Text preview for : Lexmark T520 522 T620 T622 Remanufacturing Instructions.pdf part of Lexmark T520/T522, T620/T622 Remanufacturing Instructiones System Support Series 424 - Part 1/3 pag. 29
Back to : Remanufacturing_Instr_©_. | Home
LICENSE AGREEMENT Static Control Components, Inc. (Static Control) grants this limited license to the person, firm or corporation (hereinafter "User") downloading electronically or by printing this file to use Static Control's copyrighted documents in accordance with the terms of this agreement. If you agree with the terms of the license then you may download this information. If you do not agree with the terms of the license, then you are not authorized to use this information, and any use of it may be in violation of Static Control's copyrights or trademarks. TRADEMARKS The Static Control material herein may make reference to its own trademarks, or trademarks of others. Static Control grants a limited license to the User to use Static Control's trademarks in its internal documents and for its internal purposes on the following terms and conditions. Any use of Static Control's trademark must be used in a context which makes it clear that the product reference is a Static Control Components, Inc. product, and not a product from any source. The materials provided to the User may include reference to trademarks of others. Any use the User makes of these marks should reference the owner of those marks. Nothing in this agreement constitutes any authorization by Static Control to use any of these trademarks in any context. COPYRIGHTS Static Control grants a limited license to the User to use the attached copyrighted documents. The permitted use of these documents is limited to internal purposes and needs of the company. The company is prohibited from using these copyrighted documents, or any part of them, including graphic elements, in any materials that are used outside the physical business location of the User. The User is prohibited from using any materials in any documents whether printed or electronic, which are distributed to any third party. The use of these copyrighted documents, or parts of them, including graphic elements, from these documents in marketing material, either print, electronic or web is prohibited. The sale, transfer, copying of these documents or any parts of these documents to any other party is prohibited. Static Control Components, Inc. retains all rights to its copyrighted documents, and any use of these documents by User should reference Static Control's copyrights, with the notice "copyright Static Control Components, Inc." Static Control reserves the right to cancel this license on 30-days written notice. All of the User's material incorporating Static Control's copyrighted documents shall be destroyed upon receipt of its notice of termination. The User may not distribute, share, and otherwise convey the copyrighted documents to any other persons, corporations or individuals. The User, by use of these documents, acknowledges Static Control's copyright in these materials. STATIC CONTROL DOES NOT GUARANTEE OR WARRANT DOWNLOADED INFORMATION The information User is downloading is published by Static Control in "as is" condition "with all faults". Static Control makes no representations or warranties of any kind concerning the quality, safety, or suitability of the downloadable materials, either express or implied, including without limitation any implied warranties of merchantability, fitness for a particular purpose, or non-infringement. Further, Static Control makes no representations or warranties as to the truth, accuracy or completeness of any statements, information or materials concerning items available for download. In no event will Static Control be liable for any indirect, punitive, special, incidental, or consequential damages however they may arise even if Static Control has been previously advised of the possibility of such damages.
Cartridge Reference
System Support SeriesTM 424
Lexmark® T520/T522, T620/T622
IBM® InfoPrint® 1120/1125, 1130/1140
Remanufacturing Instructions
T520/T522 T620/T622
Table of Contents
About the Printers . . . . . . . . . . . . . . .1 About the Cartridges . . . . . . . . . . .1-4 Tools & Supplies You Will Need . . . .5 Compressed Air, Use of . . . . . . . . . .5 Isopropyl Alcohol, Use of . . . . . . . .5 Cartridge, Separation of . . . . . . . .6-7 Waste Bin, Disassembly of . . . . .7-10 Waste Bin, Reassembly of . . . . .11-14 Toner Hopper, Disassembly of .15-19 Toner Hopper Reassembly of . .20-23 Filling the Hopper . . . . . . . . . . .24-25 Cartridge, Reassembly of . . . .26-27 Safeguarding Your Cartridges . . .27
About the Printers
Lexmark® Models
In July 2001 Lexmark® introduced the T520, T522, T620 and T622, the latest base models of their T-series laser printers. After seven years of Optra® products, the name was dropped, simplifying the model numbering scheme. Many of the features of the original Optra T-series were retained, with these latest T-machines containing new, faster engines based on Lexmark engine technology. The physical design was unchanged from that of their predecessors, but the engines were redesigned for faster performance and paper handling. T520 and T522 models replace the Optra M410 and M412 printers respectively, and are mostly identical to one another, except for speed and duty cycles, which were increased along with toner yields. The new series includes the base T520 and T522, the network-ready T520n and T522n, a T520d with duplex unit standard, and T520dn and T522dn network-ready models with duplex units standard. All seven models use the same print cartridges. The T520 and T522 printers were targeted at small-to-medium size workgroups, and both shipped with 5,000-page starter cartridges. The T620 model replaced the Optra T614 printers, while the T622 model replaced the Optra T616 printers. At the time of release, the T620 and T622 offered the highest yield of any office printer on the market, and were the fastest of any laser printer under $2,000. Their cartridges include a new smart chip similar to, but more powerful than those in the Optra Tseries. As with the T500 models, print speeds were increased, as were duty cycles and toner yields.
The new 600 series includes the base T620 and T622, the network-ready T620n and T622n, and T620dn and T622dn network-ready models with duplex units standard. The T620in and T622in models, released in August 2001, allowed printing of pre-programmed web pages without having to connect to a PC. The T620 and T622 printers were targeted at large workgroups and corporate enterprise applications. Both shipped with 10,000-page starter cartridges.
IBM® Models
In June 2001 IBM® announced their InfoPrint® 1000 family of workgroup laser printers, which utilizes the same Samsung® engine as the Lexmark T-series. The Infoprint 1120 is based on the Lexmark T520, and the 1125 on the T522. The Infoprint 1130 is based on the Lexmark T620, and the 1140 on the T622. IBM's Infoprint 20, 21, 32 and 40 are replaced by the new 1000series machines. The specifications for IBM's Infoprint 1000series printers are, in fact, nearly identical to those offered for the Lexmark counterparts, with the only difference being the brand name, chips, and consumable supplies. The printers were offered in the same configurations as Lexmark's, in nearly twin cartridges.
www.scc-inc.com/imaging/Imaging.htm Get the latest information on the web at Static Control's Online Engine Center at
www.scc-inc.com/Engine
System Support SeriesTM Documents are available on our Web site in Adobe® Acrobat® format. If you need additional information or technical assistance, please contact your Sales Support Team.
