 3-71
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(10)Connect the AC cord into the Printer.
Printer
AC cord
Fig. 3-72
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2.2.3 Paper feeding kit for MP tray

Printer
AC cord
Fig. 3-73
(2) Pull out the Paper tray.
Paper tray
Fig. 3-74
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Printer
1 2
Drum/toner ASSY
Front cover
Fig. 3-75
(5) Open the MP feed frame cover.
MP feed frame MP feed frame cover
Front cover
Fig. 3-76
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(6) Remove the Holder bearing MP.

Holder bearing MP
Hook
3 1 2
MP feed frame
Fig. 3-77
(7) Remove the MP roller holder ASSY.

Pin MP roller holder ASSY
4
Lift arm MP
MP feed frame
Fig. 3-78
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(8) Remove the Separation pad ASSY MP.

Separation pad ASSY MP MP feed frame
MP frame
Fig. 3-79
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< Installing Procedure > (1) Fix the Separation pad ASSY MP.
Separation pad ASSY MP MP feed frame
MP frame
Fig. 3-80
(2) Install the MP roller holder ASSY.

Pin MP roller holder ASSY
1
Lift arm MP
3
MP feed frame
Fig. 3-81
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(3) Install the Holder bearing MP.

Holder bearing MP
Hook
1 3 2
MP feed frame
Fig. 3-82
(4) Close the MP feed frame cover.
MP feed frame MP feed frame cover
Front cover
Fig. 3-83
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(5) Install the Drum /toner ASSY. (6) Close the Front cover.
Drum /toner ASSY
Front cover
Fig. 3-84
(7) Put the Paper tray into the Printer.
Paper tray
Fig. 3-85
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(8) Connect the AC cord into the Printer.
Printer
AC cord
Fig. 3-86
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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
(2) Press the front cover release button and then open the front cover.
Fig. 3-88
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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.
CAUTION:
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(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.
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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: (1) Press the front cover release button and then open the front cover.
Fig. 3-91
Fig. 3-92
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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.
(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.
Home position
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
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CHAPTER 4
1.
1.1
TROUBLESHOOTING
INTRODUCTION
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 10C and 32.5C. 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.
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CHAPTER 4 TROUBLESHOOTING
(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.
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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.
2.1
2.1.1
ERROR MESSAGE
Operator Calls
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. Error clearance by pressing the Go button.
LED
Type of error
Remedy The Toner LED will turn on for 2 seconds and off for 3 seconds. Replace the toner cartridge.
Toner low
---
Toner life end

Cartridge position error
N/A
Replace the toner cartridge with a new one.

The drum unit ASSY is not installed correctry. Put the drum unit ASSY back in.
N/A
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 Paper jam
N/A N/A
Put paper in the tray. Press the Go button. Clear the paper jam. If the printer does not start printing, press the Go button. 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.
Close the back cover of the printer and put the duplex tray back in.
Incorrect Paper size for Duplex

(HL5250DN/5270DN/ 5280DW)
Yes
Duplex disabled Yes
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LED
Type of error Front cover is open Fuser cover is open Dust on drum Too many trays
Error clearance by pressing the Go button. N/A N/A N/A N/A
Remedy Close the front cover of the printer. Close the back cover of the printer. The corona wire needs to be cleaned. Maximum number of optional trays is two. Remove additional trays. Check the cable connection between the PC and the printer. The printer memory is full and the printer cannot print full pages of a document. A print overrun occurred and the printer cannot print full pages of a document. The download buffer or the printer is full. Add more memory to the printer.
The font memory area is full. Delete fonts or add more memory to the printer.
Buffer error Yes Memory full Yes Print overrun Yes Download full Yes
Font full Yes
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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 BUFFER ERROR CARTRIDGE ERROR DIMM ERROR DOWNLOAD FULL DUPLEX DISABLED DUST ON DRUM FONT FULL FRONT COVER OPEN Check the Interface settings. The drum unit ASSY is not installed in properly. Take out the drum unit ASSY and put it back into the printer again. 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. Add more memory. Close the back cover of the printer and put the duplex tray back in. 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. Add more memory. Close the front cover of the printer. Close the fuser cover located behind the back cover of the printer. Remedy
FUSER COVER OPEN
Fig. 4-1
JAM XXX MANUAL FEED MEMORY FULL
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. 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. Add more memory. 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.
NO PAPER
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Error message NO PAPER XXX NO TRAY XXX PRINT OVERRUN SIZE ERROR DX Put paper in the empty tray.
Remedy
Put the paper tray in the printer. Cut the resolution or add the optional memory. Set Page Protection to the correct size. 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. 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. 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. Replace the toner cartridge with a new one. Maximum number of optional trays is two. Remove additional trays.
SIZE MISMATCH STORAGE FULL TONER LIFE END TOO MANY TRAYS
Maintenance message DRUM NEAR END TONER LOW TONER LIFE END REPLACE PF KITMP REPLACE PF KIT 1 REPLACE PF KIT 2 REPLACE KIT 3 REPLACE FUSER REPLACE LASER Replace the fuser unit. Replace the laser unit.
Remedy The drum unit is near the end of its life. Replace it with a new one. Buy a new toner cartridge and have it ready before you get a TONER LIFE END message. Replace the toner cartridge with a new one. Replace the paper feeding kit (paper pick up roller and separation plate) for MP tray. Replace the paper feeding kit. (Paper feed roller, separation roller, separation pad, and separation pad spring)
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2.2
2.2.1
Service Calls
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.
Error occurs.
Comfirm the LED indication.
Turn OFF/ON the power switch.
Error occurs again.

YES
NO
Refer to 5. "MALFUNCTION".
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 ###
* ### indicates the error codes.
Error occurs.
Confirm the LCD indication.
Turn OFF/ON the power switch.
Error occurs again.

YES
NO
See section 5. 'MALFUNCTIONS'.
Temporary error. Use the printer without corrective action.
Error message (Print Settings)
Error descriptions FATAL ERROR EX
Remedy Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB. Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB. Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB. Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB. Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB. Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB. Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB. Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB.
ERROR S01 ERROR S02 ERROR S03 ERROR S04 ERROR S05 ERROR S06 ERROR S07 ERROR S08
ADRL ERROR EX
ADRS ERROR EX
BUS ERROR EX (INSTRUCT)
BUS ERROR EX (DATA L/S)
SYSCALL EX
BREAKPOINT EX
RESERVED INSTRUCT EX
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Error message (Print Settings)
Error descriptions COPROCESSOR UNUSAB EX
Remedy Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB. Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB. Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB. Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB. Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB. Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB. Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB. Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB. Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB. Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB. Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB. Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB. Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB. Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB. Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB. Turn off the printer. Wait a few seconds, then turn it on again. If still remains, replace the main PCB.
ERROR S09 ERROR S10 ERROR S11 ERROR S12 ERROR S13 ERROR E49 ERROR E50 ERROR E51 ERROR E52 ERROR E54 ERROR E55 ERROR H61 ERROR H63 ERROR H66 ERROR H67 ERROR H68
ARITHMETIC OVERFLOW EX
UNDEFINED INTERRUPT
SOFTWARE1 INTERRUPT
SOFTWARE2 INTERRUPT
FUSER UNIT MALFUNCTION
FUSER UNIT MALFUNCTION
LASER BEAM DETECTION ERROR SCANNER MOTOR MALFUNCTION MAIN MOTOR LOCK ERROR
HIGH-VOLTAGE POWER SUPPLY MALFUNCTION ROM CHECKSUM ERROR
DRAM ACCESS ERROR
NVRAM WRITE ERROR
NVRAM READ ERROR
NVRAM BUS ERROR
<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. Error message Toner Low Toner Life End Cartridge Error Drum Near End No Paper Fed Tray No Paper Fed Manual No Paper Multi Purpose Tray No Paper Tray 1/2/3 Remedy Purchase a new toner cartridge and have it ready for when the Toner Life End status is indicated. Refer to 1.1 Toner Cartridge in chapter 3. Take out the toner cartridge and put it back into the printer again. 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. 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 Brothers recommended paper specifications. Refer to 3.6 Paper in chapter 1. Take out the jammed paper from the indicated area. Refer to 3.2 Paper Jams in this chapter.
Jam MP Tray Jam Tray 1/2/3 Jam Inside Jam Rear Jam Duplex 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. Close the back cover of the printer and put the duplex tray back in. Close the front cover of the printer. Close the fuser cover located behind the back cover of the printer.
Duplex Disabled Front cover open Fuser cover open
Fig. 4-2
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Error message Dust On Drum Print Overrun
Remedy Refer to 3.2 Cleaning the Corona Wire in chapter 3. 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. Error message MEMORY FULL Remedy 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. 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 RESOLUTION REDUCED TO ENABLE PRINTING (The printer has printed the document at a reduced resolution) Use Printer TrueType Fonts

PRINT OVERRUN
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.
3.1
PAPER PROBLEMS
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 The printer does not feed paper. Remedy 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. 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 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. Clear the jammed paper. Refer to 3.2 Paper Jams in this Chapter. Change the printer driver setting in Media Type to a thin setting. Pull out and lift up the output tray support flap.
The printer does not feed paper from the MP tray. The printer does not feed envelopes.
A paper jam has occurred. When printing on normal paper, it creases. When printing on Legal size paper or longer sized paper, the paper slides off the top output tray.
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. (4) Close the front cover. (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. (17) Close the front cover. (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 6 1
2 3 4
Fig. 4-5
1.
2.
3.
4.
5.
6.
7.
JAM MP TRAY
JAM TRAY1
JAM TRAY2
JAM TRAY3
JAM INSIDE
JAM REAR
JAM DUPLEX
: Paper jam in the MP tray.

: Paper jam in the upper paper tray (TRAY 1).
: Paper jam in the lower tray (TRAY 2).
: Paper jam in the lower tray (TRAY 3).
: Paper jam inside the printer.
: Paper jam where the paper comes out of the printer.
: 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: (1) Press the front cover release button and then open the front cover.
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
CAUTION:
* 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
(5) Close the front cover.
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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 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.
(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 Jam when the printer is turned on. Type of Jam Paper stuck Cause The regist front sensor or paper eject sensor is turned on. Remedy Remove the paper inside the printer. If there is no paper, check the suspect sensors refer to Factory Inspection Mode in Chapter 7. Check front registration sensor motion refer to Factory Inspection Mode in Chapter 7. Check the front registration sensor refer to Factory Inspection Mode in Chapter 7. Remove the paper dust attached to the pick-up roller. If the rubber is worn out, replace it with a new one. Check sensor motion 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). Jam caused by paper length detected as shorter than 80mm.
The regist front sensor is not returning properly and is not turning off. The regist front sensor was turned off early. Malfunction of actuator or hardware noise. Paper was not fed in at the proper timing due to paper dust or wear of the rubber pick-up roller. The paper eject sensor is not working properly and has not turned off. (single printing) The paper eject sensor or front registration sensor is not working properly and has not turned off. (continuous printing)
Bottom of paper stopped around the transfer roller.
Top of paper stopped between the paper feed roller and the pick-up roller.
Jam caused by a paper feed delay.
Top of paper stopped at 60mm from the contact point of the heat roller and pressure roller. Jam after paper is ejected.
Jam caused by the paper not being sensed when ejected from the paper eject sensor. Jam caused by the paper not being sensed when ejected from the paper eject sensor.
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 Separation pad
Step 1
Check Is the surface of the separation pad worn out?
Result Yes
Remedy 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. Possible cause Paper Step 1 Check Is the problem solved if new paper is used? Is the entrance guide dirty? Is the pressure roller dirty? Result Yes Remedy Instruct the user how to store paper so that it does not absorb moisture. Clean the entrance guide. Clean the pressure roller. Replace the fuser unit.
Fuser unit entrance guide Fuser unit
2 3
Yes Yes No
(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

Possible cause Disconnection of the pickup solenoid harness Pickup solenoid harness failure Pressure plate gear damage Clutch gear damage Step 1 Check Is the harness of the pickup solenoid disconnected? Result Yes Remedy Reconnect the harness.
2 3 4
Does the harness of the pickup solenoid work correctly? Is the pressure plate gear damaged? Is the clutch gear damaged?
No Yes Yes
Replace the pickup solenoid. Replace the pressure plate gear. 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. Possible cause Failure inside the printer Main PCB failure Step 1 Check Is it possible to print the test page with the method of Test Sample Page in Chapter 7.? Is it possible to print with another PC and printer cable? Result No Remedy Identify the error type, then refer to the specified section of this chapter. Replace the main PCB. This problem may appear under the specified system environment. Check the environment which the user used.
No Yes
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(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. Possible cause Computer Operating System Computer settings Step 1 Check Windows 95 or Windows NT4.0? Does Universal Serial Bus Controllers appear in the Device Manager tab of System Properties in Control Panel? Does Add New Hardware Wizard appear on the screen or Does test print complete? Result Yes Remedy The operating system does not support USB. This problem can be caused by your computer settings. See the computer manual.
No
USB cable/ printer damage
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.
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(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. Possible cause Printer connection Step 1 Check 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 (HL5280DW) Vender: Brother International Corporation (or 0x4f9) Driver installation 2 Are there the following files in the Extensions Folder of System Folder? <For System 9.1 9.2> BR_PrintMoniter (laser) Brother Laser No Result No Remedy 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.
Try to re-install the printer driver. Turn off the printer and PC power switch, and check all connections between them. Then, turn them on again.
Yes
(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.
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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

Possible cause Supply voltage Step 1 Check Is the correct voltage present at the outlet? Is the power cord securely plugged into the outlet? Is the fuse blown? Result No Remedy Inform the user that the correct voltage is not supplied at the outlet. Plug the power cord securely into the outlet. 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. Replace the AC power cord.
Power plug Fuse (F1, F2)
2 3
No Yes
Wiring
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
(2) No DC power supplied

Possible cause AC power supply Step 1 Check Is AC power supplied between connectors CN1-L and CN1-N when the power plug is plugged into the outlet? Turn on the power switch. Measure the voltages between the terminals. Do the measured voltage satisfy the prescribed valued in the table below? Refer to the chart *1 below. Result No Remedy Follow the same check procedure of (1) No AC power supplied. 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. Replace the low-voltage power supply PCB.
Wiring, DC load
Yes
Low-voltage power supply PCB *1 PCB Main
No
+lead pin CN8-4 CN8-5 CN8-6 CN8-7
- lead pin CN8-2, CN8-3 CN8-2, CN8-3 CN8-8 CN8-8
Voltage Approx. 24V Approx. 24V Approx. 6.5V to 13V Approx. 3.3V
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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

Possible cause Failure of connector Main motor Main PCB Step 1 2 3 Check Is the connection of connector CN4 on the main PCB correct? Is the problem solved by replacing the main motor? Is the problem solved by replacing the main PCB? Result No Yes Yes Remedy Reconnect the connector. Replace the main motor. Replace the main PCB.
(4) No paper supplied

Possible cause Separation pad / pickup roller failure Step 1 Check Is the surface of the separation pad or the pickup roller dirty or worn out? Result Yes Remedy 1) Clean the surface of the separation pad or pickup roller. 2) Replace the separation pad or pickup roller. Reconnect the connector.
Failure of connector HVPS circuit
Is the contact of the solenoid connector on the relay front PCB good? Set paper in the manual feed slot and make a test print by pressing the Go button. 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
Yes
Replace the relay front PCB.
Paper pickup clutch solenoid
No
Replace the paper pickup clutch solenoid.
Main PCB
Is the problem solved by replacing the main PCB?
Yes
Replace the main PCB.
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(5) Insufficient output from high-voltage power supply unit

Possible cause High-voltage contact High-voltage power supply PCB Step 1 Check Do any of the terminals on the high-voltage contacts have dirt or contact burns? Check the connections of the connector between the highvoltage power supply and the main PCB are secured correctly? Result Yes Remedy Clean the terminals.
Yes No
Replace the high-voltage power supply PCB. Reconnect the connector between the high-voltage power supply and the main PCB.
(6) Fixing heater temperature failure

Possible cause Poor thermistor harness contact Step 1 Check Is the contact of connector CN1 and CN2 on the relay rear PCB good? Is the contact of connector CN3 on the main PCB good? Remove the fuser unit and measure the resistance of the thermostat. Is it open circuit? Remove the fuser unit and measure the resistance of the halogen heater lamp. Is it open circuit? Result No Remedy Reconnect the connector.
2 Blown thermostat Halogen heater lamp failure 3
No Yes
Reconnect the connector. Replace the fuser unit.
Yes
Replace the fuser unit.
(7) Laser Unit failure

Possible cause Harness connection failure (1) Harness connection failure (2) Step 1 Check Is connector CN18 on the main PCB secured correctly? Is the connection of the scanner motor connector CN10 on the main PCB secure? Result No Yes 2 No Yes Remedy Reconnect the connector securely. Replace the laser unit. Reconnect the connector securely. Replace the laser unit.
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(8) Fuser unit failure

Possible cause Poor thermistor harness contact Step 1 Check Is the contact of connector CN1 and CN2 on the relay rear PCB good? Is the contact of connector CN3 on the main PCB good? Is the thermistor installed properly? Result No Remedy Reconnect the connector.
2 Thermistor assembling failure Halogen heater lamp failure 3
No Yes No
Reconnect the connector. Replace the fuser unit. Reinstall the thermistor properly. Replace the fuser unit.
Remove the fuser unit and measure the resistance of the halogen heater lamp. Is it open circuit? Is the heater harness connector connected to the low-voltage power supply PCB and fuser unit secure?
Yes
Heater harness connection failure
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

Possible cause Main PCB Step 1 Check Is it possible to print the test page with the method of Test Sample Page in Chapter 7? Does this problem appear when printing specific data or printing under a specific environment? Result No Remedy Replace the main PCB.
Software bug
Yes
Inform the Brother office of the used specific data, printer condition and system environment.
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(10) Pickup function of paper tray does not work

Possible cause Link lever does not move smoothly. Pickup roller holder ASSY does not move smoothly. Main motor failure Pressure plate drive cam failure Step 1 Check Does the link lever work? Isn't the link lever bent? Result Yes Remedy Remove the cause of nonsmooth operation of the link lever. Replace the link lever. Replace the pickup roller holder ASSY.
Does the pickup roller holder ASSY move up and down?
No
3 4
Does the main motor work? Does the pressure plate drive cam rotate?
No No
Replace the main motor. Replace the main frame L ASSY.
(11) The new toner is not sensed

Possible cause The toner cartridge is not set to the main body correctly. New toner detection switch failure Main PCB failure Step 1 Check The toner cartridge is not inserted completely. Result Yes Remedy Reset the cartridge.
Isn't the toner sensed even if the switch is held? Is the problem solved by replaceing the main PCB?
Yes
Replace the switch.
No
(12) Maximum speed is slow

Possible cause Two or more sheets of the paper in the tray are pulled to feed. Foreign body attached to the tail edge actuator Tail edge actuator failure Tail edge sensor malfunction Step 1 Check Does paper double feeding occur? Result Yes Remedy Replace the separation pad.
Is a foreign body caught on the tail edge actuator?
Yes
Remove a foreign body.
3 4
Is the tail edge actuator deformed? Is the tail edge sensor turned ON?
Yes Yes
Replace the tail edge actuator. Replace the tail edge sensor.
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(13) LED failure

Possible cause Three LEDs light up after turning the power ON. Panel PCB failure Disconnection of the panel PCB harness Regist front sensor failure Regist rear sensor failure Paper eject sensor failure Main cover switch malfunction Step A1 Check Is the printer in the service mode? Does any LED light up when pressing the Go button? Is the harness connected securely? Does the regist front sensor work correctly? Does the regist rear sensor work correctly? Does the paper eject sensor work correctly? Is the main cover switch closed securely? Result Yes Remedy Check that the Go button has been pressed or not. Replace the panel PCB. Reconnect the harness securely. Replace the regist front sensor. Replace the regist rear sensor. Replace the paper eject sensor. Check the switch.
A2 B1
No No
B2 B3 B4 B5
No No No Yes
(14) Service error indication when turning the power ON

Possible cause Disconnection of the main motor harness Disconnection of the scanner motor harness Fuser unit failure Step 1 Check Is the harness of the main motor connected? Is the harness of the scanner motor connected? Does the printer resume after opening the cover, turning the power ON and leaving the printer for ten minutes? Result No Remedy Reconnect the harness securely. Reconnect the harness securely. Replace the thermistor.
No
No
(15) The printer stops while idling

