Brother HL-5030 User manual

Brother Laser Printer
SERVICE MANUAL
MODEL: HL-5030/5040/5050/5070N
Read this manual thoroughly before maintenance work.
Keep this manual in a convenient place for quick and easy reference at all times.
January 2003
SM-PRN035

HL-5030/5040/5050/5070N SERVICE MANUAL
PREFACE
This service manual contains basic information required for after-sales service of the laser
printer (hereinafter referred to as "this machine" or "the printer"). This information is vital to
the service technician to maintain the high printing quality and performance of the printer.
This service manual covers the HL-5030/5040/5050/5070N printers.
This manual consists of the following chapters:
CHAPTER 1: GENERAL
Features, specifications, etc.
CHAPTER 2: INSTALLATION AND BASIC OPERATION
Installation conditions, Installation procedures, basic operation of the printer
etc.
CHAPTER 3: THEORY OF OPERATION
Basic operation of the mechanical system, the electrical system and the
electrical circuits and their timing information.
CHAPTER 4: DISASSEMBLY AND RE-ASSEMBLY
Procedures for disassembling and re-assembling the mechanical system.
CHAPTER 5: PERIODIC MAINTENANCE
Periodical replacements parts, consumable parts, etc.
CHAPTER 6: TROUBLESHOOTING
Reference values and adjustments, troubleshooting image defects,
troubleshooting malfunctions, etc.
CHAPTER 7: SERVICE SUPPORT SOFTWARE
Test print mode and Service menu mode, etc.
APPENDICS: PCB circuit diagrams, etc.
Information in this manual is subject to change due to improvement or redesign of the product.
All relevant information in such cases will be supplied in service information bulletins
(Technical Information).
A thorough understanding of this printer, based on information in this service manual and
service information bulletins, is required for maintaining its print quality performance and for
improving the practical ability to find the cause of problems.

TABLE OF CONTENTS
ii
TABLE OF CONTENTS
REGULATION..............................................................................................vii
SAFETY INFORMATION..............................................................................ix
CHAPTER 1 GENERAL .......................................................................... 1-1
1. FEATURES.............................................................................................................1-1
2. OVERVIEW.............................................................................................................1-3
3. SPECIFICATIONS...................................................................................................1-4
3.1 Printing..............................................................................................................................1-4
3.2 Functions..........................................................................................................................1-5
3.3 Electrical and Mechanical.................................................................................................1-6
3.4 Network.............................................................................................................................1-7
3.5 Paper................................................................................................................................1-8
3.5.1 Feedable paper...................................................................................................................1-8
3.5.2 Paper cassette capacity....................................................................................................1-10
3.5.3 Print delivery.....................................................................................................................1-10
3.6 Printing Area...................................................................................................................1-12
3.6.1 PCL5e/EPSON/IBM emulation..........................................................................................1-12
3.6.2 PCL6/BR-Script3 emulation..............................................................................................1-15
3.7 Print Speeds with Various Settings.................................................................................1-16
3.8 Toner Cartridge Weight Information...............................................................................1-17
4. SERIAL NO. DESCRIPTIONS...............................................................................1-18
CHAPTER 2 INSTALLATION AND BASIC OPERATION....................... 2-1
1. CONDITIONS REQUIRED FOR INSTALLATION ...................................................2-1
1.1 Power Supply....................................................................................................................2-1
1.2Environment......................................................................................................................2-1
1.3 System Requirements for Brother Printer Solution for Windows®....................................2-2
2. UNPACKING...........................................................................................................2-3
3. INSTALL THE PRINTER.........................................................................................2-4
3.1 For All Users.....................................................................................................................2-4
3.1.1 Install the drum unit assembly ............................................................................................2-5
3.1.2 Load paper into the paper cassette ....................................................................................2-5
3.1.3 Print a test page..................................................................................................................2-6
3.2 For Windows®Users ........................................................................................................2-7
3.3 For Macintosh Users ......................................................................................................2-11
4. PRINTING METHODS ..........................................................................................2-14
4.1 Printing from the Paper Tray...........................................................................................2-14
4.2 Printing from manual feed Tray (HL-5030/5040 only) ....................................................2-14
4.3 Printing from Multi-purpose Tray (MP Tray) (HL-5050/5070N only)...............................2-15
4.4 Printing on envelopes .....................................................................................................2-17
4.5 Printing on transparencies..............................................................................................2-21

