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Brother HL-5440D Service Manual

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HL-5440D/5450DN/5450DNT
HL-5470DW/5470DWT
HL-6180DW/6180DWT
Read this manual thoroughly before maintenance work.
Keep this manual in a convenient place for quick and easy reference at all times.
Feb 2012
SM-PRN084
84UD*
(1)
Brother Laser Printer

SERVICE MANUAL

MODEL:
Confidential

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   Summary of Contents for Brother HL-5440D

  • Page 1: Service Manual

    Brother Laser Printer SERVICE MANUAL MODEL: HL-5440D/5450DN/5450DNT HL-5470DW/5470DWT HL-6180DW/6180DWT Read this manual thoroughly before maintenance work. Keep this manual in a convenient place for quick and easy reference at all times. Feb 2012 SM-PRN084 84UD* Confidential...
  • Page 2 Equipment Paper Tray 2 (500 sheets) (500 sheets) © Copyright Brother 2012 All rights reserved. No part of this publication may be reproduced in any form or by any means without permission in writing from the publisher. All other product and company names mentioned in this manual are trademarks or registered trademarks of their respective holders.
  • Page 3 Each company whose software title is mentioned in this manual has a Software License Agreement specific to its proprietary programs. Any trade names and product names of companies appearing on Brother products, related documents and any other materials are all trademarks or registered trademarks of those respective companies.
  • Page 4: Table Of Contents

    CONTENTS REGULATION ......................vii SAFETY INFORMATION..................xiii CHAPTER 1 SPECIFICATIONS 1. SPECIFICATIONS LIST ....................... 1-1 General ..........................1-1 Network Connectivity ......................1-5 Service Information......................1-6 Supplies ..........................1-7 Paper ........................... 1-9 1.5.1 Paper handling ...................... 1-9 1.5.2 Media specifications ....................1-9 1.5.3 Type and size of paper..................
  • Page 5: Chapter 3 Disassembly/reassembly

    4.2.4 Duplex printing is not possible................2-58 4.2.5 Paper is curled ....................2-58 4.2.6 Only single surface is printed in duplex printing mode ........2-58 Troubleshooting for Image Defects..................2-59 4.3.1 Image defect examples ..................2-59 4.3.2 Troubleshooting according to image defect ............2-60 Troubleshooting for Software Problems ................
  • Page 6 9. DISASSEMBLY PROCEDURE ....................3-15 Preparation ........................3-15 Paper tray 1 ........................3-16 Back cover / Outer chute ....................3-18 Fuser cover........................3-19 MP cover ASSY ......................... 3-20 Front cover ASSY ......................3-21 Side cover L / Access cover ....................3-22 Side cover R ........................
  • Page 7: Chapter 4 Adjusting And Updating Settings

    9.40 Registration front/rear sensor PCB ASSY / Registration front actuator / Registration rear actuator / Registration actuator spring ..........3-73 10. DISASSEMBLY PROCEDURE (LT UNIT)................. 3-76 10.1 Paper tray 2 ........................3-76 10.2 T2 roller holder ASSY ......................3-78 10.3 T2 side cover L ........................3-79 10.4 T2 side cover R........................
  • Page 8 1.3.3 Set worker switches (WSW) and print worker switch setting data (function code: 10, 11)................... 5-8 1.3.4 Check LCD operation (function code: 12) ............5-10 1.3.5 Check control panel button operation (function code: 13)........5-11 1.3.6 Display software version (function code: 25)............5-12 1.3.7 Set One Push Demo function (function code: 28) ..........
  • Page 9: Chapter 7 Periodical Maintenance

    2. PRINTER SETTINGS ......................... 5-49 Printing Printer Settings ..................... 5-49 3. OTHER SERVICE FUNCTIONS....................5-57 Change ON/OFF Setting for Deep Sleep Mode (LCD model only) ........5-57 Change ON/OFF Setting for Sleep Mode (LCD model only) ..........5-57 Reset Periodic Replacement Parts (LCD model only)............5-58 Delete User Setting Information (LCD model only)............
  • Page 10: Regulation

    REGULATION Declaration of Conformity (Europe only) (HL-5470DW / HL-6180DW(T) only) We, Brother Industries, Ltd. of 15-1, Naeshiro-cho, Mizuho-ku, Nagoya 467-8561 Japan declare that this product is in compliance with the essential requirements of Directives 1999/5/EC and 2009/125/EC. The Declaration of Conformity (DoC) is available on our Website.
  • Page 11: Disconnect Device

    IEC60825-1:2007 Specification (For 220-240V models only) This product is a Class 1 laser product as defined in IEC60825-1:2007 specifications. The label shown below is attached in countries where required. This product has a Class 3B Laser Diode which emits invisible laser radiation in the Laser Unit.
  • Page 12 Radio Interference This product complies with EN55022 (CISPR Publication 22)/Class B. Recycling Information in accordance with the WEEE (2002/96/EC) and Battery (2006/66/EC) Directives Product mark Battery mark European Union only The product/battery is marked with one of the above recycling symbols. It indicates that at the end of the life of the product/battery, you should dispose of it separately at an appropriate collection point and not place it in the normal domestic waste stream.
  • Page 13 This transmitter must not be co-located or operated in conjunction with any other antenna or transmitter. Important • Changes or modifications not expressly approved by Brother Industries, Ltd. could void the user’s authority to operate the equipment. • A shielded interface cable should be used to ensure compliance with the limits for a Class B digital device.
  • Page 14 FDA regulations and must be attached to laser products marketed in the United States. MANUFACTURED: BROTHER TECHNOLOGY (SHENZHEN) LTD. NO6 Gold Garden Ind., Nanling Nanwan, Longgang, Shenzhen, China This product complies with FDA performance standards for laser products except for deviations pursuant to Laser Notice No.
  • Page 15 The purpose of the International ENERGY STAR Program is to promote the development and popularization of energy-efficient office equipment. ® As an ENERGY STAR Partner, Brother Industries, Ltd. has determined that this product ® meets the ENERGY STAR specifications for energy efficiency. Confidential...
  • Page 16: Safety Information

    SAFETY INFORMATION WARNING WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injuries. CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injuries. Important Important indicates a potentially hazardous situation which, if not avoided, may result in damage to property or loss of product functionality.
  • Page 17 To use the Machine Safely Please keep these instructions for later reference and read them before attempting any maintenance. If you do not follow these safety instructions, there is a possibility of a fire, electrical shock, burn or suffocation. WARNING ELECTRICAL HAZARDS Failure to follow the warnings in this section may create the risk of an electrical shock.
  • Page 18 Power Cord Safety: • This product is equipped with a 3-wire grounded plug. This plug will only fit into a grounded power outlet. This is a safety feature. DO NOT defeat the purpose of the grounded plug. • Use only the power cord supplied with this product. •...
  • Page 19 HOT SURFACE After you have just used the product, some internal parts of the product will be extremely hot. Wait at least 10 minutes for the product to cool down before you touch the internal parts of the product. 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...
  • Page 20: Additional Information

    Additional Information When servicing the optical system of the machine, 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 machine. A reflected beam, though invisible, can permanently damage the eyes.
  • Page 21: Chapter 1 Specifications

    CHAPTER SPECIFICATIONS Confidential...
  • Page 22 CHAPTER 1 SPECIFICATIONS This chapter lists the specifications of each model. CONTENTS 1. SPECIFICATIONS LIST ....................1-1 1.1 General........................1-1 1.2 Network Connectivity..................... 1-5 1.3 Service Information....................1-6 1.4 Supplies......................... 1-7 1.5 Paper ........................1-9 1.5.1 Paper handling ................... 1-9 1.5.2 Media specifications ...................
  • Page 23: Specifications List

    1. SPECIFICATIONS LIST General Model HL-5440D HL-5450DN HL-5450DNT HL-5470DW HL-5470DWT Print method Electrophotographic Laser Printer Resolution 1200 x 1200 dpi, HQ1200 (2400 x 600 dpi) quality, 600 x 600 dpi Print speed One-sided Up to 38/40 ppm (A4/Letter size) Two-sided...
  • Page 24 Model HL-5440D HL-5450DN HL-5450DNT HL-5470DW HL-5470DWT Noise level Sound Printing LpAm = 59 dB (A) pressure Printing LpAm = 54 dB (A) (Quiet Mode) Ready LpAm = 34 dB (A) Sound Printing LWAd = 6.79 B (A) power Printing LWAd = 6.4 B (A)
  • Page 25 Model HL-6180DW HL-6180DWT Interface Hi-Speed USB 2.0 10Base-T/100Base-TX/1000Base-T IEEE 802.11b/g/n (Infrastructure Mode / Adhoc Mode) Power Peak Average: Approximately 1200 W consumption Printing Average: Approximately 727 W (for U.S.A.), 701 W (for Europe, Asia, China, Oceania) Printing Average: Approximately 342 W (for U.S.A.), 340 W (for Europe, (Quiet Mode) Asia, China, Oceania) Ready...
  • Page 26: Computer Requirements

    <Computer requirements> Hard Processor Recom- Computer Platform & Minimum Disk Supported PC Minimum mended Operating System Version Space Interface Speed to install ® ® ® ® Windows Windows Intel Pentium 128 MB 256 MB 80 MB USB, Operating Home Edition II or equivalent 10Base-T/ System...
  • Page 27: Network Connectivity

    Network Connectivity Model HL-5440D HL-5450DN HL-5450DNT HL-5470DW HL-5470DWT Wired Network node NC-8300h network type Network type 10Base-T/100Base-TX (Ethernet) Network APOP, POP before SMTP, SMTP-AUTH, SSL/TLS security (IPPS, HTTPS, SMTP, POP), SNMP v3 802.1x (EAP-MD5, EAP-FAST, PEAP, EAP-TLS, EAP- TTLS), Kerberos...
  • Page 28: Service Information

    Service Information Model HL-5440D HL-5450DN HL-5450DNT HL-5470DW HL-5470DWT Machine life 300,000 pages (A4/Letter size) or 5 years MTBF 4,000 hours MTTR 0.5 hours Maximum monthly volume Up to 50,000 pages Periodical Fuser Unit 100,000 pages maintenance Laser Unit 100,000 pages...
  • Page 29: Supplies

    Supplies Model HL-5440D HL-5450DN HL-5450DNT HL-5470DW HL-5470DWT Toner Starter Approximately Approximately Approximately 3,000 pages cartridge Toner 3,000 pages 3,000 pages (for U.S.A., (for U.S.A., Asia, China) Europe, Asia, 2,000 pages China) (for Europe, 2,000 pages Oceania) (for Oceania) Standard Approximately 3,000 pages...
  • Page 30 Model HL-6180DW HL-6180DWT Toner Starter Approximately 3,000 pages (except for Europe) cartridge Toner 8,000 pages (for Europe) Standard Approximately 3,000 pages Toner High Yield Approximately 8,000 pages Toner Super High Approximately 12,000 pages Yield Toner When printing A4/Letter size one sided pages in accordance with ISO/IEC 19752. Shelf life: 2 years without opening (6 months after opening) Drum unit Life expectancy: Approximately 30,000 pages/drum unit...
  • Page 31: Paper

    Paper 1.5.1 Paper handling Model HL-5440D HL-5450DN HL-5450DNT HL-5470DW HL-5470DWT Paper Input Paper tray 1 250 sheets Paper tray 2 500 sheets 500 sheets 500 sheets 500 sheets (Option) (Standard (Option) (Standard equipment) equipment) MP tray 50 sheets Paper Output Face-down...
  • Page 32: Type And Size Of Paper

    1.5.3 Type and size of paper The printer loads paper from the installed paper tray or the manual feed slot. The names for the paper trays in the printer driver as follows: The name for the paper trays The name for the paper trays in the printer driver Paper tray 1 (T1) Tray 1 Paper tray 2 (T2)
  • Page 33: Printable Area

    Printable Area The figure below shows maximum unprintable areas. The unprintable areas may vary depending on the paper size or settings in the application you are using. Top (1) Left (2) Usage Document Size Bottom (3) Right (4) Print Letter 4.23 mm (0.16 inch) 6.35 mm (0.25 inch) 4.23 mm (0.16 inch)
  • Page 34: Chapter 2 Troubleshooting

