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Brother HL-5250DN series, Service Manual

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

Confidential 

2-1

 

CHAPTER 2 

THEORY OF OPERATION 

1.     OVERALL 

1.1 

General Block Diagram 

Fig. 2-1 shows a general block diagram.  

Ethernet

10/100 Base TX

(HL-5250DN/

5270DN/5280DW) 

Video control block

Engine control block

Operation block

 (Control  panel)  

 Control system

Low-voltage power

  supply block

High-voltage power

 supply block

Laser unit

Drive block
(DC motor)

Drum unit

Transfer block

Exposure

drum

Charging

 block

External device

Paper tray

Fuser unit

Paper eject tray

Paper feed system

Image generation system

Interface block
USB
Parallel

USB host
(HL-5280DW)

Wireless LAN
(HL-5280DW)

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

Extended RAM
SODIMM 144pin

Paper dust

cleaner block

Toner cartridge

Developing block

Developer unit

 

Fig. 2-1 

Summary of Contents for HL-5250DN series

Page 1: ...r Printer SERVICE MANUAL MODEL HL 5240 5240L 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 17 ...

Page 2: ...o 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 ...

Page 3: ...etc CHAPTER 4 TROUBLESHOOTING Reference values and adjustments troubleshooting image defects troubleshooting malfunctions etc CHAPTER 5 DISASSEMBLY AND RE ASSEMBLY Procedures for disassembling and re assembling the mechanical system CHAPTER 6 ADJUSTMENTS AND UPDATING OF SETTING REQUIRED AFTER PARTS REPLACEMENT CHAPTER 7 SERVICE SUPPORT SOFTWARE Test print mode and Service menu mode etc APPENDIX Di...

Page 4: ...a specifications 1 14 3 7 Printable Area 1 17 3 7 1 PCL5e EPSON IBM emulation 1 17 3 7 2 PCL6 emulation 1 20 3 8 Print Speeds with Various Settings 1 21 3 9 Toner Cartridge Weight Information 1 22 4 SERIAL NO DESCRIPTIONS 1 23 CHAPTER 2 THEORY OF OPERATION 2 1 1 OVERALL 2 1 1 1 General Block Diagram 2 1 2 ELECTRONICS 2 2 2 1 General Block Diagram 2 2 2 2 Main PCB Block Diagram 2 3 2 3 Main PCB 2 4...

Page 5: ...250DN 5270DN 5280DW 2 15 3 3 8 Paper feeding from the MP tray 2 16 3 3 9 LT tray 2 16 3 4 Toner Cartridge 2 17 3 4 1 Toner life end mode 2 17 3 4 2 New toner detection mechanism 2 19 3 4 3 Counter reset during indication of Toner Life End 2 20 3 5 Print Process 2 21 3 5 1 Charging 2 21 3 5 2 Exposure stage 2 21 3 5 3 Transfer 2 22 3 6 Sensors 2 23 3 7 Heat Control of Fuser Unit 2 24 CHAPTER 3 PERI...

Page 6: ...Error Message Printouts 4 14 3 PAPER PROBLEMS 4 15 3 1 Paper Loading Problems 4 15 3 2 Paper Jams 4 16 3 2 1 Paper jams and how to clear them for HL 5240 5250DN 4 16 3 2 2 Paper jams and how to clear them for HL 5270DN 5280DW 4 18 3 2 3 Causes countermeasures 4 26 3 3 Paper Feeding Problems 4 27 4 SOFTWARE SETTING PROBLEMS 4 29 5 MALFUNCTIONS 4 32 6 IMAGE DEFECTS 4 38 6 1 Image Defect Examples 4 3...

Page 7: ...Cover ASSY 5 26 7 11 Access Cover Side Cover L 5 28 7 12 Main PCB 5 29 7 13 Gear Plate Calking ASSY AL Develop Joint Main Motor ASSY AL 5 30 7 14 Main Shield Plate ASSY 5 32 7 15 Relay Rear PCB ASSY Connector 5 34 7 16 Relay Front PCB ASSY 5 36 7 17 MP Solenoid ASSY 5 37 7 18 Drive Release Link 5 38 7 19 T1 Solenoid ASSY 5 39 7 20 Toner Sensor PCB 5 39 7 21 Register Solenoid ASSY 5 40 7 22 Ejector...

Page 8: ... Regist Actuator Spring 5 70 7 40 Regist Actuator Front Regist Actuator Spring 5 72 7 41 Roller Holder ASSY 5 73 7 42 PE Actuator Edge Actuator Edge Actuator Spring 5 74 7 43 PE PG Sensor ASSY 5 76 7 44 Wireless PCB PCB T60H929 00 ASSY 02 For HL 5280DW 5 77 8 DISASSEMBLY PROCEDURE LT 5300 5 78 8 1 Paper Tray 5 78 8 2 LT Front Cover ASSY 5 81 8 3 LT Rear Cover 5 82 8 4 LT Side Cover L 5 82 8 5 LT S...

Page 9: ... 1 Users Mode 7 1 1 2 User Maintenance Mode 7 3 1 3 Service Mode 7 5 2 HIDDEN FUNCTION MENUS 7 15 2 1 Professional Menu 7 16 2 2 Reset Parts Life Menu 7 23 2 3 Service Menu 7 24 3 NVRAM DEFAULT VALUE 7 29 APPENDIX 1 MAIN PCB CIRCUIT DIAGRAM A 1 2 LOW VOLTAGE POWER SUPPLY PCB CIRCUIT DIAGRAM 100V 200V A 8 3 HIGH VOLTAGE POWER SUPPLY PCB CIRCUIT DIAGRAM A 10 4 POINT TO POINT CONNECTION DIAGRAM A 11 ...

Page 10: ...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...

Page 11: ... in accordance with the standards never touch it Caution Use of controls adjustments or performance of procedures other than those specified in this manual may result in hazardous radiation exposure For Finland and Sweden LUOKAN 1 LASERLAITE KLASS 1 LASER APPARAT Varoitus Laitteen käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saattaa altistaa käyttäjän turvallisuusluokan 1 ylittä...

Page 12: ...ACHTUNG Im Falle von Störungen der Lasereinheit muß diese ersetzt werden Das Gehäuse der Lasereinheit darf nicht geöffnet werden da sonst Laserstrahlen austreten können Location of the laser beam window ADDITIONAL INFORMATION When servicing the optical system of the printer be careful not to place a screwdriver or other reflective object in the path of the laser beam Be sure to take off any person...

Page 13: ...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...

Page 14: ... 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...

Page 15: ...an 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...

Page 16: ... Control panel Face down output tray support flap support flap MP tray cover ASSY Paper tray Power switch Multi purpose tray MP tray Front cover release button Face down output tray Back cover Duplex tray For HL 5250DN AC power connector Network status LEDs Light emitting diodes For HL 5250DN 10 100BASE TX port For HL 5250DN USB interface connector DIMM cover Parallel interface connector Front cov...

Page 17: ...Control panel Face down output tray support flap support flap MP tray cover ASSY Paper tray Power switch Face down output tray Multi purpose tray MP tray Back cover Duplex tray AC power connector LEDs Light emitting diodes 10 100BASE TX port USB interface connector DIMM cover Parallel interface connector Front cover ...

Page 18: ... panel Fig 1 5 1 Toner LED indicates when the Toner is low or at the end of its life 2 Drum LED indicates when the Drum is nearing the end of its life 3 Paper LED indicates when the paper tray is empty or there is a paper jam 4 Status LED will flash and change color depending on the printer status 5 Job Cancel button will stops and cancels the print operation in progress 6 Go button Wake up Error ...

Page 19: ... the memory 3 Go button Exit from the control panel menu and reprint setting Clear error messages Pause and Continue printing 4 Job Cancel button Stop and cancel the printing operation in progress 5 Reprint button Choose the reprint menu and the number of extra copies 1 999 Please enhance the RAMDISK size when you want to use the Reprint functions 6 Menu buttons Move forward through menus Move for...

Page 20: ...rinter is in the ready state when loading A4 or Letter size paper from the standard paper tray Consumables Toner cartridge Life expectancy Standard 3 500 pages cartridge High yield 7 000 pages cartridge when printing A4 or Letter size paper at 5 print coverage Shelf life 2 years 6 months after opening Drum unit Life expectancy 25 000 pages drum unit 1 page job when printing A4 or Letter size paper...

Page 21: ...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 Cap...

Page 22: ...er 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 9...

Page 23: ...z 16 MB 32 MB 50 MB 2000 Professional Intel Pentium 133 MHz 64 MB 128 MB 50 MB Me Intel Pentium 150 MHz 32 MB 64 MB 50 MB XP Home Edition XP Professional Intel Pentium 300 MHz 128 MB 128 MB 50 MB Windows XP Professional x64 Edition 2 AMD Opteron TM AMD Athlon TM 64 Intel Xeon TM with Intel EM64T Intel X Pentium with 4 Intel EM64T 256 MB 256 MB 50 MB OS 9 1 9 2 32 MB 64 MB 50 MB Apple Macintosh 3 M...

Page 24: ...to 40 C 4 to 104 F Humidity Operating 20 to 80 non condensing Storage 10 to 85 non condensing Dimensions HL 5240 5250DN W x D x H 371 x 384 x 246 mm 14 6 x 15 1 x 9 7 inches HL 5270DN 5280DW 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...

Page 25: ...support TCP IP IPv6 NDP DNS Resolver mDNS LPR LPD Custom Raw Port Port9100 IPP FTP Server Telnet SNMP HTTP TFTP SMTP Client Network type 10 100BASE TX Ethernet network Network printing Windows 95 98 Me Peer to Peer printing Windows NT 4 0 and Windows 2000 XP Home Edition XP Professional XP Professional x64 Edition TCP IP printing Macintosh printing BRAdmin Professional utility Windows 95 98 Me Win...

Page 26: ...curity SSID ESSID 128 104 64 40 bit WEP WPA PSK TKIP AES LEAP Network printing Windows 95 98 Me Peer to Peer printing Windows NT 4 0 and Windows 2000 XP TCP IP printing Macintosh printing Mac OS 10 2 4 or greater supporting TCP IP Processor Minimum Speed Pentium II or equivalent for Windows 98 Me Windows NT 4 0 Windows 2000 XP Minimum RAM 24MB for Windows 98 Me 32MB for Windows 2000 64MB for Windo...

Page 27: ...Automatic Duplex N A Yes 3 6 2 Media specifications 1 Media types The printer loads paper from the installed paper tray or the multi purpose tray The feedable media type and size are different depending on the paper tray installed The names for the paper trays in the printer driver and this guides are as follows Paper tray Tray 1 Multi purpose tray MP Tray Optional lower tray unit Tray 2 Tray 3 Du...

Page 28: ...aper Thick paper 105 g m 2 to 161 g m 2 28 to 43 lbs N A Yes N A Thick Paper or Thicker Paper Transparency Yes Up to 10 sheets A4 or Letter Yes Up to 10 sheets A4 or Letter N A Transparencies Labels N A Yes A4 or Letter N A Thicker Paper Envelopes N A Yes N A Envelopes Env Thin Env Thick Up to 10 sheets Not available for the optional Tray 2 3 2 Media size MP Tray Tray 1 Standard Tray 2 Tray3 Optio...

Page 29: ...ity 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 transparencie...

Page 30: ...low Portrait A B C D E F G F G E G G Physical page Printable area Logical page B Physical page length D Maximum logical page length F Distance from edge of physical page to edge of logical page NOTE Logical page shows the printable area for a PCL driver Printable area shows mechanical printable area of the machine Therefore the machine can only print within the shaded area when you use a PCL drive...

Page 31: ...mm 4 2 mm 0 16 50 dots B 5 JIS 182 0 mm 7 1 2 130 dots 257 0 mm 10 11 3 033 dots 170 0 mm 6 69 2 007 dots 257 0 mm 10 11 3 033 dots Ç 0 mm 4 2 mm 0 16 50 dots B 5 ISO 176 0 mm 6 93 2 078 dots 250 0 mm 9 84 2 952 dots 164 0 mm 6 46 1 936 dots 250 0 mm 9 84 2 952 dots Ç 0 mm 4 2 mm 0 16 50 dots B 6 ISO 125 0 mm 4 92 1 476 dots 176 0 mm 6 93 2 078 dots 164 0 mm 4 44 1 334 dots 176 0 mm 6 93 2 078 dot...

Page 32: ...cal page B Physical page length D Maximum logical page length F Distance from edge of physical page to edge of logical page NOTE Logical page shows the printable area for a PCL driver Printable area shows mechanical printable area of the machine Therefore the machine can only print within the shaded area when you use a PCL driver ...

Page 33: ...3 033 dots 182 0 mm 7 1 2 130 dots 247 0 mm 9 72 2 916 dots 182 0 mm 7 1 2 130 dots Ç 0 mm 4 2 mm 0 16 50 dots B 5 ISO 250 0 mm 9 84 2 952 dots 176 0 mm 6 93 2 078 dots 240 0 mm 9 44 2 834 dots 176 0 mm 6 93 2 078 dots Ç 0 mm 4 2 mm 0 16 50 dots B 6 ISO 176 0 mm 6 93 2 078 dots 125 0 mm 4 92 1 476 dots 166 4 mm 6 55 1 960 dots 125 0 mm 4 92 1 476 dots Ç 0 mm 4 2 mm 0 16 50 dots COM10 241 3 mm 9 5 ...

Page 34: ...or Letter Media type setting All models Transparency 28 30 ppm Thin Paper 28 30 ppm Plain Paper 90 sec 28 30 ppm Æ 14 ppm Recycled Paper 90 sec 28 30 ppm Æ 14 ppm Env Thin 14 ppm Thick Paper Envelopes 14 ppm Thicker Bond Paper Env Thick 3 ppm NOTE The print speed may vary according to conditions such as paper size and paper tray When a smaller size paper than A4 or Letter is printed the temperatur...

