Brother HL 1240 - B/W Laser Printer, HL-1240, HL-1250 Service Manual

© Copyright Brother 1999
All rights reserved.
No part of this publication may be reproduced in any form or by any means without permission

in writing from the publisher.
Specifications are subject to change without notice.

Trademarks:
The brother logo is a registered trademark of Brother Industries, Ltd.
Apple, the Apple Logo, and Macintosh are trademarks, registered in the United States and

other countries, and True Type is a trademark of Apple computer, Inc.
Epson is a registered trademark and FX-80 and FX-850 are trademarks of Seiko Epson

Corporation.
Hewlett Packard is a registered trademark and HP Laser Jet is a trademark of Hewlett Packard

Company.
IBM, IBM PC and Proprinter are registered trademarks of International Business Machines

Corporation.
Microsoft and MS-DOS are registered trademarks of Microsoft Corporation.
Windows is a registered trademark of Microsoft Corporation in the U.S. and other countries.

PREFACE

i

PREFACE

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

This service manual covers the HL-1240/1250 printers.
This manual consists of the following chapters:

CHAPTER 1: GENERAL

Features, specifications, etc.

CHAPTER 2: INSTALLATION AND BASIC OPERATION

Installation conditions, Installation procedures, basic operation of the printer
etc.

CHAPTER 3: THEORY OF OPERATION

Basic operation of the mechanical system, the electrical system and the
electrical circuits and their timing information.

CHAPTER 4: DISASSEMBLY AND RE-ASSEMBLY

Procedures for disassembling and re-assembling the mechanical system.

CHAPTER 5: MAINTENANCE

Periodical replacements parts, consumable parts, etc.

CHAPTER 6: TROUBLESHOOTING

Reference values and adjustments, troubleshooting image defects,
troubleshooting malfunctions, etc.

APPENDICES :

Serial No. descriptions, Drum life & page counter, Diameter / circumference
of rollers, Connection diagrams, PCB circuit diagrams, etc.

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

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

TABLE OF CONTENTS

ii

TABLE OF CONTENTS

REGULATION .............................................................................................vii

SAFETY INFORMATION .............................................................................ix

CHAPTER 1 GENERAL...........................................................................1-1

1. FEATURES..............................................................................................................1-1

2. OVERVIEW .............................................................................................................1-3

3. SPECIFICATIONS...................................................................................................1-4

3.1 Printing..............................................................................................................................1-4

3.2 Functions ..........................................................................................................................1-4

3.3 Electrical and Mechanical.................................................................................................1-5

3.4 Paper ................................................................................................................................1-6

3.4.1 Feedable paper................................................................................................................... 1-6

3.4.2 Paper cassette capacity......................................................................................................1-7

3.4.3 Print delivery....................................................................................................................... 1-8

3.5 Printing Area.....................................................................................................................1-8

3.5.1 Effective printing area.........................................................................................................1-8

3.5.2 Print guaranteed area......................................................................................................... 1-9

CHAPTER 2 INSTALLATION AND BASIC OPERATION.......................2-1

1. CONDITIONS REQUIRED FOR INSTALLATION....................................................2-1

1.1 Power Supply....................................................................................................................2-1

1.2 Environment......................................................................................................................2-1

1.3 System Requirements for Brother Printer Solution for Windows

®

.....................................2-1

2. UNPACKING ...........................................................................................................2-2

3. INSTALL THE PRINTER..........................................................................................2-3

3.1 For Windows® Users.........................................................................................................2-3

3.2 For Windows

®

Users with No CD-ROM Drive...................................................................2-5

3.2.1 Install the drum unit............................................................................................................. 2-5

3.2.2 Load paper.......................................................................................................................... 2-5

3.2.3 Print a test page.................................................................................................................. 2-5

3.2.4 Connect the printer and the computer ................................................................................2-6

3.2.5 Install the printer driver from floppy disk............................................................................. 2-6

3.3 Using the USB Interface (For Windows® 98 only).............................................................2-7

3.3.1 Connect the USB interface cable........................................................................................ 2-7

3.3.2 Install the USB driver.......................................................................................................... 2-7

3.3.3 Set the PC printer port ........................................................................................................ 2-9

3.4 For Macintosh (iMac and Power Macintosh) with USB Users Only..................................2-9

4. PAPER HANDLING ...............................................................................................2-10

4.1 Load Paper into the Paper Cassette...............................................................................2-10

4.2 Load Paper Manually......................................................................................................2-10

TABLE OF CONTENTS

iii

4.3 Two Side Printing (Manual Duplexing)............................................................................2-11

4.3.1 To print on both sides of the paper from the paper cassette ............................................ 2-11

4.3.2 To print on both sides of the paper from the manual feed slot..........................................2-12

5. CONTROL PANEL OPERATION...........................................................................2-13

5.1 Ready (Paper) LED Indications ......................................................................................2-13

5.2 Data (Toner) LED Indications .........................................................................................2-14

5.3 Drum LED Indications.....................................................................................................2-14

5.4 Alarm LED Indications ....................................................................................................2-14

5.5 Control Panel Button Operations....................................................................................2-15

5.6 Other Control Features...................................................................................................2-15

5.6.1 Sleep mode................................ ....................................................................................... 2-15

5.6.2 Test print mode.................................................................................................................2-16

CHAPTER 3 THEORY OF OPERATION.................................................3-1

1. ELECTRONICS .......................................................................................................3-1

1.1 General Block Diagram.....................................................................................................3-1

1.2 Main PCB Block Diagram .................................................................................................3-3

1.3 Main PCB..........................................................................................................................3-5

1.3.1 ASIC.................................................................................................................................... 3-5

1.3.2 ROM.................................................................................................................................... 3-8

1.3.3 DRAM..................................................................................................................................3-9

1.3.4 Optional RAM....................................................................................................................3-11

1.3.5 Optional serial I/O............................................................................................................. 3-12

1.3.6 EEPROM........................................................................................................................... 3-12

1.3.7 Reset circuit...................................................................................................................... 3-13

1.3.8 Engine I/O......................................................................................................................... 3-14

1.4 Engine PCB ....................................................................................................................3-14

1.5 Power Supply..................................................................................................................3-15

1.5.1 Low-voltage Power Supply ............................................................................................... 3-15

1.5.2 High-voltage Power Supply............................................................................................... 3-16

2. MECHANICS .........................................................................................................3-17

2.1 Overview of Printing Mechanism ....................................................................................3-17

2.2 Paper Transfer................................................................................................................3-19

2.2.1 Paper supply.....................................................................................................................3-19

2.2.2 Paper registration.............................................................................................................. 3-19

2.2.3 Paper eject........................................................................................................................ 3-20

2.3 Sensors...........................................................................................................................3-20

2.3.1 Cover sensors A and B.....................................................................................................3-20

2.3.2 Toner sensor..................................................................................................................... 3-21

2.4 Drum Unit........................................................................................................................3-21

2.4.1 Photosensitive drum .........................................................................................................3-21

2.4.2 Primary charger ................................................................................................................3-21

2.4.3 Transfer roller.................................................................................................................... 3-21

2.4.5 Cleaner ............................................................................................................................. 3-21

2.5 Toner Cartridge...............................................................................................................3-21

2.6 Print Process...................................................................................................................3-22

2.6.1 Charging ........................................................................................................................... 3-22

TABLE OF CONTENTS

iv

2.6.2 Exposure stage.................................................................................................................3-22

2.6.3 Developing........................................................................................................................ 3-23

2.6.4 Transfer............................................................................................................................. 3-24

2.6.5 Fixing stage................................ ....................................................................................... 3-24

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY ..............................4-1

1. SAFETY PRECAUTIONS ........................................................................................4-1

2. DISASSEMBLY FLOW ............................................................................................4-2

3. DISASSEMBLY PROCEDURE................................................................................4-3

3.1 AC Cord............................................................................................................................4-3

3.2 Drum Unit..........................................................................................................................4-3

3.3 Paper Cassette.................................................................................................................4-4

3.4 Front Cover.....................................................................................................................4-10

3.5 Top Cover.......................................................................................................................4-11

3.6 Main Cover......................................................................................................................4-12

3.7 Laser Unit........................................................................................................................4-13

3.8 Drive Unit........................................................................................................................4-14

3.9 Fixing Unit.......................................................................................................................4-17

3.10 Base Plate.......................................................................................................................4-25

3.11 Main PCB ASSY.............................................................................................................4-26

3.12 Lower Tray Relay PCB ASSY (HL-1250 only)................................................................4-26

3.13 Low-voltage Power Supply PCB ASSY ..........................................................................4-27

3.14 Engine PCB ASSY / High-voltage Power Supply PCB ASSY ........................................4-28

3.15 Panel PCB ASSY............................................................................................................4-30

3.16 Solenoid ASSY ...............................................................................................................4-30

3.17 Fan Motor ASSY.............................................................................................................4-33

3.18 Toner Sensor PCB ASSY (Light Emission) ....................................................................4-34

3.19 Toner Sensor PCB ASSY (Light Reception)...................................................................4-34

3.20 Paper Pick-up Roller ASSY ............................................................................................4-35

3.21 Paper Feed Roller ASSY................................................................................................4-36

4. PACKING ..............................................................................................................4-37

CHAPTER 5 PERIODIC MAINTENANCE ...............................................5-1

1. CONSUMABLE PARTS...........................................................................................5-1

1.1 Drum Unit..........................................................................................................................5-1

1.2 Toner Cartridge.................................................................................................................5-2

2. PERIODICAL REPLACEMENT PARTS...................................................................5-4

3. PERIODICAL CLEANING........................................................................................5-5

3.1 Cleaning the Printer Exterior.............................................................................................5-5

3.2 Cleaning the Drum Unit.....................................................................................................5-5

3.3 Cleaning the Scanner Window..........................................................................................5-6

3.4 Cleaning the Electrical Terminals .....................................................................................5-6

4. MTBF / MTTR..........................................................................................................5-7

TABLE OF CONTENTS

v

CHAPTER 6 TROUBLESHOOTING........................................................6-1

1. INTRODUCTION .....................................................................................................6-1

1.1 Initial Check ......................................................................................................................6-1

1.2 Warnings for Maintenance Work.......................................................................................6-2

1.3 Identify the Problem..........................................................................................................6-3

2. OPERATOR CALLS & SERVICE CALLS ................................................................6-4

2.1 Operator Calls...................................................................................................................6-4

2.2 Service Calls.....................................................................................................................6-4

3. ERROR MESSAGES............................................................................................... 6-6

3.1 Error Messages in the Status Monitor ..............................................................................6-6

3.2 Error Message Printouts...................................................................................................6-8

4. PAPER PROBLEMS................................................................................................ 6-9

4.1 Paper Load Problems.......................................................................................................6-9

4.2 Paper Jams.....................................................................................................................6-10

4.2.1 Clearing the jammed paper............................................................................................... 6-10

4.2.2 Causes & countermeasures.............................................................................................. 6-11

4.3 Paper Feeding Problems................................................................................................6-12

5. SOFTWARE SETTING PROBLEMS .....................................................................6-14

6. MALFUNCTIONS...................................................................................................6-18

7. IMAGE DEFECTS..................................................................................................6-23

7.1 Image Defect Examples..................................................................................................6-23

7.2 Troubleshooting Image Defect........................................................................................6-24

7.3 Location of Grounding Contacts .....................................................................................6-41

7.3.1 Drum unit .......................................................................................................................... 6-41

7.3.2 Printer body & paper cassette........................................................................................... 6-41

8. INCORRECT PRINTOUT ......................................................................................6-42

9. INSPECTION MODE ............................................................................................. 6-45

9.1 Test Print Mode...............................................................................................................6-45

9.2 Inspection Mode..............................................................................................................6-46

APPENDICES

1. SERIAL NO. DESCRIPTIONS................................................................................ A-1

2. DIAMETER / CIRCUMFERENCE OF ROLLERS.................................................... A-3

3. PRINT SPEEDS WITH VARIOUS SETTINGS........................................................ A-4

4. HOW TO KNOW DRUM UNIT LIFE & PAGE COUNTER ...................................... A-5

5. HOW TO USE THE SELF-DIAGNOSTICS TOOLS ............................................. A-10

6. NVRAM DEFAULT VALUE................................................................................... A-14

7. PAPER CASSETTE INFORMATION (FOR EUROPE ONLY)............................... A-15

8. CONNECTION DIAGRAM, HL-1240..................................................................... A-16

9. CONNECTION DIAGRAM, HL-1250..................................................................... A-17

10. MAIN PCB CIRCUIT DIAGRAM, HL-1240 (1/2).................................................... A-18

TABLE OF CONTENTS

vi

11. MAIN PCB CIRCUIT DIAGRAM, HL-1240 (2/2).................................................... A-19

12. MAIN PCB CIRCUIT DIAGRAM, HL-1250 (1/5).................................................... A-20

13. MAIN PCB CIRCUIT DIAGRAM, HL-1250 (2/5).................................................... A-21

14. MAIN PCB CIRCUIT DIAGRAM, HL-1250 (3/5).................................................... A-22

15. MAIN PCB CIRCUIT DIAGRAM, HL-1250 (4/5).................................................... A-23

16. MAIN PCB CIRCUIT DIAGRAM, HL-1250 (5/5).................................................... A-24

17. ENGINE PCB CIRCUIT DIAGRAM....................................................................... A-25

18. LOW-VOLTAGE POWER SUPPLY PCB CIRCUIT DIAGRAM (110 - 120V) ........ A-26

19. LOW-VOLTAGE POWER SUPPLY PCB CIRCUIT DIAGRAM (220 - 240V) ........ A-27

20. HIGH-VOLTAGE POWER SUPPLY PCB CIRCUIT DIAGRAM ............................ A-28

INDEX

REGULATION

vii

REGULATION

LASER SAFETY (110 - 120V MODEL ONLY)

This printer is certified as a Class I laser product under the US Department of Health and
Human Services (DHHS) Radiation Performance Standard according to the Radiation
Control for Health and Safety Act of 1968. This means that the printer does not produce
hazardous laser radiation.

