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Brother International HL-5150D Service Manual - Page 235

Unable to print full s of a document with the PRINT OVERRUN message.

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HL-5130/5140/5150D/5170DN SERVICE MANUAL P-2 Unable to print full pages of a document with the "PRINT OVERRUN" message. User Check (1) Press the Go switch on the control panel to print the data remaining in the printer. (2) If this does not clear the error, reduce the complexity of your document or reduce the printer resolution. (3) Expand the printer memory by adding a commercially available DIMM. (except for HL-5130) (4) Change the following setting in the printer driver and try again. The best combination of settings below will vary depending on your document. Graphic Mode / TrueTypeTM mode (except for HL-5130) / Use Printer TrueTypeTM Fonts (except for HL-5130) NOTE: This problem may appear if the data is too complex. If it is not cleared by taking the actions above, it will be impossible to print such data under the printer specifications. P-3 Unable to print full pages of a document with the "MEMORY FULL" message. User Check (1) Press the Go switch on the control panel to print the data remaining in the printer. (2) Reduce the complexity of your document or reduce the printer resolution. (3) Expand the printer memory by adding a commercially available DIMM. (except for HL-5130) NOTE: This problem may appear if the data is too complex. Possible cause Unable to recognize DIMM DIMM / main PCB failure Step 1 Check Check the memory size in Print Configuration. Is it the default size? 2 Try installing DIMM into another printer, then check the memory size in Print Settings. Is it possible to print the data? Result Yes Yes Remedy Expand the memory size by adding DIMM. If the memory is already at the maximum size, it will be impossible to print the data under the printer specifications. Replace the main PCB. No Replace the DIMM. 6-47

Section	Page
MODEL: HL-5130/5140/5150D/5170DN	1
PREFACE	3
TABLE OF CONTENTS	4
REGULATION	10
SAFETY INFORMATION	12
CHAPTER 1 GENERAL	14
1. FEATURES	14
2. OVERVIEW	17
3. SPECIFICATIONS	18
3.1 Printing	18
3.2 Functions	19
3.3 Electrical and Mechanical	20
3.4 Network	21
3.5 Paper	22
3.5.1 Feedable paper	22
3.5.2 Paper tray capacity	24
3.5.3 Print delivery	24
3.6 Printable Area	26
3.6.1 PCL5e/EPSON/IBM emulation	26
3.6.2 PCL6/BR-Script3 emulation	29
3.7 Print Speeds with Various Settings	30
3.8 Toner Cartridge Weight Information	31
4. SERIAL NO. DESCRIPTIONS	32
CHAPTER 2 INSTALLATION AND BASIC OPERATION	34
1. CONDITIONS REQUIRED FOR INSTALLATION	34
1.1 Power Supply	34
1.2 Environment	34
1.3 System Requirements for Brother Printer Solution	35
2. UNPACKING	36
3. INSTALL THE PRINTER	37
3.1 For All Users	37
3.1.1 Install the drum unit assembly	38
3.1.2 Load paper into the paper tray	38
3.1.3 Print a test page	39
3.2 For Windows. Users	40
3.3 For Macintosh Users	44
4. PRINTING METHODS	47
4.1 Printing from the Paper Tray	47
4.2 Printing from manual feed tray (HL-5130/5140 only)	47
4.3 Printing from Multi-purpose Tray (MP Tray) : HL-5150D/5170DN only	48
4.4 Printing on envelopes	50
4.5 Printing on transparencies	54
