Brother hl-5240, hl-5250dn, hl-5270dn, hl-5280dn Service Manual

Brother Laser Printer

SERVICE MANUAL

MODEL:

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

Read this manual thoroughly before maintenance work. Keep this manual in a convenient place for quick and easy reference at all times.

September 2005 SM-PRN057 (4)



Confidential

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Compilation and Publication: This manual has been complied and published, under the supervision of Brother Industries

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

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

Computer, Inc in the United States and other countries. Epson is a registered trademark and FX-80 and FX-850 are trademarks of Seiko Epson

Corporation. Hewlett Packard is a registered trademark and HP LaserJet 6P, 6L, 5P, 5L, 4, 4L 4P, III, IIIP,

II, and IIP are trademarks of Hewlett-Packard Company. IBM, IBM PC, and Proprinter are registered trademarks of International Business Machines

Corporation. Microsoft, MS-DOS, Windows and Windows NT are registered trademarks of Microsoft

Corporation in the U.S. and other countries. ENERGY STAR is a U.S. registered mark. Citrix and MetaFrame are registered trademarks of Citrix Systems, Inc. in the United State. SuSE is a registered trademark of SuSE Linux AG. RED HAT is a registered trademark of Red Hat. Inc. Mandrake is a registered trademark of Mandrake Soft SA. PostScript and PostScript 3 are trademarks of Adobe Systems Incorporated. Intel, Intel Xeon and Pentium are trademarks or registered trademarks of Intel Corporation. AMD, AMD Athlon, AMD Opeteron and combinations thereof, are trademarks of Advanced

Micro Devices, Inc. Java and all Java-based trademarks and logos are trademarks or registered trademarks of

Sun Microsystems, Inc. in the United States and other countries. All other terms and brand and product names mentioned in this Service Manual are registered

trademarks of their respective companies.

Confidential

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PREFACE

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

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

This manual consists of the following chapters:

CHAPTER 1: GENERAL

Features, specifications, etc.

CHAPTER 2: THEORY OF OPERATION

Basic operation of the mechanical system, the electrical system and the electrical circuits.

CHAPTER 3: PERIODIC MAINTENANCE

Periodical replacement parts, consumable parts, etc.

CHAPTER 4: TROUBLESHOOTING

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

CHAPTER 5: DISASSEMBLY AND RE-ASSEMBLY

Procedures for disassembling and re-assembling the mechanical system.

CHAPTER 6: ADJUSTMENTS AND UPDATING OF SETTING, REQUIRED AFTER

PARTS REPLACEMENT

CHAPTER 7: SERVICE SUPPORT SOFTWARE

Test print mode and Service menu mode, etc.

APPENDIX: Diagrams etc…

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

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

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REGULATION............................................................................................ viii

SAFETY INFORMATION .............................................................................. x

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

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

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

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

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

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

3.1 Printing ............................................................................................................................. 1-7

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

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

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

3.5 Network Connectivity...................................................................................................... 1-12

3.6 Paper ..............................................................................................................................1-14

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

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

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

3.7.1 PCL5e/EPSON/IBM emulation..........................................................................................1-17

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

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

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

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

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

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

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

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

2.1 General Block Diagram .................................................................................................... 2-2

2.2 Main PCB Block Diagram ................................................................................................. 2-3

2.3 Main PCB ......................................................................................................................... 2-4

2.3.1 CPU.....................................................................................................................................2-4

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

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

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

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

2.3.6 SDRAM ............................................................................................................................... 2-4

2.3.7 Optional RAM......................................................................................................................2-4

2.3.8 EEPROM............................................................................................................................. 2-4

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

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

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

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

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

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

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

2.4.1 Low-voltage power supply...................................................................................................2-6

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

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

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

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

3.3 Paper Transfer .................................................................................................................2-9

3.3.1 Paper supply .......................................................................................................................2-9

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

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

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

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

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

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

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

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

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

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

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

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

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

3.5.1 Charging............................................................................................................................2-21

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

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

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

3.7 Heat Control of Fuser Unit.............................................................................................. 2-24

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

1. CONSUMABLE PARTS .......................................................................................... 3-1

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

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

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

2.1 Periodical Replacement Parts ........................................................................................ 3-12

2.2 Procedures to Replace Periodical Replacement Parts .................................................. 3-13

2.2.1 Fuser unit and laser unit....................................................................................................3-13

2.2.2 Paper feeding kit for tray 1, 2, 3 ........................................................................................3-35

2.2.3 Paper feeding kit for MP tray.............................................................................................3-43

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3. PERIODICAL CLEANING ..................................................................................... 3-49

3.1 Cleaning the Inside of the Printer ...................................................................................3-49

3.2 Cleaning the Corona Wire .............................................................................................. 3-52

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

1. INTRODUCTION .................................................................................................... 4-1

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

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

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

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

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

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

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

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

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

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

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

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

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

3.1 Paper Loading Problems ................................................................................................ 4-15

3.2 Paper Jams .................................................................................................................... 4-16

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

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

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

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

4. SOFTWARE SETTING PROBLEMS .................................................................... 4-29

5. MALFUNCTIONS.................................................................................................. 4-32

6. IMAGE DEFECTS................................................................................................. 4-38

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

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

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

6.4 Location of Grounding Contacts ..................................................................................... 4-57

6.4.1 Drum unit...........................................................................................................................4-57

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

7. INCORRECT PRINTOUT ..................................................................................... 4-58

8. NETWORK PROBLEM......................................................................................... 4-60

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

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

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

8.4 Wireless Network Troubleshooting ................................................................................ 4-66

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

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

1. SAFETY PRECAUTIONS ....................................................................................... 5-1

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

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

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

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

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

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

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

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

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

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

7.5 Back Cover .....................................................................................................................5-20

7.6 DX Blank Cover (For HL-5240) ......................................................................................5-20

7.7 Outer Chute ASSY .........................................................................................................5-21

7.8 Fuser Unit ....................................................................................................................... 5-23

7.9 Tray MP ASSY................................................................................................................5-25

7.10 MP Tray Cover ASSY/Process Cover ASSY.................................................................. 5-26

7.11 Access Cover/ Side Cover L........................................................................................... 5-28

7.12 Main PCB ....................................................................................................................... 5-29

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

7.14 Main Shield Plate ASSY .................................................................................................5-32

7.15 Relay Rear PCB ASSY/Connector ................................................................................. 5-34

7.16 Relay Front PCB ASSY .................................................................................................. 5-36

7.17 MP Solenoid ASSY......................................................................................................... 5-37

7.18 Drive Release Link ......................................................................................................... 5-38

7.19 T1 Solenoid ASSY ..........................................................................................................5-39

7.20 Toner Sensor PCB .........................................................................................................5-39

7.21 Register Solenoid ASSY................................................................................................. 5-40

7.22 Ejector Solenoid ASSY (For HL-5250DN/5270DN/5280DW)......................................... 5-40

7.23 Interlock SW ASSY ........................................................................................................ 5-41

7.24 New Toner Actuator........................................................................................................ 5-41

7.25 Gear 17/20...................................................................................................................... 5-42

7.26 Side Cover R ..................................................................................................................5-44

7.27-1 Top Cover Printed ASSY (For HL-5240/5250DN) ........................................................ 5-45

7.27-2 Panel PCB ASSY..........................................................................................................5-45

7.27-3 SW Key A/B.................................................................................................................. 5-46

7.27-4 Inner Chute/Pinch Roller Holder ................................................................................... 5-47

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7.28-1 Top Cover 2 Printed ASSY (For HL-5270DN/5280DW) ............................................... 5-48

7.28-2 Inner Chute/Pinch Roller Holder ................................................................................... 5-49

7.28-3 Panel PCB ASSY.......................................................................................................... 5-50

7.28-4 SW Key A/B/C/ Set Key Printed ASSY......................................................................... 5-51

7.28-5 LCD Holder ASSY ........................................................................................................5-53

7.29 Filter................................................................................................................................ 5-55

7.30 Laser Unit ....................................................................................................................... 5-56

7.31 PS PCB Unit ................................................................................................................... 5-57

7.32 High-Voltage PS PCB ASSY ..........................................................................................5-60

7.33 Toner LED PCB Unit ASSY............................................................................................ 5-62

7.34 Fan Motor 60 Unit ........................................................................................................... 5-63

7.35 Fan Motor 60 Unit LV ..................................................................................................... 5-63

7.36 Frame L .......................................................................................................................... 5-64

7.37 Frame R.......................................................................................................................... 5-64

7.38 MP Unit........................................................................................................................... 5-65

7.39 Regist Actuator Rear/Regist Actuator Spring ................................................................. 5-70

7.40 Regist Actuator Front/Regist Actuator Spring................................................................. 5-72

7.41 Roller Holder ASSY ........................................................................................................5-73

7.42 PE Actuator, Edge Actuator, Edge Actuator Spring .......................................................5-74

7.43 PE PG Sensor ASSY...................................................................................................... 5-76

7.44 Wireless PCB (PCB T60H929.00 ASSY 02) (For HL-5280DW) .................................... 5-77

8. DISASSEMBLY PROCEDURE (LT-5300)............................................................. 5-78

8.1 Paper Tray...................................................................................................................... 5-78

8.2 LT Front Cover ASSY..................................................................................................... 5-81

8.3 LT Rear Cover ................................................................................................................5-82

8.4 LT Side Cover L.............................................................................................................. 5-82

8.5 LT Side Cover R .............................................................................................................5-83

8.6 LT PCB ASSY ................................................................................................................5-84

8.7 Connector: 55533-1219.................................................................................................. 5-85

8.8 Connector: 54702-1219.................................................................................................. 5-85

8.9 Gear 24LT ...................................................................................................................... 5-86

8.10 Collar 6 ........................................................................................................................... 5-87

8.11 LT Solenoid ASSY ..........................................................................................................5-91

8.12 Roller Holder ASSY ........................................................................................................5-92

8.13 Edge Actuator Spring .....................................................................................................5-93

8.14 PE Actuator, Edge Actuator............................................................................................ 5-94

8.15 LT Sensor PCB ASSY ....................................................................................................5-95

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

CHAPTER 6 ADJUSTMENTS AND UPDATING OF SETTINGS,

REQUIRED AFTER PARTS REPLACEMENT................... 6-1

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

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

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

1. CONTROL PANEL.................................................................................................. 7-1

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

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

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

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

2.1 Professional Menu.......................................................................................................... 7-16

2.2 Reset Parts Life Menu .................................................................................................... 7-23

2.3 Service Menu.................................................................................................................. 7-24

3. NVRAM DEFAULT VALUE ................................................................................... 7-29

APPENDIX

1. MAIN PCB CIRCUIT DIAGRAM.............................................................................. A-1

2. LOW-VOLTAGE POWER SUPPLY PCB CIRCUIT DIAGRAM (100V, 200V) ......... A-8

3. HIGH-VOLTAGE POWER SUPPLY PCB CIRCUIT DIAGRAM ............................ A-10

4. POINT TO POINT CONNECTION DIAGRAM....................................................... A-11

5. GEAR LAYOUT DRAWING .................................................................................. A-12

6. READMARKS ....................................................................................................... A-14

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REGULATION

LASER SAFETY (100 - 120V MODEL ONLY)

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

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

FDA REGULATIONS (100 - 120V MODEL ONLY)

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

The label for Japanese manufactured products

MANUFACTURED: Brother Industries, Ltd.,

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

The label for Chinese manufactured products

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

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

Caution

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

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

IEC 60825 (220-240V MODEL ONLY)

This printer is a Class 1 laser product as defined in IEC 60825 specifications. The label shown below is attached in countries where it is required.