HL-5030/5040/5050/5070N SERVICE MANUAL
iii
4.6 Printing on Both Sides of the Paper (manual duplex printing)........................................2-24
4.7 Guidelines for printing on both sides of the paper..........................................................2-26
4.8Paper orientation for printing on both sides of the paper................................................2-27
5. CONTROL PANEL OPERATION..........................................................................2-28
5.1 Control Panel Buttons & LED functions..........................................................................2-28
5.1.1 LEDs .................................................................................................................................2-28
5.1.2 Control Panel Buttons.......................................................................................................2-28
5.2 LED Indiations ................................................................................................................2-29
5.3 Service call indications ...................................................................................................2-31
5.4 Control Panel Button Operations....................................................................................2-32
5.5 Other Control Features...................................................................................................2-33
5.5.1 Sleep mode.......................................................................................................................2-33
5.5.2 Print a test page................................................................................................................2-34
5.5.3 Print Settings.....................................................................................................................2-34
5.5.4 Print fonts (For HL-5040, HL-5050 and HL-5070N)..........................................................2-35
6. NETWORK FUNCTIONS......................................................................................2-36
6.1 LED functions .................................................................................................................2-36
6.2 Network Factory default setting (For HL-5070N)............................................................2-36
7. PAPER CASSETTE INFORMATION (FOR EUROPE ONLY)...............................2-37
CHAPTER 3 THEORY OF OPERATION................................................. 3-1
1. ELECTRONICS.......................................................................................................3-1
1.1 General Block Diagram ....................................................................................................3-1
1.2 Main PCB Block Diagram.................................................................................................3-2
1.3 Main PCB..........................................................................................................................3-3
1.3.1 CPU ....................................................................................................................................3-3
1.3.2 USB.....................................................................................................................................3-5
1.3.3 IEEE 1284...........................................................................................................................3-6
1.3.4 Network Interface................................................................................................................3-7
1.3.5 ROM....................................................................................................................................3-8
1.3.6 Flash ROM..........................................................................................................................3-9
1.3.7 SDRAM.............................................................................................................................3-10
1.3.8 Optional RAM....................................................................................................................3-11
1.3.9 EEPROM...........................................................................................................................3-13
1.3.10 Reset Circuit .....................................................................................................................3-13
1.3.11 Engine I/O.........................................................................................................................3-14
1.3.12 Panel I/O...........................................................................................................................3-14
1.3.13 Video I/O...........................................................................................................................3-15
1.3.14 Power Supply....................................................................................................................3-16
1.4 Engine PCB....................................................................................................................3-17
1.5 Power Supply..................................................................................................................3-18
1.5.1Low-voltage Power Supply................................................................................................3-18
1.5.2 High-voltage Power Supply...............................................................................................3-19
2. MECHANICS.........................................................................................................3-20
2.1 Overview of Printing Mechanism....................................................................................3-20
2.2 Paper Transfer................................................................................................................3-21
2.2.1 Paper supply.....................................................................................................................3-21
2.2.2 Paper registration..............................................................................................................3-21

