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Brother's HL-5200 series comprises the HL-5240, HL5250DN, HL-5270DN and HL-5280DW
Printers The DCP-8060 and DCP-8065 and MFC-8460N, MFC-8660DN, MFC-8860DN and
MFC-8870DW are closely related.
is a true 1200 dpi, however printers are fastest at 600dpi. They will slow down to
some extent at 1200 dpi and the HL-5240 may need expansion memory to make full use of the
resolution.
This series of machines was launched in late 2005 and the HL-5240 in 2007.
PCL 6 and BR-Script3 emulations as standard
[ HL-5270DN, built in auto-Duplex, Ethernet, 32MB RAM, LCD Control Panel, Secure print
feature.
[ HL-5280DW, built in auto-Duplex, wired and wireless Ethernet. LCD Control Panel with 3
colour backlight to give an instant indication of status. Secure print capability.
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[ DCP-8060, 30ppm printer, scanner copier. Flatbed scanner optical resolution 600x2400.
[ DCP-8065DN, 30ppm printer, scanner copier. Flatbed auto-duplex scanner . Ethernet.
Both printers have PCL6 and BR-Script3
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The HL-5300 series was introduced in April 2009 replacing the HL-5200 series. The new
printers are slightly faster at 32 pages per minute. New models are the HL-5340D, HL-5370DW
and HL-5370DWT.
There are two additions to the MFC-8000 series: MFC8480DN and MFC8890DW
Toner/Drum/Paper LED and 3-colour Status LED. Buttons for Go and Job Cancel.
The HL-5270DN and HL-5280DW are the same engine as the HL-5240 and 5250 but with a
control panel.
The HL-5240 and HL-5250 are printers with no LCD display; without a user manual to hand it is
difficult to diagnose some problems:
Some of the common LED errors for the 5240/5250 are:
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To get a status page press go three times in succession
HL-5240 / 5250
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Power on holding "Go". All the LEDs will light
Then Status will turn off, now release Go, all the LEDs will turn off.
1 = Test Page
2 = Print Fonts
3 = Hex Dump
4
6 = Factory reset of the Network Adapter
All the LEDs light to indicate the network card has been reset to default.
9 = Test Sample
The HL-5270 / 5280 have a similar process except that Go is held until the message "User's
Mode" appears on the display with an orange backlight. Release the Go button and all the LEDs
should go off.
There is more on service modes below. They are required to reset consumable and maintenance
counts.
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Brother dont tend to give a duty cycle figure, perhaps understandably because the figures do tend
to be rather meaningless. In the Used manual neither it or an MTBF are stated. These printers are
lightly built.
site-city.com/articlems13 claims a duty cycle of 20,000 pages per month for the HL-5280 and the
material for their blurb presumably came from Brother in the US.
Print speeds are:
28 pages per minute for A4 sized pages and 30ppm for letter pages
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Plain paper, Bond paper, Recycled paper, Envelope, Labels, and Transparencies.
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60 to 161gsm (16 to 43 lb) through manual feed tray. 60 to 105gsm (16 to 28
lb) from standard tray.
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Draw integrated into the printer base for 250 sheets on all models.
Sizes: A4, Letter, B5 (ISO), A5, B6, A6, Exe
Types: Plain Paper, Bond Paper, Recycled Paper, Transparencies.
Weights 60 - 105gsm
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Standard output to the top of the printer holds 150 sheets.
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Not provided
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Two-side printing is provided with an auto-duplex unit on the HL-5250DN, 5270DN and
5280DW.
Manual duplex is supported on the HL-5240.
The combination of processor and memory in a printer determine how quickly the print language
can be re-interpreted as a page layout. Where a task is undemanding such as printing pages of
text there is no need for a powerful processor. Tasks such as producing a full page photograph
are much more processor and memory intensive.
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The HL-5240 memory is sufficient for most ordinary purposes but the printer may reduce the
resolution from 1200dpi to 600 dpi to print the most complicated graphics.
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All models have Parallel and USB ports
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10BaseT/100BaseTX Ethernet standard on the HL-5250DN
As well as the built-in ethernet port the printers can be attached to external print servers which
also support NetBEUI.
HL-5250DN ARP,RARP, BOOTP, DHCP, APIPA (Auto IP), ICMP, WINS/NetBIOS, DNS,
mDNS, LPR/LPD, Port9100, IPP, SMB Print, FTP, SNMP, HTTP, TELNET, SMTP, TFTP,
ICMPv6, NDP, DNS, mDNS, LPR/LPD, Port9100, IPP, FTP, SNMP, HTTP, TELNET, SMTP,
TFTP
Brother original Windows utility for printer and print server management.