Page 35: ...roduction From the serial number M5JV030390D Brand new Toner Cartridge Weight 663g 15g 723g 15g Toner Weight at Brand New Toner Cartridge 126g 126g Toner Cartridge Weight at Toner Near Empty 617g 15g 677g 15g Remain Toner Weight at Toner Near Empty 77g 77g Toner Cartridge Weight at Toner Life End 602g 15g 662g 15g Remain Toner Weight at Toner Life End 65g 65g You can print about 630 pages with 10g...

Page 36: ...riya Plant A Mie Brother C BIUK J Buji Nan Ling Factory E BITM D BIUS F BISZ 1 Printer Printed on the label attached on the rear of the main body Example U 5 2 6 8 2 A 5 J 1 1 1 1 0 1 2 Process unit Imprinted on the aluminum bag Drum unit with toner cartridge 5 A 1 1 J A 3 Drum unit Printed on the bar code label attached inside the drum unit A 5 J 5 1 0 0 1 0 4 A MODEL NO MONTH SERIAL NO DR TN REU...

Page 37: ...er cartridge M 5 J L 0 0 0 1 9 9 A 5 Laser unit On the laser unit X X XXXXXXX CARTRIDGE PRODUCTION INFO DR TN REUSE The first time M The second time N The third time P MOLD NUMBER SERIAL NUMBER YEAR MONTH DATE FACTORY ID NO PRODUCTION LINE NO MONTH YEAR FACTORY ID NO TONER VOLUME L 80g M 100g SERIAL NO PRODUCTION LINE NO MANUFACTURE DISTINCTION ...

Page 38: ...Control system Low voltage power supply block High voltage power supply block Laser unit Drive block DC motor Drum unit Transfer block Exposure drum Charging block External device Paper tray Fuser unit Paper eject tray Paper feed system Image generation system Interface block USB Parallel USB host HL 5280DW Wireless LAN HL 5280DW RAM 16MB HL 5240 32MB HL 5250DN 5270DN 5280DW Extended RAM SODIMM 14...

Page 39: ... rear sensor Toner sensor PCB Light reception Toner LED PCB Light emission Power supply fan Interlock switch Cover sensor MP sensor PCB Tray1 solenoid Regist solenoid Main motor Panel PCB DX solenoid HL 5250DN 5270DN DX unit sensor PCB MP solenoid LT solenoid Front relay PCB New toner sensor Rear relay PCB Paper eject sensor LT PCB LT1 Wireless LAN HL 5280DW Polygon motor Laser diode PCB LT Sensor...

Page 40: ...L 2 pin CN TNRSEN 2 pin CN RELAY FRONT 9 pin CN RELAY REAR 6 pin CN LT 12 pin CN LVPS 8 pin CN HVPS 23 pin CN Laser Unit 14 pin CN MAIN MOTOR 19 pin Motor Driver IC Reset IC 3 3V 3 3V Pararell I F 5 LED 2 SW HL 5240 5250DN LCD16x1 1LED 7SW HL 5270DN 5280DW DX solenoid GRIDC Toner LED 5 PWM_out HVPS 3 solenoid T1 REG MP 2 FAN MAIN HVPS 5 sensor reg_f reg_r pedg T1PE MPPE Therm1 2 HeaterON AI3 7 AI1...

Page 41: ...ode 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...

Page 42: ...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...

Page 43: ... 5V and 24V which are converted from the AC line The regulated output and the production code of each power supply are listed below Regulated Output Production Code 3 3V 1 5A 24V 2 4A 8V 0 8A 100V SRP1828UC 200V SRP1829EK 2 4 2 High voltage power supply The high voltage power supply generates and outputs the voltages and currents for the charging development and transfer functions ...

Page 44: ... ASSY Halogen heater Heat roller Pressure roller Exposure drum Duplex unit Developer roller Drum unit Regist roller Pinch roller Transfer roller Paper tray Paper tray LT unit LT unit Separation roller Feed roller Separation roller MP Feed roller Regist actuator front Feed roller TR Separation roller Feed roller Feed roller TR Regist actuator rear Pressure roller Pressure roller ...

Page 45: ...CHAPTER 2 THEORY OF OPERATION Confidential 2 8 3 2 Overview of Gears Fig 2 5 Eject solenoid LT DX Main motor Drive sub ASSY T1 solenoid MP solenoid Register solenoid LT solenoid ...

Page 46: ...ed to the gears and the gears are engaged Then the paper is gripped between the separation roller and separation pad and separated into individual sheets The paper drawn out of the paper tray pushes against the regist front actuator and the paper top position or absence of paper is detected by the actuator movement The tail edge actuator detects the end of the paper fed Feed roller TR Separation r...

Page 47: ...SSY so that it is pushed up Fig 2 7 When the feed roller is pushed up the hook is released by the lift arm and the rotation of the clutch gear is stopped Then the pressure plate is stopped to push up Fig 2 8 When a paper jam occurs the nips between the pressure roller and feed roller TR and between the pinch roller and regist roller are released which allows you to remove the jammed recording pape...

Page 48: ...regist roller to the transfer roller controls the first print position on the paper The printer starts transferring an image when a definite time passes after the paper is passed through the regist actuator rear 3 3 3 Drum unit Exposure drum Generates the latent electrostatic image and develops the image on the drum surface Primary charger Forms a uniform charge on the drum surface 1 Corona wire G...

Page 49: ...he 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 creat...

Page 50: ...fixed by heat and pressure when passing through the heat roller and the pressure roller in the fuser unit The thermistor keeps the surface temperature of the heat roller constant by detecting the surface temperature of the heat roller and turning on or off the halogen heater lamp Fig 2 11 Pressure roller Halogen heater Heat roller Fuser unit ...

Page 51: ...ds the paper is ejected from the fuser unit The paper eject actuator detects whether the paper is ejected correctly or not After the paper exits from the heat roller the paper is turned by the back cover and ejected face down into the top output tray through the eject roller ASSY Fig 2 12 When a paper jam occurs the roller in the eject roller ASSY is released to remove the jammed recording paper e...

Page 52: ...to the duplex tray where the paper skew is adjusted Afterwards the paper is ejected from the duplex tray to the path through the regist roller and the transfer roller to the transfer block in the drum unit again for process of printing on the back of sheet Fig 2 13 Eject roller ASSY Back cover Outer chute ASSY Pressure roller Duplex unit Transfer roller Exposure drum Heat roller Pinch roller Regis...

Page 53: ...e feed roller contacted with the recording paper The drawn recording paper is separated into individual sheets by the separation roller Fig 2 14 3 3 9 LT tray The motor drive is transmitted to the gear to rotate the feed roller then the recording paper is drawn out of the LT tray The drawn recording paper is separated into individual sheet by the separation roller and fed to the printer Fig 2 15 S...

Page 54: ...ng HL 5240 5250DN 5270DN 5280DW Standard 3 5K toner Page job 1 2 3 4 5 6 7 8 9 10 11 12 Cartridge life 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 ON OFF 2 310 3 915 5 096 6 000 6 715 7 295 7 774 8 177 8 520 8 817 9 075 9 302 Toner empty 5 3 500 3 500 3 500 3 500 3 500 3 500 3 500 3 500 3 500 3 500 3 500 3 500 Toner empty 4 4 375 4 375 4 375 4 375 4 ...

Page 55: ... 000 7 000 7 000 7 000 7 000 7 000 7 000 7 000 7 000 7 000 7 000 7 000 Toner empty 4 8 750 8 750 8 750 8 750 8 750 8 750 8 750 8 750 8 750 8 750 8 750 8 750 Toner empty 3 11 667 11 667 11 667 11 667 11 667 11 667 11 667 11 667 11 667 11 667 11 667 11 667 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 35 000 35 000 35 000 35 000 35 00...

Page 56: ...dard toner cartridge has Rib A and Rib B on gear 4 When the toner actuator is pushed twice the two signals that are generated by the new toner sensor tell the machine that a standard toner cartridge has been installed 4 The high yield toner cartridge only has Rib A on gear 4 When the toner actuator is pushed once the signal that is generated by the new toner sensor tell the machine that a high yie...

Page 57: ... 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 ind...

Page 58: ...mful to the human body Applicable safety standards have been complied with 3 5 2 Exposure stage After the drum is positively charged it is exposed to the light emitted from the laser unit Fig 2 18 Laser exposure unit 1 The laser beam radiated from a laser diode inside the laser unit are concentrated into a constant width by a slit in the CO lens cell and then reflected by a polygon mirror rotating...

Page 59: ... 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 n...

Page 60: ...ption Photo sensor Frame L Front cover sensor Mechanical switch Frame L PE sensor Photo sensor PE EG sensor ASSY Edge sensor Photo sensor PE EG sensor ASSY MP PE sensor Photo sensor MP PE sensor ASSY DX tray sensor Mechanical switch Relay rear PCB Fig 2 20 Frame R Toner LED PCB Light emission Chute Toner sensor PCB Light reception New toner sensor Relay front PCB High voltage PS PCB Regist rear se...

Page 61: ... Plain paper Duplex 195 180 Recycled paper 195 180 Recycled paper Small size 189 170 Recycled paper Duplex 189170 OHP 185 OHP Small size 185 OHP Duplex 185 Thin paper 195 Thin paper Small size 195 Thin paper Duplex 181 Thick paper 200 Thick paper Small size 195 Thick paper Duplex 195 Envelope Thin 200 Envelope Thin small size 200 Envelope Thin duplex 195 Envelope Others 220 Envelope Others small s...

Page 62: ... 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...

Page 63: ...W 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...

Page 64: ...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 electr...

Page 65: ...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 b...

Page 66: ...t 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 seri...

Page 67: ...the primary corona wire inside the drum unit by gently sliding the blue tab from right to left and left to right several times Fig 3 9 CAUTION Be sure to return the tab to the home position If you do not printed pages may have a vertical stripe 8 Put the drum unit and toner cartridge assembly back in the printer Close the front cover Fig 3 10 Home position ...

Page 68: ... 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 5...

Page 69: ... 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 abou...

Page 70: ...t the drum counter when you only replace the toner cartridge 3 Take out the drum unit and toner cartridge assembly Fig 3 15 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 ...

Page 71: ... 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 uni...

Page 72: ...cklever 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 of...

Page 73: ...EPLACE PF KITMP 1 100 000 pages See subscription 2 2 3 Chapter 3 NOTE 1 At 5 print coverage A4 or Letter size The actual number of printed pages will vary depending on the print jobs and paper you use 2 Paper feeding kit MP means the MP roller holder ASSY and the separation pad ASSY MP 3 Paper feeding kit for Tray 1 Tray 2 and Tray 3 means the roller holder ASSY the separation pad ASSY and the sep...

Page 74: ...eplacement Parts 2 2 1 Fuser unit and laser unit Uninstalling Procedure 1 Disconnect the AC cord from the Printer Fig 3 19 2 Press the front cover release button 3 Open the Front cover 4 Remove the Drum toner ASSY Fig 3 20 Printer AC cord Back side Front cover Drum toner ASSY Printer 2 3 4 Front side ...

Page 75: ... 14 5 Remove the DX feed ASSY or DX blank cover Fig 3 21 6 Close the Front cover 7 Pull out the Paper tray 8 Remove the paper if it is remained in the Paper tray Fig 3 22 DX feed ASSY DX blank cover Front cover Paper tray 6 7 Back side Front side ...

Page 76: ...er from the Pins 11 Remove the Back cover Fig 3 23 12 Hold the Knobs on the Outer chute ASSY and pull down this to your side 13 Remove the Arms of the Outer chute ASSY from the Pins 14 Remove the Outer chute ASSY Fig 3 24 Back cover Knob Pin Pin Pin 9 10 11 Pin 12 13 3 Back side Back side Outer chute ASSY Knob 14 12 12 ...

Page 77: ...er L by releasing the Hooks in the order of 15a to 15d Fig 3 25 16 Remove the four cup S M3x6 SR Taptite screws to remove the Shield cover and the FG harness Fig 3 26 Taptite bind B M4x12 Taptite bind B M4x12 Front cover Side cover L Hooks Hooks Hook 15a 15b 15c 15d Taptite cup S M3x6 SR Shield cover Taptite cup S M3x6 SR FG harness Front side ...

Page 78: ...ews and then remove the Side cover R by following the direction from 17a to 17d Fig 3 27 18 Disconnect the Connector of the Panel PCB Fig 3 28 Taptite bind B M4x12 Shield cover R Taptite bind B M4x12 Hook Hooks Hooks Hooks Hook 17a 17b 17c 17d Top cover printed ASSY Main PCB Connector Panel PCB Front side ...

Page 79: ...lift up the front side of the Top cover printed ASSY 21 Remove the Top cover printed ASSY Fig 3 29 22 Remove the bind B M4x16 Taptite screw Release the Hooks in the order of 22a 22b and 22c Remove the FU harness cover 1 Fig 3 30 Hooks Hooks Hooks Hook Taptite bind B M4x12 Hook Hook Top cover printed ASSY Taptite bind B M4x16 FU harness cover 1 Hooks 20 21 22a 22b 22c Back side ...

Page 80: ...er terminal S from the Fuser unit while holding the Fuser unit Fig 3 31 24 Pull the FU harness cover 2 to the direction of 24a while pressing the Hook and pull out the FU harness cover 2 from the back of the printer Fig 3 32 Fuser unit Heater terminal L Heater terminal S FU harness cover 2 Hook 24a 24b ...

Page 81: ...mistor ASSY M and Thermistor ASSY S from the Relay rear PCB ASSY and remove the harnesses of these thermistors Fig 3 33 26 Remove the cup B M4x16 Taptite screw to remove the Fuser unit Fig 3 34 Thermistor ASSY S Relay rear PCB ASSY Thermistor ASSY M Fuser unit Fuser unit Taptite cup B M4x16 ...

Page 82: ...ct to the direction of 27b while pressing the three Hooks and remove the Sub duct from the Air duct Fig 3 35 28 Remove the Filter from the Air duct NOTE The filter is dirt Be careful when disassembling or assembling it Fig 3 36 Air duct Sub duct Hooks Filter Air duct Filter 27b 27a ...