TABLE OF CONTENTS
iv
2.2.3 Paper eject........................................................................................................................3-22
2.3 Sensors...........................................................................................................................3-23
2.3.1 Cover sensors...................................................................................................................3-23
2.3.2 Toner sensors...................................................................................................................3-23
2.3.3 Cassette sensor / Paper empty sensor (HL-5040/5050/5070N only)................................3-24
2.3.4 Paper eject sensor............................................................................................................3-24
2.3.5 MP PE sensor...................................................................................................................3-25
2.4 Drum Unit........................................................................................................................3-26
2.4.1 Photosensitive drum .........................................................................................................3-26
2.4.2 Primary charger ................................................................................................................3-26
2.4.3 Transfer roller....................................................................................................................3-26
2.4.4 Cleaner .............................................................................................................................3-26
2.5 Toner Cartridge...............................................................................................................3-26
2.6 Print Process ..................................................................................................................3-26
2.6.1 Charging ...........................................................................................................................3-26
2.6.2 Exposure stage.................................................................................................................3-27
2.6.3 Developing........................................................................................................................3-28
2.6.4 Transfer.............................................................................................................................3-28
2.6.5 Fixing stage.......................................................................................................................3-29
CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY.............................. 4-1
1. SAFETY PRECAUTIONS........................................................................................4-1
2. DISASSEMBLY FLOW............................................................................................4-2
3. DISASSEMBLY PROCEDURE................................................................................4-3
3.1 AC Cord............................................................................................................................4-3
3.2 Drum Unit..........................................................................................................................4-3
3.3 Paper Tray .................................................................................................................4-4
3.4 Access Cover..................................................................................................................4-14
3.5 Rear Cover C..................................................................................................................4-14
3.6 Outer Chute (for HL-5030/5040 only) .............................................................................4-15
3.7 Rear Cover MP ASSY /Outer Chute MP ASSY (for HL-5050/5070N only) ...................4-16
3.8 Rear Cover L/R...............................................................................................................4-17
3.9 Side Cover L/R...............................................................................................................4-18
3.10 Top Cover.......................................................................................................................4-19
3.11 Front Cover ASSY (for HL-5030/5040 only) ...................................................................4-22
3.12 MP Unit (for HL-5050/5070N only) .................................................................................4-23
3.13 Fixing Unit.......................................................................................................................4-29
3.14 Laser Unit .......................................................................................................................4-38
3.15 Main PCB........................................................................................................................4-40
3.16 Base Plate/ LV Insulation Sheet.....................................................................................4-42
3.17 Engine PCB....................................................................................................................4-43
3.18High-voltage PS PCB ASSY...........................................................................................4-44
3.19Low-voltage PS PCB ASSY............................................................................................4-45
3.20 Paper Feeder..................................................................................................................4-46
3.21 Frame L/ Drive Unit.........................................................................................................4-54
3.22 Fan Motor 60 Unit LV/ Fan Motor 60 Unit.......................................................................4-58
3.23 Frame R..........................................................................................................................4-59
4. PACKING..............................................................................................................4-61

SERVICE MANUAL
v
5. GUIDELINES FOR LEAD FREE SOLDER............................................................4-62
CHAPTER 5 PERIODIC MAINTENANCE............................................... 5-1
1. CONSUMABLE PARTS...........................................................................................5-1
1.1 Drum Unit..........................................................................................................................5-1
1.2 Toner Cartridge.................................................................................................................5-3
2. PERIODICAL REPLACEMENT PARTS ..................................................................5-8
2.1Fixing Unit .........................................................................................................................5-9
2.2PaperFeeding Kit............................................................................................................5-12
3. PERIODICAL CLEANING......................................................................................5-14
3.1 Cleaning the Printer Exterior...........................................................................................5-14
3.2 Cleaning the Drum Unit ..................................................................................................5-14
3.3 Cleaning the Scanner Window.......................................................................................5-15
3.4 Cleaning the Electrical Terminals...................................................................................5-16
4. MTBF / MTTR........................................................................................................5-17
CHAPTER 6 TROUBLESHOOTING....................................................... 6-1
1. INTRODUCTION.....................................................................................................6-1
1.1 Initial Check......................................................................................................................6-1
1.2 Warnings for Maintenance Work......................................................................................6-2
1.3 Identify the Problem..........................................................................................................6-3
2. OPERATOR CALLS & SERVICE CALLS................................................................6-4
2.1 Operator Calls...................................................................................................................6-4
2.2 Service Calls.....................................................................................................................6-5
3.ERROR MESSAGE.................................................................................................6-6
3.1 Error Message in the Status Monitor................................................................................6-6
3.2 Error Message Printouts...................................................................................................6-7
4.PAPER PROBLEMS................................................................................................6-8
4.1 Paper Loading Problems..................................................................................................6-8
4.2 Paper Jams ......................................................................................................................6-9
4.2.1 Clearing jammed paper.......................................................................................................6-9
4.2.2 Causes & countermeasures..............................................................................................6-13
4.3 Paper Feeding Problems................................................................................................6-14
5.SOFTWARE SETTING PROBLEMS.....................................................................6-16
6. MALFUNCTIONS..................................................................................................6-19
7. IMAGE DEFECTS.................................................................................................6-24
7.1 Image Defect Examples .................................................................................................6-24
7.2 Diameter of Rollers.........................................................................................................6-24
7.3 Troubleshooting Image Defect .......................................................................................6-25
7.4 Location of Grounding Contacts.....................................................................................6-44
7.4.1 Drum unit ..........................................................................................................................6-44
7.4.2 Printer body & Paper cassette ..........................................................................................6-44
8.INCORRECT PRINTOUT......................................................................................6-45
9. NETWORK PROBLEM..........................................................................................6-48

