Brother HL-1110 User manual

Confidential
Brother Laser Printer
SERVICE MANUAL
MODEL:
HL-1110/1111/1112/1118
Read this manual thoroughly before maintenance work.
Keep this manual in a convenient place for quick and easy reference at all times.
May 2013
SM-PRN092
84UE03
(2)

Confidential
TRADEMARKS
The Brother logo is a registered trademark of Brother Industries, Ltd.
Brother is a trademark of Brother Industries, Ltd.
Microsoft, Windows, Windows Vista, Windows Server, Outlook and Internet Explorer are either
registered trademarks or trademarks of Microsoft Corporation in the United States and/or other
countries.
Apple, Macintosh, Safari and Mac OS are trademarks of Apple Inc., registered in the U.S. and other
countries.
Linux is the registered trademark of Linus Torvalds in the U.S. and other countries.
Intel and Pentium are trademarks of Intel Corporation in the U.S. and/or other countries.
Adobe, Photoshop and Reader are either registered trademarks or trademarks of Adobe Systems
Incorporated in the United States and/or other countries.
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.
© Copyright Brother 2013
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.
Specifications are subject to change without notice.
Model All models
Machine life 50,000 pages (A4/Letter size) or 5 years
Part life (Fuser unit) Up to 50,000 pages
Part life (Laser unit) Up to 50,000 pages
Maximum monthly volume Up to 10,000 pages

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CONTENTS
REGULATION ........................................................................................................... iv
SAFETY INFORMATION........................................................................................... vi
CHAPTER 1 TROUBLESHOOTING
1. INTRODUCTION .......................................................................................................................... 1-1
1.1 Checks before Commencing Troubleshooting..................................................................... 1-1
2. OVERVIEW .................................................................................................................................. 1-3
2.1 Cross-section Drawing......................................................................................................... 1-3
2.2 Paper Feeding ..................................................................................................................... 1-4
2.3 Operation of Each Part ........................................................................................................ 1-5
2.4 Block Diagram ..................................................................................................................... 1-6
2.5 Main Components................................................................................................................ 1-7
3. LED DISPLAY .............................................................................................................................. 1-8
3.1 LED Display when Operator Call Occurs............................................................................. 1-8
3.2 LED Display when Service Call Occurs............................................................................. 1-10
3.3 Error Messages for Maintenance Printing ......................................................................... 1-13
3.4 Error Display when Service Call Occurs............................................................................ 1-14
3.5 Image Defects.................................................................................................................... 1-15
4. ERROR CAUSE AND REMEDY ................................................................................................ 1-16
4.1 Troubleshooting for Paper Feeding Problems ................................................................... 1-16
4.1.1 No paper is fed from paper tray........................................................................... 1-16
4.1.2 Paper becomes wrinkled ..................................................................................... 1-17
4.1.3 Paper is curled ................................................................................................... 1-17
4.1.4 Paper is jammed ................................................................................................. 1-18
4.2 Troubleshooting According to Image Defect...................................................................... 1-19
4.2.1 Light..................................................................................................................... 1-19
4.2.2 Faulty registration................................................................................................ 1-20
4.2.3 Dark..................................................................................................................... 1-20
4.2.4 Poor fixing ........................................................................................................... 1-21
4.2.5 Completely blank................................................................................................. 1-21
4.2.6 Image distortion................................................................................................... 1-22
4.2.7 All black ............................................................................................................... 1-22
4.2.8 Dirt on the back of paper ..................................................................................... 1-23
4.2.9 Vertical streaks.................................................................................................... 1-23
4.2.10 Black vertical streaks on a light background ....................................................... 1-23
4.2.11 Black horizontal stripes ....................................................................................... 1-24
4.2.12 White vertical streaks .......................................................................................... 1-24
4.2.13 White horizontal streaks ...................................................................................... 1-25