Page 83: ...RIODIC MAINTENANCE Confidential 3 22 29 Remove the Pin of the Air duct from the frame Slide the Air duct to the direction of 29b and remove the Air duct Fig 3 37 Laser unit Air duct 29a 29b 3 Pin Pin Pin Hook Hook ...

Page 84: ...s end or short circuited 32 Remove the Protective film 33 Pull out the flat cable from the Core 34 Remove the Laser unit NOTE Be careful not to lose the Protective film attached on the flat cable Do not touch the Laser scanner window directly Fig 3 38 Laser unit Taptite cup S M3x6 Taptite cup S M3x6 Core Protective film Laser unit Main PCB Polygon motor Flat cable LD harness Flat cable Polygon mot...

Page 85: ...rotective film 3 Install the flat cable Refer to 4 HARNESS ROUTING in Chapter 5 NOTE When connecting flat cable s do not insert them at an angle After insertion check that the cables are not at an angle Fig 3 39 4 Install the Air duct into the Laser unit Fig 3 40 Laser unit Taptite cup S M3x6 Taptite cup S M3x6 Laser unit Air duct 4a 4b Pin Pin Hook Hook Core Protective film ...

Page 86: ...40 5250DN 5270DN 5280DW SERVICE MANUAL Confidential 3 25 5 Install the Filter into the Air duct Fig 3 41 6 Install the Sub duct into the Air duct Fig 3 42 Air duct Filter Air duct Sub duct Hooks Filter 6a 6b ...

Page 87: ...To prevent the deformation of the pressure roller the fuser unit spare part is shipped with its pressure roller at low nip pressure Before installing the fuser unit turn back the levers to the normal position by following instructions below 1 Put the fuser unit on a flat horizontal surface Pull up each of the blue tab a on the right side and left side 2 Make sure that the black lever b is in the p...

Page 88: ...e the Fuser unit with the bind B M4x16 Taptite screw Fig 3 43 8 Connect the connectors of the Thermistor ASSY M and Thermistor ASSY S onto the relay rear PCB ASSY Fig 3 44 Fuser unit Taptite bind B M4x16 Thermistor ASSY S Relay rear PCB ASSY Thermistor ASSY M Fuser unit ...

Page 89: ...DIC MAINTENANCE Confidential 3 28 9 Install the FU harness cover 2 Fig 3 45 10 Install the Heater terminal L and Heater terminal S Fig 3 46 FU harness cover 2 Hook Fuser unit Heater terminal L Heater terminal S 9a 9b ...

Page 90: ...ness cover 1 with the bind B M4x16 Taptite screw Fig 3 47 12 Secure the Top cover printed ASSY with the two bind B M4x12 Taptite screws Fig 3 48 Taptite bind B M4x16 FU harness cover 1 Hooks Hooks Hooks Hooks Hook Taptite bind B M4x12 Hook Hook Top cover printed ASSY 11a 11b 12a 12b ...

Page 91: ... PCB Fig 3 49 14 Catch the Hooks in the order of the arrows and secure the Side cover R with the two bind B M4x12 Taptite screws Fig 3 50 Taptite bind B M4x12 Side cover R Taptite bind B M4x12 Hook Hooks Hooks Hooks Hook 14a 14b 14d 14c Top cover printed ASSY Main PCB Connector Panel PCB ...

Page 92: ... M3x6 SR Taptite screws Fig 3 51 16 Catch the Hooks in the order of the arrows and secure the Side cover L with the two bind B M4x12 Taptite screws Fig 3 52 Taptite bind B M4x12 Taptite bind B M4x12 Side cover L Hooks Hooks Hook 16a 16b 16c 16d Front cover Shield cover Taptite cup S M3x6 SR Taptite cup S M3x6 SR FG harness ...

Page 93: ...f the Outer chute ASSY onto the Pin of the machine body and install the Outer chute ASSY Fig 3 53 18 Catch the Arm of the Back cover onto the Pin of the machine body and install the Back cover Fig 3 54 Outer chute ASSY Back cover 17a 17c Pin Pin 17b Pin Pin 18a 18b 18c ...

Page 94: ...ICE MANUAL Confidential 3 33 19 Install the DX feed ASSY or DX blank cover Fig 3 55 20 Install the Drum toner ASSY into the Printer 21 Close the Front cover Fig 3 56 DX feed ASSY DX blank cover Printer Drum toner ASSY Front cover 21 20 ...

Page 95: ...CHAPTER 3 PERIODIC MAINTENANCE Confidential 3 34 22 Put the Paper tray into the Printer Fig 3 57 23 Connect the AC cord into the Printer Fig 3 58 Paper tray Printer AC cord ...

Page 96: ...eding kit for tray 1 2 3 Uninstalling Procedure 1 Disconnect the AC cord from the Printer Fig 3 59 2 Press the front cover release button 3 Open the Front cover 4 Remove the Drum toner ASSY Fig 3 60 Printer AC cord Front cover Drum toner ASSY Printer 2 3 4 Front side Back side ...

Page 97: ...ential 3 36 5 Remove the DX feed ASSY or DX blank cover Fig 3 61 6 Close the Front cover 7 Pull out the Paper tray 8 Remove the paper from the Paper tray Fig 3 62 DX feed ASSY DX blank cover Back side Front cover Paper tray 6 7 Front side ...

Page 98: ...k side of the Separation pad ASSY 10 Push the Hooks provided on both sides of the Separation pad ASSY inwards 11 Pull up the Separation pad ASSY 12 Remove the Separation pad spring Fig 3 63 Paper tray Separation pad ASSY Hook Hook Hooks 10 10 9 11 Separation pad spring Front side ...

Page 99: ...of the arrow 14a and pull out the pin of the Roller holder ASSY Then turn the Roller holder ASSY to the direction of the arrow 14b Fig 3 64 15 Slide the Roller holder ASSY to the direction of the arrow 15a Then lift up the gear side of the Roller holder ASSY to the direction of the arrow 15b and pull it out to the direction of the arrow 15c to remove Fig 3 65 Lift arm Roller holder ASSY Paper feed...

Page 100: ...g the roller holder ASSY align the section A on the shaft of the roller holder ASSY with the hole on the paper feed frame Fig 3 66 2 Assemble the Lift arm onto the Pin of the Roller holder ASSY 3 Place the Printer on its base Fig 3 67 Roller holder ASSY Paper feed frame Lift arm Roller holder ASSY Paper feed frame Pin 1a 1b 1c 2a 2b A ...

Page 101: ... MAINTENANCE Confidential 3 40 4 Install the DX feed ASSY or DX blank cover Fig 3 68 5 Install the Drum toner ASSY and close the Front cover Fig 3 69 DX feed ASSY DX blank cover Printer Drum toner ASSY Front cover 5a 5b ...

Page 102: ... into the Paper tray and turn the Separation pad ASSY to the direction of the arrow 7c to catch the Hooks into the Paper tray NOTE Check that the Separation pad spring is assembled correctly Fig 3 70 8 Put the Paper tray into the Printer Fig 3 71 Paper tray Separation pad ASSY Hook Paper tray Hook Hooks Separation pad spring 7a 7b 7b 7c ...

Page 103: ...CHAPTER 3 PERIODIC MAINTENANCE Confidential 3 42 9 Connect the AC cord into the Printer Fig 3 72 Printer AC cord ...

Page 104: ...feeding kit for MP tray Uninstalling Procedure 1 Disconnect the AC cord from the Printer Fig 3 73 2 Press the front cover release button 3 Open the Front cover 4 Remove the Drum toner ASSY Fig 3 74 Printer AC cord Front cover Drum toner ASSY Printer 2 3 4 Back side Front side ...

Page 105: ... PERIODIC MAINTENANCE Confidential 3 44 5 Open the MP feed frame cover Fig 3 75 6 Remove the Holder bearing MP Fig 3 76 MP feed frame cover Front cover Holder bearing MP Hook MP feed frame 6c 6b 6a MP feed frame ...

Page 106: ...der ASSY 8 Slide the MP roller holder ASSY to the direction of the arrow 8a and put it up to remove Fig 3 77 9 Turn the back side of the Separation pad ASSY MP to the direction of the arrow 9a and put it up to remove Fig 3 78 Separation pad ASSY MP MP roller holder ASSY Pin MP feed frame Lift arm MP 7 8a 8b MP feed frame MP frame 9b 9a ...

Page 107: ...e Separation pad ASSY MP to the direction of the arrow 1b until it is locked Fig 3 79 2 Lift up the Lift arm MP and put the MP roller holder ASSY into the MP feed frame Put the Pin of the MP roller holder ASSY into the hole of the Lift arm MP Fig 3 80 Separation pad ASSY MP MP roller holder ASSY Pin MP feed frame MP frame MP feed frame Lift arm MP 1a 1b ...

Page 108: ...3 Put the Holder bearing MP into the MP feed frame and turn the Holder bearing MP to the direction of the arrow 3c to lock Fig 3 81 4 Close the MP feed frame cover Fig 3 82 Holder bearing MP Hook MP feed frame cover Front cover MP feed frame 3a 3b 3c MP feed frame ...

Page 109: ...DIC MAINTENANCE Confidential 3 48 5 Install the Drum toner ASSY into the Printer 6 Close the Front cover Fig 3 83 7 Connect the AC cord into the Printer Fig 3 84 Printer AC cord Drum toner ASSY Front cover 5 6 Printer ...

Page 110: ...ndow 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 po...

Page 111: ...n before you touch the internal parts of the printer 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 Handle the toner cartridge carefully If toner scatters on your hands or clothes wipe or wash it off with cold water at once To prevent damage to the printer from static electricity D...

Page 112: ...ANUAL Confidential 3 51 4 Wipe the scanner window with a dry lint free cloth Fig 3 88 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 ...

Page 113: ...he 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 89 2 Take out the drum unit and toner cartridge assembly Fig 3 90 ...

Page 114: ...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 Fig 3 91 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...

Page 115: ...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...

Page 116: ...s 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 Wa...

Page 117: ...em 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 ...

Page 118: ... A Replace the toner cartridge with a new one Cartridge position error N A The drum unit ASSY is not installed correctly Put the drum unit ASSY back in Drum near end The drum unit is near the end of its life We recommend that you get a new drum unit to replace the current one The Drum LED will turn on for 2 seconds and off for 3 seconds No paper fed tray N A Put paper in the tray Press the Go butt...

Page 119: ...tion of Ground Contacts in this Chapter Too many trays N A Maximum number of optional trays is two Remove additional trays Buffer error Yes Check the cable connection between the PC and the printer Memory full Yes The printer memory is full and the printer cannot print full pages of a document Print overrun Yes A print overrun occurred and the printer cannot print full pages of a document Download...

Page 120: ... DIMM correctly Turn off the printer Wait a few seconds and then turn it on again If this error message appears again replace the DIMM with a new one DOWNLOAD FULL Add more memory DUPLEX DISABLED Close the back cover of the printer and put the duplex tray back in 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 DUS...

Page 121: ... or MP tray that is selected in the printer driver and then press Go button or set the size of paper you loaded in by using the control panel STORAGE FULL The RAMDISK size is set to 0 MB Increase the RAMDISK size Or there is no space to store jobs Delete unnecessary macros or fonts TOO MANY TRAYS Maximum number of optional trays is two Remove additional trays Maintenance message Maintenance messag...

Page 122: ...he specific combination of ON OFF and status color of the LED Instruct the user to turn off the power switch wait a few seconds and then turn it on again and try to print again If the error is not cleared and the same service call appears refer to 5 MALFUNCTIONS to take the corrective action Refer to 5 MALFUNCTION NO YES Error occurs Error occurs again Comfirm the LED indication Turn OFF ON the po...

Page 123: ...dentify 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 correc...

Page 124: ...t on again If still remains replace the main PCB ERROR S03 ADRS ERROR EX Turn off the printer Wait a few seconds then turn it on again If still remains replace the main PCB ERROR S04 BUS ERROR EX INSTRUCT Turn off the printer Wait a few seconds then turn it on again If still remains replace the main PCB ERROR S05 BUS ERROR EX DATA L S Turn off the printer Wait a few seconds then turn it on again I...

Page 125: ... then turn it on again If the same still occurs replace the laser unit If still remains replace the main PCB ERROR E54 MAIN MOTOR LOCK ERROR Turn off the printer Wait a few seconds then turn it on again If the same error occurs replace the main motor If still remains replace the main PCB ERROR E55 HIGH VOLTAGE POWER SUPPLY MALFUNCTION Turn off the printer Wait a few seconds then turn it on again I...

Page 126: ...e 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 ag...

Page 127: ...ear 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 Cal...

Page 128: ...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 TrueT...

Page 129: ...r does not feed paper from the MP tray Fan the paper well and put it back in firmly Make sure that you have chosen the MP Tray in the Paper Source pf the printer driver The printer does not feed envelopes The printer can feed envelopes from the multi purpose tray Your application software must be set up correctly to print on the envelope size you are using This is usually done in the page setup or...

Page 130: ...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...

Page 131: ...e 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 ...

Page 132: ...DE Paper jam inside the printer 6 JAM REAR Paper jam where the paper comes out of the printer 7 JAM DUPLEX Paper jam in the duplex tray Check where the jam is and clear the jammed paper as follows If the error message still appears on the LCD after you remove the jammed paper there may be more paper jammed somewhere else Check the printer thoroughly After you have removed all the jammed paper open...

Page 133: ...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 tra...

Page 134: ...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...

Page 135: ...oved 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...

Page 136: ...dle the toner cartridge carefully If toner scatters on your hands or clothes wipe or wash it off with cold water at once To avoid print quality problems DO NOT touch the shaded parts shown in the illustrations 4 Put the toner cartridge back into the drum unit until you hear it lock into place If you put the cartridge in properly the blue lock lever will lift automatically Fig 4 12 5 Close the fron...

Page 137: ...ely 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 ...

Page 138: ...lectricity 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 do...