TABLE OF CONTENTS
vi
9.1 Installation Problem........................................................................................................6-48
9.2 Intermittent Problem .......................................................................................................6-49
9.3 TCP/IP Troubleshooting .................................................................................................6-50
9.4 UNIX Troubleshooting ....................................................................................................6-50
9.5 Windows NT/LAN Server (TCP/IP) Troubleshooting......................................................6-51
9.6 Windows 95/98/Me (or later) Peer to Peer Print (LPR) Troubleshooting .......................6-51
9.7 Windows 95/98/Me (or later) Peer to Peer (HP JetAdmin Compatible Method) Troubleshooting....
........................................................................................................................................6-52
9.8 Windows 95/98/Me/NT 4.0/2000 (or later) Peer to Peer Print (NetBIOS) Troubleshooting ..
........................................................................................................................................6-52
9.9 Brother Internet Print (TCP/IP) Troubleshooting ............................................................6-52
9.10 Windows 95/98/Me/2000/XP IPP Troubleshooting.........................................................6-53
9.11 Novell Netware Troubleshooting.....................................................................................6-53
9.12 AppleTalk Troubleshooting.............................................................................................6-54
9.13 DLC/LLC Troubleshooting..............................................................................................6-54
9.14Web Browser Troubleshooting (TCP/IP)........................................................................6-54
CHAPTER 7 SERVICE SUPPORT SOFTWARE.................................... 7-1
1. CONTROL PANEL..................................................................................................7-1
1.1 Test Print Mode ................................................................................................................7-1
1.2 Service Mode....................................................................................................................7-2
1.3 Inspection Mode ...............................................................................................................7-3
2. HOW TO KNOW DRUM UNIT LIFE & PAGE COUNTER.......................................7-5
3. HOW TO USE THE SELF-DIAGNOSTICS TOOLS ................................................7-8
4. NVRAM DEFAUT VALUE......................................................................................7-12
5. HOW TO REWRITE HL-5030/5040/5050/5070N FLASH ROM.............................7-13
APPENDICES
1.MAIN PCB CIRCUIT DIAGRAM, HL-5030/5040/5050 (1/3).....................................A-1
2.MAIN PCB CIRCUIT DIAGRAM, HL-5030/5040/5050 (2/3).....................................A-2
3.MAIN PCB CIRCUIT DIAGRAM, HL-5030/5040/5050 (3/3).....................................A-3
4.MAIN PCB CIRCUIT DIAGRAM, HL-5070N (1/4)....................................................A-4
5.MAIN PCB CIRCUIT DIAGRAM, HL-5070N (2/4)....................................................A-5
6.MAIN PCB CIRCUIT DIAGRAM, HL-5070N (3/4)....................................................A-6
7.MAIN PCB CIRCUIT DIAGRAM, HL-5070N (4/4)....................................................A-7
8.POINT TO POINT CONNECTION DIAGRAM.........................................................A-8
9. ENGINE PCB CIRCUIT DIAGRAM (1/2).................................................................A-9
10. ENGINE PCB CIRCUIT DIAGRAM (2/2) ..............................................................A-10
11. LOW-VOLTAGE POWER SUPPLY PCB CIRCUIT DIAGRAM (120V)..................A-11
12. LOW-VOLTAGE POWER SUPPLY PCB CIRCUIT DIAGRAM (230V)..................A-12
13.HIGH-VOLTAGE POWER SUPPLY PCB CIRCUIT DIAGRAM.............................A-13

HL-5030/5040/5050/5070N SERVICE MANUAL
CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY
1. SAFETY PRECAUTIONS
To avoid creating secondary problems by mishandling, follow the warnings and precautions below
during maintenance work.
WARNING
(1) Always turn off the power switch and unplug the power cord from the power outlet
before accessing any parts inside the printer.
(2) Some parts inside the printer are extremely hot immediately after the printer is
used. When opening the front cover or rear cover to access any parts inside the
printer, never touch the red colored parts shown in the following figures.
!
CAUTION:
(1) Be careful not to lose screws, washers, or other parts removed.
(2) Be sure to apply grease to the gears and applicable positions specified in this chapter.
(3) When using soldering irons or other heat-generating tools, take care not to accidentally
damage parts such as wires, PCBs and covers.
(4) Before handling any PCBs, touch a metal portion of the equipment to discharge any static
electricity charge on your body, or the electronic parts or components may be damaged.
(5) When transporting PCBs, be sure to wrap them in the correct protective packaging.
(6) Be sure to replace self-tapping screws correctly, if removed. Unless otherwise specified,
tighten screws to the following torque values.
TAPTITE, BIND or CUP B
M3: 0.7N ym
M4: 0.8N ym
TAPTITE, CUP S
M3: 0.8N ym
SCREW
M3: 0.7N ym
M4: 0.8N ym
(7) When connecting or disconnecting cable connectors, hold the connector body, not the
cables. If the connector has a lock, release the connector lock first to release it.
(8) After a repair, check not only the repaired portion but also all connectors. Also check
that other related portions are functioning properly before operational checks.