1120/1125
1130/1140
1.800.488.2426 (USA) 919.774.3808 (Int'l) +44 (0) 118 923 8800 (UK) [email protected] (USA e-mail) [email protected].(UK e-mail) www.scc-inc.com/imaging/Imaging.htm
About the Cartridges
Lexmark® The cartridges for the new T-series printers include new smart chips, similar to, but more powerful than those in the Optra T-series, with a "signature" feature added. The physical design of the cartridges was modified to make them Continued on page 2
Version II February 2003
Lexmark® T520/T522, T620/T622 Remanufacturing Instructions ®
IBM 1120/1125, 1130/1140
Continued from page 1 incompatible with the Optra models. Standard and high yield cartridges in both Prebate and non-Prebate versions are available, as well as a MICR cartridge and a high yield Prebate cartridge for special label applications. An electronic chip is located on the drum electrical contact side of the waste bins. This chip allows the printer to recognize what type of cartridge has been installed. If an incorrect chip is present, an "Unsupported Print Cartridge" error appears on the display panel. Only two encoder wheels are used for all models of the cartridges. Prebate/Return Program wheels are black, non-Prebate/ non-Return Program wheels are white. An identification code is stamped on each wheel, with 12A0110 on the Prebate/Return (both standard and high-yield) wheels. The code 12A0601 is on both the Standard and high-yield non-Prebate/non-Return Program wheels. The chip and wheel settings are matched. A non-Prebate/nonReturn Program wheel and Prebate/Return Program chip (or vise versa) on the same cartridge will result in an "Unsupported Print Cartridge" error message being displayed when the cartridge is installed in the printer. However, when both the proper chip and wheel combination is present, this error message will not be displayed.
IBM® Static Control's Imaging Labs have determined that, with the proper chips, the cartridges are interchangeable between Lexmark and IBM printers, respective of the model compatibility. IBM® has a Return Program similar to Lexmark's Prebate offering that provides customers with an upfront discounted price on select cartridges. This discount is based on a customer's commitment to return the empty cartridge back to IBM with the postage paid label included in the original packaging. 1120/1125, 1130/1140 cartridges come in Standard, Standard Return, High-Yield, High-Yield Return and MICR versions.
Key Points
The cartridge waste bin sections are designed with compatibility features that make them unusable in any Optra® or other T-series machines. The T520/T522 and 1120/1125 cartridges have a notch molded into the edge of the waste bin that the T620/T622 and 1130/1140 cartridges do not. Instead, the T620/T622 and 1130/1140 waste bins feature corners that are inset. Because of these features the T520/T522and 1120/1125 cartridges are not interchangeable with T620/T622 and 1130/1140, or vice versa. The original Optra® T-series cartridges utilized a drum shutter. The designs were changed with the release of the T-series, excluding this shutter and exposing the drum. IBM versions reflect the same changes. Additional precautions should be used when handling and packaging these cartridges to avoid light and impact damage to the OPC drum.
OEM doctor bar springs are stamped with either a "15V" (T520/522, 1120/1125), "16V" (T620/622), or "V" (1130/1140). SCC replacement doctor bars are stamped with either "T5" (T520/522, 1120/1125) or "T6" (T620/622, 1130/1140)
Static Control's Imaging Labs have determined that, with the proper chips, the cartridges are interchangeable between the two brands, respective of the model compatibility. Many of Optra S, Se and T cartridge components are compatible with the T520/T522, T620/T622, as well as the IBM 1120/1125 and 1130/1140 cartridges. For more information, log onto www.sccinc.com/imaging/Imaging.htm.
page 2 SSSTM424
Lexmark® T520/T522, T620/T622 Remanufacturing Instructions ®
IBM 1120/1125, 1130/1140
Lexmark ® Printer and Cartridge Information
Lexmark® T500 Series Printer Information
Printer Name:
Lexmark® T520 (base) Lexmark® T520d (duplex std) Lexmark® T520n (network-ready) Lexmark® T520dn (duplex/network-ready) Lexmark® X520 MFP (print/copy/fax/scan) Lexmark® T522 (base) Lexmark® T522n (network-ready) Lexmark® T522dn (duplex/network-ready) Lexmark® X522 MFP (print/copy/fax/scan)
Price
$699 $799 $1,049 $1,129 $1,999 $899 $1,299 $1,549 $3,650
Introduced
July 2001 July 2001 July 2001 July 2001 June 2001 July 2001 July 2001 July 2001 June 2001
Print Speed
20ppm 20ppm 20ppm 20ppm 19ppm 25ppm 25ppm 25ppm 24ppm
Cartridge Information
Cartridge Types:
Cartridge Part # (OEM): MSRP* Avg. Street Price:* OEM Rated Page Yield: (@5%)
Standard
12A6730 *$160 $110 7,500
Standard Prebate
12A6830 $179 $128 7,500
High Yield
12A6735 $469 $324 20,000
High Yield Prebate
12A6835 $421 $271 20,000
High Yield (Labels)
12A6839 $421 $271 20,000
MICR
STI-204520 $350 $240 14,000
Model Compatibility
Lexmark® T520 (base) Lexmark® T520d (duplex standard) Lexmark® T520n (network-ready) Lexmark® T520dn (duplex/network-ready) Lexmark® X520 MFP
Prices as of February 2003
Lexmark® T522 (base) Lexmark® T522n (network-ready) Lexmark® T522dn (duplex/network-ready) Lexmark® X522 MFP
IBM® Infoprint® 1120/1125 Unisys® UDS-130/UDS-132**
**Cartridge components are compatible, cartridges are not
Lexmark® T600 Series Printer Information
Printer Name:
Lexmark® T620 (base) Lexmark® T620n (network-ready) Lexmark® T620dn (duplex/network-ready) Lexmark® T620in (internet-ready/network-ready) Lexmark® X620 MFP (print/copy/scan/fax) Lexmark® T622 (base) Lexmark® T622n (network-ready) Lexmark® T622dn (duplex/network-ready) Lexmark® T622in (internet-ready/network-ready)
Price
$1,099 $1,579 $1,939 $1,699 $8,710 $1,699 $2,149 $2,449 $2,199
Introduced
June 2001 June 2001 June 2001 Aug. 2001 Summer 2001 June 2001 June 2001 June 2001 Aug. 2001
Print Speed
30ppm 30ppm 30ppm 30ppm 30ppm 40ppm 40ppm 40ppm 40ppm
Cartridge Information
Cartridge Types:
Cartridge Part # (OEM): MSRP: * Avg. Street Price: * OEM Rated Page Yield (@5%):
Standard
12A6760 $242 $193 10,000
Standard Prebate
12A6860 $192 $137 10,000
High Yield
12A6765 $521 $360 30,000