    CHAPTER TROUBLESHOOTING Confidential...
  • Page 35 CHAPTER 2 TROUBLESHOOTING This chapter details error messages and codes which the incorporated self-diagnostic function of the machine will display if any error or malfunction occurs. If any error message appears, refer to this chapter to find which parts should be checked or replaced. The latter half of this chapter provides sample problems which could occur in the main sections of the machine and related troubleshooting procedures.
  • Page 36 4.6 Troubleshooting for Control Panel Problems............2-75 4.6.1 Nothing is displayed on the LCD .............. 2-75 4.6.2 LEDs are not activated ................2-75 4.6.3 Control panel is inoperable............... 2-75 4.7 Troubleshooting for Toner and Drum Problems........... 2-76 4.7.1 New toner is not detected................. 2-76 4.7.2 Cartridge error (toner cartridge cannot be detected)........
  • Page 37: Introduction

    1. INTRODUCTION Troubleshooting is a collection of solution procedures that service personnel should follow if an error or malfunction occurs in the machine. It is difficult to determine troubleshooting procedures for all possible problems that may occur in the future. Therefore, this chapter describes typical problem cases and recovery procedures for these.
  • Page 38: Checks Before Commencing Troubleshooting

    Checks before Commencing Troubleshooting Check the following items before commencing repairs on the machine. Operating environment (1) The machine is placed on a flat, stable surface. (2) The machine is used in a clean environment where the temperature is between 10°C (50°F) and 32.5°C (90.5°F) and the relative humidity is maintained between 20% and 80%.
  • Page 39 Others (1) Condensation When the machine is moved to a warm room from a cold location, condensation may occur inside the machine, causing various problems as listed below. • Condensation on the surface of optical devices such as the lens, reflecting mirror and protection glass may cause light print image.
  • Page 40: Overview

    2. OVERVIEW Cross-section Drawing Heat unit Laser unit Developer roller <Back side> <Front side> Eject roller 2 Registration rear actuator Exposure drum Fuser unit Registration front actuator Eject pinch roller Registration roller MP tray Back cover Front cover Outer chute MP separation roller MP pick-up roller Eject roller 1...
  • Page 41: Paper Feeding

    Paper Feeding <Back side> <Front side> Manual feed slot path Duplex path Paper tray 1 path Paper tray 2 path Fig. 2-2 Confidential...
  • Page 42: Operation Of Each Part

    Operation of Each Part Part name Operation T1 pick-up roller Picks up the paper from paper tray 1. T1 separation roller / Separates the paper fed from paper tray 1 into single sheets. T1 separation pad T1 paper feed actuator Detects paper tray 1.
  • Page 43 Part name Operation Toner sensor Detects the toner remaining in the cartridge. When the toner is below the specified level, the user is notified that the toner cartridge needs replacing soon. New toner sensor Detects the toner volume when a new toner cartridge is set. (Does not react to the starter toner cartridge even if it is new.) When a new toner cartridge is detected, the developer roller counter and the developing bias voltage value are reset, and...
  • Page 44: Block Diagram

    Block Diagram Panel PCB (LED) (Wireless LAN model only) Panel PCB Backlight Wireless LAN (LCD) MP-PE sensor PCB Fuser unit HVPS PCB T1 paper feed sensor PCB Center thermistor Eject sensor Registration front/rear sensor PCB Side thermistor Back cover Halogen-heater sensor LVPS PCB Power switch...
  • Page 45: Main Components

    Main Components Paper stack levers Paper stack levers Panel printed ASSY Top cover ASSY Top cover ASSY LCD holder Panel light guide SW key printed ASSY Rubber key printed ASSY Panel light guide Backlight PCB ASSY Panel PCB ASSY Panel PCB ASSY Back cover Air duct...
  • Page 46: Error Indications

    3. ERROR INDICATIONS This machine includes a self-diagnosis function. If the machine does not work normally it judges that an error has occurred, and indicates the corresponding error message on the LCD, which in turn helps the service men to quickly find out the problem. Error Codes The errors with a mesh background in the table below do not occur in the normal operation.
  • Page 47 Error Refer Error Refer Problem Problem codes codes 4500 An unidentified error occurred. 2-31 5B00 An unidentified error occurred. 2-35 4600 An unidentified error occurred. 2-31 5C00 An unidentified error occurred. 2-35 4700 An unidentified error occurred. 2-31 5D00 An unidentified error occurred. 2-35 4800 An unidentified error occurred.
  • Page 48 Error Refer Error Refer Problem Problem codes codes Detected an error in the Detected discharge when the 7100 synchronized signal of the 2-38 8300 number of rotations of the drum 2-40 polygon motor for the laser unit. has exceeded twice the life limit. The eject sensor remains ON Cannot detect the signal from (paper pass detected) for more...
  • Page 49 Error Refer Error Refer Problem Problem codes codes When printing from the MP tray, the MP paper empty sensor 9300 2-45 AB00 An unidentified error occurred. 2-49 detected that there was no paper set in the MP tray. When printing from paper tray 1, the T1 paper feed sensor 9400 2-46...
  • Page 50 Error Refer Error Refer Problem Problem codes codes Fuser unit error (except error C300 An unidentified error occurred. 2-50 DD00 codes 6A00 to 6F00, 7600, 2-51 7800, DE00, and E200) When the center thermistor of the fuser unit is higher than the idle temperature, the side C400 An unidentified error occurred.
  • Page 51 Error Refer Error Refer Problem Problem codes codes The country code was not F900 2-56 FD00 An unidentified error occurred. 2-56 entered correctly. FA00 An unidentified error occurred. 2-56 FE00 An unidentified error occurred. 2-56 FB00 An unidentified error occurred. 2-56 FF00 An unidentified error occurred.
  • Page 52: Error Messages

    Error Messages The error messages displayed on the LCD of the machine and their description are shown in the table below. Error Refer Error Message Description codes Access Denied Failed to authenticate the print limit ID when 2-73 PC-print was executed. Cartridge Error The new toner sensor could not detect the new C000...
  • Page 53 Error Refer Error Message Description codes Jam MP Tray The registration front sensor does not detect paper pass within the specified time after the 8C00 2-44 paper was picked up from the MP tray. Jam Rear The eject sensor remains ON (paper pass detected) for more than the specified time 8400 2-41...
  • Page 54: Error Messages

    Error Refer Error Message Description codes Replace Toner The toner sensor detected no toner remaining or the number of rotations of the developer 6300 2-36 roller has reached the upper limit. Self-Diagnostic Rechecking the error after the power switch was turned OFF and then ON again because an error was detected by the center thermistor of the fuser unit.
  • Page 55: Led Display (led Model)

    LED Display (LED Model) 3.3.1 LED display when operator call occurs Determine the message details according to the LED display on the control panel. Refer to the page shown in the "Refer to:" column in the table below to take appropriate measures. Most errors are automatically cleared after measures are taken.
  • Page 56 Error Refer Type of problem codes The side thermistor of the fuser unit detected a temperature higher than the specified value. 7500 2-38 Ready state under a low temperature environment. The front cover sensor detected that the front cover was open. A100 2-49 The eject sensor detected that the fuser cover was...
  • Page 57 Error Refer Type of problem codes When printing from the MP tray, paper tray 1, or 9000 2-45 paper tray 2, the size of paper set in the MP tray, 9100 2-45 paper tray 1 or paper tray 2 does not match the size 9200 2-45 specified by the driver.
  • Page 58 Error Refer Type of problem codes The registration front sensor does not detect paper pass within the specified time after the first side was printed in duplex printing mode. 5700 2-34 The eject sensor remains ON (paper pass detected) for more than the specified time even after the registration rear sensor detected the end of paper 8400 2-41...
  • Page 59: Led Display When Service Call Occurs

    3.3.2 LED display when service call occurs When a service call occurs, the six LEDs flash. Pressing the [Go] and [Cancel] buttons simultaneously allows you to identify the location of the problem based on the combination of the LED status: lit, flashing or unlit. In the event that a service call occurs, instruct end users to turn the power switch OFF and then ON again after several seconds.
  • Page 60 Press [Go] and Press [Go] and Error Refer Type of problem [Cancel] [Cancel] codes simultaneously once simultaneously twice The center thermistor of the fuser unit has not reached the specified temperature within the specified time. 6A00 2-37 The center thermistor of the fuser unit has not reached the specified temperature within the specified time.
  • Page 61 Press [Go] and Press [Go] and Error Refer Type of problem [Cancel] [Cancel] codes simultaneously once simultaneously twice The center thermistor of the fuser unit detected a temperature rise greater than the specified value within the specified time. 7600 2-39 The center thermistor of the fuser unit detected a temperature fall greater than the specified value...
  • Page 62 Press [Go] and Press [Go] and Error Refer Type of problem [Cancel] [Cancel] codes simultaneously once simultaneously twice Write error in the EEPROM of the main PCB E600 2-53 Malfunction of the flash memory on the main PCB F000 2-55 Fuser unit error (except error codes 6A00 to 6F00, 7600, 7800, DE00, and E200)
  • Page 63 Press [Go] and Press [Go] and Error Refer Type of problem [Cancel] [Cancel] codes simultaneously once simultaneously twice Cannot detect the synchronized signal of the main motor. The speed of the main motor does not stabilize within the specified time. 7A00 2-39 Detected an error in the synchronized signal of the polygon...
  • Page 64: Troubleshooting

    4. TROUBLESHOOTING Error Cause and Remedy Error code 0B00 This error does not usually occur during normal use. The possible causes are noise around the installation site, fluctuation of the power supply voltage, and failures in the software. An unidentified error occurred. Step Cause Remedy...
  • Page 65 Error code 0E00 This error does not usually occur during normal use. The possible causes are noise around the installation site, fluctuation of the power supply voltage, and failures in the software. An unidentified error occurred. Step Cause Remedy Main PCB failure Replace the main PCB ASSY.
  • Page 66 Error code 1E00 Drum End Soon The number of rotations of the drum unit is reaching the life limit. Step Cause Remedy Replace the drum unit with a Replace the main PCB ASSY. new one and reset the drum counter. If the error display is not cleared, the main PCB is faulty.
  • Page 67 Error code 3B00 Print Unable 3B An error occurred during access to the DRAM in the main PCB. Step Cause Remedy Main PCB failure Replace the main PCB ASSY. Error codes 3C00 to 4300 These errors do not usually occur during normal use. The possible causes are noise around the installation site, fluctuation of the power supply voltage, and failures in the software.
  • Page 68 Error code 5000 Replace Drum The number of rotations of the drum unit has reached the life limit. (Printing does not stop.) <User Check> • Prepare the drum unit. Step Cause Remedy Replace the drum unit with a Replace the main PCB ASSY. new one and reset the drum counter.
  • Page 69 Error code 5500 Replace Laser Printable pages set for the laser unit have reached the limit. (Printing does not stop.) Step Cause Remedy End of life of the laser unit Replace the laser unit. Main PCB failure Replace the main PCB ASSY. Error code 5600 Cover is Open The eject sensor detected that the fuser cover was open.
  • Page 70 Error code 5700 Jam Duplex The registration front sensor does not detect paper pass within the specified time after the first side was printed in duplex printing mode. <User Check> • Remove the paper jammed in the duplex paper feed system. •...
  • Page 71: Fuser Error

    Error code 5800 Fuser Error Any of error codes 6A00 to 6F00, 7600, 7800, DD00, DE00, or E200 (fuser unit error) occurred when the power switch was turned ON or sleep mode was released. Error code 5900 Self-Diagnostic Rechecking the error after the power switch was turned OFF and then ON again because an error was detected by the center thermistor of the fuser unit.
  • Page 72: Replace Toner

    Error code 6300 Replace Toner The toner sensor detected no toner remaining or the number of rotations of the developer roller has reached the upper limit. <User Check> • Replace the toner cartridge. Step Cause Remedy Toner sensor PCB failure Refer to "1.3.8 Check sensor operation (function code: 32)"...
  • Page 73 Error code 6A00 Fuser Error / Print Unable 6A The center thermistor of the fuser unit has not reached the specified temperature within the specified time. Error code 6B00 Fuser Error / Print Unable 6B The center thermistor of the fuser unit has not reached the specified temperature within the specified time.
  • Page 74 Error code 7000 This error does not usually occur during normal use. The possible causes are noise around the installation site, fluctuation of the power supply voltage, and failures in the software. An unidentified error occurred. Step Cause Remedy Main PCB failure Replace the main PCB ASSY.
  • Page 75 Error code 7600 Fuser Error / Print Unable 76 The center thermistor of the fuser unit detected a temperature rise greater than the specified value within the specified time. Error code 7800 Fuser Error / Print Unable 78 The center thermistor of the fuser unit detected a temperature fall greater than the specified value within the specified time.
  • Page 76: Drum Error