Possible cause Front cover failure New toner detection switch failure Process unit terminal failure Laser unit failure Step 1 2 Check Is the cover opened by vibration during idling? Does the new toner detection switch work correctly? Are the terminals of the process unit dirty? Does the laser unit work correctly? Result Yes No Remedy Replace the front cover. Replace the new toner detection switch. Clean the terminals. Replace the laser unit.
3 4
Yes No
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6.
6.1
IMAGE DEFECTS
Image Defect Examples
I-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-7 Black horizontal stripes
I-9 White vertical streaks
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I-10 White horizontal streaks
I-11 Faulty registration
I-12 Poor fixing
I-13 Image distortion
I-14 Faint print
I-15 White spots
I-16 Black spots
I-17 Black band
I-18 Gray background
I-19 Hollow print
I-20 Downward fogging of solid black
I-21 Horizontal lines
I-22 Light rain
I-23 Ghost
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.
1
2
3
4
5
6
Parts Name
Paper Feed Roller
Transfer Roller
Exposure Drum
Heat Roller
Pressure Roller
Developer Roller
Diameter (The pitch which appears in the image)
14.0 mm (44.0 mm)

15.2 mm (48.2 mm)
30.0 mm (94.2 mm)
25.0 mm (78.5 mm)
25.0 mm (78.5 mm)
20.0 mm (42.7 mm)
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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.
When using the printer for a special job, such as printing of name cards, print quality cannot be guaranteed.
CAUTION:
(I-1) Light
User Check (1) Check the printers 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. Possible cause Toner sensor failure (printer side) Toner sensor failure (toner cartridge side) Drum connection failure HVPS / Main PCB failure Dirt on the scanner window Laser unit failure Step 1 Check Can printing be started with the drum unit and toner cartridge removed? Is the problem solved when 4 or 5 pages are printed after the toner cartridge is replaced with a full one? Are all the contacts between the drum unit and printer body connected correctly? Is the harness connection between the HVPS and the main PCB correct? Is there any dirt on the scanner window? Is the problem solved after replacing the laser unit? Result Yes Remedy Check if the toner sensor is dirty and check the toner sensor connection. The wiper of the toner cartridge is defective. Replace the toner cartridge. Clean contact electrodes both on the drum unit and in the printer body. Replace the HVPS or the main PCB. Wipe it off with a soft clean paper. Replace the laser unit. (1), (4), (5), (6)
Ground contacts
Yes
No
Yes
5 6
Yes Yes
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(I-2) Dark
User Check (1) Check the paper used meets the recommended paper specifications. (2) Check the printers 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.
Possible cause Corona failure (contact failure) Drum unit failure Toner cartridge failure High-voltage power supply PCB failure
Step 1
Check Are the charge electrodes between the printer body and the drum unit dirty? Is the problem solved after replacing the drum unit? Is the problem solved after replacing the toner cartridge? Is the connections of the connector between the highvoltage power supply PCB and the main PCB secured correctly? Are there any disconnected connectors?
Result Yes
Remedy Clean both electrodes.
Ground contacts
(3)
2 3
Yes Yes
Replace the drum unit with a new one. Replace the toner cartridge with a new one. Replace the highvoltage power supply PCB.
Yes
Main PCB failure
No
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(I-3) Completely blank
Possible cause Developing bias contact failure Drum unit
Step 1
Check Are the developing bias contacts between the printer body and drum unit dirty? Are the drum shaft and drum electrode of the printer body connected correctly?
Result Yes
Remedy Clean the electrodes at both sides. Clean the shaft and the electrode. Check the connection between the shaft and the electrode. Replace the drum unit. Replace the toner cartridge with a new one. Reconnect the connector correctly.
Ground contacts
(4) (1) (1)
Yes No
Drum unit failure Toner cartridge failure Scanner harness connection failure Main PCB failure
3 4
Is the problem solved after replacing the drum unit? Is the problem solved after replacing the toner cartridge? Is the scanner harness connected securely? (Check if there is any play in the connection.) Are printing signals being input to the laser unit? Is the problem solved after replacing the main PCB?
Yes Yes
No
Yes
Laser unit failure
Is the scanner interlock lever damaged? Is the scanner mirror broken or loose?
Yes No
Replace the laser unit. Replace the highvoltage power supply PCB.
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(I-4) All black

User Check (1) Clean the corona wire of the drum unit. (2) The drum unit may be damaged. Install a new drum unit.
Possible cause Corona failure
Step 1 2 3
Check Is the corona wire dirty? Is the corona wire broken? Are the charge electrodes between the printer body and the drum unit dirty? Is the laser unit connected to the main PCB correctly?
Result Yes Yes Yes
Remedy Clean the corona wire with the wire cleaner. Replace the drum unit. Clean both electrodes.
Ground contacts
(2)
(3)
No Connect the harness between the laser unit and the main PCB correctly. Replace the highvoltage power supply PCB. Replace the main PCB. Replace the laser unit.
Harness connection
High-voltage power supply PCB failure Main PCB failure Laser unit failure
Is the problem solved after replacing the high-voltage power supply PCB? Is the problem solved after replacing the main PCB? Is the problem solved after replacing the laser unit?
Yes
6 7
Yes Yes
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(I-5) Dirt on the back of paper
Possible cause Fuser unit dirty
Step 1
Check Is the pressure roller dirty? Is any other area in the printer dirty?
Result Yes
Remedy Clean the pressure roller referring to the following procedure. Replace the drum unit Replace the high-voltage power supply PCB.
Dirt in the drum unit
Is the transfer roller dirty? Is the problem solved after replacing the drum unit?
Yes No
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.
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(I-6) Black and blurred vertical streaks

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.
Possible cause Corona failure Corona failure
Step 1 2
Check Is the corona wire dirty? Is the vertical block streak about 10mm wide? (Check if the wire cleaner is at its home position.) Is the paper tray or feed system on the drum unit dirty with toner? Is the surface of the drum scratched? Is the surface of the drum dirty with toner in streaks? Is the surface of the heat roller scratched?
Result Yes Yes
Remedy Clean the corona wire with the wire cleaner. Return the wire cleaner to its home position.
Dirt in the paper feed system Scratch on the drum Cleaning failure Scratch on the heat roller NOTE:
Yes
Clean the toner off.
4 5 6
Yes Yes Yes
Replace the drum unit. Replace the drum unit. Replace the fuser unit.
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.
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(I-7) Black and blurred horizontal stripes

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.
Possible cause Scratch on the drum
Step 1
Check Are the horizontal stripes at 74mm (exposure drum) intervals? Are the horizontal stripes at 42.7mm (developer roller) intervals?
Result Yes
Remedy The exposure drum was scratched. Replace the drum unit. After printing several pages, the problem will disappear. If not, replace the toner cartridge. Replace the heat roller. Clean both electrodes.
Ground contacts
Toner stuck on the developer roller
Yes
Scratch on the heat roller Corona contact failure High-voltage power supply PCB failure
3 4
Are the horizontal stripes at 79mm (heat roller) intervals? Are the charge electrodes between the printer body and the drum unit dirty? Is the problem solved after replacing the high-voltage power supply PCB?
Yes Yes
(3)
Yes Replace the highvoltage power supply PCB.
(I-8) Black vertical streaks (in a gray background)
Possible cause Translucent stain on the scanner window
Step 1
Check Is there any dirt on the scanner window?
Result Yes
Remedy 1) Clean the scanner window. 2) If it is not effective, replace the laser unit. Clean the corona wire with the wire cleaner.
Ground contacts
Corona failure
Is the corona wire dirty?
Yes
(2)
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(I-9) White vertical streaks

User Check (1) Try to wipe the scanner window with a soft cloth. (2) The toner cartridge may be damaged. Install a new toner cartridge. (3) Check the printers 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.
Possible cause Translucent stain on the scanner window Transfer failure Condensation
Step 1
Check Is there any dirt on the scanner window? Is the transfer roller scratched? Has condensation occurred inside the printer?
Result Yes
Remedy 1) Clean the scanner window. 2) If it is not effective, replace the laser unit.
2 3
Yes Yes
Replace the drum unit. Try to print several pages or leave the printer 2 hours to allow it to reach room temperature.
(I-10) White horizontal streaks

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. (4) The drum unit may be damaged. Install a new drum unit.
Ground contacts
Possible cause Developing bias contact failure
Step 1
Check Are the developing bias contacts between the printer body and toner cartridge dirty?
Result Yes
Remedy Clean the electrodes at both sides.
(4)
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(I-11) Faulty registration
Possible cause Excessive paper load Print paper
Step 1
Check Is the paper loaded in the paper tray more than 27mm high? Is the specified weight of the recommended paper being used? Is the first printing position within 1mm of the tolerance specification? Is the regist rear sensor off from the correct position? Is the rotation torque of the drum unit heavy?
Result Yes
Remedy Instruct the user to keep paper loads below 27mm in depth. Recommend to use the specified types of paper. Adjust the Y offset by using the utility software supplied. Reposition the sensor to the correct position. Replace the drum unit.
No
Yes
Regist rear sensor position incorrect Drum unit failure
Yes
Yes
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(I-12) Poor fixation
Possible cause Print paper Nip release lever Toner sensor failure (When printing is faint.)
Step 1 2
Check Is thick paper of more than 43lb being used? Does the position of the nip release levers in the fuser unit decompress the nip pressure? Is the problem solved by replacing the drum unit or the toner cartridge?
Result Yes Yes
Remedy Recommend to use the specified types of paper. Return the nip release levers to the original position. 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. Fit the thermistor correctly. Replace the low-voltage power supply PCB.
Yes
Fuser unit thermistor failure Low-voltage power supply PCB failure
4 5
Is the thermistor fitted correctly? Is the problem solved by replacing the low-voltage power supply PCB?
No Yes
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.
2 1
Fig. 4-20
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(I-13) Image distortion
Possible cause Laser unit installation Scanner LD emission failure Scanner motor rotation failure Scanner connection failure
Step 1
Check Is the laser unit secured to the frame incorrectly? (Check if there is any play.) Is the laser diode or the scanner motor defective?
Result Yes
Remedy Secure the unit correctly and tighten the screws. Replace the laser unit.
Yes
Is the scanner harness connected properly? (Check if it is coming loose.)
No
Connect the harness correctly.
(I-14) Faint print

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Possible cause Printer installation Toner cartridge
Step 1 2
Check Is the printer placed horizontally? Does the problem happen immediately after replacing the toner cartridge with a new one? Is the scanner window dirty? Is the problem solved by replacing the laser unit?
Result No Yes
Remedy Place the printer on a flat surface. Remove and carefully shake the toner cartridge horizontally.
Scanner window dirty Laser unit failure
3 4
Yes Yes
Clean the scanner window with a soft dry cloth. Replace the laser unit.
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(I-15) White spots

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. (2) The drum unit may be damaged. Install a new drum unit.
Possible cause Drum unit failure
Step 1
Check Are the white spot at 94.2mm intervals?
Result Yes
Remedy 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. Replace the drum unit. Replace the toner cartridge with a new one. Damp (wet) paper might be used. Recommend to change freshly unpacked paper. 1) Replace the drum unit. 2) Advise the user of the specified print environment.
2 No toner Print paper 3 4
Is the problem solved after replacing the drum unit? Is the toner in the toner cartridge almost empty? Is the problem solved after changing to specified freshly unpacked paper? Does the problem still appear after the printer has warmed up?
Yes Yes Yes
Environment
Yes
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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.)
White Spots on black text and graphics at 94 mm (3.7 in.) intervals
Black Spots at 94 mm (3.7 in.) intervals
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.
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(I-16) Black spots

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. (2) The drum unit may be damaged. Install a new drum unit.
Possible cause Drum unit
Step 1
Check Are the spots at 94.2mm intervals? (The problem is not solved after printing a few pages.)
Result Yes
Remedy 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. Clean contact electrode both on the drum unit and in the printer body. 1) Check and clean the heat roller with a cloth dampened with alcohol. 2) Replace the fuser unit. Replace the high-voltage power supply PCB.
Ground contacts
Drum connection failure Fuser unit
Is the contact between the drum unit and printer body connected correctly? Are the spots at 79mm intervals? (The problem is not solved after printing a few pages.)
No
(7)
Yes
High-voltage power supply PCB failure
Is the problem solved after replacing the high-voltage power supply PCB?
Yes
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(I-17) Black band
Possible cause Corona failure Corona dirty
Step 1 2
Check Is the wire cleaner at its home position? Is the corona wire dirty?
Result No Yes
Remedy Return the wire cleaner to its home position. 1) Clean the corona wire. 2) If the problem still appears after cleaning, replace the drum unit.
Ground contacts
(2)
(2)
(I-18) Gray background
Possible cause Print paper
Step 1
Check Does the paper being used meet the paper specification (weight, etc.).
Result No Yes Yes
Remedy Recommend to use the specified types of paper. Recommend to change to freshly unpacked paper. Toner sensor failure. Clean the toner sensor and check the toner sensor connection. Replace the toner cartridge. Replace the drum unit. Replace the high-voltage power supply PCB.
Toner sensor failure (printer side) Toner cartridge failure Drum unit failure
Is Ready LED still lighted after the toner cartridge and drum unit are taken out? (The front cover is closed.) Is the problem solved after replacing the toner cartridge? Is the problem solved after replacing the drum unit?
3 4
Yes Yes No
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.
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(I-19) Hollow print

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 printers environment, conditions such as high humidity may cause this situation to occur. Possible cause Print paper Step 1 Check Is thick paper of more than 43lb being used or extremely rough surface paper? Result Yes No Remedy Recommend to use the specified types of paper. Refer and compare with I-15.
(I-20) Downward fogging of solid black
Possible cause Toner cartridge failure High-voltage power supply PCB failure
Step 1 2
Check Is the problem solved after replacing the toner cartridge? Is the problem solved after replacing the high-voltage power supply PCB?
Result Yes Yes
Remedy Replace the toner cartridge. Replace the high-voltage power supply PCB.
(I-21) Horizontal lines
Possible cause Paper tray contacts Drum unit
Step 1
Check Are the ground contacts on the right side of the paper tray connecting correctly? Are the high-voltage power supply and drum unit contacted correctly?
Result No
Remedy Clean the contacts.
No
Clean the contacts.
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(I-22) Light rain
Possible cause Drum unit failure Drum connection failure High-voltage power supply PCB failure
Step 1 2
Check Is the problem solved after replacing the drum unit? Is the contact between the drum unit and printer body connected correctly? Is the problem solved after replacing the high-voltage power supply PCB?
Result Yes No
Remedy Replace the drum unit. Clean contact electrode both on the drum unit and in the printer body. Replace the highvoltage power supply PCB.
Ground contact
(7)
Yes
(I-23) Ghost
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 printers 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. Possible cause Driver setting Step 1 Check Is thin paper such as 64g/m used under the thick paper mode?
2
Result Yes
Remedy 1) Change the current mode to the normal mode from the driver setting. 2) Print 5 or 6 blank pages if this problem occurs. Replace the drum unit. Replace the high-voltage power supply PCB.
Drum unit failure High-voltage power supply PCB failure
2 3
Is the problem solved after replacing the drum unit? Is the problem solved after replacing the high-voltage power supply PCB?
Yes Yes
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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. (2) The toner cartridge may be damaged. Install a new toner cartridge. (3) The drum unit may be damaged, or may be nearly at the end of life. Install a new drum unit.
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6.4
6.4.1
Location of Grounding Contacts

Drum unit
Toner cartridge (2) Wire cleaner
Drum Unit
(3) Charge (5) Grid (4) Developer roller (1) Exposure drum (6) Transfer roller (7) Cleaner
Fig. 4-25
6.4.2
Printer body & paper tray

(5) Grid (7) Cleaner
(3) Charge
(4) Developer roller
(1) Exposure drum (6) Transfer roller Fig. 4-26
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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. Possible cause Failure inside the printer Step 1 Check Is it possible to print the test page with the method of Test Sample Page in Chapter 7? Result No Remedy 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 / TrueType
TM
mode / Use Printer TrueType
TM
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. Possible cause Main PCB failure Step 1 Check Is it possible to print after reducing the data of a document? Result Yes Remedy Replace the main PCB.
(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 printers 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 Users 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.
Network status LEDs (Light emitting diodes) (For HL-5250DN)
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).
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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 Users 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.
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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 Users 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) (2) (3) (4) From the Go menu, select Applications. Open the Utilities folder. Double-click the Printer Setup Utility icon. 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.
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(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-toPeer 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-toPeer 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).

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CHAPTER 5
1.
DISASSEMBLY AND RE-ASSEMBLY
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 y m M4: 0.8N y m TAPTITE, CUP S M3: 0.5N y 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.
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CHAPTER 5 DISASSEMBLY AND RE-ASSEMBLY
2.
PACKING
Accessory bag
AC power cord
Option carton Drum/toner ASSY
Pad
Pad
Printer
Pad
Carton
Fig. 5-1
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3.
1
SCREW TORQUE LIST

Frame L/Drive Unit
Parts code 085311016 087320616 085311016 085411216 085411216 Parts name Taptite, bind B M3 x 10 Taptite, cup S M3 x 6 Taptite, bind B M3 x 10 Taptite, bind B M4 x 12 Taptite, bind B M4 x 12 Location Paper eject solenoid Main motor T1, MP Regist solenoid Gear plate Main shield Pcs. 1 4 3 8 3
Tightening torque N m (kgf cm)
No. 1 2 3 4 5
0.5 0.1(51) 0.7 0.1(71) 0.5 0.1(51) 0.9 0.1(91) 0.9 0.1(91)
Frame Unit
Parts code LM2048001 085411216 085411216 085411216 085411216 085411216 085411216 LM5867001 LM5867001 087320616 Parts name Screw, pan (S/P washer) M3.5 x 6 Taptite, bind B M4 x 12 Taptite, bind B M4 x 12 Taptite, bind B M4 x 12 Taptite, bind B M4 x 12 Taptite, bind B M4 x 12 Taptite, bind B M4 x 12 Taptite, cup S M3 x 6 SR Taptite, cup S M3 x 6 SR Taptite, cup S M3 x 6 Location Ground wire SW holder Under bar Paper feed unit HVPS LVPS Base plate Main PCB Shield cover Scanner plate Pcs. 1 1 4 8 2 2 9 4 4 6
No. 1 2 3 4 5 6 7 8 9 10
0.5 0.05 (50.5) 0.8 0.1(81) 0.7 0.1(71) 0.8 0.1(81) 0.8 0.1(81) 0.8 0.1(81) 0.8 0.1(81) 0.75 0.1(7.51) 0.75 0.1(7.51) 0.7 0.1(71)
Paper Feeder
Parts code 085310816 085310816 085310816 085411216 Parts name Taptite, bind B M3 x 8 Taptite, bind B M3 x 8 Taptite, bind B M3 x 8 Taptite, bind B M4 x 12 Location PE, EG sensor MP, PE sensor MP paper feed frame Regist frame (2), MP tray unit (2), Chute 2 (2) Pcs. 1 1 2 6 0.7 0.1(71)
No. 1 2 3 4
0.5 0.1(51) 0.5 0.1(51) 0.5 0.1(51)
Cover
Parts code 085411216 087310816 085411216 Parts name Taptite, bind B M4 x 12 Taptite, cup B M3 x 8 Taptite, bind B M4 x 12 Location Inner chute Panel PCB Cover Pcs. 6 (7) 3 6
No. 1 2 3
0.8 0.1(81) 0.5 0.1(51) 0.8 0.1(81)
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4.
HARNESS ROUTING
MP PE sensor ASSY
Hook "A"
MP feed frame
Printer top side (Printer body upside down)
Hole Hook "B"
Hook "A"
MP PE sensor ASSY
MP feed frame
High-voltage PS PCB ASSY
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PE EG sensor ASSY
Hook "B" Hole "A"
PE EG sensor ASSY
Hook "B" Paper feed frame
Hole "A" PE EG sensor ASSY Paper feed frame
Hook "A"
Interlock SW ASSY
Relay front PCB ASSY Hooks
Pin
Interlock SW ASSY
Frame L
Pin
Hook
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Toner sensor PCB unit ASSY