High Yield Prebate
12A6865 $471 $304 30,000
High Yield (Labels)
12A6869 $471 $304 30,000
MICR
STI-204070 $350 $240 15,000
Model Compatibility
Lexmark® T620 (base) Lexmark® T620n (network-ready) Lexmark® T620dn (duplex/network-ready) Lexmark® T620in (internet-ready/network-ready) Lexmark® X620 MFP (print/copy/scan/fax)
Prices as of February 2003
Lexmark® T622 (base) IBM® Infoprint® 1130/1140 Lexmark® T622n (network-ready) Unisys® UDS-134/UDS136** Lexmark® T622dn (duplex/network-ready) Lexmark® T622in (internet-ready/network-ready)
**Cartridge components are compatible, cartridges are not
SSSTM 424 page 3
Lexmark® T520/T522, T620/T622 Remanufacturing Instructions ®
IBM 1120/1125, 1130/1140
IBM® Printer and Cartridge Information
IBM® InfoPrint® 1120/1125 Series Printer Information
Printer Name:
InfoPrint® 1120 InfoPrint® 1120d InfoPrint® 1120n InfoPrint® 1120dn InfoPrint® 1125 InfoPrint® 1125n InfoPrint® 1125dn
Price
$721 $853 $1,082 $1,221 $928 $1,340 $1,599
Introduced
September 2001 September 2001 June 2001 June 2001 June 2001 June 2001 June 2001
Print Speed
20ppm 20ppm 20ppm 20ppm 25ppm 25ppm 25ppm
Cartridge Information
Cartridge Types:
Cartridge Part # (OEM): MSRP:* Avg. Street Price:* OEM Rated Page Yield (@5%):
Starter
N/A N/A N/A 5,000
Standard
28P2491 $192 $175 7,500
Standard Return
28P2493 $144 $136 7,500
High Yield
28P2492 $373 $325 20,000
High Yield Return
28P2494 $325 $300 20,000
MICR
TBN-920M-I $N/A $299 7,500
MICR High Yield
TBN-920MX-I N/A $375 20,000
Model Compatibility
IBM® Infoprint® 1120/1125 Lexmark® T520 (base) Lexmark® T520d (duplex standard) Lexmark® T520n (network-ready) Lexmark® T520dn (duplex/network-ready) Lexmark® X520 MFP
**Cartridge components are compatible, cartridges are not
Lexmark® T522 (base) Lexmark® T522n (network-ready) Lexmark® T522dn (duplex/network-ready) Lexmark® X522 MFP Unisys® UDS-130/UDS-132**
Prices as of February 2003
IBM® InfoPrint® 1130/1140 Series Printer Information
Printer Name:
InfoPrint® 1130 InfoPrint® 1130n InfoPrint® 1130in InfoPrint® 1130dn InfoPrint® 1140 InfoPrint® 1140n InfoPrint® 1140in InfoPrint® 1140dn
Price
$1,199 $1,697 $1,082 $1,999 $1,759 $2,217 $2,270 $2,535
Introduced
July 2001 July 2001 August 2001 July 2001 July 2001 July 2001 August 2001 July 2001
Print Speed
30ppm 30ppm 30ppm 30ppm 40ppm 40ppm 40ppm 40ppm
Cartridge Information
Cartridge Types:
Cartridge Part # (OEM): MSRP:* Avg. Street Price:* OEM Rated Page Yield (@5%):
Starter
N/A N/A N/A 5,000
Standard
28P2007 $279 $214 10,000
Standard Return
28P2009 $164 $160 10,000
High Yield
28P2008 $414 $398 30,000
High Yield Return
28P2010 $364 $348 30,000
MICR
TBN-930 $N/A $406 30,000
Model Compatibility
IBM® Infoprint® 1130/1140 Lexmark® T620 (base) Lexmark® T620n (network-ready) Lexmark® T620dn (duplex/network-ready) Lexmark® T620in (internet-ready/network-ready) Lexmark® X620 MFP (print/copy/scan/fax)
**Cartridge components are compatible, cartridges are not
Lexmark® T622 (base) Lexmark® T622n (network-ready) Lexmark® T622dn (duplex/network-ready) Lexmark® T622in (internet-ready/network-ready) Unisys® UDS-134/UDS136**
Prices as of February 2003
page 4 SSSTM 424
Lexmark® T520/T522, T620/T622 Remanufacturing Instructions ®
IBM 1120/1125, 1130/1140
Tools and Supplies You Will Need
Tools and Supplies
Items Recommended for Basic Remanufacturing:
· Phillips Screwdriver · Small Flat-blade Screwdriver · Needlenose Pliers or Hook Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .HTOOL · Ionized Compressed Air for Cleaning . . . . . . . .AIRGUNSET · 91-99% Isopropyl Alcohol . . . . . . . . . . . . . . . . . . . . . . . .(Below) · Cotton-Tipped Applicator . . . . . . . . . . . . . . . . . . . . . . . . .Q-TIP · Lint-free Cleaning Cloth . . . . . . . . . . . . . . . . . . . . . .LFCCLOTH · Felt/Foam Scraper Tool . . . . . . . . . . . . . . . . . . . . . . . . .FSTOOL · Hopper Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4059HJIG · Odyssey® OPC Drum (with gears) . . . . . . . .OS4059DRG-PNP · Toner: 270g Bottle, T520/T522 . . . . . . . . . . . . . . . . . . . . . .LT520-270B 635g Bottle, T520/T522 . . . . . . . . . . . . . . . . . . . . . .LT520-635B 280g Bottle T620/T622 . . . . . . . . . . . . . . . . . . . . . . .LT620-280B 855g Bottle T620/T622 . . . . . . . . . . . . . . . . . . . . . . .LT620-855B
For Wiper Blade Replacement:
· Wiper Blade (blade only) . . . . . . . . . . . . . . . . . . . . .4059BLADE · Wiper Blade (w/PCR Cleaning Assembly) . . . . . . . . . . . .4059BLADE-AS · Wiper Blade Sealing Strip . . . . . . . . . . . . . . . . .4059WBSSTRIP · Wiper Blade Adhesive Strip . . . . . . . . . . . . .(4059WBASTRIP) · Shallow trough for dipping the wiper blade · Replacement Instructions . . . . . . . . . . . . . . . . . . . . . . .SSSTM #8
For Developer Roller Sealing Blade Replacement:
· Developer Roller Sealing Blade Kit . . . . . . . . . .4059DRSBKIT · Inner Sealing Blade . . . . . . . . . . . . . . . . . . . . . . .4059INSB-TAB · Outer Sealing Blade . . . . . . . . . . . . . . . . . . . . . . . . .4059OUTSB · Replacement Instructions . . . . . . . . . . . . . . . . . . . . . .SSSTM #149
For Doctor Bar Replacement:
· Odyssey® Doctor Bar Installation Kit . . . . . . .IBMDBARKIT-4 Contains 1 Seal Strip, Putty · Odyssey® Doctor Bar w/ Leaf Spring . . .(OSIBMDBAR-4059) · Replacement Instructions . . . . . . . . . . . . . . . . . . . . . .SSSTM #151 For more information about other replacement components available for these cartridges, contact a member of your Static Support Team, or visit our Web site at www.scc-inc.com/imaging/Imaging.htm
For Recovery Blade Replacement:
· PolyBladeTM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PRECB-4059 · Insertion Tool (PolyBladeTM) . . . . . . . . . . . . . . . . . . .RBIKIT-PBL · Mylar-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4059RECBLADE · Insertion Tool (Mylar) . . . . . . . . . . . . . . . . . . . . . . . . .RBITOOL
Use of Isopropyl Alcohol
For best results, we recommend using ONLY 91-99% for cleaning as directed in these instructions. 91% isopropyl alcohol is available at most major drug stores; 99% isopropyl alcohol is available through distributors of chemical products. Follow the alcohol manufacturer's safety instructions.