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

FDA REGULATIONS (110 - 120V MODEL ONLY)

The US Food and Drug Administration (FDA) has implemented regulations for laser
products manufactured on and after August 2, 1976. Compliance is mandatory for
products marketed in the United States. One of the following labels on the back of the
printer indicates compliance with the FDA regulations and must be attached to laser
products marketed in the United States.

The label for Japanese manufactured products

MANUFACTURED: K
BROTHER INDUSTRIES, LTD.

15-1, Naeshiro-cho, Mizuho-ku, Nagoya 467-8561,
Japan.
This product complies with FDA radiation performance
standards, 21 CFR Subchapter J.

The label for Chinese manufactured products

MANUFACTURED: C
BROTHER Corporation (Asia) Ltd.
Shenzen Buji Nan Ling Factory

Gold Garden Ind., Nan Ling Village, Buji, Rong Gang,
Shenzen, CHINA
This product complies with FDA radiation performance
standards, 21 CFR Subchapter J.

Caution

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

REGULATION

viii

IEC 825 (220-240V MODEL ONLY)

This printer is a Class I laser product as defined in IEC 825 specifications. The label
shown below is attached in countries where required.

CLASS 1 LASER PRODUCT
APPAREIL LASER DE CLASSE 1
LASER KLASSE 1 PRODUKT

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

Caution

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

For Finland and Sweden
LUOKAN 1 LASERLAITE
KLASS 1 LASER APPARAT

Varoitus! Laitteen käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saattaa
altistaa käyttäjän turvallisuusluokan 1 ylittävälle näkymättömälle lasersäteilylle.

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

1.

SAFETY INFORMATION

ix

SAFETY INFORMATION

CAUTION FOR LASER PRODUCT (WARNHINWEIS FUR LASER DRUCKER)

CAUTION: When the machine during servicing is operated with the cover open, the

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

CAUTION: In case of any trouble with the laser unit, replace the laser unit itself. To

prevent direct exposure to the laser beam, do not try to open the enclosure
of the laser unit.

ACHTUNG: Im Falle von Störungen der Lasereinheit muß diese ersetzt werden. Das

Gehäuse der Lasereinheit darf nicht geöffnet werden, da sonst
Laserstrahlen austreten können.

<Location of the laser beam window>

ADDITIONAL INFORMATION

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

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

CAUTION

INVISIBLE LASER RADIATION WHEN OPEN AND INTERLOCK DEFEATED.
AVOID DIRECT EXPOSURE TO BEAM. CLASS 3B LASER PRODUCT.

ADVARSEL

USYNLIG LASER STRÅLING NÅR KABINETLÅGET STÅR ÅBENT.
UNGDÅ DIREKTE UDSÆTTELSE FOR STRÅLING. KLASSE 3B LASER.

VARNING

OSYNLIG LASERSTRÅLNING NÄR DENNA DEL ÄR ÖPPNAD OCH SPÄRRAR
ÄR URKOPPLADE. STRÅLEN ÄR FARLIG. KLASS 3B LASER APPARAT.

VARO!

AVATTAESSA JA SUOJALUKITUS OHITETTAESSA OLET ALTTIINA
NÄKYMÄTTÖMÄLLE LASERSÄTEILYLLE. ÄLÄ KATSO SÄTEESEEN. LUOKAN
3B LASERLAITE.

ADVARSEL

USYNLIG LASERSTRÅLING.UNNGÅ DIREKTE KONTAKT MED LASERENHETEN
NÅR TOPPDEKSELET ER ÅPENT. KLASSE 3B LASERPRODUKT.

ATTENTION

RADIATIONS LASER INVISIBLES QUANDOUVERT ET VERROUILLAGE ENLEVE.
EVITER EXPOSITIONS DIRECTES AU FAISCEAU. PRODUIT LASER CLASSE 3B.

VORSICHT

UNSICHTBARE LASERSTRAHLUNG WENN ABDECKUNG
GEÖFFENT UND SICHERHEITSVERRIEGELUNG
ÜBERBRÜCKT. NICHT DEM STRAHL AUSSETZEN.
SICHERHEITSKLASSE 3B.

ATENCIÓN

RADIACIÓN LASER INVISIBLE CUANDO SE ABRE
LA TAPA Y EL INTERRUPTOR INTERNO ESTÁ
ATASCADO. EVITE LA EXPOSICIÓN DIRECTA
DE LOS OJOS. PRODUCTO LASER CLASE 3B.

SAFETY INFORMATION

x

DEFINITIONS OF WARNINGS, CAUTIONS AND NOTES

The following conventions are used in this service manual:

WARNING

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

!

CAUTION:

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

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

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

WARNING

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

WARNING

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

WARNING

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

CHAPTER 1 GENERAL

1-1

CHAPTER 1 GENERAL

1. FEATURES

This printer has the following features;

High Resolution and Fast Print Speed

<HL-1240>
True 600 x 600 dots per inch (dpi) (GDI mode), true 300 x 300 dots per inch (dpi) (PCL mode)
with microfine toner and up to 12 pages per minute (ppm) print speed (A4 or Letter paper).

<HL-1250>
True 600 x 600 dots per inch (dpi) and 1200 x 600 dpi for graphics with microfine toner and 12
pages per minutes (ppm) print speed (A4 or Letter paper).

Versatile Paper Handling

The printer loads paper automatically from the paper cassette. The paper cassette can hold
A4, letter, B5, Executive A5 and A6 sizes of paper. The manual feed slot allows manual paper
loading sheet by sheet so you can use a variety of types and sizes of paper.

Front Operation

Basic operation of the printer can be controlled from the front panel.

Enhanced Printing Performance and User-Friendly Operation for Windows



The dedicated printer driver for Microsoft Windows 95/98, Windows 3.1 and Windows NT

4.0 are available on the CD-ROM supplied with your printer. You can easily install them into
your Windows



system using our installer program. The driver supports our unique

compression mode to enhance printing speed in Windows



applications and allows you to
choose various printer settings including toner save mode, custom paper size, sleep mode,
gray scale adjustment, resolution, water mark and many layout functions. You can easily
setup these print options through the Printer Setup Menu.

Printer Status Monitor with Bi-directional Parallel Interface

The printer driver can monitor the status of your printer using bi-directional parallel
communications. IEEE-1284 bi-directional parallel printer cable is recommended.

The printer status monitor program can show the current status of your printer. When printing,
the animated dialog box appears on your computer screen to show the current printing
process. If an error occurs, a dialog box will appear to let you know what to correct. If you
have turned on the interactive Help ( Windows 95/98 only) you can get visual guidance on your
PC screen on the actions in the event of certain printer errors.

Quick Print Setup

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

Enhanced Memory Management

The printer provides its own data compression technology in its printer hardware and the
supplied printer driver software, which can automatically compress graphic data and font data
efficiently into the printer’s memory. You can avoid memory errors and print most full page 600
dpi graphic and text data, including large fonts, with the standard printer memory.

CHAPTER 1 GENERAL

1-2

USB Interface (for Windows



98, iMac and Power Macintosh G3 Using USB)

The printer can be connected using the Universal Serial Bus (USB) interface to a PC or Mac
which has a USB interface. Drivers that allow you to use the USB port are provided on the
CD-ROM supplied with the printer.

Remote Printer Console Program for DOS

The utility program, Remote Printer Console (RPC), is available on the CD-ROM supplied with
your printer. When you operate your computer in a DOS (Disk Operating System)
environment, this program allows you to easily change the default settings of the printer such
as fonts, page setup and emulations.

This program also provides a status monitor program, which is a Terminate-and-Stay Resident
(TSR) program. It can monitor the printer status while running in the background and report
the current status or errors on your computer screen.

Popular Printer Emulation Support

These printers support the following printer emulation modes;
The HL-1240 supports HP LaserJet IIP.
The HL-1250 supports HP LaserJet 6P (PCL6), Epson FX-850 and IBM Proprinter XL. When
you use DOS application software or Windows



version 3.0 or earlier, you can use any of
these emulations to operate the HL-1250 printer. The printer also supports auto-emulation
switching between HP and Epson or HP and IBM. If you want to set the printer emulation, you
can do it using the Remote Printer Console Program.

High Resolution Control & Advanced Photoscale Technology (for HL-1250 only)

High Resolution Control (HRC) technology provides clear and crisp printouts. Use this function
to get smooth text print quality.

Advanced Photoscale Technology (APT) enables the printer to print graphics in 256
grayscales, producing nearly photographic quality. Use this function when you want to print
photographic images.

Environment-Friendly

<Economy Printing Mode>
This feature will cut your printing cost by saving toner. It is useful for obtaining draft copies for
proof-reading. You can select from two economy modes, 25% toner saving and 50% toner
saving, through the Windows



printer driver supplied with your printer.

<Sleep Mode (Power Save Mode)>
Sleep mode automatically reduces power consumption when the printer is not in use for a
certain period of time. The printer consumes less than 5W (HL-1240) or 6W (HL-1250) 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 around 3,000 pages for the standard cartridge and around 6,000 pages for the
optional high-capacity cartridge, which is both cost both effective and ecologically friendly.

Bar Code Print (for HL-1250 only)

The printer can print the following 11 types of bar codes;



Code 39



US-PostNet



EAN-8



Code 128



ISBN



EAN-13



Interleaved 2 of 5



UPC-A



EAN-128



Codabar



UPC-E

CHAPTER 1 GENERAL

1-3

2. OVERVIEW

<Front View>

Fig. 1-1

<Rear View>

Fig. 1-2

Fig. 1-3

HL-1240

HL-1250

Output tray

Manual feed paper guides

Paper cassette

Control panel

Tray extension flap

Front cover

Power switch

Manual feed slot

Rear cover

Paper indicator

USB interface connector

Power switch

Parallel interface connector

Rear cover

AC power inlet

USB interface connector

Modular jack for Lower Tray Unit

AC power inlet

Parallel interface connector

CHAPTER 1 GENERAL

1-4

3. SPECIFICATIONS

3.1 Printing

Print method Electrophotography by semiconductor laser beam scanning
Laser Wave length: 780 nm

Output: 5mW max

Resolution HL-1240: 600 x 600 dots/inch (GDI)

300 x 300 dots/inch (under DOS or other operating
system)

HL-1250: 1200(H) x 600(V) dots/inch (for Windows



DIB
graphics)
600 x 600 dots/inch (for Windows



and DOS)
300 x 300 dots/inch (under Apple Macintosh using the
optional RS-100M)

Print quality Normal printing mode

Economy printing mode (up to 25% and 50% toner saving)

Print speed Up to 12 pages/minute*

(when loading A4 or Letter-size paper from the paper cassette.)
Warm-up Max. 45 seconds at 23C (73.4F)
First print 15 seconds

(when loading A4 or Letter-size paper from the paper cassette.)
Print media Toner cartridge

Life expectancy: 3,000 pages/cartridge (Standard cartridge)

6,000 pages/cartridge (High-capacity cartridge)

(when printing A4 or Letter-size paper at 5% print coverage)
Developer Drum unit

Life expectancy: 20,000 pages/drum unit

*NOTE:
Print speed varies depending on the paper size or media type. For details, refer to APPENDIX

3 ‘PRINT SPEEDS WITH VARIOUS SETTINGS’.