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

Caution

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

For Finland and Sweden LUOKAN 1 LASERLAITE KLASS 1 LASER APPARAT

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

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

Internal laser radiation

Maximum radiation power: 5 mW

Wave length: 770 – 810 nm

Laser class: Class 3B

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SAFETY INFORMATION

CAUTION FOR LASER PRODUCT (WARNHINWEIS FUR LASER DRUCKER)

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

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

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

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

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

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

ADDITIONAL INFORMATION

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

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

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

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 “W ARNING” messages included in this manual.

WARNING

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

WARNING

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

WARNING

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

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CHAPTER 1 GENERAL

1. FEATURES

This printer has the following features.

High Resolution and Fast Print Speed

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

Versatile Paper Handling

The printer loads paper automatically from the paper tray. The paper tray can hold A4, letter, B5 (ISO), B5 (JIS), A5, B6 (ISO), A6, Executive, Folio and Legal* size of paper. You can use a variety of types and sizes of paper when printing from the Multi-purpose tray. Width: 69.9 to

215.9 mm (2.75 to 8.5 in) Length: 116 to 406.4 mm (4.57 to 16 in). A4, Letter, Legal sizes of paper can be held when automatic duplex print. *Legal paper is not available in some regions.

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

Front Operation

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



Enhanced Printing Performance and User-Friendly Operation for Windows

The dedicated printer driver for Microsoft Windows



2000/XP Home Edition/XP Professional/XP Professional x64 Edition are available



Windows 95/98/Me, Windows NT 4.0 and

on the CD-ROM supplied with your printer. You can easily install them into your Windows system using our installer program. The driver supports our unique compression mode to enhance printing speed in Windows



applications and allows you to choose various printer



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

Printer Status Monitor with Bi-directional Parallel Interface

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

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

Quick Print Setup

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

Enhanced Memory Management

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

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CHAPTER 1 GENERAL

USB Interface (for Windows Professional X64 Edition, Mac OS



98/Me/2000/XP Home Edition/XP Professional/XP



9.1-9.2/ Mac OS



X 10.2.4 or greater)

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

Popular Printer Emulation Support

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

Environment-Friendly

<Economy Printing Mode (Toner Save Mode)> This feature will cut your printing cost by saving toner. It is useful for obtaining draft copies for

proof-reading. You can select the toner saving economy mode through the Windows



printer

driver supplied with your printer.

<Sleep Mode (Power Save Mode)> Sleep mode automatically reduces power consumption when the printer is not in use for a

certain period of time. The printer consumes less than 8.5W when in sleep mode.

<Low Running Cost> Since the toner cartridge is separate from the drum unit, you need to replace only the toner

cartridge after printing around 3,500 (Standard cartridge) pages or 7,000 (High yield cartridge) at 5% coverage for A4 paper for the standard cartridge, which is both cost effective and ecologically friendly.

Bar Code Print

The printer can print the following 11 types of bar codes

• Code 39 • US-PostNet • EAN-8

• Code 128 • ISBN • EAN-13

• Interleaved 2 of 5 • UPC-A • EAN-128

• Codabar • UPC-E

Network Feature (for HL-5250DN/5270DN/5280DW)

The Brother printer has built in multi protocol network capability as standard. This allows multiple host computers to share the printer on a 10/100Mb wired Ethernet or IEEE

802.11b/802.11g wireless Ethernet network. Any users can print their jobs as if the printer was directly connected to their computer. Users on Windows Windows to 9.2, Mac OS

2000/XP Home Edition/XP Professional/XP Professional x64 Edition, Mac OS® 9.1

X 10.2.4 or greater simultaneously can access this printer. For further

95/98/Me, Windows® NT4.0,

information, see the Network User’s Guide supplied with the printer. The wireless network function is supported by the HL-5280DW only.

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2. PARTS NAMES AND FUNCTIONS

2.1 Overview

(HL-5240/5250DN)

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

Front cover release button

Control panel

Face-down output tray support flap (support flap)

MP tray cover ASSY

Paper tray

Face-down output tray

Multi-purpose tray (MP tray)

Fig. 1-1

Front cover

Power switch

Back cover

Duplex tray (For HL-5250DN)

C power connector

USB interface connector

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

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

Fig. 1-2

DIMM cover

Parallel interface connector

Network status LEDs (Light emitting diodes) (For HL-5250DN)

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CHAPTER 1 GENERAL

(HL-5270DN/5280DW)

Control panel

Face-down output tray support flap (support flap)

MP tray cover ASSY

Front cover release button

Paper tray

Face-down output tray

Front cover

Power switch

Multi-purpose tray (MP tray)

Fig. 1-3

Back cover

Duplex tray

C power connector

USB interface connector

10/100BASE-TX port

DIMM cover

Parallel interface connector

LEDs (Light emitting diodes)

Fig. 1-4

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

2.2 Control Panel

(HL-5240/5250DN)

There are the four Light Emitting Diodes (LEDs) (Toner, Drum, Paper and Status) and two control buttons (Go and Job Cancel) on the control panel.

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

2. Drum

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

3. Paper

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

4. Status

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

5. Job Cancel button

will stops and cancels the print operation in progress.

6. Go button

Wake-up / Error recovery / Form feed / Reprint

Fig. 1-5

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CHAPTER 1 GENERAL

(HL-5270DN/5280DW)

Fig. 1-6

1. LCD

• Off: The printer is off or in sleep status.

• Green (General): Ready to print.

Printing Warming up Job canceling

• Red (Error): There is a problem with the printer.

• Orange (Setting): The printer is offline.

Choosing a menu Setting number of reprints. Pause

2. Data LED: Orange

• On: Data is in the printer memory.

• Blinking: Receiving or processing data.

• Off: No remaining data in the memory.

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

4. Job Cancel button

Stop and cancel the printing operation in progress.

5. Reprint button

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

6. Menu buttons

• +: Move forward through menus.

Move forward through the available options.

• -: Move backward through menus.

Move forward through the available options.

• Set: Choose the control panel menu.

Set the chosen menus and settings.

• Back: Go back one level in the menu structure.

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3. SPECIFICATIONS

3.1 Printing

Print method Electrophotography by semiconductor laser beam scanning

Laser Wavelength: 770 - 810nm

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

Output: 5mW max Laser class: Class B

Resolution <Windows

Windows Edition and Mac OS



95, WindowsNT



XP Home Edition/XP Professional/XP Professional x64



4.0, Windows



98/Me, Windows



2000,

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

<Linux> 600dpi/ 300dpi

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

Print quality Normal printing mode

Economy printing mode (Toner saving mode)

Print speed Normal

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

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

First print Less than 8.5 seconds when the printer is in the ready state.

(when loading A4 or Letter-size paper from the standard paper tray)

Consumables <Toner cartridge>

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

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

NOTE:

Print speed varies depending on the paper size or media type. For details, refer to 3.8 ‘Print

Speeds with Various Settings’ in this Chapter.

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CHAPTER 1 GENERAL

3.2 Functions

Processor 266MHz

Emulation BR-Script 3 (PostScript

Memory <Standard>



3TM), HP LaserJet (PCL6), Epson FX-850 and

IBM Proprinter XL

16 MB (HL-5240) 32MB (HL-5250DN/5270DN/5280DW)

DIMM

(HL-5240) The HL-5240 printer has 16 MB of standard memory and one slot for optional memory expansion. You can expand the memory up to 528 MB by installing dual in-line memory modules (DIMMs).

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

“DIMM types”

You can install the following DIMMs:

• 128 MB Buffalo Technology VN133-D128/ VN133-X128

• 256MB Buffalo Technology VN133-D256

• 512MB Buffalo Technology VN133-D512

• 64 MB TechWorks 12165-0004

• 128 MB TechWorks 12462-0001

• 256MB TechWorks 12485-0001

• 512MB TechWorks 12475-0001

In general, the DIMM must have the following specifications:

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

NOTE:

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

Interface Standard:

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

Hi-Speed USB 2.0 IEEE 1284 Parallel

Option:

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

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

1-8

Hi-Speed USB 2.0 IEEE 1284 Parallel

10/100 BASE-TX

N/A N/A

Hi-Speed USB 2.0 IEEE 1284 Parallel

10/100 BASE-TX Wireless LAN IEEE802.11 b/g

Confidential

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

Resident Fonts (HL-5240/5250DN)

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

(HL-5270DN/5280DW)

<PCL>

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



<PostScript

3TM>

66 fonts

Option Font (HL-5240/5250DN/5270DN/5280DW)

BT-1000 (Agfa Barcode Font)

Printer driver <Windows

• PCL Driver for Windows



Windows



2000 and Windows XP Home Edition/XP

95/98/Me, Windows NT 4.0,

Professional/XP Professional x64 Edition *

* Download the printer driver for Windows

Edition from http://solutions.brother.com



• Generic PCL Driver for Windows NT Windows



XP Home Edition/XP Professional/XP Professional

4.0, Windows 2000 and

x64 Edition



• BR-Script 3 (PPD file) for Windows



<Macintosh

• Brother Laser Driver for Mac OS

95/98/Me, Windows NT 4.0



9.1 to 9.2 and Mac OS X

10.2.4 or greater



• BR-Script 3 (PPD file) for Mac OS

9.1 to 9.2 and Mac OS X

10.2.4 or greater



XP Professional x64

<Linux*>

• LPR Driver for Linux

• CUPS driver for Linux

* Download the printer driver for Linux from

http://solutions.brother.com

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CHAPTER 1 GENERAL

Utilities (HL-5240)

System Requirements

Computer Platform & Operating System Version

Windows

Macintosh

Interactive Help*

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

Interactive Help*, Driver Deployment Wizard**

* Interactive Help: Instructional animations for problem solving. ** The Driver Deployment Wizard automates the installation of a

printer in a peer-to-peer network.