Use of Compressed Air
As of April 28, 1971, the Occupational Safety & Health Administration (OSHA) Standard, 29 CFR 1910.242 paragraphs a & b for general industry requires effective chip guarding and personal protective equipment (PPE) when using compressed air. When cleaning residual toner particles from cartridges using a compressed air system, you must use air nozzles meeting OSHA requirements. Air nozzles that regulate air pressure to a maximum of 30 psi comply with this standard. Refer to the OSHA publication for any updates or changes that have occurred since the date noted above.
SSSTM 424 page 5
Lexmark® T520/T522, T620/T622 Remanufacturing Instructions ®
IBM 1120/1125, 1130/1140
Separation of the Cartridge
The steps for remanufacturing both Lexmark and IBM cartridges are the same. The Lexmark model is shown in all photos.
1. Position the cartridge
Place the cartridge on your work surface with the top of the cartridge face-down, drum up (FIG 1).
Using SCC's Hook Tool (HTOOL) or a pair of needlenose pliers, gently release the hopper tension spring from the post on the opposite side of the cartridge (FIG 3).
Remove spring from post
FIG 1
FIG 3
2. Release the hopper tension springs
Using SCC's Hook Tool (HTOOL) or a pair of needlenose pliers, gently release the hopper tension spring from the post on one side of the cartridge (FIG 2).
3. Remove the developer roller drive gear
Using a small flat-blade screwdriver, carefully pry the developer roller drive gear away from the cartridge. Remove the gear by pulling it straight off the developer roller shaft (FIG 4).
Remove spring from post
Developer Roller Drive Gear
FIG 2
FIG 4
NOTE
Do not overstretch or deform the spring. Testing has indicated that stretched tension springs can contribute to light print defects.
page 6 SSSTM 424
Lexmark® T520/T522, T620/T622 Remanufacturing Instructions ®
IBM 1120/1125, 1130/1140
4. Release the hopper stabilizer posts
The hopper is secured to the waste bin section by two stabilizer posts that install in receptacles at each end of the waste bin section. To release the posts, carefully pull the drive gear end of the waste bin away from the hopper (FIG 5). Pull the end of the hopper away from the waste bin until the post is free from the receptacle (FIG 6).
Once the drive gear end stabilizer post is clear of the waste bin, lift the end of the hopper to clear the waste bin. Shift the hopper toward the drive gear side of the cartridge to clear the post on the opposite side of the waste bin (FIG 7).
Stabilizer Post Receptacle
Flex the drive gear end of the waste bin away from the hopper Hopper Stabilizer Post Hopper Stabilizer Post
FIG 7
Stabilizer Post Receptacle
FIG 5
Separate the two halves of the cartridge.
FIG 6
Disassembly of the Waste Bin
1. Remove the drum
Position the waste bin section on your work surface with the top of the waste bin face down, drum up (FIG 8). Using a flat-blade screwdriver, slide the retaining ring (E-ring) off the drum axle on the small helical gear end (FIG 9).
Retaining E-ring
Small Helical Gear
FIG 9 FIG 8
Retaining E-Ring
SSSTM 424 page 7
Lexmark® T520/T522, T620/T622 Remanufacturing Instructions ®
IBM 1120/1125, 1130/1140
NOTE
Only the small helical gear end retaining ring needs to be taken off to allow removal of the drum axle. A replacement drum axle retaining ring is available if the original ring is lost or damaged.
A torsion spring is located on a hub on the large helical gear end of the drum that prevents the drum from rotating in the wrong direction. You will need to remove this torsion spring from the large helical gear end of the drum for use on your replacement OPC. Carefully twist the spring while pulling it off the hub (FIG 12). You may first need to use a flat-blade screwdriver to move the spring out enough to grasp it in your fingers.
While supporting the small helical gear end of the drum in one hand, remove the drum axle from the large helical gear end of the drum (FIG 10).
Drum Axle
Large Helical Gear
Remove axle in this direction
FIG 10
Twist the spring while carefully pulling it off the hub
FIG 12
Lift the drum by the small helical gear and remove the drum from the waste bin (FIG 11).
NOTE
Take care not to stretch or otherwise distort the torsion spring.
2. Remove the recovery blade (optional)
Inspect the recovery blade for damage (FIG 13). If there is no obvious damage, the blade may be left in place. If replacement is necessary, peel the blade off and clean the lip of the waste bin with 91-99% isopropyl alcohol. FIG 11
Recovery Blade
NOTE
For best results, Static Control recommends replacing the OPC drum after the OEM cycle and after each remanufacturing cycle. A replacement drum with gears is available from Static Control.
FIG 13
page 8 SSSTM 424
Lexmark® T520/T522, T620/T622 Remanufacturing Instructions ®
IBM 1120/1125, 1130/1140
NOTE
Once the recovery blade is removed, it should not be reused. Both mylar (4059RECBLADE) and PolyBladeTM (PRECB-4059) recovery blades are available from Static Control.
NOTE
This foam seal must be cut through before removal of the wiper blade. A small flat-blade screwdriver works well for this and poses less risk than using a sharp blade.
3. Remove the wiper blade and PCR cleaning assembly
Static Control recommends that the wiper blade, with attached PCR cleaning assembly and PCR cleaning felt, be replaced with each remanufacturing cycle (FIG 14). Using a small flat-blade screwdriver, cut through the area (foam) where the wiper blade stamping butts against the body of the waste bin (FIG 16).
Wiper Blade
PCR Cleaning Assembly Base
CAUTION If using an instrument with a sharp blade, use extreme care. Severe injury may result from misuse.
PCR Cleaning Felt Wiper Blade Stamping
FIG 14
NOTE
Starter cartridges may not have PCR felts.
FIG 16
Turn the waste bin over. A thin foam seal is attached between the wiper blade stamping and the plastic waste bin housing (FIG 15).
NOTE
Wiper Blade Foam
If remanufacturing a second (or subsequent) cycle cartridge, there may be a clear sealing tape over the area of the foam seal. In this case, the foam has already been cut through. If tape is present, it should be removed before proceeding.
FIG 15
SSSTM 424 page 9
Lexmark® T520/T522, T620/T622 Remanufacturing Instructions ®
IBM 1120/1125, 1130/1140
If tape is present peel it from the waste bin housing, taking care not to damage the wiper blade end foams which may be attached at each end of the seal tape (FIG 17).
Turn the waste bin on end, and while holding the laser port shutter open, remove the wiper blade (FIG 19).