    Error codes 7B00 and 7C00 These errors do not usually occur during normal use. The possible causes are noise around the installation site, fluctuation of the power supply voltage, and failures in the software. An unidentified error occurred. Step Cause Remedy Main PCB failure Replace the main PCB ASSY.
  • Page 77 Error code 8400 Jam Rear The eject sensor remains ON (paper pass detected) for more than the specified time even after the registration rear sensor detected the end of paper pass. <User Check> • Remove the paper jammed in the rear section of the machine. Step Cause Remedy...
  • Page 78 Error codes 8600 and 8700 These errors do not usually occur during normal use. The possible causes are noise around the installation site, fluctuation of the power supply voltage, and failures in the software. An unidentified error occurred. Step Cause Remedy Main PCB failure Replace the main PCB ASSY.
  • Page 79 Error code 8A00 Jam Tray 1 The registration front sensor does not detect paper pass within the specified time after the T1 paper feed sensor detected paper pass. Error code 8B00 Jam Tray 2 The registration front sensor does not detect paper pass within the specified time after the T2 paper feed sensor detected paper pass.
  • Page 80 Error code 8C00 Jam MP Tray The registration front sensor does not detect paper pass within the specified time after the paper was picked up from the MP tray. <User Check> • Remove the paper jammed in the MP tray. Step Cause Remedy...
  • Page 81: Size Mismatch

    Error code 9000 Size Mismatch When printing from the MP tray, the size of paper set in the MP tray does not match the size specified by the driver. Error code 9100 Size Mismatch When printing from paper tray 1, the size of paper set in paper tray 1 does not match the size specified by the driver.
  • Page 82 Error code 9400 No Paper When printing from paper tray 1, the T1 paper feed sensor detected that there was no paper set in paper tray 1. <User Check> • Set the paper in paper tray 1. Step Cause Remedy Connection failure of the T1 Check the connection of the T1 paper feed paper feed sensor harness...
  • Page 83 Error code 9600 No Paper When printing with the tray designation set to AUTO, the MP paper empty sensor, T1 paper feed sensor and T2 paper feed sensor all detected that there was no paper set in the MP tray, paper tray 1 and paper tray 2. <User Check>...
  • Page 84 Error code 9A00 Manual Feed There is no paper set in the MP tray when feeding from the MP tray is designated from the driver. Step Cause Remedy MP paper empty actuator 1 or 2 Reattach the MP paper empty actuator 1 or 2. caught in some sections of the machine Failure of MP paper empty...
  • Page 85: Cartridge Error

    Error code A100 Cover is Open The front cover sensor detected that the front cover was open. <User Check> • Close the front cover. Step Cause Remedy Connection failure of the front Check the connection of the front cover sensor cover sensor harness harness, and reconnect it if necessary.
  • Page 86 Error codes C100 to C600 These errors do not usually occur during normal use. The possible causes are noise around the installation site, fluctuation of the power supply voltage, and failures in the software. An unidentified error occurred. Step Cause Remedy Main PCB failure Replace the main PCB ASSY.
  • Page 87 Error codes CA00 to DC00 These errors do not usually occur during normal use. The possible causes are noise around the installation site, fluctuation of the power supply voltage, and failures in the software. An unidentified error occurred. Step Cause Remedy Main PCB failure Replace the main PCB ASSY.
  • Page 88 Error code DE00 Print Unable DE When the center thermistor of the fuser unit is higher than the idle temperature, the side thermistor detected a temperature lower than the specified temperature. <User Check> • Turn OFF the power switch. After several seconds, turn ON the power again and check that this error is reset.
  • Page 89 Error code E200 Print Unable E2 When the center thermistor of the fuser unit is higher than the idle temperature, the side thermistor detected a temperature higher than the specified temperature. <User Check> • Turn OFF the power switch. After several seconds, turn ON the power again and check that this error is reset.
  • Page 90 Error codes E700 to EB00 These errors do not usually occur during normal use. The possible causes are noise around the installation site, fluctuation of the power supply voltage, and failures in the software. An unidentified error occurred. Step Cause Remedy Main PCB failure Replace the main PCB ASSY.
  • Page 91 Error code EF00 Print Unable EF The supplied power is unstable. <User Check> • Turn OFF the power switch. After several seconds, turn ON the power again and check that this error is reset. Step Cause Remedy Low-voltage power supply PCB Replace the low-voltage power supply PCB failure ASSY, and then reset the irregular power...
  • Page 92 Error code F900 Machine Error F9 The country code was not entered correctly. Step Cause Remedy Power switch was turned OFF Reenter the country code. while "PARAMETER INIT" is (Refer to "1.3.16 Setting by country (function displayed during execution of code: 74)"...
  • Page 93: Troubleshooting For Paper Feeding Problems

    Troubleshooting for Paper Feeding Problems End users can solve problems related to paper feeding as long as they follow the User Check items. If the problem still cannot be solved, implement each procedure according to the step number in the tables below. 4.2.1 Multiple sheets of paper are fed <User Check>...
  • Page 94: Duplex Printing Is Not Possible

    4.2.4 Duplex printing is not possible <User Check> - Close the back cover completely. - Set the paper tray correctly. - Check that the face-up mode is not selected. - Set the driver setting to duplex printing. - Use A4 or Letter-size paper. - Set the duplex tray correctly.
  • Page 95: Troubleshooting For Image Defects

    Troubleshooting for Image Defects 4.3.1 Image defect examples Light Faulty registration Dark Poor fixing Completely blank Dirt on the back of paper Vertical streaks Image distortion All black Black vertical streaks Black horizontal Vertical streaks White horizontal Faint print streaks in a light background stripes Downward fogging...
  • Page 96: Troubleshooting According To Image Defect

    4.3.2 Troubleshooting according to image defect End users can solve problems related to image defects as long as they follow the User Check items. If the problem still cannot be solved, implement each procedure according to the step number in the tables below. Light <User Check>...
  • Page 97 Electrodes location of the toner cartridge and drum unit Fig. 2-6 Electrodes location of the machine Fig. 2-7 2-61 Confidential...
  • Page 98: Faulty Registration

    Faulty registration <User Check> - Check that the appropriate paper type is selected in the driver. Step Cause Remedy Adjusted value of the laser unit is Refer to "2.1 Entering Adjusted Value of incorrect. Laser Unit" in Chapter 4, and enter the adjusted value of the laser unit again.
  • Page 99: Poor Fixing

    Poor fixing <User Check> - Check the usage environment of the machine. Using the machine in high temperature and humidity or low temperature and humidity conditions can cause this problem. - Select "Improve Toner Fixing" in the driver. - Clean the corona wire. - Replace the drum unit with a new one.
  • Page 100: Image Distortion

    Image distortion Step Cause Remedy Laser unit attachment failure Attach the laser unit correctly, and firmly tighten the screws. Harness connection failure Check the connection of all harnesses. If faulty, reconnect them. Dirt on high-voltage electrodes and Clean the high-voltage electrodes and electrodes of the machine electrodes of the machine.
  • Page 101: Vertical Streaks

    Dirt on the back of paper <User Check> - This problem may disappear after printing multiple sheets of paper. - Replace the toner cartridge with a new one. Step Cause Remedy Dirt on paper feed system Wipe off the dirt. Dirt on the fuser unit Replace the fuser unit.
  • Page 102 Black vertical streaks in a light background <User Check> - Clean inside the machine and the corona wire of the drum unit. - Refer to the User's Guide to remove the dirt from the exposure drum using a cotton applicator. - Replace the drum unit with a new one.
  • Page 103 White horizontal streaks <User Check> - This problem may disappear after printing multiple sheets of paper. When the machine has not been used for long periods, try printing several sheets of paper. - Replace the drum unit with a new one. - Replace the toner cartridge with a new one.
  • Page 104 Black horizontal stripes <User Check> - Clean inside the machine and the corona wire of the drum unit. - The paper tray earth spring on the machine side may be dirty. Clean it with a dry cloth. - This problem may disappear after printing multiple sheets of paper. - When the horizontal stripes appear at intervals of 45.3 mm, replace the toner cartridge with a new one.
  • Page 105: Faint Print

    Faint print <User Check> - Check that the machine is installed on a level surface. - Replace the toner cartridge with a new one. - Replace the drum unit with a new one. Step Cause Remedy Relay front PCB failure Replace the relay front PCB ASSY.
  • Page 106: White Spots

    White spots <User Check> - Turn ON the power switch, and open the front cover and the back cover. Leave the machine for a while to remove condensation. - Select "Improve Toner Fixing" in the driver. - When the white spots appear at intervals of 45.3 mm, replace the toner cartridge with a new one.
  • Page 107: Black Spots

    Black spots <User Check> - When the black spots appear at intervals of 45.3 mm, replace the toner cartridge with a new one. - Refer to the User's Guide to remove the dirt from the exposure drum using a cotton applicator. - When the black spots appear at intervals of 94.2 mm, replace the drum unit with a new one.
  • Page 108 Ghost <User Check> - Check the usage environment of the machine. Using the machine in high temperature and humidity or low temperature and humidity conditions can cause this problem. - Check that the appropriate paper type is selected in the driver. - Select "Reduce Ghosting"...
  • Page 109: Troubleshooting For Software Problems

    (3) Select "USB" at the bottom of "Hardware" in the "Content" on the left side of the screen. (4) Select "HL-XXXX" in the "USB Device Tree". (5) Check the "Product ID" under "HL-XXXX". Product ID (hexadecimal) • HL-5440D : 004Ah • HL-5450DN : 004Bh • HL-5470DW : 004Ch •...
  • Page 110: Troubleshooting For Network Problems

    Troubleshooting for Network Problems 4.5.1 Cannot print via network connection <User Check> - Check the relevant section in the Network Setting Guide. - Check the network connection. - Reset the network. (Refer to the User's Guide.) Step Cause Remedy Connection failure of the wireless Reconnect the wireless LAN PCB harness.
  • Page 111: Troubleshooting For Control Panel Problems

    Troubleshooting for Control Panel Problems 4.6.1 Nothing is displayed on the LCD Step Cause Remedy AC cord failure Replace the AC cord. Connection failure of the panel Check the connection of the panel harness, harness and reconnect it if necessary. Connection failure of the backlight Check the connection of the backlight harness...
  • Page 112: Troubleshooting For Toner And Drum Problems

    Troubleshooting for Toner and Drum Problems 4.7.1 New toner is not detected <User Check> - Be sure to set a new toner cartridge. Step Cause Remedy New toner actuator caught in some Reattach the new toner actuator. sections of the machine Connection failure of the relay front Reconnect the relay front PCB harness.
  • Page 113: Troubleshooting For Fuser Unit Problems

    Troubleshooting for Fuser Unit Problems 4.8.1 Fuser unit failure Step Cause Remedy Harness connection failure Check the harness connection between the between fuser unit and eject sensor fuser unit and the eject sensor PCB, and reconnect it if necessary. Harness connection failure Check the harness connection between the between fuser unit and low-voltage fuser unit and the low-voltage power supply...
  • Page 114: Troubleshooting For Laser Unit Problems

    Troubleshooting for Laser Unit Problems 4.9.1 Laser unit failure <User Check> - Turn ON the power switch, and open the front cover and the back cover. Leave the machine for a while to remove condensation. Step Cause Remedy Earth plate contact failure Check the contact of the laser unit earth plate, and retighten the screws.
  • Page 115: Troubleshooting For Pcb Problems

    4.10 Troubleshooting for PCB Problems 4.10.1 Main PCB failure <User Check> - Turn the power switch OFF and then ON again. - Install the latest firmware. Step Cause Remedy Main PCB failure Replace the main PCB ASSY. 4.10.2 High-voltage power supply PCB failure Step Cause Remedy...
  • Page 116: Troubleshooting For Other Problems