Page 139: ...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 ...

Page 140: ...y paper length detected as shorter than 80mm The regist front sensor was turned off early Malfunction of actuator or hardware noise Check the front registration sensor refer to Factory Inspection Mode in Chapter 7 Top of paper stopped between the paper feed roller and the pick up roller Jam caused by a paper feed delay Paper was not fed in at the proper timing due to paper dust or wear of the rubb...

Page 141: ...put 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 Step Check Result Remedy Paper 1 Is the problem solved if new paper is used Yes Instruct the user how to store paper so that it does not absorb moisture Fuser unit entrance guide 2 Is the entrance guide dirty Yes Clean...

Page 142: ... of a malfunction refer to 5 MALFUNCTIONS in this Chapter 5 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 Step Check Result Remedy Disconnection of the pickup solenoid harness 1 Is the harness of the pickup solenoid disconnected Yes Reconnect the harne...

Page 143: ...hat 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 T...

Page 144: ...does not support USB Computer settings 2 Does Universal Serial Bus Controllers appear in the Device Manager tab of System Properties in Control Panel No This problem can be caused by your computer settings See the computer manual USB cable printer damage 3 Does Add New Hardware Wizard appear on the screen or Does test print complete No The USB cable is damaged Replace the cable If the same problem...

Page 145: ... and PC with the USB cable directly Driver installation 2 Are there the following files in the Extensions Folder of System Folder No Try to re install the printer driver For System 9 1 9 2 BR_PrintMoniter laser Brother Laser Yes Turn off the printer and PC power switch and check all connections between them Then turn them on again 6 Unable to print from the application when using Macintosh with US...

Page 146: ...s there a broken wire between the AC input connector of the low voltage power supply and the power plug Yes Replace the AC power cord 2 No DC power supplied Possible cause Step Check Result Remedy AC power supply 1 Is AC power supplied between connectors CN1 L and CN1 N when the power plug is plugged into the outlet No Follow the same check procedure of 1 No AC power supplied Wiring DC load 2 Turn...

Page 147: ... cause Step Check Result Remedy Separation pad pickup roller failure 1 Is the surface of the separation pad or the pickup roller dirty or worn out Yes 1 Clean the surface of the separation pad or pickup roller 2 Replace the separation pad or pickup roller Failure of connector 2 Is the contact of the solenoid connector on the relay front PCB good No Reconnect the connector HVPS circuit Set paper in...

Page 148: ...ector CN1 and CN2 on the relay rear PCB good No Reconnect the connector Poor thermistor harness contact 2 Is the contact of connector CN3 on the main PCB good No Reconnect the connector Blown thermostat 3 Remove the fuser unit and measure the resistance of the thermostat Is it open circuit Yes Replace the fuser unit Halogen heater lamp failure 4 Remove the fuser unit and measure the resistance of ...

Page 149: ...r harness connector connected to the low voltage power supply PCB and fuser unit secure No Reconnect the connectors securely NOTE This problem will be cleared if leaving the printer power ON for ten minutes If the heater is cooled down sufficiently this problem may be cleared by following steps 1 Check that the front cover is open 2 Turn on the printer power switch while pressing the Go button Be ...

Page 150: ...e Step Check Result Remedy The toner cartridge is not set to the main body correctly 1 The toner cartridge is not inserted completely Yes Reset the cartridge New toner detection switch failure 2 Isn t the toner sensed even if the switch is held Yes Replace the switch Main PCB failure 3 Is the problem solved by replacing the main PCB No Replace the main PCB 12 Maximum speed is slow Possible cause S...

Page 151: ...in cover switch closed securely Yes Check the switch 14 Service error indication when turning the power ON Possible cause Step Check Result Remedy Disconnection of the main motor harness 1 Is the harness of the main motor connected No Reconnect the harness securely Disconnection of the scanner motor harness 2 Is the harness of the scanner motor connected No Reconnect the harness securely Fuser uni...

Page 152: ... t o u t t e s t p r i n t o P r i n t o u t t e s t p r i n t o P r i n t o u t t e s t p r i n t o u t t e s t p r i n t o u t t e s t P r i n t o u t t e s t p r i n t o P r i n t o u t t e s t p r i n t o u t t e s t p r i n t o u t t e s t P r i n t o u t t e s t p r i n t o P r i n t o u t t e s t p r i n t o P r i n t o u t t e s t p r i n t o u t t e s t p r i n t o u t t e s t P r i n t o...

Page 153: ...ner sensor failure toner cartridge side 2 Is the problem solved when 4 or 5 pages are printed after the toner cartridge is replaced with a full one Yes The wiper of the toner cartridge is defective Replace the toner cartridge Drum connection failure 3 Are all the contacts between the drum unit and printer body connected correctly No Clean contact electrodes both on the drum unit and in the printer...

Page 154: ...rtridge Yes Replace the toner cartridge with a new one High voltage power supply PCB failure 4 Is the connections of the connector between the high voltage power supply PCB and the main PCB secured correctly Yes Replace the high voltage power supply PCB Main PCB failure 5 Are there any disconnected connectors No Replace the main PCB User Check 1 Check the paper used meets the recommended paper spe...

Page 155: ...failure 3 Is the problem solved after replacing the drum unit Yes Replace the drum unit Toner cartridge failure 4 Is the problem solved after replacing the toner cartridge Yes Replace the toner cartridge with a new one Scanner harness connection failure 5 Is the scanner harness connected securely Check if there is any play in the connection No Reconnect the connector correctly Main PCB failure 6 A...

Page 156: ...Is the laser unit connected to the main PCB correctly No Connect the harness between the laser unit and the main PCB correctly High voltage power supply PCB failure 5 Is the problem solved after replacing the high voltage power supply PCB Yes Replace the high voltage power supply PCB Main PCB failure 6 Is the problem solved after replacing the main PCB Yes Replace the main PCB Laser unit failure 7...

Page 157: ...e 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 but...

Page 158: ...g failure 5 Is the surface of the drum dirty with toner in streaks Yes Replace the drum unit Scratch on the heat roller 6 Is the surface of the heat roller scratched Yes Replace the fuser unit NOTE If you print the same pattern especially vertical streaks continuously electrostatic charge performance of the drum will decrease temporarily and black vertical streaks may appear on the paper This prob...

Page 159: ...ailure 4 Are the charge electrodes between the printer body and the drum unit dirty Yes Clean both electrodes 3 High voltage power supply PCB failure 5 Is the problem solved after replacing the high voltage power supply PCB Yes Replace the high voltage power supply PCB I 8 Black vertical streaks in a gray background Possible cause Step Check Result Remedy Ground contacts Translucent stain on the s...

Page 160: ...eloping bias contacts between the printer body and toner cartridge dirty Yes Clean the electrodes at both sides 4 User Check 1 Try to wipe the scanner window with a soft cloth 2 The toner cartridge may be damaged Install a new toner cartridge 3 Check the printer s environment High temperature and high humidity conditions can cause this problem 4 Damp wet paper might be used Try to change to freshl...

Page 161: ...ified weight of the recommended paper being used No Recommend to use the specified types of paper Print paper 3 Is the first printing position within 1mm of the tolerance specification Yes Adjust the Y offset by using the utility software supplied Regist rear sensor position incorrect 4 Is the regist rear sensor off from the correct position Yes Reposition the sensor to the correct position Drum u...

Page 162: ... the toner cartridge Yes 1 Toner is empty 2 The toner sensor is defective Clean the toner sensor 3 If the wiper in the toner cartridge is broken replace the toner cartridge with a new one Fuser unit thermistor failure 4 Is the thermistor fitted correctly No Replace the fuser unit Low voltage power supply PCB failure 5 Is the problem solved by replacing the low voltage power supply PCB Yes Replace ...

Page 163: ...s t P r i n t o u t t e s t p r i n t o P r i n t o u t t e s t p r i n t o P r i n t o u t t e s t p r i n t o u t t e s t p r i n t o u t t e s t P r i n t o u t t e s t p r i n t o P r i n t o u t t e s t p r i n t o P r i n t o u t t e s t p r i n t o u t t e s t p r i n t o u t t e s t P r i n t o u t t e s t p r i n t o P r i n t o u t t e s t p r i n t o P r i n t o u t t e s t p r i n t o ...

Page 164: ...tridge almost empty Yes Replace the toner cartridge with a new one Print paper 4 Is the problem solved after changing to specified freshly unpacked paper Yes Damp wet paper might be used Recommend to change freshly unpacked paper Environment 5 Does the problem still appear after the printer has warmed up Yes 1 Replace the drum unit 2 Advise the user of the specified print environment User Check 1 ...

Page 165: ...m 3 7 in Fig 4 22 2 Turn the drum unit gear by hand while looking at the surface of the OPC drum Fig 4 23 3 When you have found the mark on the drum that matches the print sample wipe the surface of the OPC drum with a cotton swab until the dust or paper powder on the surface comes off Fig 4 24 CAUTION DO NOT clean the surface of the photosensitive drum with a sharp object White Spots on black tex...

Page 166: ...orrectly No Clean contact electrode both on the drum unit and in the printer body 7 Fuser unit 3 Are the spots at 79mm intervals The problem is not solved after printing a few pages Yes 1 Check and clean the heat roller with a cloth dampened with alcohol 2 Replace the fuser unit High voltage power supply PCB failure 4 Is the problem solved after replacing the high voltage power supply PCB Yes Repl...

Page 167: ...t the paper specification weight etc Yes Recommend to change to freshly unpacked paper Toner sensor failure printer side 2 Is Ready LED still lighted after the toner cartridge and drum unit are taken out The front cover is closed Yes Toner sensor failure Clean the toner sensor and check the toner sensor connection Toner cartridge failure 3 Is the problem solved after replacing the toner cartridge ...

Page 168: ... failure 2 Is the problem solved after replacing the high voltage power supply PCB Yes Replace the high voltage power supply PCB I 21 Horizontal lines Possible cause Step Check Result Remedy Paper tray contacts 1 Are the ground contacts on the right side of the paper tray connecting correctly No Clean the contacts Drum unit 2 Are the high voltage power supply and drum unit contacted correctly No C...

Page 169: ...y Driver setting 1 Is thin paper such as 64g m 2 used under the thick paper mode Yes 1 Change the current mode to the normal mode from the driver setting 2 Print 5 or 6 blank pages if this problem occurs Drum unit failure 2 Is the problem solved after replacing the drum unit Yes Replace the drum unit High voltage power supply PCB failure 3 Is the problem solved after replacing the high voltage pow...

Page 170: ...ck 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 ...

Page 171: ...witch Unplug the machine from the AC power outlet and leave the machine for a few minutes Then wipe the electrodes above carefully with a dry lint free cloth Be careful not to change the shapes of the electrodes Toner cartridge Drum Unit 4 Developer roller 1 Exposure drum 6 Transfer roller 5 Grid 7 Cleaner 3 Charge 2 Wire cleaner 4 Developer roller 3 Charge 7 Cleaner 5 Grid 1 Exposure drum 6 Trans...

Page 172: ...o the printer only 6 Turn off the Status Monitor in the Device Options tab in the printer driver 7 Try printing the test page referring to Test Sample Page in Chapter 7 8 Try resetting the factory settings Possible cause Step Check Result Remedy Failure inside the printer 1 Is it possible to print the test page with the method of Test Sample Page in Chapter 7 No Identify the error type then refer ...

Page 173: ...ually the first two lines and last two lines of text cannot print leaving 62 printable lines Adjust the top and bottom margins in your document to allow for this P 5 The printer sometimes prints a couple of characters and then ejects the page User Check For DOS environment only The application printer emulation setting and the printer s emulation do not match Check in the application software whic...

Page 174: ...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 th...

Page 175: ...er 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...

Page 176: ...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...

Page 177: ... 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 pr...

Page 178: ...eset 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 t...

Page 179: ...o 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 pr...

Page 180: ...tings Wireless connection problem The wireless network connection is sometimes disabled The wireless network connection status is affected by the environment where the Brother printer and other wireless devices are located The following conditions may cause connection problems A concrete or metal framed wall is installed between the Brother printer and the access point Electric appliances such as ...

Page 181: ...tic electricity charged in your body may damage electronic parts When transporting PCBs be sure to wrap them in conductive sheets 5 When replacing the PCB and all the other related parts put on a grounding wrist band and perform the job on a static mat Also take care not to touch the conductor sections on the flat cables or on the wire harness 6 Be sure to replace self tapping screws correctly if ...

Page 182: ...CHAPTER 5 DISASSEMBLY AND RE ASSEMBLY Confidential 5 2 2 PACKING Fig 5 1 Accessory bag AC power cord Option carton Pad Printer Carton Pad Pad Drum toner ASSY ...

Page 183: ...12 Paper feed unit 8 0 8 0 1 8 1 5 085411216 Taptite bind B M4 x 12 HVPS 2 0 8 0 1 8 1 6 085411216 Taptite bind B M4 x 12 LVPS 2 0 8 0 1 8 1 7 085411216 Taptite bind B M4 x 12 Base plate 9 0 8 0 1 8 1 8 LM5867001 Taptite cup S M3 x 6 SR Main PCB 4 0 75 0 1 7 5 1 9 LM5867001 Taptite cup S M3 x 6 SR Shield cover 4 0 75 0 1 7 5 1 10 087320616 Taptite cup S M3 x 6 Scanner plate 6 0 7 0 1 7 1 3 Paper F...

Page 184: ...SEMBLY AND RE ASSEMBLY Confidential 5 4 4 HARNESS ROUTING MP PE sensor ASSY 1 High voltage PS PCB ASSY Hook A Hook B MP feed frame MP feed frame Hole Hook A Printer top side Printer body upside down MP PE sensor ASSY ...

Page 185: ...ck SW ASSY 3 Interlock SW ASSY Relay front PCB ASSY Hooks Frame L Pin Hook Pin High voltage PS PCB ASSY PE EG sensor ASSY PE EG sensor ASSY Paper feed frame Paper feed frame Hook A Hook B Hook B Hole A Hole A Printer top side Printer body upside down PE EG sensor ASSY 2 ...

