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Brother HL-4040CN Service Reference Manual

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Brother Color Laser Printer
SERVICE REFERENCE MANUAL
Read this manual thoroughly before maintenance work.
Keep this manual in a convenient place for quick and easy reference at all times.
January 2007
SM-PRN060
(10)
MODEL:
HL-4040CN/4040CDN/
4050CDN/4070CDW
Confidential

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  • Page 1 Brother Color Laser Printer SERVICE REFERENCE MANUAL MODEL: HL-4040CN/4040CDN/ 4050CDN/4070CDW Read this manual thoroughly before maintenance work. Keep this manual in a convenient place for quick and easy reference at all times. January 2007 SM-PRN060 (10) Confidential...

  • Page 2: Reference 1 Specifications

    (hereinafter referred to as "the machine"). This information is vital to the service personnel to maintain the high printing quality and performance of the machine. This service reference manual covers the HL-4040CN/4040CDN/4050CDN/4070CDW machines. This manual consists of the following chapters:...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS REFERENCE 1 SPECIFICATIONS ........... Ref.1-1 1. COMPONENTS ....................Ref.1-1 2. SPECIFICATIONS LIST ..................Ref.1-2 2.1 Printing.......................... Ref.1-2 2.2 Functions ........................Ref.1-4 2.3 Electronics and Mechanics................... Ref.1-6 2.4 Network Connectivity....................Ref.1-7 2.5 Service Information..................... Ref.1-10 2.6 Paper .......................... Ref.1-11 2.6.1 Paper handling ....................

  • Page 4: Components

    REFERENCE 1 SPECIFICATIONS COMPONENTS The equipment consists of the following major components: LCD panel PCB ASSY Top cover ASSY Paper eject ASSY DX/SX Back cover upper Top cover panel ASSY Back cover ASSY Transfer HVPS PCB unit Belt unit drive motor ASSY Laser unit Side cover R ASSY Fuser unit...

  • Page 5: Specifications List

    SPECIFICATIONS LIST Printing Model HL-4040CN HL-4040CDN HL-4050CDN HL-4070CDW Print method Electrophotography by semiconductor laser beam scanning Laser Method: 1 polygon motor, 4 laser beams Wavelength: 780nm~800nm Output: 30mW (Max)  Resolution 2400dpi Windows 2000/XP/ XP Professional x64 Edition, Windows ...
  • Page 6 Model HL-4040CN HL-4040CDN HL-4050CDN HL-4070CDW Consumables Belt unit Life expectancy: 50,000pages/ belt unit Life expectancy will vary depending on number of continuous printing pages. (Refer to “Life of Belt Unit” in Chapter 5, “2.3 Printout of Printer Settings” of the Service Manual.) * when printing A4/ Letter-size paper.

  • Page 7: Functions

    Functions <Controller> Model HL-4040CN HL-4040CDN HL-4050CDN HL-4070CDW 300MHz Memory Standard 64MB Option 1 DIMM slot; expandable up to 576MB Interface Hi-Speed USB 2.0, 10BASE- Hi-Speed Hi-Speed T/100BASE-TX Ethernet USB 2.0, USB 2.0, IEEE 1284 IEEE 1284 Parallel, Parallel, 10BASE- 10BASE-...
  • Page 8 BRScript3 printer driver) The data including JBIG2 image file, JPEG2000 image file and layered files are not supported. HL-4040CN cannot print PRN files of duplex printing which are created by HL-4040CDN, HL- 4050CDN or HL-4070CDW printer driver. <System requirements> Computer Platform & Operating...

  • Page 9: Electronics And Mechanics

    Electronics and Mechanics Model HL-4040CN HL-4040CDN HL-4050CDN HL-4070CDW Power Printing Average 510W at 25°C (77°F) consumption Standby Average 85W at 25°C (77°F) Sleep Average 20W at 25°C (77°F) Average 23W at 25°C (77°F) Noise level Sound Printing: 54dB(A) Pressure Standby: 30dB(A) Sound power Monochrome printing: LWAd = 6.6Bell(A)

  • Page 10: Network Connectivity

    Minimum PowerPC G4/G5, Intel Core™ Solo/Duo, Processor Processor PowerPC G3 350MHz Minimum RAM 128MB Recommended 160MB  Operating Mac OS X 10.2.4 or greater system If you want to use the IPv6 protocol, visit http://solutions.brother.com for more information. Confidential Ref.1-7...
  • Page 11 Data rates 802.11b 11/5.5/2/1 Mbps 802.11g 54/48/36/24/18/12/11/9/6/5.5/2/1 Mbps A wireless network connection is supported only between the Brother printer and an access   point for PC’s running Windows XP Professional x64 Edition and Windows Server 2003 x64 Edition.
  • Page 12 Windows NT 4.0, Windows 2000 Professional /  Server / Advanced Server, Windows Professional/XP Professional x64 Edition, Windows   Vista , Windows Server 2003/2003 x64 Edition BRAdmin Professional and Web BRAdmin are available as a download from http://solutions.brother.com Confidential Ref.1-9...

