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Brother Printer and MFC "Replace Toner" messages.

Brother printers and fax machines. Gotta love 'em.  They're inexpensive, reliable, and durable. But their tech support speaks little English, and they're famous for stopping in mid-job because the marketing department designed counter thinks you're out of toner. Surprise! There's gold in them thar consumables, and Brother won't tell. There's a lot more pages left after they tell you but a new one, if you know how to get the durn machine to reset. Caution: Try these at your own risk. These are short term fixes, i.e., 3AM and 50 pages to go.. Toner waste and/or new toner may not have the right electrical static charge to work properly or for long.

And yes, Brother tech support ticked me off.

If you (like us) have a large selection of Brother Printers and fax machines, and tire of having to replace toner cartridges when you know full well that there's still plenty of life left, here is a table of Printer Reset Codes and sensor cover-ups.
No more "Toner end of life, replace toner" error code messages until its really time!

MFC-7840 - HL-5040 - HL-5250 - MFC-7420

Model

Message

Software Reset

BLACK ELECTRICAL TAPE!

Software Counting   Per their marketing department, make the user replace the cartridge before its really empty. Read below.  
Optical Sensing     Generally, there's an optical sensor that either doesn't see all the toner, or doesn't like a Non-Brother cartridge.
Blocking the "window" on the cartridge will keep the light from reaching the sensor, thus defeating the low-toner warning. Black Electrical Tape and a little experimentation works wonders. Just don't let the tape get away and wound up in the works.

If the model has a low-toner detector there will be a hole/window on each end of the cartridge. Remove the cartridge and hold one end up to a bright light. Looking at the other end you may be able to see light through a hole/window on that end. When the toner gets low the light can go all the way through and be seen by a sensor that tells the printer's "brain" that the toner is low. The light source and sensor are mounted inside the printer cabinet, so there are also corresponding holes in the tray, so the light beam isn't obstructed. The purpose of the tape is to intentionally obstruct the light beam, so the "brain" thinks the cartridge is full. Some block the hole/window on the cartridge, some block the corresponding hole in the tray, it doesn't make any difference as long as the light beam is blocked from reaching the sensor.

MFC-7420   1. Open the front cover door.
2. Press the "Options" button.
3. Type *00 on the keypad.
 
MFC-7840
MFC-7840W
"Toner end of life. Replace toner"   Put Electric tape on the 1/2 inch hole in the drum tray, right side away from the gears. Photocell looks at the side of the toner cart through the hole. This also fixes aftermarket carts that don't reset properly.
       
       
MFC-8640     The toner level sensor, is a little bubble eye on the inside right wall of the printer cavity where the toner/drum cartridge rests. Look with a flashlight, you will see it a few inches from the front. Cover it up with black tape.
MFC-9440
MFC-9440N
  1. With power on, open the toner access main door (You will get a "door open" message in the LCD.)
2. Hit the "Clear/Back" button and... ta-dah!!! you go right to the “Toner Reset Menu” (cue Vienna Boy's choir sounds here).
3. Using the up ^ Down > "Search" arrow buttons, you can then scroll through reset options for each of the printer's [4] toner cartridges!
Code: B. = black; C. = cyan; M. = magenta and Y. = yellow
4. For each for these cartridges is the option to reset for low yield = S (small?) or High Yield = H
5. Using the number keypad, select option #1 (to reset each to the size you have installed.
6. Hit the "Clear/Back" button to get out of the menu, close door ad the problem is FINALLY solved.
 
MFC-9840     Tape the sensor hole on the right side of the toner.
9840CDW     Some brother cartridges use what is called a "flag gear". The gear turns slowly every time the cartridge is used. When it gets to the end of its range, a spring stops it from turning further and the printer will not print until the cartridge is replaced. When a cartridge is refilled, this flag gear must be reset or printer will think the cartridge is still empty and it will not work. You can also squeeze some extra life out of a used cartridge using this method. Caution: in cartridges that have a built-in waste toner reservoir, resetting the flag gear can result in continuing to print when the reservoir is full and spilling waste toner into your printer. This can ruin your printer, so be careful. In printers that have a separate waste toner receptacle, this is not an issue.


Flag Gear Resets:

1. Orient cartridge so that you are looking at the end of the cartridge with the developer roller to your left. (This is the opposite end from the filler cap). You should see 2 phillips head screws, one at the top right, one at the bottom left. You should also see part of the gray flag gear through an opening in the end cap.

2. Remove screws and the end cap they were holding in place (one or 2 gears may fall out when you do this, but they should be simple to pop back into place).

3. Note attachment point of the spring over flag gear, then temporarily remove it so you can reset the gear.

4. Remove the flag gear and reinstall it so that its teeth are just beginning to mesh with the adjoining gear.

5. Reinstall the spring.

6. Reinstall the end cap.

HL-1400   Quick Fix:

1. Open the front cover and leave open while completing the following steps.
2. Turn the printer off.
3. Hold the 'go' button while turning the printer on. All panel lights should be on.
4. Release the 'go' button.
5. Press the 'go' button 2 times.
6. Pause.
7. Press the 'go' button 5 times.
8. The toner light should be off.
9. The paper light should be on or flashing.
10. Close cover. The ready light should be the only light on.

 
HL-2040   Quick Fix:

1. Open the front cover and leave open while completing the following steps.
2. Turn the printer off.
3. Hold the 'go' button while turning the printer on. All panel lights should be on.
4. Release the 'go' button.
5. Press the 'go' button 2 times.
6. Pause.
7. Press the 'go' button 5 times.
8. The toner light should be off.
9. The paper light should be on or flashing.
10. Close cover. The ready light should be the only light on.

 
HL-2070   Keep the printer on.
Open the front cover.
Take out the toner.
Hold 'Go' Until all LED's light up.
Put in the toner.
Close the cover.
 
HL-4040
HL-4070
  1) Open the door as if you were going to change the toners
2) Press the Clear/Back button
3) The Reset Menu appears
4) Reset all of the TNR-S settings(four of them - one for each color). If two settings are shown for each cartridge, reset all 8.
The "window" to tape is on the gear side and has a clear plastic thing hidden behind another plastic guard with a hole that lined up with the clear plastic window.
HL-4050   For the toner life reset menu:
1 Open the front cover of the printer
2 press and hold the cancel button
3 press the reprint button WHILE still holding cancel
4 If a reset menu displays, reset all the cartridges
 
HL-5040
HL-5240

TN-580

    Link to resetting the flag gear.


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