SERVICE UPDATE No.

Print Unable 2A or No Waste Toner error HL4040CN, HL4040CDN, HL4070CDW April 16th, 2010 v2 Symptoms:
Print Unable 2A or No Waste Toner error on the display.

P1292_EN

Possible cause:
Firmware upgrade required Waste Toner Box defective or missing Waste toner sensors defective Belt Cleaner Release Assembly defective

Recommendation:
Upgrade the firmware. Replace parts as needed.

Step 1: Verify that the Engine Controller firmware is version 1.17 or higher
This issue may be caused by obsolete firmware. In order to check the firmware version: a. On the control panel of the machine, enter maintenance mode by pressing the following keys one after the other: OK, GO, and then the UP arrow key four times. The keys should be pressed within 2 seconds of each other. b. The control panel should start flashing when you have successfully entered Maintenance mode. If the lights are not flashing, press the Cancel key and repeat step a. c. d. Press the UP arrow key until Maintenance 25 appears on the display. Press the OK key. Press the DOWN arrow key until the display shows ENG: Ver x.xx where x.xx is the firmware version of the Engine Controller. Press Cancel. e. Press the DOWN or UP arrow key until the display reads Maintenance 99. Press the OK key to exit Maintenance Mode. If the engine firmware version is lower than 1.17, an upgrade may resolve the issue. Go to http://www.brother-usa.com/downloads/Default.aspx for the latest firmware. If the firmware is version 1.17 or higher and or the firmware upgrade does not resolve the issue, suspect a hardware failure.

Note: A firmware upgrade is always recommended on any machine that is functional. Firmware upgrades provide enhancements to the machines usability and functionality. Upgrades may prevent problems in the future. Page 1 of 15

SERVICE UPDATE No.

Print Unable 2A or No Waste Toner error HL4040CN, HL4040CDN, HL4070CDW April 16th, 2010 v2

P1292_EN

Step 2: 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 box is present and appears to be seated properly, go to step 3.

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.

Step 3: Verify that the waste toner sensors are functioning

a. b. c. d. e. f. Open the front cover. Remove the drum, toners, belt unit and waste toner pack. Place the machine in full maintenance mode (OK, GO, then the UP arrow key four times). Press the DOWN or UP arrow keys until Maintenance 32 appears on the display. Press the OK key. C1P1R1********** appears on the display. Press the GO key until DV****BCNWFW appears on the display. Using a piece of paper or other non conductive object, block the Near Waste (NW) sensor (left sensor, see figure 3) The NW should disappear from the display when the sensor is blocked and reappear when the sensor is not blocked. If the sensor does not follow this behavior, see the section for Sensor Replacement. Block the Full Waste (FW) sensor (right sensor, see figure 4). The FW sensor should disappear from the display when the sensor is blocked and reappear when the sensor is not blocked. If the sensor does not follow this behavior, see the section for Sensor Replacement.

g.

Page 2 of 15

SERVICE UPDATE No.

Print Unable 2A or No Waste Toner error HL4040CN, HL4040CDN, HL4070CDW April 16th, 2010 v2
h. i. Press CANCEL. Exit maintenance mode by pressing the DOWN or UP arrow key until Maintenance 99 appears on the control panel. Press the OK key. If both sensors appear to be operational, proceed to section 4 (drive frame gear test).

P1292_EN

Figure 3 Location of the Near Waste Toner (NW) sensor.

Figure 4 Location of the Waste Toner Full (FW) sensor.

Step 4: Verify movement of the drive frame gear

a. b. c. d. Open the front cover. Remove the drum, toners, belt unit and waste toner pack. Locate the front cover interlock switch (Figure 5). Locate the drive gear on the left side of the printer (see Figure 6). Place a screwdriver (or other suitable object) under the bottom of the interlock switch. Push the switch UP. e. The print engine will start to run. Please Wait appears on the display.

Page 3 of 15

SERVICE UPDATE No.

Print Unable 2A or No Waste Toner error HL4040CN, HL4040CDN, HL4070CDW April 16th, 2010 v2

P1292_EN

Figure 5 Front cover interlock switch

Figure 6 Drive Frame Assembly gear

f.

The gear should turn and continue to turn until the NO WASTE TONER message reappears on the display. If the gear does not turn or only moves intermittently, replace the Drive Frame Assembly (See section titled Drive Frame Assembly Replacement.

Note: Even if gear movement is present, the tech should replace the Drive Frame Assembly on any model with a serial number less than F8J286890 as a preventive measure.

Step 5: Check the Belt Cleaner Release Assembly

a. Locate the Belt Cleaner Release Assembly (Figure 7). Verify that the assembly is completely flush with the printer frame. The assembly is attached to the printer frame with small pegs (Figure 8). 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. Verify that the actuator moves freely (Figure 7) 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. If the actuator is sticking or does not move freely, the technician is encouraged to clean the assembly rather than replace it due to the complexity of the repair. If replacement is absolutely necessary or if the reliability of the assembly is in question, refer to Service Update P1223 (No Paper Fed Clicking Noise) for removal and replacement instructions.

b.