  • Page 13: Service Information

    Service Information These are key service information to maintain the product. Machine life: 200,000pages or 5years MTBF (Meantime between failure): Up to 4,000hours MTTR (Meantime to repair): Average 30minutes Monthly volume: 35,000pages Periodical replacement parts: Parts Approximate Life Fuser unit & Toner filter frame ASSY 80,000pages Laser unit 100,000pages...

  • Page 14: Paper

    Paper 2.6.1 Paper handling Model HL-4040CN HL-4040CDN HL-4050CDN HL-4070CDW Paper Input Multi-purpose 50sheets tray Paper tray (T1) 250sheets Lower tray (LT) 500sheets Paper Face-down 150sheets Output * Duplex Manual Duplex Automatic Duplex * Calculated with 80g/m (20lb) paper 2.6.2 Media specifications...

  • Page 15: Type And Size Of Paper

    2.6.3 Type and size of paper The printer loads paper from the installed paper tray or the multi-purpose tray. The names for the paper trays in the printer driver as follows; Paper tray (T1) Tray 1 Multi-purpose tray (MP) MP Tray Optional lower tray unit (LT) Tray 2 (for HL-4050CDN/4070CDW)

  • Page 16: Printable Area

    Printable Area 2.7.1 PCL5e emulation When using PCL emulation, the edges of the paper that cannot be printed on are shown below. Portrait Physical page Printable area Logical page Physical page length Maximum logical page length Distance from edge of physical page to edge of logical page   Note: - “Logical page” shows the printable area for a PCL driver. - “Printable area”...
  • Page 17 The table below shows the printable areas when printing on Portrait for each paper size. Size 215.9mm 279.4mm 203.2mm 279.4mm 6.35mm 4.2mm Letter 8.5” 11.0” 8.0” 11.0” 0.25” 0.16” (2,550dots) (3,300dots) (2,400dots) (3,300dots) (75dots) (50dots) 215.9mm 355.6mm 203.2mm 355.6mm 4.2mm Legal 8.5”...
  • Page 18 Landscape       Physical page Printable area Logical page B             Physical page length D             Maximum logical page length F              Distance from edge of physical                 page to edge of logical page Note: - “Logical page” shows the printable area for a PCL driver. - “Printable area” shows mechanical printable area of the machine. - Therefore, the machine can only print within the shaded area when you use a PCL driver. Confidential Ref.1-15...

  • Page 19: Pcl6 Emulation

    The table below shows the printable areas when printing on Landscape for each paper size. Size 279.4mm 215.9mm 269.3mm 215.9mm 5.0mm 4.2mm Letter 11.0” 8.5” 10.6” 8.5” 0.2” 0.16” (3,300dots) (2,550dots) (3,180dots) (2,550dots) (60dots) (50dots) 355.6mm 215.9mm 345.5mm 215.9mm 4.2mm Legal 14.0”...

  • Page 20: Print Speeds With Various Settings

    Print Speeds with Various Settings Print speed is up to 20ppm for A4 size and 21ppm 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;...

  • Page 21: Reference 2 Theory Of Operation

    REFERENCE 2 THEORY OF OPERATION GENERAL BLOCK DIAGRAM Fig. Ref2-1 Ref. 2-1 Confidential...

  • Page 22: Electronics General Block Diagram

    ELECTRONICS GENERAL BLOCK DIAGRAM Fig. Ref2-2 Confidential Ref. 2-2...

  • Page 23: Mechanics

    MECHANICS Cross-section Drawing Exposure drum (M) Exposure drum (C) Paper eject roller shaft ASSY Exposure drum (Y) Exposure drum (K) Outer chute Supply roller Develop roller Registration rear actuator Thermistor Registration roller Heat roller MP registration front actuator Paper eject actuator MP paper feed roller MP PE actuator Pressure roller ASSY...

  • Page 24: Paper Feeding

    Paper Feeding The following figure shows the paper feeding paths. MP path Paper tray path LT path DX path Fig. Ref2-4 Ref. 2-4 Confidential...

  • Page 25: Plate-Up Function Of The Paper Tray

    3.2.1 Plate-up Function of the Paper Tray The plate of the paper tray is pushed up by the force exerted by the motor not by springs so as to keep paper-feeding performance constant irrespective of the quantity of papers remaining in the tray.