Remove tape
Wiper Blade
Laser Port Shutter
FIG 19
FIG 17
4. Clean the waste bin
Dump all remaining toner from the waste bin and clean it using ionized, dry, filtered, compressed air. Take care not to damage the recovery blade, if left in place. Be sure to remove any foam that may have stuck to the waste bin when the wiper blade was removed.
Turn the cartridge over so that the wiper blade stamping is visible. Using a Phillips screwdriver, remove the screws from each end of the wiper blade stamping (FIG 18).
Remove two Phillips screws
FIG 18
page 10 SSSTM 424
Lexmark® T520/T522, T620/T622 Remanufacturing Instructions ®
IBM 1120/1125, 1130/1140
Reassembly of the Waste Bin
1. Install a replacement recovery blade (if needed)
Replacement recovery blades are available from Static Control in either mylar (4059RECBLADE) or polyurethane (PRECB-4059). With the printed side of the tool up and the brown paper backing side of the blade down (opposite the label side of the tool), insert the blade in the slot on the installation tool. Slide the blade back and forth to make sure it is fully seated in the slot. Center the blade in the tool (FIG 21).
Make sure the old recovery blade has been completely removed, along with all adhesive material. If needed, clean the lip of the waste bin with a lint-free cleaning cloth dampened with 91-99% isopropyl alcohol (FIG 20).
Center the blade end-to-end
FIG 21
Recovery blade on lip of the waste bin
FIG 20
While holding the blade in place in the tool, carefully peel the brown paper backing from the blade to expose the adhesive (FIG 22).
Paper Backing
NOTE
The use of solvents other than alcohol may adversely affect the bond between the adhesive and the cartridge or blade. DO NOT use a scraper blade on a plastic mounting surface.
FIG 22 Static Control has developed a tool to help with easy placement of the recovery blade. A slot along the length of the tool holds the recovery blade at the proper angle (RBITOOL for mylar blades, RBIKIT-PBL for polyurethane blades).
NOTE
After making sure the lip of the waste bin is clean, dry and smooth, secure the waste bin so that both hands are free.
Once the brown paper backing has been removed, DO NOT touch the adhesive.
SSSTM 424 page 11
Lexmark® T520/T522, T620/T622 Remanufacturing Instructions ®
IBM 1120/1125, 1130/1140
Hold the installation tool with both hands. Position the new recovery blade over the mounting surface, adhesive side down, with the top edge of the blade flush with the edge of the lip on the waste bin (FIG 23).
2. Install the wiper blade
Recovery blade attached to installation tool
NOTE A small amount of lubricant applied to the working edge of the blade will help prevent blade "flip overs" during the first drum rotations. Static Control recommends the use of a system-qualified toner for this purpose, since Kynar lubricating powder (normally recommended for use in Canon® cartridges) can cause print defects in Lexmark® units, if transfered to the PCR.
Dip the edge of the blade in a long, shallow trough containing only toner system-qualified for use in the cartridge you are remanufacturing (FIG 25). Repeat once to insure even coverage. FIG 23
When the blade is positioned correctly, roll the installation tool down (away from you) so the recovery blade adhesive adheres to the mounting surface, and the recovery blade pulls free of the tool. Using your finger, gently smooth the blade in place from the center outward to the ends to remove any ripples or air pockets (FIG 24).
FIG 25
Remove all ripples and air pockets
NOTE
Use only toner qualified for use in the cartridge you are remanufacturing, and avoid getting toner on the PCR cleaning assembly.
Position the waste bin with the cartridge handle up. Open the shutter and install the wiper blade (FIG 26). Note that the PCR cleaning assembly on the wiper blade stamping is face up. FIG 24
Cartridge Handle Laser port shutter
PCR Cleaning Assembly
NOTE
If the blade extends above the plastic lip of the waste bin, paper jams and possible toner leakage may occur.
If you are installing a PolyBladeTM, use your fingers to carefully peel the white reinforcement paper from the recovery blade.
Wiper Blade Stamping
FIG 26
page 12 SSSTM 424
Lexmark® T520/T522, T620/T622 Remanufacturing Instructions ®
IBM 1120/1125, 1130/1140
Turn the waste bin section over so that the wiper blade stamping and PCR cleaning assembly are visible, and secure the wiper blade with two Phillips screws (FIG 27).
After carefully peeling the backing from the seal tape, place the tape strip in position over the area where the wiper blade edge sticks out of the waste bin housing (FIG 29).
Wiper Blade Edge
Phillips Screws
FIG 27 FIG 29
3. Install the sealing tape
Turn the waste bin section over. Using a lint-free cloth dampened with 91-99% isopropyl alcohol, clean the base of the wiper blade and the area of the waste bin housing (FIG 28). Use your finger to smooth out any air bubbles or wrinkles in the tape, pressing firmly around the foams at each end of the wiper blade (FIG 30).
Wiper Blade End Foams
Laser Port Shutter
FIG 28 FIG 30
NOTE
Whether remanufacturing an older or a newer-style cartridge, Static Control recommends the use of a sealing tape over the wiper blade edge (between the wiper blade stamping and the waste bin housing) to prevent toner leakage.
NOTE
Do not place the seal strip over the laser port shutter.
After cleaning the area, allow a few minutes for the alcohol to dry. The sealing surface must be completely dry before installing the sealing tape.
SSSTM 424 page 13
Lexmark® T520/T522, T620/T622 Remanufacturing Instructions ®
IBM 1120/1125, 1130/1140
4. Replace the drum
Static Control recommends replacing the OPC drum after the OEM and each remanufacturing cycle.
While supporting the drum with one hand, insert the drum axle. Carefully slide it in along the entire length of the drum (FIG 33).
Drum Axle
Install the torsion spring (removed from the previous drum) on the same hub (large helical gear end) with the hooked end of the spring toward the outside (FIG 31).
FIG 33 Install a retaining ring on the large helical gear end of the drum axle (FIG 34). If the original ring is lost or damaged, a replacement retaining ring is available from Static Control. FIG 31
Hook toward the outside
Retaining Ring
NOTE
To prevent damage to the drum electrical contact (installed in the small helical gear) always install the drum axle through the small helical gear end of the drum.
Notch
FIG 34
5. Rotate the drum
Place the drum in the waste bin section with the small helical gear at the non-contact end of the waste bin (FIG 32). Rotating the drum will help lubricate the wiper blade and prevent blade "flip overs". The toner removed from the drum by the wiper blade will fall into the waste bin. Rotate the drum at least six full rotations in its normal operating direction (FIG 35).
Small Helical Gear
FIG 32
FIG 35
page 14 SSSTM 424
Lexmark® T520/T522, T620/T622 Remanufacturing Instructions ®
IBM 1120/1125, 1130/1140
Disassembly of the Hopper Section
1. Remove the encoder wheel
The encoder wheel allows the printer to sense the level of toner in the cartridge, and is also a source of cartridge information for the printer. Damage to the wheel can affect the operation of the cartridge. Using a small flat-blade screwdriver, pry the encoder wheel off from the base of the wheel (FIG 36). Place the encoder wheel in an area where it is protected from impact damage. While keeping the feet of the spring in place, gently press down on the center of the spring (to release it from the spring seat) and rotate the spring toward you. You may use your fingers or needlenose pliers (FIG 38). Lift the spring up and out of the hopper.