4.6 Printing on Both Sides of the Paper (manual duplex printing)	57
4.7 Paper orientation for printing on both sides of the paper	59
4.8 Printing on both sides of the paper (automatic duplex printing) : For HL-5150D and HL-5170DN	60
5. CONTROL PANEL OPERATION	61
5.1 Control Panel Buttons & LED functions	61
5.1.1 LEDs	61
5.1.2 Control Panel Buttons	61
5.2 LED Indications	62
5.3 Service call indications	64
5.4 Control Panel Button Operations	65
5.5 Other Control Features	66
5.5.1 Sleep mode	66
5.5.2 Print a test page	67
5.5.3 Printer Settings	67
5.5.4 Print fonts (For HL-5140, HL-5150D, and HL-5170DN)	68
6. NETWORK FUNCTIONS (FOR HL-5170DN)	69
6.1 LED functions	69
6.2 Network Factory default setting (For HL-5170DN)	69
7. PAPER TRAY INFORMATION (FOR EUROPE ONLY)	70
CHAPTER 3 THEORY OF OPERATION	71
1. ELECTRONICS	71
1.1 General Block Diagram	71
1.2 Main PCB Block Diagram	72
1.3 Main PCB	73
1.3.1 CPU	73
1.3.2 USB	75
1.3.3 IEEE1284	76
1.3.4 Network Interface	77
1.3.5 ROM	78
1.3.6 Flash ROM	79
1.3.7 SDRAM	80
1.3.8 Optional RAM	81
1.3.9 EEPROM	83
1.3.10 Reset Circuit	83
1.3.11 Engine I/O	84
1.3.12 Panel I/O	84
1.3.13 Video I/O	85
1.3.14 Power Supply	86
1.4 Engine PCB	87
1.5 Power Supply	88
1.5.1 Low-voltage power supply	88
1.5.2 High-voltage power supply	89
2. MECHANICS	90
2.1 Overview of Printing Mechanism	90
2.2 Paper Transfer	91
2.2.1 Paper supply	91
2.2.2 Paper registration	92
2.2.3 Paper eject	92
2.2.4 Duplex printing (HL-5150D/5170DN only)	93
2.3 Sensors	94
2.3.1 Cover sensors	94
2.3.2 Toner sensors	94
2.3.3 Cassette sensor / Paper empty sensor (HL-5140/5150D/5170DN)	95
2.3.4 Paper eject sensor	95
2.3.5 MP-PE sensor (HL-5150D/5170DN)	96
2.3.6 DX sensor (HL-5150D/5170DN)	96
2.3.7 Regist sensor	97
2.3.8 Rear cover sensor (HL-5150D/5170DN)	97
2.4 Drum Unit	98
2.4.1 Photosensitive drum	98
2.4.2 Primary charger	98
2.4.3 Transfer roller	98
2.4.4 Cleaner	98
2.5 Toner Cartridge	98
2.6 Print Process	98
2.6.1 Charging	98
2.6.2 Exposure stage	99
2.6.3 Developing	100
2.6.4 Transfer	100
2.6.5 Fixing stage	101
CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY	102
1. SAFETY PRECAUTIONS	102
2. DISASSEMBLY FLOW	103
3. DISASSEMBLY PROCEDURE	104
3.1 AC Cord	104
3.2 Drum Unit	104
3.3 Paper Tray	105
3.4 DX Feed ASSY (HL-5150D/5170DN)	115
3.5 Access Cover	118
3.6 Rear Cover C	118
3.7 Outer Chute (HL-5130/5140)	119
3.8 Rear Cover MP ASSY / Outer Chute MP ASSY (HL-5150D/5170DN)	120
3.9 Rear Cover L/R	121
3.10 Side Cover L/R	122
3.11 Top Cover	123
3.12 Front Cover ASSY (HL-5130/5140)	126
3.13 MP Unit (HL-5150D/5170DN)	127
3.14 Fixing Unit	133
3.15 Rear Cover Sensor (HL-5150D/5170DN)	142
3.16 Laser Unit	142
3.17 Main PCB	144
3.18 Base Plate / LV Insulation Sheet	146
3.19 DX-Sensor PCB ASSY (HL-5150D/5170DN)	147
3.20 Engine PCB	148
3.21 High-voltage PS PCB ASSY	149
3.22 Low-voltage PS PCB ASSY	149
3.23 Paper Feeder	151
3.24 Frame L / Drive Unit	159
3.25 Fan Motor 60 Unit LV / Fan Motor 60 Unit	163
3.26 Frame R	164
4. PACKING	166
5. LUBRICATION	167
6. GUIDELINES FOR LEAD FREE SOLDER	169
CHAPTER 5 PERIODIC MAINTENANCE	172
1. CONSUMABLE PARTS	172
1.1 Drum Unit	172
1.2 Toner Cartridge	174
2. PERIODICAL REPLACEMENT PARTS	179
2.1 Fixing Unit	180
2.2 Paper Feeding Kit	183
3. PERIODICAL CLEANING	185