Page 186: ...fidential 5 6 Register solenoid ASSY 5 Register solenoid ASSY Relay front PCB ASSY Hooks Hook Hook Hook Hook Frame L Hook Pin Pin Toner sensor PCB unit ASSY 4 Toner sensor PCB unit ASSY Relay front PCB ASSY Hooks Hook Hook Frame L Hook Pin Pin ...

Page 187: ...DN 5280DW SERVICE MANUAL Confidential 5 7 7 T1 solenoid ASSY Relay front PCB ASSY Hooks Hook Pin Pin Hooks T1 solenoid ASSY Frame L 6 MP solenoid ASSY Relay front PCB ASSY Hooks Hooks MP solenoid ASSY Frame L Hook Pin Pin ...

Page 188: ... RE ASSEMBLY Confidential 5 8 9 Laser unit Laser unit Frame L Holes Core Hook Gear cover Main PCB Polygon motor Flat cable Protective film LD harness Flat cable 8 Relay front PCB ASSY Relay front PCB ASSY Main PCB Hook Frame L ...

Page 189: ...70DN 5280DW SERVICE MANUAL Confidential 5 9 11 Fan motor 60 unit LV Frame L Hooks Hook Hook Hook Fan motor 60 unit LV Toner LED PCB unit ASSY Fan motor 60 unit Frame L Hooks Fan motor 60 unit Toner LED PCB unit ASSY 10 ...

Page 190: ...5 DISASSEMBLY AND RE ASSEMBLY Confidential 5 10 Frame L Hooks Hook Hook Hole Toner LED PCB unit ASSY Printer top side Printer body upside down High voltage PS PCB ASSY Hook Hooks Hole Toner LED PCB unit ASSY 12 ...

Page 191: ...ield cover Shield cover FG harness FG harness Main PCB Main PCB PS PCB unit 13 FG harness 14 PS PCB unit Inlet harness ASSY Power supply switch Hook Hooks Core A view A view PS PCB unit terminal Printer top side Printer body upside down Base plate LV SW holder ASSY ...

Page 192: ...Frame L Wireless PCB PCB T60H929 00 ASSY 02 Wireless PCB harness LD harness Main PCB Main PCB Wireless PCB PCB T60H929 00 ASSY 02 16 High Voltage PS PCB ASSY 15 High Voltage PS PCB ASSY Hole Insulation sheet Printer top side Printer body upside down HVPS PCB harness Flat cable HVPS PCB harness Flat cable Main PCB ...

Page 193: ... SERVICE MANUAL Confidential 5 13 5 LUBRICATION BG2 BG2 KANTO KASEI BG MU 2 mm dia Ball BG2 BG2 KANTO KASEI BG MU 2 mm dia Ball Gear 82R Drive sub ASSY Apply grease on the cogs of the motor side DEV gear 37R joint drive Gear cover ...

Page 194: ...er Holder 7 27 2 Panel PCB ASSY 7 27 3 SW Key A B 7 28 4 SW Key A B C Set Key Printed ASSY 7 28 3 Panel PCB ASSY 7 28 2 Inner Chute Pinch Roller Holder 7 28 5 LCD Holder ASSY 7 31 PS PCB Unit 7 32 High Voltage PS PCB ASSY 7 33 Toner LED PCB Unit ASSY 7 14 Main Shield Plate ASSY 7 26 Side Cover R 7 42 PE Actuator Edge Actuator Edge Actuator Spring 7 43 PE EG Sensor ASSY 7 41 Roller Holder ASSY 7 39...

Page 195: ...SSEMBLY PROCEDURE 7 1 AC Cord 1 Disconnect the AC cord from the Printer Fig 5 2 7 2 Drum Toner ASSY 1 Press the front cover release button 2 Open the Front cover 3 Remove the Drum toner ASSY Fig 5 3 AC cord Front cover Drum toner ASSY 1 2 3 Printer Back side Front side ...

Page 196: ...onfidential 5 16 7 3 DX Feed ASSY 1 Remove the DX feed ASSY Fig 5 4 7 4 Paper Tray 1 Close the Front cover 2 Pull out the Paper tray 3 Remove the paper from the Paper tray Fig 5 5 Front cover Paper tray DX feed ASSY 2 1 Back side Front side ...

Page 197: ... of the Separation pad ASSY 5 Push the Hooks provided on both sides of the Separation pad ASSY inwards 6 Pull up the Separation pad ASSY Fig 5 6 7 Remove the Separation pad spring Fig 5 7 Hook Paper tray Separation pad spring Paper tray Separation pad ASSY 5 4 5 6 Hook Hooks Front side ...

Page 198: ... DISASSEMBLY AND RE ASSEMBLY Confidential 5 18 8 Remove the Lift gear 46 Fig 5 8 9 Remove the Gear 21 16 Fig 5 9 Paper tray Lift gear 46 Hook Gear 21 16 Paper tray Plate up plate Plate up plate Hook Lift gear 46 ...

Page 199: ...HL 5240 5250DN 5270DN 5280DW SERVICE MANUAL Confidential 5 19 10 Remove the Gear 15 Fig 5 10 Paper tray Gear 15 Front side ...

Page 200: ...k cover 2 Remove the Arms of the Back cover from the Pins 3 Remove the Back cover Fig 5 11 7 6 DX Blank Cover For HL 5240 1 Push the Hooks on both sides of the DX blank cover inwards to release them and remove the DX blank cover Fig 5 12 Back cover Pin Pin 1 2 3 DX blank cover Hook Hook ...

Page 201: ... Remove the Outer chute ASSY Fig 5 13 4 Remove the bind B M3x8 Taptite screw 5 Lift up the side where the eject actuator is assembled of the Sub outer chute slightly to the direction of 5a and move the Sub outer chute to the direction of 5b 6 Lift up the Sub outer chute to remove Fig 5 14 Outer chute ASSY 1 3 Pin Pin 2 1 1 Back side Pin Sub outer chute Hooks Outer chute ASSY Taptite bind B M3x8 6 ...

Page 202: ...direction of 7b 8 Lift up the Eject actuator to remove 9 Remove the Eject actuator spring Fig 5 15 Assembling Note When assembling the Eject actuator spring ensure that its direction is correct referring to the figure below Fig 5 16 Sub outer chute Hook 9 Rib Eject actuator Eject actuator spring Sub outer chute Eject actuator spring Eject actuator 8 7b 7a ...

Page 203: ...ite screw Release the Hooks in the order of 1a 1b and 1c Remove the FU harness cover 1 Fig 5 17 2 Remove the Heater terminal L and Heater terminal S from the Fuser unit while holding the Fuser unit Fig 5 18 FU harness cover 1 Taptite bind B M4x16 Hooks 1a 1b 1c Heater terminal L Heater terminal S Fuser unit ...

Page 204: ...ok and pull out the FU harness cover 2 from the back of the printer Fig 5 19 4 Disconnect the connectors of the Thermistor ASSY M and Thermistor ASSY S from the Relay rear PCB ASSY and remove the harnesses of these thermistors Fig 5 20 Hook FU harness cover 2 3a 3b Thermistor ASSY S Thermistor ASSY M Fuser unit Relay rear PCB ASSY ...

Page 205: ...e screw and then remove Fuser unit Fig 5 21 7 9 Tray MP ASSY 1 Open the MP tray cover ASSY 2 Release the Bosses of the Tray MP ASSY from the MP tray cover ASSY 3 Remove the Tray MP ASSY Fig 5 22 Fuser unit Taptite cup B M4x16 Process cover ASSY Tray MP ASSY 1 2 3 MP tray cover ASSY 2 Boss Boss ...

Page 206: ...cover ASSY 3 Release the Hook to remove the Process cover stopper Fig 5 23 4 Remove the MP tray cover ASSY and the Process cover ASSY to the direction of 4a and 4b to release the Bosses and remove them Fig 5 24 Hook Process cover stopper MP tray cover ASSY Drive release link 1 Process cover ASSY 2 3 Process cover ASSY MP tray cover ASSY 4a 4b Boss Boss ...

Page 207: ...r ASSY from the MP tray cover ASSY Fig 5 25 6 Remove the cup B M4x10 Taptite screw and then remove the Process cover stopper Fig 5 26 7 Remove the Support lap from the Process cover Fig 5 27 Process cover ASSY MP tray cover ASSY Process cover stopper Support lap Process cover Taptite cup B M4x10 Process cover Arm ...

Page 208: ...de Cover L 1 Remove the Access cover Fig 5 28 2 Remove the two bind B M4x12 Taptite screws and then remove the Side cover L by releasing the Hooks from 2a to 2d Fig 5 29 Access cover 2d Taptite bind B M4x12 Hooks 2a Side cover L Taptite bind B M4x12 Hooks Hook 1 2b 2c Left side ...

Page 209: ...g the flat cable s do not insert it at an angle After insertion check that the cable is not at an angle Fig 5 31 Assembling Note When assembling the Main PCB ensure to place the Ferrite Core correctly Refer to APPENDIX 7 LOCATION OF THE FERRITE CORE in details Shield cover Taptite cup S M3x6 SR Taptite cup S M3x6 SR LD harness Flat cable DX solenoid connector Panel PCB connector Relay front Flat c...

Page 210: ...evelop 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 NOTE Be careful not to drop the gear Fig 5 33 Screws Main PCB Taptite cup S M3x6 SR FG harness Taptite bind B M4x12 Taptite bind B M4x12 Taptite cup S M3x6 Frame L Gear pla...

Page 211: ...S M3x6 Taptite screws and then remove the Main motor ASSY AL Fig 5 34 5 Remove the Develop joint from the Gear plate calking ASSY AL Fig 5 35 Taptite cup S M3x6 Taptite cup S M3x6 Main motor ASSY AL Gear plate calking ASSY AL Taptite cup S M3x6 Gear plate calking ASSY AL Develop joint ...

Page 212: ... 3 Remove the bind B M4x12 Taptite screw and then remove the Plate Fig 5 37 Assembling Note When assembling the Plate ensure to put the Plate into the base plate LV When assembling the Plate secure the screw at the Frame L side first then the screw at the base plate LV side Insulation sheet Frame L Plate Frame L Taptite bind B M4x12 Pin Pin Taptite bind B M4x12 ...

Page 213: ...ew and then remove the Main shield plate ASSY Fig 5 38 Assembling Note When assembling the Main shield plate ASSY be careful not to bend the Ground wire AL of the Frame L Fig 5 39 Main shield plate ASSY Ground wire AL Inner chute AL Joint cover Taptite bind B M4x12 Taptite cup S M3x6 Main shield plate ASSY Frame L Taptite bind B M4x12 ...

Page 214: ...ASSY Connector 1 Remove the Relay rear PCB ASSY Fig 5 40 2 Remove the Connector harness 3 Disconnect the LT connector while pressing the Hook inwards Fig 5 41 Relay rear PCB ASSY Frame L Hook LT connector Hook Hook Frame L Connector harness DX sensor For HL 5250DN 5270DN 5280DW ...

Page 215: ...40 5250DN 5270DN 5280DW SERVICE MANUAL Confidential 5 35 Assembling Note When assembling the LT connector ensure that its direction is correct referring to the figure below Fig 5 42 Frame L LT connector Boss ...

Page 216: ...e Relay front PCB ASSY 2 Disconnect the five connectors from the Relay front PCB ASSY Fig 5 43 Fig 5 44 Frame L Relay front PCB ASSY Hook Pin Hook Pin Relay front PCB ASSY Toner sensor PCB connector Inter lock SW connector MP solenoid connector T1 solenoid connector Register solenoid connector ...

Page 217: ...7 17 MP Solenoid ASSY 1 Remove the cup B M3x8 Taptite screw and then remove the Spring Fig 5 45 Assembling Note When assembling the Spring ensure that its direction is correct referring to the figure below Fig 5 46 Taptite cup B M3x8 Spring Frame L Frame L Spring ...

Page 218: ...e Drive release cam slightly and remove the Drive release cam from the Frame L 2 Turn the Drive release link to the direction of the arrow 2 until the groove of the Drive release link is aligned with the guide of the boss as shown in the figure below 3 Remove the Drive release cam Fig 5 48 Drive release cam Drive release link Frame L 2 1 3 MP solenoid ASSY Solenoid release spring P R MP solenoid l...

Page 219: ...enoid release spring Fig 5 49 7 20 Toner Sensor PCB 1 Remove the Toner sensor PCB unit ASSY from the Frame L Fig 5 50 2 Remove the PT sensor holder from the Toner sensor PCB ASSY AL Fig 5 51 Taptite bind B M3x10 Solenoid release spring T1 solenoid ASSY Frame L T1 solenoid lever Frame L Hooks Toner sensor PCB unit ASSY Hooks PT sensor holder Toner sensor PCB ASSY AL ...

Page 220: ...lease spring Fig 5 52 7 22 Ejector Solenoid ASSY For HL 5250DN 5070DN 5280DW 1 Remove the bind B M3x10 Taptite screw 2 Remove the Ejector solenoid and the Solenoid release spring Fig 5 53 Frame L Solenoid release spring Taptite bind B M3x10 Register solenoid ASSY Register solenoid lever Solenoid release spring Taptite bind B M3x10 Ejector solenoid Frame L Ejector solenoid lever ...

Page 221: ...ator 1 Remove the New toner actuator and the New toner actuator spring Fig 5 55 Assembling Note When assembling the New toner actuator spring ensure that its direction is correct referring to the figure below Fig 5 56 Frame L Interlock SW ASSY Hooks Hook New toner actuator Frame L New toner actuator spring New toner actuator spring New toner actuator Hook Hook ...

Page 222: ...CHAPTER 5 DISASSEMBLY AND RE ASSEMBLY Confidential 5 42 7 25 Gear 17 20 23 1 Remove the Gear 23 Fig 5 57 2 Remove the Gear 20 Fig 5 58 Gear 23 Hook Frame L Frame L Gear 20 Hook ...