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4.2.14 Faint print ............................................................................................................ 1-25
4.2.15 White spots.......................................................................................................... 1-26
4.2.16 Black spots .......................................................................................................... 1-26
4.2.17 Black band........................................................................................................... 1-27
4.2.18 Downward fogging of solid color ......................................................................... 1-27
4.2.19 Horizontal lines.................................................................................................... 1-27
4.2.20 Ghost................................................................................................................... 1-28
4.2.21 Fogging ............................................................................................................... 1-28
4.3 Troubleshooting for Software Problems ............................................................................ 1-29
4.3.1 Cannot print data................................................................................................. 1-29
4.4 Troubleshooting for Toner and Drum Problems ................................................................ 1-30
4.4.1 Replaced the toner cartridge with a new one
but still seeing LED display prompting toner cartridge replacement. .................. 1-30
4.4.2 Toner cartridge cannot be detected .................................................................... 1-30
4.4.3 Failed to detect toner cartridge............................................................................ 1-30
4.4.4 Drum error ........................................................................................................... 1-31
4.4.5 Drum unit cannot be detected. ............................................................................ 1-31
4.4.6 Replace drum unit (replaced the drum unit with a new one
but still seeing LED display prompting toner cartridge replacement) .................. 1-31
4.5 Troubleshooting for Fuser Unit Problems .......................................................................... 1-32
4.5.1 Fuser unit failure.................................................................................................. 1-32
4.6 Troubleshooting for Laser Unit Problems .......................................................................... 1-32
4.6.1 Laser unit failure.................................................................................................. 1-32
4.7 Troubleshooting for Other Problems.................................................................................. 1-33
4.7.1 Machine does not turn ON or LED does not light................................................ 1-33
4.7.2 Top cover is open................................................................................................ 1-33
4.7.3 Unusual noise is coming from the machine......................................................... 1-33
4.7.4 Memory failure..................................................................................................... 1-34
4.7.5 Print failure .......................................................................................................... 1-34
4.7.6 Paper size failure................................................................................................. 1-34
4.7.7 Main motor failure................................................................................................ 1-34
4.7.8 Power supply voltage failure ............................................................................... 1-34
4.7.9 High voltage power supply PCB failure ............................................................... 1-35
4.7.10 Main PCB failure ................................................................................................. 1-35
CHAPTER 2 DISASSEMBLY/REASSEMBLY
1. PACKING ..................................................................................................................................... 2-1
2. TIGHTENING TORQUE LISTS .................................................................................................... 2-2
3. LUBRICATION ............................................................................................................................. 2-3
4. OVERVIEW OF GEARS............................................................................................................... 2-3
5. HARNESS ROUTING................................................................................................................... 2-4
6. DISASSEMBLY FLOW CHART................................................................................................... 2-7

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7. DISASSEMBLY PROCEDURE .................................................................................................... 2-8
7.1 Preparation .......................................................................................................................... 2-8
7.2 Back cover ........................................................................................................................... 2-9
7.3 Top cover ASSY ................................................................................................................ 2-10
7.4 Tray cover ASSY ............................................................................................................... 2-13
7.5 Side cover L....................................................................................................................... 2-14
7.6 Side cover R ...................................................................................................................... 2-15
7.7 Low voltage power supply PCB unit .................................................................................. 2-16
7.8 Fuser unit........................................................................................................................... 2-18
7.9 High voltage power supply PCB ASSY.............................................................................. 2-19
7.10 Main PCB ASSY ................................................................................................................ 2-20
7.11 Front cover......................................................................................................................... 2-21
7.12 Laser unit........................................................................................................................... 2-22
7.13 Motor encoder PCB ASSY................................................................................................. 2-24
7.14 Eject sensor PCB ASSY.................................................................................................... 2-25
7.15 Paper feed/paper printing position sensor PCB ASSY ...................................................... 2-26
7.16 New toner sensor PCB ASSY............................................................................................ 2-27
CHAPTER 3 ADJUSTING AND UPDATING SETTINGS AS REQUIRED AFTER
PARTS REPLACEMENT
1. IF YOU REPLACE THE MAIN PCB ASSY .................................................................................. 3-1
1.1 Installing Firmware (Main Firmware) ................................................................................... 3-2
1.1.1 Checking firmware version .................................................................................... 3-2
1.1.2 Installing firmware (Main program)........................................................................ 3-2
1.2 Setting by Country ............................................................................................................... 3-3
1.3 Setting Serial Number and Entering Adjusted Value of Laser Unit...................................... 3-5
2. IF YOU REPLACE THE LASER UNIT ......................................................................................... 3-6
2.1 Entering Adjusted Value of Laser Unit................................................................................. 3-7
3. IF YOU REPLACE THE LOW VOLTAGE POWER SUPPLY PCB UNIT.................................... 3-8
3.1 Resetting Irregular Power Supply Detection Counter .......................................................... 3-8
CHAPTER 4 SERVICE FUNCTIONS
1. PRINTING PRINTER SETTINGS ................................................................................................. 4-1
2. RESETTING DRUM COUNTER................................................................................................... 4-3
3. SWITCHING BETWEEN CONTINUE MODE AND STOP MODE ............................................... 4-3
4. TEST PRINTING .......................................................................................................................... 4-4
5. MAINTENANCE PRINTING ......................................................................................................... 4-5
6. RESETTING TONER MANUALLY............................................................................................... 4-7
APPENDIX 1 SERIAL NUMBERING SYSTEM
APPENDIX 2 DELETING USER SETTING INFORMATION