Processor Speed Minimum

RAM

95*1, 98, 98SE 486/66 MHz 8 MB 16 MB 40 MB

NTWorkstation 4.0 *1Intel Pentium 75 MHz 16 MB 32 MB 50 MB

2000 Professional Intel Pentium 133 MHz 64 MB 128 MB 50 MB

Me Intel Pentium 150 MHz 32 MB 64 MB 50 MB

XP Home Edition



Pentium 300 MHz 128 MB 128 MB 50 MB

Intel

XP Professional

XP Professional x64 Edition

AMD Opteron AMD Athlon



Intel

XeonTM with Intel

EM64T



X Pentium with 4 Intel

Intel

256 MB 256 MB 50 MB

EM64T

OS 9.1-9.2 32 MB 64 MB 50 MB Apple



Mac OS



X10.2.4 or

All base models meet minimum requirements

128 MB 160 MB 50 MB

greater

Recom-

mended

RAM

Available Hard Disk Space

*1 USB is not supported under Windows 95 or Windows NT 4.0.



*2 Download the printer driver for Windows

http://solutions.brother.com

XP Professional x64 Edition from

*3 Power Macintosh with an Apple original pre-installed USB port.

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3.3 Electronics and Mechanics

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

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

Power consumption Printing: Average 610 W at 25°C (77°F)

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

Noise level <Sound pressure>

Printing: 53dB (A) Standing by: 27dB (A)

Printing: LWAd=6.4 Bell (A) Standing by: 4.0 Bell (A)

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

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

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

Average 620 W at 25°C (77°F) (HL-5280DW)

Average 9 W (HL-5250DN/5270DN) Average 12 W (HL-5280DW)

Humidity Operating: 20 to 80% (non condensing)

Storage: 10 to 85% (non condensing)

Dimensions (HL-5240/5250DN) <W x D x H>

371 x 384 x 246 mm (14.6 x 15.1 x 9.7 inches) (HL-5270DN/5280DW) <W x D x H>

393 x 384 x 259 mm (15.5 x 15.1 x 10.2 inches)

Weight (HL-5240)

Approximately 8.3 kg (18.3 lb.), not including the drum unit and toner

cartridge.

Approximately 9.5 kg (20.9 lb.) including the drum unit and toner

cartridge.

(HL-5250DN) Approximately 8.6 kg (19.0 lb.), not including the drum unit and toner

cartridge.

Approximately 9.8 kg (21.6 lb.) including the drum unit and toner

cartridge.

(HL-5270DN/5280DW) Approximately 8.8 kg (19.4 lb.), not including the drum unit and toner

cartridge.

Approximately 10.0 kg (22.0 lb.) including the drum unit and toner

cartridge

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

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CHAPTER 1 GENERAL

3.4 Service Information

These are key service information to maintain the product. Machine life: 200,000 pages/ 5 years MTBF (Meantime between failure): Up to 4000 hours MTTR (Meantime to repair): Average 30 minutes Monthly volume: 20,000 pages Periodical replacement parts:

Fuser Unit 100,000 pages Separator pad holder assembly 100,000 pages Pick up roller assembly 100,000 pages Laser Unit 100,000 pages

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

3.5 Network Connectivity

• NC-6400h (HL-5250DN/5270DN/5280DW)

Operating system support

Protocol support

Network type 10/100BASE-TX Ethernet network Network

printing

Management utilities

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

Parts Approximate Life



Windows Edition/XP Professional/XP Professional x64 Edition, Mac OS

95/98/Me, Windows NT  4.0, Windows  2000/XP Home



9.1 to 9.2, Mac OS



X 10.2.4 or greater

TCP/IP: IPv4 APR, RARP, BOOTP, DHCP, APIPA (Auto IP),

WINS, NetBIOS name resolution, DNS Resolver, mDNS. LPR/LPD, Custom Raw Port/Port9100, SMB Print, IPP, FTP Server, Telnet, SNMP, HTTP, TFTP, SMTP Client

TCP/IP: IPv6 NDP, DNS Resolver, mDNS, LPR/LPD, Custom Raw

Port/Port9100, IPP, FTP Server, Telnet, SNMP, HTTP, TFTP, SMTP Client



Windows Windows x64 Edition TCP/IP printing, Macintosh

BRAdmin Professional utility

BRAdmin Light

Web BRAdmin

95/98/Me Peer-to-Peer printing, Windows NT  4.0 and



2000/XP Home Edition/XP Professional/XP Professional



Windows

95/98/Me, Windows NT  4.0, Windows 



printing

2000/XP Home Edition/XP Professional/XP Professional x64 Edition



Mac OS

Windows Server, Windows

X 10.2.4 or greater



2000 Professional / Server / Advanced



XP Home Edition/XP

Professional/XP Professional x64 Edition Professional

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

Network interface 10/100BASE-TX Ethernet Printer interface Parallel Support protocol TCP/IP, NetBEUI Management features

Embedded web server support SNMP / MIB support TELNET remote console BRAdmin Professional compatible Flash memory for easy updating of firmware

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

Network node type NC-7200w Operating system

support

Protocol support

Windows Mac OS

TCP/IP: IPv4



98/Me, Windows NT  4.0, Windows  2000/XP



X 10.2.4 or greater

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

TCP/IP: IPv6

NDP, DNS Resolver, mDNS, LPR/LPD, Custom Raw Port/Port9100, IPP, FTP Server, Telnet,

SNMP, HTTP, TFTP, SMTP Client Network type IEEE 802.11b/g wireless Frequency 2412-2472 MHz RF channels

USA/Canada 1-11 Europe/Oceania 1-13 Japan 1-14

Communication

Infrastructure, Ad-hoc 802.11

mode

802.11b 11/5.5/2/1 Mbps Data rates

802.11g 54/48/36/24/18/12/9/6 Mbps

Link distance 70 m (233 ft.) at lowest data rate (The distance rate will vary upon

environment and other equipment location.)

Network security SSID/ESSID, 128 (104) / 64 (40) bit WEP, WPA-PSK (TKIP/AES),

LEAP



Network printing

Computer requirements (for drivers, BRAdmin Professional, Peer-to-Peer software, etc.)

Macintosh  connection

Windows Windows NT Macintosh

Processor Minimum Speed

Minimum RAM

Recommended RAM

Computer

Processor Minimum

95/98/Me Peer-to-Peer printing



4.0 and Windows  2000/XP TCP/IP printing



printing (Mac OS  10.2.4 or greater supporting TCP/IP)



Pentium

Windows NT

24MB for Windows

32MB for Windows

64MB for Windows

32MB for Windows

64MB for Windows

128MB for Windows

II or equivalent for Windows  98/Me,



4.0, Windows  2000/XP



98/Me



2000



98/98SE/Me



2000



Wireless (AirPort) ready Power Macintosh

All base models meet minimum requirements

Speed Minimum RAM

Recommended

128MB for Mac OS

160MB for Mac OS



X 10.2.4 or greater



X 10.2.4 or greater

RAM

Management utilities

BRAdmin Professional

BRAdmin Light

Web BRAdmin

Windows



2000/XP

Mac OS

Windows

Advanced Server, Windows



98/Me, Windows NT  4.0, Windows



X 10.2.4 or greater



2000 Professional / Server /



XP Professional



*1: Web BRAdmin are available as a download from http://solutions.brother.com.

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CHAPTER 1 GENERAL

3.6 Paper

3.6.1 Paper handling

Paper Input*

Multi-purpose tray 50 sheets

Paper tray (Standard) 250 sheets

Lower tray (Option) 250 sheets

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

Paper Output*

Face-down 150 sheets

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

Duplex

Manual Duplex Yes

Automatic Duplex N/A Yes

3.6.2 Media specifications

(1) Media types

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

All models

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

Paper tray Tray 1

Multi-purpose tray MP Tray

Optional lower tray unit Tray 2/ Tray 3

Duplex tray for automatic duplex

DX printing (for HL5250DN/5270DN/5280DW)

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

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

Plain paper

75 g/m2 to 105

g/m

(20 to 28 lbs.)

Recycled

paper

Bond paper

Rough paper-

60 g/m2 to 161

g/m

(16 to 43 lbs.)

Thin paper

60 g/m2 to 75

g/m

(16 to 20 lbs.)

Thick paper

105 g/m2 to 161

g/m

(28 to 43 lbs.)

Transparency

Tray 1/2/3 MP Tray DX

Yes Yes Yes

Yes

60 g/m2 to 105

g/m

(16 to 28 lbs.)

Yes

60 g/m g/m

to 161

(16 to 43 lbs.)

N/A

Yes Yes Yes

N/A Yes N/A

Yes

Up to 10 sheets A4 or Letter **

Yes

Up to 10 sheets A4 or Letter

N/A

Choose the media type from the printer driver

Plain paper

Recycled paper

Bond paper

Thin paper

Thick Paper or Thicker Paper

Transparencies

Labels

Envelopes

N/A Yes

A4 or Letter

N/A Yes N/A

N/A

Thicker Paper

Envelopes, Env. Thin, Env. Thick

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

(2) Media size

MP Tray Tray 1 (Standard)

Width:

69.9 to 215.9 mm (2.75 to 8.5 in.)

Length:

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

Tray 2, Tray3 (Option)

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

A4, Letter, Legal*

116 to 406.4 mm (4.57 to 16 in.)

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

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CHAPTER 1 GENERAL

(3) Media weights

Tray 1 MP Tray DX

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

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

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

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

(4) Recommended paper

Plain paper

Xerox Premier 80 g/m Xerox Business 80 g/m

Europe USA

Xerox 4200DP 20lb Hammermill Laser Paper 24lb

M-real DATACOPY 80 g/m2

Recycled paper

Transparency

Label

Xerox Recycled Supreme N/A

3M CG3300 3M CG 3300

Avery laser label L7163 Avery laser label #5160

* This printer can use recycled paper that meets the DIN 19309 specification.

