I have a brother hl-5140 printer. I get a "ghosting" effect on prints, especially with larger font sizes, and an even more pronounced effect on heavier paper. This is a relatively new situation (just this month) I've had the printer since 9/06, have printed probably 25,000 to 30,000 pages using both the OEM, and aftermarket toner cartridges, and did replace the drum in late 2008. No problems, until recently. Cleaned it too ... no change. THANKS!
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Re: ghosting on prints
Wrong paper type can cause this, also if it is damp or too thick. Also
check that you have the correct type of paper (thickness) selected in
the driver. Ghosting can also be caused by a faulty drum unit, since you just replaced it maybe there is warranty left on it?.
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On the HL-5140, you can print out a config page which will show the page count on it by pressing down the Go button (the blue button). Hold it for a few seconds, until the config page starts to print out.
Replace the paper pcik-up rolly assembly. MAKE SURE TO get a good look at how the existing one is installed before removing it. It needs a little tweeking to get the new one in and everything lined up correctly.
Also replace the separation page on the paper tray itself.
Look for part number PF-1 Kit or OEM PART #:LJ7920001
The only diagrams I could find on-line of the inside of the printer I found by searching for "brother pl-prn067". Look at pages 8-9.
Just maybe it is the size of the original e-mail and your monitor makes it appear larger. The way that I do it is to copy and past the email into a word processor,like WORD, then set the type font to the size that I want before printing, then print from that file
Fonts and sizes are typically controlled by the application you are using. Are you sure you are increasing the font size? I've had some users confused by the zoom feature which is more like a magnifying lens. It just makes thing larger for viewing purposes and does not affect the print size. To change the actual font size of a document already created you would first highlight the text in the document. In Word (other applications are similar) you would then select Format from the main menu bar, then select Font. In the next box that appears you would click on the Font tab, and then in the Size field select a larger font size. After that click on OK and you should see your font size change.
Let us know if that was your problem or not.