Brother HL-4040CN Technical manual

SERVICE
UPDATE No.
P1292_EN
Print Unable 2A or No Waste Toner error
HL4040CN, HL4040CDN, HL4070CDW
August 6th, 2013 v3
Page 1of 11
Symptoms:
Print Unable 2A or “No Waste Toner” error on the display.
Possible cause:
Waste toner box may not be installed correctly
Belt cleaner assembly actuator or sensor may be failing
Drive frame assembly not being driven correctly
Recommendation:
Test machine and replace parts as needed.
Step 1: Verify that the Waste Toner Box is installed in the machine
A missing waste toner box will cause this error. Verify that it is installed in the machine (Figure 1). If the box
is present, verify that there are no foreign materials under the box that may prevent it from seating properly in
the machine (Figure 2). If the error continues try replacing the waste toner box. If the error still continues to
occur, continue to the step 2.
Figure 1
Location of Waste Toner Pack Drum and belt unit removed from
machine.
Figure 2
Foreign material will prevent proper installation of Waste Toner
Box.

SERVICE
UPDATE No.
P1292_EN
Print Unable 2A or No Waste Toner error
HL4040CN, HL4040CDN, HL4070CDW
August 6th, 2013 v3
Page 2of 11
Step 2: Check the Belt Cleaner Release Assembly
A. To check the assembly with all the supplies removed. Locate the Belt Cleaner Release Assembly (Figure
3).
Figure 3
B. Verify that the assembly is completely flush with the printer frame. The assembly is attached to the printer
frame with small pegs (Figure 5). If the pegs are not aligned properly, the assembly may not be flush with
the print frame. If the assembly is not flush, reseat the assembly as needed.
C. There is an actuator location on the back of the belt cleaner release assembly (Figure 4). It is an actuator
that can be pressed down. Verify the actuator is moving smoothly by pushing down on the actuator.
Repeat the test at least 10 times. The actuator should move smoothly and return to the UP position
when finger pressure is removed from the actuator. The sensor that this actuator activates (belt cleaner
release sensor) can be checked using maintenance mode 32. See Chapter 5 Service Functions in the
service manual.
I. If the actuator is sticking or does not move freely we recommend you clean the assembly
II. If the actuator still does not move freely or the belt cleaner release sensor fails
maintenance mode 32 test, then replace the belt cleaner release assembly. Refer to
Service Update F1249 (No Paper Fed –Clicking Noise) for removal and replacement
instructions

SERVICE
UPDATE No.
P1292_EN
Print Unable 2A or No Waste Toner error
HL4040CN, HL4040CDN, HL4070CDW
August 6th, 2013 v3
Page 3of 11
Figure 4
Belt Cleaner Release Assembly
Arrow points to the location of the actuator
Figure 5
Location of pegs on Belt Cleaner Release Assembly
D. If Error continues replace the drive frame assembly.
Step 3: Drive Frame Assembly Replacement
A. Remove the two M3X8 taptite screws from the rear cover. Remove the rear cover.

SERVICE
UPDATE No.
P1292_EN
Print Unable 2A or No Waste Toner error
HL4040CN, HL4040CDN, HL4070CDW
August 6th, 2013 v3
Page 4of 11
B. Remove the two cup S M3x8 Taptite screws. Remove the Back cover upper.

SERVICE
UPDATE No.
P1292_EN
Print Unable 2A or No Waste Toner error
HL4040CN, HL4040CDN, HL4070CDW
August 6th, 2013 v3
Page 5of 11
C. Remove the 3 M4X12 taptite screws and the M3X8 screw from the left side cover. Remove the cover.
D. Remove the three cup S M3x6 Taptite screws, cup B M4x12 Taptite screw and cup S M4x8 Taptite
screw, and then remove the Side plate LB. Remove the three screws securing the Main PCB to the
machine.
E. Remove the cup S m3x6 Taptite screw and blind b M4x12 Taptite screw, and then remove the Ground
plate.