(5) Moisture content

Moisture content

4% to 6% by weight

CAUTION:

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

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

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

• Avoid using coated paper such as vinyl coated paper.

• Avoid using preprinted or highly textured paper.

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

printers.

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

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

• Do not use organizer sheets that are stuck together. The glue that is used might caused

damaged to the printer.

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

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

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Confidential

3.7 Printable Area

3.7.1 PCL5e/EPSON/IBM emulation

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

Portrait

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

NOTE:

Physical page

Printable area

Logical page

B Physical page length

Maximum logical page length

Distance from edge of physical page to edge of logical page

• “Logical page” shows the printable area for a PCL driver.

• “Printable area” shows mechanical printable area of the machine.

• Therefore, the machine can only print within the shaded area when you use a PCL driver.

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CHAPTER 1 GENERAL

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

Size A B C D E F G

Letter

Legal

Folio

Executive

A 4

A 5

A 6

B 5 (JIS)

B 5 (ISO)

B 6 (ISO)

COM10

MONARCH

C 5

DL L

NOTE:

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

except B5 (ISO), B6 (ISO).

• The dot size is based on 300 dpi resolution.

215.9 mm

8.5” (2,550 dots)

215.9 mm

8.5” (2,550 dots)

215.9 mm

8.5” (2,550 dots)

184.15 mm

7.25” (2,175 dots)

210.0 mm

8.27” (2,480 dots)

148.5 mm

5.85” (1,754 dots)

105.0 mm

4.13” (1,240 dots)

182.0 mm

7.1” (2,130 dots)

176.0 mm

6.93” (2,078 dots)

125.0 mm

4.92” (1,476 dots)

104.78 mm

4.125” (1,237 dots)

98.43 mm

3.875” (1,162 dots)

162.0 mm

6.38” (1,913 dots)

110.0 mm

4.33” (1,299 dots)

220.0 mm

8.66” (2,598 dots)

279.4 mm

11.0” (3,300 dots)

355.6 mm

14.0” (4,200 dots)

330.2mm

13.0” (3,900 dots)

266.7 mm

10.5” (3,150 dots)

297.0 mm

11.69” (3,507 dots)

210.0 mm

8.27” (2,480 dots)

148.5 mm

5.85” (1,754 dots)

257.0 mm

10.11” (3,033 dots)

250.0 mm

9.84” (2,952 dots)

176.0 mm

6.93” (2,078 dots)

241.3 mm

9.5” (2,850 dots)

190.5 mm

7.5” (2,250 dots)

229.0 mm

9.01” (2,704 dots)

220.0 mm

8.66” (2,598 dots)

110.0 mm

4.33” (1.299 dots)

203.2 mm

8.0” (2,400 dots)

203.2 mm

8.0” (2,400 dots)

203.2 mm

8.0” (2,400 dots)

175.7 mm

6.92” (2,025 dots)

198.0 mm

7.79” (2,338 dots)

136.5 mm

5.37” (1,612 dots)

93.0 mm

3.66” (1,098 dots)

170.0 mm

6.69” (2,007 dots)

164.0 mm

6.46” (1,936 dots)

164.0 mm

4.44” (1,334 dots)

92.11 mm

3.63” (1,087 dots)

85.7 mm

3.37” (1,012 dots)

150.0 mm

5.9” (1,771 dots)

98.0 mm

3.86” (1,157 dots)

207.4 mm

8.17” (2,450 dots)

279.4 mm

11.0” (3,300 dots)

355.6 mm

14.0” (4,200 dots)

330.2mm

13.0” (3,900 dots)

266.7 mm

10.5” (3,150 dots)

297.0 mm

11.69” (3,507 dots)

210.0 mm

8.27” (2,480 dots)

148.5 mm

5.85” (1,754 dots)

257.0 mm

10.11” (3,033 dots)

250.0 mm

9.84” (2,952 dots)

176.0 mm

6.93” (2.078 dots)

241.3 mm

9.5” (2,850 dots)

190.5 mm

7.5” (2,250 dots)

229.0 mm

9.01” (2,704 dots)

220.0 mm

8.66” (2,598 dots)

110.0 mm

4.33” (1.299 dots)

6.35 mm

0.25” (75 dots)

6.35 mm

0.25” (75 dots)

6.01 mm

0.24” (71 dots)

6.35 mm

0.25” (75 dots)

6.01 mm

0.24” (71 dots)

6.27 mm

0.25” (74 dots)

0 mm

4.2 mm

0.16” (50 dots)

4.2 mm

0.16” (50 dots)

4.2 mm

0.16” (50 dots)

4.2 mm

0.16” (50 dots)

4.2 mm

0.16” (50 dots)

4.2 mm

0.16” (50 dots)

4.2 mm

0.16” (50 dots)

4.2 mm

0.16” (50 dots)

4.2 mm

0.16” (50 dots)

4.2 mm

0.16” (50 dots)

4.2 mm

0.16” (50 dots)

4.2 mm

0.16” (50 dots)

4.2 mm

0.16” (50 dots)

4.2 mm

0.16” (50 dots)

6.27 mm

0.25” (74 dots)

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Landscape

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

NOTE:

Physical page

Printable area

B Physical page length

D Maximum logical page length

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

Logical page

• “Logical page” shows the printable area for a PCL driver.

• “Printable area” shows mechanical printable area of the machine.

• Therefore, the machine can only print within the shaded area when you use a PCL driver.

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CHAPTER 1 GENERAL

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

Size A B C D E F G

Letter

Legal

Folio

Executive

A 4

A 5

A 6

B 5 (JIS)

B 5 (ISO)

B 6 (ISO)

COM10

MONARCH

C 5

DL L

NOTE:

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

except B5 (ISO), B6 (ISO).

• The dot size is based on 300 dpi resolution.

279.4 mm

11.0” (3,300 dots)

355.6 mm

14.0” (4,200 dots)

330.2mm

13.0” (3,900 dots)

266.7 mm

10.5” (3,150 dots)

297.0 mm

11.69” (3,507 dots)

210.0 mm

8.27” (2,480 dots)

148.5 mm

5.85” (1,754 dots)

257.0 mm

10.11” (3,033 dots)

250.0 mm

9.84” (2,952 dots)

176.0 mm

6.93” (2,078 dots)

241.3 mm

9.5” (2,850 dots)

190.5 mm

7.5” (2,250 dots) 229 mm

9.01” (2,704 dots) 220 mm

8.66” (2,598 dots) 110 mm

4.33” (1,299 dots)

215.9 mm

8.5” (2,550 dots)

215.9 mm

8.5” (2,550 dots)

215.9 mm

8.5” (2,550 dots)

184.15 mm

7.25” (2,175 dots)

210.0 mm

8.27” (2,480 dots)

148.5 mm

5.85” (1,754 dots)

105.0 mm

4.13” (1,240 dots)

182.0 mm

7.1” (2,130 dots)

176.0 mm

6.93” (2,078 dots)

125.0 mm

4.92” (1,476 dots)

104.78 mm

4.125” (1,237 dots)

98.43 mm

3.875” (1,162 dots) 162 mm

6.38” (1,913 dots) 110 mm

4.33” (1,299 dots) 220 mm

8.66” (2,598 dots)

269.3 mm

10.6” (3,180 dots)

345.5 mm

13.6” (4,080 dots)

320.0mm

12.6” (3,780 dots)

256.6 mm

10.1” (3,030 dots)

287.0 mm

11.2” (3,389 dots)

200.0mm

7.87” (2,362 dots)

138.5 mm

5.45” (1,636 dots)

247.0 mm

9.72” (2,916 dots)

240.0 mm

9.44” (2,834 dots)

166.4 mm

6.55” (1,960 dots)

231.1 mm

9.1” (2,730 dots)

180.4 mm

7.1” (2,130 dots)

219.0 mm

8.62” (2,586 dots)

210.0 mm

8.26” (2,480 dots)

97.5 mm

3.84” (1,151 dots)

215.9 mm

8.5” (2,550 dots)

215.9 mm

8.5” (2,550 dots)

215.9 mm

8.5” (2,550 dots)

184.15 mm

7.25” (2,175 dots)

210.0 mm

8.27” (2,480 dots)

148.5 mm

5.85” (1,754 dots)

105.0 mm

4.13” (1,240 dots)

182.0 mm

7.1” (2,130 dots)

176.0 mm

6.93” (2,078 dots)

125.0 mm

4.92” (1,476 dots)

104.78 mm

4.125” (1,237 dots)

98.43 mm

3.875” (1,162 dots) 162 mm

6.38” (1,913 dots) 110 mm

4.33” (1,299 dots) 220 mm

8.66” (2,598 dots)

5.0 mm

0.2” (60 dots)

5.0 mm

0.2” (60 dots)

4.8 mm

0.19” (59 dots)

5.0 mm

0.2” (60 dots)

4.8 mm

0.19” (59 dots)

6.27 mm

0.25” (74 dots)

0 mm

4.2 mm

0.16” (50 dots)

4.2 mm

0.16” (50 dots)

4.2 mm

0.16” (50 dots)

4.2 mm

0.16” (50 dots)

4.2 mm

0.16” (50 dots)

4.2 mm

0.16” (50 dots)

4.2 mm

0.16” (50 dots)

4.2 mm

0.16” (50 dots)

4.2 mm

0.16” (50 dots)

4.2 mm

0.16” (50 dots)

4.2 mm

0.16” (50 dots)

4.2 mm

0.16” (50 dots)

4.2 mm

0.16” (50 dots)

4.2 mm

0.16” (50 dots)

6.27 mm

0.25” (74 dots)

3.7.2 PCL6 emulation

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

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3.8 Print Speeds with Various Settings

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

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

Media type setting All models

Transparency 28/30 ppm

Thin Paper 28/30 ppm

Plain Paper 28/30 ppm

Recycled Paper 28/30 ppm

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

Thick Paper,

14 ppm

Envelopes, Env.Thin

Thicker/Bond Paper,

3 ppm

Env.Thick

Media type setting All models

Transparency 28/30 ppm

Thin Paper 28/30 ppm

Plain Paper 90 sec 28/30 ppm Æ 14 ppm

Recycled Paper 90 sec 28/30 ppm Æ 14 ppm

Env.Thin 14 ppm

Thick Paper,

14 ppm

Envelopes

Thicker/Bond Paper,

3 ppm

Env.Thick

NOTE:

• The print speed may vary according to conditions, such as paper size and paper tray.