Server Based Management Utility for Windows IIS 4.0/5.0 mode only, downloadable from
http://solutions.brother.com Printer and print server management through Web browser
Printer and print server management operates under Mac OS X 10.2.4 or greater.
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Both the HL-5240 and HL-5250DN support PCL6 and Brothers version of Postscript, IBM
Proprinter XL and Epson FX-850
PostScript 3 emulation as standard using BR-Script 3 with 66 scalable, 12 bitmap and 11 bar
codes.
PCL 6 emulation standard with 49 scalable, 12 bitmap and 11 bar codes
IBM ProPrinter XL
Epson FX-850
Bar Codes are: Code39, Interleaved 2 of 5, EAN-8, EAN-13, UPC-A, UPC-E, EAN-128,
Codabar, FIM (US-PostNet), ISBN, Code128
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Operating Systems
PCL Printer Driver for Windows 95 / 98 / Me, NT4.0 / 2000 Professional/ XP Home Edition/ XP
Professional
BR-Script 3 (PPD file for Windows 95 / 98 /Me, NT4.0 / 2000 Professional/ XP Home Edition/
XP Professional
Macintosh® Brother Laser Driver for Mac 9.1-9.2, Mac OS X 10.2.4 or greater BR-Script 3
(PPD file for Mac 9.1- 9.2, and Mac OS X 10.2.4 or greater)
Utilities:
Interactive Help: Instructional movie for the solution when any error message appears Status
Monitor
Driver Deployment Wizard: Guides you through the steps of installing a Brother network printer
on a networked Windows PC
Linux GDI Printer Driver for Linux BR-Script 3 (PPD file for Linux)
Linux systems using CUPS come with drivers built in for the HL-5240, HL-5250DN and HL-
5270DN using BR-Script3
Power Consumption
Printing Average 610W at 25c
Standby Average 80W at 25c
Sleep HL-5240 Average 8W at 25c
Sleep HL-5250DN Average 9W at 25c
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Has both Powersave and Toner Save features. The "D" versions are duplex which can nearly
halve paper consumption.
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WxDxH 371 x 384 x 246mm
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HL-5240 = 9.5kg
HL-5250DN = 9.8kg
Noise level (Declared per ISO9296) :
These printers use a separate toner cartridge and drum giving better economy than some
competing machines. Fusers and roller kits are also available.
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TN3170 Refill Kits and separate Reset Gears can be bought to reset the "toner life end" message
when a cartridge has been refilled. Naturally you will get no support from Brother themselves for
doing this. At least one clone cartridge maker has a cartridge which is compatible with the HL-
5030 -5070 and 5130 - 5170 series printers as well as the 5240 - 5270 series.
Brother's website warns that the Lights or LCD may go on displaying the message "Toner Life
End / Replace Toner". This is normally caused by part-used toners, the printer needs to see a new
toner. Clone and refil toner may give the same issue unless the reset gear is changed.
"
The obvious point is that Brother have persisted with the idea of a separate toner and drum. This
should give greater economy than having a single cartridge with both components built in. The
extra issue of having two things to buy and two parts to go wrong might conflict with economy
in some cases. Brothers customer base tend to be small and home offices who are more sensitive
to the cost of purchasing printers and consumables than they are to the costs falling on
centralised technical support.
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There is a choice between 3,500 page yield appropriate for small office use and 7,000 page yield
which will meet the needs of larger offices and frequent users.
Brother use an unusual mechanism to inform the printer when they have been replaced.
Cartridges ship with a spring loaded half-cog engaged. The cog turns and presses a couple of
actuators to show the cartridge was installed and whether it was standard or high yield.
One it has been informed of the cartridge and yield the printer adjusts the bias voltage according
to how much toner is left. One common technique to fix printer faults may not work as a result,
swapping a part used toner from one printer into another won't cause the reset to happen and the
printer will have the wrong toner level - so the fault won't properly clear and both printers might
now malfunction giving over heavy print or a grey background. See Uninet imaging's PDF on
refurbishing the cartridges for details. (search for TN-550 inurl:uninetimaging)
Brother cartridges are also unusual because there is no waste toner bottle. Residual toner on the
drum is taken up by a blade and a charge brush in the drum assembly. The charge on the brush is
changed during a cleaning cycle and residual toner is then transfered back to the developer and
then into the supply hopper. As the toner gets low the printer increases the charge on the
developer to compensate for the poor triboelectric properties of the toner. If cartridges are
recycled and the wrong toner is used Ultimately the charge brush becomes clogged and won't
take up waste toner from the drum anymore and it transfers instead to the page giving a grey
background.
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Brother use different cartridge codes for different regions. Sometimes it is helpful to know these
codes when researching information about the printer.