Pin
Frame L
Hook
Pin
Hook
Hook Toner sensor PCB unit ASSY
Register solenoid ASSY

Pin
Frame L
Hook
Hook
Pin Hook
Hook
Register solenoid ASSY
Hook
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MP solenoid ASSY
Pin
Frame L
Hooks
Pin
Hook
MP solenoid ASSY
T1 solenoid ASSY
Relay front PCB ASSY Pin Hooks
Frame L
Hooks
Pin
Hook
T1 solenoid ASSY
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Relay front PCB ASSY

Frame L
Hook
Main PCB
Laser unit
Frame L Laser unit Core Holes
LD harness connector
Main PCB
Hook Protective film Polygon motor connector Gear cover
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10
Fan motor 60 unit LV

Frame L Hooks
Toner LED PCB unit ASSY
11
Fan motor 60 unit

Hooks
Hook Frame L Hook
Hook
Fan motor 60 unit
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12

Hooks Frame L Hook
Hook
Hole
Hook
Hooks Hole
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13
PS PCB unit

Base plate LV
PS PCB unit Hook

SW holder ASSY
Power supply switch

PS PCB unit terminal
<A view>
<A view> Core Inlet harness ASSY Hooks
14
FG harness
Main PCB
Shield cover
Main PCB
Shield cover
FG harness
FG harness
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15
High-Voltage PS PCB ASSY

Insulation sheet Hole High-Voltage PS PCB ASSY
Main PCB
HVPS PCB harness (Flat cable) HVPS PCB harness (Flat cable) Printer top side (Printer body upside down)
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5.
LUBRICATION
Gear 82R
Apply grease on the cogs of the motor side
BG2
Drive sub ASSY
* BG2: KANTO KASEI BG- MU (2 mm dia. Ball)
BG2
DEV gear 37R joint drive
Gear cover
* BG2: KANTO KASEI BG- MU (2 mm dia. Ball)
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6.
DISASSEMBLY FLOW
Disassembly / Re-Assembly (sec.)
Basic Operation
7.1
5s / 5s 7.2
AC Cord
5s / 5s 7.3
Drum/ Toner ASSY
5s / 5s 7.4
DX Feed ASSY
10s / 10s
Paper Tray
7.7 7.5
40s / 50s
Fuser Unit
5s / 5s
Back Cover
7.6
15s / 20s
Outer Chute ASSY
7.8
15s / 15s
Tray MP ASSY
7.9
30s / 30s
MP Tray Cover ASSY/ Process Cover ASSY
7.10
35s / 40s
Access Cover/ Side Cover L
7.11
Main PCB
50s / 50s
7.12
55s / 60s
7.13
35s / 45s 20s / 30s
7.14
45s / 50s 15s / 20s 15s / 20s 15s / 20s 20s / 25s 20s / 30s 15s / 15s
Gear Plate Calking ASSY AL/ Develop Joint/ Main Motor ASSY AL
Main Shield Plate ASSY
Relay Rear PCB ASSY/ Connector
7.24
20s / 20s
Gear 17/20
7.35
Frame L
25s / 25s
7.15
7.16
20s / 30s
7.17
15s / 20s
7.19 7.18
7.20
Relay Front PCB ASSY
MP Solenoid ASSY
Drive Release Link
Toner Sensor PCB
Register Solenoid ASSY
T1 Solenoid ASSY
7.37
MP Unit
70s / 70s
7.38
10s / 20s
7.39
5s / 10s
7.21 7.22 7.23
Regist Actuator Rear/ Regist Actuator Spring
Regist Actuator Front/ Regist Actuator Spring
Ejector Solenoid ASSY
7.40 7.25
10s / 10s 25s / 40s
Interlock SW ASSY
Roller Holder ASSY
30s / 35s
Side Cover R
7.36
Frame R
20s / 20s 15s / 15s 10s / 10s 10s / 10s
7.41
New Toner Actuator
7.32 7.33 7.34
PE Actuator/ Edge Actuator/ Edge Actuator Spring
Toner LED PCB Unit ASSY
7.42
20s / 20s
Fan Motor 60 Unit
PE EG Sensor ASSY
Fan Motor 60 Unit LV
7.26-1
25s / 10s
(HL-5240/5250DN)
7.26-2
10s / 10s
7.26-3
10s / 10s
7.26-4
45s / 50s
Top Cover Printed ASSY
Panel PCB ASSY
SW Key A/ B
Inner Chute/ Pinch Roller Holder
7.27-1
25s / 10s
7.27-2
45s / 50s
7.27-3
15s / 15s
7.27-4
15s / 20s
7.27-5
20s / 20s
Top Cover2 Printed ASSY
(HL-5270DN/5280DW)
Inner Chute/ Pinch Roller Holder
Panel PCB ASSY
SW Key A/ B/ C SW Key Printed ASSY
LCD Holder ASSY
7.28
10s / 15s
Filter
7.29
40s / 40s
Laser Unit
7.30
70s / 70s
PS PCB Unit
7.31
40s / 40s
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7.
7.1
DISASSEMBLY PROCEDURE
AC Cord
(1) Disconnect the AC cord from the Printer.
Printer
AC cord
Fig. 5-2
7.2
Drum/Toner ASSY
1 2
Drum/toner ASSY
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7.3
DX Feed ASSY
(1) Remove the DX feed ASSY.
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.
Front cover
2
Paper tray
Fig. 5-5
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(3) Remove the Separation pad ASSY.

2
Hook
Hook
Paper tray
Fig. 5-6
(4) Remove the Separation pad spring.
Paper tray
Fig. 5-7
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(5) Remove the Lift gear 46.
Paper tray Hooks Lift gear 46

Fig. 5-8
(6) Remove the Gear 21-16.
Gear 21-16
Paper tray
Fig. 5-9
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(7) Remove the Gear 15.
Gear 15
Paper tray
Fig. 5-10
7.5
Back Cover
(1) Remove the Back cover.
Pin
2 1 3
Pin Back cover Fig. 5-11
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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.
Pin
2 1
3 1
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.
Eject actuator spring Rib
4
Eject actuator
3 2 1
Outer chute ASSY
Hook
Fig. 5-13
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7.7
Fuser Unit
(1) Remove the bind B M4x16 Taptite screw, and then remove the FU harness cover 1.
Hooks
FU harness cover 1
Fig. 5-14
(2) Remove the Heater terminal L and Heater terminal S from the Fuser unit.
Heater terminal S Fig. 5-15
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(3) Remove the FU harness cover 2.
FU harness cover 2
1
Hook
Fig. 5-16
(4) Disconnect the connectors of the Thermistor ASSY M and Thermistor ASSY S from the Relay rear PCB ASSY.
Thermistor ASSY S
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(5) Remove the cup B M4x16 Taptite screw, and then remove Fuser unit.
Fuser unit
Fig. 5-18
7.8
Tray MP ASSY
(1) Open the MP tray cover ASSY. (2) Remove the Tray MP ASSY.
Process cover ASSY
3 1
MP tray cover ASSY
Tray MP ASSY Fig. 5-19
5-23
Confidential
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.
Process cover ASSY
2
Drive release link
3
Hook MP tray cover ASSY
Process cover stopper
Fig. 5-20
(3) Remove the MP tray cover ASSY and the Process cover.
2 1 3
Process cover
MP tray cover ASSY Fig. 5-21
5-24
Confidential
(4) Remove the Process cover ASSY from the MP tray cover ASSY.
Process cover ASSY
MP tray cover ASSY
Fig. 5-22
(5) Remove the cup B M4x10 Taptite screw, and then remove the Process cover stopper.
Process cover
Process cover stopper
Fig. 5-23
5-25
Confidential
(6) Remove the Support flap from the Process cover.

Support flap
Process cover
Fig. 5-24
5-26
Confidential
7.10
Access Cover/Side Cover L

(1) Remove the Access cover.
Access cover
1 2
Fig. 5-25
(2) Remove the two bind B M4x12 Taptite screws, and then remove the Side cover L.
Taptite, bind B M4x12 Hook
1
Side cover L
5 2
Hooks
4 3
Fig. 5-26
Hooks
5-27
Confidential
7.11
Main PCB
(1) Remove the four cup S M3x6 SR Taptite screws, remove the FG harness and then remove the Shield cover.
Shield cover FG harness Fig. 5-27
(2) Disconnect the four connectors and six flat cables from the Main PCB.
LD harness connector (Flat cable) DXsolenoid connector Panel PCB connector Relay front connector (Flat cable)
Polygon motor connector (Flat cable)
Main PCB
LVPS PCB connector
Main motor connector (Flat cable) Relay rear connector (Flat cable)
LT connector Fig. 5-28
HVPS PCB connector (Flat cable)
5-28
Confidential
(3) Remove the four cup S M3x6 SR Taptite screws and two Screws to remove the Main PCB.
Main PCB
Screws
FG harness
Fig. 5-29
5-29
Confidential
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.
Gear plate calking ASSY AL
Taptite, cup S M3x6
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.
Taptite, cup S M3x6
Main motor ASSY AL Taptite, cup S M3x6
Taptite, cup S M3x6 Fig. 5-31
5-30
Confidential
(5) Remove the Develop joint from the Gear plate calking ASSY AL.
Develop joint
Fig. 5-32
7.13
Main Shield Plate ASSY

(1) Remove the Insulation sheet.
Insulation sheet
Frame L
Fig. 5-33
5-31
Confidential
(2) Remove the bind B M4x12 Taptite screw. (3) Remove the bind B M4x12 Taptite screw, and then remove the Plate.
Plate Pin Frame L
Pin
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.
Taptite, cup S M3x6
Main shield plate ASSY
Frame L
Fig. 5-35
5-32
Confidential
7.14
Relay Rear PCB ASSY/Connector

(1) Remove the Relay rear PCB ASSY.
Relay rear PCB ASSY
Hook Frame L
Fig. 5-36
(2) Remove the Connector harness. (3) Disconnect the LT connector.

LT connector Hook Connector harness
Frame L Hook
Fig. 5-37
5-33
Confidential
7.15
Relay Front PCB ASSY

(1) Remove the Relay front PCB ASSY. (2) Disconnect the five connectors from the Relay front PCB ASSY.
Pin
Hook
Frame L Hook Fig. 5-38 Pin
Inter lock SW connector Toner sensor PCB connector
MP solenoid connector
Register solenoid connector T1 solenoid connector
Relay front PCB ASSY Fig. 5-39
5-34
Confidential
7.16
MP Solenoid ASSY
(1) Remove the cup B M3x8 Taptite screw, and then remove the Spring.
Frame L
Taptite, cup B M3x8
Spring
Fig. 5-40
(2) Remove the bind B M3x10 Taptite screw. (3) Remove the MP solenoid ASSY, Solenoid release spring P/R and MP solenoid lever.
Taptite, bind B M3x10 Solenoid release spring P/R
MP solenoid lever MP solenoid ASSY
Frame L
Fig. 5-41
5-35
Confidential
7.17
Drive Release Link

(1) Remove the Drive release cam and the Drive release link.
Drive release link
Drive release cam
Frame L
Fig. 5-42
7.18
T1 Solenoid ASSY
(1) Remove the bind B M3x10 Taptite screw. (2) Remove the T1 solenoid ASSY and the Solenoid release spring.
Solenoid release spring
T1 solenoid ASSY
T1 solenoid lever
Frame L
Fig. 5-43
5-36
Confidential
7.19
Toner Sensor PCB

(1) Remove the Toner sensor PCB unit ASSY from the Frame L.
Toner sensor PCB unit ASSY
Hooks Frame L
Fig. 5-44
(2) Remove the PT sensor holder from the Toner sensor PCB ASSY AL.
PT sensor holder
Toner sensor PCB ASSY AL
Hook
Fig. 5-45
5-37
Confidential
7.20
Register Solenoid ASSY

(1) Remove the bind B M3x10 Taptite screw. (2) Remove the Register solenoid ASSY and the Solenoid release spring.
Taptite, bind B M3x10 Solenoid release spring Register solenoid ASSY Register solenoid lever
Frame L
Fig. 5-46
7.21
Ejector Solenoid ASSY

(1) Remove the bind B M3x10 Taptite screw. (2) Remove the Ejector solenoid and the Solenoid release spring.
Taptite, bind B M3x10 Solenoid release spring Frame L Ejector solenoid
Ejector solenoid lever
Fig. 5-47
5-38
Confidential
7.22
Interlock SW ASSY
(1) Remove the Interlock SW ASSY from the Frame L.
Interlock SW ASSY
Frame L Hooks
Fig. 5-48
7.23
New Toner Actuator

(1) Remove the New toner actuator and the New toner actuator spring.
New toner actuator Hook New toner actuator spring
Frame L
Fig. 5-49
5-39
Confidential
7.24
Gear 17/20
Hook
Gear 17
Frame L
Fig. 5-50

Hook
Gear 20 Frame L
Fig. 5-51
5-40
Confidential
(3) Remove the Gear 17 (black).

Hook Gear 17 (black) Frame L
Fig. 5-52
(4) Remove the Gear 17 (white).

Hook
Gear 17 (white) Frame L
Fig. 5-53
5-41
Confidential
7.25
Side Cover R
(1) Remove the two bind B Taptite screws, and then remove the Side cover R.
Taptite, bind B M4x12 Hook Side cover R
4
Hook
Hooks
3
Hooks Hooks Fig. 5-54
5-42
Confidential
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.
Hooks Top cover printed ASSY Hooks Hook
1 2
Hook
Hook
Hook
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.
Taptite, cup B M3x8
Panel PCB ASSY
Top cover printed ASSY Fig. 5-56
5-43
Confidential
7.26-3 SW Key A/B

(1) Remove the SW key A from the Top cover printed ASSY.
SW key A
Top cover printed ASSY
Fig. 5-57
(2) Remove the SW key B from the Top cover printed ASSY.
SW key B
Top cover printed ASSY Fig. 5-58
5-44
Confidential
7.26-4 Inner Chute/Pinch Roller Holder

(1) Remove the six bind B M4x12 Taptite screws, and then remove the Inner chute.
Inner chute
Hooks
Top cover printed ASSY Hooks
Fig. 5-59
(2) Turn the Inner chute. (3) Remove the Pinch roller holder from the Inner chute.
Pinch roller holder Inner chute
Pinch roller holder
Fig. 5-60
5-45
Confidential
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.
Hooks Top cover 2 printed ASSY Hooks Hook
1 2
Hook
Hook
Hook
Fig. 5-61
5-46
Confidential
7.27-2 Inner Chute/Pinch Roller Holder

(1) Remove the seven bind B M4x12 Taptite screws, and then remove the Inner chute.
1 2
Inner chute
3 4
7
6
Hooks
5
Top cover 2 printed ASSY Hooks
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.
Pinch roller holder Inner chute
Pinch roller holder
Fig. 5-63
5-47
Confidential
7.27-3 Panel PCB ASSY

(1) Disconnect the LCD panel PCB harness and Back light PCB harness from the LCD panel PCB ASSY.
LCD panel PCB harness Back light PCB harness
LCD panel PCB ASSY
Top cover 2 printed ASSY
Fig. 5-64
(2) Remove the three cup B M3x8 Taptite screws, and then remove the LCD panel PCB ASSY. 2 3
LCD panel PCB ASSY Taptite, cup B M3x8
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.
5-48
Confidential
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.
SW key A

Fig. 5-66
(2) Remove the SW key B from the Top cover 2 printed ASSY.
SW key B
Fig. 5-67
(3) Remove the SW key C from the Top cover 2 printed ASSY.
SW key C
Fig. 5-68
5-49
Confidential
(4) Remove the Set key film.

Set key film
Set key printed ASSY
Fig. 5-69
(5) Remove the Set key printed ASSY from the Top cover 2 printed ASSY.
Set key printed ASSY
Fig. 5-70
(6) Remove the Key top from the Set key printed ASSY.
Key top
Set key printed ASSY Fig. 5-71
5-50
Confidential
7.27-5 LCD Holder ASSY

(1) Remove the LCD holder from the Top cover 2 printed ASSY.
LCD holder
Fig. 5-72
(2) Remove the Back light PCB ASSY from the LCD holder.
Back light PCB ASSY
LCD holder
Fig. 5-73
5-51
Confidential
(3) Remove the LCD panel PCB ASSY from the LCD holder.
LCD panel PCB ASSY
LCD holder
Fig. 5-74
(4) Remove the Back light film from the LCD holder.
Back light film
LCD holder
Fig. 5-75
5-52
Confidential
7.28
Filter
(1) Remove the Sub duct from the Air duct.
Air duct
Filter
Hooks
Sub duct
Fig. 5-76
(2) Remove the Filter from the Air duct.
Air duct
Filter
Fig. 5-77
5-53
Confidential
7.29
Laser Unit
(1) Remove the Air duct from the Laser unit.
Hook Laser unit
Hook
1 2
Hook
Air duct Hook
Hook
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.
Laser unit
Taptite, cup S M3x6 Protective film Core
Taptite, cup S M3x6
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.
5-54
Confidential
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.
Taptite bind B M4x12 Taptite bind B M4x12
Base plate LV
PS PCB unit terminal
Screw pan (S/P washer) M3.5x6
Fig. 5-80
(4) Remove the two bind B M4x12 Taptite screws, and then remove the LV insulation sheet.
LV insulation sheet
Fig. 5-81
5-55
Confidential
(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.
Frame R
1 2
SW holder ASSY Fan motor 60 unit LV
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.
Inlet harness ASSY SW holder
Power supply switch
Fig. 5-83
5-56
Confidential
(8) Remove the PS PCB unit. (9) Remove the harness from the PS PCB unit.
PS PCB unit
Fig. 5-84
5-57
Confidential
7.31

(1) Remove the four bind B M4x12 Taptite screws, and then remove the Base plate HV.
Taptite, bind B M4x12 Base plate HV
Pin
Pin
Fig. 5-85
(2) Remove the bind B M4x12 Taptite screw, and then remove the HV insulation sheet.
Taptite, bind B M4x12 HV insulation sheet
Pin Pin Fig. 5-86
5-58
Confidential
(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.
High-voltage PS PCB ASSY Taptite, bind B M4x12
Pins
Fig. 5-87
MP PE sensor connector PE EG sensor connector Toner LED PCB connector
Fig. 5-88
5-59
Confidential
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.
Frame R
Hook
Pins
Toner LED PCB unit ASSY Hook Fan motor 60 unit LV connector
Fan motor 60 unit connector
Toner LED PCB
Fig. 5-89
(3) Remove the LED holder from the Toner LED PCB.
LED holder
Hook Fig. 5-90
Toner LED PCB
5-60
Confidential
7.33
Fan Motor 60 Unit

(1) Remove the Fan motor 60 unit from the Frame R.
Frame R
Fan motor 60 unit
Fig. 5-91
7.34
Fan Motor 60 Unit LV

(1) Remove the Fan motor 60 unit LV from the Frame R.
Frame R
Fig. 5-92
5-61
Confidential
7.35
Frame L
(1) Remove the six bind B M4x12 Taptite screws from the Frame L. (2) Remove the Frame L.
Taptite, bind B M4x12 Taptite, bind B M4x12 Taptite, bind B M4x12
Under bar Frame L
Under bar
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.
Frame R
Taptite, bind B M4x12 Fig. 5-94
5-62
Confidential
7.37
MP Unit
(1) Cut the Binder.
Binder Paper feed frame Cut PE EG sensor connector
MP PE sensor connector
Fig. 5-95
(2) Remove the two bind B M3x8 Taptite screws, and then remove the MP feed frame.
Taptite, bind B M3x8 MP feed frame Taptite, bind B M3x8
Hook
Paper feed frame Hook Fig. 5-96
NOTE: When removing the MP feed frame, cut the binder bundling the harnesses with nippers or the like.
5-63
Confidential
(3) Open the MP feed frame cover.

MP feed frame cover
MP feed frame
Fig. 5-97
(4) Remove the Holder bearing MP from the MP feed frame.

Holder bearing MP Hook
2 1
MP feed frame
Fig. 5-98
5-64
Confidential
(5) Remove the MP roller holder ASSY from the MP feed frame.
Lift arm MP
MP feed frame
1 2
3
Hook
MP roller holder ASSY
Fig. 5-99
(6) Remove the PE actuator MP B from the MP feed frame.

PE actuator MP B
Hook
1
PE actuator MP B
MP feed frame Fig. 5-100
5-65
Confidential
(7) Remove the PE actuator MP from the MP feed frame.