• When a smaller size paper than A4 or Letter is printed, the temperature on both edges of

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

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

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CHAPTER 1 GENERAL

3.9 Toner Cartridge Weight Information

Toner Cartridge Weight (approximate weight)

High yield toner cartridge

(TN580 US, TN-3170 EUR/EEU

TN-3185 AP)

Brand new Toner Cartridge Weight 727g 787g

From the first production

From the serial number:

M5JD021965D~

Toner Weight at Brand New Toner Cartridge

Toner Cartridge Weight at Toner Near Empty

Remain Toner Weight at Toner Near Empty

Toner Cartridge Weight at Toner Life End

Remain Toner Weight at Toner Life End

Standard toner cartridge

(TN-550 US, TN-3130EUR/EEU

TN-3145 AP)

Brand new Toner Cartridge Weight 663g 723g Toner Weight at Brand New Toner

Cartridge Toner Cartridge Weight at Toner

Near Empty Remain Toner Weight at Toner

Near Empty

From the first production

190g 190g

617g (± 13g) 677g (± 13g)

77g 77g

605g (± 10g) 665g (± 10g)

68g 68g

126g 126g

617g (± 13g) 677g (± 13g)

77g 77g

From the serial number:

M5JV030390D~

Toner Cartridge Weight at Toner Life End

Remain Toner Weight at Toner Life End

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

NOTE: The figure has varied quite a bit, for example from 590 pages to 720 pages, on a comparison of

printing test results.

602g (± 10g) 662g (± 10g)

65g 65g

NOTE:

• Without yellow protector, DR cover.

• Toner cartridge weight may vary within 2 to 3g depending on the cartridge weight.

• From the serial number “M5JV030390D~” for the standard toner cartridge and

“M5JD021965D~” for the high yield toner cartridge, 60g is over in the total weight of a toner cartridge because of a different type of the Develop Roller.

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4. SERIAL NO. DESCRIPTIONS

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

< ID for production month >

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

< ID for year >

5: 2005 6: 2006

< ID for factory >

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

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

(2) Process unit: Imprinted on the aluminum bag

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

< SERIAL NO. >

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

SEQUENTIAL NO.

FACTORY ID NO.

YEAR

MONTH

(Drum unit with toner cartridge)

5 A 1 1 J A

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

YEAR

MONTH

PRODUCTION LINE NO.

FACTORY ID NO.

DATE

A 5 J 5 1 0 0 1 0 4 A

MONTH

YEAR

FACTORY ID NO.

TONER VOLUME

SERIAL NO.

PRODUCTION LINE NO.

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

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CHAPTER 1 GENERAL

(4) Toner cartridge: Imprinted on the aluminum bag

(5) Laser unit: On the laser unit

5 A 3 0 J A

YEAR

MONTH

DATE

Printed on the bar code label attached on the toner cartridge

CARTRIDGE PRODUCTION INFO.

M 5 J L 0 0 0 1 9 9 A

MONTH

YEAR

FACTORY ID NO.

TONER VOLUME L: 80g M: 100g

PRODUCTION LINE NO.

FACTORY ID NO.

SERIAL NO.

PRODUCTION LINE NO.

X X XXXXXXX

SERIAL NUMBER

MOLD NUMBER

MANUFACTURE DISTINCTION

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

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CHAPTER 2 THEORY OF OPERATION

1. OVERALL

1.1 General Block Diagram

Fig. 2-1 shows a general block diagram.

Control system

Extended RAM SODIMM 144pin

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

Video control block

USB host (HL-5280DW)

Ethernet

10/100 Base TX

(HL-5250DN/

5270DN/5280DW)

Interface block USB Parallel

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

Wireless LAN (HL-5280DW)

External device

supply block

Low-voltage power

supply block

High-voltage power

Laser unit

Drum unit

Charging

block

Engine control block

Transfer block

Exposure

drum

Developer unit

Developing block

Toner cartridge

Drive block (DC motor)

Paper dust

cleaner block

Operation block

(Control panel)

Paper tray

Fuser unit

Paper eject tray

Paper feed system

Image generation system

Fig. 2-1

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CHAPTER 2 THEORY OF OPERATION

2. ELECTRONICS

2.1 General Block Diagram

Main fan

Power supply fan

Sensor PCB (PE+PEDGE)

MP sensor PCB

Tray1 solenoid

Regist solenoid

MP solenoid

Interlock switch (Cover sensor)

Toner LED PCB (Light emission)

Toner sensor PCB (Light reception)

High-voltage power supply

Regist front sensor

Regist rear sensor

Front relay PCB

New toner sensor

Wireless LAN (HL-5280DW)

Polygon motor

Laser diode PCB

Fig. 2-2

Main PCB

Low-voltage power supply

Rear relay PCB

Paper eject sensor

DX solenoid (HL-5250DN/5270DN)

LT PCB

Main motor

Panel PCB

Fuser thermistor

DX unit sensor PCB

LT Sensor PCB (PE+PEDGE)

LT solenoid

LT1

LT Sensor PCB (PE+PEDGE)

LT solenoid

LT2

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2.2 Main PCB Block Diagram

Fig. 2-3 shows the block diagram of the main PCB.

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

MAX 512MB

SO-DIMM

SPD

Pararell IF

USB2.0

(Laser Diode PCB)

8 pin

CN (Laser Unit)

14 pin

CN (MAIN MOTOR)

19 pin

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

D16/A13

CDCC GA

IEEE 1284

2.0 High Speed

+3.3V

+5V

+3.3V

SDRAM

EEPROM

16kbit

Xtal(for Sysclk/USB)

48.00MHz

Xtal(for Video)

23.4617MHz

Motor Driver IC

Reset IC

Regulator 5V 3.3V

Regulator

3.3V 1.5V

CLK

INT

DATA

REQn

RSTn

VBUS

D+/D-

SCAN_CTR/ MAIN_CTR/ MAIN_FR

ASIC

CPU Core

(Sapphire 266MHz)

Fig. 2-3

Mask ROM Flash ROM

8MB Internal: 16MB

CSROM0/

RD/WR

D16/A24

EXCS0/

RD/WR

INTn

RSTn

INTn

RSTn

Network IC

(LAN9115)

HL-5250DN: TCP/IP

HL-5270DN: Full Protocol

EXCS1/

Rb/WR

USB HOST

ISP 1362

HL-5280DW

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

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

DX solenoid

3 solenoid (T1/REG/MP)

3 sensor (Front_Cover/Toner sensor/Process NEW)

ComparatorHTLIMITN

AI1:2

AI3:7

2 sensor (PaperOut/DX tray)

5 Analog_in (HVPS)

GRIDC

5 PWM_out (HVPS)

2 FAN (MAIN/HVPS)

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

Toner LED

HeaterON

4 sensor (pedgex2/PEx2)

2 solenoid

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

CSROM1/

RD/WR

D16/A24

12.00MHz

CN (RELAY FRONT)

Therm1/2

+24V

+8V +3.3V

+24VRET

LAN

Xtal

25.00MHz

Wireless

LAN

Xtal

CN (PANEL)

10 pin

CN (DXSOL)

2 pin

CN (TNRSEN)

2 pin

9 pin

CN (RELAY REAR)

6 pin

CN (HVPS)

23 pin

CN (LVPS)

8 pin

CN (LT)

12 pin

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CHAPTER 2 THEORY OF OPERATION

2.3 Main PCB

For the entire circuit diagram of the main PCB.

2.3.1 CPU

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

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

2.3.2 USB interface (2.0 High Speed)

Stores the data received from the PC into DRAM as controlled by the DMA controller. The transmission speed is 12Mbps.

2.3.3 IEEE1284 interface

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

2.3.4 Network interface

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

2.3.5 ROM

< ROM 0 >

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

< ROM 1: Demo Specification For US, Canada>

16 Mbit ROM (2 MB) is fitted. (HL-5240) 32 Mbit ROM (4 MB) is fitted. (HL-5250DN)

< ROM 1: Standard Specification >

16 Mbit ROM (2 MB) is fitted. (HL-5250DN) 32 Mbit ROM (4 MB) is fitted. (HL-5270DN/5280DW)

2.3.6 SDRAM

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

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

2.3.7 Optional RAM

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

2.3.8 EEPROM

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

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2.3.9 Reset circuit

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

2.3.10 Panel I/O

The interface with the panel board is connected to ASIC.

2.3.11 Video I/O

The video signal is directly output from ASIC to laser unit.

2.3.12 Power supply

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

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

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

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

2.3.13 Wireless LAN

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

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CHAPTER 2 THEORY OF OPERATION

2.4 Power Supply

2.4.1 Low-voltage power supply

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

The regulated output and the production code of each power supply are listed below;

Regulated Output Production Code +3.3V / 1.5A +24V / 2.4A, +8V / 0.8A

2.4.2 High-voltage power supply

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

100V: SRP1828UC 200V: SRP1829EK

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3. MECHANICS

3.1 Overview of Printing Mechanism

Eject roller ASSY

Fuser unit

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

Laser unit

Developer roller

Back cover

Outer chute ASSY

Halogen heater

Heat roller

Pressure roller

Exposure drum

Duplex unit

Transfer roller

Paper tray

Paper tray (LT unit)

Drum unit

Pinch roller

Separation roller MP

Feed roller

Regist roller

Regist actuator front

Feed roller TR

Pressure roller

Regist actuator rear

Separation roller

Feed roller

Feed roller TR

Pressure roller

Separation roller

Feed roller

LT unit

Fig. 2-4

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CHAPTER 2 THEORY OF OPERATION

3.2 Overview of Gears

Eject solenoid

MP solenoid

T1 solenoid

LT solenoid

Main motor (Drive sub ASSY)

Fig. 2-5

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3.3 Paper Transfer

3.3.1 Paper supply

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

Pinch roller

Regist roller

PE actuator

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

Feed roller TR

Pressure roller

Separation roller

Feed roller

Paper

Fig. 2-6

Plate

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

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CHAPTER 2 THEORY OF OPERATION

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

P/P clutch hook A2

P/P clutch hook A1

P/P gear 29 clutch cam

P/P clutch hook B

P/P differential

P/P gear 22/B23 tray drive

Gear 15

Plate ASSY

Plate up plate

Lift gear 46

Fig. 2-7

Gear 21-16

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

Stop

Fig. 2-8

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

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3.3.2 Paper registration

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

Exposure drum

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

Drum/toner ASSY

Transfer roller

Regist actuator rear

Regist roller

Regist actuator front

Fig. 2-9

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

3.3.3 Drum unit

 Exposure drum

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

 Primary charger

Forms a uniform charge on the drum surface.