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The printer drum has a yield of 25,000 pages. The "Drum" LED will blink when the drum is near
the end of it's useful life but the printer will continue to work and can be used until drum wear
gives a print problem (probably faded print or streaking)
The Drum is known as DR-520 in the US. DR-3115 is the Asian version.
Drums may also be available in remanufactured and compatible forms. As usual we warn the
whilst there may be substantial savings ove manufacturers originals quality and reliability could
be less certain.
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Brother tech support have taken to requiring a proof of purchase before they will help.
With the machine is turned on and the drum LED is blinking replace the drum unit and reseat the
toner cartridge. Leave the front cover open. Press and hold the "Go" button for four seconds until
all the LEDs light up. Now release the "Go" button. Close the front cover. The counter is reset
and the machine should perform normally. (The instructions are the same as for the HL-5150)
c
Laser printer fusers adhere toner to the page using a combination of pressure and heat. Fusers fail
when the non-stick surface wears out and the printer will warn of this after 100,000 pages. Fusers
can fail more quickly if they are used with innapropriate toner or media.
Fuser failure is indicated by Status light red and Toner light on on the HL-5240 and 5250. (It
could also be a cause of all lights flashing). Other printers in the series have LCD displays and
will give an explicit message: "REPLACE FUSER".
LU0214001 110 Volt Fixing Unit (Yield 100,000 pages) aka LM6665001, LM6665001,
There are two 230 Volt fusers listed and used in the UK and EU. Both are available from UK
distributors although the LU0217001 seems to be the common code.
The 110Volt fuser is normally used in the US but there may be uses in the UK such as
construction sites.
The fuser is not particularly easy to change. Details are given in the service manual but briefly:
c Power Off and Unplug the printer. Potentially live terminals will be exposed when
working on the printer. Let the fuser cool before attempting to work on it.
c Remove the drum toner assembly and put them in a clean dark place.
c Remove the duplex feed assaembly or the blank cover at the rear of the printer.
c Pull the paper tray completely out of the printer.
c Remove the back cover flap from its pins on either side.
c Remove the outer chute assembly by pulling at the knobs on either side.
c Remove the front and sides to get access to the fuser wiring harnesses.
c Release the heater power terminals and the termistor terminals.
c Remove the fuser screw(s) and it can be removed from the printer.
c The air filter should also be changed.
The service manual gives details and should be consulted if there is any doubt.
The fuser in the HL-5200 series printers is a conventional roller with halogen-lamp heater
design. This means it takes some time to heat from a cold start but it does make it more easily
repairable.
To reset the fuser requires the printer to be put in service mode. (hold go at power on ). An
outline of the Maintenance Reset procedures are given below.
Brother literature suggests a Maintenance Kit intended for use at 100,000 pages. There is no
trace of this in the parts manual or suppliers lists. Buy a fuser and periodic maintenance parts.
Most spares appear to be available in February 2010. Those commonly required are:
LM6753001 - MP Paper Feed Roller & Separation Pad for Periodic Maintenance. Needed
when the printer gives the message "REPLACE PF KIT MP".
LM5852001 - Feed Roller Assembly & Separation Pad Kit for Periodic Maintenance.
Needed when the printer gives the message "REPLACE PF KIT1" etc.
"REPLACE PF KIT2" and "REPLACE PF KIT3" raise the same issue for trays 2 & 3 if they are
fitted. They also take the LM5852001 Kit.
LM5750001 Laser Unit. May be needed when the printer gives the message "REPLACE
LASER".
The PCB Assemblies tend to be quite expensive and on a lead time of 7-10 days. They are sealed
and not returnable once the package is opened.
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Changing the roller holder assemblies involves taking out the drum assembly and putting it in a
clean dark place. Pull out the paper tray and change the separation pad which is secured by hooks
at either side. Put the tray to one side.
c Turn the printer upside down , the feed roller roller assembly is located underneath.
c Push the lift arm so that the pin of the roller holder disengages.
c Turn the roller holder so it srotates upright.
c Slide the roller holder assembly so it goes one way then lift and pull the other way and it
should lift out.
The service manual gives details and should be consulted if there is doubt as to the procedure.
Changing the laser unit or the rollers will involve putting the printer in maintenance mode. An
outline of the Maintenance Reset procedures are given below.
c corona wire (clean the primary corona wire in the drum assembly using the blue slider)
c scoring of the drum - visible on the shiny surface of the drum itself
c contamination and wear of the developer roller causing greyish marks or grey print
c stray toner, hair or other marks on the optics - clean the window with a dry lint-free cloth.
Greyed print can also be caused by using an incorrectly refurbished cartridge. The printer has an
unusual mechanism that recycles used toner but adjusts for the effect of this by changing the bias
voltages.
Vertical or recurring marks down the page are likely to be a mark on a roller. Which roller can be
determined by looking at the spacing of the marks.