Doctor Bar Leaf Spring
D
nly ce Air Ois Surfa sed pres On Th Com ids With se Liqu Clean h Or U Touc o Not
This
Side
Up
Leaf Spring Feet
FIG 38
FIG 36
NOTE
NOTE
To avoid damaging the encoder wheel (warp, crack or break), do not pull on its edges to remove it from the hopper.
Do not leave the leaf spring installed in the hopper when the developer roller is not present. The pressure from the leaf spring will force the doctor bar from its installed position.
3. Remove the doctor bar 2. Remove the doctor bar leaf spring
Using needlenose pliers, remove the plastic doctor bar end blocks (if present) located on each end of the leaf spring (FIG 37). The amount of doctor bar putty used is critical. Too little and toner leakage will result. Too much and it will work its way behind the doctor bar onto the developer roller, damaging both and causing print defects. Using the felt/foam scraper tool, carefully remove the putty on each end of the doctor bar (FIG 39). Note the amount of putty removed and discard it.
e Up Only face Sidessed AirThis Sur pr ThitisComLiquids On W h se Clean h Or U Touc Not Do
Doctor Bar End Blocks
Leaf Spring
Doctor Bar Developer Roller
FIG 37
Do No
Up Only ce Side ed Air is Surfa ss ThisCompreuids On Th ith e Liq nW Clea h Or Us t Touc
NOTE
ALWAYS remove the doctor bar and leaf spring before removing the developer roller.
Remove the putty from each end of the doctor bar
FIG 39
SSSTM 424 page 15
Lexmark® T520/T522, T620/T622 Remanufacturing Instructions ®
IBM 1120/1125, 1130/1140
NOTE
The use of too much doctor bar putty is a common cause of doctor bar and developer roller contamination and resulting failures in remanufactured cartridges. Remember to notice how much putty you remove. Do not reuse what is removed - it is already contaminated with toner.
Carefully remove the doctor bar from the hopper by lifting it straight up and out (FIG 42). HINT: If not wearing gloves, a strip of tape placed on the doctor bar will act as a "handle" and help you to avoid touching the developer roller with your bare fingers.
Using the felt/foam scraper tool, peel up one end of the doctor bar sealing strip (FIG 40).
Do
Up r Only rface ide sed Ai This Su is Smpres On Thith Coe Liquids n W Us Cleauch Or To Not
Do No
e nW Cleauch Or Us t To
Up ly ce ide d Air On Surfa is S presse This Thith ComLiquids On
FIG 42
Seal Strip
FIG 40
Grasp the strip with needlenose pliers and remove it slowly so that the adhesive remains on the strip (FIG 41).
e Up Only face Sidessed AirThis Sur pr ThitisComLiquids On W h se Clean h Or U uc To o Not
4. Remove the developer roller
NOTE
D
Do not touch the surface of the developer roller with your fingers. Use gloves or other protective materials.
Using a small flat-blade screwdriver, carefully pry the brass electrical contact bushing away from the cartridge and remove the bushing (FIG 43).
FIG 41
Developer Roller
NOTE
The doctor bar may need to be held in place while removing the sealing strip.
Electrical Contact Bushing
FIG 43
page 16 SSSTM 424
Lexmark® T520/T522, T620/T622 Remanufacturing Instructions ®
IBM 1120/1125, 1130/1140
While handling only the developer roller shaft, carefully move the end of the developer roller forward and away from the hopper (FIG 44).
Remove any conductive grease from the developer roller shaft using a lint-free cloth or cotton-tipped swab dampened with 9199% isopropyl alcohol (FIG 47).
Developer Roller Developer Roller Shaft
FIG 47 FIG 44
Being careful to handle the roller only by the shafts, hold onto the shaft on the non-geared side of the hopper. Push in on the shaft on the geared side until your finger is flush with the cartridge housing and remove the developer roller from the hopper section (FIG 45).
NOTE
Do not apply alcohol to any part of the developer roller other than the shaft.
5. Remove the hopper cap
The hopper cap is made up of two parts: a filter and a breather cap. Using a small flat-blade screwdriver to pry the cap up, remove the entire hopper cap assembly (FIG 48).
Move forward and out
Push in until flush with housing
FIG 45
Remove the plastic washers from each end of the developer roller (FIG 46).
Do not damage latching clips
FIG 48
NOTE
Be careful not to damage the latching clips that secure the top portion of the cap to the breather portion of the cap.
Plastic Washers
FIG 46
SSSTM 424 page 17
Lexmark® T520/T522, T620/T622 Remanufacturing Instructions ®
IBM 1120/1125, 1130/1140
Clean the hopper cap using ionized, dry, filtered, compressed air. Be sure to clean the filter in the cap (FIG 49).
7. Check the developer roller sealing blades
Developer roller sealing blades prevent toner leakage from the developer chamber. The inner sealing blade is in direct contact with the developer roller, and the secondary outer sealing blade is located outside the hopper (FIG 51).
Filter Outer Sealing Blade Inner Sealing Blade with Tabs & Caulk
FIG 49
6. Clean the toner hopper
Dump any remaining toner from the hopper and clean the hopper with ionized, dry, filtered, compressed air.
FIG 51
NOTE
Often light print problems can be a result of toner embedded in the surface of the toner adder roller. For best results, Static Control recommends cleaning the toner adder roller each remanufacturing cycle to remove compacted toner.
NOTE
Using ionized, dry, filtered, compressed air clean the toner adder roller and the areas around the gasket seal. Clean small sections of the roller at a time by rotating the roller slowly while directing the air stream back and forth along the roller surface (FIG 50).
Both inner and outer blades are made of polyester and have poor "memory", meaning that once bent or kinked they do not return to their original configuration. Damaged blades can cause toner leakage that results in "sprinkles" of toner on the printed page or, more noticeably, as toner on the edge of the paper. Static Control recommends replacing the developer blades only when they are damaged or are loose (4059INSB/4059OUTSB).
Toner Adder Roller Gasket Seal
Gasket Seal
If the inner and outer developer roller sealing blades need to be replaced, refer to System Support SeriesTM 149, "How to install your 4059 Developer Roller Sealing Blades".
Inner Sealing Blade with Tabs & Caulk
Outer Sealing Blade
FIG 50
If the sealing blades do not need replacing at this time, carefully clean them using ionized, dry, filtered, compressed air.
NOTE
Be careful not to touch the toner adder roller or the developer roller sealing blades with the air gun nozzle.
SSSTM 424 page 18
Lexmark® T520/T522, T620/T622 Remanufacturing Instructions ®
IBM 1120/1125, 1130/1140
8. Clean the developer roller end seal
Use a dry cotton-tipped or lint-free swab to clean toner and debris from the seals at each end of the hopper (FIG 52).