(1) Corona wire

Generates the ion charge on the drum.

(2) Grid

Spreads the ion charge evenly over the drum surface.

 Transfer roller

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

 Cleaner

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

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CHAPTER 2 THEORY OF OPERATION

3.3.4 Developing

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

Corona wire

Exposure drum

Developer roller

Supply roller

Blade

Transfer roller

Fig. 2-10

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3.3.5 Fixing stage

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

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

Fuser unit

Heat roller

Halogen heater

Pressure roller

Fig. 2-11

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CHAPTER 2 THEORY OF OPERATION

3.3.6 Paper eject

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

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

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

Eject roller ASSY

Back cover

Paper eject actuator

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

Heat roller

Pressure roller

Fig. 2-12

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

After the paper exits from the eject roller ASSY with the front of sheet printed, the eject roller ASSY rotates conversely and feeds the paper to the duplex tray, where the paper skew is adjusted.

Afterwards, the paper is ejected from the duplex tray to the path through the regist roller and the transfer roller to the transfer block in the drum unit again for process of printing on the back of sheet.

Eject roller ASSY

Heat roller

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

Back cover

Outer chute ASSY

Pressure roller

Duplex unit

Transfer roller

Regist actuator rear

Fig. 2-13

Exposure drum

Regist roller

Pinch roller

Regist actuator front

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CHAPTER 2 THEORY OF OPERATION

3.3.8 Paper feeding from the MP tray

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

Separation roller MP

Feed roller

3.3.9 LT tray

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

Separation pad ASSY MP

Fig. 2-14

MP tray cover ASSY

Feed roller TR

Separation roller

Separation pad

Feed roller

Paper

Plate

Fig. 2-15

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

3.4 Toner Cartridge

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

3.4.1 Toner life end mode

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

The following graph shows the number of printable pages in the case of A4 printing.

HL-5240/5250DN/5270DN/5280DW(Standard (3.5K) toner)

Page/job 123456789101112

Cartridge life

Cartridge life+ON/OFF

Toner empty (5%)

Toner empty (4%)

Toner empty (3%)

Toner empty (2%)

Toner empty (1%)

4,200 6,329 7,615 8,477 9,094 9,559 9,920 10,210 10,447 10,645 10,813 10,957 2,310 3,915 5,096 6,000 6,715 7,295 7,774 8,177 8,520 8,817 9,075 9,302 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 4,375 4,375 4,375 4,375 4,375 4,375 4,375 4,375 4,375 4,375 4,375 4,375 5,833 5,833 5,833 5,833 5,833 5,833 5,833 5,833 5,833 5,833 5,833 5,833 8,750 8,750 8,750 8,750 8,750 8,750 8,750 8,750 8,750 8,750 8,750 8,750

17,500 17,500 17,500 17,500 17,500 17,500 17,500 17,500 17,500 17,500 17,500 17,500

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

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

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

Cartridge life

20,000

18,000

16,000

14,000

12,000

Cartridge life+ON/OFF

Toner empty (5%)

Toner empty (4%)

Toner empty (3%)

Toner empty (2%)

Toner empty (1%)

10,000

8,000

Printable pages

6,000

4,000

2,000

123456789101112

Page / Job

2-17

Confidential

CHAPTER 2 THEORY OF OPERATION

HL-5240/5250DN/5270DN/5280DW(High Capacity (7K) toner)

Page/job 123456789101112

Cartridge life

Cartridge life+ON/OFF

Toner empty (5%)

Toner empty (4%)

Toner empty (3%)

Toner empty (2%)

Toner empty (1%)

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

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

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

40,000

35,000

30,000

25,000

8,400 12,658 15,231 16,954 18,189 19,117 19,840 20,420 20,894 21,290 21,626 21,913 4,620 7,831 10,191 12,000 13,430 14,589 15,548 16,354 17,041 17,634 18,150 18,604 7,000 7,000 7,000 7,000 7,000 7,000 7,000 7,000 7,000 7,000 7,000 7,000

8,750 8,750 8,750 8,750 8,750 8,750 8,750 8,750 8,750 8,750 8,750 8,750 11,667 11,667 11,667 11,667 11,667 11,667 11,667 11,667 11,667 11,667 11,667 11,667 17,500 17,500 17,500 17,500 17,500 17,500 17,500 17,500 17,500 17,500 17,500 17,500 35,000 35,000 35,000 35,000 35,000 35,000 35,000 35,000 35,000 35,000 35,000 35,000

Cartridge life

Cartridge life+ON/OFF

Toner empty (5%)

Toner empty (4%)

Toner empty (3%)

Toner empty (2%)

Toner empty (1%)

20,000

15,000

Printable pages

10,000

5,000

123456789101112

Page / Job

• The number of rotation of the developer roller per page is as follows;

1. One printed page only or the first page of continuous printing = 11 rotations

2. The second page or later = 3.6 rotations

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

2-18

Confidential

3.4.2 New toner detection mechanism

(1) The motor drive is transmitted to the gear (4) through a few gears.

(2) When the gear (4) is rotated, the rib A on the gear (4) pushes against a new toner

actuator, and a new toner sensor detects the actuator motion. Then, the toner sensor detects that a new toner cartridge is installed.

(3) For the high yield toner cartridge, the rib B is provided on the gear (4) as shown in the

figure below so that a new toner actuator is pushed against twice by both ribs A and B.

(4) When the toner actuator is pushed twice, the two signals are transmitted to a new toner

sensor, and it is detected that the high yield toner cartridge is installed.

For the standard toner cartridge, the rib B is not provided, and a new toner actuator is pushed only once by the rib A. In this case, the one signal is transmitted to a new toner sensor so that it is detected that the standard toner cartridge is installed.

Relay front PCB ASSY

New toner actuator

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

Gear (4)

New toner sensor

Gear (1)

Gear (2)

Fig. 2-16

Rib B

Rib A

Gear (3)

2-19

Confidential

CHAPTER 2 THEORY OF OPERATION

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

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

[Density] [Voltage]

Toner property Actual control

Print density

[Density] [Voltage]

Print density

Bias voltage

[Used toner amount] [Used toner amount]

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

The bias voltage is changed with the steps described below:

(1) When the new toner sensor detects that the toner cartridge is replaced with a new (full)

one, the developing bias is set to 400V (initialized).

(2) After that, the bias voltage is stepped down according to the number of prints.

3.4.3 Counter reset during indication of “Toner Life End”

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

Toner Life End

(Toner empty)

Bias voltage

Toner Life End (Developer count full)

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

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

Coverage of each toner: Continued

Not used.

Development bias: Reset (Default)

When a new toner is inserted (Reset gear

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

is at the position of factory set.)

Coverage of each toner: Reset (0)

Development bias: Reset (Default)

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Confidential

3.5 Print Process

3.5.1 Charging

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

Voltage circuit

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

---

luminum drum sleeve

Organic photoconductor layer

Grid

HVPS

Exposure drum

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

3.5.2 Exposure stage

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

Laser detector

Toric Lens

Laser diode

Corona wire

CO Lens

Fig. 2-17

Drum

Laser beam

Paper

Laser beam

f θ lens

Polygon mirror

Motor

Fig. 2-18

< Laser exposure unit >

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

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

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CHAPTER 2 THEORY OF OPERATION

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

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

Surface potential (V)

1 Cycle of drum

+900

+400

+100

Drum sleeve

3.5.3 Transfer

(1) Transfer process

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

2 1

(a)

(b)

Time

Fig. 2-19

Primary charging

Laser beam exposure and developing

(a) Unexposed area

(Non image area)

(b) Exposed area

(Image area)

Transfer the image to paper

(2) Cleaning process of transfer roller

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

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Confidential

3.6 Sensors

Sensor name Type Located on

Regist front sensor Photo sensor High-voltage PS PCB

Regist rear sensor Photo sensor High-voltage PS PCB

Paper eject sensor Photo sensor Relay rear PCB

New toner sensor Photo sensor Relay front PCB

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

Toner LED PCB

Photo sensor Frame R

(Light emission)

Toner sensor PCB

Photo sensor Frame L

(Light reception)

Front cover sensor Mechanical switch Frame L

PE sensor Photo sensor PE EG sensor ASSY

Edge sensor Photo sensor PE EG sensor ASSY

MP PE sensor Photo sensor MP PE sensor ASSY

DX tray sensor Mechanical switch Relay rear PCB

Front cover sensor

Frame L

Chute

Frame R

Toner LED PCB (Light emission)

Regist frame

Paper eject sensor (Relay rear PCB)

DX tray sensor

New toner sensor (Relay front PCB)

Toner sensor PCB (Light reception)

Regist rear sensor

High-voltage PS PCB

Paper feed frame

MP PE sensor

PE EG sensor

PE sensor

Edge sensor

Regist front sensor

Fig. 2-20

2-23

Confidential

CHAPTER 2 THEORY OF OPERATION

3.7 Heat Control of Fuser Unit

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

< Fixing temperature of each media type >

Media type

Plain paper 213/185

Plain paper (Small size) 200/185

Plain paper (Duplex) 195/180

Recycled paper 195/180

Recycled paper (Small size) 189/170

Recycled paper (Duplex) 189170

OHP 185

OHP (Small size) 185

Fixing temperature (°C)

(approximately)

[Full speed / Half speed]

OHP (Duplex) 185

Thin paper 195

Thin paper (Small size) 195

Thin paper (Duplex) 181

Thick paper 200

Thick paper (Small size) 195

Thick paper (Duplex) 195

Envelope (Thin) 200

Envelope (Thin, small size) 200

Envelope (Thin, duplex) 195

Envelope (Others) 220

Envelope (Others, small size) 220

Envelope (Others, duplex) 205

NOTE:

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

2-24

Confidential

CHAPTER 3 PERIODIC MAINTENANCE

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

WARNING

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

and wash the clothes in cold water to avoid stains.

• Be careful to inhale toner.

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

outlet before accessing any parts inside the printer.

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

• When opening the front cover or back cover to access any parts inside the printer,

never touch the shaded parts shown in the following figures.

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

1. CONSUMABLE PARTS

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

1.1 Toner Cartridge

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

NOTE:

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

density setting.