2
The HL-5200 series printers are built to a well established format with a paper cassette in the
base, delivery tray on the top and the mechanism in between. An "S" shaped path leads from the
tray(s), through the print mechanism and out into the delivery tray.
Paper is picked from the tray by a separation roller which begins to push the media from the tray.
The paper is driven to a registration station where it is signalled by an actuator and then stops
momentarily.
A latent image is meanwhile built on the exposure drum which is metal but coated with two
plastic layers together called "OPC" (Organic Photoconductor). The drum is in the center of the
printer (its green and rotates clockwise in the diagram). The upper layer of the drum is charged
to several hundred volts by a corotron charge unit above it.
The laser assembly above the drum contains a mirror which scans the beam across the drum as it
turns. The laser is modulated (turned on and off) rapidly. Where the laser is on the drum's OPC
conducts, discharging the surface. Elsewhere the surface is left conducting.
The drum now turns to face the developer roller (cyan blue in the picture). The developer also
carries a charge, different from that on the drum and triboelectrically attractive to the toner
powder in the cartridge. The developer therefore carries a thin but consistent layer of toner next
to the drum. Where the voltage is different the toner adheres to the drum giving a developed
image.
The paper is now released from the registration station and proceeds between the drum and the
transfer roller. The transfer roller carries yet another voltage which strips most of the toner off
the OPC surface and onto the paper.
Paper with lose toner on its surface now travels into the fuser - a pair of heated rollers. The
heated roller part-melts the toner to the point where it is sticky and the pressure roller forces it
into the page. Normally the page exits onto the top of the printer.
Duplex pages partly exit but then reverse back into the printer and travel down the outside of the
outer chute and through the duplex unit to re-emerge face down at the registration station.
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These printers are a design introduced in 2005 and were succeeded in April 2009. Printers may
still be in distribution and offered new in March 2010. Brokers and refurbishers are likely to
offer the printer as-is or complete with a recycled toner. The user manual can be found on the
Internet. Linux systems come with drivers built in for HL-5240, HL-5250DN and HL-5270DN
using BR-Script3.
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We offer repair in North East England
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Brother printers often have a maintenance mode intended for service technicians with access to a
service manual and technical support. The instructions below are intended as a memory aid for
technicians, not as a comprehensive howto to for end users repairing their own printers. Note
that changing maintenance mode settings without understanding the implications can damage or
disable a printer. If in doubt, consult the service manual.
Procedures can differ by printer model because the HL-5240 and 5250 have no LCD panel and
fewer buttons than other models.
The HL-5240 and HL-5250 require a Brother supplied Windows program called MAINTE.EXE
which should be extracted into the hl5200 folder.
Put the printer into maintenance mode by: opening the front cover, turn on with the GO button
held, All the lights come on, then status goes out. Release the Go button and all the lights go out.
Press Go for two seconds or so and the Paper LED should light. Close the front cover. The
printer should now be in periodic maintenance mode. Now run brmainte.exe. A windows applet
allows you to reset the relevant counts.
Items that can be reset are: Fuser Unit, Laser Unit, PF Kit for Tray 1, PF Kit for Tray 2, PF Kit
for Tray 3, Paper Feeding Kit for MP Tray.
Put the printer into maintenance mode by: opening the front cover, turn on with the GO button
held, the messages "USERS MODE" is shown on the LCD. Release the Go button. Press Go for
two seconds or so and the Data LED should light and the message "PIT3 MODE should be
shown on the LCD. Close the front cover. The printer should now be in periodic maintenance
mode.
The HL-5270DN and HL5280DW also have a Reset Parts Life Menu entered by pressing Go and
"+" at the same time until "RESET PARTS LIFE" appears on the LCD. Select the item using +/-,
to go back to a higher level press back. Press the "Set" switch to activate an option. Pressing
"Back" repeatedly or "Go" will exit the service menu.
2
There are three optional extras, up to two extra trays, expansion memory and a print server.
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LT-5300 Lower tray expands the paper input capacity. (May still be available)
Two optional lower trays (Tray 2 or Tray 3) can be installed. Each lower tray can hold up to 250
sheets of 80 gsm (21 lb) paper.
With both optional trays installed, the printer can hold up to 800 sheets of paper.
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The HL-5240 has 16MB base memory and can be expanded to 528MB with a DIMM.
The HL-5250DN has 32MB base memory and can be expanded to 544MB with a DIMM.
Brother's user manual says:
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F2A046-10 - IEEE-1284 Bi-directional Cable (Almost any recent parallel cable can be used but
older cable may have wiring that will not allow reliable parallel transfer).
As usual it is easier to find the US version of the manuals on the Internet - but note that all the
part numbers are different.c