PE actuator MP
MP feed frame
Fig. 5-101
(8) Remove the bind B M3x8 Taptite screw, and then remove the MP PE sensor ASSY.
Taptite, bind B M3x8 MP PE sensor ASSY
MP feed frame Fig. 5-102
5-66
Confidential
(9) Remove the Separation pad ASSY MP from the MP frame.
Separation pad ASSY MP
MP frame
Fig. 5-103
(10) Remove the MP separation spring from the MP frame.

MP separation spring
MP frame
Fig. 5-104
5-67
Confidential
7.38
Regist Actuator Rear/Regist Actuator Spring

(1) Turn the Paper feed unit. (2) Remove the Actuator cover from the Paper feed unit.
Actuator cover
Hook Paper feed unit Hook
Fig. 5-105
(3) Remove the Regist actuator rear and the Regist actuator spring from the Paper feed unit.
Regist actuator rear Regist actuator spring
4
Paper feed unit
2 1
Hook
Fig. 5-106
5-68
Confidential
7.39
Regist Actuator Front/Regist Actuator Spring

(1) Remove the Regist actuator front and the Regist actuator spring from the Paper feed unit.
Regist actuator front
4
Regist actuator spring Hook
3 2 1
Paper feed unit
Fig. 5-107
5-69
Confidential
7.40
Roller Holder ASSY

(1) Release the Pin of the Roller holder ASSY from the Lift arm.
Lift arm Pin
Roller holder ASSY
Paper feed frame
Fig. 5-108
(2) Remove the Roller holder ASSY. 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.
Roller holder ASSY Paper feed frame
3 2
A
Fig. 5-109
5-70
Confidential
7.41
PE Actuator/Edge Actuator/Edge Actuator Spring

(1) Remove the Edge actuator spring.
Edge actuator spring
Paper feed frame
Edge actuator
Hooks
Fig. 5-110
(2) Remove the Separation R shaft bearing.

Separation R shaft bearing
Paper feed frame
Fig. 5-111
5-71
Confidential
(3) Remove the Separation roller drive shaft, then remove the Edge actuator and PE actuator.
Edge actuator
PE actuator
Separation roller drive shaft
3 2
Paper feed frame
Fig. 5-112
5-72
Confidential
7.42
PE EG Sensor ASSY
(1) Remove the two bind B M3x8 Taptite screws, and then remove the MP frame.
Taptite bind B M3x8 MP frame
Taptite bind B M3x8
Paper feed frame
Fig. 5-113
(2) Remove the bind B M3x8 Taptite screw, and then remove the PE EG sensor ASSY.
Taptite bind B M3x8
PE EG sensor ASSY
Paper feed frame
Fig. 5-114
5-73
Confidential
8.
8.1
DISASSEMBLY PROCEDURE (LT-5300)

Paper Tray
(1) Pull out the Paper tray from the LT-5300.
Paper tray
Fig. 5-115
(2) Remove the Separation pad ASSY.

2
Hook Hook
Paper tray
Fig. 5-116
5-74
Confidential
(3) Remove the Separation pad spring.

Paper tray
Fig. 5-117
(4) Remove the Lift gear 46.
Paper tray Hook Lift gear 46 Fig. 5-118
5-75
Confidential
(5) Remove the Gear 21-16.
Gear 21-16
Paper tray
Fig. 5-119
Gear 15
Paper tray
Fig. 5-120
5-76
Confidential
8.2
LT Front Cover ASSY

(1) Remove the two bind B M4x12 Taptite screws. (2) Remove the LT front cover ASSY.
LT front cover ASSY
Taptite, bind B M4x12 Fig. 5-121
(3) Remove the LT front paper guide from the LT front cover ASSY.
LT front paper guide
LT front cover ASSY
Hooks
Fig. 5-122
5-77
Confidential
8.3
LT Back Cover
(1) Remove the two cup S M3x6 Taptite SR screws. (2) Remove the LT back cover.
Taptite, cup S M3x6 SR LT back cover
Fig. 5-123
8.4
LT Side Cover L
(1) Remove the bind B M4x12 Taptite screw. (2) Remove the cup S M3x6 Taptite SR screw. (3) Remove the LT side cover L.
3
Boss
Hooks LT side cover L
Hooks Fig. 5-124
5-78
Confidential
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.
Taptite, cup S M3x6 SR Boss
LT side cover R
4
Hooks
1 5
2
Fig. 5-125
5-79
Confidential
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.
Hook
LT PCB ASSY
LT frame L Taptite, bind B M4x12
LT PCB ASSY
LT sensor harness ASSY 1 connector
LT sensor PCB connector
LT sensor harness ASSY 2 connector Fig. 5-126
LT solenoid connector
5-80
Confidential
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.
Connector: 55533-1219 Hook Hook
LT sensor harness ASSY 1
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.
LT sensor harness ASSY 2
Hook LT frame L Hook Connector: 54702-1219 Fig. 5-128
5-81
Confidential
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.
LT frame L Hook
Gear 20 T1 roller drive
Fig. 5-129
(3) Remove the Retaining ring E4. (4) Remove the Gear 24 LT from the LT frame L.
Retaining ring E4 LT frame L
Gear 24 LT
Fig. 5-130
5-82
Confidential
8.10
Collar 6
(1) Remove the Gear plate ground spring from the LT frame L.
LT frame L
Gear plate ground spring
Fig. 5-131
(2) Remove the cup S M3x6 Taptite SR screw, and then remove the Feed roller ground plate.
Taptite, cup S M3x6 SR LT frame L Feed roller ground plate
Fig. 5-132
5-83
Confidential
(3) Remove the T1 sector gear spring LT from the LT frame L.

T1 sector gear spring LT LT frame L
Fig. 5-133
(4) Remove the LT solenoid harness from the hooks of the LT drive unit.
LT drive unit Hooks Hooks
LT solenoid harness
LT solenoid ASSY
Fig. 5-134
5-84
Confidential
(5) Remove the cup S M3x6 Taptite screw. (6) Remove the four bind B M4x12 Taptite screws, and then remove the LT drive unit.
Taptite, bind B M4x12 Taptite, bind B M4x12
LT drive unit
Taptite, cup S M3x6
Ground wire top
LT frame L
Fig. 5-135
(7) Remove the Clutch spring from the LT drive unit.

Clutch spring LT drive unit
Fig. 5-136
5-85
Confidential
(8) Remove the Collar 6. (9) Remove the Clutch arm ASSY from the LT drive unit.
Collar 6 Clutch arm ASSY
LT drive unit
Fig. 5-137
(10) Remove the Collar 6 from the Clutch arm ASSY.

Collar 6 Clutch arm ASSY
Fig. 5-138
5-86
Confidential
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.
Solenoid release spring P/R Taptite, bind B M3x10 LT frame L
LT solenoid ASSY
Fig. 5-139
5-87
Confidential
8.12
Roller Holder ASSY

(1) Remove the Lift arm from the Pin of the Roller holder ASSY.
Lift arm
Pin
Roller holder ASSY
LT paper feed frame
Fig. 5-140
(2) Remove the Roller holder ASSY. 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.
Roller holder ASSY Paper feed frame
3 2
A
Fig. 5-141
5-88
Confidential
8.13
Edge Actuator Spring

(1) Remove the Edge actuator spring.
Edge actuator spring
LT paper feed frame
Edge actuator
Hooks
Fig. 5-142
5-89
Confidential
8.14
PE Actuator , Edge Actuator

(1) Remove the Separation R shaft bearing.
Separation R shaft bearing
Hook LT paper feed frame
Fig. 5-143
(2) Remove the Separation roller drive shaft, then remove the Edge actuator and PE actuator.
Edge actuator
PE actuator
Separation roller drive shaft
LT paper feed frame
Fig. 5-144
5-90
Confidential
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.
Taptite, cup S M3x6 SR Taptite, bind B M4x12 Under bar
Taptite, cup S M3x6 SR Taptite, bind B M4x12 LT frame L
Under bar
Fig. 5-145
(3) Remove the two cup S M3x6 Taptite SR screws, and then remove the LT paper feed frame.
LT paper feed frame
LT frame R
Fig. 5-146
5-91
Confidential
(4) Remove the two cup B M3x12 Taptite screws, and then remove the LT front beam.
LT front beam
LT paper feed frame
Fig. 5-147
(5) Remove the bind B M3x8 Taptite screw, and then remove the LT sensor PCB ASSY.
LT sensor PCB ASSY
LT paper feed frame
Fig. 5-148
5-92
Confidential
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. Model HL-5240 HL-5250DN HL-5270DN HL-5280DW Main PCB (For a supplied part) ROM 0 8 Mbyte Flash ROM x 1 8 Mbyte Flash ROM x 1 8 Mbyte Flash ROM x 1 8 Mbyte Flash ROM x 1 N/A 2 Mbyte Flash ROM x 1 4 Mbyte Flash ROM x 1 4 Mbyte Flash ROM x 1 ROM 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 HL-5250DN HL-5270DN HL-5280DW LM9076001 LZ0683001 LM9077001 LZ0683001 LM9110001 LZ0683001 LM9064001 LM9138001 LZ0683001 MAIN PCB ASSY 5240 FW: MAIN CONTROLLER AL MAIN PCB ASSY 5250 FW: MAIN CONTROLLER AL MAIN PCB ASSY 5270 FW: MAIN CONTROLLER AL MAIN PCB ASSY 5280DW US MAIN PCB ASSY 5280DW EU FW: MAIN CONTROLLER AL
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CHAPTER 6 ADJUSTMENTS AND UPDATING OF SETTINGS, REQUIRED AFTER PARTS REPLACEMENT
<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: First six digits of the part number of the firmware $: Alphabet representing the revision of the firmware. Download the required firmware from the databank, extract it and copy the extracted files into the hl5200 folder that has been created in the C drive. 6) Setting file of the default paper size: Download the 5200setup.zip file from PrUt050007 in the databank. Then, extract this file. S5200E (A4 size), s5200U (Letter size), s5200I (A4 size, Israeli font setting for Israel), AL_CHN.pjl (A4 size, Thin paper setting for China) 7) BR_DEVELOP.zip file Download the above file from PrUt050009 in the databank and copy it into the hl5200 folder that has been created in the C drive. Extract the copied file. 8) MAINTE.EXE file Download the above files from the databank and copy it into the hl5200 folder that has been created in the C drive. Extract the copied file and run the bramainte.exe file by double-clicking. Refer to the following steps for installing the printer driver. LZXXXX_$.BLF
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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

Fuser Unit Laser Unit Paper feeding kit for Tray 1 Paper feeding kit for Tray 2 Paper feeding kit for Tray 3 Paper feeding kit for MP tray
Item
Reset Fuser Counter Reset Laser Counter Reset PF Kit 1 Counter Reset PF Kit 2 Counter Reset PF Kit 3 Counter 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
1.
SERVICE SUPPORT SOFTWARE
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 Once Twice Three times Four times Five times Each mode starts after 2 seconds. (1) Test Sample Page (2) Print Fonts (3) Hex Dump Mode (4) PCB ONLY Mode (5) 1push Printing Recovery Mode * All LEDs are lit for 1 second and the printer returns to the ready status. (6) Network Factory Reset 1 (APIPA: ON) * All LEDs are lit for 1 second and the printer returns to the ready status. (7) Network Factory Reset 2 (APIPA: OFF) * All LEDs are lit for 1 second and the printer returns to the ready status. (8) NV-RAM Factory Reset * All LEDs are lit for 1 second and the printer returns to the ready status. (1) Test Sample Page
Six times
Seven times
Eight times
More than nine times
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CHAPTER 7 SERVICE SUPPORT SOFTWARE
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) (2) Test Sample Page
The printer prints a demo page. The printer returns to the ready status after printing.
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) (6) (7) (8)
1push Printing Recovery Mode

Demo page print is possible by pressing Go button after the power supply is turned on.
Network Factory Reset 1 (APIPA: ON)

The network setting is reset to its factory setting. (APIPA is ON)
Network Factory Reset 2 (APIPA: OFF)

The network setting is reset to its factory setting. (APIPA is OFF)
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. (5) Close the front cover. <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. (5) Close the front cover.
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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 when replacing with a new toner cartridge Bias voltage Bias voltage when replacing with a used toner cartridge
Dark
Density when replacing with a new toner cartridge Print density Density when replacing with a used toner cartridge
Light
Toner empty
[Used toner amount]
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. (5) Press the Go button. (6) Close the front cover. <High Yield 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. (5) Press the Go button twice. (6) Close the front cover.
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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. (1 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. (2 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. (1 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. (2 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.)
nd st nd st
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1 step Press the Go button once. Once Twice
st
2 step
nd
Each mode starts after 2 seconds. (1) Factory Inspection Mode (2) Continuous Grid Pattern Print Mode (3) Fuser Unit Test Print (4) NV-RAM Value Dump Mode (5) RAM Check Printing of the internal data for the factory inspection. * Factory use. (6) Printing for Maintenance * The machine starts printing after closing the front cover. (7) Print Settings * The machine starts printing after closing the front cover. (8) Sleep Mode Indication (OFF/Dimmed) (9) Sleep Mode Setting (ON/OFF) * All LEDs are lit for 1 second and the printer returns to the ready status. (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. (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. (12) Fixed USB Speed * All LEDs are lit for 1 second and the printer returns to the ready status. (13) USB Speed Indication (ON/OFF) * All LEDs are lit for 1 second and the printer returns to the ready status.
Three times Four times Five times Six times
Press the Go button twice.
Once
Twice
Three times Four times
Five times
Six times
Seven times
Eight times
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. 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.)
(2)
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(3)
Activate each sensor listed below manually and verify that the Status LED (HL5240/5250DN) 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 )
Chute Front cover sensor Frame R
Toner LED PCB (Light emission) Frame L Paper eject sensor (Relay rear PCB)
MP PE sensor
PE EG sensor DX tray sensor New toner sensor (Relay front PCB) Toner sensor PCB (Light reception) Regist rear sensor High-voltage PS PCB Fig. 7-1 Regist front sensor PE sensor
Edge sensor
(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. 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. 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.
(3)
(4)
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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. 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.
(6)
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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;
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< 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) 1 page/job 2 pages/job 18 pages/job (9 + 11) / 11 = 1.82 (9 + 11 + 3.6) / 11 = 2.15 (9 + 11 + 3.6 x 17) / 11 = 7.38 Hot start (page) 11 / 11 = 1 (11 + 3.6) / 11 = 1.33 (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) (11)
Developer Roller Counter Reset 1 (For the standard toner) 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.
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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 Go Reprint + Set To Users Mode Continuous test printing Hex Dump Mode Version Check Initializing the NVRAM Function
<Pressing the 2 button when the printer is turned ON> Panel Set & Back Go & + Go & Back -&+ Go & Set Factory Line Inspection Mode Clearing the E50 (FUSERMULF) Rewriting the Flash ROM Checking the hardware (DRAM check, etc.) Function
<Pressing the 2 button in the normal status> Panel Go & + Go & Set - & Set Function RESET PARTS LIFE (Clearing the counters of the periodical replacement parts) Professional Menu 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 Go & (+, Set) Go & (-, +, Set) Function Service Menu (Acquiring the service information such as the number of replacement or paper jam occurrence, error, etc.) Developer Menu (Setting the specific function for the engineers)
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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 TRAY SETTING MANUAL FEED PAPER IN=CONT* Feeds paper automatically when printing using the manual feed function. Feeds paper by pressing the Go button when printing using the manual feed function. Selects the User setting 1 as the current printer setting. Saves the current printer setting as the User setting 1. 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. 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. 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. 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. HP LaserJet 4 compatible. HP LaserJet 3 compatible. When receiving DC3 in FX emulation, ignores the data received before DC1. Not ignore the data even DC3 is received. Item to be Set Description
PAPER IN=STOP
RESET SETTINGS SAVE SETTINGS SAVE FONT PRIMARY FONT
RESET SETTING1 SAVE SETTING1
SET ID=####
SECONDARY FONT
SET ID=####
DOWNLOAD FONT
DOWNLOAD=####
SAVE MACRO (When a macro is registered if the LaserJet emulation is selected.) TRAYCOMMAND MODE READOUT SELECT
SET ID=####
TRAY COM.=NORM.* TRAY COM.=SPEC. READOUT=ON
READOUT=OFF*
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Title & Subtitle FONT SELECT SCALABLE FONT (Only when the LaserJet emulation is selected.)
Item to be Set FONT=ALL* FONT=LJ4
Description Enables all scalable fonts when selecting PCL font setting. Disables the fonts below when selecting PCL font setting. Atlanta, Bermuda Script, PC Brussels, Copenhagen, Germany, Portugal, Calgary, San Diego, US Roman Selects primary fonts in LaserJet emulation. Selects secondary fonts in LaserJet emulation. Places Esszet on E1h of IBM character set. Places Beta on E1h of IBM character set. Does not convert into bold even if the same character is entered into the same position in the FX or XL emulation. Converts into bold if the same character is entered into the same position in the FX or XL emulation. (The print speed is lowered.) Creates the bold and italic letters from the download font. Does not create the bold and italic letters from the download font. Creates the bold and italic letters from the bitmap font. Does not create the bold and italic letters from the bitmap font. Sets the pitch of the condense letter in the EPSON/IBM emulation to 16.66 pitches. Sets the pitch of the condense letter in the EPSON/IBM emulation to 17.14 pitches. Disables the European Parliament fonts. Enables the European Parliament fonts. Disables the bold brougham font. Enables the fold brougham font.
FONT SELECT
PRIMARY FONT SECONDARY FONT
IBM CHR SET MODE
IBM E1H=Esszet* IBM E1H=Beta
W BOLD ON/OFF
W BOLD=OFF*
W BOLD=ON
DLFNT Bd/It
DLFNT Bd/It=NO* DLFNT Bd/It=YES
B PROD ON/OFF
B PROD=ON* B PROD=OFF
CONDENCE SELECT
CONDENC=16.66p*
CONDENC=17.14p
OEM FONT SELECT
OEMFONT=DISABLE* OEMFONT=ENABLE
DARKFONT SELECT
DARKFONT=DISABLE* DARKFONT=ENABLE
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Title & Subtitle FONT SELECT BRO FONT SELECT
Item to be Set BROBITM=DISABLE* BROBITM=ENABLE
Description Disables the internal brougham bitmap fonts of 10 and 12 pitches. Enables the internal brougham bitmap fonts of 10 and 12 pitches. Normal mode Israel Mode The priority of selection for 300dpi bitmap fonts is standard (=low). Command <ESC><CR>!1T The priority of selection for 300dpi bitmap fonts is high. Command <ESC><CR>!2T Only similar size fonts are selectable as scalable is selected. All size fonts are selectable as scalable font is selected.
ISR FONT SELECT 300DPI PRIORITY
ISRFONT=DISABLE ISRFONT=ENABLE 3B PRIO=LOW*
3B PRIO=HIGH
FX/XL SCALE FONT (Setting related to the default font and font selected on the panel in the EPSON/IBM emulation.) FX/XL SCALE ITA. (Setting related to italic of scalable font when the EPSON/IBM emulation.) PAPER&TRAY SIZE
SCAL.F=NORMAL* SCAL.F=ALL SIZE
ITA=OBLIQUE* ITA=ITALIC SEL
Makes upright font oblique to have italic as scalable font is selected. Uses the upright font to have italic as scalable font is selected. Printers to be shipped to the other area than USA and Canada have the A4 size setting by default. Printers to be shipped to USA and Canada have the Letter size setting by default. ACK signal is sent out before BUSY signal goes down. ACK signal is sent out when BUSY signal goes down. The ON/OFF setting of the reprint function follows the setting of the user menu. Turns the reprint function OFF forcedly. Default setting. A problem may occur when printing the binary data though Ctrl-T, Ctrl-C and the like are enabled. Allows you to print the binary data though Ctrl-T and the like are disabled.
DEF PAPER=A4
DEF PAPER=LT
PARALLEL MENU STB/ACK DELAY CDCC BSSL=L* CDCC BSSL=H