3.2 Functions

CPU HL-1240: MB86833 66MHz

HL-1250: MB86832 66MHz
Emulation HL-1240: Brother Printing Solution for Windows



HP LaserJet IIP (PCL level 4)

HL-1250: Brother Printing Solution for Windows



Automatic emulation selection among HP LaserJet 6P
(PCL level 6), EPSON FX-850 or IBM Proprinter XL

CHAPTER 1 GENERAL

1-5

Printer driver



Windows



3.1/3.11, Windows 95/98, Windows NT 4.0 driver:

supporting Brother Native Compression mode



Windows



3.1/3.11, Windows 95/98 driver: supporting bi-

directional capacity



iMac, Power Macintosh G3 with USB printer driver



Optional Macintosh driver available for System 6.0.7 or higher
(for HL-1250 only)

Interface



Bi-directional parallel



Universal Serial Bus (USB)



Optional RS-422A/RS-232C serial (RS-100M) available (for HL­1250 only)

Memory HL-1240: 2.0 Mbytes

HL-1250: 4.0 Mbytes

Expandable up to 36 Mbytes by installing an industry

standard SIMM
Control panel 1 button and 4 LEDs
Diagnostics Self-diagnostic program

3.3 Electrical and Mechanical

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

Europe and Australia: AC 220 to 240V, 50 Hz/60 Hz

Power consumption Printing (peak)*: 940 W or less

Printing (average): 340 W or less
Standing by: 80 W or less
Sleep*: 5 W or less (HL-1240) / 6 W or less (HL-1250)

Noise Printing: 49 dB A or less

Standing by: 27 dB A or less

Temperature Operating: 10 to 32.5C (50 to 90.5F)

Non operating: 0 to 40C (38 to 104F)
Storage: -20 to 40C (-4 to 104F)

Humidity Operating: 20 to 80% (non condensing)

Storage: 10 to 85% (non condensing)

Dimensions A4 paper cassette installed: 360 x 370 x 235 mm
(W x D x H) (14.2 x 14.6 x 9.3 inches)

Legal paper cassette installed: 360 x 430 x 235 mm

(14.2 x 16.9 x 9.3 inches)

A4 lower paper cassette installed: 360 x 370 x 345 mm
(HL-1250 only) (14.2 x 14.6 x 13.6 inches)
Legal lower paper cassette installed: 360 x 430 x 345 mm
(HL-1250 only) (14.2 x 16.9 x 13.6 inches)

Weight Approx. 9.2 kg (20.2 lb.) including the drum unit.

Approx. 12.7 kg (27.9 lb.) including the drum unit and Lower Tray unit.

CHAPTER 1 GENERAL

1-6

*NOTE:



The peak figure of power consumption is worked out when the halogen heater lamp is
turned ON.



The peak figure of power consumption is worked out excluding inrush current value.



The peak figure of power consumption is a reference value and should be used internally at
Brother offices only.



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

3.4 Paper

3.4.1 Feedable paper

(1) Type & size

Feeding source Paper type Paper size

Paper cassette Normal paper

Transparencies

A4, Letter, B5 (ISO), A5, A6, Executive, Legal*

Manual feed slot Normal paper A4, Letter, B5 (JIS/ISO), A5, A6, Executive, Legal

70-216 x 116-356 mm

(2.75-8.5 x 4.57-14 inches)
Envelopes DL, C5, COM10, Monarch, B5 (ISO)
Organizers J, K, L sizes of DAY-TIMER
Labels A4, Letter
Transparencies A4, Letter
Other sizes 70-216 x 116-356 mm (2.75-8.5 x 4.57-14 inches)

Optional lower
paper cassette
( HL-1250 only)

Normal paper
Transparencies

A4, Letter, B5 (ISO), A5, Executive, Legal*

*NOTE:
Legal-size paper can be printed with the standard paper cassette or the optional lower cassette

for the US and Canada models only.

(2) Other paper specifications
<Paper Cassette>

Cut sheet
Basis weight 64 to 105 g/m2 (17 to 28 lb.)
Caliper 0.08 to 0.13 mm (0.003 to 0.005 in.)
Moisture content 4% to 6% by weight

<Manual Feed Slot>

Cut sheet Envelope

Basis weight 64 to 158 g/m2 (17 to 43 lb.) 75 to 90 g/m2 (20 to 24 lb.)

single thickness

Caliper 0.08 to 0.2 mm (0.003 to 0.008 in.) 0.084 to 0.14 mm (0.003 to 0.005 in.)

single thickness

Moisture content 4% to 6% by weight 4% to 6% by weight

CHAPTER 1 GENERAL

1-7

(3) Recommended paper



Letter: Xerox 4200 (75 g/m

2

)



A4: Xerox 80 Premier Paper (80 g/m

2

)



Label: Avery laser label or equivalent



Transparency: 3M CG3300 or equivalent

!

CAUTION:

When you are choosing print media, be sure to follow the information given below to prevent
any paper jams, print quality problems or printer damage;



It is recommended to use long-grained paper for the best print quality. If short-grained
paper is being used, it might be the cause of paper jams.



Use neutral paper. Do not use acid paper to avoid any damage to the drum unit.



Avoid using coated paper such as vinyl coated paper.



Avoid using preprinted or highly textured paper.



It is recommended to use labels or transparencies which are designed for use in laser
printers.



Avoid feeding labels with the carrier sheet exposed, or the printer will be damaged.



Before loading paper with holes such as organizer sheets, be sure to fan the stack well.



Do not use organizer sheets that are stuck together. The glue that is used might caused
damaged to the printer.



When printing on the back of pre-printed paper, if the paper is curled, be sure to straighten
the paper as much as possible.



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

3.4.2 Paper cassette capacity

(1) Maximum load height
Paper cassette:

<Normal paper> Up to 27mm (1.06 inches) in height

(250 sheets of 80 g/m

2

A4/Letter paper)

<Transparencies> 10 sheets

(2) Paper feed conditions

Type Weight Cassette

Manual feed

(1 sheet)

Normal paper (cut sheet)

64 to 80 g/m

2



(250 sheet)



158 g/m

2

✕



Labels

✕



Special paper (cut sheet)

Envelopes

✕



Organizers

✕



CHAPTER 1 GENERAL

1-8

3.4.3 Print delivery

(1) Output tray stacking
capacity: Maximum 150 sheets (80 g/m

2

)

face-down only
(2) Straight paper path output at the rear of the printer
capacity: 1 sheet **Thicker paper printing is recommended.

face-up only

NOTE:



When using the straight paper path feed and the rear output method for thicker paper
printing, lift up the rear cover at the rear of the printer.



Face-down: Delivery with the printed face of the paper downwards.
Face-up: Delivery with the printed face of the paper upwards.

3.5 Printing Area

3.5.1 Effective printing area

The effective printing area means the area within which the printing of all the data received
without any omissions can be guaranteed.

4.23mm

4.23mm

208mm

2,400 (80 characters)

25 25

NOTE:



The units in the above figure are dot size
based on 300 dpi resolution.



25 dots at both sides is for italic characters.

(1) Supported by the engine

(2) Supported by the emulation

CHAPTER 1 GENERAL

1-9

3.5.2 Print guaranteed area

A

E

CE

B

D

F

F

The values above vary depending on the paper size. For details, see the table on the next
page.

CHAPTER 1 GENERAL

1-10

The table below shows the print guaranteed areas for each paper size.

Size A B C D E F

A 4

210.0 mm

8.27”
(2,480 dots)

297.0 mm

11.69”
(3,507 dots)

203.2 mm

8.0”
(2,400 dots)

288.5 mm

11.36”
(3,407 dots)

3.4 mm

0.13”
(40 dots)

4.23 mm

0.17”
(50 dots)

Letter

215.9 mm

8.5”
(2,550 dots)

279.4 mm

11.0”
(3,300 dots)

203.2 mm

8.0”
(2,400 dots)

270.9 mm

10.67”
(3,200 dots)

6.35 mm

0.25”
(75 dots)



Legal

215.9 mm

8.5”
(2,550 dots)

355.6 mm

14.0”
(4,200 dots)

203.2 mm

8.0”
(2,400 dots)

347.1 mm

13.67”
(4,100 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)

241.5 mm

9.5”
(2,852 dots)



Executive

184.15 mm

7.25”
(2,175 dots)

266.7 mm

10.5”
(3,150 dots)

175.7 mm

6.92”
(2,025 dots)

258.2 mm

10.17”
(3,050 dots)

6.35 mm

0.25”
(75 dots)



A 5

148.5 mm

5.85”
(1,754 dots)

210.0 mm

8.27”
(2,480 dots)

136.5 mm

5.37”
(1,612 dots)

201.5 mm

7.93”
(2,380 dots)

6.01 mm

0.24”
(71 dots)



A 6

105.0 mm

4.13”
(1,240 dots)

148.5 mm

5.85”
(1,754 dots)

93.0 mm

3.66”
(1,098 dots)

140.0 mm

5.51”
(1,654 dots)



Organizer
(J size)

69.85 mm

2.75”
(825 dots)

116.0 mm

4.57”
(1,370 dots)

56.2 mm

2.21”
(675 dots)

107.5 mm

4.23”
(1,270 dots)

6.35 mm

0.25”
(75 dots)



Organizer
(K size)

95.25 mm

3.75”
(1,125 dots)

171.45 mm

6.75”
(2,025 dots)

86.78 mm

3.42”
(975 dots)

162.98 mm

6.42”
(1,925 dots)



Organizer
(L size)

139.7 mm

5.5”
(1,650 dots)

215.9 mm

8.5”
(2,550 dots)

131.23 mm

5.17”
(1,500 dots)

207.43 mm

8.17”
(2,450 dots)



COM10

104.78 mm

4.125”
(1,237 dots)

241.3 mm

9.5”
(2,850 dots)

92.11 mm

3.63”
(1,087 dots)

232.8 mm

9.16”
(2,750 dots)



MONARCH

98.43 mm

3.875”
(1,162 dots)

190.5 mm

7.5”
(2,250 dots)

85.7 mm

3.37”
(1,012 dots)

182.0 mm

7.16”
(2,150 dots)



C 5

162 mm

6.38”
(1,913 dots)

229 mm

9.01”
(2,704 dots)

150.0 mm

5.9”
(1,771 dots)

220.5 mm

8.68”
(2,604 dots)

6.01 mm

0.24”
(71 dots)



DL

110 mm

4.33”
(1,299 dots)

220 mm

8.66”
(2,598 dots)

98.0 mm

3.86”
(1,157 dots)

211.5 mm

8.33”
(2,498 dots)



NOTE:



The paper sizes indicated here should conform to the nominal dimensions specified by JIS.



A4 paper must accommodate 80 characters printed in pica pitch (203.2 mm).



The dot size is based on 300 dpi resolution.



Organizer is not supported by any printer emulations (commands).

CHAPTER 2 INSTALLATION AND BASIC OPERATION

2-1

CHAPTER 2 INSTALLATION AND BASIC OPERATION

1. CONDITIONS REQUIRED FOR INSTALLATION

1.1 Power Supply



The source voltage must stay within ±10% of the rated voltage shown on the rating plate.



The power cord, including extensions, should not exceed 5 meters (16.5 feet).



Do no share the same power circuit with other high-power appliances, particularly an air
conditioner, copier or shredder. If it is unavoidable that you must use the printer with these
appliances, it is recommended that you use an isolation transformer or a high-frequency
noise filter.



Use a voltage regulator if the power source is not stable.

1.2 Environment



The printer should be installed near a power outlet, which is easily accessible.



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



The printer should be used in a well ventilation room.



Place the printer on a flat, horizontal surface.



Keep the printer clean. Do not place the printer in a dusty place.



Do not place the printer where the ventilation hole of the printer is blocked. Keep
approximately 100 mm (4 inches) between the ventilation hole and the wall.