Seals are located at each end of the hopper
FIG 55
FIG 52
11. Clean the developer roller
Clean the developer roller with ionized, dry, filtered, compressed air (FIG 56). Set the roller aside where it will be protected.
9. Clean the developer roller contact
Using a cotton-tipped applicator dampened with 91-99% isopropyl alcohol, clean the developer roller contact on the cartridge (FIG 53).
Developer Roller Electrical Contact
FIG 56
FIG 53
NOTE
10. Clean the doctor bar support areas
Using 91%-99% isopropyl alcohol and a cotton-tipped applicator, remove any toner and/or putty from the slots (both ends of cartridge) where the doctor bar will rest (FIG 54 & 55).
Oils from your skin will adhere to the developer roller surface, resulting in print defects. Do not touch the surface of the developer roller with your bare skin, and take care not to nick the surface of the roller with the air gun.
FIG 54
SSSTM 424 page 19
Lexmark® T520/T522, T620/T622 Remanufacturing Instructions ®
IBM 1120/1125, 1130/1140
Reassembly of the Hopper Section
1. Install the plastic developer roller washers
Install one plastic washer on each end of the developer roller shaft (FIG 57). If lost or damaged, replacement washers can be obtained from Static Control (IBMWASHER). Install the contact end of the developer roller (FIG 59). Make sure the plastic washer fits inside the cartridge housing.
Housing
Plastic Washer
FIG 59
FIG 57 Replace the brass electrical contact bushing on the contact end of the developer roller shaft (FIG 60).
NOTE
Washers are to help reduce friction only and not for sealing purposes. Using more than one washer per end will not help reduce toner leakage, and may actually contribute to other print defects.
Developer Roller
2. Install the developer roller
Insert the keyed end of the developer roller shaft into the noncontact end of the hopper (FIG 58).
ly ce Air On Surfa s ressedOn Thi Comp uids With e Liq Cleanch Or Us t Tou Do No
This
Side
Up
Electrical Contact Bushing
FIG 60
Insert the keyed end of the shaft into the non-contact end of the cartridge
FIG 58
3. Install the doctor bar
Static Control recommends replacing the OEM doctor bar with a new Odyssey® doctor bar and leaf spring (OSIBMDBAR-4059 / OSOPTSEDBAR / OSOPTTDBAR). The Doctor Bar Installation Kit (IBMDBARKIT-4) includes doctor bar putty, seal strip and detailed instructions that make installation quick and easy (doctor bar and springs sold separately from kit).
page 20 SSSTM 424
Lexmark® T520/T522, T620/T622 Remanufacturing Instructions ®
IBM 1120/1125, 1130/1140
For initial installations, Static Control's Odyssey® Doctor Bar should be installed with the printed side facing the outside of the hopper (FIG 61). The working surface of the bar must face the developer roller.
Carefully place the Odyssey® Doctor Bar into the slots where it will rest. Unless flipping the bar for a second cycle, the doctor bar should be installed with the printed side up [see note printed on bar] (FIG 63).
Installation Slots
Do
Only ce his S d ir TCompressseOnAThis Surfa Liquid n With Clea uch Or Use To Not
ide U
p
D
nly ce Air Ois Surfa sed pres On Th Com ids With se Liqu Clean h Or U uc To o Not
This
Side
Up
Working edge of doctor bar
FIG 61
Doctor Bar
FIG 63
NOTE
Always wear gloves when working with the Odyssey® Doctor Bar, and take care not to damage the working edge of the bar.
Clean the doctor bar sealing strip mounting surface (the lip of the hopper and the top edge of the doctor bar) with 91%-99% isopropyl alcohol and a cotton-tipped applicator (FIG 64). Allow the alcohol to dry completely.
Lip of the hopper
If remanufacturing a cartridge with an Odyssey® Doctor Bar already installed, the bar can be re-used one time. Simply turn the bar end-to-end for a second cycle (FIG 62). DO NOT flip topto-bottom. The working surface of the bar must face the developer roller.
Cotton Swab
Top edge of the doctor bar
Worn side of doctor bar
This Side Up
Up Only rface Sidessed AirThis Su re ThitihsCompiquids On n W r Use L Clea h O
FIG 64
Clean With Compressed Air Only Do Not Touch Or Use Liquids On This Surface
NOTE
Working edge of doctor bar Unused side of doctor bar (install with unprinted side facing you)
FIG 62
DO NOT saturate the cotton on the applicator. Excess alcohol can run down the back side of the bar, into the toner.
NOTE
Be extremely careful not to damage the developer roller while removing or installing the doctor bar.
SSSTM 424 page 21
Lexmark® T520/T522, T620/T622 Remanufacturing Instructions ®
IBM 1120/1125, 1130/1140
Expose the doctor bar sealing strip adhesive by peeling off and folding back 1 to 2 inches of the BROWN paper backing from one end of the doctor bar sealing strip (FIG 65).
Go over the seal once again, pressing down with your felt/foam scraper tool to secure the strip into place and remove any air bubbles.
Exposed Adhesive
Using a flat-head screwdriver, peel up one corner of the white reinforcement paper (FIG 68).
White Paper Reinforcement Brown Backing
FIG 65
e Up Only ce Sidessed Air is Surfa pr ThisComLiquids On Th ith e nW Clea h Or Us Touc Not Do
Place the end of the sealing strip flush with the end of the doctor bar and flush against the hopper (FIG 66).
FIG 68
Flush with the end of the doctor bar
Remove the reinforcement paper using needlenose pliers (FIG 69).
Sealing Strip
Do N
se nW Cleauch Or U ot To
T res ThitihsComLpiquids On
Up Only rface Side sed Air his Su
Flush against the hopper
FIG 66
Sealing Strip White Paper Reinforcement
Carefully press the strip into place, peeling the backing off slowly as you progress. You may want to use your felt/foam scraper tool to press the strip into place, smoothing out any wrinkles and air pockets (FIG 67).
e Up Only ce Sidessed Air is Surfa pr ThisComLiquids On Th ith e nW Clea h Or Us t Touc Do No
FIG 69
Sealing Strip
Felt/Foam Scraper Tool
NOTE
Do
nly ir O urface ed A is S ress n Th omp ids O ith Cse Liqu nW Cleauch Or U To Not
This
Side
Up
DO NOT seal the ends of the doctor bar with rigid caulking or glue. This can change or eliminate the downforce exerted on the doctor bar by the leaf spring, transforming the bar into a "fixed" rather than a "spring-loaded" doctor bar.
Brown Backing
NOTE
FIG 67
The amount of doctor bar putty used is critical. Too little and toner leakage will result. Too much and it will work its way behind the doctor bar onto the developer roller, damaging both and causing print defects.
page 22 SSSTM 424
Lexmark® T520/T522, T620/T622 Remanufacturing Instructions ®
IBM 1120/1125, 1130/1140
After insuring that all toner has been removed from the corners, apply a small amount of fresh doctor bar putty (approximately the same amount you removed at the beginning of the instructions) in each corner at the end of the doctor bar to complete the seal. Use a small flat-head screwdriver or felt/foam scraper tool to press the putty in place where the bar and hopper meet (FIG 70).