REPRINT ON/OFF
REPRINT=ON*
REPRINT=OFF
PS BINARY SELECT
PS BINARY=ASCII*
PS BINARY=BIN
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Title & Subtitle PS QUOTE BINARY
Item to be Set PS QUOTEBIN=OFF* PS QUOTEBIN=ON
Description Not accept the binary data even with special codes. Accepts the binary data with special codes. Does not rewrite the IMAGEMSK procedure. Rewrites the IMAGEMSK procedure.
PS IMAGE MASK
PS IMAGEMSK=OFF* PS IMAGEMSK=ON
PS CELL MODE PS STATUS ECHO PROTECT OFF MODE
PS CEIL=FLOOR* PS CEIL=CEIL STATUS ECHO=ON* STATUS ECHO=OFF PRO.OFF=AUTO* Carries out the page protect if it is turned OFF. (Memory full, Print overrun) Specification up to the fourth Mask ROM. Normal resetting. Form feeds a printable page only. Deletes all white pages having no data. Deletes only the page that both sides of paper is white. Does not reduce the resolution automatically. Reduces the resolution to 300dpi when the total memory is 2Mbytes. Reduces the resolution to 300dpi. OFF: 1 page is fixed for the copy page number. PJL JOB TIMEOUT is effective. PJL JOB TIMEOUT does not carry out.
PRO.OFF=NORMAL HP ESC E COMMAND DPX FF SUP. MODE HP ESC E=RESET* HP ESC E=F/F DPX SUP. =NOMAL* DPX SUP. =SPEC. PS300RESO PS300RESO=NO* PS300RESO=IF 2M PS300RESO=FORCE COPY PAGES JOB TIMEOUT SEL COPY PAGES=ON* COPY PAGES=OFF TIMEOUT=ON* TIMEOUT=OFF PICKUP RETRY SET JOB CANCEL TIME PSCOPYPAGE 1JOB1PAGE SEL PICKUP RETRY=2* (0-7) TIME OUT=???sec PSCOPYPAGE=L3* PSCOPYPAGE=L2 1JOB1PAGE=SX* 1JOB1PAGE=DX APPLEUSBPS BINARY=OFF* BINARY=ON
Changes the PS copypage operator from Level3 to Level2. Duplex=ON makes the printing speed of 1 page of data faster. Sets up the printing mode. (Simplex/Duplex) Enables to print PS Pure Binary data via Mac USB.
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Title & Subtitle MP CAS ADJUST
Item to be Set MPTRAY YADJUST PCTRAY YADJUST DUPLEX YADJUST MPTRAY XADJUST TRAY1 XADJUST TRAY2 XADJUST TRAY3 XADJUST DUPLEX XADJUST
Description Adjusts the position of starting scanning in each paper tray. -50 to 50 dot (300dpi) 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.) 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. 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. Checks toner with the duty level of 2%. (Default) Checks toner with the duty level of 8%. Does not detect the toner low error. The media type of Tray1 follows the one set in the print data. Fixes the media of Tray1 to plain paper. Fixes the media of Tray1 to transparencies. Fixes the media of Tray1 to thin paper. Fixes the media of Tray1 to bond paper. Fixes the media of Tray1 to recycled paper.
PS FONT CACHE
CLEAR CACHE=OFF* CLEAR CACHE=ON
POWER SAVE
POWER SAVE=ON* POWER SAVE=OFF
TONER LOW Changes the timing when the toner low error is detected. 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.
TONERLOW=ON* TONERLOW=DELAY TONERLOW=OFF T1 FIX=OFF* T1 FIX=PLAIN T1 FIX=TRANS. T1 FIX=THIN T1 FIX=BOND T1 FIX=RECYCLED
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Title & Subtitle T2 MEDIA FIX Selects the media type of Tray2. 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.
Item to be Set T2 FIX=OFF* T2 FIX=PLAIN T2 FIX=TRANS. T2 FIX=THIN T2 FIX=BOND T2 FIX=RECYCLED
Description The media type of Tray2 follows the one set in the print data. Fixes the media of Tray2 to plain paper. Fixes the media of Tray2 to transparencies. Fixes the media of Tray2 to thin paper. Fixes the media of Tray2 to bond paper. Fixes the media of Tray2 to recycled paper. The media type of Tray3 follows the one set in the print data. Fixes the media of Tray3 to plain paper. Fixes the media of Tray3 to transparencies. Fixes the media of Tray3 to thin paper. Fixes the media of Tray3 to bond paper. Fixes the media of Tray3 to recycled paper. Identifies the model and determines the default value automatically. HL-5240/5250DN: ON HL-5270DN/5280W: OFF Sets the default value of PCL error print to OFF. Sets the default value of PCL error print to ON.
T3 MEDIA FIX Selects the media type of Tray3. 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.
T3 FIX=OFF* T3 FIX=PLAIN T3 FIX=TRANS. T3 FIX=THIN T3 FIX=BOND T3 FIX=RECYCLED
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=AUTO*
DEF ERRPRT=OFF DEF ERRPRT=ON
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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 Reset Parts Life Menu Item to be Set DRUM UNIT PF KITMP PF KIT 1 PF KIT 2 PF KIT 3 FUSER UNIT LASER UNIT Description Initializes the drum unit remaining life. Initializes the paper feeding kit MP remaining life. Initializes the paper feeding kit 1 remaining life. Initializes the paper feeding kit 2 remaining life. Initializes the paper feeding kit 3 remaining life. Initializes the fuser unit remaining life. Initializes the laser unit remaining life.
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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 SERVICE INFO Subtitle PAGE COUNT JAM COUNT JAM MP TRAY JAM TRAY1 JAM TRAY2 JAM TRAY3 JAM INSIDE JAM REAR JAM DUPLEX REPLACE COUNT TONER DRUM UNIT PF KIT MP PF KIT 1 PF KIT 2 PF KIT 3 FUSER UNIT LASER UNIT COVERAGE PRINT PAGES A4/LTR PAGE LGL/A4LONG PAGE B5/EXE PAGE ENVELOPE PAGE A5 PAGE OTHER PAGE Displays the number of the fuser unit replacement. Displays the number of the laser unit replacement. Displays the average coverage (when printing Letter size paper at 100% print coverage). 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. Displays the 10 latest errors in order of newest to the oldest. Displays the number of the toner cartridge unit replacement. Displays the number of the drum unit replacement. Displays the number of the PF kit replacement. PF kit MP/1/2/3 = PF kit for MP Tray / Tray1 / Tray2 / Tray3. Description Displays the number of printing pages. Displays the number of jam occurrence.
ERROR HISTORY
1:####### 2:####### 3:####### 10:#######
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Title LIFE PERIOD
Subtitle DRUM UNIT PF KIT FUSER UNIT LASER UNIT
Description Displays the drum unit life period. (page) Displays the PF kit life period. (page) Displays the fuser unit life period. (page) Displays the laser unit life period. (image) Sets up the timing of showing CHANGE DRUM SOON message. Default setting: 90%, Setting range: 1 to100%
DRUM LIFE CHK % 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.) JAM COUNT JAM MP TRAY JAM TRAY1 JAM TRAY2 JAM TRAY3 JAM INSIDE JAM REAR JAM DUPLEX REPLACE COUNT TONER DRUM UNIT PF KIT MP PF KIT 1 PF KIT 2 PF KIT 3 FUSER UNIT LASER UNIT REMAIN LIFE DRUM UNIT DRUM UNIT2 PF KIT MP PF KIT 1 PF KIT 2 PF KIT 3 FUSER UNIT LASER UNIT
Displays the total number of paper jam occurrence. The number of paper jam occurrence can be changed only to 0. (Reset only)
Displays the number of the toner cartridge replacement. Displays the number of the drum unit replacement. Displays the number of the PF kit replacement. PF kit MP/1/2/3 = PF kit for MP Tray / Tray1 / Tray 2 / Tray 3.
Displays the number of the fuser unit replacement. Displays the number of the laser unit replacement. Displays the drum unit remaining life counters. (page) Displays the drum unit remaining life counters. (rotation) Displays the PF kit remaining life counters. PF kit MP/1/2/3 = PF kit for MP Tray / Tray1 / Tray 2 / Tray 3.
Displays the fuser unit remaining life counters. Displays the laser unit remaining life counters.
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Title RESET COUNT NV-RAM DEBUG PPDS SUBSET TEST MENU
Subtitle CLEAR COVERAGE CLEAR ERROR HIST NV-RAM HEX PRINT ON/OFF FAN TEST FAN 1=ON/OFF* MOTOR TEST MAIN MOTOR=ON/OFF* SCAN MOTOR=ON/OFF* SENSOR TEST FRONT COVER=ON/OFF T1 KOUTAN=ON/OFF T2 KOUTAN=ON/OFF T3 KOUTAN=ON/OFF REGI-ATO=ON/OFF EJECT=ON/OFF T1 PAPER=ON/OFF T2 PAPER=ON/OFF T3 PAPER=ON/OFF MP PAPER=ON/OFF DX UNIT=ON/OFF REAR COVER=ON/OFF NEW TONER=ON/OFF T2 CONNECT=ON/OF F T3 CONNECT=ON/OF F T4 CONNECT=ON/OF F
Description Initialize average coverage counter. Initialize error history. Prints NV-RAM HEX dump. Supports the PPDS Subset command in the FX Emulation mode. Carries out movement test of FANs. Carries out movement test of main fan, LVPS fan. Carries out movement test of main motor. Carries out movement test of scanner motor.
Front cover sensor (ON: Close) T1 tail edge sensor T2 tail edge sensor T3 tail edge sensor
REGI-MAE=ON/OFF Regist front sensor Regist rear sensor Paper eject sensor Tray 1 paper sensor Tray 2 paper sensor Tray 3 paper sensor MP Tray paper sensor The DX unit is closed. (ON: Close) Back cover sensor (ON: Close) New toner sensor Tray 2 connect sensor
Tray 3 connect sensor
Tray 4 connect sensor
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Title MAINTENANCE PRINT
Subtitle
Description 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).
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3.
NVRAM DEFAULT VALUE

The default values for the main items to be set in NVRAM are as follows; Items Timing of Drum LED ON Development switching timing 25,000 pages (Counted from the drum unit life.) 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 noncontinuous printing) Fixing temperature Transparency: 185C Smaller size mode Paper size Thin paper: 195C Plain paper: 213C Thick paper: 200C Thicker/Bond paper: 200C (in non-continuous printing) Descriptions
Refer to 3.8 PRINT SPEEDS WITH VARIOUS SETTINGS in Chapter 1. The default paper size is "A4". The paper size needs to be changed in US and other countries.
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Appendix 1. Main PCB Circuit Diagram, HL-5240/5250DN/5270DN/5280DW (1/6)
1 2 3 4 5 6 7 8
Main Asic (Valkyrie)

MAIN ASIC(2/3) MAIN ASIC(1/3)
A
SGND
C103 C5P
TP500
R135 100
TP258
U6
Y6 SXOUT SSCG_AVDD sys_clk PLL SSCG_AGND SXIN E20 IORDN F19 IOWRN V20 RSTICN E19 CSROMN0 F18 CSROMN1
TP320 TP318 TP319 TP317
Y4
TP254
L17 (1608) R245 BLM11P300SPB TP255 1 (1608) +1.5V C232 C106 (2012) SGND System PLL 1.35V 1.65V
C208 C22P
TP502
R243 100
TP220
U6
P1 VXOUT APLL_AVDD U1
TP223
L9 (1608) R156 BLM11P300SPB TP191 1 (1608) +1.5V C119 C106 (2012)
A
(VIDEO PLL SGND )
C231
2 SGND
C120
X2
1 SMD-49 TP501 48.00MHz R106 1k
R134 4.7k W6
Y3
C103
X3
1 SMD-49 23.46178MHz
R244 1M R1 VXIN
TP503
V1 APLL_AGND W2 VDON0/PA08
C103
Laser/PO
C102 C5P
R272 R105
MAIN ASIC(3/3)
150MHz TP6 TP250
47 47 3-2A/3-3A/4-1A 3-2A/3-3A/4-1A
IO_RD_N IO_WR_N
C209 C22P
U4 VDON1/PA09 M4 CAL0/PA10/VIB0 N4 CAL1/PA11/VIB1
R500
33
5-4A 2-6E
VDON DIMM_SPD_CLK W18 LD_MON 5-5B
U6
V17 AI0/BD_SMP AD_AVDD V14 AD_AGND Y18 THM_CENTER 5-2B/5-7D AI1 AD_AVREFP U14 AD_AVREFM Y17 THM_EDGE 5-2B/5-7D AI2 E5 VDD_E5 E7 VDD_E7 G5 VDD_G5 W17 FB_VCLN 5-2C AI3/FB_VCLN VDD_U2 P5 VDD_P5 P4 SGND +1.5V T5 VDD_T5 T4 VDD_T4 U7 VDD_U7 T7 VDD_T7 Y13 VDD_Y13 T14 VDD_T14 T16 VDD_T16 P16 VDD_P16 K16 VDD_K16 W15 G16 AI6 VDD_G16 E16 VDD_E16 E14 VDD_E14 E11 VDD_E11 Y15 FB_TR 5-2D AI7/FB_TR VDD_E10 E10 C237 C103 SGND J5 SGND +1.5V C238 C103 +1.5V FB_TRCCV 5-2D SGND C245 C103 C241 C103 +1.5V SGND C230 C103 C248 C103 +1.5V SGND C221 C103 C227 C103 U2 C229 C103 +1.5V SGND C222 C103 +1.5V SGND V16 A3.3V C247 C103 SGND A3.3V
TP333
RESET_N 3-2A/3-5A/3-6E C68 C101 SGND D20 LAN_INT 4-1B
R271 R269
33 33 3-3A 3-2A ROM0_CS_N ROM1_CS_N W1 VBDN 5-4A VBDN
TP30 TP215
5-4B
VENBN
D19 EXINTN0 EXCSN0 D18 EXINTN1 EXCSN1/PA01 C19 EXINTN2/PD01 EXCSN2/PA02 C20 DREQN/PD00 DACKN/PA00
TP328 TP323 TP374
@R273 33 4-1A
V2 ENB0/PA12/VIOP0 R4 ENB1/PA13/VIOP1 U3
TP29 TP249
LAN_CS_N
F17 E17
R253 10k (ASIC def )
5-4B SGND
LDHALF
E18 SGND 3-1D/4-1E DATA[0] DATA[1] DATA[2] DATA[3] DATA[4] DATA[5] DATA[6] DATA[7] DATA[8] DATA[9] DATA[10] DATA[11] DATA[12] DATA[13] DATA[14] DATA[15] 5 6 7 8 5 6 7 8 5 6 7 8 5 6 7 8 RA15 4 33 3 2 1
TP331
R268 10k SGND

TP316 ASIC def )
LDHALF/PA14/TLED
TP340
5-1E
TNRLED
ID_BUS 5-6C 3-1D/4-1D PWM_TNRSEN ADR[24-1] TNR_SEN SGND ADR[2] REG_SOL ADR[3] T1_SOL ADR[4] MP_SOL ADR[5] DX_SOL ADR[6] LT1_SOL ADR[7] LT2_SOL ADR[8] ADR[9] ADR[10] ADR[11] +3.3V ADR[12] FAN_MAIN_24V ADR[13] ADR[14] ADR[15] ADR[16] High Speed UART2/PIO ADR[17] PCLK/PC11 ADR[18] PNLSW0 ADR[19] ADR[20] ADR[21] PNLLED0 ADR[22] PNLSW1 ADR[23] Debug UART ADR[24] DEBUG_RXD 4-7F W19 PHRXD CDCC I/F PHTXD PHOTO_RXD 4-7E Y19 DBGRXD DBGTXD U17 4-6F PHOTO_TXD U16 4-6E DEBUG_TXD 5-4C
TP25
G1 IDADC0/PWMA1/PB00
TP41
Local BUS U19 DATA00 R18 DATA01 U20 DATA02 T19 DATA03 DATA04 DATA05 DATA06 P18 DATA07 RA13 33 3 2 1
TP330
5-6C 10k R234 5-7B (ASIC def 5-7A 5-7B 5-7E 5-5D 5-5E R239 10k +3.3V 5-2D HVVCLN 5-1E FAN_MAIN_12V R240 100 )
J4 IDADC1/PWMA2/PB01 H2 IDADC2/PWMA3/PB02 H1 IDADC3/PWMA4/PB03 J3 J2 IDADC5/PB05 J1 IDADC6/PB06 K3 IDADC7/PB07 K2 IDADC8/PF04 M1 IDINT/PB14 IDRSTN/PWMA0 IDCLK H4
TP245 TP22
DATA[15-0]
M18 ADR01 ADR02 ADR03 L18 ADR04 L19 ADR05 ADR06 ADR07 K17 ADR08 K19 DATA08 ADR09 ADR10 ADR11 J20 DATA11 DATA12 DATA13 DATA14 DATA15 ADR12 J19 ADR13 ADR14 ADR15 H19 ADR16 J17 ADR17 ADR18 ADR19 H18 ADR20 G19 ADR21 ADR22 ADR23 G17 ADR24 SDRAM F20 TP324 G18 G20 TP327 H17 J18 TP325 H20 K20 TP322 K18 DATA10 DATA09 L20 TP326 L17 M19 TP343 M20
8 7 6 5 8 7 6 5 8 7 6 5 8 7 6 5 8 7 6 5 8 7 6 5
1 RA8 33 2 3 4 1 RA7 33 2 3 4 1 RA5 33 2 3 4 1 RA4 33 2 3 4 1 RA3 33 2 3 4 1 RA2 33 2 3 4
ADR[1]
TP18 TP187
H3 5-4C PNLLED3 W16 FB_DEV 5-2C AI4/FB_DEV
2 1
T20 4 RA14 33 R19 TP332 3 P17
TP407 TP242
R20 P19 N18 N17
Y16 K1 R241
TP218
TP219
K4 IDBGNT/PB09 L3 IDRACK/PB13 IDRREQ/PB12 L4 IDDREQ/PB10 IDDACK/PB11 IDBREQ/PB08
33
4-1B 5-1F
FB_GRID LAN_RST FAN_PS_24V
5-2C
AI5/FB_GRID
R252 10k )TP247
L1 L2
5-1E (ASIC def
5-1F
FAN_PS_12V
P20 4 RA12 33 M17 TP329 3 N19 2 N20 1
High Speed UART1 HEATERON2 5-1A G2 HS1RXD/HEAT2 HS1TXD/HEAT1 V4 5-4C P2 HS2RXD/PDI HS2TXD/PDO U5
TP24 TP23
F1
5-1A
HEATERON1
5-4C 5-4C
Low Speed AD/C
IDADC4/PWMA5/PB04
VDD_P4
PNLLED1 PNLLED2
High Speed UART3/PIO 5-4C W20 HS3RXD/PC03 U18 HS3CTS/PC05 HS3RTS/PWMA8

TP21
Y20 HS3TXD/PWMA7 R17
5-2C GRIDC 5-4C PNLLED4 TMODEN CH2 +3.3V

TP226
VDD3_J5 K5 VDD3_K5 M5 VDD3_M5 W5 TSTMODEN Y5 TSTCLK VDD3_T3 V6 VDD3_V6 U13 VDD3_U13 T13 VDD3_T13 U15 TMC2 T18 TEN +1.5V V13 TAPC_NWIRE_SEL W14 L7 (1608) BLM18PG300SN1B +3.3V C88 C106 (2012) L6 UGND (Analog 0 SGND (1608) J9 GND_J9 K9 GND_K9 L9 GND_L9 GND_F5 H5 GND_M9 M10 GND_M10 M11 GND_M11 GND_N5 GND_L5 N5 GND_H5 L5 M9 GND_E6 F5 E6 ) THMODE W13 NOTAP_TEST_SEL L16 SGND BUNRI E12 VDD3_E12 E9 VDD3_E9 C242 C103 VDD3_D17 C236 C103 D17 VDD3_J16 VDD3_M16 J16 C240 C103 VDD3_U15 M16 C244 C103 C226 C103 T3 C225 C103
+3.3V
SGND
+3.3V C228 C103 SGND
B16 +3.3V 2-1C SD_D[15-0]