Do not place the printer where it is exposed to direct sunlight. Use a blind or a heavy
curtain to protect the printer from direct sunlight when the printer is unavoidably set up near
a window.



Do not place the printer near devices that contain magnets or generate magnetic fields.



Do not subject the printer to strong physical shocks or vibrations.



Do not expose the printer to open flames or salty or corrosive gasses.



Do not place objects on top of the printer.



Do not place the printer near an air conditioner.



Keep the printer horizontal when carrying.



Do not cover the slots in the side cover.

1.3 System Requirements for Brother Printer Solution for Windows



Check the following system requirements to setup and operate the printer using Brother
Printing Solution for Windows:



IBM PC or compatible with 80486 SX or higher microprocessor



10MB of space available on your hard disk for the printer driver and all fonts.



Microsoft Windows



3.1/3.11, Windows 95/98 or Windows NT 4.0

CHAPTER 2 INSTALLATION AND BASIC OPERATION

2-2

2. UNPACKING

When unpacking the printer, check to see that all of the following components are included in
the carton.

Fig. 2-1

NOTE:
Components may vary depending on the country.

AC cord

Printer

Paper cassette

Drum unit
(with Toner cartridge included)

Documents

CD-ROM

Floppy disk

CHAPTER 2 INSTALLATION AND BASIC OPERATION

2-3

3. INSTALL THE PRINTER

You need to implement hardware setup and driver installation to use the printer.
Firstly, identify the Operating System on your computer. Then, purchase the appropriate

interface cable (parallel or USB) for your computer.
The installation programs for the hardware setup and driver installation are contained on the

supplied CD-ROM.
If you do not have a CD-ROM drive, you can install the printer driver from the supplied floppy

disk. (See Subsection 3.2 ‘For Windows

®

Users with No CD-ROM Drive’.)

3.1 For Windows® Users

(1) Turn on your PC power. Close all the applications running on your PC.
(2) Insert the supplied CD-ROM into the CD-ROM drive.
(3) The opening screen will appear automatically in Windows



95/98/NT4.0.

NOTE:
If the opening screen does not appear;
Click

Start

and select

Run

. Then, type

D:\START

in the command line box and click OK. (If

your CD-ROM drive is not D, type the correct drive letter instead of “

D

”.)

In Windows



3.1;

Click the File menu in the Program Manager screen and select

Run

. Then, type

D:\START

in
the command line box and click OK. (If your CD-ROM drive is not D, type the correct drive
letter instead of “

D

”.)

(4) Select the model of your printer.

Fig. 2-2

(5) Select the language you want, then follow

the instructions on the screen.

Fig. 2-3

CHAPTER 2 INSTALLATION AND BASIC OPERATION

2-4

(6) Click the

Initial Setup

button.

Fig. 2-4

(7) You can view the Initial Setup operations

in the video movie.

Fig. 2-5

(8) Click the interface cable you are going to

use, Parallel or USB.

Fig. 2-6

(9) If you click the

NOW

button, you can

install the printer driver immediately.

(10) After the printer driver has been installed,

the HL-1240 or HL-1250 window will
appear. Follow the on-screen messages
to complete the installation.

Fig. 2-7

If your printer is connected using a parallel interface cable, the setup is now completed. If you
want to connect your printer using a USB interface cable, refer to Subsection 3.3 ‘Using the

USB Interface (For Windows



98 only)’.

CHAPTER 2 INSTALLATION AND BASIC OPERATION

2-5

3.2 For Windows® Users with No CD-ROM Drive

If you do not have a CD-ROM drive, setup the printer following the steps below, then install the
printer driver from the floppy disk.

3.2.1 Install the drum unit

(1) Open the front cover.
(2) Unpack the drum unit assembly and rock

it from side to side 5 or 6 times to
distribute the toner evenly inside the
cartridge. (Fig. 2-8)

Fig. 2-8

(3) Install the drum unit into the printer until it snaps into place and close the front cover.

3.2.2 Load paper

(1) Pull the paper cassette completely out of the printer.
(2) Slide the paper guides to the paper size

you want until they snap into a slot. (Fig.
2-9)

Fig. 2-9

(3) Load paper into the paper cassette.

Check that paper is flat placed. (Fig. 2-

10) Paper should be loaded up to the
lines on the sliding guide.

(4) Re-install the paper cassette into the

printer.

Fig. 2-10

3.2.3 Print a test page

(1) Check that the power switch is off.
(2) Connect the AC power cord to the printer.
(3) Plug the AC power cord into an AC outlet,

then turn on the power switch. (Fig. 2-11)

Fig. 2-11

AC power cord

CHAPTER 2 INSTALLATION AND BASIC OPERATION

2-6

(4) Extend the tray extension flap. After the

printer has warmed up the Ready LED
changes from blinking to lit. (Fig. 2-12)

(5) Press the control panel button. The

printer will print a test page. Check the
test page printed correctly.

Fig. 2-12

3.2.4 Connect the printer and the computer

(1) Turn off the power switch.
(2) Connect the parallel interface to the

computer, then connect it to the printer.
(Fig. 2-13)

(3) Use the clips on the printer connector to

secure the parallel interface cable.

(4) Turn on the printer power switch.

Fig. 2-13

3.2.5 Install the printer driver from floppy disk

(1) Turn on the computer power. If the “Add New Hardware Wizard” window appears, click

the

Cancel

button.
(2) Insert the supplied floppy disk into the floppy disk drive.
(3) Install the printer driver using the Setup.exe file.

In Windows



95/98

i) Click the

Start

button and select

Run

.

ii) Type A:\SETUP and click OK. (If your floppy disk drive is not A, insert the correct drive

letter instead of ‘A’.)

iii) Follow the instructions that appear on the screen.

In Windows



3.1

i) Click File menu in the Program Manager screen and select

Run

.

ii) Type A:\SETUP click OK. (If your floppy disk drive is not A, insert the correct drive letter

instead of ‘A’.)

iii) Follow the instructions that appear on the screen.

Parallel interface

cable

CHAPTER 2 INSTALLATION AND BASIC OPERATION

2-7

3.3 Using the USB Interface (For Windows 98 only)

3.3.1 Connect the USB interface cable

(1) Check that the printer power switch is on.
(2) Connect the USB interface cable to the

computer, then connect it to the printer.
(Fig. 2-14)

Fig. 2-14

3.3.2 Install the USB driver

(1) The “Add New Hardware Wizard” window

will appear. Click the

Next

button.

Fig. 2-15

(2) Select “Search for the best driver for your

device.” Click the

Next

button.

Fig. 2-16

USB interface

cable

CHAPTER 2 INSTALLATION AND BASIC OPERATION

2-8

(3) Insert the supplied CD-ROM into the CD-

ROM drive and select “CD-ROM drive”.
Click the

Next

button.

Fig. 2-17

(4) Click the

Next

button, then the USB driver

will be installed.

Fig. 2-18

(5) Click the

Finish

button.

Fig. 2-19

(6) Click the

Yes

button, then your PC will re-

start.

Fig. 2-20

CHAPTER 2 INSTALLATION AND BASIC OPERATION

2-9

3.3.3 Set the PC printer port

Your PC printer port has to be set to “USB port”.
(1) Click the

Start

button and select Printers in Settings.
(2) Select your printer model icon in Printers so that the printer icon is highlighted.
(3) Select Properties from the File menu, then click the Details tab.
(4) Select

BRUSB: (USB Printer Port)

in the

“Print to the following port” box. (Fig. 2-

21)

(5) Click the OK button to close the

Properties dialog box. The setup is now
completed.

Fig. 2-21

NOTE:
Both the parallel cable and USB interface cable can be connected to the printer at the same

time.

3.4 For Macintosh (iMac and Power Macintosh) with USB Users Only

You can setup the printer following the Initial Setup instructions on the supplied CD-ROM.

(1) Turn on the computer power, then insert the CD-ROM into the CD-ROM drive. The

window shown below will appear automatically.

Fig. 2-22

(2) Click the “Instructional Video” icon in the window above to view the Initial Setup operations

in the video movie.

(3) Click the “Printer Driver Installer” icon in the window above to install the printer driver.

CHAPTER 2 INSTALLATION AND BASIC OPERATION

2-10

4. PAPER HANDLING

The printer provides two types of paper loading method; paper cassette and manual feed slot.

4.1 Load Paper into the Paper Cassette

You can load normal paper and transparencies into the paper cassette. If you load paper into
the paper cassette, the printer automatically feeds paper sheet by sheet and ejects the printed
page into the output tray.

For the details on cassette loading, refer to Subsection 3.2.2 ‘Load Paper’ in this chapter and

Subsection 3.4 ‘Paper’ in CHAPTER 1.

4.2 Load Paper Manually

You can feed envelopes, labels and organizers as well as normal paper and transparencies
into the manual feed slot. (For details on feedable paper, see Subsection 3.4 ‘Paper’ in

CHAPTER 1.)

When using the manual feed slot, follow the steps below;
(1) Select the manual feed mode in the printer driver, and send the print data to the printer.

NOTE:
A ‘NO PAPER’ message is shown in the status monitor until a sheet of paper is inserted into

the manual feed slot.

(2) Set the width of the manual feed slot paper

guides using both hands to the paper width to be
used. (Fig. 2-23)

Fig. 2-23

(3) Insert the paper into the manual feed slot with

both hands until the front edge of the paper
touches the paper feed roller.

(4) Hold the paper in this position until the printer

feeds the paper a short distance, then let go of
the paper. (Fig. 2-24)

Fig. 2-24

(5) After the printer ejects the printed page, insert the next sheet of paper as in the previous

step. The printer will wait until you insert the next sheet of paper. Repeat this as necessary
for the number of pages you need to print.

NOTE:
It is recommended to remove printed pages immediately after printing if the output tray

extension flap is not extended.

CHAPTER 2 INSTALLATION AND BASIC OPERATION

2-11

The printer has a

straight paper path

from the manual feed slot to the rear of the printer when
the rear cover is lifted up. Use this paper feed and output method when printing on thicker
paper or card.

(1) Select the manual feed mode in the printer

driver.

(2) Lift up the rear cover at the rear of the printer.

(Fig. 2-25)
(3) Send the print data to the printer.
(4) Follow Steps (3) to (4) in the previous page to

load paper.
(5) Close the rear cover of the printer.

Fig. 2-25

!

CAUTION:

Remove each sheet immediately after printing. Stacking the sheets may cause curl or media
feed jams.

4.3 Two Side Printing (Manual Duplexing)

The supplied printer driver allows you to do manual duplex printing.
When using the manual duplex function, note the following information;

!

CAUTION:



If the paper is too thin, it may cause wrinkling.



If paper is curled, straighten it and then set it into the paper cassette.



The paper type should be regular paper. Do not use bond paper.



When setting paper into the paper cassette, empty the cassette first, then insert the printed
paper only, printed side face up. (Do not add the printed paper onto the top of the unprinted
paper stack.)



If the paper is not feeding correctly, the paper might be curled. Remove the paper and
straighten it.

4.3.1 To print on both sides of the paper from the paper cassette

(1) Select the required manual duplex printing mode from the driver.
(2) The printer will automatically print all the even numbered pages on one side of the paper

first.
(3) Remove the printed even numbered pages from the output tray.
(4) Re-insert them into the paper cassette, loading

the paper with the side to be printed (blank side)
face down, and the top edge toward you. Follow
the instructions on the computer screen. (Fig. 2-

26)

(5) The printer will now automatically print all the

odd pages on the reverse side of the paper.

Fig. 2-26

CHAPTER 2 INSTALLATION AND BASIC OPERATION

2-12

4.3.2 To print on both sides of the paper from the manual feed slot

!

CAUTION:



Before re-inserting the sheets, straighten them, or paper feed errors will occur.



The use of very thin or very thick paper is not recommended.



When the manual duplex function is used, it is possible that paper jams may occur or print
quality may not be satisfactory.

(1) Select the required manual duplex printing mode and manual feed mode from the driver.
(2) Using both hands, insert the paper into the manual feed slot with the side to be printed

first facing upwards. Follow the instructions on the computer screen.
(3) Repeat action (2) until you have printed all the even numbered pages.
(4) Remove the printed even numbered pages from the output tray
(5) Re-insert them in order into the manual feed slot,

loading the paper with the side to be printed
(blank side) face up, and the top edge towards
the printer. Follow the instructions on the
computer screen. (Fig. 2-27)

(6) Repeat action (5) until you have printed all the

odd numbered pages on the reverse side of the
paper.