Page 223: ...HL 5240 5250DN 5270DN 5280DW SERVICE MANUAL Confidential 5 43 3 Remove the Gear 17 black Fig 5 59 4 Remove the Gear 17 white Fig 5 60 Gear 17 black Hook Frame L Gear 17 white Hook Frame L ...

Page 224: ...ial 5 44 7 26 Side Cover R 1 Remove the two bind B M4x12 Taptite screws and then remove the Side cover R by following the direction from 1a to 1d Fig 5 61 Taptite bind B M4x12 Taptite bind B M4x12 Side cover R Hooks Hooks Hook 1d 1c 1b 1a Hook Hooks ...

Page 225: ...ver printed ASSY and lift up the front side of the Top cover printed ASSY 3 Remove the Top cover printed ASSY Fig 5 62 7 27 2 Panel PCB ASSY 1 Turn the Top cover printed ASSY upside down 2 Remove the three cup B M3x8 Taptite screws and then remove the Panel PCB ASSY Fig 5 63 Taptite bind B M4x12 Hook Hook Hook Hook Hooks Hooks Top cover printed ASSY 3 Taptite cup B M3x8 Panel PCB ASSY Top cover pr...

Page 226: ...SEMBLY Confidential 5 46 7 27 3 SW Key A B 1 Remove the SW key A from the Top cover printed ASSY Fig 5 64 2 Remove the SW key B from the Top cover printed ASSY Fig 5 65 Top cover printed ASSY SW key A Top cover printed ASSY SW key B ...

Page 227: ...embling Note When assembling the Inner chute secure the screws according to the order of alphabet described in the figure above 4 Turn the Inner chute upside down 5 Remove the Pinch roller holder from the Inner chute Fig 5 67 Assembling Note When assembling the Pinch roller holder be sure that its direction is correct as shown in the figure above Taptite bind B M4x12 Taptite bind B M4x12 Taptite b...

Page 228: ... printed ASSY 2 Release all Hooks of the Top cover 2 printed ASSY and lift up the front side of the Top cover 2 printed ASSY 3 Remove the Top cover 2 printed ASSY Fig 5 68 4 Remove the Panel Plate Printed ASSY from the Top cover 2 printed ASSY Fig 5 69 Taptite bind B M4x12 Hook Hook Hook Hook Hooks Hooks Top cover 2 printed ASSY 3 Front side 2 Top cover 2 printed ASSY Panel Plate Printed ASSY Hook...

Page 229: ...mbling Note When assembling the Inner chute secure the screws according to the order of alphabet described in the figure above 4 Turn the Inner chute upside down 5 Remove the Pinch roller holder from the Inner chute Fig 5 70 Assembling Note When assembling the Pinch roller holder be sure that its direction is correct as shown in the figure above Taptite bind B M4x12 Taptite bind B M4x12 Taptite bi...

Page 230: ...at cable s do not insert it at an angle After insertion check that the cable is not at an angle Fig 5 72 2 Remove the three cup B M3x8 Taptite screws and then remove the LCD panel PCB ASSY Fig 5 73 Assembling Note When assembling the LCD panel PCB ASSY secure the screws according to the order of alphabet described in the figure above Taptite cup B M3x8 LCD panel PCB ASSY Top cover 2 printed ASSY L...

Page 231: ...SSY 1 Remove the SW key A from the Top cover 2 printed ASSY Fig 5 73 2 Remove the SW key B from the Top cover 2 printed ASSY Fig 5 74 3 Remove the SW key C from the Top cover 2 printed ASSY Fig 5 75 Top cover 2 printed ASSY SW key A SW key B Top cover 2 printed ASSY SW key C Top cover 2 printed ASSY ...

Page 232: ...m Fig 5 76 5 Remove the Set key printed ASSY from the Top cover 2 printed ASSY Fig 5 77 6 Remove the Key top from the Set key printed ASSY Fig 5 78 Top cover 2 printed ASSY Set key printed ASSY Key top Set key printed ASSY Top cover 2 printed ASSY Set key printed ASSY Set key film ...

Page 233: ...NUAL Confidential 5 53 7 28 5 LCD Holder ASSY 1 Remove the LCD holder from the Top cover 2 printed ASSY Fig 5 79 2 Remove the Back light PCB ASSY from the LCD holder Fig 5 80 Top cover 2 printed ASSY LCD holder LCD holder Back light PCB ASSY ...

Page 234: ...CHAPTER 5 DISASSEMBLY AND RE ASSEMBLY Confidential 5 54 3 Remove the LCD from the LCD holder Fig 5 82 4 Remove the Back light film from the LCD holder Fig 5 83 LCD holder LCD LCD holder Back light film ...

Page 235: ...ct to the direction of 1b while pressing the three Hooks and remove the Sub duct from the Air duct Fig 5 83 2 Remove the Filter from the Air duct NOTE The filter is dirt Be careful when disassembling or assembling it Fig 5 84 Sub duct Air duct Hooks Filter Air duct Filter 1a 1b Hook Back side ...

Page 236: ...tite screws 3 Remove the Protective film 4 Pull out the flat cable from the Core 5 Remove the Laser unit NOTE Be careful not to lose the Protective film attached on the flat cable Do not touch the Laser scanner window directly Fig 5 86 Assembling Note Before assembling the Laser unit make sure put on the Core Hook Air duct Hook Hook Hook Hook Laser unit 1a 1b Taptite cup S M3x6 Taptite cup S M3x6 ...

Page 237: ...he Base plate LV 3 Remove the Screw pan S P washer M3 5x6 from the Base plate LV to remove the PS PCB unit terminal Fig 5 87 4 Remove the two bind B M4x12 Taptite screws and then remove the LV insulation sheet Fig 5 88 Base plate LV Taptite bind B M4x12 Screw pan S P washer M3 5x6 PS PCB unit terminal Taptite bind B M4x12 LV insulation sheet Taptite bind B M4x12 Back side ...

Page 238: ...rness ASSY from the SW holder 8 Press the Hooks on both sides of the Power supply switch pull out the Power supply switch to the direction of 8a and pull the wire out of the groove on the SW holder Fig 5 90 Assembling Note When assembling the power supply switch onto the SW holder give attention to the direction of the switch SW holder ASSY Fan motor 60 unit LV Taptite bind B M4x12 Frame R 6 5 Rig...

Page 239: ...fidential 5 59 9 Remove the harness of the fuser unit and power supply harness 10 Put each harness through the space where the fan 60 unit is assembled and remove the PS PCB unit 11 Remove the harness from the PS PCB unit Fig 5 91 PS PCB unit 10 11 ...

Page 240: ...e the four bind B M4x12 Taptite screws and then remove the Base plate HV Fig 5 92 2 Remove the bind B M4x12 Taptite screw and then remove the HV insulation sheet Fig 5 93 Taptite bind B M4x12 Base plate HV Taptite bind B M4x12 HV insulation sheet Pin Pin Pin Pin Taptite bind B M4x12 Front side ...

Page 241: ...Taptite screw and then remove the High voltage PS PCB ASSY 4 Disconnect the three connectors from the High voltage PS PCB ASSY Fig 5 94 Fig 5 95 Taptite bind B M4x12 High voltage PS PCB ASSY Toner LED PCB connector High voltage PS PCB ASSY PE EG sensor connector MP PE sensor connector Pins ...

Page 242: ... unit ASSY from the Frame R 2 Disconnect the two connectors from the Toner LED PCB Fig 5 96 3 Release the two Hooks to remove the LED holder from the Toner LED PCB Fig 5 97 Toner LED PCB unit ASSY Frame R Hook Hook Pins Hook Toner LED PCB LED holder Toner LED PCB Fan motor 60 unit LV connector Fan motor 60 unit connector Right side Hook ...

Page 243: ...nfidential 5 63 7 34 Fan Motor 60 Unit 1 Remove the Fan motor 60 unit from the Frame R Fig 5 98 7 35 Fan Motor 60 Unit LV 1 Remove the Fan motor 60 unit LV from the Frame R Fig 5 99 Fan motor 60 unit Frame R Fan motor 60 unit LV Frame R Right side ...

Page 244: ...rews from the Frame L 2 Remove the Frame L Fig 5 100 7 37 Frame R 1 Remove the five bind B 4x12 Taptite screws from the Frame R 2 Remove the Frame R Fig 5 101 Taptite bind B M4x12 Taptite bind B M4x12 Frame L Taptite bind B M4x12 Taptite bind B M4x12 Under bar Under bar Taptite bind B M4x12 Frame R Right side ...

Page 245: ...h nippers Fig 5 102 2 Remove the two bind B M3x8 Taptite screws 3 Lift up the back side of the MP feed frame and pull up the MP feed frame to remove Fig 5 103 Taptite bind B M3x8 Hook Hook MP feed frame 3a 3b Paper feed frame Taptite bind B M3x8 Binder Paper feed frame Cut PE EG sensor connector MP PE sensor connector ...

Page 246: ...ASSEMBLY Confidential 5 66 4 Open the MP feed frame cover Fig 5 104 5 Release the Hook to remove the Holder bearing MP from the MP feed frame Fig 5 105 5a 5b Holder bearing MP Hook MP feed frame 5c MP feed frame cover MP feed frame ...

Page 247: ...d pull it up to remove Fig 5 106 7 Turn the MP feed frame upside down 8 Slide the PE actuator MP B to the direction of 8b while pressing the Hook to the direction of 8a and pull it up to remove Fig 5 107 MP feed frame Lift arm MP MP roller holder ASSY Hook 6a 6b MP feed frame PE actuator MP B PE actuator MP Hook 8a 8b 8c ...

Page 248: ...9 Turn the PE actuator MP to the direction of 9a and pull it up to remove Fig 5 108 10 Remove the bind B M3x8 Taptite screw and then remove the MP PE sensor ASSY Fig 5 109 MP feed frame PE actuator MP MP feed frame MP PE sensor ASSY Taptite bind B M3x8 9a 9b ...

Page 249: ...1 Lift up the back of the Separation pad ASSY MP to the direction of 11a and pull up the Separation pad ASSY MP to remove Fig 5 110 12 Remove the MP separation spring from the MP frame Fig 5 111 Separation pad ASSY MP MP frame MP frame MP separation spring 11a 11b ...

Page 250: ...hat its direction is correct referring to the figure below Fig 5 112 7 39 Regist Actuator Rear Regist Actuator Spring 1 Turn the Paper feed unit upside down 2 Release the Hook A of the Actuator cover to pull up the Actuator cover to remove Fig 5 113 Actuator cover Paper feed unit Hook A Hook B Bosses MP separation spring ...

Page 251: ...he Regist actuator rear to remove Then remove the Regist actuator spring from the Regist actuator rear Fig 5 114 Assembling Note When assembling the Regist actuator spring ensure that its direction is correct referring to the figure below Fig 5 115 Paper feed unit Regist actuator rear Hook 3a 3b 3c Regist actuator spring 3d Regist actuator rear Regist actuator spring Hook Hook ...

Page 252: ...n of 1a and pull up the Regist actuator front to remove Then remove the Regist actuator spring from the Regist actuator front Fig 5 116 Assembling Note When assembling the Regist actuator spring ensure that its direction is correct referring to the figure below Fig 5 117 Regist actuator front Hook Paper feed unit 1b 1a 1c Regist actuator spring 1d Regist actuator front Regist actuator spring Hook ...

Page 253: ... 2 Slide the Roller holder ASSY to the direction of 2a Then lift up the gear side of the Roller holder ASSY to the direction of 2b and pull it out to the direction of 2c to remove Fig 5 119 Assembling Note When 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 Lift arm Roller holder...

Page 254: ...Actuator Edge Actuator Edge Actuator Spring 1 Remove the Edge actuator spring Fig 5 120 2 Release the hook and remove the Separation R shaft bearing Fig 5 121 Edge actuator Hooks Edge actuator spring Paper feed frame Separation R shaft bearing Paper feed frame Hook ...

Page 255: ...RVICE MANUAL Confidential 5 75 3 Pull out the Separation roller drive shaft to the direction of the arrow and remove the Edge actuator and PE actuator Fig 5 122 Edge actuator PE actuator Paper feed frame Separation roller drive shaft ...

Page 256: ...ove the two bind B M3x8 Taptite screws and then remove the MP frame Fig 5 123 2 Remove the bind B M3x8 Taptite screw and then remove the PE EG sensor ASSY Fig 5 124 PE EG sensor ASSY Taptite bind B M3x8 Paper feed frame Paper feed frame Taptite bind B M3x8 Taptite bind B M3x8 MP frame ...

Page 257: ...reless PCB harness 2 Remove the Wireless PCB PCB T60H929 00 ASSY 02 and Wireless PCB holder from the Frame R Fig 5 125 3 Remove the Wireless PCB PCB T60H929 00 ASSY 02 from the Wireless PCB holder Fig 5 126 Frame R Hook Wireless PCB harness Wireless PCB PCB T60H929 00 ASSY 02 Wireless PCB holder Hook Wireless PCB PCB T60H929 00 ASSY 02 Wireless PCB holder ...

Page 258: ...er Tray 1 Pull out the Paper tray from the LT 5300 Fig 5 127 2 Pull up the back side of the Separation pad ASSY 3 Push the Hooks provided on both sides of the Separation pad ASSY inwards 4 Pull up the Separation pad ASSY Fig 5 128 Paper tray Separation pad ASSY Paper tray Hooks 3 3 2 4 Hook Hook ...

Page 259: ...0DW SERVICE MANUAL Confidential 5 79 5 Remove the Separation pad spring Fig 5 129 6 Remove the Lift gear 46 Fig 5 130 Separation pad spring Paper tray Paper tray Lift gear 46 Hook Hook Lift gear 46 Plate up plate Plate up plate ...

Page 260: ...CHAPTER 5 DISASSEMBLY AND RE ASSEMBLY Confidential 5 80 7 Remove the Gear 21 16 Fig 5 131 8 Remove the Gear 15 Fig 5 132 Paper tray Gear 21 16 Paper tray Gear 15 ...

