Strong Noise on Brother HL-5240

Usually the noise is coming from the Swing Plate Assembly. This is an assembly with plastic gears that the fuser rides on and if they loose a tooth, it makes noise

Pull out a paper cassette, lift up the printer and under you see paper feed roller (it is rubber), just clean roller with cloth and water or alcohol.

When the alarm and data lights are on, means that the toner is empty and you wont be able to print until you purchase a new toner and replace it.
Copy the link below to see how to replace the toner.

http://welcome.solutions.brother.com/BSC/public/us/ca/en/faq/faq/000000/000000/000065/faq000065_011.html?reg=us&c=ca&lang=en&prod=hl1440_all&Cat=7

I've been told labels have to be manually fed on that printer.

Is it making any noise? Mine was making a popping sound and I took the tray out, unlocked the back paper length guide and gave the paper a little more room. (be sure to put it in the locked position when you are done). That appears to have fixed the problem for now.

do a test print... see you manual. You hold a button for 3 seonds and it'll print a test page. If that works you should be OK. Make sure that your paper tray is NOT over loaded. Maybe try less paper. Try the manual feed using one sheet of paper

Most likely something has broken in the loading gear. Never pull paper against the normal flow, of course, you know that now. Unless you can locate the broken part and replace it, I'm afraid there's not much you can do other than manually feed the paper.

sounds like the fuser gear is broken.

you will have to lift all the compartments up and look for any loose paper.

Does it make the same sound if you feed the single sheet through the bypass with the paper drawer removed? I hate to say it, but your printer's paper feed mechanism may need replaced. Go to http://www.brother-usa.com/AskUs/default.aspx and ask Brother to diagnose this one; I think they'll confer with me and should be able to point you to a nearby Brother-authorized repair center. Let me know what happens!