    4.11 Troubleshooting for Other Problems 4.11.1 Machine is not turned ON <User Check> - Connect the AC cord correctly. Step Cause Remedy Connection failure of the panel PCB Check the connection of the panel PCB harness harness, and reconnect it if necessary. Panel PCB failure Replace the panel PCB ASSY.
  • Page 117 CHAPTER DISASSEMBLY/REASSEMBLY Confidential...
  • Page 118 CHAPTER 3 DISASSEMBLY/REASSEMBLY This chapter describes procedures for disassembling and reassembling the machine with relates notes. The provided disassembly order flow enables you to take in the disassembly procedure of related part at a glance. At the start of disassembling, you can check the disassembly order flow which guides you through a shortcut to get to the part.
  • Page 119 9.21 Registration clutch / T1 clutch................... 3-46 9.22 Main frame L ASSY ....................3-47 9.23 Main motor ASSY ..................... 3-49 9.24 Develop joint gear 37 / Develop joint ................ 3-51 9.25 LT drive gear 29 ......................3-52 9.26 Toner sensor PCB ASSY ..................3-53 9.27 MP solenoid ......................
  • Page 120: Safety Precautions

    1. SAFETY PRECAUTIONS To avoid creating secondary problems by mishandling, follow the warnings and precautions below during maintenance work. WARNING Some parts inside the machine are extremely hot immediately after the machine is used. When opening the front cover ASSY or back cover to access any parts inside the machine, never touch the shaded parts shown in the following figures.
  • Page 121: Packing

    2. PACKING T2 styrofoam pad R T2 styrofoam pad F T2 carton Setup guide USB cable Option carton AC cord Polystyrene pad ASSY Protective material ASSY Polystyrene pad ASSY Machine Polystyrene pad ASSY Polystyrene pad ASSY Carton Carton spacer Carton spacer Carton outer Confidential...
  • Page 122: Screw Catalogue

    3. SCREW CATALOGUE Screw pan Taptite bind B Screw pan Taptite bind B M3x6 M3x10 Screw pan Taptite bind B M4x8 M4x12 Screw bind Taptite cup S Taptite cup S Screw bind M3x8 SR M3x4 Taptite flat B Taptite flat B M3x10 Screw pan (S/P washer) Screw pan (S/P washer)
  • Page 123: Screw Torque List

    0.8±0.1(8±1) Fuser unit Taptite pan B M4x14 0.8±0.1(8±1) Main PCB ASSY Taptite cup S M3x8 SR 0.5±0.1(5±1) Parallel interface (HL-5440D only) Screw pan M3x6 0.5±0.1(5±1) Laser unit Taptite cup S M3x8 SR 0.8±0.05(8±0.5) Taptite cup S M3x8 SR (Fastening side of scanner 0.8±0.1(8±1)
  • Page 124 0.8±0.1(8±1) Taptite bind B M4x12 0.8±0.1(8±1) Drive HL-5440D Taptite cup S M3x8 SR 0.5±0.1(5±1) ASSY Except for HL-5440D Taptite bind B M4x12 0.8±0.1(8±1) Main motor ASSY Taptite cup S M3x8 SR 0.8±0.1(8±1) Main motor cover Taptite bind B M3x10 0.5±0.1(5±1)
  • Page 125: Lubrication

    5. LUBRICATION Lubricating oil type Lubrication point Quantity of lubrication (Maker name) Fuser drive gear 39 10 places Develop one way clutch 53 5 places FLOIL BG-10KS (Kanto Kasei) 1.5 mm dia. ball Develop clutch 51R 1 places Develop joint gear 37 4 places Fuser drive gear 39 Fig.
  • Page 126: Overview Of Gears

    6. OVERVIEW OF GEARS <Layout view> 11 11 11 Fig. 3-5 <Development view> 9 9 9 3 3 3 6 6 6 5 5 5 8 8 8 2 2 2 7 7 7 1 1 1 4 4 4 Fig.
  • Page 127 <Layout view> Fig. 3-7 <Development view> Fig. 3-8 Note: • When handling gears, make sure that frame L faces up. Otherwise all gears come off. <Name of gears> LY4448 Fuser gear 22/33 LY4436 Eject idle gear 19 LY4438 Eject sector gear 33 LY4435 Eject idle gear 20 LY4444...
  • Page 128: Harness Routing

    7. HARNESS ROUTING Main PCB ASSY Toner LED harness (RD, BL, WH) Hooks Relay front harness (WH) Wireless LAN harness (Shield) Hook Duplex solenoid harness (WH) Panel harness (WH) Laser unit flat cable Center/side thermistor harness (RD, BL, WH) Main HVPS flat cable Main PCB ASSY Back cover sensor harness (WH, BK)
  • Page 129 Relay front PCB ASSY Hooks Relay front PCB ASSY Front cover sensor Front cover sensor harness (RD, WH) Hooks Hooks Registration clutch harness (BK) MP solenoid harness (WH) Registration clutch MP solenoid T1 clutch harness (BK) Drive sub ASSY T1 clutch Hooks Hooks Hooks...
  • Page 130 Fuser unit Fuser unit Fuser unit Hook Hook Hook Low-voltage- Hook heater harness Center thermistor harness Heater harness (WH) (GR x 2) Side thermistor harness (WH x 2) High-voltage power supply PCB ASSY T1 paper feed sensor harness (RD, BL, WH) MP paper empty High-voltage power sensor PCB ASSY...
  • Page 131 Toner LED PCB ASSY/Main fan Toner LED harness (RD, BL, WH) Hook Hooks Hook Toner LED PCB ASSY Main fan harness (RD, WH) Main fan Laser unit Laser unit flat cable Core Laser unit Toner LED harness (RD, BL, WH) Hooks Harness colors may be changed for any reason.
  • Page 132 Low-voltage power supply PCB ASSY FG harness Low-voltage-heater harness Low-voltage power supply PCB ASSY Inlet Power switch Note: • Attach the FG harness outermost over the heater harness. Hook Tape Tape Hook Hooks Tape Hole Tape Low-voltage power supply harness Harness colors may be changed for any reason.
  • Page 133: Disassembly Flow Chart

    8. DISASSEMBLY FLOW CHART Disassembly / Re-Assembly (second) 9.8 Side cover R 9.2 Paper tray 1 9.34 T1 roller holder 9.7 Side cover L / ASSY Access cover 10/10 5/10 10/10 9.5 MP cover ASSY 9.37 MP roller holder ASSY / MP separation 5/10 9.16 Scanner earth pad ASSY / MP...
  • Page 134: Disassembly Procedure

    9. DISASSEMBLY PROCEDURE Preparation Disconnecting Cables and Removing Accessories Prior to proceeding with the disassembly procedure, (1) Disconnect the following: • AC cord • USB cable (if connected) • LAN cable (if connected) • Parallel cable (if connected) (2) Remove the following: •...
  • Page 135: Paper Tray 1

    Paper tray 1 Note: • Paper tray 1 (250 sheets, 500 sheets): T1 Paper tray 2 (500 sheets): T2 • The illustration shows paper tray 1 (500 sheets). (1) Remove the two taptite bind B M4x12 screws from the paper tray 1. (2) Lift the plate to remove "A"...
  • Page 136 (6) Push the hook on the lift gear Z27M10 (or lift gear Z48M10) while lifting the plate-up plate, and remove the lift gear Z27M10 (or lift gear Z48M10) from the paper tray 1. 250 sheets: Lift gear Z27M10 500 sheets: Lift gear Z48M10 (7) Remove the gear Z22M10 and the idle gear Z18M10 from the paper tray 1.
  • Page 137: Back Cover / Outer Chute

    Back cover / Outer chute (1) Open the back cover. (2) Push both ribs of the back cover in the direction of the arrows, and remove the two bosses on the outer chute. Note: • Be careful not to damage the ribs inside the back cover. Boss Rear nip release link Back cover...
  • Page 138: Fuser Cover

    Fuser cover (1) Push the two knobs on the fuser cover, and pull the fuser cover down in the direction of the arrow. (2) Remove the fuser cover from the bosses on the fuser unit, and remove the fuser cover from the machine.
  • Page 139: Mp Cover Assy

    MP cover ASSY (1) Open the MP cover ASSY. (2) Remove the two hooks on the MP paper guide ASSY from the two bosses on the front cover ASSY. Note: • When removing the MP paper guide ASSY from the bosses on the front cover ASSY, pull it out strongly in the direction of arrow 2.
  • Page 140: Front Cover Assy

    Front cover ASSY (1) Push the front cover release button, and open the front cover ASSY. (2) Release the two hooks, and remove the develop joint link from the front cover ASSY. (3) Release the hook, and remove the nip release link from the front cover ASSY. Hook Hook Nip release link...
  • Page 141: Side Cover L / Access Cover

    (4) Release the hook, and remove the access cover from the side cover L. Note: • HL-5440D is not equipped with an access cover. Assembling Note: • For HL-5440D, raise the two locks for the parallel interface to the upright position, and then attach the side cover L. 3-22 Confidential...
  • Page 142: Side Cover R

    Side cover R (1) Remove the taptite cup B M4x12 screw from the front side of the side cover R. (2) Remove the taptite cup B M4x12 screw from the back side of the side cover R. (3) Keep the two front hooks held down, and rotate the side cover R in the direction of arrow 3b while pushing it in the direction of arrow 3a.
  • Page 143: Top Cover Assy

    (1) Remove the four taptite cup S M3x8 SR screws, and remove the main shield cover plate from the machine. Note: • HL-5440D is not equipped with a main shield cover plate. (2) Disconnect the panel harness from the main PCB ASSY, and release the panel harness from the securing fixtures.
  • Page 144 (3) Remove the two taptite cup B M4x12 screws from the front side of the top cover ASSY. (4) Release the six hooks. Lift the front side of the top cover ASSY, and pull the top cover ASSY in the direction of the arrow to remove it from the machine. Hook Top cover ASSY Taptite cup B M4x12...
  • Page 145: Control Panel

    9.10 Control panel LED model (1) Release the panel harness from the securing fixtures. (2) Remove the three taptite pan B M3x8 screws, and remove the panel PCB ASSY from the top cover ASSY. (3) Remove the panel light guide from the top cover ASSY. (4) Remove the SW key printed ASSY from the top cover ASSY.
  • Page 146 LCD model (1) Release the panel harness from the securing fixtures. (2) Disconnect the backlight harness from the panel PCB ASSY, release the four hooks, and remove the panel PCB ASSY from the top cover base. (3) Remove the rubber key printed ASSY and the panel light guide. (4) Remove the two taptite bind B M4x12 screws "a", and remove the inner chute ASSY from the top cover ASSY.
  • Page 147 (7) Release the four hooks to remove the panel printed ASSY from the top cover ASSY. (8) Release the two hooks to remove the LCD holder from the top cover ASSY. (9) Release the two hooks to remove the LCD from the LCD holder. Hook LCD holder Hook...
  • Page 148: Paper Stack Lever

    9.11 Paper stack lever (1) Remove the two paper stack levers from the top cover ASSY. Paper stack levers Top cover ASSY Fig. 3-27 3-29 Confidential...
  • Page 149: Wireless Lan Pcb (wireless Network Model Only)

    9.12 Wireless LAN PCB (Wireless Network model only) (1) Disconnect the wireless LAN harness from the wireless LAN PCB. (2) Release the hook to remove the wireless LAN PCB from the machine. Wireless LAN harness Wireless LAN PCB Hook Main PCB ASSY Fig.
  • Page 150: Fuser Unit

    9.13 Fuser unit CAUTION Some parts inside the machine are extremely hot immediately after the machine is used. When opening the front cover or back cover to access any parts inside the machine, never touch the shaded parts shown in the following figures. Note: •...
  • Page 151 (4) Release the heater harness of the fuser unit from the guide on the main frame R, and disconnect the heater harness from the low-voltage-heater harness. <Frame R side> Guide Heater harness Low-voltage-heater harness Fuser unit Fig. 3-30 Harness routing: Refer to “3.Fuser unit”.
  • Page 152 (7) Remove the taptite pan B M4x14 screw, and remove the fuser unit from the machine. Note: • Make sure that the front cover is closed when removing the fuser unit. Fuser unit Taptite pan B M4x14 Fig. 3-32 Assembling Note: •...
  • Page 153: Main Pcb Assy