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

used will change.

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

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

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Confidential

CHAPTER 3 PERIODIC MAINTENANCE

(HL-5240/5250DN)

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

If the LED shows this message, the printer has nearly run out of toner. Buy a new toner cartridge and have it ready before you get a “Toner Life End” message.

NOTE:

The Toner LED will blink continuously if the toner cartridge is nearly empty.

Fig. 3-1

(HL-5270DN/5280DW)

Appears at intervals.

TONER LOW

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

(HL-5240/5250DN)

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

Fig. 3-2

(HL-5270DN/5280DW)

Appears at intervals.

TONER LIFE END

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

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

3-2

Confidential

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

NOTE:

* To ensure high quality printing, make sure to use genuine Brother toner cartridges.

* It is recommended to clean the printer when replacing the toner cartridge.

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

Fig. 3-3

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

Fig. 3-4

CAUTION:

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

disposable paper or cloth in case you accidentally spill or scatter toner.

* To prevent damage to the printer from static electricity, DO NOT touch the electrodes shown

in the illustration.

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CHAPTER 3 PERIODIC MAINTENANCE

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

CAUTION:

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

it off with cold water at once.

* To avoid any degradation of the print quality, DO NOT touch the shaded parts shown in the

illustrations.

Fig. 3-5

NOTE:

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

of the cartridge.

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

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

(4) Unpack the new toner cartridge. Hold the cartridge level with both hands and gently rock it

from side to side five or six times to spread the toner evenly inside the cartridge.

Fig. 3-6

3-4

Confidential

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

CAUTION:

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

cartridges are left unpacked for a long time the toner life will be shortened.

* If an unpacked drum unit is put in direct sunlight or room light, the unit may be damaged.

* Brother strongly recommends that you do not refill the toner cartridge provided with your

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

* Printing with a third-party toner or third-party toner cartridge may reduce not only the print

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

* Put the toner cartridge in the drum unit immediately after you have removed the protective

cover. To prevent any degradation to the print quality, DO NOT touch the shaded parts shown in the illustrations.

(5) Pull off the protective cover.

Fig. 3-7

(6) Put the new toner cartridge firmly into the drum unit until you hear it lock into place. If you

put it in properly, the lock lever will lift automatically.

Fig. 3-8

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Confidential

CHAPTER 3 PERIODIC MAINTENANCE

CAUTION:

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

(7) Clean the primary corona wire inside the drum unit by gently sliding the blue tab from right

to left and left to right several times.

Home position

Fig. 3-9

CAUTION:

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

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

Fig. 3-10

3-6

Confidential

1.2 Drum Unit

A new drum unit can print approximately 25,000 A4 or Letter size single-sided pages at 5% coverage.

NOTE:

* There are many factors that determine the actual drum life, such as the temperature,

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

* For the best performance, use only genuine Brother toner. The printer should be used only in

a clean, dust-free environment with adequate ventilation.

* Printing with a third-party drum unit may reduce not only the print quality but also the quality

and life of the printer itself. Warranty coverage does not apply to problems caused by the use of a third-party drum unit.

(HL-5240/5250DN)

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

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

Fig. 3-11

(HL-5270DN/5280DW)

Appears at intervals.

DRUM NEAR END

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

3-7

Confidential

CHAPTER 3 PERIODIC MAINTENANCE

CAUTION:

* While removing the drum unit, handle it carefully as it may contain toner.

* Every time you replace the drum unit, be sure to clean the inside of the printer.

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

(HL-5240/5250DN)

(1) Make sure that the printer is turned on and the Drum LED is blinking. Press the front

cover release button and then open the front cover.

(HL-5270DN/5280DW)

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

and then open the front cover.

Fig. 3-12

(HL-5240/5250DN)

(2) Press and hold down Go for about 4 seconds until all the LEDs light up. Once all four

LEDs are lit, release Go.

Fig. 3-13

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Confidential

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

(HL-5270DN/5280DW)

(2) Hold down Go until the message “DRUM CLEAR” is displayed on the LCD, then release

Go.

Fig. 3-14

Improper Setup:

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

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

Fig. 3-15

CAUTION:

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

disposable paper or cloth in case you accidentally spill or scatter toner.

* To prevent damage to the printer from static electricity, DO NOT touch the electrodes shown

in the illustration.

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CHAPTER 3 PERIODIC MAINTENANCE

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

CAUTION:

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

it off with cold water at once.

* To avoid any degradation of the print quality, DO NOT touch the shaded parts shown in the

illustrations.

Fig. 3-16

NOTE:

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

of the cartridge.

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

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

(5) Unpack the new drum unit.

CAUTION:

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

3-10

Confidential

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

(6) Put the toner cartridge firmly into the new drum unit until you hear it lock into place. If you

put the cartridge in properly, the blue locklever will lift automatically.

Fig. 3-17

CAUTION:

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

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

Fig. 3-18

(HL-5240/5250DN)

(8) Close the front cover.

Make sure that the Drum LED is now off.

(HL-5270DN/5280DW)

(8) Close the front cover. Make sure that the “DRUM NEAR END” message on the LCD in

now off.

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CHAPTER 3 PERIODIC MAINTENANCE

2. PERIODICAL REPLACEMENT PARTS

2.1 Periodical Replacement Parts

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

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

Parts Name

Fuser Unit

Laser Unit Paper feeding kit

for Tray 1 *3 Paper feeding kit

for Tray 2 *3 Paper feeding kit

for Tray 3 *3 Paper feeding kit

for MP tray *2

LCD Message

(HL-5270DN

/5280DW)

REPLACE FUSER

REPLACE LASER

REPLACE PF KIT1

REPLACE PF KIT2

REPLACE PF KIT3

REPLACE PF

KITMP

Qty

Approximate Life *1

(number of prints)

1 100,000 pages

See subscription

2.2.1, Chapter 3

1 100,000 pages

See subscription

2.2.2, Chapter 3

1 100,000 pages

See subscription

2.2.3, Chapter 3

Replacement

Procedure

NOTE: *1

At 5% print coverage (A4 or Letter size). The actual number of printed pages will vary depending on the print jobs and paper you use.

*2 Paper feeding kit MP means the MP roller holder ASSY and the separation pad ASSY MP.

*3 Paper feeding kit for Tray 1, Tray 2 and Tray 3 means the roller holder ASSY, the separation pad ASSY and the separation pad spring. Tray 1, Tray 2 and Tray 3 are the same kit.

NOTE: * Always turn off the power switch of the printer and unplug the power cord from the power

outlet before replacing the periodical replacement parts.

* If the Fuser Unit is replaced after errors related to the Fuser Unit occur, it is necessary to

leave the printer power ON for ten minutes after part replacement. This will make the printer to be released from errors.

* To reset the count of each periodical replacement parts, refer to “2.IF YOU REPLACE THE

PERIODICAL MAINTENANCE PARTS”, Chapter 6.

3-12

Confidential

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

2.2 Procedures to Replace Periodical Replacement Parts

2.2.1 Fuser unit and laser unit

< Uninstalling Procedure >

(1) Disconnect the AC cord from the Printer.

Printer

(2) Press the front cover release button.

(3) Open the Front cover.

(4) Remove the Drum/toner ASSY.

Fig. 3-19

C cord

Printer

Drum/toner ASSY

Front cover

Fig. 3-20

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CHAPTER 3 PERIODIC MAINTENANCE

(5) Remove the DX feed ASSY or DX blank cover.

DX feed ASSY/ DX blank cover

Fig. 3-21

(6) Close the Front cover. (7) Pull out the Paper tray. (8) Remove the paper if it is remained in the Paper tray.

Front cover

Paper tray

Fig. 3-22

3-14

Confidential

(9) Open the Back cover.

(10) Remove the Arms of the Back cover from the Pins.

(11) Remove the Back cover.

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

Fig. 3-23

Back cover

(12) Hold the Knobs on the Outer chute ASSY and pull down this to your side.

(13) Remove the Arms of the Outer chute ASSY from the Pins.

(14) Remove the Outer chute ASSY.

Fig. 3-24

3-15

Knob

Outer chute ASSY

Knob

Confidential

CHAPTER 3 PERIODIC MAINTENANCE

(15) Open the Front cover, remove the two bind B M4x12 Taptite screws, and then remove the

Side cover L by releasing the Hooks in the order of 15a to 15d.

Taptite, bind B M4x12

Side cover L

15d

Hook

15a

Front cover

Hooks

Taptite, bind B M4x12

15c

15b

Fig. 3-25

Hooks

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

harness.

Taptite, cup S M3x6 SR

Shield cover

FG harness

Fig. 3-26

3-16

Confidential

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

(17) Remove the two bind B M4x12 Taptite screws, and then remove the Side cover R by

following the direction from 17a to 17d.

Taptite, bind B M4x12

Hook

Shield cover R

17d

Hook

17a

Taptite, bind B M4x12

Hooks

17b

Hooks

Fig. 3-27

(18) Disconnect the Connector of the Panel PCB.

17c

Top cover printed ASSY

Connector

Main PCB

Panel PCB

Fig. 3-28

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CHAPTER 3 PERIODIC MAINTENANCE

(19) Remove the two bind B M4x12 Taptite screws from Top cover printed ASSY.

(20) Release all Hooks of the Top cover printed ASSY and lift up the front side of the Top

cover printed ASSY.

(21) Remove the Top cover printed ASSY.

Hooks

Top cover printed ASSY

Hook

Fig. 3-29

Taptite, bind B M4x12

(22) Remove the bind B M4x16 Taptite screw. Release the Hooks in the order of 22a, 22b and

22c. Remove the FU harness cover 1.

22b

22a

Fig. 3-30

3-18

Hooks

22c

Taptite, bind B M4x16

FU harness cover 1

Confidential

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

(23) Remove the Heater terminal L and Heater terminal S from the Fuser unit while holding the

Fuser unit.

Heater terminal L

Fuser unit

Heater terminal S

Fig. 3-31

(24) Pull the FU harness cover 2 to the direction of 24a while pressing the Hook and pull out

the FU harness cover 2 from the back of the printer.

24a

FU harness cover 2

Hook

24b

Fig. 3-32

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CHAPTER 3 PERIODIC MAINTENANCE

(25) Disconnect the connectors of the Thermistor ASSY M and Thermistor ASSY S from the

Relay rear PCB ASSY, and remove the harnesses of these thermistors.