Page 261: ...Y 1 Remove the two bind B M4x12 Taptite screws 2 Remove the LT front cover ASSY Fig 5 133 3 Remove the LT front paper guide from the LT front cover ASSY while pulling the two hooks inwards Fig 5 134 LT front cover ASSY Taptite bind B M4x12 LT front cover ASSY LT front paper guide Hooks ...

Page 262: ...r Fig 5 135 8 4 LT Side Cover L 1 Remove the bind B M4x12 Taptite screw 2 Remove the cup S M3x6 Taptite SR screw 3 Release the Hooks in the order of the arrows and remove the LT side cover L Fig 5 136 Taptite cup S M3x6 SR LT rear cover Taptite cup S M3x6 SR Taptite bind B M4x12 LT side cover L Hooks Hooks 3d 3a 3b 3c 3e Boss Back side Left side ...

Page 263: ...e Cover R 1 Remove the bind B M4x12 Taptite screw 2 Remove the cup S M3x6 Taptite SR screw 3 Release the Hooks in the order of the arrows and remove the LT side cover R Fig 5 137 Taptite bind B M4x12 Taptite cup S M3x6 SR LT side cover R Hooks Boss 3d 3b 3a 3e 3c Right side ...

Page 264: ...ctors from the LT PCB ASSY 2 Remove the bind B M4x12 Taptite screw and then remove the LT PCB ASSY Fig 5 138 Hook Taptite bind B M4x12 LT PCB ASSY LT sensor PCB connector LT sensor harness ASSY 1 connector LT PCB ASSY LT solenoid connector LT sensor harness ASSY 2 connector LT frame L Left side ...

Page 265: ... Connector 55533 1219 while pressing the Hooks inwards Fig 5 139 8 8 Connector 54702 1219 1 Remove the LT sensor harness ASSY 2 from the Connector 54702 1219 2 Disconnect the Connector 54702 1219 while pressing the Hooks inwards Fig 5 140 Connector 55533 1219 Hook Hook LT sensor harness ASSY 1 LT frame L LT sensor harness ASSY 2 LT frame L Connector 54702 1219 Hook Hook ...

Page 266: ...at the LT frame L is at the top 2 Release the Hook to remove the Gear 20 T1 roller drive from the LT frame L Fig 5 141 3 Remove the Retaining ring E4 4 Remove the Gear 24 LT from the LT frame L Fig 5 142 LT frame L LT frame L Gear 20 T1 roller drive Hook Retaining ring E4 Gear 24 LT Left side ...

Page 267: ... Collar 6 1 Remove the Gear plate ground spring from the LT frame L Fig 5 143 2 Remove the cup S M3x6 Taptite SR screw and then remove the Feed roller ground plate Fig 5 144 LT frame L Gear plate ground spring Taptite cup S M3x6 SR LT frame L Feed roller ground plate ...

Page 268: ... spring LT from the LT frame L Fig 5 145 Assembling Note When assembling the T1 sector gear spring LT ensure that its direction is correct referring to the figure below Fig 5 146 LT frame L T1 sector gear spring LT LT drive unit T1 sector gear T1 sector gear spring LT LT frame L Hook ...

Page 269: ... LT drive unit Fig 5 147 5 Remove the cup S M3x6 Taptite screw 6 Remove the four bind B M4x12 Taptite screws and then remove the LT drive unit Fig 5 148 LT frame L Taptite bind B M4x12 Taptite cup S M3x6 Taptite bind B M4x12 LT drive unit Ground wire top LT drive unit LT solenoid harness Hooks Hooks LT solenoid ASSY ...

Page 270: ...h spring from the LT drive unit Fig 5 149 8 Remove the Collar 6 9 Remove the Clutch arm ASSY from the LT drive unit Fig 5 150 10 Remove the Collar 6 from the Clutch arm ASSY Fig 5 151 LT drive unit Clutch spring LT drive unit Collar 6 Clutch arm ASSY Collar 6 Clutch arm ASSY ...

Page 271: ... 5 91 8 11 LT Solenoid ASSY 1 Remove the bind B M3x10 Taptite screw and then remove the LT solenoid ASSY 2 Remove the Solenoid release spring P R from the LT solenoid ASSY Fig 5 152 Taptite bind B M3x10 LT frame L Solenoid release spring P R LT solenoid ASSY ...

Page 272: ...he Roller holder ASSY to the direction of the arrow 2a Then lift up the gear side of the Roller holder ASSY to the direction of the arrow 2b and pull it out to the direction of the arrow 2c to remove Fig 5 154 Assembling Note When 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 Lift arm LT paper feed frame Pin Rolle...

Page 273: ...HL 5240 5250DN 5270DN 5280DW SERVICE MANUAL Confidential 5 93 8 13 Edge Actuator Spring 1 Remove the Edge actuator spring Fig 5 155 LT paper feed frame Edge actuator spring Hooks Edge actuator ...

Page 274: ...nd remove the Separation R shaft bearing Fig 5 156 2 Pull out the Separation roller drive shaft to the direction of the arrow and remove the Edge actuator and PE actuator Fig 5 157 PE actuator Edge actuator Separation roller drive shaft LT paper feed frame Separation R shaft bearing LT paper feed frame Hook ...

Page 275: ...he four cup S M3x6 Taptite SR screws and then remove the LT frame L Fig 5 158 3 Remove the two cup S M3x6 Taptite SR screws and then remove the LT paper feed frame Fig 5 159 Taptite cup S M3x6 SR LT frame R LT frame L Taptite cup S M3x6 SR Taptite cup S M3x6 SR Taptite bind B M4x12 Taptite bind B M4x12 Under bar Under bar LT paper feed frame ...

Page 276: ...o cup B M3x12 Taptite screws and then remove the LT front beam Fig 5 160 5 Remove the bind B M3x8 Taptite screw and then remove the LT sensor PCB ASSY Fig 5 161 Taptite cup B M3x12 LT paper feed frame LT front beam Taptite bind B M3x8 LT paper feed frame LT sensor PCB ASSY ...

Page 277: ...h ROM x 1 4 Mbyte Flash ROM x 1 HL 5280DW 8 Mbyte Flash ROM x 1 4 Mbyte Flash ROM x 1 What to do when replacing the main PCB Rewriting the firmware ROM of the printer Setting the default paper size Setting the serial number Which part to use for the operation HL 5240 MAIN PCB ASSY 5240 FW MAIN CONTROLLER AL HL 5240L MAIN PCB ASSY 5240L FW MAIN CONTROLLER 5240L HL 5250DN MAIN PCB ASSY 5250 FW MAIN ...

Page 278: ...re Alphabet representing the revision of the firmware 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 Extract this file to set the default paper size 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 Copy i...

Page 279: ...onnected 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 The printer goes back to the normal mode automat...

Page 280: ...SETTINGS REQUIRED AFTER PARTS REPLACEMENT Confidential 6 4 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 ...

Page 281: ... 5240 5250DN 5270DN 5280DW SERVICE MANUAL Confidential 6 5 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 ...

Page 282: ...matically when the printer remains no operation while the Status LED is lighting 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 t...

Page 283: ... 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...

Page 284: ...et 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 th...

Page 285: ... 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 ...

Page 286: ...e 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 ...

Page 287: ...ANUAL Confidential 6 11 10 Select Input Information from Menu 11 Select the applicable model name And check the port USB that the printer is connected through 12 Select the item of each periodical maintenance parts and check ON and click OK ...

Page 288: ...set Laser Counter Paper feeding kit for Tray 1 Reset PF Kit 1 Counter Paper feeding kit for Tray 2 Reset PF Kit 2 Counter Paper feeding kit for Tray 3 Reset PF Kit 3 Counter Paper feeding kit for MP tray Reset PF Kit MP Counter After resetting any of counts print the Print Settings to make sure a bar graph indicating the remaining life of each periodical maintenance parts full up ...

Page 289: ...t 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 the Data LED is off 5 Press the Go button If the Go button is pressed the Data LED is lighted If the Go button is released the LED is out Press the Go button Each mode starts after 2 seconds Once 1 Test Sam...

Page 290: ...a as hexadecimal code To exit from this mode you have to turn off the printer 4 PCB ONLY Mode Even when the engine error occurs and PCB exchange is required for recovery the printer can be started ignoring the engine error if this mode is used NVRAM data can be obtained 5 1push Printing Recovery Mode Demo page print is possible by pressing Go button after the power supply is turned on 6 Network Fa...

Page 291: ... 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 abo...

Page 292: ...Density transition Bias voltage Print density Toner empty Used toner amount Dark Light Bias voltage when replacing with a new toner cartridge Density when replacing with a new toner cartridge Bias voltage when replacing with a used toner cartridge Density when replacing with a used toner cartridge In such a case follow the steps below in order to initialize the developing bias forcedly Standard Ca...

Page 293: ...ner Drum Paper LEDs are lighted 7 2 nd 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 the Data L...

Page 294: ...s to the ready status Five times 12 Developer Roller Counter Reset 1 For the standard toner All LEDs are lit for 1 second and the printer returns to the ready status Six times 13 Developer Roller Counter Reset 2 For the high capacity toner All LEDs are lit for 1 second and the printer returns to the ready status Seven times 14 Fixed USB Speed All LEDs are lit for 1 second and the printer returns t...

Page 295: ...s 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 whi...

Page 296: ...id pattern prints is displayed at the same time The machine does not go back to the ready state unless the power is turned off and on To finish the continuous grid pattern print mode press the Job Cancel button 3 Fuser unit Test Print This is to print the following three patterns to check the fuser unit Grid pattern with a serial number on it Gray pattern Black pattern When this operation is compl...

Page 297: ...ON OFF Switching This is to switch ON ShortBind or OFF LongBind invalid for some models of the duplex setting Whenever switching the setting the current setting is changed to the other one 8 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 replaceme...

Page 298: ...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 C...

Page 299: ...HL 5240 5250DN 5270DN 5280DW SERVICE MANUAL Confidential 7 11 ...

Page 300: ...eparated 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 Dru...

Page 301: ... 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 model...

Page 302: ...tion is completed 12 Developer Roller Counter Reset 1 For the standard toner 13 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 T...

Page 303: ...inting Version Check Hex Dump Mode Set Initializing the NVRAM Pressing the 2 button when the printer is turned ON Panel Function Set Back Rewriting the Flash ROM Go Checking the hardware DRAM check etc Go Back Factory Line Inspection Mode Go Set Clearing the E50 FUSERMULF Pressing the 2 button in the normal status Panel Function Go RESET PARTS LIFE Clearing the counters of the periodical replaceme...

Page 304: ...itches To go back to a higher level select the exit menu in the same level using the switches How to input a Value or set for a Professional Menu Mode Enter the required mode as explained above The setting appearing on the display is the current setting Select the required setting using the switches then press the Set switch The previous value remains if the Set switch is not pressed How to exit t...

Page 305: ...the last two digits SECONDARY FONT SET ID Saves the current secondary fonts in LaserJet emulation into the storage devices ROM Disk After fixing the first three digits with the Set button set the last two digits DOWNLOAD FONT DOWNLOAD Saves the downloaded fonts in LaserJet emulation into the storage devices ROM Disk After fixing the first three digits with the Set button set the last two digits SA...

Page 306: ...n the FX or XL emulation W BOLD ON OFF W BOLD ON Converts into bold if the same character is entered into the same position in the FX or XL emulation The print speed is lowered DLFNT Bd It NO Creates the bold and italic letters from the download font DLFNT Bd It DLFNT Bd It YES Does not create the bold and italic letters from the download font B PROD ON Creates the bold and italic letters from the...

Page 307: ...cted ITA OBLIQUE Makes upright font oblique to have italic as scalable font is selected FX XL SCALE ITA Setting related to italic of scalable font when the EPSON IBM emulation ITA ITALIC SEL Uses the upright font to have italic as scalable font is selected DEF PAPER A4 Printers to be shipped to the other area than USA and Canada have the A4 size setting by default PAPER TRAY SIZE DEF PAPER LT Prin...

Page 308: ...UP NOMAL Deletes all white pages having no data DPX FF SUP MODE DPX SUP SPEC Deletes only the page that both sides of paper is white PS300RESO NO Does not reduce the resolution automatically PS300RESO IF 2M Reduces the resolution to 300dpi when the total memory is 2Mbytes PS300RESO PS300RESO FORCE Reduces the resolution to 300dpi COPY PAGES ON COPY PAGES COPY PAGES OFF OFF 1 page is fixed for the ...

Page 309: ... disabled for the next job POWER SAVE ON POWER SAVE POWER SAVE OFF Implements the power save setting It is not allowed to set the power save setting to OFF on the panel When the setting to OFF the power save time is not displayed on the panel TONERLOW ON Checks toner with the duty level of 2 Default TONERLOW DELAY Checks toner with the duty level of 8 TONER LOW Changes the timing when the toner lo...

Page 310: ...t data T3 FIX PLAIN Fixes the media of Tray3 to plain paper T3 FIX TRANS Fixes the media of Tray3 to transparencies T3 FIX THIN Fixes the media of Tray3 to thin paper T3 FIX BOND Fixes the media of Tray3 to bond paper 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 a...

Page 311: ...he same time until the menu RESET PARTS LIFE appears on the LCD display Select the required item part name using the switches then press the Set switch Function Table Title Item to be Set Description DRUM UNIT Initializes the drum unit remaining life PF KITMP Initializes the paper feeding kit MP remaining life PF KIT 1 Initializes the paper feeding kit 1 remaining life PF KIT 2 Initializes the pap...

Page 312: ...e Go button How to access the Required Menu Use either or switch to scroll through the menu listing To select an item press the Set switch Then the sub menu will appear Scroll through the sub menu items using the switches To go back to a higher level press the Back button How to exit the Service Menu There are two options to exit the Professional Menu mode either to press Go switch at any sub menu...