  • Page 26: Paper Supply

    3.2.2 Paper Supply The T1 paper 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 T1 separation roller. Subsequently, stacks of paper are caught between the T1 separation roller and T1 separation pad, they are then separated into single sheets.

  • Page 27: Paper Registration

    3.2.3 Paper Registration The front-edge position of a sheet of paper after separation by the separation roller is detected by the T1 registration front actuator. Then, the paper is fed further for a certain time, and its front edge hits the stopped registration roller so that the paper skew is corrected. After such correction, the registration roller is rotated in the normal direction and the paper is carried to the belt unit.

  • Page 28: Paper Eject

    3.2.4 Paper Eject Toner on paper is fused by the heat roller and pressure roller ASSY of the fuser unit. Paper moves along the outer chute and is ejected into the face-down output tray from the paper eject roller shaft ASSY with its print side down. Paper eject roller shaft ASSY Outer chute Fuser unit...

  • Page 29: Paper Feeding For Duplex Printing (Dx) (Hl-4040Cdn/ 4050Cdn/ 4070Cdw Only)

    3.2.5 Paper Feeding for Duplex Printing (DX) (HL-4040CDN/ 4050CDN/ 4070CDW only) After the paper eject actuator detects the edge of the paper and a certain volume of paper is sent from the paper eject roller shaft ASSY, it rotates against the normal direction of rotation, thereby enabling the paper to be pulled in and pass between the outer chute and the back cover.

  • Page 30: Paper Feeding From The Mp Tray (Mp)

    3.2.6 Paper Feeding from the MP Tray (MP) When the MP paper feed roller making contact with paper is driven, the paper is drawn out of the MP tray. The drawn paper is separated into individual sheets by the MP separation roller. MP registration front actuator MP tray MP paper feed roller...

  • Page 31: Paper Feeding From The Tray 2 (Lt) (Hl-4050Cdn/ 4070Cdw Only)

    3.2.7 Paper Feeding from the Tray 2 (LT) (HL-4050CDN/ 4070CDW only) The driving force from the paper feed/belt cleaner motor is transmitted to the gear of tray 2 (LT) to rotate the LT paper feed roller so that the paper is fed. The paper is separated into individual sheets by the LT separation roller and fed to the machine.

  • Page 32: Toner Cartridge

    Toner Cartridge 3.3.1 Methods for Detecting and Counting Toner Life “Toner Life End” is displayed through the following two ways. First, such indication is displayed when detection is performed by the toner sensor; second, it is displayed at the time when a rotation rate of the develop roller reaches its upper limit.

  • Page 33: Toner Life End

    3.3.2 Toner Life End A new toner cartridge can print with standard toner approximately 2,500 (black), 1,500 (yellow, magenta, cyan), with high capacity toner, approximately 5,000 (black), 4,000 (yellow, magenta, cyan) in the case of A4 or Letter size single-sided pages at 5% coverage. If printing A4 paper at 5% print coverage or less, the “Toner Life End”...
  • Page 34 Standard toner cartridge (Yellow, Magenta, Cyan) * Approximately 1500 pages Page/job 1,800 2,763 3,364 3,773 4,071 4,297 4,474 4,617 4,735 4,833 4,917 4,989 Cartridge life 1,092 1,845 2,396 2,816 3,147 3,415 3,637 3,822 3,980 4,116 4,235 4,339 Cartridge life+ON/OFF 1,500 1,500 1,500 1,500...
  • Page 35 High-capacity toner cartridge (Black) * Approximately 5000 pages Page/job 6,000 9,212 11,212 12,578 13,570 14,323 14,914 15,390 15,782 16,110 16,389 16,629 Cartridge life 3,639 6,150 7,986 9,387 10,491 11,385 12,122 12,740 13,267 13,721 14,116 14,463 Cartridge life+ON/OFF 5,000 5,000 5,000 5,000 5,000 5,000...
  • Page 36 High-capacity toner cartridge (Yellow, Magenta, Cyan) * Approximately 4000 pages Page/job 5,000 7,676 9,343 10,482 11,308 11,935 12,428 12,825 13,152 13,425 13,658 13,858 Cartridge life 3,033 5,125 6,655 7,822 8,743 9,487 10,101 10,617 11,056 11,434 11,763 12,052 Cartridge life+ON/OFF 4,000 4,000 4,000 4,000...