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REGULATION
Declaration of Conformity (Europe only)
We, Brother Industries, Ltd.
15-1, Naeshiro-cho, Mizuho-ku, Nagoya 467-8561 Japan
declare that this product is in conformity with the essential requirements of all relevant
directives and regulations applied within the European Community.
The Declaration of Conformity (DoC) can be downloaded from our website. Visit
http://solutions.brother.com/ and:
→select “Europe”
→select your country
→select your model
→select “Manuals” and your language, then click “Search”
→select Declaration of Conformity
→click “Download”.
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. The Laser Unit should not be opened under any circumstances.
Internal Laser radiation
Wave Length: 770 - 800 nm
Output: 25 mW max.
Laser Class: Class 3B
Disconnect Device
WARNING
Use of controls, adjustments or performance of procedures other than those specified
in this manual may result in hazardous radiation exposure.
CAUTION
This product must be installed near an electrical socket that is easily accessible. In
case of emergencies, you must disconnect the power cord from the electrical socket
to shut off power completely.
%.#55.#5'4241&7%6
#22#4'+..#5'4&'%.#55'
.#5'4-.#55'241&7-6

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Recycling Information in accordance with the WEEE (2002/96/EC) and
Battery (2006/66/EC) Directives
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.
International ENERGY STAR®Qualification Statement
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.
Product mark Battery mark
European Union only

vi Confidential
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.
Prohibition icons indicate actions that must not be performed.
Electrical Hazard icons alert you to possible electrical shock.
Fire Hazard icons alert you to the possibility of fire.
Hot Surface icons warn you not to touch product parts that are hot.
Note Notes tell you how you should respond to a situation that may arise or give tips about
how the operation works with other features.

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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.
In addition, you could create an electrical short, which may create the risk of a fire.
There are high voltage electrodes inside the product. Before you access the inside of
the product, including for routine maintenance such as cleaning, make sure you have
unplugged the power cord from the AC power outlet. Never push objects of any kind
into this product through cabinet slots, since they may touch dangerous voltage points
or short out parts.
DO NOT handle the plug with wet hands.
DO NOT use this product during an electrical storm.
Always make sure the plug is fully inserted. DO NOT use the product or handle the
cord if the cord has become worn or frayed.
This product should be connected to an AC power source within the range indicated
on the rating label. DO NOT connect it to a DC power source or inverter.
POWER CORD SAFETY:
• Use only the power cord supplied with this product.
• DO NOT allow anything to rest on the power cord. DO NOT place this product
where people can walk on the cord.
• DO NOT place this product in a position where the cord becomes stretched, or
where strain is otherwise put on the cord. Doing so may cause the cord to become
worn or frayed.
• Brother strongly recommends that you DO NOT use any type of extension cord.

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• DO NOT put a toner cartridge and drum unit assembly into a fire. It could explode,
resulting in injuries.
• DO NOT use flammable substances, any type of spray, or an organic solvent/liquid
containing alcohol or ammonia to clean the inside or outside of the product. Doing
so could cause a fire or electrical shock. Instead, use only a dry, lint-free cloth.
DO NOT attempt to operate this product with a paper jam or with stray pieces of paper
inside the product. Prolonged contact of the paper with the drum unit could cause a
fire.
DO NOT use a vacuum cleaner to clean up scattered toner. Doing this might cause
the toner dust to ignite inside the vacuum cleaner, potentially starting a fire. Please
carefully clean the toner dust with a dry, lint-free soft cloth and dispose of it according
to local regulations.
HOT SURFACE
After you have just used the product, some internal parts of the product will be
extremely hot. Wait at least 15 minutes for the product to cool down before you touch
the internal parts of the product.
CAUTION
Lightning and power surges can damage this product! We recommend that you use a
quality surge protection device on the AC power line, or unplug the machine during a
lightning storm.
Violently closing the top cover without mounting the toner cartridge and the drum unit
can damage this product.