Page 313: ...ray1 Tray2 Tray3 FUSER UNIT Displays the number of the fuser unit replacement LASER UNIT Displays the number of the laser unit replacement COVERAGE Displays the average coverage when printing Letter size paper at 100 print coverage PRINT PAGES A4 LTR PAGE LGL A4LONG PAGE B5 EXE PAGE ENVELOPE PAGE A5 PAGE SERVICE INFO OTHER PAGE Displays the number of pages when printing each paper size PRINT PAGES...

Page 314: ...number of the drum unit replacement PF KIT MP PF KIT 1 PF KIT 2 PF KIT 3 Displays the number of the PF kit replacement PF kit MP 1 2 3 PF kit for MP Tray Tray1 Tray 2 Tray 3 FUSER UNIT Displays the number of the fuser unit replacement LASER UNIT Displays the number of the laser unit replacement REMAIN LIFE DRUM UNIT Displays the drum unit remaining life counters page DRUM UNIT2 Displays the drum u...

Page 315: ...movement test of scanner motor SENSOR TEST FRONT COVER ON OFF Front cover sensor ON Close T1 KOUTAN ON OFF T1 tail edge sensor T2 KOUTAN ON OFF T2 tail edge sensor T3 KOUTAN ON OFF T3 tail edge sensor REGI MAE ON OFF Regist front sensor REGI ATO ON OFF Regist rear sensor EJECT ON OFF Paper eject sensor T1 PAPER ON OFF Tray 1 paper sensor T2 PAPER ON OFF Tray 2 paper sensor T3 PAPER ON OFF Tray 3 p...

Page 316: ...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 ...

Page 317: ...ges Standard cartridge 7 000 pages High yield cartridge are printed It is switched to 400V again when the toner cartridge is replaced with the new one Counted from the number of the drum rotation in non continuous printing Fixing temperature Transparency 185 C Thin paper 195 C Plain paper 213 C Thick paper 200 C Thicker Bond paper 200 C in non continuous printing Smaller size mode Refer to 3 8 PRI...

Page 318: ...OL 5 5D LT1_SOL R240 100 5 4C PNLLED3 5 4C PNLLED4 5 2C GRIDC 5 6C PWM_TNRSEN U6 UPD800268F1 011 MN9 A AI0 BD_SMP W18 AI1 Y18 AI2 Y17 AI3 FB_VCLN W17 AI4 FB_DEV W16 AI5 FB_GRID Y16 AI6 W15 AI7 FB_TR Y15 TSTMODEN W5 TSTCLK Y5 TMC1 Y7 TMC2 W7 TEN T18 TAPC_NWIRE_SEL V13 THMODE W14 NOTAP_TEST_SEL W13 BUNRI L16 GND_J9 J9 GND_K9 K9 GND_L9 L9 GND_M9 M9 GND_M10 M10 GND_M11 M11 GND_M12 M12 GND_L12 L12 GND_...

Page 319: ...62 137 DQ31 138 DQ63 139 VSS 140 VSS 141 SDA DMM3 RS144A2B 13 142 SCL 143 VDD 144 VDD 145 FG DMM3 RS144A2B 13 146 FG C130 C104 C128 C104 C141 C104 C127 C104 C137 C104 C136 C104 C126 C104 C125 C104 C140 C104 C123 C104 C135 C104 C122 C104 C134 C104 C121 C104 C133 C104 1 3D 3B SD_BA0 1 3E 3B SD_BA1 1 3D SD_CS1_N 1 3D SD_CS2_N 1 3D 3B SD_RAS_N 1 3D 3B SD_CAS_N 1 3D 3B SD_WE_N 1 3D SD_CLK1 1 3D SD_CLK2...

Page 320: ...43 10k R93 10k R39 10k R85 10k R305 10k R40 10k R76 10k R44 10k R87 10k R46 10k R36 10k R37 10k R48 10k R277 10k R304 10k R81 10k R86 10k R88 10k R306 10k C54 C103 C55 C103 TP301 1 1A 2A 5A RESET_N TP356 TP414 TP431 TP402 TP426 TP421 TP398 TP420 TP423 TP418 TP427 TP401 TP429 TP415 TP430 TP400 TP425 TP417 TP422 TP408 TP375 TP416 TP419 TP428 TP310 TP305 TP304 TP348 TP344 TP303 TP309 TP350 TP308 TP34...

Page 321: ...G_RST 1 4F JTAG_DI 1 5F JTAG_DO 1 5F NTRC_CLK 1 5F NTRC_END 3 3V R270 4 7k R132 10k 3 3V SGND 1 4F JTAG_RMODE BKTGIO 3 3V R119 10k ZD3 UDZS6 8B R188 0 FG1 R126 0 SGND 7 2 RA10 0 8 1 5 4 6 3 6 3 7 2 RA9 0 8 1 5 4 RA6 0 8 1 7 2 6 3 5 4 5 4 6 3 7 2 RA1 0 8 1 RA27 33 8 1 7 2 6 3 5 4 RA24 100 8 1 7 2 6 3 5 4 6 3 5 4 RA31 100 8 1 7 2 7 2 RA28 100 8 1 5 4 6 3 RA20 1 5k 8 1 7 2 6 3 5 4 RA21 1 5k 8 1 7 2 5...

Page 322: ...C102 R194 100 1 7A LD_MON TP31 R67 33 1 2W 10mm pitch R278 1k R286 10k ZD1 BZX85 C11 PITCH 15 TP365 TP364 TP366 1 6B FAN_PS_12V TP394 R68 10k R69 1k 1 6B FAN_PS_24V IMSA 9615S 23A PP 2 FAN_PS C18 C102 1608 TP412 1 1F LT_DET3 C220 C169 C103 C12 C103 5A COVER VDD5I C163 C103 TP3 L10 0 1608 TP123 Q8 DTC114YUA C B E R169 68k 3 3V 3 3V 3 3V 3 3V 3 3V 3 3V 3 3V 3 3V 3 3V 3 3V 3 3V 3 3V 5 0V 8 0V 5 0V 24...

Page 323: ...V 40 SGND 5 0V 5 0V R144 10k 3 3V U2 RQ5RW33B VDD 2 CE 4 VOUT 3 GND 1 R129 100k SGND R110 100k SGND TP206 TP204 TP200 TP203 TP199 TP201 TP202 TP5 TP363 TP362 TP361 TP336 TP337 TP335 TP152 TP154 TP103 TP105 TP102 TP104 TP297 TP263 TP262 TP212 U5 TB6577FG HA1 13 HA1 12 HB1 15 HB1 14 HC1 17 HC1 16 CW CCW 25 LP1_1 21 LP1_2 22 HA2 31 HA2 30 HB2 33 HB2 32 HC2 35 HC2 34 FG2 2 LP2_1 4 LP2_2 5 VDD1 1 VDD36...

Page 324: ...R 2 SGND TP813 RA802 33 7 2 1 FG SGND TP804 U801 R5520H001A T1 FB IN 4 EN 1 GND 2 OUT 5 FLG 3 C802 C103 TP823 C811 C106 2125 TP819 TP841 3 3V TP828 8 1 R807 100 R803 100 R822 22 TP842 TP845 5 4 R810 100 SGND C807 C27P TP847 TP812 TP807 3 3V R817 10k SGND U800 ISP1362BD CS 21 RD 20 WR 22 RESET 32 INT1 30 INT2 31 D0 63 D1 64 D2 2 D3 3 D4 5 D5 6 D6 7 D7 8 D8 10 D9 11 D10 12 D11 13 D12 15 D13 16 D14 1...

Page 325: ...APPENDIX Confidential A 8 Low voltage PS Circuit 100V D B A C E F E D B A C F 1 1 2 3 4 6 7 8 2 3 4 5 6 7 8 5 Appendix 2 Low voltage Power Supply PCB Circuit Diagram 100V NAME ...

Page 326: ...240 5250DN 5270DN 5280DW SERVICE MANUAL A 9 Confidential Low voltage PS Circuit 200V D B A C E F E D B A C F 1 1 2 3 4 6 7 8 2 3 4 5 6 7 8 5 Appendix 2 Low voltage Power Supply PCB Circuit Diagram 200V NAME ...

Page 327: ...APPENDIX Confidential A 10 D B A C E F E D B A C F 1 1 2 3 4 6 7 8 2 3 4 5 6 7 8 5 Appendix 3 High Voltage Power Supply Circuit Diagram NAME High Voltage PS Circuit ...

Page 328: ...ND 5VI FB_GRID LT_DET2 FAN_MAIN MP_PE_SEN PEDG_SEN TNRLED HU REG_REAR_SEN HV HU HV 5V S0V U U V W HU HU HV HV HW HW 5V S0V U U V V W W FG FG HL5280DW only USB CN7 DIMM RELAY_ REAR 4 3 6 5 2 1 SWI GND LED0 PNLRST 5VI 8 7 CN17 10 9 6 5 DX_SOL PANEL FG GND DATA DATA 5V FG 4 3 CN800 6 5 2 1 WIRELESS LAN CN2 12 6 5 4 7 3 2 1 LT OPTION CN8 8 6 5 4 7 3 2 1 22 18 17 16 19 15 14 13 21 20 12 8 7 6 9 5 4 3 1...

Page 329: ...LUM LM5054001 REGISTOR GEAR 19 PLANETARY LM5056001 FEEDER GEAR 21 31 PENDULUM LM5057001 FEEDER GEAR 48 LM5050001 DX GEAR 27 68 L LM5023001 P P GEAR 29 CLUTCH CAM LM5071001 T1 GEAR 50 45 SECTOR LM5070001 T1 GEAR 31 47 LM5460001 P P DIFFERENTIAL LM5028001 P P GEAR 147 37 INTERNAL LM5027001 P P GEAR 15 PLANETARY LM5026001 P P GEAR 32CARRIER LM5025001 P P GEAR 17 CENTER LM5053001 REGISTER GEAR 48 CARR...

Page 330: ... EJECT GEAR 28 SECTOR LM5461001 REGISTER DIFFERENTIAL LM5025001 P P GEAR 17 CENTER LM5026001 P P GEAR 32CARRIER LM5027001 P P GEAR 15 PLANETARY LM5028001 P P GEAR 147 37 INTERNAL LM5055001 REGISTER GEAR 159 43 INTERNAL LM5054001 REGISTOR GEAR 19 PLANETARY LM5052001 REGISTER GEAR 21 CENTER LM5053001 REGISTER GEAR 48 CARRIER LM5065001 MP GEAR 55 60 SECTOR LM5056001 FEEDER GEAR 21 31 PENDULUM LM50570...

Page 331: ...Refer to 2 1 2 Operator calls for HL 5270DN 5280DW Chapter 4 3 Reset parts life HL 5240 5250DN Refer to 2 IF YOU REPLACE THE PERIODICAL MAINTENANCE PARTS Chapter 6 HL 5270DN 5280DW Refer to 2 2 Reset Parts Life Menu Chapter 7 4 Paper specification Refer to 3 6 Paper Chapter 1 5 Machine specification Refer to 3 SPECIFICATIONS Chapter 1 6 Diameter of rollers Refer to 6 2 Diameter of Rollers Chapter ...

Page 332: ...y in order to comply with the EMI Electromagnetic interface standard when assembling Refer to the following chart as well to know the necessary ferrite core depending on models RELAY FRONT HARNESS AL FERRITE CORE 16X9X5X0 5 FERRITE CORE 16X9X5X0 5 LD HARNESS AL CORE 23 8X15X6 3X 1 1 Polygon Motor FFC FERRITE CORE 26 0X9 5X5 0X1 2 Main Motor FFC 1 2 3 4 ...

Page 333: ...LF HL 5240 KOR HL 5240 IND HL 5240 RUS HL 5240 PAN NORDIC HL 5240 BEL FRA NL HL 5240 EEU GENERAL HL 5240 MOF BEL HL 5240 CONSIP ITA HL 5250DN US HL 5250DN CAN HL 5250DN GER HL 5250DN UK HL 5250DN ARL HL 5250DN SWI HL 5250DN SPA POR HL 5250DN ITA HL 5250DN ISR HL 5250DN CHN HL 5250DN PHL HL 5250DN SAF HL 5250DN SGP GULF HL 5250DN IND HL 5250DN RUS HL 5250DN PAN NORDIC HL 5250DN BEL FRA NL HL 5250DN...

Page 334: ...N GER HL 5270DN UK HL 5270DN ARL HL 5270DN SWI HL 5270DN SPA POR HL 5270DN ITA HL 5270DN ISR HL 5270DN PHL HL 5270DN SAF HL 5270DN SGP GULF HL 5270DN RUS HL 5270DN PAN NORDIC HL 5270DN BEL FRA NL HL 5270DN EEU GENERAL HL 5280DW US HL 5280DW CAN HL 5280DW GER HL 5280DW UK HL 5280DW SWI HL 5280DW GENERAL HL 5280DW PAN NORDIC HL 5250DNT US ...

Page 335: ...pages A4 5 coverage 1 From the standard paper tray and optional paper tray 2 2 The toner cartridge supplied with the HL 5240 is able to print approx 3 500 A4 pages at 5 coverage Print Speeds with Various Settings A4 Letter size Media type setting HL 5240L Transparency Thin Paper 24 ppm Plain Paper Recycled Paper 24 ppm Thick Paper Envelopes Env Thin 14 ppm Thicker Bond Paper Env Thick 3 ppm Smalle...

Page 336: ...of A4 printing HL 5240L Starter 2 0K toner Page job 1 2 3 4 5 6 7 8 9 10 11 12 Cartridge life 2 400 3 616 4 352 4 844 5 197 5 462 5 669 5 834 5 970 6 083 6 179 6 261 Cartridge life ON OFF 1 320 2 237 2 912 3 429 3 837 4 168 4 442 4 673 4 869 5 038 5 186 5 315 Toner empty 5 2 000 2 000 2 000 2 000 2 000 2 000 2 000 2 000 2 000 2 000 2 000 2 000 Toner empty 4 2 500 2 500 2 500 2 500 2 500 2 500 2 50...

Page 337: ...r 7 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 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 Press the ...

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