  • Page 37: New Toner Detection

    3.3.3 New Toner Detection When a toner cartridge is changed, discrimination between new and secondhand toner cartridges is performed by means of the new toner detection mechanism shown below. <New Toner Detection Mechanism> The rotation of the gear (1) of the toner cartridge is transmitted to the reset gear, and the rib of the gear pushes down the reset upper lever attached to the drum unit.
  • Page 38 <Developing Bias Voltage> When the new toner detection mechanism detects the change to a new toner cartridge, the developing bias voltage is reset. Toner in use tends to have a low printing density at the time of first use, but the density gradually becomes higher after a certain period of use. The properties of the toner is controlled by means of the developing bias voltage.

  • Page 39: Print

    Print 3.4.1 Principle of Color Overlapping The human eye distinguishes one color from others by receiving light’s three primary colors (Red, Green, Blue). When monochrome lights are received, each color can be sensed. However, when two-color lights, red (R) and green (G), are received, they are recognized as “yellow”;...

  • Page 40: Basic Printing Principle

    3.4.2 Basic Printing Principle The printing process consists broadly of 6 processes: Charging, Exposure, Development, Transfer, Fusing and Cleaning. 1. Charging: The surface of the drum is electrically charged (Primary Charge). 2. Exposure: A printed image is formed on the surface of the drum by applying laser beam (Electrostatic Latent Image).

  • Page 41: Print Process

    3.4.3 Print Process 1. Charging The flow of the ion charge is controlled by the constant voltage of the grid 870 V to ensure it is distributed evenly on the drum surface. In order to coat toner on the exposure drum, the drum needs to be evenly electrified.
  • Page 42 2. Exposure Four laser beams 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. The evenly charged exposure drum is irradiated with reflected light and exposed. Surface potential is lowered by such exposure and an Electrostatic latent image is formed.
  • Page 43 3. Development Toner is attracted to the latent-image area on the exposure drum where surface potential is lowered due to exposure. By controlling the developing bias voltage supplied to the develop roller, the amount of toner taken to the drum is adjusted to keep printing density constant. Charging Laser beam 150 V...
  • Page 44 4. Transfer By applying a minus charge to the belt unit, the toner adhered to the exposure drum is transferred to paper. Exposure drum (K) Exposure drum (Y) Exposure drum (M) Exposure drum (C) EL PCB (K) EL PCB (M) EL PCB (C) EL PCB (Y) Belt unit...
  • Page 45 5. Fusing The toner transferred on to the paper passes between the heat roller and the pressure roller ASSY in the fuser unit and are fused by heat and pressure. The thermistor detects surface temperature of the heat roller and turns ON/OFF the halogen heater lamp to keep the temperature constant.
  • Page 46 6. Toner cleaning (1) Toner remaining on the exposure drum which has not completely been transferred on to the paper is pulled onto the cleaning roller with a lower potential and the drum is cleaned. (2) After the above step, the potential of the roller is raised during printing, and such attracted toner is returned to the drum again.

  • Page 47: Switch Between Color Print Mode And Monochrome Print Mode

    3.4.4 Switch between Color Print Mode and Monochrome Print Mode By switching the mode between color print and monochrome print to avoid unnecessary load on the toner cartridges and keep the specified product life, the rotation and press/release operations of the develop roller are controlled, and the print operation is executed. <Rotation of the develop roller>...

  • Page 48: Appendix 1 Toner Cartridge Weight Information

    APPENDIX 1 TONER CARTRIDGE WEIGHT INFORMATION Note: This information shows approximate weight of the toner cartridge. Toner weight is subject to change due to redesign of the machine. Depending on the serial number of toner cartridge, the weight of toner cartridge will be different. Refer to the table shown below for details.
  • Page 49 Table 2 High-capacity toner cartridge BK (5K) Y (4K) M (4K) C (4K) (TN-115, TN-135, TN-155) Brand New Toner Cartridge Weight 685g 681g 653g 670g (±10g) (±10g) (±10g) (±10g) Toner Weight at “Brand New Toner Cartridge” 150g 146g 118g 135g Toner Cartridge Weight at “Toner Near Empty”...

  • Page 50: Appendix 2 References

    APPENDIX 2 REFERENCES This page provides reference information. It is possible to get the full instructions of the subjects by just clicking on the links below. 1. Error codes (Refer to “2.1 Error Indication”, Chapter 1 of the Service Manual.) 2.

  • Page 51: Appendix 3 Glossary

    APPENDIX 3 GLOSSARY ACRONYMS AND TECHNICAL TERMS In this manual and the Service Manual, the manual specific acronyms and technical terms are used in addition to the generally used ones. The table below contains typical acronyms and technical terms that are used throughout these manuals. APIPA Automatic Private IP Addressing LCD Liquid Crystal Display...

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