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Caution for Laser Product (WARNHINWEIS fur Laser drucker)
CAUTION: When the machine during servicing is operated with the cover open, the
regulations of VBG 93 and the performance instructions for VBG 93 are
valid.
CAUTION: In case of any trouble with the laser unit, replace the laser unit itself. To
prevent direct exposure to the laser beam, do not try to open the enclosure
of the laser unit.
ACHTUNG: Im Falle von Störungen der Lasereinheit muß diese ersetzt werden. Das
Gehäuse der Lasereinheit darf nicht geöffnet werden, da sonst
Laserstrahlen austreten können.
Additional Information
When servicing the optical system of the 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.
Since the beam is invisible, the following caution in print is attached on the laser unit.
<Location of the laser beam window>

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Troubleshooting/Disassembling/Assembling Notes
• To avoid creating secondary problems by mishandling, follow the warnings and
precautions below during maintenance work.
• Be careful not to lose screws, washers, or other parts removed.
• Be sure to apply grease to applicable positions specified in this manual.
• When using soldering irons or other heat-generating tools, take care not to accidentally
damage parts such as wires, PCBs and covers.
• Static electricity charged in your body may damage electronic parts. When transporting
PCBs, be sure to wrap them in conductive sheets.
• When replacing PCBs and all the other related parts, put on a grounding wrist band and
perform the job on a static mat. Also take care not to touch the conductor sections on the
flat cables or on the wire harness.
• After disconnecting flat cables, check that each cable is not damaged at its end or short-
circuited.
• When connecting flat cables, do not insert them at an angle. After insertion, check that the
cables are not inserted at an angle.
• When connecting or disconnecting harnesses, hold the connector body, not the cables. If
the connector is locked, release it first.
• After a repair, check not only the repaired portion but also harness treatment. Also check
that other related portions are functioning properly.
• Be careful not to close the top cover forcefully without mounting the toner cartridge and the
drum unit. It can damage the machine.
• After assembly, it is recommended to conduct a dielectric test and continuity test.
• Be sure to unplug the AC cord before removing any covers or PCBs, adjusting the
machine, or conducting continuity tests using a tester.
• The insulation sheet should not be damaged.

1-1 Confidential
CHAPTER 1 TROUBLESHOOTING
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 problems and recovery procedures for these. These will help service
personnel identify and repair other similar defective sections.
Be sure to observe the Troubleshooting/Disassembling/Assembling Notes during
maintenance work for troubleshooting.
1.1 Checks before Commencing Troubleshooting
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 10°C (50°F) to
32.5°C (90.5°F), and the relative humidity is maintained between 20% and 80%.
(3) The machine is not exposed to direct sunlight, excessive heat, moisture, or dust.
(4) Hold the machine level while moving it.
Power supply
(1) Power described on the rating label attached on the machine is supplied. Power
fluctuation should be within ±10% of the rated voltage.
(2) The AC input power supply is within the regulated value.
(3) The cables and harnesses are connected correctly.
(4) The fuses are not blown.
Paper
(1) The recommended type of paper is being used.
(2) The document is not damp.
(3) Short-grained paper or acid paper is not used.
Consumable parts
(1) The drum unit (including toner cartridge) is set correctly.

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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.
• If the exposure drum is cold, the electrical resistance of the photosensitive layer is
increased, making it impossible to obtain the correct print density.
• Condensation on the charge unit may cause corona charge leakage, resulting in
image defects.
• Condensation on the plate may cause paper feed problems.
If condensation has formed in the machine, leave the machine for at least two hours until
it reaches room temperature.
If the drum unit is unpacked soon after it is moved to a warm room from a cold location,
condensation may occur inside the unit which may cause printing failure.
Leave the drum unit for one or two hours until it reaches room temperature, and then
unpack it.
(2) Low temperature
The motor may not operate normally in a cold environment because too much load is
applied to each drive. In this case, increase the room temperature.
Cleaning
Use a soft lint-free cloth.
WARNING
DO NOT use any flammable spray or flammable solvent such as alcohol, benzine,
or thinner to clean the machine. DO NOT use these articles near the machine.