Page 4 of 15

SERVICE UPDATE No.

Print Unable 2A or No Waste Toner error HL4040CN, HL4040CDN, HL4070CDW April 16th, 2010 v2

P1292_EN

Figure 7 Belt Cleaner Release Assembly Arrow points to the location of the actuator

Figure 8 Location of pegs on Belt Cleaner Release Assembly

Step 5: Replace the Waste Toner Pack If the drive frame assembly was replaced, firmware upgrade was done, and the belt cleaner release assembly is functional, replace the waste toner box.

Page 5 of 15

SERVICE UPDATE No.

Print Unable 2A or No Waste Toner error HL4040CN, HL4040CDN, HL4070CDW April 16th, 2010 v2
Drive Frame Assembly Replacement 1. Remove the two M3X8 taptite screws from the rear cover. Remove the rear cover.

P1292_EN

2.

Remove the two cup S M3x8 Taptite screws. Remove the Back cover upper.

Page 6 of 15

SERVICE UPDATE No.

Print Unable 2A or No Waste Toner error HL4040CN, HL4040CDN, HL4070CDW April 16th, 2010 v2
3.

P1292_EN

Remove the 3 M4X12 taptite screws and the M3X8 screw from the left side cover. Remove the cover.

4.

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.

Page 7 of 15

SERVICE UPDATE No.

Print Unable 2A or No Waste Toner error HL4040CN, HL4040CDN, HL4070CDW April 16th, 2010 v2
5. 6.

P1292_EN

Remove the cup S m3x6 Taptite screw and blind b M4x12 Taptite screw, and then remove the Ground plate. Remove the two cup Sm3x6 Taptite screws, and then remove the ground spring plate.

7.

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.

Page 8 of 15

SERVICE UPDATE No.

Print Unable 2A or No Waste Toner error HL4040CN, HL4040CDN, HL4070CDW April 16th, 2010 v2
8.

P1292_EN

Remove the five S M3x6 Taptite screws, and then remove the Engine PCB Assy from the frame unit.

9.

Remove the cup S M3x6 Taptite screw, and then remove the Main PCB ASSY as shown by arrows 4a and 4b.

Page 9 of 15

SERVICE UPDATE No.

Print Unable 2A or No Waste Toner error HL4040CN, HL4040CDN, HL4070CDW April 16th, 2010 v2
10.

P1292_EN

Remove the Engine insulation sheet from the Harness shield plate, which is fixed with a two-sided adhesive tape.

11.

Remove the three cup S M3x6 Taptite screws, and then remove the Harness shield plate from the Frame Unit.

Page 10 of 15

SERVICE UPDATE No.

Print Unable 2A or No Waste Toner error HL4040CN, HL4040CDN, HL4070CDW April 16th, 2010 v2
12. Remove the four cup S M3x6 Taptite screws, and then remove the Engine PCB plate.

P1292_EN

13.

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.

Page 11 of 15

SERVICE UPDATE No.

Print Unable 2A or No Waste Toner error HL4040CN, HL4040CDN, HL4070CDW April 16th, 2010 v2
14.

P1292_EN

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.

15.

Install parts in the reverse order. ENSURE THAT THE MACHINE WORKS BEFORE REINSTALLING ALL OF THE COVERS. Place the back cover on the machine in order to make it functional and to perform test.

Page 12 of 15

SERVICE UPDATE No.

Print Unable 2A or No Waste Toner error HL4040CN, HL4040CDN, HL4070CDW April 16th, 2010 v2
Waste Toner Sensor Replacement 1. 2. Power off the machine. Remove the Drum/Toner unit, Belt Unit and Waste Toner pack. Move the Positioning pin 1a as shown, and slide the Hooks to the direction of the arrow 1b, and then remove the Waste toner sensor holder from the Middle plate.

P1292_EN

3.

Release the Hook to remove the Waste toner sensor cover from the Waste toner sensor holder.

Page 13 of 15

SERVICE UPDATE No.

Print Unable 2A or No Waste Toner error HL4040CN, HL4040CDN, HL4070CDW April 16th, 2010 v2
4.

P1292_EN

Release the three Hooks of each Waste toner sensor to remove the two Waste toner sensors from the Waste toner sensor holder.

5.

Disconnect the Connectors (yellow and blue) from each of the Waste toner sensors.

Page 14 of 15

SERVICE UPDATE No.

Print Unable 2A or No Waste Toner error HL4040CN, HL4040CDN, HL4070CDW April 16th, 2010 v2

P1292_EN

Problems that may be encountered while testing the machine:

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 13).

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 12).

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 12).

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.

Page 15 of 15