Fig. 2-27

CHAPTER 2 INSTALLATION AND BASIC OPERATION

2-13

5. CONTROL PANEL OPERATION

There are four LEDs and a button on the control panel. The LEDs indicate the printer status,
and pressing the button enables several functions in the printer.

Drum

Ready

Alarm

Paper

Toner

Data

Fig. 2-28

5.1 Ready (Paper) LED Indications

The Ready LED indicates the current status of the printer.

LED Printer status

OFF The power switch is off, or the printer is in sleep mode.

If the printer is in sleep mode, it will wake up automatically when it
receives data or when you press the control panel button.

Blinking <Blinking at 1 second intervals>

The printer is warming up.
<Blinking at 2 seconds intervals>

The printer is cooling down and stops printing until the internal
temperature of the printer lowers.

ON The printer is ready to print.

This LED also works as the Paper LED with the Alarm LED. They blink simultaneously to
indicate a paper error. See Subsection 2.1 ‘Operator Calls’ in CHAPTER 6 for details.

Error Action

Paper jam Clear the paper jam and press the panel button if the printer

does not automatically resume printing.
No paper Load paper in the printer and press the panel button.
Misfeed Re-install the paper and press the panel button.

Control Panel Button

LEDs

CHAPTER 2 INSTALLATION AND BASIC OPERATION

2-14

5.2 Data (Toner) LED Indications

The Data LED indicates the current status of the print data process.

LED Printer status

OFF The printer has no print data.
Blinking The printer is receiving data from the computer or the printer is

processing data in memory.

ON Print data remains in the printer memory. If the Data LED is on for a

long period of time and nothing has printed, you need to press the
button to print the remaining data.

This LED also works as the Toner LED with the Alarm LED. They blink simultaneously to
indicate a toner error. See also Subsection 2.1 ‘Operator Calls’ in CHAPTER 6 for details.

Error Action

Toner low Indicates that the toner cartridge is nearly empty. Purchase a

new toner cartridge ready for when the ‘Toner empty’ error is

indicated.
Toner empty Replace the toner cartridge with a new one.

5.3 Drum LED Indications

The Drum LED indicates the drum unit is nearly at the end of its life.

LED Printer status

OFF The drum unit can be used.
ON The drum unit is nearly at the end of its life. It is recommended to

obtain a new drum unit to replace the current one.

5.4 Alarm LED Indications

The Alarm LED blinks (with no other LEDs) to indicate a printer error status such as “cover
open” or “memory full”.

If any other error occurs, the printer indicates the error by blinking the Alarm LED with another
LED or by printing an error report. Refer to Subsection 2.2 ‘Service Calls’ in CHAPTER 6.

CHAPTER 2 INSTALLATION AND BASIC OPERATION

2-15

5.5 Control Panel Button Operations

The control panel button is used for the following purposes depending on the situation.

Operation Description

Cancel printing If the button is pressed during printing, the printer immediately stops

printing and ejects the paper.

Wake-up If the printer is in sleep mode, pressing the button wakes it up into the

ready status. It will take up to 45 seconds for the printer to go into the
ready status.

Form feed If the Data LED is on, press the button. The printer prints any data

remaining in the printer memory.

Error recovery If an error occurs, the printer will recover from some errors automatically.

If the error does not clear automatically, press the button to clear the error
and continue printer operation.

Reprint function You can reprint a print job without sending it from the computer again.

When you press the button with the Data LED off, the printer reprints the
last job you printed if the whole job can be kept in printer memory. If the
print job is too large or there is insufficient memory, the last page only will
be reprinted.

5.6 Other Control Features

The printer has the following useful features;

5.6.1 Sleep mode

When the printer does not receive data for a certain period of time (timeout), it enters sleep
mode. The default timeout is 5 minutes and it is automatically adjusted to the most suitable
time-out setting depending on the frequency of your printer use (Intelligent Sleep Mode).

While the printer is in sleep mode, all the LEDs are off and it is as if it was turned off, but the
printer can still receive data from the computer. Receiving a print file or document
automatically wakes up the printer to start printing. Pressing the button also wakes up the
printer.

NOTE:



When the printer goes into sleep mode, the fan will not stop until the printer engine has
cooled down. The fan running time varies depending on the sleep mode timeout because
the fan running conditions are defined as follows;

1) The fan runs for 10 minutes whenever printing finishes.

2) The fan runs while the printer is in ready status.

3) The fan runs for at least 5 minutes after the printer goes into sleep mode.
(EX: If the timeout is 5 minutes, the fan will be running for 5 minutes after the printer goes

into sleep mode.)



Sleep mode allows the print engine to cool, so the temperature of the room and how long
the printer has been in sleep mode affects the warm-up time. This warm-up time can take
up to 45 seconds. The Ready LED blinks to indicate that the printer is warming up.



You can change the timeout for the sleep mode with the supplied printer driver (all models)
or Remote Printer Console program. The time-out setting is in the range of 1 to 15 minutes.
Refer to the Help section in the printer driver or RPC program for more information about
the sleep mode setting.

CHAPTER 2 INSTALLATION AND BASIC OPERATION

2-16

5.6.2 Test print mode

The printer incorporates various test print modes. The printer enters into each test print mode
by panel button operation.

For details on test print mode, see Subsection 9.1 ‘Test Print Mode’ in CHAPTER 6.

CHAPTER 3 THEORY OF OPERATION

3-1

CHAPTER 3 THEORY OF OPERATION

1. ELECTRONICS

1.1 General Block Diagram

Fig. 3-1 shows a general block diagram of the HL-1240 printer.

Video control block

Interface block

(Parallel / USB)

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

Drum

Charging

block

External device

Paper tray unit

Paper cassette

Manual feed

Fixing unit

Paper eject block

Paper feed system

Image generation system

RAM 2MB

Paper dust

cleaner block

Developing

block

Toner cartridge

Fig. 3-1

HL-1240

CHAPTER 3 THEORY OF OPERATION

3-2

Fig. 3-2 shows a general block diagram of the HL-1250 printer.

Optional RAM (SIMM)
(max. 32Mbytes)

Optional I/F board
(Mac. RS-232C)

Expansion

memory I/O

Expansion I/O

Video control block

Engine control block

Operation block

(Operation panel)

Control system

Low-voltage power

supply block

High-voltage power

supply block

Laser unit

Drive block
(DC motor)

Drum unit

Transfer block

Drum

Charging

block

External deviceExternal device

Paper tray unit

Paper cassette

Manual feed

Fixing unit

Paper eject block

Paper feed system

Image generation system

Interface block

(Parallel / USB)

RAM 4MB

Paper dust

cleaner block

Developing

block

Toner cartridge

Fig. 3-2

HL-1250

CHAPTER 3 THEORY OF OPERATION

3-3

1.2 Main PCB Block Diagram

Fig. 3-3 shows the block diagram of the main PCB of the HL-1240 printer.

Reset Circuit

Program + Font ROM

1.0 Mbytes

RAM

(2.0 Mbytes)

EEPROM (128 8 bits)

A S I C

Oscillator (32.7MHz)

Address Decoder

DRAM Control

Timer

FIFO

CDCC Parallel I/O

Soft Support

EEPROM I/O

Engine Control I/O

To Engine PCB

CPU Core

(MB86833)

BUS

INT

To PC

USB I/O

To PC

Fig. 3-3

HL-1240

CHAPTER 3 THEORY OF OPERATION

3-4

Fig. 3-4 shows the block diagram of the main PCB of the HL-1250 printer.

Reset Circuit

Program + Font ROM

4.0 Mbytes

RAM

(4.0 Mbytes)

Option RAM (SIMM)

(max. 32Mbytes)

Option Serial I/O

(RS232C & RS422A)

EEPROM (512 x 8 bits)

CPU Core

(MB86832)

A S I C

Oscillator (32.7MHz)

Address Decoder

DRAM Control

Timer

FIFO

CDCC Parallel I/O

Soft Support

EEPROM I/O

Engine Control I/O

To Engine PCB

BUS

INT

To PC

USB I/O

To PC

Fig. 3-4

HL-1250

CHAPTER 3 THEORY OF OPERATION

3-5

1.3 Main PCB

1.3.1 ASIC

A Fujitsu 32bit RISC CPU, MB86833 (SPARC lite) is built in the ASIC. While the CPU is driven
with a clock frequency of 33 MHz in the user logic block, it itself runs at 66 MHz, which is
generated by multiplying the source clock by two.

The functions of the interface block communication with external devices are described below;
(1) IEEE1284

Stores the data received from the PC into DRAM as controlled by the DMA controller. It is

applicable to both normal receiving and bi-directional communication (nibble mode, byte
mode, ECP mode).

(2) USB interface
Stores the data received from the PC into DRAM as controlled by the DMA controller. The

transmission speed is 12Mbps.

(3) Engine GA transfer circuit
Communicates with the engine GA by a full-duplex synchronous serial method. The

communication speed is 2Mbps.

Fig. 3-5

HL-1240

CHAPTER 3 THEORY OF OPERATION

3-6

A Fujitsu 32bit RISC CPU, MB86832 (SPARC lite) is built in the ASIC. While the CPU is driven
with a clock frequency of 33 MHz in the user logic block, it itself runs at 66 MHz, which is
generated by multiplying the source clock by two.

The functions of the interface block communication with external devices are described below;
(1) IEEE1284

Stores the data received from the PC into DRAM as controlled by the DMA controller. It is

applicable to both normal receiving and bi-directional communication (nibble mode, byte
mode, ECP mode).

(2) USB interface
Stores the data received from the PC into DRAM as controlled by the DMA controller. The

transmission speed is 12Mbps.

(3) Engine GA transfer circuit
Communicates with the engine GA by a full-duplex synchronous serial method. The

communication speed is 2Mbps.

HL-1250

CHAPTER 3 THEORY OF OPERATION

3-7

Fig. 3-6

CHAPTER 3 THEORY OF OPERATION

3-8

1.3.2 ROM

An 8 Mbits ROM (x 16 bit) is mounted into this socket.

Fig. 3-7

Two 16 Mbits ROMs (x 16 bit) are mounted into these sockets.

Fig. 3-8

HL-1240

HL-1250

CHAPTER 3 THEORY OF OPERATION

3-9

1.3.3 DRAM

A 16M-bit DRAM (x 16 bits) is used as the RAM.

Fig. 3-9

HL-1240

CHAPTER 3 THEORY OF OPERATION

3-10

Two 16M-bit DRAMs (x 16 bits) are used as the RAM.

Fig. 3-10

HL-1250

CHAPTER 3 THEORY OF OPERATION

3-11

1.3.4 Optional RAM

A 32bit (72 pin) SIMM can be fitted as optional RAM. The main PCB has one slot and the
capacity of SIMM can be from 1 Mbyte to 32 Mbytes.

Fig. 3-11

HL-1250

CHAPTER 3 THEORY OF OPERATION

3-12

1.3.5 Optional serial I/O

The interrupt of the serial I/O is input to the EXINT terminal of the ASIC, and is recognized by
the CPU. A 32-byte register is provided for this I/O, which is read from and written to by the
CPU.

Fig. 3-12

1.3.6 EEPROM

The EEPROM is X24C01A type of two-wire method with a 128 x 8 bits configuration.

Fig. 3-13

The EEPROM is X24C04 type of two-wire method with a 512 x 8 bits configuration.

Fig. 3-14

HL-1250

HL-1240

HL-1250

CHAPTER 3 THEORY OF OPERATION

3-13

1.3.7 Reset circuit

The reset IC is a RN5VD42A. The reset voltage is 4.2V (typ.) and the LOW period of reset is
80ms (typ.)

Fig. 3-15

The reset IC is a RN5VD42A. The reset voltage is 4.2V (typ.) and the LOW period of reset is
80ms (typ.)

Fig. 3-16

HL-1240

HL-1250

CHAPTER 3 THEORY OF OPERATION

3-14

1.3.8 Engine I/O

Fig. 3-17 shows the engine interface circuit. The interface with the engine PCB is by full­duplex synchronous serial method.

Fig. 3-17

Fig. 3-18 shows the engine interface circuit. The interface with the engine PCB is by full­duplex synchronous serial method.

Fig. 3-18

1.4 Engine PCB

The gate array which transforms the serial signal from the main PCB into the parallel signal is
mounted on the engine PCB.