3.1 Cleaning the Printer Exterior	185
3.2 Cleaning the Drum Unit	185
3.3 Cleaning the Scanner Window	186
3.4 Cleaning the Electrical Terminals	187
4. SERVICE INFORMATION	188
CHAPTER 6 TROUBLESHOOTING	189
1. INTRODUCTION	189
1.1 Initial Check	189
1.2 Warnings for Maintenance Work	190
1.3 Identify the Problem	191
2. OPERATOR CALLS & SERVICE CALLS	192
2.1 Operator Calls	192
2.2 Service Calls	193
3. ERROR MESSAGE	195
3.1 Error Message in the Status Monitor	195
3.2 Error Message Printouts	196
4. PAPER PROBLEMS	197
4.1 Paper Loading Problems	197
4.2 Paper Jams	198
4.2.1 Clearing jammed paper	198
4.2.2 Causes & countermeasures	202
4.3 Paper Feeding Problems	203
5. SOFTWARE SETTING PROBLEMS	205
6. MALFUNCTIONS	208
7. IMAGE DEFECTS	213
7.1 Image Defect Examples	213
7.2 Diameter of Rollers	213
7.3 Troubleshooting Image Defect	214
7.4 Location of Grounding Contacts	233
7.4.1 Drum unit	233
7.4.2 Printer body & Paper tray	233
8. INCORRECT PRINTOUT	234
9. NETWORK PROBLEM	237
9.1 Installation Problem	237
9.2 Intermittent Problem	238
9.3 TCP/IP Troubleshooting	239
9.4 UNIX Troubleshooting	239
9.5 Windows NT/LAN Server (TCP/IP) Troubleshooting	240
9.6 Windows 95/98/Me (or later) Peer to Peer Print (LPR) Troubleshooting	240
9.7 Windows 95/98/Me (or later) Peer to Peer (HP JetAdmin Compatible Method) Troubleshooting	241
9.8 Windows 95/98/Me/NT 4.0/2000/XP Peer to Peer Print (NetBIOS) Troubleshooting	241
9.9 Brother Internet Print (TCP/IP) Troubleshooting	241
9.10 Windows 95/98/Me/2000/XP IPP Troubleshooting	242
9.11 Novell Netware Troubleshooting	242
9.12 AppleTalk Troubleshooting	243
9.13 DLC/LLC Troubleshooting	243
9.14 Web Browser Troubleshooting (TCP/IP)	243
CHAPTER 7 SERVICE SUPPORT SOFTWARE	244
1. CONTROL PANEL	244
1.1 Test Print Mode	244
1.2 Service Mode	245
1.3 Inspection Mode	246
2. HOW TO KNOW DRUM UNIT LIFE & PAGE COUNTER	248
1. Printing out the Print Settings	248
2. Contents Overview	249
2.1 Page 1	249
2.2 Page 2	249
2.3 Page 3 (HL-5170DN only)	251
3. How to Read the Maintenance Information	252
3. HOW TO USE THE SELF-DIAGNOSTICS TOOLS	253
1. Troubleshooting for Printer won’t print	253
2. Diagnostics	254
3. Printer Information	256
4. NVRAM DEFAULT VALUE	257
5. HOW TO REWRITE HL-5130/5140/5150D/5170DN FLASH ROM	258
1. Controller Firmware	260
2. Network Firmware (ROM 1) (for HL-5170DN only)	261
3. Set the serial number	262
Appendix 1. Main PCB Circuit Diagram, HL-5130/5140/5150D (1/3)	264
Appendix 2. Main PCB Circuit Diagram, HL-5130/5140/5150D (2/3)	265
Appendix 3. Main PCB Circuit Diagram, HL-5130/5140/5150D (3/3)	266
Appendix 4. Main PCB Circuit Diagram, HL-5170DN (1/4)	267
Appendix 5. Main PCB Circuit Diagram, HL-5170DN (2/4)	268
Appendix 6. Main PCB Circuit Diagram, HL-5170DN (3/4)	269
Appendix 7. Main PCB Circuit Diagram, HL-5170DN (4/4)	270
Appendix 8. Point To Point Connection Diagram	271
Appendix 9. Engine PCB Circuit Diagram (1/2)	272
Appendix 10. Engine PCB Circuit Diagram (2/2)	273
Appendix 11. Low-voltage Power Supply PCB Circuit Diagram (120V)	274
Appendix 12. Low-voltage Power Supply PCB Circuit Diagram (230V)	275
Appendix 13. High-voltage Power Supply PCB Circuit Diagram	276
APPENDIX 14. HARNESS ROUTING	277
APPENDIX 15. LOCATION TO ATTACH THE ADDITIONAL RIBS	278