    • When connecting the flat cable(s), insert it straight. After insertion, check that the cable is not at an angle. • Only HL-5440D is equipped with a parallel interface. Wireless LAN harness Duplex solenoid harness Toner LED harness...
  • Page 154 Screw pan M3x6 Parallel interface Lock Taptite cup S M3x8 SR Main PCB ASSY Fig. 3-35 Assembling Note: • For HL-5440D, raise the two locks for the parallel interface to the upright position, and then attach the main PCB ASSY. 3-35 Confidential...
  • Page 155: Laser Unit

    9.15 Laser unit (1) Disconnect the laser unit flat cable from the laser unit. (2) Remove the four taptite cup S M3x8 SR screws, and remove the laser unit from the machine. Note: • Be careful not to touch the lens of the laser unit. Taptite cup S M3x8 SR Taptite cup S M3x8 SR Laser unit flat cable...
  • Page 156: Low-voltage Power Supply Pcb Assy

    9.16 Low-voltage power supply PCB ASSY (1) Remove the two taptite cup S M3x8 SR screws, and remove the scanner earth plate from the machine. (2) Remove the three taptite cup S M3x8 SR screws, taptite bind B M4x12 screw and screw pan M4x8, washer spring 2-4, washer 5, and remove the LV shield plate cover from the machine.
  • Page 157 Housing Marking FG harness Power switch Power switch Marking Inlet Screw pan M4x8 Washer 5 Taptite flat B M3x10 Washer spring 2-4 <Section B> Fig. 3-38 Assembling Note: • When attaching the power switch, align the marking on the power switch with the marking on the machine.
  • Page 158 (7) Remove the taptite cup S M3x8 SR screw and the two taptite bind B M4x12 screws to remove the low-voltage power supply PCB ASSY from the machine, and disconnect the low-voltage power supply harness from the low-voltage power supply PCB ASSY. Low-voltage power supply harness Low-voltage power supply PCB ASSY...
  • Page 159: Toner Led Pcb Assy

    9.17 Toner LED PCB ASSY (1) Remove the LV shield plate ground spring from the LV shield plate and the machine. (2) Remove the taptite cup S M3x8 SR screw, and lift the under bar earth plate R from the LV shield plate.
  • Page 160 (4) Remove the taptite bind B M4x12 screw, and release the hook to open the back side of the hold cover 1. Then remove the hold cover 1 from the machine in the direction of the arrow. (5) Release the toner LED harness from the securing fixtures. (6) Remove the taptite pan B M3x8 screw, and pull out "A"...
  • Page 161: Main Fan

    9.18 Main fan (1) Slide the straight cam in the direction of arrow 1a to remove the boss on the nip release link from the groove on the straight cam. Then slide the straight cam in the direction of arrow 1b to remove it from the machine. Boss Nip release link Straight...
  • Page 162 (2) Remove the two taptite bind B M4x12 screws, and release the hook to open the upper side of the hold cover 2. (3) Release the main fan harness from the securing fixtures, and remove the main fan from the machine. Hold cover 2 Hook Taptite bind B M4x12...
  • Page 163: Air Duct / Filter

    9.19 Air duct / Filter (1) Release the hook, and remove the filter from the air duct. (2) Push the two pins of the air duct to release the pins, and pull the air duct in the direction of the arrow to remove it from the machine. Filter Hook Air duct...
  • Page 164: Relay Front Pcb Assy

    9.20 Relay front PCB ASSY (1) Release the relay front harness from the securing fixtures. (2) Release the two hooks to remove the front cover sensor from the machine, and then release the front cover sensor harness from the hook. Note: •...
  • Page 165: Registration Clutch / T1 Clutch

    9.21 Registration clutch / T1 clutch (1) Release the registration clutch harness and the T1 clutch harness from the securing fixtures. (2) Remove collar 6, and remove the registration clutch from the machine. (3) Release the hook, and remove the T1 clutch from the machine. Note: •...
  • Page 166: Main Frame L Assy

    9.22 Main frame L ASSY (1) Remove the two taptite bind B M4x12 screws, and remove the rear under bar from the machine. Note: • Only HL-6180DW/6180DWT is equipped with a rear under bar. (2) Remove the two taptite bind B M4x12 screws, and remove the front under bar and the under bar earth plate R.
  • Page 167 (6) Remove the three taptite cup S M3x8 SR screws and four taptite bind B M4x12 screws, and remove the main frame L ASSY from the machine. Then pull out the low-voltage power supply harness, the eject sensor harness and the main HVPS flat cable from the main frame L ASSY.
  • Page 168: Main Motor Assy

    (1) Remove the eight taptite bind B M4x12 screws, and remove the drive sub ASSY from the main frame L ASSY. For HL-5440D, screw A (taptite cup S M3x8 SR) must be removed. Note: • When removing the drive sub ASSY, be careful not to damage the shaft of the drive sub ASSY.
  • Page 169 Note: • Do not allow the metallic gear shaft of the main motor ASSY and drive sub ASSY to face down. Failure to observe this may cause the steel plate to bend. (2) Remove the four taptite cup S M3x8 SR screws, and remove the main motor ASSY and the main motor cover from the drive sub ASSY.
  • Page 170: Develop Joint Gear 37 / Develop Joint

    9.24 Develop joint gear 37 / Develop joint (1) Tilt the develop joint to remove it from the drive sub ASSY, and then remove the develop joint spring from the drive sub ASSY. Note: • When removing the develop joint, be careful not to damage the hooks. (2) Pull out the develop joint gear 37 from the drive sub ASSY.
  • Page 171: Lt Drive Gear 29

    9.25 LT drive gear 29 (1) Pull out the LT drive gear 29 from the main frame L ASSY. LT drive gear 29 Main frame L ASSY Fig. 3-53 3-52 Confidential...
  • Page 172: Toner Sensor Pcb Assy

    9.26 Toner sensor PCB ASSY (1) Remove the MP sector gear spring from the main frame L ASSY. (2) Release the toner sensor harness from the securing fixtures. (3) Release the two hooks to remove the toner sensor PCB ASSY from the main frame L ASSY.
  • Page 173: Mp Solenoid

    9.27 MP solenoid (1) Remove the MP drive gear 18 from the main frame L ASSY. (2) Release the MP solenoid harness from the securing fixtures. (3) Remove the taptite bind B M3x10 screw, and remove the MP solenoid and the MP solenoid lever from the main frame L ASSY.
  • Page 174: Develop Clutch 51r / Develop One Way Clutch 53

    9.28 Develop clutch 51R / Develop one way clutch 53 (1) Remove the develop idle gear 53 from the main frame L ASSY. (2) Remove the develop shaft gear 22 from the main frame L ASSY. (3) Release the develop clutch harness from the securing fixtures, and remove the develop clutch 51R from the main frame L ASSY.
  • Page 175: New Toner Actuator

    9.29 New toner actuator (1) Remove "A" on the new toner actuator spring from the main frame L ASSY. Turn the new toner actuator in the direction of the arrow, and release the hook to remove the new toner actuator from the main frame L ASSY. (2) Remove the new toner actuator spring from the new toner actuator.
  • Page 176: Fuser Drive Gear 39

    9.30 Fuser drive gear 39 (1) Remove the four taptite bind B M4x12 screws, and release the two hooks to remove the main PCB shield calking ASSY from the main frame L ASSY. Then pull out the duplex solenoid harness from the main PCB shield calking ASSY. Note: •...
  • Page 177 (2) Remove the fuser drive gear 39 from the main frame L ASSY. Fuser drive gear 39 Main frame L ASSY Fig. 3-59 3-58 Confidential...
  • Page 178: Duplex Solenoid

    9.31 Duplex solenoid (1) Remove the eject idle gear 20 from the main frame L ASSY. (2) Remove the eject switch arm spring from the main frame L ASSY. (3) Remove the eject switch arm from the main frame L ASSY. (4) Remove the eject sector gear spring from the main frame L ASSY.
  • Page 179: Back Cover Sensor

    9.32 Back cover sensor (1) Release the back cover sensor harness from the securing fixtures. (2) Release the two hooks, and remove the back cover sensor from the main frame L ASSY. Back cover sensor harness Hook Hook Back cover sensor Main frame L ASSY Back cover sensor Hook...
  • Page 180: Lt Connector (t1)

    9.33 LT connector (T1) (1) Remove the three taptite bind B M4x12 screws, and remove the bottom frame L from the main frame L ASSY. Then pull out the LT harness from the main frame L ASSY. (2) Release the two hooks to remove the LT connector (T1) from the bottom frame L. Note: •...
  • Page 181: T1 Roller Holder Assy

    9.34 T1 roller holder ASSY (1) Push the T1 lift arm in the direction of arrow 1, and remove the boss on the T1 roller holder ASSY from the T1 lift arm. (2) Turn the T1 roller holder ASSY in the direction of arrow 2a, and slide it in the direction of arrow 2b to remove it from the T1 separation roller shaft.
  • Page 182: High-voltage Power Supply Pcb Assy

    9.35 High-voltage power supply PCB ASSY (1) Remove the four taptite bind B M4x12 screws and the two screw pan (S/P washer) M3x12 DB screws. Slightly lift the base plate and slide it in the direction of the arrow to remove it from the machine.
  • Page 183 (2) Open the HV insulation sheet. Remove the two taptite bind B M4x12 screws, and release the two hooks. Lift the HV insulation sheet and the high-voltage power supply PCB ASSY, and remove the feed ground spring from the machine. High-voltage power supply PCB ASSY Feed ground spring Taptite bind B M4x12...
  • Page 184 (3) Disconnect the registration front/rear sensor harness, the T1 paper feed sensor harness and the MP paper empty sensor harness from the high-voltage power supply PCB ASSY, and remove the high-voltage power supply PCB ASSY from the machine. (4) Disconnect the main HVPS flat cable from the high-voltage power supply PCB ASSY. MP paper empty sensor harness T1 paper feed sensor harness Main HVPS flat cable...
  • Page 185: Eject Sensor Pcb Assy

    9.36 Eject sensor PCB ASSY (1) Release the eject sensor harness from the securing fixtures. (2) Release the hook, and remove the eject sensor PCB ASSY from the machine. Hook Eject sensor harness Eject sensor PCB ASSY Fig. 3-67 Harness routing: Refer to “4.High-voltage power supply PCB ASSY”.
  • Page 186: Mp Roller Holder Assy / Mp Separation Pad Assy / Mp Separation Pad Spring

    9.37 MP roller holder ASSY / MP separation pad ASSY / MP separation pad spring (1) Open the MP roller cover. Release the hook on the MP holder bushing, and slide the MP holder bushing in the direction of arrow 1 to remove it from the machine. (2) Slide the MP roller holder ASSY in the direction of arrow 2a to remove it from the MP separation roller shaft.
  • Page 187: T1 Paper Feed Sensor Pcb Assy / T1 Paper Feed Actuator / T1 Paper Feed Actuator Spring

    9.38 T1 paper feed sensor PCB ASSY / T1 paper feed actuator / T1 paper feed actuator spring (1) Release the T1 paper feed sensor harness (white connector) from the securing fixtures. (2) Remove the taptite bind B M3x10 screw, and release the hook to remove the T1 paper feed actuator holder ASSY from the machine.
  • Page 188 (3) Turn the T1 paper feed actuator in the direction of arrow 3a, and push the hook on the T1 paper feed actuator holder to slide the T1 paper feed actuator in the direction of arrow 3b to remove it from the T1 paper feed actuator holder. (4) Remove the T1 paper feed actuator spring from the T1 paper feed actuator.
  • Page 189 9.39 MP paper empty sensor PCB ASSY / MP paper empty actuator 1 / MP paper empty actuator 2 (1) Remove the five taptite bind B M4x12 screws, and remove the main frame R from the machine. Then pull out the low-voltage power supply harness from the main frame R. Low-voltage power supply harness Main frame R.
  • Page 190 (2) Release the MP paper empty sensor harness from the paper feed frame ASSY. (3) Remove the two taptite bind B M3x10 screws, and release the two hooks to remove the MP feed frame from the paper feed frame ASSY. Then pull out the MP paper empty sensor harness from the paper feed frame ASSY.
  • Page 191: Mp Paper Empty Sensor Pcb Assy