The engine PCB controls the following parts by using the transferred signal data;



Main motor



Toner sensor



Panel PCB



Cover sensor



Fan motor



Front registration sensor



Thermistor



Rear registration sensor



Polygon motor



Upper paper cassette sensor (HL-1250 only)



Solenoid



Lower paper cassette registration sensor (HL-1250 only)



High-voltage power supply

HL-1240

HL-1250

CHAPTER 3 THEORY OF OPERATION

3-15

1.5 Power Supply

1.5.1 Low-voltage power supply

The power supply uses a switching regulation system to generate the regulated DC power (+5
V and +24 V), 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
+5 V / 1.6 A

+24 V / 2.15 A

100V: MPW1555
200V: MPW1455

Heater
Circuit

Thermal

Fuse

Lightning

Surge

Absorber

Feedback

Line

Filter

Fuse

Rectifier

Oscillator

24V

Regulation

Circuit

24V

5V

Lamp

(Heater)

(Engin Circuit)

Fuse

5V

Regulation

Circuit

Fig. 3-19

CHAPTER 3 THEORY OF OPERATION

3-16

1.5.2 High-voltage power supply

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

Transfer Roller

Supply
Roller

Photosensitive

Drum

Development

Roller

Corona

Unit

Current

Regulator

Current

Regulator

Voltage

Regulator

Voltage

Regulator

B1

B102 Q81

B101 Q101

Voltage

Regulator

Z51 VR51

VR22

24VI

GND

R1

Fig. 3-20

CHAPTER 3 THEORY OF OPERATION

3-17

2. MECHANICS

2.1 Overview of Printing Mechanism

Fig. 3-21

Second eject roller

Paper

First eject roller

Rear cover

Paper Cassette

Pressure plate

Rear registration

sensor lever

Separation

pad

Front registration

sensor lever

Cassette pressure roller

Paper pick-up roller

Paper feed roller

Supply roller

Toner sensor

Agitator

Blade

Development roller

Scanner motor

Polygon mirror

Laser Unit

Corona wire

Heat roller

Cleaner

Photosensitive drum

Thermistor

Eject sensor lever

Pressure roller

Drum Unit

Fixing Unit

Transfer roller

CHAPTER 3 THEORY OF OPERATION

3-18

Laser

Main PCB

Engine

PCB

Polygon Motor

Laser Unit

Cover Sensor (A)

Main Motor

Solenoid

Fan Motor

Toner Sensor PCB (light emission)

Toner Sensor PCB (light reception)

Thermistor (for Heat Roller)

Panel PCB

Low-Voltage

Power Supply

PCB

Fixing Unit

Halogen
Heater
Lamp

Front Registration
Sensor

Rear Registration
Sensor

Upper Paper
Cassette Sensor
(HL-1250)

Lower Paper
Cassette
Registration Sensor
(HL-1250)

High-

Voltage

Power

Supply

PCB

Drum Unit

Primary Charger (Corona Wire)
Primary Charger (Grid)

Supply Roller

Transfer Roller

Development Roller

Cover Sensor (B)

Fig. 3-22

CHAPTER 3 THEORY OF OPERATION

3-19

2.2 Paper Transfer

2.2.1 Paper supply

The paper pick-up roller picks up one sheet of paper from the paper cassette every time it is
rotated and feeds it to the paper feed roller.

Fig. 3-23

The paper is gripped between the paper pick-up roller and the separation pad and separated
into individual sheets.

The pick-up roller is directly connected to the clutch mechanism, whose rotation is stopped by
the stopper arm. When the pick-up solenoid is activated, the clutch mechanism is engaged by
the solenoid action and the paper pick-up roller is driven. The paper drawn out of the tray by
the pick-up roller pushes against the front registration sensor lever and the paper top
position/absence of paper is detected by sensing the motion of the lever.

2.2.2 Paper registration

After the paper top position is detected by the front registration sensor, the paper, separated
into individual sheets by the paper pick-up roller, is fed further for a specified time, and the
paper top position reaches the paper feed roller so that the paper skew is adjusted. Then, the
solenoid is turned off, the paper feed roller starts turning, and the paper is fed to the transfer
block in the drum unit.

Fig. 3-24

The rear registration sensor in the path from the feed roller to the transfer roller controls the
first print position on the paper.

Pinch roller

Paper pick-up roller

Front registration

sensor lever

Paper feed roller

Pinch roller

Separation pad

Pressure plate

Photosensitive drum

Transfer roller

Paper feed roller

Rear registration

sensor lever

CHAPTER 3 THEORY OF OPERATION

3-20

2.2.3 Paper eject

After the printing image on the photosensitive drum is transferred onto the paper, the paper is
fed to the fixing unit to fix unfixed toner onto the paper.

Afterwards, the paper is ejected from the fixing unit by the first eject roller in the fixing unit. The
eject sensor lever detects whether the paper is ejected correctly or not.

After the paper exits from the first eject roller, the paper is turned by the rear cover and ejected
face down into the top output tray through the second eject roller. If the rear cover is open, the
paper is ejected face up straight to the printer rear (straight paper path).

Fig. 3-25

2.3 Sensors

2.3.1 Cover sensors A and B

Detect opening and closing of the front cover.

Fig. 3-26

Second eject roller

First eject roller

Rear cover

Eject sensor lever

Cover sensor (A)

Cover sensor (B)

CHAPTER 3 THEORY OF OPERATION

3-21

2.3.2 Toner sensor

Detects if there is toner in the toner cartridge. The toner sensor at the left side emits light
through the window on the left side of the toner cartridge, then the toner sensor at the right
side receives it when the toner is low. They also detect whether or not the drum unit is
installed. (The toner cartridge is installed in the drum unit.)

Fig. 3-27

2.4 Drum Unit

2.4.1 Photosensitive drum

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

2.4.2 Primary charger

Forms a uniform charge on the drum surface.
(1) Corona wire

Generates the ion charge on the drum.
(2) Grid

Spreads the ion charge evenly over the drum surface.

2.4.3 Transfer roller

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

2.4.4 Cleaner

Removes the paper dust or dirt on the surface of the photosensitive drum.

2.5 Toner Cartridge

Develops the electrostatic latent image on the photosensitive drum with toner and forms the
visible image.

Toner sensor

(light emission)

Toner sensor
(light reception)

CHAPTER 3 THEORY OF OPERATION

3-22

2.6 Print Process

2.6.1 Charging

The drum is charged to approximately 870V by an ion charge which is generated by the
primary charger. The charge is generated by ionization of the corona wire, which has a DC
bias from the high-voltage power supply applied to it. The flow of the ion charge is controlled
by the grid to ensure it is distributed evenly on the drum surface. The aluminum drum sleeve
in the photosensitive drum is grounded.

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

-

-

-

-

-

-

-

-

---

Organic Photoconductor layer

Aluminum drum sleeve

Photosensitive
Drum

HVPS

870V

Voltage

Regulator

Grid

Corona wire

Fig. 3-28

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

2.6.2 Exposure stage

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

Fig. 3-29

Drum

Lens

Laser beam

Polygon mirror

Paper

Laser detector

Laser diode

Motor

Laser beam

f  lens

CHAPTER 3 THEORY OF OPERATION

3-23

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

1 Cycle of drum

Surface Potential (V)

+870

+420

+200

123

(a)

(b)

Time

1
2

3

Primary charging
Laser beam exposure and developing

(a) Unexposed area
( Non image area )
(b) Exposed area
( Image area )

Transfer the image to paper

Drum
Sleeve

0

Fig. 3-30

2.6.3 Developing

Developing causes the toner to be attracted to the electrostatic image on the drum so as to
transform it into a visible image.

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

Fig. 3-31

Photosensitive drum

Corona wire

Development roller

Blade

Supply roller

Transfer roller

CHAPTER 3 THEORY OF OPERATION

3-24

2.6.4 Transfer

(1) Transfer process
After the drum has been charged and exposed, and has received a developed image, the

toner formed is transferred onto the paper by applying a negative charge to the back of
the paper. The negative charge applied to the paper causes the positively charged toner

to leave the drum, and adhere to the paper. As a result, the image is visible on the paper.
(2) Cleaning process of transfer roller
If the toner is not transferred onto the paper perfectly it is possible that there may be

residual toner on the drum which will adhere to the transfer roller. The transfer voltage

changes to a positive voltage during non-printing rotation of the drum. Therefore the

transfer roller is cleaned by returning the positively charged toner adhering to the transfer

roller onto the photo-conductive drum.

2.6.5 Fixing stage

The image transferred to the paper by static electricity is fixed by heat and pressure when
passing through the heat roller and the pressure roller in the fixing 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. 3-32

First eject roller

Thermistor

Pressure roller

Heat roller

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-1

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

1. SAFETY PRECAUTIONS

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

WARNING

(1) Always turn off the power switch and unplug the power cord from the power outlet

before accessing any parts inside the printer.

(2) Some parts inside the printer are extremely hot immediately after the printer is

used. When opening the front cover or rear cover to access any parts inside the
printer, never touch the red colored parts shown in the following figures.

!

CAUTION:

(1) Be careful not to lose screws, washers, or other parts removed.
(2) Be sure to apply grease to the gears and applicable positions specified in this chapter.
(3) When using soldering irons or other heat-generating tools, take care not to accidentally

damage parts such as wires, PCBs and covers.

(4) Before handling any PCBs, touch a metal portion of the equipment to discharge any static

electricity charge on your body, or the electronic parts or components may be damaged.
(5) When transporting PCBs, be sure to wrap them in the correct protective packaging.
(6) Be sure to replace self-tapping screws correctly, if removed. Unless otherwise specified,

tighten screws to the following torque values.

TAPTITE, BIND or CUP B
M3: 70N



cm

M4: 80N



cm

TAPTITE, CUP S
M3: 80N



cm

SCREW
M3: 70N



cm

M4: 80N



cm

(7) When connecting or disconnecting cable connectors, hold the connector body, not the

cables. If the connector has a lock, release the connector lock first to release it.
(8) After a repair, check not only the repaired portion but also all connectors. Also check that

other related portions are functioning properly before operational checks.

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-2

2. DISASSEMBLY FLOW

1

AC CORD

DRUM UNIT

2

PAPER CASSETTE

3

MAIN COVER

6

4

FRONT COVER

5

TOP COVER

LASER UNIT

7

FIXING UNIT

9

DRIVE UNIT

8

BASE PLATE

10

PCBs

MAIN PCB ASSY

11

LOW-VOLTAGE

PS PCB ASSY

13

14

ENGINE PCB ASSY

/ HIGH-VOLTAGE

PS PCB ASSY

12

LOWER TRAY RELAY

PCB ASSY (HL-1250 only)

20

PAPER PICK-UP

ROLLER ASSY

18

TONER SENSOR

PCB ASSY (emission)

19

TONER SENSOR

PCB ASSY (reception)

PANEL PCB ASSY

15

SOLENOID ASSY

16

FAN MOTOR

17

A

A

B

B

21

PAPER FEED

ROLLER ASSY

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-3

3. DISASSEMBLY PROCEDURE

3.1 AC Cord

(1) Disconnect the AC cord from the printer AC inlet.

Fig. 4-1

3.2 Drum Unit

(1) Open the front cover and remove the drum unit from the printer.

Fig. 4-2

Printer

AC cord

Drum unit

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-4

3.3 Paper Cassette

(1) Close the front cover, pull out the paper cassette from the printer and remove the paper

from the cassette.

Fig. 4-3

(2) Remove the separation pad holder ASSY by pulling it upwards, then remove the

separation pad spring from the paper cassette.

Fig. 4-4

Paper cassette

Paper cassette

Separation pad spring

Separation pad holder

Front cover

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-5

NOTE:
When replacing/re-assembling the separation pad holder, remove the old grease and apply a

suitable amount of grease referring to the figure below;

Fig. 4-5

(3) Turn the paper cassette upside down, then remove the cassette cover film by peeling it

carefully from the underside of the cassette.
(4) Remove the M3x8 Taptite screw and remove the paper cassette cover from the front of

the cassette.

Fig. 4-6

NOTE:

·

'The cover film must not be reused after it has been removed. Always replace it with a new
one.

·

The screw securing the paper cassette cover indicated RED in the figure above is very
special. When disassembling/re-assembling the screw, you need a special screw driver.
Refer to the parts reference list.