45MHz
E1 SDBKUPN DIMM_VDD G3 DIMMD_GND D1 GND_D1 C207 C103 +3.3V (SDRAM CLK SGND G4 DIMMD00 SDCLK0 F2 DIMMD01 SDCLK1 E2 DIMMD02 SDCLK2 F3 DIMMD04 SDCKE
TP240 TP243 TP214 TP213
) 4-8B CDCC_DATA 4-8B CDCC_INT_N 4-8B 2-3B SD_CLK0 SD_CLK1 SD_CLK2 Y14 USB_VCC 4-8E VBUS/PC14 C249 C101 V11 USB_RPU USB_AVDD C87 Y12 USB_AVSS T10 SD_CS2_N 2-7D USB_DATA_M USB_DATA_P 4-8D 4-8D R265 39 T11 USB_RSDP
TP288 (+3.3V input) 22.5MHz 22.5MHz 22.5MHz
Test
SD_D[15-0]
V3 CDCC_DATA Y2 CDCC_INTN U6 CDCC_REQN USB USB_PVDD CDCC_RSTN CDCC_CLK
Y1 V5
TP224
R154 10
45MHz
4-8B CDCC_CLK 4-8B CDCC_RST_N SGND
+3.3V C243 C103 SGND
Y7 TMC1 W7
SD_D[0] SD_D[1] SD_D[2] SD_D[3] SD_D[4]
D2 C1 C2 E3 DIMMD03 D3 F4 DIMMD05 B1 DIMMD06 SDCSN0 SDCSN1 SDCSN2 C3 DIMMD07 A1 DIMMD08 E4 DIMMD09 D4 DIMMD10 SDRASN SDCASN B2 DIMMD11 D5 DIMMD12 A2 DIMMD13 SDWEN D6 DIMMD14 B3 DIMMD15 SDBA0 SDBA1 C4
R151 R150 R149
82 33 33
90MHz 90MHz
CDCC_REQ_N
2-7D
90MHz
V8
TP253
L18 (1608) R256 BLM11P300SPB TP257 1 (1608) C234 C106 (2012)
+3.3V C239 C103 SGND +3.3V
2-7D R236 100 2-3B R260 R133 R122 68 33 33

45MHz 45MHz 45MHz
C233 W8 USB_PVSS W11 C103
(PLL UGND
SD_CKE
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]
D
+3.3V
B12 C12 TP280 A13 TP278

TP281
SGND SD_CS0_N 2-3B SD_CS1_N 2-7D R266 1.5k 1%(F)
TP290
C86 C103 C103 +3.3V
C82 C104
C81 C104
TP259
SGND C223 C103 SGND
Y8 USB_DP USB_VDD331 Y9 USB_GND1 U11 USB_VDD151 W10 USB_GND2 U8 USB_RREF USB_COM

)
T9 USB_DM
B13 D12 TP273

TP241
R123 R248
47 47
C101 C103
(Digital SGND +1.5V
TP256
45MHz
2-3B/2-7D
45MHz
SD_RAS_N SD_CAS_N
2-3B/2-7D A14
TP272
T8 USB_RSDM
R121
47
45MHz
2-3B/2-7D C11 A12 TP238

TP275
SD_WE_N UGND
R254 TP251 39 Y11 R125 1.6k 1%(F) DCFGS

TP291 (
C246 C103
(Digital SGND
UGND
47 47
POWER
R247 R124
45MHz
2-3B/2-7C
45MHz
SD_BA0 SD_BA1
M12 GND_M12 T2 R235 33

TP221 TP615
R3 GND_R3 R5 GND_R5 T6 GND_T6 V7 GND_V7 W12 GND_W12 V12 GND_V12 U12 GND_U12 T12 GND_T12 V15 GND_V15 T15 GND_T15 R16 GND_R16 N16
DC MOTOR CTL / PIO R2 DCFGS/PC08 DCFR/VS/PC06 T1 DCCTL/PC07 SCANER MOTOR CTL/PIO N3 P3
L12 GND_L12 6-5B 6-5B DCFR DCCTL +3.3V J11 GND_J11 J10 K12 GND_K12 J12 GND_J12
2-3B/2-7C D13 R250 R258 R262 R259 R251 R120 R249 R116 10 10 47 47 47 47 47 47
45MHz
6-7C
PEDG_SEN 5-2D REG_F_SEN 5-2D REG_R_SEN 5-2D PO_SEN 5-7E PNEW_SEN 5-7B FRONT_COVER_SEN 5-7C T1_PE_SEN 5-2D MP_PE_SEN 5-2E DX_UNIT_SEN 5-7E LT1_PE_SEN 5-4E LT1_PEDG_SEN 5-4E LT2_PE_SEN 5-4E LT2_PEDG_SEN 5-4E LT_DET1 5-4F LT_DET2 5-4F LT_DET3 5-4F
DIMMD16/PE00 C5 DIMMD17/PE01 A3 DIMMD18/PE02 A4 DIMMD19/PE03 B4 DIMMD20/PE04 C6 DIMMD21/PE05 B5 DIMMD22/PE06 A5 DIMMD23/PE07 B6 DIMMD24/PE08 D7 DIMMD25/PE09 C7 DIMMD26/PE10 A6 DIMMD27/PE11 B7 DIMMD28/PE12 C8 DIMMD29/PE13 D8 DIMMD30/PE14 A7 DIMMD31/PE15
SDDQM0 SDDQM1 SDDQM2 SDDQM3 SDDQM4 SDDQM5 SDDQM6 SDDQM7 C13 TP283 B14 TP276 A15 TP274 C14 TP277 D14 TP284 B15 TP279 A16 TP244
TP271
2-3B/2-7B
45MHz
SD_DQM0 SD_DQM1 SD_DQM2 SD_DQM3 N2 SD_DQM4 SD_DQM5 SD_DQM6 SD_DQM7 2-1A

45MHz
2-3B/2-7B
45MHz
R152 10k
2-7B
45MHz
6-5D
TP209
6-5D
R148 10k
SCNFGS
SCNFGS/PC10
SCNCTL/PC09 N1
SCNCTL
GND_J10 K10 GND_K10 L10 GND_L10 L11 GND_L11 K11 GND_K11 5-2D 5-2D 5-2D HVPWMDEV HVPWMCHG HVPWMTRCV HVPWMTRCC W9 GND_W9 V9 GND_V9 U9 GND_U9 Y10 GND_Y10 V10 GND_V10 U10 SGND GND_U10
2-7B
45MHz
HEATER CTL/PIO HTLIMITN 5-3B HTLMTN/PC13 RLYOFFN/PC12

TP210
2-7B
45MHz
5-1A
RLYOFFN
2-7B
45MHz
HVPS/PIO M3 REV0/PWMDEV W4 REV1/PWMCHG

TP216 TP252 TP222 TP217 TP20
2-7B
45MHz
R238 5.6k R255 1 R242 0 R237 1
2-7B
SD_ADR[12-0]
W3 REV2/PWMVCLN M2 REV3/PWMTRCC V19 REV4/EXCSN2BN CPU/JTAG
GND_N16 H16 GND_H16 F16 GND_F16 E15 GND_E15 E13 GND_E13 E8 GND_E8 SGND
D9 MA00 B8 MA01 A8 MA02 C9 MA03 B9 MA04 A9 MA05 C10 MA06 A10 MA07 B10 MA08 MA09 MA10 D10 TP236 D11
TP235 TP237
8 7 6 5 8 7 6 5 8 7 6 5
C102
C102
PNLLED5 R153 1k L5 (1608) R104 TP314 1 (1608) BLM18PG300SN1B +1.5V C66 C106 (2012) SGND SGND
C102
C104 C114
1 RA38 47 2 3 4 1 RA36 47 2 3 4 1 RA37 47 2 3 4
SD_ADR[0] SD_ADR[1] SD_ADR[2] SD_ADR[3] PLL_AVDD SD_ADR[4] SD_ADR[5] PLL_AGND SD_ADR[6] SD_ADR[7] JTAG_RST SD_ADR[8] SD_ADR[9] JTAG_CK SD_ADR[10] SD_ADR[11] JTAG_MS SD_ADR[12] 4-5E A17 JTAG_RMODE/BKTGIO 4-5E C15 2-6E EEPROM_CLK JTAG_DI 4-5E JTDI UPD800268F1-011-MN9-A JTDO RMODE_BKTGIO 4-5E B17 JTMS NTRC_DATA2 NTRC_DATA3 4-5E A18 JTCK NTRC_DATA0 NTRC_DATA1 B18 JTRST NTRC_CLK
5-4C
R147 6.8k
5-2D
B20
TP315
C113
C116
C67 B19 C103
C117
10%
UPD800268F1-011-MN9-A SGND
D16 4-5E C18 A20 A19 D15 4-5F 4-5F 4-5F 4-5F C17 NTRC_END C16 4-5E 4-5E NTRC_END JTAG_DO NTRC_DATA0 NTRC_DATA1 NTRC_DATA2 NTRC_DATA3 NTRC_CLK
A11 MA11 B11 MA12

TP234
R246 47 R263 100

100kHz
EEPROM V18 EEPROM_DATA SDA 2-6E UPD800268F1-011-MN9-A SCL

TP287
T17
CODE NAME B512210CIR (1/6)

8
A-1
Confidential
APPENDIX
1 2 3 4 5 6 7 8
SDRAM,SODIMM,EEPROM
A A
1-3E SD_ADR[12-0] 45MHz
IMA[12-0]
45MHz
SD_ADR[0] SD_ADR[1] SD_ADR[2] SD_ADR[3] SD_ADR[4] SD_ADR[5] SD_ADR[6] SD_ADR[7]

TP179 TP143 TP144 TP188
8 7 6 5
R219 R218 R226 R225
1 RA30 47 2 3 4
47 47 47 47
IMA[0]
TP145
TP56 TP57 TP142
IMA[1] IMA[2] IMA[3] IMA[4] SD_CS0_N IMA[5] SD_RAS_N IMA[6] SD_CAS_N IMA[7] SD_WE_N IMA[8] IMA[9] IMA[10] IMA[11] IMA[12] SD_CLK0 SD_CKE
90MHz 45MHz
SDRAM(128Mbit/256Mbit)
R207 0
TP42 TP181 TP131 TP132
144PIN SO-DIMM CN12

DMD[0] +3.3V DMD[1] DMD[2] DMD[3] DMD[4] SD_DQM0 DQ0 SD_DQM2 DQ1 SD_DQM1 DQ2 SD_DQM3 DQ3 SD_DQM4 DQ4 SD_DQM6 DQ5 SD_DQM5 DQ6 SD_DQM7 DQ7 DQ8
45MHz
144PIN SO-DIMM CN12

23 25 115 117 24 26 116 118 1-3E/3B
45MHz
144PIN SO-DIMM CN12

+3.3V 11 C130 C104 SGND 1 12 C139 C104 SGND 2 27 C129 C104 SGND +3.3V 21 28 C138 C104 SGND 22 45 C128 C104 SGND +3.3V C141 C104 SGND +3.3V C127 C104 SGND +3.3V C137 C104 SGND +3.3V C136 C104 SGND +3.3V 76 81 C126 C104 SGND +3.3V 75 101 C125 C104 SGND +3.3V C140 C104 SGND +3.3V 92 113 C123 C104 SGND +3.3V C135 C104 SGND 108 129 C122 C104 SGND 119 130 C134 C104 SGND 120 143 C121 C104 SGND 139 144 C133 C104 SGND 140 145 VSS FG VSS VDD VSS VDD VSS VDD VSS VDD 107 114 VSS VDD VSS VDD 91 102 VSS VDD VSS VDD VSS VDD 56 82 VSS VDD 55 64 VSS VDD 36 63 VSS VDD 35 46 VSS VDD VSS VDD VSS VDD VSS VDD VSS VDD VDD
@U11
19
1
0.5
TP182 TP189 TP120 TP121
TP58
TP59 TP55 TP77
1-3D
45MHz
CS R228 47 R227 47 R229 47

TP43 TP129 TP82 TP83
VDD1 14 VDD14 27 VDD27 3 VDDQ3 9

C103 C189 C103 C146 C103
3 5 7 9 13 15 17 19 37 39 41 43 47 49 51 53 83 85 87 89 93 95 97 99 121 123 125 127 131 133 135 137 4 6 8 10 14 16 18 20 38 40 42 44 48 50 52 54 84 86 88 90 94 96 98 100 122 124 126 128 132 134 136 138
DQMB0 DQMB1 DQMB2 DQMB3 +3.3V DQMB4 DQMB5 DQMB6 +3.3V DQMB7
18
1-3D/7D
45MHz
RAS
17
1-3E
TP248 45MHz 45MHz
1-3D/7D
45MHz
CAS
16
1-3E/3B 1-3E
TP268 45MHz 45MHz 45MHz 45MHz
SD_ADR[8] SD_ADR[9] SD_ADR[10] SD_ADR[11] SD_ADR[12]
8 7 6 5
1 RA29 47 2 3 4
1-3D/7D
45MHz
WE
15 LDQM
VDDQ9 43 VDDQ43 49 UDQM VDDQ49 28 CLK VSS28 41 CKE 20 BA0 A12/NC6 12 BA1 VSSQ12 46 VSSQ46 52 VSSQ52 2 DQ0 4 DQ1 5 DQ2 7 DQ3 8 DQ4 DQ5 DQ6 DQ7 DQ8 DQ9 DQ10 DQ11 DQ12 DQ13
TP51
TP50 TP49 TP48
1-3E
TP286
TP119 TP118 TP117 TP176
TP76
TP54 TP75 TP74
R230
TP147 TP116
47
TP146
DMD[5] DMD[6] DMD[7]
SD_DQM1
45MHz
39
C187
SD_DQM0
1-3E
TP246
1-3E/7B 1-3E/7B R216 0

TP133 TP81
1-3E
TP174
R224
47
TP113
1-3E
TP175
C103 C190
C103 C145
C103
38 37 VSS41 VSS54
1-3D 1-3D
TP211 45MHz
DMD[0] DMD[1] DMD[2] DMD[3] DMD[4] DMD[5] SGND DMD[0] DMD[1] DMD[2] DMD[3] DMD[4] DMD[5] DMD[6] DMD[7] DMD[8] DMD[9] DMD[8] DMD[10] DMD[9] DMD[11] DMD[10] DMD[12] DMD[11] DMD[13] DMD[12] DMD[14] DMD[13] DMD[15] DMD[14] DMD[15] DMD[0] DMD[1] DMD[2] DMD[3] DMD[4] DMD[8] DMD[9] DMD[10] DMD[11] DMD[12] DMD[13] DMD[14] DMD[15] DMD[6] DMD[7]
TP177
TP80
C188
@R217 47
54
DQ9 DQ10 DQ11 DQ12 DQ13 DQ14 DQ15 DQ16 DQ17 DQ18 DQ19 DQ20 DQ21 DQ22 DQ23 DQ24 DQ25 DQ26 DQ27 DQ28 DQ29 DQ30 DQ31 DQ32 SD_CAS_N DQ33 SD_WE_N DQ34 DQ35 SD_CLK1 DQ36 DQ37 SD_CLK2 DQ38 DQ39 80 DQ40 DQ41 DQ42 DQ43 DQ44 DQ45 DQ46 DQ47 DQ48 DQ49 DQ50 DQ51 DQ52 DQ53 DQ54 DQ55 DQ56 DQ57 DQ58 DQ59 DQ60 DQ61 DQ62 DQ63 SGND EEPROM_CLK 1-3F
TP285 TP124 TP185 TP134 TP186 TP92 TP128
R215 47
TP122 TP178
SD_BA0 SD_BA1
1-3D/7C
45MHz
R214 47
TP79 TP78
21
1-3E/7C
+3.3V SD_ADR[0] SD_ADR[1] SD_ADR[2] SD_ADR[3] SD_ADR[4] SD_ADR[5] SD_ADR[6] SD_ADR[7] SD_ADR[8] SD_ADR[9] SD_ADR[10] SD_ADR[11] SD_ADR[12] SGND 29 31 33 30 32 34 103 104 105 109 111 112 70 72 A0 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10/AP A11 A12 A13,DSP
54pin TSOPII
8 7 6 5 8 7 6 5 8 7 6 5 8 7 6 5
1 RA23 22 2 3 4 1 RA22 22 2 3 4 1 RA25 22 2 3 4 1 RA26 22 2 3 4
IMA[0] IMA[1]
23 A0 24 A1 25 A2 26 A3 29 A4 30 A5 31 A6 32 A7 33 A8 34 A9 22
IMA[2] IMA[3] IMA[4] IMA[5] SD_D[15-0] 1-1C IMA[6] IMA[7] 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]
TP198
TP195 TP192 TP197
10 TP47 11TP46 13TP45 42TP44 44 TP85 45TP86 47TP87 48TP88 50 TP89 51TP90 53TP91
TP93
8 7 6 5 8 7 6 5 8 7 6 5 8 7 6 5
1 RA35 33 2 3 4 1 RA34 33 2 3 4 1 RA33 33 2 3 4 1 RA32 33 2 3 4
DMD[0]
TP141 TP140 TP139 TP138
IMA[8] IMA[9] IMA[10] IMA[11] IMA[12]
DMD[1] DMD[2] DMD[3] DMD[4] DMD[5] DMD[6] DMD[7] DMD[8] DMD[9] DMD[10] DMD[11] DMD[12] DMD[13] DMD[14] DMD[15]
A10/AP 35 A11 36 40 NC
TP84
SD_BA0 SD_BA1
106 1-3D/3B 110 1-3E/3B

45MHz
BA0 BA1
A12/NC36 DQ14 DQ15
TP196
TP194 TP193 TP190
TP136 TP137 TP135 TP94
SD_CS1_N SD_CS2_N SD_RAS_N
69 71 65 66 67
K4S281632F-UC75
1-3D
TP130 45MHz 45MHz 45MHz
nCS0 nCS1 nRAS nCAS nWE
1-3D
TP180
1-3D/3B 1-3D/3B
45MHz
TP173
TP171 TP170 TP168
TP115 TP172 TP114 TP169
1-3D/3B
90MHz
SD_D[11] SD_D[12] SD_D[13] SD_D[14] SD_D[15]
61 62 74 68
1-3D
TP184
CK0 CKE0 CK1 CKE1 NC/CB7 +3.3V NC/CB0 NC/CB4 NC/CB1 +3.3V NC/CB5 NC NC,nMWAIT/CB2,nMWAIT +3.3V NC,nMIRQ/CB6,nMIRQ NC/CB3 +3.3V SDA SCL DMM3-RS144A2B-13 SGND
DMD[5] DMD[6] DMD[7] DMD[0] DMD[1] DMD[2] DMD[3] DMD[4] DMD[5] DMD[6] DMD[7] DMD[8] DMD[9] DMD[10]
+3.3V
90MHz
TP167
TP165 TP164 TP162
TP112 TP166 TP111 TP163
1-3D
TP183
57 58 59 60 73 77 78 79
+3.3V
TP125 TP127
R220 4.7k EEPROM_DATA

DIMM_SPD_CLK
R223 100
TP108
TP126
141
TP110
1-1F 142
1-6A
TP616
DMD[11] DMD[12] DMD[13] DMD[14] DMD[15] DMD[8] DMD[9] DMD[10] DMD[11] DMD[12] DMD[13] DMD[14] DMD[15]
16kbits EEPROM
C203 C103 +3.3V
SGND
146
FG
DMM3-RS144A2B-13
@U13
8 6 5 R222 100
TP109
VCC SCL SDA TEST
VSS A0 A1 A2
4 1 2 3
SGND +3.3V
M24C16-WMN6TP
45MHz DMD[15-0]
DMD[15-0]
DMD[15-0]
CODE NAME
1 2 3 4 5 6 7
B512210CIR (2/6)
8
A-2
Confidential

1 2 3 4 5 6 7 8
ROM, Reset IC, Board id

A
ROM1
@U14 1-3A 26 ROM1_CS_N 1-3A/3A/4-1A TP312 11 IO_WR_N 1-3A/3A/4-1A 28 IO_RD_N 15 +3.3V 1-1A/5A/6E RESET_N @R267 1k
TP405 TP404
A
FLASH (64/32Mbit)
37
ROM0
32
+3.3V @C253 C104 SGND ROM0_CS_N 1-3A IO_WR_N IO_RD_N
TP321 TP380
MIRROR FLASH (128/64Mbit) @U15

43
CE
VCC
CE
13
1-3A/2A/4-1A 1-3A/2A/4-1A
TP379 TP424
VCC 52
+3.3V @C251 C104 SGND
WE
OE
WE
34
VSS27
VSS46
27
46
OE
17
VSS52 33 VSS33 29
RY/BY
BYTE
RY/BY
53
+3.3V 1-1A/2A/6E
47
BYTE
14
12
RESET
NC 13
+3.3V
MASK ROM (128/64Mbit)
RESET_N @R56 1k
TP455
RESET
VI/0(VCCQ)
+3.3V
ADR[1] ADR[2] ADR[3] ADR[4] ADR[5] ADR[6]
25
24 23 22 21 20 19 18
8 7
A0
A1 A2 A3
WR/ACC
14
+3.3V
@U16
24
37
CE
27
VCC37 38 VCC38
+3.3V
ADR[1] ADR[2] ADR[3]