Fuser unit

Thermistor ASSY M

Thermistor ASSY S

Relay rear PCB ASSY

Fig. 3-33

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

Taptite, cup B M4x16

Fig. 3-34

3-20

Fuser unit

Confidential

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

(27) Slide the Sub duct to the direction of 27b while pressing the three Hooks and remove the

Sub duct from the Air duct.

ir duct

Filter

27b

27a

Hooks

Sub duct

Fig. 3-35

(28) Remove the Filter from the Air duct.

NOTE:

The filter is dirt. Be careful when disassembling or assembling it.

ir duct

Filter

Fig. 3-36

3-21

Confidential

CHAPTER 3 PERIODIC MAINTENANCE

(29) Remove the Pin of the Air duct from the frame. Slide the Air duct to the direction of 29b

and remove the Air duct.

29a

Hook

ir duct

Fig. 3-37

Laser unit

Hook

29b

3-22

Confidential

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

(30) Remove the six cup S M3x6 Taptite screws.

(31) Remove the two Flat cable from the Main PCB.

(32) Remove the Protective film.

(33) Pull out the flat cable from the Core.

(34) Remove the Laser unit.

NOTE:

- Be careful not to lose the Protective film attached on the flat cable.

- Do not touch the Laser scanner window directly.

Laser unit

Polygon motor (Flat cable)

LD harness (Flat cable)

Taptite, cup S M3x6

LD harness (Flat cable)

Main PCB

Polygon motor (Flat cable)

Protective film

Core

Laser unit

Fig. 3-38

3-23

Confidential

CHAPTER 3 PERIODIC MAINTENANCE

< Installing Procedure >

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

(2) Put the flat cable through the Core and Protective film.

(3) Install the flat cable. (Refer to “4. HARNESS ROUTING” in Chapter 5.)

Laser unit

Taptite, cup S M3x6

Core

Protective film

Taptite, cup S M3x6

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

Fig. 3-39

Laser unit

Hook

ir duct

Fig. 3-40

3-24

Confidential

(5) Install the Filter into the Air duct.

Filter

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

ir duct

Fig. 3-41

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

ir duct

Filter

Hooks

Fig. 3-42

Sub duct

3-25

Confidential

CHAPTER 3 PERIODIC MAINTENANCE

• DO NOT subject the fuser unit to strong physical shocks or vibrations.

• DO NOT touch the rollers and the electrodes to prevent damage to the fuser unit In

the following figures.

CAUTION:

To prevent the deformation of the pressure roller, the fuser unit spare part is shipped with its

pressure roller at low nip pressure. Before installing the fuser unit, turn back the levers to the

normal position by following instructions below.

(1) Put the fuser unit on a flat, horizontal surface. Pull up each of the blue tab (a) on the right

side and left side.

WARNING

(a)

(b)

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

(b)

(a)

3-26

Confidential

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

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

Fuser unit

Taptite, bind B M4x16

Fig. 3-43

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

rear PCB ASSY.

Thermistor ASSY M

Fuser unit

Thermistor ASSY S

Relay rear PCB ASSY

Fig. 3-44

3-27

Confidential

CHAPTER 3 PERIODIC MAINTENANCE

(9) Install the FU harness cover 2.

FU harness cover 2

Hook

Fig. 3-45

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

Heater terminal L

Fuser unit

Fig. 3-46

3-28

Heater terminal S

Confidential

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

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

11a

11b

Taptite, bind B M4x16

Hooks

Fig. 3-47

FU harness cover 1

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

Hooks

12a

Top cover printed ASSY

Hook

12b

Hook

Fig. 3-48

3-29

Taptite, bind B M4x12

Confidential

CHAPTER 3 PERIODIC MAINTENANCE

(13) Connect the Connector of the Panel PCB.

Top cover printed ASSY

Connector

Main PCB

Fig. 3-49

Panel PCB

(14) Catch the Hooks in the order of the arrows and secure the Side cover R with the two bind

B M4x12 Taptite screws.

Taptite, bind B M4x12

14a

Hooks

Hook

14b

Fig. 3-50

Side cover R

Hooks

Hook

14c

14d

Taptite, bind B M4x12

Hooks

3-30

Confidential

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

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

Taptite, cup S M3x6 SR

Shield cover

Taptite, cup S M3x6 SR

FG harness

Fig. 3-51

(16) Catch the Hooks in the order of the arrows and secure the Side cover L with the two bind

B M4x12 Taptite screws.

Taptite, bind B M4x12

Hook

Side cover L

16a

16d

Hooks

16b

16c

Fig. 3-52

3-31

Hooks

Front cover

Taptite, bind B M4x12

Confidential

CHAPTER 3 PERIODIC MAINTENANCE

(17) Catch the Arm of the Outer chute ASSY onto the Pin of the machine body and install the

Outer chute ASSY.

17b

17c

17a

Outer chute ASSY

Fig. 3-53

(18) Catch the Arm of the Back cover onto the Pin of the machine body and install the Back

cover.

18b

18c

18a

Fig. 3-54

3-32

Back cover

Confidential

(19) Install the DX feed ASSY or DX blank cover.

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

DX feed ASSY/ DX blank cover

Fig. 3-55

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

(21) Close the Front cover.

Printer

Drum /toner ASSY

Front cover

Fig. 3-56

3-33

Confidential

CHAPTER 3 PERIODIC MAINTENANCE

(22) Put the Paper tray into the Printer.

Paper tray

Fig. 3-57

(23) Connect the AC cord into the Printer.

Printer

C cord

Fig. 3-58

3-34

Confidential

2.2.2 Paper feeding kit for tray 1, 2, 3

< Uninstalling Procedure >

(1) Disconnect the AC cord from the Printer.

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

Printer

C cord

Fig. 3-59

(2) Press the front cover release button.

(3) Open the Front cover.

(4) Remove the Drum/toner ASSY.

Printer

Drum/toner ASSY

Front cover

Fig. 3-60

3-35

Confidential

CHAPTER 3 PERIODIC MAINTENANCE

(5) Remove the DX feed ASSY or DX blank cover.

DX feed ASSY/ DX blank cover

Fig. 3-61

(6) Close the Front cover.

(7) Pull out the Paper tray.

(8) Remove the paper from the Paper tray.

Front cover

Paper tray

Fig. 3-62

3-36

Confidential

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

(9) Pull up the back side of the Separation pad ASSY.

(10) Push the Hooks provided on both sides of the Separation pad ASSY inwards.

(11) Pull up the Separation pad ASSY.

(12) Remove the Separation pad spring.

Separation pad spring

Hooks

Hook

Separation pad ASSY

Hook

Paper tray

Fig. 3-63

3-37

Confidential

CHAPTER 3 PERIODIC MAINTENANCE

(13) Turn the Printer upside down.

NOTE:

• Pull out and put into the paper tray so that the Roller holder ASSY is lowered.

• If the Roller holder ASSY is remained up, it cannot be removed.

(14) Push the Lift arm to the direction of the arrow 14a and pull out the pin of the Roller holder

ASSY. Then, turn the Roller holder ASSY to the direction of the arrow 14b.

Lift arm

Roller holder ASSY

Paper feed frame

14b

14a

Fig. 3-64

(15) Slide the Roller holder ASSY to the direction of the arrow 15a. Then, lift up the gear side

of the Roller holder ASSY to the direction of the arrow 15b and pull it out to the direction of the arrow 15c to remove.

Roller holder ASSY

15c

15b

Paper feed frame

15a

Fig. 3-65

3-38

Confidential

< Installing Procedure >

(1) Install the Roller holder ASSY.

NOTE: When assembling the roller holder ASSY, align the section “A” on the shaft of the roller holder ASSY with the hole on the paper feed frame.

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

Roller holder ASSY

“A”

Paper feed frame

Fig. 3-66

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

(3) Place the Printer on its base.

Lift arm

Fig. 3-67

3-39

Roller holder ASSY

Paper feed frame

Confidential

Brother hl-5240, hl-5250dn, hl-5270dn, hl-5280dn Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

PREFACE

TABLE OF CONTENTS

REGULATION

SAFETY INFORMATION

CHAPTER 1 GENERAL

1. FEATURES

2. PARTS NAMES AND FUNCTIONS

2.1 Overview

2.2 Control Panel

3. SPECIFICATIONS

3.1 Printing

3.2 Functions

3.3 Electronics and Mechanics

3.4 Service Information

3.5 Network Connectivity

3.6 Paper

3.6.1 Paper handling

3.6.2 Media specifications

3.7 Printable Area

3.7.1 PCL5e/EPSON/IBM emulation

3.7.2 PCL6 emulation

3.8 Print Speeds with Various Settings

3.9 Toner Cartridge Weight Information

4. SERIAL NO. DESCRIPTIONS

CHAPTER 2 THEORY OF OPERATION

1. OVERALL

1.1 General Block Diagram

2. ELECTRONICS

2.1 General Block Diagram

2.2 Main PCB Block Diagram

2.3 Main PCB

2.3.1 CPU

2.3.2 USB interface (2.0 High Speed)

2.3.3 IEEE1284 interface

2.3.4 Network interface

2.3.5 ROM

2.3.6 SDRAM

2.3.7 Optional RAM

2.3.8 EEPROM

2.3.9 Reset circuit

2.3.10 Panel I/O

2.3.11 Video I/O

2.3.12 Power supply

2.3.13 Wireless LAN

2.4 Power Supply

2.4.1 Low-voltage power supply

2.4.2 High-voltage power supply

3. MECHANICS

3.1 Overview of Printing Mechanism

3.2 Overview of Gears

3.3 Paper Transfer

3.3.1 Paper supply

3.3.2 Paper registration

3.3.3 Drum unit

3.3.4 Developing

3.3.5 Fixing stage

3.3.6 Paper eject

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

3.3.8 Paper feeding from the MP tray

3.3.9 LT tray

3.4 Toner Cartridge

3.4.1 Toner life end mode

3.4.2 New toner detection mechanism

3.4.3 Counter reset during indication of “Toner Life End”

3.5 Print Process

3.5.1 Charging

3.5.2 Exposure stage

3.5.3 Transfer

3.6 Sensors

3.7 Heat Control of Fuser Unit

CHAPTER 3 PERIODIC MAINTENANCE

1. CONSUMABLE PARTS

1.1 Toner Cartridge

1.2 Drum Unit

2. PERIODICAL REPLACEMENT PARTS

2.1 Periodical Replacement Parts