SERVICE
UPDATE No.
P1292_EN
Print Unable 2A or No Waste Toner error
HL4040CN, HL4040CDN, HL4070CDW
August 6th, 2013 v3
Page 6of 11
F. Remove the two cup Sm3x6 Taptite screws, and then remove the ground spring plate.
G. Disconnect all the connectors from the Main PCB ASSY.
Note: After disconnecting the flat cables, check that each cable is not damaged at its end.
Note: When connecting the flat cables, do not insert it at an angle. After insertion into the connector,
verify that the cable is not at an angle.

SERVICE
UPDATE No.
P1292_EN
Print Unable 2A or No Waste Toner error
HL4040CN, HL4040CDN, HL4070CDW
August 6th, 2013 v3
Page 7of 11
H. Remove the five S M3x6 Taptite screws, and then remove the Engine PCB Assy from the frame unit.
I. Remove the cup S M3x6 Taptite screw, and then remove the Main PCB ASSY as shown by arrows 4a
and 4b.

SERVICE
UPDATE No.
P1292_EN
Print Unable 2A or No Waste Toner error
HL4040CN, HL4040CDN, HL4070CDW
August 6th, 2013 v3
Page 8of 11
J. Remove the Engine insulation sheet from the Harness shield plate, which is fixed with a two-sided
adhesive tape.
K. Remove the three cup S M3x6 Taptite screws, and then remove the Harness shield plate from the Frame
Unit.

SERVICE
UPDATE No.
P1292_EN
Print Unable 2A or No Waste Toner error
HL4040CN, HL4040CDN, HL4070CDW
August 6th, 2013 v3
Page 9of 11
L. Remove the four cup S M3x6 Taptite screws, and then remove the Engine PCB plate.
M. Remove the three bind B M4x12 Taptite screws, and then remove the Drive Frame Unit Assy from the
Frame unit. Disconnect the Connector from the Drive Frame Unit Assy.
Note: When handling the drive frame assembly, be careful to keep any loose connecting gears with the
part so that they can be transferred to the replacement part.
N. Disconnect the Connector from the Drive Frame Unit Assy.

SERVICE
UPDATE No.
P1292_EN
Print Unable 2A or No Waste Toner error
HL4040CN, HL4040CDN, HL4070CDW
August 6th, 2013 v3
Page 10 of 11
O. Ensure that the gear shown in photo below is present (the gear can be removed from the old assembly if
necessary. IF THE GEAR IS NOT PRESENT, THE PAPER WILL NOT FEED IN THE MACHINE.
P. Install parts in the reverse order. After the machine is back together. Power on the machine verifying
there is no error messages and make a test print to test that the machine is working properly.

SERVICE
UPDATE No.
P1292_EN
Print Unable 2A or No Waste Toner error
HL4040CN, HL4040CDN, HL4070CDW
August 6th, 2013 v3
Page 11 of 11
The following error or conditions may occur during testing of machine from incorrect
installation of parts:
Print Unable 27
Possible cause - The red cable leading to the motor on the Drive Frame Unit assembly is not
connected or not properly seated (see step 3-M).
Print Unable 3A
Possible cause - The small cable harness leading from CN4 (Engine) on the Main PCB that
connects to the Engine Controller CN28 (Cont_IF) is missing or not connected properly.
Print Unable 28
Possible cause - Engine Controller cable CN5 is missing or not connected properly. Cable may be
trapped behind the Engine PCB plate (see step 3-L).
Print Unable 29
Possible cause –Engine Controller cable CN4 is missing or not properly connected. Cable may be
trapped behind the Engine PCB plate (see step 3-L).
No display. Fan noises can be heard coming from the machine and it will not boot.
Possible cause –Cable from connector CN5 (Power) leading to the Engine Controller CN23 (Ctrl
Power) is not connected or not seated properly.