    (5) Turn MP paper empty actuator 2 in the direction of arrow 5a, and push the hook in the direction of arrow 5b to slide MP paper empty actuator 1 in the direction of arrow 5c to remove it from the MP feed frame in the direction of arrow 5d. (6) Turn MP paper empty actuator 2 in the direction of arrow 5a, and remove it from the MP feed frame in the direction of arrow 6.
  • Page 192: Registration Front/rear Sensor Pcb Assy / Registration Front Actuator / Registration Rear Actuator / Registration Actuator Spring

    9.40 Registration front/rear sensor PCB ASSY / Registration front actuator / Registration rear actuator / Registration actuator spring (1) Release the low-voltage power supply harness from the securing fixtures. (2) Release the two hooks, and remove the paper feed frame from the feed chute. Hook Paper feed frame Hook...
  • Page 193 (3) Remove the earth registration spring from the hook on the feed chute, and remove the earth registration spring from the feed chute. (4) Remove the electrode TR from the hook on the registration actuator holder ASSY, and remove the electrode TR from the registration actuator holder ASSY. (5) Release the hook, and remove the registration actuator holder ASSY from the feed chute.
  • Page 194 (6) Remove the registration actuator spring from the registration front actuator and the registration actuator holder ASSY. (7) Turn the registration front actuator to remove it from the guide, and then slide it in the direction of the arrow to remove it from the registration actuator holder ASSY. (8) Remove the registration actuator spring from the registration rear actuator and the registration actuator holder ASSY.
  • Page 195: Disassembly Procedure (lt Unit)

    10. DISASSEMBLY PROCEDURE (LT UNIT) 10.1 Paper tray 2 (1) Remove the two taptite bind B M4x12 screws from paper tray 2. (2) Lift the plate to remove "A" on the T2 tray indicator from the plate, remove the four bosses, and remove the T2 tray cover from paper tray 2.
  • Page 196 (6) Push the hook on the lift gear Z48M10 while lifting the plate-up plate, and remove the lift gear Z48M10 from paper tray 2. (7) Remove the gear Z22M10 and the idle gear Z18M10 from paper tray 2. Plate-up plate Hook Paper tray 2 Plate-up plate...
  • Page 197: T2 Roller Holder Assy

    10.2 T2 roller holder ASSY (1) Push the T2 lift arm in the direction of arrow 1a, and remove the boss on the T2 roller holder ASSY from the T2 lift arm. Then turn the T2 roller holder ASSY in the direction of arrow 1b.
  • Page 198: T2 Side Cover L

    10.3 T2 side cover L (1) Remove the taptite bind B M4x12 screw from the front side of the T2 side cover L. (2) Release the two front hooks, two top hooks and four bottom hooks, and remove the T2 side cover L from the LT unit.
  • Page 199: T2 Side Cover R

    10.4 T2 side cover R (1) Remove the taptite bind B M4x12 screw from the front side of the T2 side cover R. (2) Release the two front hooks, two top hooks and four bottom hooks, and remove the T2 side cover R from the LT unit.
  • Page 200: T2 Front Cover Assy

    10.5 T2 front cover ASSY (1) Remove the taptite cup S M3x8 SR screw from the T2 front cover ASSY. (2) Release the two hooks on the T2 front cover ASSY, and remove the T2 front cover ASSY from the LT unit. LT unit Taptite cup S M3x8 SR Hook...
  • Page 201: T2 Relay Pcb Assy

    10.6 T2 relay PCB ASSY (1) Disconnect all harnesses from the T2 relay PCB ASSY. T2 paper feed sensor harness LT harness T2 relay PCB ASSY T2 clutch harness Fig. 3-85 (2) Release the hook to remove the core of the LT connector ASSY (T2) from the LT unit. (3) Release the hook to remove the T2 relay PCB ASSY from the LT unit.
  • Page 202: T2 Clutch

    10.7 T2 clutch (1) Release the T2 clutch harness from the securing fixtures. (2) Release the hook on the T2 clutch, and remove the T2 clutch from the LT unit. T2 clutch LT unit T2 clutch harness Hook Fig. 3-87 3-83 Confidential...
  • Page 203: T2 Paper Feed Sensor Pcb Assy

    10.8 T2 paper feed sensor PCB ASSY (1) Remove the four taptite bind B M4x12 screws securing the two under bars, and remove the two under bars from the LT unit. Taptite bind B M4x12 Under bars Taptite bind B M4x12 LT unit Fig.
  • Page 204 (3) Remove the three taptite cup S M3x8 SR screws, and remove the T2 paper feed frame unit from the LT unit. Then pull out the T2 paper feed sensor harness from the LT unit. LT unit T2 paper feed sensor harness T2 paper feed frame unit Taptite cup S M3x8 SR...
  • Page 205 (6) Remove the taptite bind B M3x10 screw, and release the hook to remove the T2 paper feed actuator holder ASSY from the T2 paper feed frame unit. Then pull out the T2 paper feed sensor harness from the T2 paper feed frame unit. Hook Taptite bind B M3x10 T2 paper feed actuator holder ASSY...
  • Page 206 (7) Turn the T2 paper feed actuator in the direction of arrow 7a, and push the hook on the T2 paper feed actuator holder ASSY to slide the T2 paper feed actuator in the direction of arrow 7b to remove it from the T2 paper feed actuator holder ASSY. (8) Remove the T2 paper feed actuator spring from the T2 paper feed actuator.
  • Page 207: T2 Back Cover

    10.9 T2 back cover (1) Remove the two taptite bind B M4x12 screws, and remove the T2 back cover from the LT unit. T2 back cover Taptite bind B M4x12 LT unit Fig. 3-94 3-88 Confidential...
  • Page 208: Lt Connector Assy (t2)

    10.10 LT connector ASSY (T2) (1) Release the two hooks, and remove the LT connector ASSY (T2) from the LT unit. LT connector ASSY (T2) Hooks LT unit Fig. 3-95 3-89 Confidential...
  • Page 209 CHAPTER ADJUSTING AND UPDATING SETTINGS AS REQUIRED AFTER PARTS REPLACEMENT Confidential...
  • Page 210: As Required After Parts Replacement

    CHAPTER 4 ADJUSTING AND UPDATING SETTINGS AS REQUIRED AFTER PARTS REPLACEMENT This chapter describes adjustments and updating of settings, which are required if the main PCB ASSY and some other parts have been replaced. CONTENTS 1. IF YOU REPLACE THE MAIN PCB ASSY..............4-1 1.1 Installing Firmware (Sub Firmware, Main Firmware) ..........
  • Page 211: If You Replace The Main Pcb Assy

    LZXXXX: First six digits of the part number of the firmware (E.g.) LZXXXX_$.upd $: Alphabetic character representing the revision version of the firmware (Not provided for HL-5440D) Main firmware LZXXXX: First six digits of the part number of the firmware (E.g.) LZXXXX_$.upd...
  • Page 212: Installing Firmware (sub Firmware, Main Firmware)

    (5) Open the temporary folder and double- Paper and Error LEDs flash once, and click "FILEDG32.EXE" to start it, and then go out. The machine enters select the "Brother Maintenance USB firmware installing mode. Printer". (5) Close the front cover.
  • Page 213 (9) The Ready LED flashes randomly (9) Turn OFF the power switch of the during installing. When installing is machine. completed, the machine restarts and returns to the ready state automatically. Do not disconnect the USB cable or turn OFF the power switch of the computer until installing is completed.
  • Page 214: Setting Default Paper Size

    (4) Double-click "FILEDG32.EXE" to start it. Drag and drop the PJL file modified in step (3) onto the "Brother Maintenance USB Printer" icon. (5) Wait for five seconds, and then turn OFF the power switch of the machine.
  • Page 215: Setting Serial Number And Entering Adjusted Value Of Laser Unit

    (3) Double-click the "brusbsn.exe" file that was copied to the temporary folder to start it. (4) Click "Laser 11Model". (5) In the [Port] field, select the port number assigned to the Brother Maintenance USB Printer. If the port number is unknown, follow the steps below to check it.
  • Page 216 (7) Enter the number (last digit) on the laser serial number label attached to the location shown in the illustration below in the [K= ] field. Laser serial number label Laser plate Laser unit Fig. 4-1 (8) Enter the numbers (from sixth last digit to second last digit) on the laser serial number label in the [Scanner Video Clk] field.
  • Page 217: If You Replace The Laser Unit

    2. IF YOU REPLACE THE LASER UNIT <What to do after replacement> • Entering adjusted value of laser unit What you need to prepare (1) One USB cable ® (2) Create a temporary folder on the C drive of the computer (Windows XP or higher).
  • Page 218: Entering Adjusted Value Of Laser Unit

    (3) Double-click the "brusbsn.exe" file that was copied to the temporary folder to start it. (4) Click "Laser 11Model". (5) In the [Port] field, select the port number assigned to the Brother Maintenance USB Printer. If the port number is unknown, follow the steps below to check it.
  • Page 219 (7) Enter the number (last digit) on the laser serial number label attached to the location shown in the illustration below in the [K= ] field. Laser serial number label Laser plate Laser unit Fig. 4-2 (8) Enter the numbers (from sixth last digit to second last digit) on the laser serial number label in the [Scanner Video Clk] field.
  • Page 220: If You Replace The Low-voltage Power Supply Pcb Assy

    (3) Double-click "FILEDG32.EXE" on the computer to start it, and select the "Brother Maintenance USB Printer". (4) Drag and drop the "SQWAVE.PJL" file onto the "Brother Maintenance USB Printer" icon. (5) Turn OFF the power switch of the machine. 4-10...
  • Page 221: If You Replace The High-voltage Power Supply Pcb Assy

    (2) Connect the computer to the machine with the USB cable. (3) Double-click "FILEDG32.EXE" on the computer to start it, and select the "Brother Maintenance USB Printer". (4) Drag and drop the "PREDISCHAGESET_RESET.pjl" file onto the "Brother Maintenance USB Printer"...
  • Page 222: If You Replace Any Periodic Replacement Parts

    (3) Double-click "FILEDG32.EXE" on the computer to start it, and select the "Brother Maintenance USB Printer". (4) Drag and drop the periodic parts resetting PJL file onto the "Brother Maintenance USB Printer" icon. (5) Turn OFF the power switch of the machine.
  • Page 223: Service Functions

    CHAPTER SERVICE FUNCTIONS Confidential...
  • Page 224: Chapter 5 Service Functions

    CHAPTER 5 SERVICE FUNCTIONS Describes the maintenance mode which is exclusively designed for the purpose of checking the settings and adjustments using the buttons on the control panel. This chapter also covers not-disclosed-to-users function menus, which activate settings and functions or reset the parts life.
  • Page 225 1.4 Details of Maintenance Mode Functions Using [Go] Button for LED Models ..5-35 1.4.1 Test printing ....................5-35 1.4.2 Print font list....................5-36 1.4.3 Change USB No. return value..............5-36 1.4.4 HEX Dump mode ..................5-36 1.4.5 Network Reset / Factory Reset / Settings Reset ........5-36 1.4.6 Engine error ignore mode.................
  • Page 226: Maintenance Mode

    1. MAINTENANCE MODE Maintenance mode is exclusively designed for checking, setting and adjusting the machine using the buttons on the control panel. LCD models are equipped with the same maintenance mode functions as those of the color printer. Using these functions, you can conduct operational checks of sensors or test printing, display the log information or error codes, and change the worker switches (WSW) etc.
  • Page 227: Method Of Entering Maintenance Mode For Service Personnel

    1.1.2 Method of entering maintenance mode for service personnel <Operating Procedure> How to enter maintenance mode for service personnel (LCD models) (1) Press the [OK] button and then the [Go] button while the machine is in the ready state. Then, press the [ ] button four times to enter maintenance mode.
  • Page 228: List Of Maintenance Mode Functions

    List of Maintenance Mode Functions 1.2.1 List of maintenance mode functions for LCD models Function Function Refer to: code Initialize EEPROM parameters 1.3.1 (5-6) Print test pattern 1.3.2 (5-7) Set worker switches (WSW) 1.3.3 [1] (5-8) Print worker switch (WSW) setting data 1.3.3 [2] (5-9) Check LCD operation 1.3.4 (5-10)
  • Page 229: List Of Maintenance Mode Functions Using [go] Button For Led Models