Paper cassette

Paper pick-up roller

Taptite, TORX pan M3x8

Cassette cover film

Grease: Molykote PG-662

(1 rice-grain size)

Paper cassette cover

Paper cassette

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-6

(5) Keeping the paper cassette upside down, release the pressure roller holder assembly

from the cassette by releasing the metal mounting plate from the plastic retaining boss.

Use a flat screwdriver to press the metal plate forwards until it clears the boss and then

remove the pressure roller holder assembly downwards from the cassette.
(6) Remove the cassette pressure roller from the assembly, then remove the pressure roller

shaft from the pressure roller.
(7) Remove the sponge holder ASSY from the holder. The two sponge holder springs will

also come off.

Fig. 4-7

(8) Keeping the paper cassette upside down, remove the two M2.6x5 Taptite screws.
(9) Unhook the catches of each side guide, then press the lock lever towards the front of the

cassette to release the pressure plate.

Fig. 4-8

Cassette pressure roller

Pressure roller holder

Paper cassette

Taptite, cup M2.6x5

Taptite, cup M2.6x5

Side guide rack

Pressure roller shaft

(catches)

Sponge holder ASSY

Lock lever

Sponge holder springs

Paper cassette
(Back side)

Pressure roller holder

Flat screwdriver

Step (9)

Side guide L

Side guide rack

Side guide L

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-7

(10) Turn the cassette the correct way up and slide the two paper guides to the center of the

cassette.
(11) Remove the side guides Left and Right from the paper cassette.

Fig. 4-9

(12) Unhook the two catches (A) of the pressure plate while pulling the plastic frame outwards,

then unhook the other two catches (B) of the plate while pulling the plastic frame outwards

to remove the pressure plate ASSY.
(13) Unhook the pressure plate spring from the plastic hook to remove the two pressure plate

springs.

Fig. 4-10

Pressure plate ASSY

Pressure

plate spring

Paper cassette

(hook)

Plastic frame

Step (12)

Step (13)

(catches (A))

Step (12)

(catch (B))

Side guide L

Side guide R

Paper cassette

➀

➁

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-8

!

CAUTION:

When unhooking the catches to remove the pressure plate, do not bend the pressure plate,
gently ease the plastic cover. If the pressure plate is deformed, paper feeding problems may
occur.

NOTE:
When re-assembling the pressure plate ASSY, ensure that the paper indicator arm is under the

pressure plate.

(14) Remove the release lever extension spring.
(15) Unhook the two catches and rotate the lock lever to remove it downwards from the

cassette.

Fig. 4-11

NOTE:
When re-assembling the lock lever, insert it upwards from underneath the cassette and rotate it

until the two catches lock into place..

(16) Slide the rear paper guide fully forwards in the cassette and remove it from the slot.

Fig. 4-12

Paper cassette

Rear paper guide

Release lever

extension spring

Paper cassette

Lock lever

➀

➁

➂

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-9

(17) Turn the cassette upside down and remove the one M3x8 Taptite screw to remove the

side guide gear. Then remove the one friction spring.
(18) Remove the two side guide racks.
(19) Remove the paper indicator.

Fig. 4-13

NOTE:
When re-assembling the side guide racks, they should both be aligned so that the wide end of

the racks are in line with the inside edge of the paper guide release slots in the cassette before
refitting the spring and gear.

Taptite cup M3x8

Side guide gear

Friction spring

Side guide rack

Side guide rack

Paper indicator

➀

➁

Step (19)

➀

➀

➁

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-10

3.4 Front Cover

(1) Open the front cover.
(2) Remove the four M3x8 Taptite screws from the main cover.

Fig. 4-14

(3) Position the front cover at the angle of 45 degrees and release the bosses at the right and

left hand sides and the link at the left hand side.
(4) Remove the front cover.

Fig. 4-15

Front cover

Taptite, bind M3x8

Taptite, bind M3x8

Front cover

Front cover

Link

45

°

(boss)

(boss)

Main cover

➀

➂

➁

Step (3)

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-11

3.5 Top Cover

(1) Remove the two M3x10 Taptite screws securing the top cover.
(2) Release the hooks on either side of the top cover from the bosses on the main cover by

pulling the top cover forwards.

Fig. 4-16

(3) Open the rear cover, then release the hooks (A) at the right and left hand sides of the top

cover while pushing them towards the side of the printer from the rear.
(4) Lift up the top cover and release the hooks (B) at the right and left hand sides of the top

cover to remove the top cover.

Fig. 4-17

Taptite, cup M3x10

Taptite, cup M3x10

Top cover

Step (2)

Top cover

(hook (B))

(hook (B))

(hook (A))

Rear cover

Step (3)

Rear cover

(boss)

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-12

(5) Turn the top cover upside down and remove the second eject roller ASSY by lifting the

middle of the roller upwards until the roller releases from the cover.

Fig. 4-18

3.6 Main Cover

(1) Remove the two M3x8 Taptite screws from the rear of the main cover.
(2) Release the hooks at the right and left hand top sides of the printer, then, while pulling the

cover outwards to clear the power socket and switch, lift up the main cover to remove it

complete with the rear cover.

Fig. 4-19

Top cover

Second eject roller ASSY

Rear cover

Taptite, bind M3x8

(hook)

(hook)

Main cover

Step (1)

Taptite, bind M3x8

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-13

(3) Bend the tray extension flap upwards slightly to remove the tray extension flap.

Fig. 4-20

(4) Release the rear cover springs Left and Right from the hooks on the main cover.
(5) Remove the rear cover complete with the rear cover springs Left and Right from the main

cover.
(6) Remove the four pinch rollers and four pinch roller springs by moving them to the vertical

and then removing them by lifting them upwards.

Fig. 4-21

Tray extension flap

Main cover

➀

Rear cover

➁

Rear cover

Main cover

Rear cover

spring R/L

Pinch roller

Pinch roller

spring

Pinch roller

Step (4)

Step (6)

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-14

3.7 Laser Unit

(1) Remove the three M3x16 Taptite screws.
(2) Push the P harness cover to the right to release it from the hook and remove the P

harness cover.
(3) Disconnect the LD harness and the polygon motor connector.
(4) Taking care not to touch the lens and mirror, remove the laser unit.

Fig. 4-22

!

CAUTION:

·

Never touch the reflect mirror and lens inside the laser unit. If there is any dirt or dust on
the mirror or lens, blow it off using an air gun.

·

Never touch the scanner window on the printer body. If there is any dirt or dust on the
window, blow it off using an air gun. If cleaning the underside of the scanner window, wipe
off dirt or dust with soft clean paper. Refer to subsection 3.3 ‘Cleaning the Scanner

Window’ in CHAPTER 5.

Fig. 4-23

Taptite, cup M3x16

Polygon motor harness

Taptite, cup M3x16

Taptite, cup M3x16

Laser unit

P harness

cover

(hook)

Laser unit

LD harness

Reflect mirror

Polygon motor harness

Lens

Scanner window

Printer body

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-15

3.8 Drive Unit

(1) Place the printer body carefully on its right hand side so that the drive unit is at the top.
(2) Remove the five M3x6 Taptite screws securing the gear plate.
(3) Disconnect the heater harness connector and release the panel PCB harness from the

hooks.
(4) Carefully lift the drive unit and while supporting the PCB, disconnect the main motor

connector.
(5) Remove the drive unit.

Fig. 4-24

(6) Remove the four M3x6 Taptite screws to remove the main motor ASSY from the drive unit.

Fig. 4-25

Taptite, cup M3x6

Taptite, cup M3x6

Taptite, cup M3x6

Taptite, cup M3x6

Taptite, cup M3x6

Main motor ASSY

Main motor connector

D

rive unit

Heater harness
connector

Panel PCB harness

Drive unit

Frame

Taptite, cup M3x6

(hook)

Step (4)

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-16

NOTE:
When replacing/re-assembling the main motor, remove the old grease and apply a suitable

amount of grease referring to the figure below;

Fig. 4-26

(7) Remove the development joint complete with the joint spring, then remove the link.

Fig. 4-27

Grease: Molykote PG-662
(1 rice-grain size)

Joint spring

Development joint

Link

Main motor ASSY

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-17

3.9 Fixing Unit

(1) Place the main frame on its base so that the rear side is facing you.
(2) Press the two hooks inwards to remove gear 59.
(3) Disconnect the two connectors of the heater harness and release the harness from the

hooks on the top of the fixing unit.
(4) Remove the one M3x8 Taptite screw and two shoulder screws securing the fixing unit,

taking care not to lose the contact spring fitted to the front left hand should screw position.

Fig. 4-28

NOTE:
When re-assembling the fixing unit, ensure you do not forget to assemble gear 59.

(5) Lift up the fixing unit and move it toward you and to the left to allow the drive gear to clear

the frame and then disconnect the thermistor connector from the engine PCB.
(6) Remove the fixing unit from the main frame.

Fig. 4-29

Shoulder screw

Thermistor connector

Main frame

Engine PCB

Heater harness

connector

Main frame

Heater harness

G

ear 59

Gear 59

Fixing unit

Taptite, cup M3x8

Step (2)

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-18

NOTE:
When re-assembling the fixing unit, align the fixing unit frame at the drive unit side into the

concave part of the main frame.

Fig. 4-30

(7) Remove the M3x10 screw to remove the star wheel holder ASSY from the fixing unit by

lifting the left hand end of the assembly slightly and then moving the assembly to the right

to release the right hand end from the fixing unit frame.

Fig. 4-31

Main frame

Fixing unit

(concavity)

Fixing unit

Main frame

Fixing unit

Star wheel holder ASSY

Screw, bind M3x10

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-19

(8) Remove the two M3x20 Taptite screws from the top of the fixing unit frame.
(9) Release the thermistor harness from the hooks.
(10) Release the two hooks at the right and left sides securing the fixing unit cover to the fixing

unit frame.

Fig. 4-32

(11) Remove the fixing unit cover from the fixing unit frame.

Fig. 4-33

Fixing unit frame

Fixing unit cover

(hook)

(hook)

(hook)

(hook)

Fixing unit frame

(hook)

Thermistor harness

(hook)

Taptite, cup M3x20

Thermistor harness

Taptite, cup M3x20

Fixing unit frame

(hook)

(hook)

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-20

(12) Remove the one M3x10 Taptite screw securing the halogen lamp connector plate at the

drive unit side of the fixing unit frame and then loosen the M3x6 screw at the other side.
(13) Lift the right hand end of the heat roller and remove the halogen heater lamp from the heat

roller.

Fig. 4-34

!

CAUTION:

•

Never touch the surface of the halogen heater lamp.

•

When securing the screw to assemble the halogen lamp connector plate, ensure to use the
plastic jig as shown in the figure below to avoid the edge of the halogen heater lamp
damaged;

Fig. 4-35

NOTE:
When re-assembling the halogen heater lamp, ensure that the direction of the halogen heater

lamp is correct referring to the figure above.

Halogen heater lamp

Heat roller

Taptite, pan M3x10

Screw, cup M3x6

Halogen heater lamp

Heat roller

Colored side
115V: Yellow
230V: Purple

Halogen lamp
connector plate

PR99156

Taptite, pan M3x10

Halogen lamp

connector plate

Plastic jig

Halogen heater lamp

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-20A

(14) Lift and remove the heat roller. The heat roller gear will also come off.
(15) Remove the heat roller bearing from the left hand end of the heat roller. To remove the

bearing at the gear side, first remove the washer, then remove the bearing.

Fig. 4-36

Heat roller

Heat roller bearing

Heat roller gear

Heat roller bearing

Washer

PR99156

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-21

!

CAUTION:

Never touch the surface of the heat roller.

NOTE:

·

When re-assembling the heat roller to the fixing unit frame, place the two projections at the
right hand side of the roller onto the bosses on the frame as shown in the figure below.

Fig. 4-36

·

When re-assembling the heat roller to the fixing unit frame, ensure you do not damage the
heat roller with the four hooks on the fixing unit frame.

Fig. 4-37

Heat roller

Fixing unit frame

(hooks)

(hooks)

Heat roller gear

Heat roller bearing

Heat roller

(projection)

(boss)

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-22

(16) Remove the heat roller cleaner complete with the cleaner spring from the fixing unit frame

by lifting it upwards until the spring releases from the frame.
(17) Remove the cleaner spring from the heat roller cleaner.