TP426 TP427 TP430 TP428 TP431 TP429 TP425 TP408 TP402 TP401 TP400 TP375 TP398 TP418 TP417 TP416 TP414 TP423 TP422 TP419 TP421 TP420 TP415
31 A0 26 A1 25 A2 24 A3 23 A4 22 A5 21 A6 20 A7 10 A8 A9 8 A10 7 A11 6 A12 5 A13 4 A14 3 A15 54 A16 19 A17 18 A18 11 A19 12 A20 15 A21 2 A22 1 A23 56 A24 55
DQ14 DQ13 DQ12 DQ11 DQ10 DQ9 DQ8 DQ7 DQ6 DQ5
27 NC27 28 NC28 30 NC30

16
SGND
48PIN TSOP1
A4 A5 A6 A7
A8 A9
DQ0 DQ1 DQ2

DQ3 DQ4 DQ5 DQ6
29 31 33
35 38 40 42
DATA[0] DATA[1] DATA[2] DATA[3] DATA[4] DATA[5] DATA[6] DATA[7] DATA[8] DATA[9] DATA[10] DATA[11] DATA[12] DATA[13] DATA[14] DATA[15] ADR[1] ADR[2] ADR[3] ADR[4] ADR[5] ADR[6] ADR[7] ADR[8] ADR[9] ADR[10] ADR[11] ADR[12] ADR[13]
OE
25 VSS25 1 26
ADR[7] ADR[8] ADR[9] ADR[10] ADR[11] ADR[12] ADR[13] ADR[14] ADR[15] ADR[16] ADR[17] ADR[18] ADR[19] ADR[20] ADR[21]
+3.3V
BYTE
VSS26 47 VSS47
@C254 C104
ADR[4] ADR[5] ADR[6] ADR[7]
WP/ACC
+3.3V
23 A0 22 A1 21 A2 20 A3 19 A4 18 A5 17 A6 VSS48
48
SGND
ADR[8] ADR[9] ADR[10] ADR[11] ADR[12] ADR[13] ADR[14]
6 5 4
3 2 1 48
17 16 9 10
A10 A11 A12

A13 A14 A15 A16
A17 A18
DQ7
DQ8 DQ9 DQ10 DQ11 DQ12 DQ13 DQ14
44
30 32 34 36 39 41 43 45
56pin TSOP1
35 DQ0 37 DQ1 39 DQ2 41 DQ3 44 DQ4 46 48 50 36 38 40 42 45 47 49 51

TP348 TP350 TP349 TP307 TP305 TP344 TP345 TP346 TP310 TP309 TP308 TP306 TP304 TP303 TP302 TP342
DATA[0] DATA[1] DATA[2] DATA[3] DATA[4] DATA[5] DATA[6] DATA[7] DATA[8] DATA[9] DATA[10] DATA[11] DATA[12] DATA[13] DATA[14] DATA[15]
48pin TSOP1
16 A7 10 A8 9 A9 8 A10 7 A11 6 A12 5 A13
28 D0 30 D1 32 D2 34 D3 39 D4 41 D5 43 D6 45
DATA[0] DATA[1] DATA[2] DATA[3] DATA[4] DATA[5] DATA[6] DATA[7] DATA[8] DATA[9] DATA[10] DATA[11] DATA[12] DATA[13] DATA[14] DATA[15]
ADR[15] ADR[16] ADR[17] ADR[18] ADR[19] ADR[20] ADR[21] ADR[22] ADR[23]
A19 DQ15/A-1 A20
MBM29PL32BM90TN-K-E1
ADR[14]
C
FLASH PIN
ADR[15] ADR[16] ADR[17] ADR[18]

TOSHIBA FUJITSU FUJITSU DL type LV type Mirror 64M 64M A21 ACC WP A19 Vccq Vss A19 A21 WP/ACC RY/BY Byte Vcc
4 A14 3 A15 2 A16 15 A17 D10 14 A18 D11 11 A19 D12 13 A20 D13 12 A21 D14 36 A22 D15/A-1 D9 D8 D7
29 31 33 35 40 42 44 46
ADR[19]
OKI OKI P2ROM P2ROM 32M A19 NC
WP/ACC
ADR[20] ADR[21] ADR[22] ADR[23]
SGND
A25
DQ15/A-1
16M A19 NC NC
PIN 9 13 14 15 47 *NC pin
64M A19 A21 NC NC Byte
32M A19 NC NC NC Byte
MBM29PL64LM-10PCM
MR27V12850J-034TN
RY/BY RY/BY Byte Byte
ADR[24-1]
1-3B/4-1D
DATA[15-0] 1-1B/4-1E
+3.3V
ADR[1] ADR[2]
10k 10k 10k 10k 10k 10k 10k 10k 10k R282 R300 R301 R299 R298 R297 R295 R294 R293 R292 R291
R290
10k 10k 10k 10k 10k 10k 10k 10k 10k 10k 10k 10k 10k 10k 10k 10k 10k 10k 10k 10k 10k 10k
R93 R48 R88 R46 R87
ADR[3] ADR[4] ADR[5] ADR[6] ADR[7] ADR[8] ADR[9] ADR[10] ADR[11] ADR[12] ADR[13] ADR[14]
ADR[3] ADR[4] ADR[5] ADR[6] ADR[7] ADR[8] ADR[9] ADR[10] ADR[11] ADR[12] ADR[13] ADR[14] ADR[15]
RESET IC
R44 R86
+3.3V U4 2
TP356
4 VDD OUT
TP301
R43 R39 R76 R38 R75 R37 R74 R36 R35 R277 R85 R42 R79 R40 @R81
SGND
3 CD 1
1-1A/2A/5A
RESET_N
C55 C103 C54 C103
VSS S-80928CLNB
10k 10k
10k
10k 10k
R289 R276
ADR[16] ADR[17]
ADR[16] ADR[17] ADR[18] ADR[19]
10k 10k
10k
R80 R296
@R83
ADR[20] ADR[21] ADR[22] ADR[23]
ADR[20] ADR[21] ADR[22] ADR[23] ADR[24]

TP413
10k @R306
10k @R305 10k R304
F
SGND
CODE NAME
1 2 3 4 5 6 7
B512210CIR (3/6)
8
A-3
Confidential
APPENDIX
1 2 3 4 5 6 7 8
LAN I/F, CDCC I/F, USB I/F, Debug Serial I/F

A
@C27 C8P @X1 SMD-49 25.00MHz FG2
TP505
CDCC CN13
0V 0V 16 17 18 19 20 21 22 23 +3.3V 24 25 26 27
1 2 3
@U1 6 XTAL1 70 @R95 10k +3.3V

TP385
SGND @R58 @C30 C10P

TP504
@R57 1M 5 XTAL2 330

TP435
PME
@C32 C104 @C33 C104
@C59 C104 @C60 C104
+5V 0V 0V 0V 0V 0V 0V
0.5
R501 1.5k +5.0V C196 C192 C103 C103 +5.0V C202 C103 7 VDD57 16 VDD516 30 VDD3 C200 C103 +5.0V SGND
4
CDCC_GA
U12
1 VDD51
SGND 94 @R284 12.4k 87 EXRES1 92 10 nRD 93 nWR 72 IRQ TPO+ 78 nRESET TPOC10P 83 SPEED_SEL
TP357 TP354 95
SGND
LAN @CN5
12 FG 11 FG
LAN_CS_N
1-3A
TP384
nCS
L3.3V LGND @R60 (2012) @R91 49.9 (2012) @C43 @R62 49.9 (2012) @C31 10 1%(F)
16VDC (1005) 10%(B) C223 2B LAN_LEDA_N +3.3V (1608) @R308 100
15 GND15 26 GND26
IO_RD_N IO_WR_N
1-3A/3-2A/3-3A 1-3A/3-2A/3-3A @R96 100 1-1A

TP353
RBIAS
TP388 TP433
SGND @R307 12k 1%(F)
7 LED1_C
yellow
0V 0V 0V 1:TX+ 0V 0V 2:TX3:RX+
4:not use 5:not use
8 LED1_A 1 TCT 2 TD+ 3 TD4 RD+
79
LGND
28 29 30 10 11 12 13 32
C101 C101 C101 C101 C101
LAN_INT LAN_RST
RA20 1.5k SGND RA27 33 8 7 6 5

8 7 6 5
R212 1.5k 21 RSTN/SIN

TP64 TP72
R208 1k 1-6D C191 C101

TP60
1-6B
TP351
@R97 10k
@R283 100
TP386
0V ACKn BUSY PE
CDCC_RST_N
@C255 C102 SGND
74 TPI+ 76 FIFO_SEL TPI-
@C44
TP391 TP390
C682
1 2 3 4 24 INTN
B
SGND
5 RD6 RCT @R98 100 +3.3V (1608) LAN_LEDB_N 2B 10 LED2 9 LED2 08B0-1X1T-03-F
orange green
6:RX7:not use 8:not use
82
B
22.5MHz
(2012) 98 GPIO0/nLED1 99 GPIO1/nLED2 100 GPIO2/nLED3

TP436 Link&Activ Speed
@C45 (2012) 49.9 @R89
C682
SGND R211
TP63
SELECT FLTn
C4
C3
C2
C1
4A 4B
LAN_LEDA_N LAN_LEDB_N SGND 10k
49.9 @R90 (1005) 25VDC 10%(B) C103 @C257 LGND
1-4D 33
TP95
CDCC_INT_N
R213 33
TP68
6 ACKN 5 BUSY
TP67
Full Duplex R601
+5.0V @DA3
22 REQN/SOUT
TP62
R209 33
TP225
22.5MHz
CDCC_REQ_N 1-4D
4 PE 3 SELECT 28 FLTN 2 AFN CLK/SCK 25
C154
C153
C143
C142
C197
9 +3.3V 71 RESERVE71
TP387 TP355
DF5A6.8FU(F) SGND 14 36 31 1
C4 C3 C2 C1
ATEST 73 RESERVE73 75 RESERVE75 84 RESERVE84

TP389
RA21 1.5k
8 7 6 5
TP96 TP98
45MHz
1-6C
TP149
CDCC_CLK
SGND 8 7 6 5
RA24 100 1 2 3 4
C101 C101 C101 C101
TP53 TP52 TP70 TP66
ATFEEDn SELINn INPRIMn 67 EED/GPO3/nD16BUS 69 EECLK 68 EECS/GPO4

TP352 TP607
SGND
29 SELINN 27 INITN 17 STBN DATA
23
TP65
R210 33
TP148
22.5MHz
1-4C
CDCC_DATA
R600 10k SGND
STBn
+5.0V
13
1 2 3 4 1 2 3 4
@ZD3
TP383
@DA4 DF5A6.8FU(F) RA18 2.2k

A
AMC
C201 C199
0.5mm pitch 100pin TQFP
UDZS6.8B 8 +3.3V DI1 @C28 C103 11 SGND DI4 DI5 7 @C260 C106 4 SGND
TP434
30pin TSOP
C
ADR[1] ADR[2] ADR[3] ADR[4] ADR[5] ADR[6] ADR[7] 18 A1 17 A2 16 A3 15 A4 14 A5 13 A6 12 A7
RA19 2.2k RA31 100 8 7 6 5 8 7 6 5 1 2 3 4 1 2 3 4

C101 C101 C101 C101 C101
TP150
C198
C195
TP69
20 SMC
TP61
SGND 2 3 4 5 6 7 8 9
C4 C3 C2 C1 C4 C3 C2
VDD_REF
SGND
18 D0 19 D1 14 D2 12 D3 11 D4 10 D5 9 D6 8 D7
DI2 DI3
TP97 TP151 TP101 TP73 TP100 TP71 TP99
VSS_REF
DI6 DI7 @C259 C103 DI8
VDD_PLL
GND_PLL
RA28 100 @DA2
C101
C101
C101
C1
CDCC-GA
C193
C194
C152
C151
C150
ADR[24-1]
1-3B/3-1D VDD_CORE3 VDD_CORE65
3 65 @C52 C106 C612 C103
TP381
NC NC
33 34 35
NC NC NC
@DA1DF5A6.8FU(F)
DF5A6.8FU(F)
SGND SGND R136 0
@C53 C103
NC
1 GND_CORE1 66 GND_CORE66 L3.3V @L2 (1608) BLM18PG300SN1B 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] 8 7 6 5 8 7 6 5 8 7 6 5 8 7 6 5 1 @RA10 0 2 3 4 1 @RA9 0 2 3 4 1 @RA6 0 2 3 4 1 @RA1 0 2 3 4 SGND 39 VDD(D17)
TP600 TP601 TP602 TP603
FG SGND FG
37 38 R186 0
SGND SGND
C149
C148
C147
NC
15
NC
A A
D
USB CN7
64 D0
TP382
81 AVDD81 85
C103 C103
TP438
+3.3V 89
C106
R188 0
DM FG1 DP 3
2 1-4D 1-4D
USB_DATA_M USB_DATA_P
63 D1 62 D2 59 D3 58 D4 AVDD91 AVDD89 AVDD85
91
PC_+5V +3.3V
@C256 @C42 @C40
1 R108 10k 1-4D SGND SGND R126 0 SGND R107 15k

TP334
TP378
57 D5 56 D6 53 D7 52 D8 AGND86 88 D9 50 D10 49 D11 46 D12 AGND90 AGND88 90

TP359
77 AGND77 80 AGND80 86
CN6 S0V VDD3 JTAG_CK OT1 SGND LGND JTAG_DI JTAG_MS JTAG_RST 1 2 3 4 5 6 7
TP608 TP609 TP610 TP611
GND SGND +3.3V R132 10k
SGND R109 0
USB_VCC
FG FG 1-4F 1-4F 1-4F 1-4F 1-5F JTAG_CK JTAG_MS JTAG_RST JTAG_DI JTAG_DO
6 5
TP376
51
LG5459001 CONNECTOR:UBR24-4K2300
DATA[5] DATA[6] DATA[7] DATA[15-0] 1-1B/3-1D
TP377
45 D13 44 D14 43 D15 40 VDD(D16) 38 VDD(D18) 37 VDD(D19) 36 VDD(D20) 33 VDD(D21) 32 VDD(D22) 31 VDD(D23) VDD97 VDD61 VDD55 VDD48 VDD35 VDD42 VDD28 VDD20 VREG
2 +3.3V 20
@C29 C103
JTAG_DO
E
+3.3V
@U9
VCC 5 +3.3V
28
@C26 C103
TP269
35 42 48
@C38 C103 @C37 C103 @C25 C103
R270 4.7k +3.3V SGND R119 10k 1-4F 1-5F 9 10 11 1-5F 12 13 14

TP313 TP282
DEBUG @CN20
DBRXD 1
@R184 10k
1 2
B A
GND Y
3 4
SGND 1-4C
TP33
DEBUG_RXD
TC7SH08FU(F) DBTXD JTAG_RMODE/BKTGIO NTRC_CLK NTRC_END 2 1-6C

TP8
55 61 97
@C51 C103 @C50 C103 @C39 C103
DEBUG_TXD
(SSOP5) 5V->3.3V Level
B2B-PH-K-Y(LF)
@C261 C103 19
JTAG_RMODE NTRC_CLK SGND NTRC_END NTRC_DATA0 NTRC_DATA1 NTRC_DATA2 NTRC_DATA3
TP311
PHOTO-DEBUG CN19
PHTXD 1 1-6C 2
TP7
U8
VCC PHOTO_TXD 1 B A GND Y 3 4 1-4C
TP32
1-5F
TP270
+3.3V
TP604 TP605
30 VDD(D24) 29 VDD(D25) 26 VDD(D26) 25 VDD(D27) 24 VDD(D28) 23 GND47 VDD(D29) 22 VDD(D30) 21 VDD(D31) GND96 GND60 GND54 GND41 GND34 GND27 GND19
27 34 41 47 54 60 96 SGND
NTRC_DATA0 NTRC_DATA1 NTRC_DATA2 NTRC_DATA3 PHRXD
SGND PHOTO_RXD
2 R183 10k
1-5F
TP612
1-5F
TP613
B2B-PH-K-M(LF)
1-5F
TP614
F
TP606
BM14B-SRSS-TB (SMD 16x3.6)
SGND
@CN15
+5.0V SGND 1 2 5V GND
LAN9115
B2B-PH-K-PK(LF)(SN)
CODE NAME B512210CIR (4/6)

8
A-4
Confidential

1 2 3 4 5 6 7 8
Other PCB I/F Conector (LVPS HVPS LD PANEL RELAY_F RELAY_R TNR_SEN DX_SOL LT(opt.)
A
+3.3V R140 10k RLYOFFN 1-6E TP161 HEATERON1 1-6C HEATERON2 1-4C
C704 C705
)
LD
7B COVER/VDD5I (200mA) 1 C175 C103 5VI
LVPS
L8 SGND R139 10k C105 C102 SGND C205 C102 C E
47k
A
CN18
CN8 RELAYOFFN
TP267
CN8 HEATERONN1 +3.3V
SGND C173 C103 +5.0V +3.3V

R198 R197 R182
GND
RELAY_FRONT
+24V CN16 9 D7 1SS355 DA6 A1 C SDS2838 A2 0.5 450mA 8 T1_SOL +24V
5V
Q13
4.7k
SGND
A3.3V C101 R142 680 U7 1%(F) TP156 3 + R141 18k 1%(F) SGND 2 -
R607 B 10k
SGND
10k
DTC143ZUA TP28 SGND TP157 Q12

4.7k
10k
680
R190 1k R189 0 R191 3 DATA TP38 6 PWMENB REG_SOL 1-4B R202 390 TP12 B Q10 C 2SC5865 E 5
C174 C104 10% C176 C102 C172 C101 C166 C27P
SGND C204 C102 SGND E

47k
HEATER HARD-LIMIT 295 3.3V 0V HARD LIMIT ON
10
CN8 HEATERONN2
VBDN 1-4A VDON 1-6A R193 VENBN 1-6A
BD T1_SOL 1-4B
TP37
R200 470
TP10 B
Q9 C 2SC5865 E 625mA 7 REG_SOL
1 LM393PT B
BLM18RK221SN1D (1608)
+5.0V
DTC143ZUA U7 8 V+ VLM393PT 4 THM_CENTER 1-7A/7D SGND
+24V_2 TP1 TP260 TP450
TP701 TP700 TP702 4 5
0 R192 LDHALF
C206 C103
+24V A3.3V R161 1.2k TP11 TP451 TP229 TP295 TP396 +3.3V PGND C210 U7 5 + 18k 1%(F) R160 6 7 LM393PT R606 10k HTLIMITN 1-4E SGND C100 EEE1AA101SP C501 10V ( 6.3) TP4 TP373 TP347 TP153 TP227 C104 (1608) C103 C724 C235
CN8 +24V CN8 +24V
LDHALF 1-6A R196 4.7k
450mA TP39
C714 C715 C716
68k
MP_SOL
R199 10k
R201 10k
SGND HEATER HARD-LIMIT 308 3.3V 0V HARD LIMIT ON
CN8 2 24VRET CN8 3 24VRET
R203 10k
MP_SOL 1-4B
R204 470
TP13 B
Q11 C 2SC5865 E C157 C158 C159 C102 PGND +3.3V PGND
SGND
SGND
1%(F)
TP106
CN8 S0V
TP31 LD_MON 1-7A
ANALOG
R194
100
LD_MON
C101 SGND SGND
C185 7 C89 C103 CN8 +3.3V IMSA-9615S-08A-PP-A C102 PNEW_SEN 1-1E TP3 CN8 6 +8V B10B-EH SGND COVER/VDD5I (to LD POWER) 5A +3.3V C160 C102 SGND Q8 C SW0 /PNLDI
10k
TP14
R167 68k R166 100 4 L10 0 (1608) C168 C101 PNEW_SEN
+3.3V SGND THM_EDGE 1-7B/7D +8.0V TP228 TP453 TP15
(200mA) C163 C103
F_COV_SEN
HVPS
CN1 22 C9 C104 +24V_2 VCC24
LED L H
PORT (RESET)
PANEL
R178 TP26 R179 1k R180 1k 4.7k +5.0V 7 +3.3V 8
C712 C713
TP123 CN17 FRONT_COVER_SEN 1-1E
R169 68k
SGND SGND +5.0V C169 C103 SGND +3.3V 5 +5V
C
TP449 FB_VCLN 1-7B C72 C102 SGND TP397 R13 FB_DEV 1-7B C73 C102 SGND TP448 GRIDC 1-6C FB_GRID 1-7B FB_TRCCV 1-7C FB_TR 1-7C TP399 TP446 TP447 C85 C84 C83 C70 R14 R16 R11 R12 100 100 100 100 ANALOG ANALOG ANALOG 100 C6 C102 SGND R17 100 C7 C102
PGND
11
24RET
PNLSW0 1-4C TP27 PNLSW1 1-4C C115 C102 SGND C252 C102 R181 1k
B E
47k
S0V
SW1 +3.3V SGND
21
FB_VCLN
DTC114YUA
SGND
C101 L11 0 0 0 0 0 0
R195 68k 1 2 3 4 5 6 LED5 LED4 LED3 LED2/PNLDO TNR_SEN 1-4B 1 LM393PT
R168 470k U10 + 3 - 2