    1.2.2 List of maintenance mode functions using [Go] button for LED models <List of end-user accessible maintenance mode functions> No. of times No. of times [Go] button is [Go] button is Front pressed to Refer pressed to Function cover enter select maintenance function...
  • Page 230 (Continued from previous page) No. of times No. of times [Go] button is [Go] button is Front pressed to Refer pressed to Function cover enter select maintenance function mode Open Maintenance printing 5-44 Print maintenance data and frame pattern 5-46 Print Network Configuration 5-47 Change ON/OFF setting for sleep function...
  • Page 231: Details Of Maintenance Mode Functions For Lcd Models

    Details of Maintenance Mode Functions for LCD Models 1.3.1 Initialize EEPROM parameters (function code: 01, 91) <Function> This function is to initialize the setting values for operation parameters, user switches, and worker switches (WSW) registered in the EEPROM. Entering function code 01 initializes most EEPROM areas.
  • Page 232: Print Test Pattern (function Code: 09)

    1.3.2 Print test pattern (function code: 09) <Function> This function is to print a test pattern (print quality check sheet) to check any missing image and print quality. <Operation Procedure> (1) Press the [ ] or [ ] button in the initial state of maintenance mode to display "Maintenance 09"...
  • Page 233: Set Worker Switches (wsw) And Print Worker Switch Setting Data (function Code: 10, 11)

    1.3.3 Set worker switches (WSW) and print worker switch setting data (function code: 10, 11) [1] Set worker switches (WSW) (function code: 10) <Function> The worker switches shown in the table below can be used to set the function to satisfy various requirements.
  • Page 234 [2] Print worker switch (WSW) setting data (function code: 11) <Function> This function is to print the setting items of the worker switches and the set details. <Operation Procedure> (1) Press the [ ] or [ ] button in the initial state of maintenance mode to display "Maintenance 11"...
  • Page 235: Check Lcd Operation (function Code: 12)

    1.3.4 Check LCD operation (function code: 12) <Function> This function is to check that the LCD on the control panel is operating normally. <Operation Procedure> (1) Press the [ ] or [ ] button in the initial state of maintenance mode to display "Maintenance 12"...
  • Page 236: Check Control Panel Button Operation (function Code: 13)

    1.3.5 Check control panel button operation (function code: 13) <Function> This function is to check that the buttons on the control panel operate normally. <Operation Procedure> (1) Press the [ ] or [ ] button in the initial state of maintenance mode to display "Maintenance 13"...
  • Page 237: Display Software Version (function Code: 25)

    1.3.6 Display software version (function code: 25) <Function> This function is to check the version information of the firmware or programs, or check sum information. <Operation Procedure> (1) Press the [ ] or [ ] button in the initial state of maintenance mode to display "Maintenance 25"...
  • Page 238: Set One Push Demo Function (function Code: 28)

    1.3.7 Set One Push Demo function (function code: 28) <Function> This function is to implement Demo printing by pressing the [Go] button, and is mainly used for sales promotion at dealers. This function is disabled once printing is performed from the computer.
  • Page 239: Check Sensor Operation (function Code: 32)

    1.3.8 Check sensor operation (function code: 32) <Function> This function is to check that the sensors are operating normally. <Operation Procedure> (1) Press the [ ] or [ ] button in the initial state of maintenance mode to display "Maintenance 32" on the LCD. (2) Press the [OK] button.
  • Page 240 Location of sensors MP paper empty actuator 2 Registration rear actuator New toner actuator Eject sensor MP paper empty sensor Back cover MP paper empty sensor actuator 1 T1 paper feed sensor New toner sensor T1 paper feed actuator Toner sensor Registration front actuator Registration front/rear sensor Front cover sensor...
  • Page 241: Display Lan Connection Status (function Code: 33)

    1.3.9 Display LAN connection status (function code: 33) <Function> This function is to check the connection status of the wired LAN. <Operation Procedure> (1) Press the [ ] or [ ] button in the initial state of maintenance mode to display "Maintenance 33"...
  • Page 242: Print Dump List (function Code: 40)

    1.3.10 Print Dump List (function code: 40) <Function> This function is to print the EEPROM information. <Operation Procedure> (1) Press the [ ] or [ ] button in the initial state of maintenance mode to display "Maintenance 40" on the LCD. (2) Press the [OK] button.
  • Page 243: Change Usb No. Return Value / Adjust Left-end Print Start Position On Second Side When Duplex Printing / Change On/off Setting For Deep Sleep Function (function Code: 45)

    1.3.11 Change USB No. return value / Adjust left-end print start position on second side when duplex printing / Change ON/OFF setting for Deep Sleep function (function code: 45) Change USB No. return value <Function> ® When the operating system (OS) installed on the computer is Windows Vista , and the machine is connected to this computer using USB2.0FULL, the OS may not be able to obtain the USB device serial number depending on the computer and USB device.
  • Page 244 Change ON/OFF setting for Deep Sleep function when Deep Sleep function is enabled and machine has Storage Data (Secure) <Function> When the machine has the Storage Data (Secure) available, use this function to set whether to permit the machine to enter Deep Sleep mode. Description DpSlp.StrDt = ON The Deep Sleep function is activated even when the machine has...
  • Page 245: Continuous Print Test (function Code: 67)

    1.3.12 Continuous print test (function code: 67) <Function> This function is to conduct paper feed and eject tests while printing patterns. <Operation Procedure> (1) Press the [ ] or [ ] button in the initial state of maintenance mode to display "Maintenance 67"...
  • Page 246 Fig. 5-6 5-21 Confidential...
  • Page 247: Print Frame Pattern (single-side Printing) (function Code: 69)

    1.3.13 Print frame pattern (single-side printing) (function code: 69) <Function> This function is to print the frame pattern on a single side of the paper to check for printing flaws. <Operation Procedure> Be sure to set the Letter size paper for test pattern printing before commencing the following procedure.
  • Page 248 Fig. 5-7 5-23 Confidential...
  • Page 249: Print Frame Pattern (duplex Printing) (function Code: 70)

    1.3.14 Print frame pattern (duplex printing) (function code: 70) <Function> This function is to print the frame pattern on both sides of the paper and check for printing flaws. <Operation Procedure> Be sure to set the Letter size paper for test pattern printing before commencing the following procedure.
  • Page 250 (First side) (Second side) Fig. 5-8 5-25 Confidential...
  • Page 251: Print Solid Pattern (function Code: 71)

    1.3.15 Print solid pattern (function code: 71) <Function> This function is to print the solid pattern to check whether the developer roller or exposure drum is dirty or damaged. <Operation Procedure> Be sure to set the Letter size paper for test pattern printing before commencing the following procedure.
  • Page 252: Setting By Country (function Code: 74)

    1.3.16 Setting by country (function code: 74) <Function> This function is to customize the machine according to language, function settings, and worker switch settings. <Operation Procedure> (1) Press the [ ] or [ ] button in the initial state of maintenance mode to display "Maintenance 74"...
  • Page 253 <Country code list> HL- 5470DW/ HL- 5472DW/ HL- 6182DW/ HL- 6182DW/ Country 5470DWT 5472DWT 6180DWT 6182DWT U.S.A. 0101 4201 Canada 0102 4202 Brazil 0142 4242 Argentina 0136 4236 Chile 0136 Germany 0104 4204 U.K. 0104 4204 France 0104 4204 Iberia 0104 4204 Italy...
  • Page 254: Print Maintenance Information (function Code: 77)

    1.3.17 Print maintenance information (function code: 77) <Function> This function is to print the maintenance information, such as remaining amount of consumables, the number of replacements, and counter values (refer to the next page). The details to be printed are almost the same as the second page of Printer Settings. <Operation Procedure>...
  • Page 255 Display information Model name Remaining life of laser unit Serial number Total printed pages Model code Accumulated average coverage Check sum for WSW, PSW, USW, and Average coverage by the toner cartridge which is currently used Main firmware version Drum page count Sub firmware version Rotations of the drum Boot firmware version...
  • Page 256: Check Fan Operation (function Code: 78)

    1.3.18 Check fan operation (function code: 78) <Function> This function is to check that the main fan is operating normally. The rotation speed is changed among three settings: 100%, 50% and OFF. <Operation Procedure> (1) Press the [ ] or [ ] button in the initial state of maintenance mode to display "Maintenance 78"...
  • Page 257: Display Machine Log Information (function Code: 80)

    1.3.19 Display machine log information (function code: 80) <Function> This function is to display the log information on the LCD. <Operation Procedure> (1) Press the [ ] or [ ] button in the initial state of maintenance mode to display "Maintenance 80"...
  • Page 258 Description LABEL:00000000 Printed labels HAGAKI:00000000 Printed post cards TTL_JAM:00000000 Total paper jams that have occurred MP_JAM:00000000 Paper jams that have occurred in the MP tray TR1_JAM:00000000 Paper jams that have occurred in paper tray 1 IN_JAM:00000000 Paper jams that have occurred in the machine RE_JAM:00000000 Paper jams that have occurred at the ejecting section or back cover...
  • Page 259: Display Machine Error Code (function Code: 82)

    1.3.20 Display machine error code (function code: 82) <Function> This function is to display the latest error code on the LCD. <Operation Procedure> (1) Press the [ ] or [ ] button in the initial state of maintenance mode to display "Maintenance 82"...
  • Page 260: Details Of Maintenance Mode Functions Using [go] Button For Led Models

    Details of Maintenance Mode Functions Using [Go] Button for LED Models End-user accessible maintenance mode functions 1.4.1 Test printing This function is to print a test pattern (print quality check sheet) to check any missing image and print quality. Fig. 5-11 5-35 Confidential...
  • Page 261: Print Font List

    1.4.2 Print font list This function is to print the font list. 1.4.3 Change USB No. return value ® When the operating system (OS) installed on the computer is Windows Vista and the machine is connected to this computer using USB2.0FULL, the OS may not be able to obtain the USB device serial number depending on the computer and USB device.
  • Page 262: Engine Error Ignore Mode

    1.4.6 Engine error ignore mode When an engine error occurs and the machine cannot be recovered unless the main PCB is replaced, using this function enables the machine to start, ignoring the engine error, to retrieve the EEPROM data. 1.4.7 One Push print recovery mode The One Push Demo function allows you to perform Demo printing by pressing the [Go] button (mainly used for sales promotion at dealers).
  • Page 263: Check Sensor Operation

    Maintenance mode functions for service personnel 1.4.8 Check sensor operation This function is to check whether the sensors or electromagnetic clutch are operating normally. While sensor operation is being checked, the Ready LED flashes one to three times each time the sensor or switch status changes from ON to OFF or OFF to ON. Operate the sensor OFF to ON as below to check the operation of the corresponding solenoid or clutch.
  • Page 264: Print Continuous Lattice Pattern

    1.4.9 Print continuous lattice pattern This function is to print a lattice pattern continuously. When the power switch is turned OFF and then ON again or the [Cancel] button is pressed, the machine returns to the ready state. 1.4.10 Print fuser unit inspection This function is to print a lattice pattern, gray pattern and black pattern on separate pages to inspect the fuser unit.
  • Page 265: Print Eeprom Dump

    1.4.11 Print EEPROM Dump This function is to print all of the current EEPROM data. When completed, the machine returns to the ready state automatically. (The same function as E2PDUMP MAIN ALL described in "1.3.10 Print Dump List (function code: 40)" in this chapter) 1.4.12 Check RAM This function is to check the entire RAM, instead of the partial RAM check normally performed.
  • Page 266: Print Machine Quality Inspection Pattern

    1.4.13 Print machine quality inspection pattern 1 This function is to print five patterns to inspect quality. The fifth pattern is printed continuously until the function is canceled by pressing the [Cancel] button. Fig. 5-14 5-41 Confidential...
  • Page 267: Change On/off Setting For Duplex Printing

    1.4.14 Change ON/OFF setting for duplex printing This function allows you to change the duplex printing setting to ON or OFF. The setting applied is reversed each time this mode is entered. The setting currently applied can be determined by pressing the [Go] button seven times and checking the LED status after several seconds.
  • Page 268 1.4.16 Print machine quality inspection pattern 2 This function is to print five patterns consecutively to inspect quality. Printing continues until the function is cancelled by pressing the [Cancel] button. Fig. 5-15 5-43 Confidential...
  • Page 269: Maintenance Printing