Fig. 4-38

NOTE:

·

When re-assembling the heat roller cleaner complete with the cleaner spring onto the fixing
unit frame, ensure the direction of the roller is correct referring to the figure above.

·

Ensure also that the spring is seated correctly in the locating channel and does not protrude
from either end.

(18) Remove the pressure roller from the fixing unit cover by gently levering the right hand side

upwards to release it from the bearing and then sliding it to the right to remove it.
(19) Remove the pressure roller cleaner complete with the cleaner spring from the fixing unit

cover by lifting it upwards until the spring releases from the cover.
(20) Remove the cleaner spring from the pressure roller cleaner.

Fig. 4-39

Cleaner spring

Heat roller cleaner

Fixing unit frame

Cleaner spring

Pressure roller cleaner

Fixing unit cover

Pressure roller

Heat roller cleaner

Cleaner spring

Pressure roller cleaner

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-23

NOTE:

·

When re-assembling the pressure roller cleaner complete with the cleaner spring onto the
fixing unit cover, ensure the direction of the roller is correct referring to the figure above.

·

Ensure also that the spring is seated correctly in the locating channel and does not protrude
from either end.

(21) Release the thermistor harness from the hooks on the fixing unit frame and then remove

the one M3x12 Taptite screw and remove the thermistor.

Fig. 4-40

NOTE:
When re-assembling the thermistor to the fixing unit frame, ensure the direction of the

thermistor is correct referring to the figure below;

Fig. 4-41

Thermistor

Taptite, cup M3x12

Fixing unit frame

(hooks)

Thermistor

Taptite, cup M3x12

Fixing unit frame

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-24

(22) Press the two catches holding the idle gear 13 to the frame and then remove the idle gear

13. Slide the first eject roller to the left until the slot in the roller shaft aligns with the slot in

the frame and then remove the roller by pulling it forwards.

Fig. 4-42

(23) Remove the eight eject pinch rollers and pinch springs by lifting them upwards until the

springs release from the frame.

Fig. 4-43

Fixing unit frame

Idle gear 13

First eject roller

Fixing unit frame

Pinch spring

Eject pinch roller

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-25

3.10 Base Plate

(1) Turn the main frame upside down.
(2) Remove the five M4x10 Taptite screws and 16 (sixteen) M3x8 Taptite screws from the

base plate.
(3) Slide the base plate to the rear of the printer to remove it.

!

CAUTION:

Do not remove the ground wire connected to the base plate if it is not necessary to remove the
low-voltage power supply unit. Unnecessary disconnection of the ground wire may cause
increased printer noise.

Fig. 4-45

!

CAUTION:

•

When re-assembling the base plate, be sure that the ground wire connected to the paper
feed roller ASSY is fixed into the slit on the plastic chute referring to the figure below;

Fig. 4-46

Taptite, bind M4x10

Taptite, bind M3x8

Taptite, bind M3x8

Taptite, bind M3x8

Taptite, bind M3x8

Base plate

Main frame

Ground wire connection

(slit)

Ground wire

Plastic chute

Main frame

PR99156

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-25A

•

When securing the screws to assemble the base plate, ensure to use the jig shaft referring
to the figure below so that the engine PCB is assembled correctly;

Fig. 4-47

PR99156

Taptite, bind M4x10

Taptite, bind M4x10

Main frame

Base plate

Jig shaft

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-26

3.11 Main PCB ASSY

(1) Remove the two M3x8 screws from the I/F plate to release the main PCB.
(2) Lift the insulation sheet and remove the main PCB ASSY.
(3) Disconnect the three connectors for the low-voltage power supply, engine PCB and LD.

Fig. 4-46

3.12 Lower Tray Relay PCB ASSY (For HL-1250 only)

(1) Remove the M3x6 Taptite screw and remove the lower tray relay PCB ASSY.

Fig. 4-47

Taptite, cup M3x6

Lower tray relay
PCB ASSY

Lower tray relay PCB ASSY

Main frame

Screw M3x8

Insulation sheet

Main PCB

Low-voltage power supply connector

Engine PCB connector

LD connector

I/F plate

➀

➁

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-27

3.13 Low-Voltage Power Supply PCB ASSY

(1) Remove the M3x8 Taptite screw to remove the insulation sheet.
(2) Slightly lift up the low-voltage power supply PCB ASSY from the frame and disconnect the

engine PCB connector. Then lift the power supply PCB ASSY further and disconnect the

halogen heater lamp connector.
(3) Remove the M3.5x6 screw to disconnect the ground wire from the base plate.

Fig. 4-48

(4) Remove the M3x6 Taptite screw securing the AC inlet holder.
(5) Turn the AC inlet to the right to release it and remove the AC inlet ASSY and the low-

voltage power supply PCB together.

Fig. 4-49

NOTE:
When re-assembling the AC inlet holder, fix the holder onto the positioning bosses first, then

secure it to the frame with the screw. (Refer to the figure above.)

Taptite, bind M3x8

AC inlet holder

Low-voltage power

supply PCB ASSY

Ground wire

Screw M3.5x6

Halogen heater
lamp connector

Engine PCB connector

Low-voltage power
supply PCB ASSY

Base plate

Taptite, cup M3x6

AC inlet holder

Main frame

(positioning boss)

Insulation sheet

Step (2)

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-28

3.14 Engine PCB ASSY / High-Voltage Power Supply PCB ASSY

(1) Remove the M4x12 Taptite screw to remove the insulation sheet.
(2) Remove the three M4x12 Taptite screws securing the engine PCB and the high-voltage

power supply PCB.
(3) Lift the engine PCB and high-voltage power supply PCB together and disconnect the

connector which connects two PCBs together to remove the high-voltage power supply

PCB ASSY.
(4) If necessary, remove the T/R electrode helical spring from the T/R plate.

Fig. 4-50

!

CAUTION:

Be sure not to lose the T/R electrode helical spring after removing it.

NOTE:
When re-assembling the T/R electrode helical spring onto the plate, press the spring onto the

plate firmly with a flat bladed screwdriver and ensure that it is retained securely.

Screw, bind M4x12

Screw, bind M4x12

Engine PCB ASSY

High-voltage power
supply PCB ASSY

T/R electrode

helical spring

T/R plate

Insulation sheet

Screw, bind M4x12

Step (4)

Step (3)

PR99153

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-29

(5) Disconnect the 11 (eleven) connectors for HL-1240 or 12 (twelve) connectors for HL-1250

from the engine PCB to remove the engine PCB ASSY.

Fig. 4-51

!

CAUTION:

·

Even if you want to remove only one of either the engine and high-voltage power supply

PCBs, ensure you remove all screws securing both PCBs and disconnect the central

connector while lifting both of them up. Failure to do may damage the PCBs.

·

When re-assembling the engine PCB, ensure it is aligned with the positioning boss first.

Be careful the main motor harness is not caught between the engine PCB and the frame.

·

When re-assembling the engine PCB or high-voltage power supply PCB, ensure the

central connector is connected correctly.

Main PCB connector

Toner sensor (light
emission) connector

Fan motor connector

Thermistor connector

Low-voltage power

supply connector

Polygon motor connector

Panel PCB
connector

Lower paper cassette
connector (HL-1250 only)

Main motor connector

Solenoid connector

Engine PCB ASSY

Low-voltage power
supply connector
(for HVPS)

Toner sensor (light
reception) connector

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-30

3.15 Panel PCB ASSY

NOTE:
Be sure to remove the drive unit and disconnect the panel PCB connector on the engine PCB

before removing the panel PCB ASSY.

(1) Remove the M3x6 Taptite screw, then remove the panel PCB ASSY.

Fig. 4-52

3.16 Solenoid ASSY

NOTE:
Be sure to remove the drive unit and disconnect the solenoid connector on the engine PCB

before removing the solenoid ASSY.

(1) Place the main frame so that the drive unit side is at the top.
(2) Release the catch and remove the planetary gear from the paper pick-up roller shaft.
(3) Remove the planetary gear from the paper feed roller shaft and gear 56.

Fig. 4-53

Planetary gear
(for paper pick-up roller)

Planetary gear
(for paper feed roller)

(catch)

Gear 56

Main frame

Solenoid

Planetary gear

(for paper pick-up roller)

Panel PCB

Taptite, cup M3x6

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-31

(4) Release the catch and remove the clutch levers for the feed roller and pick-up roller.

Fig. 4-54

!

CAUTION:

When removing the clutch levers, the clutch lever spring may come off. Be sure not to lose it.

(5) Place the main frame the right way up and remove gear 59.

Fig. 4-55

NOTE:
When re-assembling the fixing unit, ensure you do not forget to assemble gear 59.

Clutch lever spring

Clutch lever

(for paper pick-up roller)

Clutch lever
(for paper feed roller)

Solenoid

Main frame

Gear 59

Main frame

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-32

(6) Turn the main frame upside down.
(7) Remove the two M3x6 Taptite screws and release the solenoid harness from the hook and

remove the cassette guide L/F.

Fig. 4-56

(8) Remove the M3x4 screw and the tape on the solenoid harness and remove the solenoid

ASSY.

Fig. 4-57

!

CAUTION:

When removing the solenoid, the solenoid rod and spring may come off. Be careful not to
loose them. (Refer to the figure above.)

Taptite, cup M3x6

Cassette guide L/F

Screw, bind M3x4

Solenoid ASSY

Main frame

Tape

Rod

Step (7)

Spring

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-33

3.17 Fan Motor ASSY

NOTE:
Be sure to remove the fixing unit and disconnect the fan motor connector on the engine PCB

before removing the fan motor ASSY.

(1) Place the main frame so that the fan motor ASSY is at the top.
(2) Remove the two M3x6 Taptite screws securing the fan cover.
(3) Remove the fan motor ASSY with the fan cover and remove the fan motor ASSY from the

cover.

Fig. 4-58

NOTE:
When re-assembling the fan motor, fix the harness into the groove on the motor, then fix the

motor onto the bosses.

Fig. 4-59

Taptite, cup M3x6

Taptite, cup M3x6

Fan motor ASSY

Fan cover

Main frame

Manufacturer sticker side

Fan cover

(groove)

Fan motor

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-34

3.18 Toner Sensor PCB ASSY (Light Emission)

NOTE:
Be sure to disconnect the toner sensor (light emission) connector on the engine PCB before

removing the toner sensor PCB ASSY (light emission).

(1) Release the hooks of the toner sensor PCB ASSY (light emission) and remove it.

Fig. 4-60

3.19 Toner Sensor PCB ASSY (Light Reception)

NOTE:
Be sure to disconnect the toner sensor (light reception) connector on the engine PCB before

removing the toner sensor PCB ASSY (light reception).

(1) Remove the one M3x6 Taptite screw and release the hooks, then remove the toner sensor

PCB ASSY (light reception).

Fig. 4-61

Toner sensor PCB ASSY

(light emission)

(hooks)

(hooks)

Taptite, cup M3x6

Toner sensor PCB ASSY
(light reception)

Toner sensor holder

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-35

3.20 Paper Pick-up Roller ASSY

NOTE:
Be sure to remove all the covers and the base plate before removing the paper pick-up roller

ASSY.

(1) Place the main frame upside down.
(2) Unhook the hook to remove the inner gear 54, gear 45 and gear 20 from the main frame.
(3) Remove the bearing from the paper pick-up roller shaft.
(4) Release the hook on the bearing at the other side of the shaft and remove the paper pick-

up roller ASSY and the shaft from the main frame.

Fig. 4-62

(4) Remove the bearing and the paper pick-up roller ASSY from the shaft.

Fig. 4-63

Bearing

Main frame

Paper pick-up roller ASSY

(hook)

Paper pick-up roller ASSY

Paper pick-up roller ASSY

Paper pick-up roller shaft

Step (4)

Bearing

Gear 20

Gear 45

Gear 54

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY

4-36

3.21 Paper Feed Roller ASSY

NOTE:
Be sure to remove all the covers and the PCBs before removing the paper feed roller ASSY.

(1) Unhook the black plastic hook on the shaft to remove gear 21.

Fig. 4-64

(2) Turn the main frame the right way up.
(3) Unhook the hook on the bearing, then slightly slide the paper feed roller ASSY to the drive

unit side.
(4) Lift up and remove the paper feed roller with the bearing and joint and remove the bearing

and joint from the paper feed roller ASSY.

Fig. 4-65

Gear 21

(hook)

(hook)

Bearing

Paper feed roller ASSY

Joint

Bearing