TP17
TP16
R170
10k
TNR_SEN
18
FB_DEV
SGND +3.3V
1k 19 20 12 13 GRIDC FB_GRID FB_TRCCV FB_TR
100k
100k
C181
C182
C180
C184
100k
C183
C179
PNLLED5 1-5E PNLLED4 1-6C PNLLED3 1-6B PNLLED2 1-6C PNLLED1 1-6C PNLLED0 1-4C
PWM PWM
L12 L13 L14 L15
C161 C102 +5.0V
IMSA-9615S-09A-PP-A
R15
TP19
LED1/PNLCLK LED0/PNLRST PWM_TNRSEN 1-4B
SGND R171 10k U10 5 + U10 8 V+ 7 LM393PT TP40 C186 C103 VLM393PT 4
PWM
8 7 6 5
L16
R205 10k
SGND C165 C103
GND
R173
RA39
R172
R206 68k
C162 C103 10% SGND
C164 C103 10% SGND
SGND
6 -
SGND C101 +5.0V
10
+5V SGND
SGND C102 HVVCLN 1-4B HVPWMDEV 1-7E HVPWMCHG 1-7E HVPWMTRCC 1-7E HVPWMTRCV 1-7E
68k 68k 68k
SGND 23 16 15 10 14 PWM_VCLN PWM_DEV PWM_CHG PWM_TRCC /TRCV +24V_2

68k 68k
SGND
S10B-PH-K-S(LF) TP441 R63 THM_CENTER 1-7A/2B C69 10k A3.3V R29 18k 1%(F) SGND 0 C12 C103 SGND ANALOG ANALOG 1 5 6 S0V THM_CENTER THM_EDGE C103 (1608) L1
RELAY_REAR
CN3 4 VDD3
LT(opt)
CN2 2 C10 C104 PGND 1 C617 C103 SGND R47 LT1_SOL 1-4B LT2_SOL 1-4B BLM15AG601SN1D R55
68k 68k
SGND 24V THM_EDGE 1-7B/2B C71 C103 TP440 R64 24RET 10k R30 18k 1%(F)
C3 SGND
C2
C4
C5
C8
+3.3V
R10
R2
100 100 100 100 100
R6
R3
R7
C101 R8 REG_F_SEN 1-1E REG_R_SEN 1-1E PEDG_SEN 1-1E T1_PE_SEN 1-1E MP_PE_SEN 1-1E TP444 TP445 TP442 TP372 TP443 C212 C211 SGND C102 Q15 C
C101
8 9 6 5 7
REG_FRONT_SEN REG_REAR_SEN PEDG_SEN T1_PE_SEN MP_PE_SEN
R9 R4 R1 R5 C218 C219 C213 +5.0V R274 10k R275

TP339
C15 C101
C16 C101
LT1_SOL SGND SGND +3.3V R28 68k TP439 R61 R59 C216 C102 PO_SEN 1-1E DX_UNIT_SEN 1-1E 100 100 C13 C101 C14 C101 IMSA-9615S-06A-PP-A TP437 C224 C102 SGND R27 68k 3 2 PO_SEN DX_UNIT_SEN
10
BLM15AG601SN1D
LT2_SOL
C707 C706 SGND
C709 C708 C101 C710 RA42

8 7
R54
R45
68k
5 6
SGND (1608) L600 4
Q14 B E A1577
+3.3V
+24V_2 +3.3V E
R281 1k ZD5 UDZS36B
820 TP338
+3.3V 0 1/2W 4 R67 33 (10mm pitch) TNRLED TP409 LT1_PE_SEN 1-1E TP410 LT1_PEDG_SEN 1-1E TP454 LT2_PE_SEN 1-1E TP456 LT2_PEDG_SEN 1-1E RA41 1 2 4 3
C100 C215 C214 C98
3V
TNRLED 1-6B
C711
B
10k 47k
100 8 7 5 6
5 6 11 12
C24 C23 C22 C21
LT1_PE LT1_PEDG LT2_PE LT2_PEDG
SGND
SGND
DTC114YUA
R287 1k
TP371
SGND
1k
SGND
0.4 QA1 1 5 TP395 +3.3V 6 IMX17 QA1 4 2 TP369 3 IMX17 PGND SGND A1 ZD2 110mA SGND C1 C103
17
R73
S0V
DX_SOL
+24V @CN14 1 +24V @D6 1SS355
R280 1k
FAN_MAIN_24V 1-4B
VCC3.3V
TP368 R72 1k
C700 C702 R288 10k R71 10k
RA43
8 7
68k
6
FAN_MAIN
C102 SGND
+3.3V
C101 TP36 SGND R163 820

C101 C717
0.5 TP35 B R162 10k @Q7 C 2SD1484K E PGND LT_DET3 SGND B12B-PH-K-S(LF) SGND C102
180mA
2 DX_SOL
FAN_MAIN_12V 1-4B
TP370
(PITCH=15) BZX85-C11 +24V_2 DA5 C SDS2838 A2
C19 C102 (1608) PGND TP452 LT_DET1 1-1E TP411 LT_DET2 1-1F TP412 LT_DET3 1-1F
SGND
RA40 1 2
C217 C220
100 8 7 6
7 8 9
C614 C615 C616
DX_SOL 1-4B LT_DET1 LT_DET2
C144
S2B-PH-K-S(LF)
+24V_2
R279 1k ZD4 UDZS36B
C101 +3.3V
PGND
3 RA40 4
C99
R285 1k
TP367
1k
100 5
RA43 4
68k 5
0.4 QA2 1 5 TP394 6 IMX17 QA2 4

R286 10k R68 10k
110mA
R70
FAN_PS C102 C101 SGND
R278 1k
FAN_PS_24V 1-6B
C18 C102 (1608) PGND (PITCH=15) BZX85-C11
IMSA-9615S-23A-PP
F
SGND
SGND
TP364 R69 1k
C701 C703
ZD1
FAN_PS_12V 1-6B
2 TP365 3 IMX17 PGND
TP366
C101
SGND
CODE NAME
3 4 5 6 7
SGND
B512210CIR (5/6)
8
A-5
Confidential
APPENDIX
1 2 3 4 5 6 7 8
REGURATOR, MOTOR DRIVER
A
1.5V(FOR ASIC)
D5 RB751V-40
A
REGULATOR
Q6 LD1117DT-R +3.3V IN ADJ

TP207
TP239
CH1 1.5V +1.5V
MAIN MOTOR DRIVER

CN4
(TO Main ASIC Logic)
(2125)
OUT R146 1%(F) C111 C104
HU+ HUHV+ HVHW+
19 18 17 16 15 14 12 13 L4 L3
RA11 2 1 4 3 R100 R99 0
1k 7 8
TP264 TP298 C103 TP294 C79 TP265 TP293
U5 13 HA1+ 12 HA115 HB1+ C103 C78 14 HB117 RS1 2W 2%(G) (PITCH=15) OUT1_C 5B 27 R92 0.33 PGND OUT1_A 28 OUT1_B 26 5B MAIN_WOUT 5B MAIN_VOUT 29 MAIN_UOUT
C504
EEE1AA101SP 10V C100 ( 6.3)
1%(F)
1k
C613
C106
R145
EEE1AA101SP 10V C100 ( 6.3)
5 6 1k TP292 1k
C502
C110 C104
200
SGND
SGND
HWS0V +5V
SGND 0 C34 +5.0V C103 TP363 C103 MAIN_UOUT 7A C103 TP361 C608 C103 C611 7B C103 TP337 C606 C102 MAIN_WOUT DCCTL 7B 1-6E R111 R112 56k 1%(F) C506 C75 C102 SGND SGND FG31 HA2+ C103 C90 30 HA233 OUT2_C 8 HB2+ C103 TP199 C91 TP202 TP203 32 HB235 HC2+ C103 TP201 C92 R144 10k +3.3V +5.0V C103 SCNFGS 1-4E SGND TP152 SCANNER_UOUT C103 C609 C610 TP105 C103 C607 7C SCANNER_WOUT 7C TP102 C103 7C R128 R127 100k 1%(F) C507 C94 C102 SGND 1 +5.0V C104 C106 18 SGND 19 S-GND19 TB6577FG S-GND18 P-GND38 36 VDD36 37 P-GND37 38 PGND VDD1 VCC2 C93 C104 NC11 C221 20 VCC1 3 +24V C96 50V C100 C76 C104 +24V_2 C61 50V C100 SCNCTL 1-6E SCANNER_VOUT 100k 1%(F) TP233 C95 TP231 C102 TP230 4 LP2_1 5 LP2_2 6 NC6 11 TP232 TP266 C104
TP212 TP262
HC1+
B
U U 11 10 9 8
B
16 HC125 CW/CCW
C77 TP206
TP362
3.3V(Analog 3.3V)
D4 TP341 TP2 2 +5.0V VDD VOUT RB751V-40
REGULATOR
U V V
TP336 7 6 5 TP335 4 3
DCFR 1-6E MAIN_VOUT
TP261 C74
TP263
21 LP1_1 22 LP1_2 23 FGO 10k R257 +3.3V 24 FGS1

TP208
TP5
U2 3
TP360 A3.3V (TO Main ASIC A/D

)
V W W
C718
C720
C722
R110
CE RQ5RW33B
GND
C57 C104
PGND
C58 C104
C505
EEE1AA101SP 10V C100 ( 6.3)
W FG+ FG-
100k
56k 1%(F)
2 1 7C
FG+ FG7C C101
C221
DCFGS 1-4E TP296 C63 R102 7 4C SCANNER_UOUT 9 5D SCANNER_VOUT 10 5D SCANNER_WOUT 5D 0.47 PGND 1.0 1W (PITCH=12.5) FG+ 4C C64 C104 R103 10k 1%(F) C104 1.5k 1%(F) +5.0V
R101
150k
1%(F) TP299 C62 C471
SGND
SGND
IMSA-9615S-19A-PP-A OUT2_A OUT2_B
SCANNER MOTOR DRIVER

CN10 HU+ HUHV+ 14 13 12 11 10 9 8 RA17 2 1 4 3 R138 R137 1k 7 8 5 6 TP204 1k 1k 34 HC22 FG2 TP200 RS2
R114
C
U3 3 1 R113 10k 1%(F) 4 TA75S01F
TP297
+5.0V U3 5 V+ VTA75S01F 2 SGND C65 C103
5.0V
D3
REGULATOR
RB751V-40
HVHW+ HW-
SGND
Q5 +8.0V IN GND C46 C104 OUT LD1117S50 C47 C104 +5.0V
+5V
C503
EEE1AA101SP 10V C100 ( 6.3) SGND
S0V COILU COILU COILV COILV COILW
7 6
TP154 5 TP103 4 3 2 TP104 1
SGND
C719
C721
C723
R129
100k
COILW
SGND
PGND
C101
IMSA-9615S-14A-PP-A
CODE NAME
1 2 3 4 5 6 7
B512210CIR (6/6)
8
A-6
Confidential

Appendix 2. Low-voltage Power Supply PCB Circuit Diagram (100V)
1 2 3 4 5 6 7 8
NAME
1 2 3 4 5 6 7
Low-voltage PS Circuit (100V)

8
A-7
Confidential
APPENDIX
Appendix 2. Low-voltage Power Supply PCB Circuit Diagram (200V)
1 2 3 4 5 6 7 8
NAME
1 2 3 4 5 6 7
Low-voltage PS Circuit (200V)

8
A-8
Confidential

Appendix 3. High-Voltage Power Supply Circuit Diagram
1 2 3 4 5 6 7 8
NAME
1 2 3 4 5 6 7
High-Voltage PS Circuit
8
A-9
Confidential
APPENDIX 4
POINT TO POINT CONNECTION DIAGRAM
USB
CN7
Parallel Interface
CN13
LAN
CN5
DIMM
CN12
CN16-9
RELAY_ FRONT
+24V
T1_SOL
-8
-7
LT2_PEDG LT2_PE
LT2_SOL LT_DET3 LT_DET2
CN2-12
-11 -10 -9 -8
LT(OPTION)
REG_SOL
MP_SOL +5V PNEW_SEN
TNR_SEN S0V F_COV_SEN
THM_EDGE THM_CENTER VDD3 PO_SEN
DX_UNIT_SEN S0V
-6 -5 -4
-3 -2 -1
CN3-6
LT_DET1
LT1_PEDG
-7 -6 -5 -4 -3
-2 -1
LT1_PE +3V LT1_SOL +24V 24VRET
RELAY_ REAR
-5 -4
-3 -2
-1
HEATERONN1
CN8-8
-7 -6 -5 -4 -3
-2 -1
S0V +3.3V +8V +24V +24V 24VRET 24VRET
LVPS
DX_SOL
CN14-2 -1
CN18-8
DX_SOL
+24V
BD
LD_MON PWNENB LDFALF +5V DATA GND +5VI
+5VI GND SWI SW0/ PNLDI LED0/ PNLRST LED1/ PNLCLK
LED2/ PNLDO LED3 LED4 LED5
LD
-7 -6
-5 -4
-3 -2
-1
CN17-10
PWM_VCLN
VCC24 FB_VCLN
FB_GRID
CN1-23 -22
HVPS
-21
-20
GRIDC
-19 -18 -17 -16 -15

-14 -13
-12 -11
-10
PANEL
-9 -8
-7 -6
-5
-4 -3
-2 -1
Main PCB
FB_DEV S0V PWM_DEV PWM_CHG /TRCV FB_TR FB_TRCCV 24RET PWN_TRCC REG_REAR_SEN
REG_FRONT_SEN
-9 -8 -7 -6 -5
-4 -3
-2 -1
CN4-19 -18 -17 -16 -15
-14 -13
-12 -11
-10
CN800-6
FG GND DATADATA+ +5V FG
WIRELESS LAN
-5 -4
-3 -2
-1
MP_PE_SEN PEDG_SEN T1_PE_SEN TNRLED FAN_MAIN

FAN_PS VCC3.3V
HL5280DW only
HU+ HUHV+ HVHW+ HW-
MAIN MOTOR DRIVER
+5V S0V U U
U
-9 -8 -7 -6 -5
-4 -3
-2 -1
CN10-14 -13
-12 -11
-10
V V V W
W W FG+
FGHU+ HUHV+ HVHW+ HW+5V S0V U U V V W W
-9 -8 -7 -6
-5 -4 -3
-2 -1
SCANNER MOTOR DRIVER
A-10
Confidential
APPENDIX 5
1. HL-5240
GEAR LAYOUT DRAWING
LM5016001 EJECTOR GEAR 16
LM5475001 EJECTOR GEAR 44SX
LM5053001 LM5052001 REGISTER REGISTER GEAR 48 LM5055001 CARRIER REGISTER GEAR 21 GEAR 159/43 CENTER INTERNAL
LM5461001 REGISTER DIFFENTIAL
LM5065001 MP GEAR 55/60 SECTOR
LM5019001 EJECTOR GEAR 22 LM5048001 FUSER GEAR 39R H/R DRIVE
LM5056001 FEEDER GEAR 21/31 PENDULUM
LM5042001 FUSER GEAR 17/63R PENDULUM
LM5057001 FEEDER GEAR 48 LM5054001 REGISTOR GEAR 19 PLANETARY LM5050001 DX GEAR 27/68 L LM5023001 P/P GEAR 29 CLUTCH CAM
LM5025001 P/P GEAR 17 CENTER LM5026001 P/P GEAR 32CARRIER LM5027001 P/P GEAR 15 PLANETARY LM5028001 P/P GEAR LM5460001 LM5070001 T1 GEAR 31/47 147/37 P/P INTERNAL DIFFERENTIAL
LM5071001 T1 GEAR 50/45 SECTOR
A-11
Confidential
APPENDIX
2.
HL-5250DN/ 5270DN/ 5280DW

LM5016001 EJECTOR GEAR 16 LM5015001 EJECTOR SWITCH ARM LM5016001 EJECTOR GEAR 16
LM5053001 LM5461001 LM5052001 REGISTER LM5055001 REGISTER LM5056001 REGISTER GEAR 48 REGISTER FEEDER GEAR 21/31 DIFFERENTIAL GEAR 21 CARRIER GEAR 159/43 PENDULUM CENTER INTERNAL
LM5013001 GEAR 28 SECTOR LM5019001 EJECTOR GEAR 22 LM5048001 LM5042001 FUSER GEAR FUSER GEAR 39R H/R DRIVE 17/63R PENDULUM
LM5057001 FEEDER GEAR 48
LM5050001 DX GEAR 27/68 L LM5054001 REGISTOR GEAR 19 PLANETARY
LM5023001 P/P GEAR 29 CLUTCH CAM LM5023001 P/P GEAR 29 CLUTCH CAM
LM5025001 P/P GEAR 17 CENTER
LM5026001 P/P GEAR LM5027001 32CARRIER P/P GEAR 15 PLANETARY
LM5071001 LM5028001 LM5460001 T1 GEAR 50/45 P/P GEAR P/P LM5070001 SECTOR 147/37 DIFFERENTIAL T1 GEAR 31/47 INTERNAL
A-12
Confidential

Brother 5240-5250D-5270DN Service Manual

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Brother 5240-5250D-5270DN Service Manual

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Brother Laser Printer

SPECIFICATIONS .................................................................................................. 1-7

Printable Area................................................................................................................. 1-17

SERIAL NO. DESCRIPTIONS .............................................................................. 1-23

CHAPTER 2 THEORY OF OPERATION................................................. 2-1

ELECTRONICS ...................................................................................................... 2-2

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

Power Supply.................................................................................................................... 2-6

MECHANICS .......................................................................................................... 2-7

Toner Cartridge .............................................................................................................. 2-17

Print Process .................................................................................................................. 2-21

Sensors .......................................................................................................................... 2-23 Heat Control of Fuser Unit.............................................................................................. 2-24

CHAPTER 3 PERIODIC MAINTENANCE ............................................... 3-1

PERIODICAL REPLACEMENT PARTS ................................................................ 3-12

PERIODICAL CLEANING ..................................................................................... 3-50

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

ERROR MESSAGE ................................................................................................ 4-4

Service Calls..................................................................................................................... 4-8

PAPER PROBLEMS ............................................................................................. 4-15

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

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

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

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

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

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

HIDDEN FUNCTION MENUS .................................................................................7-15

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

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

<Location of the laser beam window>

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

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

Code 39 Code 128 Interleaved 2 of 5 Codabar

US-PostNet ISBN UPC-A UPC-E

EAN-8 EAN-13 EAN-128

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

PARTS NAMES AND FUNCTIONS

Multi-purpose tray (MP tray)

Back cover DIMM cover

Duplex tray (For HL-5250DN) Parallel interface connector

10/100BASE-TX port (For HL-5250DN)

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

(HL-5270DN/5280DW) <Front View>

Multi-purpose tray (MP tray)

Parallel interface connector

USB interface connector LEDs (Light emitting diodes)

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

2.2 Control Panel

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

Print quality Print speed

Warm-up First print Consumables

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

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

Available Hard Disk Space

16 MB 32 MB 128 MB 64 MB 128 MB 256 MB

OS 9.1-9.2 Mac OS X10.2.4 or greater

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

Electronics and Mechanics

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

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

Network type Network printing

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

All models 50 sheets 250 sheets 250 sheets

All models 150 sheets

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