    1.4.17 Maintenance printing This function is to print maintenance information, such as the remaining amount of consumables, the number of replacements, and counter values (refer to the next page details). (The same function as that described in "1.3.17 Print maintenance information (function code: 77)"...
  • Page 270 Display information Model name Remaining life of laser unit Serial number Total printed pages Model code Accumulated average coverage Check sum for WSW, PSW, USW, and Average coverage by the toner cartridge which is currently used Main firmware version Drum page count Sub firmware version Rotations of the drum Boot firmware version...
  • Page 271: Print Maintenance Data And Frame Pattern

    1.4.18 Print maintenance data and frame pattern This function is to print maintenance data on the first side and print the frame pattern on the second side in duplex printing mode. Short Bind is automatically applied to duplex printing in this mode.
  • Page 272: Print Network Configuration

    1.4.19 Print Network Configuration This function is to print the wired or wireless network setting information. (Network items of Printer Settings are printed.) When this function is used for a model without LAN or when the LAN function is disabled through the PJL setting, a test pattern is printed.
  • Page 273: Change Ready Led Light Intensity In Sleep Mode

    1.4.23 Change Ready LED light intensity in sleep mode This function is to set the Ready LED status in sleep mode whether to turn it OFF completely or light it at low light intensity. The setting applied is reversed each time this mode is entered. The setting currently applied can be determined by pressing the [Go] button ten times and checking the LED status after several seconds.
  • Page 274: Printer Settings

    2. PRINTER SETTINGS Printing Printer Settings Printer Settings can be printed. The title, model name and serial number are printed on all pages. <Operation Procedure> LED model LCD model (1) Press the [Go] button three times while (1) Press the [OK] button three times the machine is in the ready state.
  • Page 275 • LCD model Fig. 5-19 5-50 Confidential...
  • Page 276 Printer Settings (1st page) Various machine settings are output. Display items are shown only when the conditions are satisfied. Printer Settings (2nd page) The machine information and maintenance information are output in the following order: (1) Machine information Display items are output in the following order. 1) Main Controller Main ROM Version (main controller firmware version) 2) NET ROM Version (network model only) 3) RAM Size (MB)
  • Page 277 Life of toner cartridge <Method of detecting toner volume> Toner volume is monitored by the toner sensor and by the number of rotations of the developer roller. When the toner sensor detects that the toner has run out or when the number of rotations of the developer roller reaches the limit, "Replace Toner"...
  • Page 278 To avoid problems caused by abrasion of the developer roller surface or deterioration of the toner sealing, the machine prohibits printing when the number of rotations of the developer roller reaches the limit, displaying a message prompting the user to replace the toner cartridge before the toner runs out.
  • Page 279 <Relationship between average number of pages printed per job and life of toner cartridges> (40/42PPM model) Average pages printed (page/job) Cartridge life (Starter) 2710 3636 4104 4386 4575 4710 4812 4891 Cartridge life (Standard) 3484 4675 5277 5640 5882 6056 6187 6288 Cartridge life (High) 6581 8831 9967 10653 11111 11439 11686 11878 Cartridge life (Super high)
  • Page 280 Life of drum unit <How to read the life of drum unit> • The band graph indicates 100% initially, and then gradually decreases. • When the band graph indicates 10%, the machine displays a message prompting the user to replace the drum. <How to determine the end of life of drum unit>...
  • Page 281 The number of drum rotations required for fuser unit warm-up operation (max.): 34.2. Example: When fuser unit warm-up operation (max.) is performed before printing Continuous pages printed Page count based on number of drum rotations (pages) 1 page [34.2 + 12.2 + {3.8 x (1 - 1)}] / 15 = 3.1 2 pages [34.2 + 12.2 + {3.8 x (2 - 1)}] / 15 = 3.3 18 pages...
  • Page 282: Other Service Functions

    3. OTHER SERVICE FUNCTIONS Change ON/OFF Setting for Deep Sleep Mode (LCD model only) This function allows you to change the Deep Sleep mode setting to ON or OFF. <Operation Procedure> (1) While the machine is in the ready state, press the [ ] or [ ] button to display "General Setup"...
  • Page 283: Reset Periodic Replacement Parts (lcd Model Only)

    Reset Periodic Replacement Parts (LCD model only) This function is used to reset the corresponding counter after a periodic replacement part has been replaced correctly or to reset an error caused due to a consumable part being replaced by the user via an incorrect procedure. <Operation Procedure>...
  • Page 284: Change Usb No. Return Value / Adjust Left-end Print Start Position On Second Side When Duplex Printing / Change On/off Setting For Deep Sleep Function (lcd Model Only)

    Change USB No. Return Value / Adjust Left-end Print Start Position on Second Side when Duplex Printing / Change ON/OFF Setting for Deep Sleep Function (LCD model only) (The same function as that described in "1.3.11 Not-disclosed-to-users functions (function code: 45)" in this chapter) Change USB No.
  • Page 285 Adjust left-end print start position on second side when duplex printing (LCD model only) <Function> In the event that the left-end print start position deviates on the second side when duplex printing, use this function to adjust the position left and right. The adjustable range is -100 to 750 (unit: 300 dpi).
  • Page 286: Reset Drum Counter (led Model Only)

    Reset Drum Counter (LED model only) This function is to reset the drum unit counter after the drum unit has been replaced using the correct procedure. <Operation Procedure> (1) Open the front cover while the machine is in the ready mode. Press and hold the [Go] button for at least four seconds.
  • Page 287: Wiring Diagram

    CHAPTER WIRING DIAGRAM Confidential...
  • Page 288 CHAPTER 6 WIRING DIAGRAM This chapter provides the wiring diagram for the connections of the PCBs. CONTENTS 1. WIRING DIAGRAM ....................... 6-1 Confidential...
  • Page 289 1. WIRING DIAGRAM Wiring diagram Confidential...
  • Page 290: Periodical Maintenance

    CHAPTER PERIODICAL MAINTENANCE Confidential...
  • Page 291 CHAPTER 7 PERIODICAL MAINTENANCE CONTENTS 1. SAFETY PRECAUTIONS ..................... 7-1 2. PERIODICAL REPLACEMENT PARTS ............... 7-2 Preparation ......................... 7-2 Fuser unit ........................7-3 Laser unit ........................7-7 MP paper feeding kit ....................7-12 Paper feeding kit 1 ....................7-13 Paper feeding kit 2 ....................7-15 Confidential...
  • Page 292: Safety Precautions

    1. SAFETY PRECAUTIONS To avoid creating secondary problems by mishandling, follow the warnings and precautions below during maintenance work. WARNING Some parts inside the machine are extremely hot immediately after the machine is used. When opening the front cover or back cover to access any parts inside the machine, never touch the shaded parts shown in the following figures.
  • Page 293: Periodical Replacement Parts

    2. PERIODICAL REPLACEMENT PARTS Preparation Prior to proceeding with the disassembly procedure, (1) Disconnect the following: • AC cord • USB cable (if connected) • LAN cable (if connected) • Parallel cable (if connected) (2) Remove the following: • Paper tray 1 •...
  • Page 294 Fuser unit (1) Open the back cover. (2) Push both ribs of the back cover in the direction of the arrows, and remove the two bosses on the outer chute. Note: • Be careful not to damage the ribs inside the back cover. Boss Rear nip release link Back cover...
  • Page 295: Fuser Unit

    (5) Push the two knobs on the fuser cover, and pull the fuser cover down in the direction of the arrow. (6) Remove the fuser cover from the bosses on the fuser unit, and remove the fuser cover from the machine. Boss Fuser cover Fuser unit...
  • Page 296 (10) Release the heater harness of the fuser unit from the guide on the main frame R, and disconnect the heater harness from the low-voltage-heater harness. <Frame R side> Guide Heater harness Low-voltage-heater harness Fuser unit Fig. 7-6 Harness routing: Refer to “3.Fuser unit”.
  • Page 297 (13) Remove the taptite pan B M4x14 screw, and remove the fuser unit from the machine. Note: • Make sure that the front cover is closed when removing the fuser unit. Fuser unit Taptite pan B M4x14 Fig. 7-8 Confidential...
  • Page 298 Laser unit (1) Open the back cover. (2) Remove the two taptite cup B M4x12 screws from the back side of the side cover L and the side cover R. Taptite cup B M4x12 Side cover L Back cover Side cover R Fig.
  • Page 299 Fig. 7-11 Assembling Note: • For HL-5440D, raise the two locks for the parallel interface to the upright position, and then attach the side cover L. (6) Release the seven hooks, and remove the side cover R from the machine.
  • Page 300 (7) Remove the four taptite cup S M3x8 SR screws, and remove the main shield cover plate from the machine. Note: • HL-5440D is not equipped with a main shield cover plate. (8) Disconnect the panel harness from the main PCB ASSY, and release the panel harness from the securing fixtures.
  • Page 301 (9) Remove the two taptite cup B M4x12 screws from the front side of the top cover ASSY. (10) Release the six hooks. Lift the front side of the top cover ASSY, and pull the top cover ASSY in the direction of the arrow to remove it from the machine. Hook Top cover ASSY Taptite cup B M4x12...
  • Page 302: Laser Unit

    (11) Disconnect the laser unit flat cable from the laser unit. (12) Remove the four taptite cup S M3x8 SR screws, and remove the laser unit from the machine. Note: • Be careful not to touch the lens of the laser unit. Taptite cup S M3x8 SR Taptite cup S M3x8 SR Laser unit flat cable...
  • Page 303: Mp Paper Feeding Kit

    MP paper feeding kit (1) Push the front cover release button, and open the front cover ASSY. (2) Open the MP roller cover. Release the hook on the MP holder bushing, and slide the MP holder bushing in the direction of arrow 2 to remove it from the machine. (3) Slide the MP roller holder ASSY in the direction of arrow 3 to remove it from the MP separation roller shaft.
  • Page 304: Paper Feeding Kit

    Paper feeding kit 1 Note: • Paper tray 1 (250 sheets, 500 sheets): T1 Paper tray 2 (500 sheets): T2 • The illustration shows paper tray 1 (250 sheets). (1) Remove the two taptite bind B M4x12 screws from the paper tray 1. (2) Lift the plate to remove "A"...
  • Page 305 (6) Push the T1 lift arm in the direction of arrow 6, and remove the boss on the T1 roller holder ASSY from the T1 lift arm. (7) Turn the T1 roller holder ASSY in the direction of arrow 7a, and slide it in the direction of arrow 7b to remove it from the T1 separation roller shaft.
  • Page 306 Paper feeding kit 2 (1) Remove the two taptite bind B M4x12 screws from the paper tray 2. (2) Lift the plate to remove "A" on the T2 tray indicator from the plate, remove the four bosses, and then remove the T2 tray cover ASSY from the paper tray 2. Taptite bind B M4x12 Bosses T2 tray cover ASSY...
  • Page 307 (6) Push the T2 lift arm in the direction of arrow 6a, and remove the boss on the T2 roller holder ASSY from the T2 lift arm. Then turn the T2 roller holder ASSY in the direction of arrow 6b. Boss T2 lift arm T2 roller holder ASSY...
  • Page 308 APPENDIX SERIAL NUMBERING SYSTEM Confidential...
  • Page 309: Appendix 1 Serial Numbering System

    APPENDIX 1 SERIAL NUMBERING SYSTEM Serial number label (1 location) <How to Read> Serial number Manufacturing line Product Serial number (6-digit) identification code Manufacturing factory No. Year of manufacture 2: 2012 3: 2013 Month of manufacture A : January E : May J : September B : February F : June...
  • Page 310 APPENDIX DELETING USER SETTING INFORMATION This appendix provides instructions on how to delete user setting information recorded in the machine. Confidential...
  • Page 311: Appendix 2 Deleting User Setting Information

    APPENDIX 2 DELETING USER SETTING INFORMATION The user setting information for the machine is stored in the main PCB. You can return this to the default settings following the procedure below. <Operating Procedure> Common to all models (1) Press and hold the [Go] button with the front cover of the machine closed, and turn ON the power switch of the machine.
  • Page 312 APPENDIX INSTALLING MAINTENANCE DRIVER Confidential...
  • Page 313: Appendix 3 Installing Maintenance Driver

    APPENDIX 3 INSTALLING MAINTENANCE DRIVER To identify multiple terminals connected to the computer via USB, the computer needs to configure the corresponding number of virtual USB devices using a driver or software. If you connect multiple machines to your computer, the same number of virtual USB devices will be automatically configured on your computer.

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