HL-5030/5040/5050/5070N SERVICE MANUAL
CHAPTER 6 TROUBLESHOOTING
1. INTRODUCTION
1.1 Initial Check
(1) Operating environment
Check if :
• The source voltage stays within ±10% from the rated voltage shown on the rating plate.
• The printer is installed on a solid, level surface.
• The room temperature is maintained between 10°C and 32.5°C. The relative humidity
is maintained between 20% and 80%.
• The printer is not located in a dusty place.
• The printer is not exposed to ammonia fumes or other harmful gases.
• The printer is not located in a hot or humid area (such as near water or a humidifier).
• The printer is not exposed to direct sunlight.
• The room is well-ventilated.
• The printer is not placed where the ventilation hole of the printer is blocked.
(2) Print paper
Check if :
• A recommended type of print paper is being used. [If the paper is too thick or too thin,
or tends to curl, paper jams or paper feed problems may occur, or printed images may
be blurred.]
• The print paper is damp. [If so, use fresh paper, and check whether the print quality
improves or not.]
• The print paper is short-grained paper or acid paper. [If so, print quality problems may
occur.]
For further information on paper, refer to subsection 3.5 ‘Paper’ in CHAPTER 1.
(3) Consumable parts
Check if:
• The LEDs on the printer control panel indicate “TONER EMPTY”. If the LEDs indicate
“TONER EMPTY”, replace the cartridge with a new one.
For further information on consumable parts, refer to 1. ‘CONSUMABLE PARTS’ in
CHAPTER 5.

CHAPTER 6 TROUBLESHOOTING
(4) Others
Condensation:
When the printer is moved from a cold room into a warm room in cold weather,
condensation may occur inside the printer, causing various problems as listed below:
• Condensation on the optical surfaces such as the scanning mirror, lenses, the
reflection mirror and the protection glass may cause the print image to be light.
• If the photosensitive drum is cold, the electrical resistance of the photosensitive layer is
increased, making it impossible to obtain the correct contrast when printing.
• Condensation on the corona unit may cause corona charge leakage.
• Condensation on the hopper plate and separation pad may cause paper feed troubles.
If condensation has occurred, print several pages or leave the printer for 2 hours to allow it to
reach room temperature.
If the drum unit is unpacked soon after it is moved from a cold room to a warm room,
condensation may occur inside the unit, which may cause incorrect images. Instruct the user
to allow the unit to come to room temperature before unpacking it. This will take one or two
hours.
1.2 Warnings for Maintenance Work
To avoid creating secondary problems by mishandling, follow the warnings below during
maintenance work.
WARNING
(1)Always turn off the power switch and unplug the power cord from the power outlet
before accessing any parts inside the printer.
(2)Some parts inside the printer are extremely hot immediately after the printer is used.
When opening the front cover or rear cover to access any parts inside the printer,
never touch the shaded parts shown in the following figures.

Brother HL-5030 HL-5040 HL-5050 HL-5070N service manual
Brother HL-5030 HL-5040 HL-5050 HL-5070N service manual
Brother HL-5030 HL-5040 HL-5050 HL-5070N service manual
Brother HL-5030 HL-5040 HL-5050 HL-5070N service manual
Brother HL-5030 HL-5040 HL-5050 HL-5070N service manual
Brother HL-5030 HL-5040 HL-5050 HL-5070N service manual
Brother HL-5030 HL-5040 HL-5050 HL-5070N service manual
Brother HL-5030 HL-5040 HL-5050 HL-5070N service manual
Brother HL-5030 HL-5040 HL-5050 HL-5070N service manual