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2. OVERVIEW
2.1 Cross-section Drawing
Fig. 1-1
Laser unit
Plate Pick-up roller Separation Pad
Paper feed
actuator L/R
Separation roller
Paper printing
position actuator
Back cover
Transfer roller
Exposure drum
Corona wire
Fuser unit
Pressure roller
Eject actuatorEject roller
Supply roller
Developer roller
Heat roller
Tray cover

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2.2 Paper Feeding
Fig. 1-2
Feed path

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2.3 Operation of Each Part
Part name Operation
Pick-up roller Feeds paper from the paper tray.
Separation roller /
Separation pad
Separates paper fed from paper tray into single sheets.
Paper feed actuator L/R
(Paper feed sensor L/R)
Determines if the sheet of paper is of printable size.
Detects paper jams in the front section of the machine.
Paper printing position
actuator
(Paper printing position
sensor)
Detects the front edge of paper to adjust the paper printing
position.
Detects paper jams in the center section of the machine.
Detects the front and rear edges of paper to determine the
paper size.
Heat roller
Pressure roller
Fuses the toner transferred to paper by heat and pressure, and
feeds paper to the eject roller.
Eject actuator
(Eject sensor)
Determines whether paper is ejected from the fuser unit.
Detects paper jams in the rear section of the machine.
Eject roller Feeds paper to the output tray.

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2.4 Block Diagram
Fig. 1-3
High voltage power supply PCB
Low voltage power supply PCB
Polygon motor
Main PCB
Main motor
Thermostat
Halogen
heater
Fuser unit
Laser unit
AC-DC converter
Motor driver
EEPROM Serial ROM
ASIC
LED
Pick-up
solenoid
New toner sensor PCB
Laser
control
PCB
Eject sensor PCB
Paper feed
sensor
Paper printing
position sensor
Paper feed/paper printing
position sensor PCB
Motor encoder PCB
Relay TRIAC
Encoder
Eject sensor
Thermistor
(Center)

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2.5 Main Components
Fig. 1-4
Back cover Dress cover
Process cover
ASSY
Insulation roof
Motor drive belt
Side cover L
Toner cartridge
Motor encoder
PCB ASSY
Pick-up roller
holder ASSY
Laser unit
Low voltage PCB
insulation sheet
Side cover R Switch key
Top cover
Paper stopper
Paper stopper 2
High voltage power
supply PCB ASSY
Main PCB ASSY
Low voltage shield plate cover
Pick-up roller
holder shaft
Paper feed/paper
printing position
sensor PCB ASSY
Fuser unit
Drive sub ASSY
Eject sensor
PCB ASSY
New toner sensor
PCB ASSY
Paper rear guide
Front cover
Tray cover
ASSY
Drum unit
Low voltage power
supply PCB unit
Laser unit
cover

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3. LED DISPLAY
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.
Error LED indications are automatically cleared after measures are taken. If not automatically
cleared, press the button to reset the machine.
LED status in the table below: Unlit Lit Flashing
LED LED display Type of problem
No. of times the
button is
pressed to reset
Refer
to:
Error LED flashes once
every 0.5 seconds and
stays unlit for a second.
Dot count or developer roller
counter of the toner is reaching or
has reached the upper limit (when
setting toner continuous printing). N/A 4.4.1
Error LED flashes three
times every 0.5
seconds and stays unlit
for a second.
The number of rotations of the
drum unit is reaching or has
reached the upper limit. N/A 4.4.6
Error LED flashes once
every 0.5 seconds and
stays unlit for a second.
Dot count or developer roller
counter of the toner has reached
the upper limit (when setting toner
stop mode).
4.4.1
No toner cartridge 4.4.2
Dot count or developer roller
counter of the toner has reached
the upper limit or forced outage
level when the toner continuous
printing is set.
4.4.1
Error LED flashes twice
every 0.5 seconds and
stays unlit for a second.
The paper feed sensor does not
detect paper pass within the
specified time while printing.
4.1.4
The paper printing position
sensor does not detect paper
pass within the specified time
after the paper feed sensor
detected paper pass.
4.1.4