While holding one end of the leaf spring in each hand, insert the center bend into the plastic seat on the hopper (FIG 72).
Center bend positioned in plastic seat
Replace putty in each corner
Do N
e Up Only ace Sidessed Air is Surf pr ThisComLiquids On Th ith se nW Clea h Or U uc ot To
FIG 72
Developer Roller
FIG 70
NOTE
Be careful not to get any of the putty on the developer roller.
4. Install the doctor bar leaf spring
Use only the doctor bar leaf spring included with Static Control's Odyssey® Doctor Bar specifically designed for your cartridge.
Using minimal pressure, push up on the ends of the spring until they can be positioned onto the top of the doctor bar (FIG 73). The arrow on the spring should point toward you with the number upright.
NOTE
T520/T522, T620/T622 cartridges require a difference in doctor bar leaf spring height and tension than the Optra® cartridges. SCC leaf springs are specially designed for these individual cartridges. When installing a new SCC Odyssey® Doctor Bar, the old leaf spring must be replaced with the one packaged with the new doctor bar. For easy identification, SCC replace-
ment doctor bars are stamped with either "T5" (T520/522, 1120/1125) or "T6" (T620/622, 1130/1140) (FIG 71).
Push up on the ends of the spring until they seat on top of the doctor bar
FIG 73
Identification Marks
5T6 9V
T6
T5
59 VT5
SCC Replacement T520/T522, 1120/1125 Leaf Spring
SCC Replacement T620/T622, 1130/1140 Leaf Spring
FIG 71
SSSTM 424 page 23
Lexmark® T520/T522, T620/T622 Remanufacturing Instructions ®
IBM 1120/1125, 1130/1140
Filling the Toner Hopper
1. Fill the hopper with toner
Shake the toner bottle to aerate the toner before filling the hopper (FIG 74). To make filling easier, Static Control recommends using a funnel attachment on the toner bottle.
NOTE
Over-filling the toner hopper will flood the development station, defeating this system. Use only the amount of toner specified for your particular cartridge.
Use funnel attachment for filling
2. Install the hopper cap
Install the hopper cap assembly (FIG 76), making sure the latching clips are secured to the cap.
Latching Clips
FIG 74
NOTE
As the toner paddle moves back and forth inside the hopper it pushes toner toward the development station. An arm on the toner paddle lifts a toner metering bar allowing toner to move from the reservoir over a short wall and onto the sponge roller in the development station. This system prevents excess toner from flowing over the wall and flooding the development station, insuring that the maximum toner load for the desired page yield is maintained, avoiding a number of potential print defects (FIG 75).
FIG 76
3. Install the encoder wheel
An encoder wheel is installed at the contact end of the hopper. These wheels are the same for both T520/T522 and T620/T622 cartridges.
Toner Reservoir (Hopper) Arm Toner Metering Bar
Development Station
Paddle
Standard and High-Yield Prebate/Return Program cartridge wheels are black and have the code 12A0110 stamped on their surface. Standard and High-Yield Non-Prebate/Non-Return Program cartridge wheels are white and are stamped with 12A0601 (FIG 77).
Prebate/Return Program wheel Toner Level Wall
FIG 75
Non-Prebate/non-Return Program wheel
FIG 77
page 24 SSSTM 424
Lexmark® T520/T522, T620/T622 Remanufacturing Instructions ®
IBM 1120/1125, 1130/1140
On the end of the cartridge opposite that of the hopper cap, there is a spring-loaded gear that resembles the "Pacman" character, which is another part of the cartridge's toner sensing system (FIG 78). This gear can pop out of alignment if not held in place on the shaft when the encoder wheel is installed, resulting in either a "toner sensor" error message or a "32 Unsupported Print Cartridge" error message.
With one hand, hold the spring-loaded gear in place. With the other hand, press down on the center of the wheel until it is fully secured on the axle (FIG 80).
Press on the center of the wheel
Spring Loaded "Pacman" Gear
Encoder Wheel / Toner Agitator Paddle Axle
FIG 80
FIG 78
NOTE
Make sure the encoder wheel you are installing is the correct wheel for your cartridge. If installed on the wrong cartridge (Prebate/Return Program on Non-Prebate/Non-Return Program, and vise-versa), the error message "Unsupported Print Cartridge" will be displayed when the cartridge is installed.
Align the key of the axle with the key in the base of the wheel and place the encoder wheel on the toner agitator paddle axle (FIG 79). Do not press the wheel in place at this time.
Encoder Wheel
Toner Agitator Paddle Axle
Wheel Base
FIG 79
SSSTM 424 page 25
Lexmark® T520/T522, T620/T622 Remanufacturing Instructions ®
IBM 1120/1125, 1130/1140
Reassembly of the Cartridge
1. Reassemble the sections
Position the waste bin section on your work surface with the drum face up (FIG 81).
2. Install the hopper tension springs
Using Static Control's Hook Tool (HTOOL) or a pair of needlenose pliers, attach the tension springs to the spring posts on each end of the cartridge (FIG 84).
Spring Post
FIG 81 Being careful not to scratch the drum, install the left end of the hopper first by positioning the stabilizer post in the receptacle in the waste bin section (FIG 82).
FIG 84
NOTE
Always replace both hopper tension springs even if only one is missing or damaged. Replacing only one spring may cause uneven tensions, resulting in print defects. Replacement Hopper Tension Springs (4059HTS) are available from Static Control.
FIG 82
At the opposite end of the cartridge, carefully pull the end of the waste bin outward and position the right stabilizer post in the receptacle in the waste bin (FIG 83).
3. Install the drive gear
Install the developer roller drive gear on the end of the developer roller shaft (FIG 85).
Developer Roller Drive Gear
FIG 83 FIG 85
page 26 SSSTM 424
Lexmark® T520/T522, T620/T622 Remanufacturing Instructions ®
IBM 1120/1125, 1130/1140
Your cartridge is now ready for post-testing in your printer.
Compatibility Tab
NOTE
The T520/T522, T620/T622, 1120/1125, and 1130/1140 waste bins have a "compatibility" tab located on the small helical gear end of the waste bin housing (FIG 86). This tab is the same on all eight models, and prevents the cartridges from being inserted into an incompatible printer, such as an Optra® S or T.
Static Control recommends post-testing your cartridges after remanufacturing, and stresses that you make certain to post-test your cartridge in the correct printer.
FIG 86
Safeguarding Your Cartridges
Avoid OPC Impact Damage During Shipping The design of the hopper and waste bin sections allows the potential for impact damage to the OPC drum and developer roller anytime the cartridge is being moved, and especially during shipping. This damage can result in print defects. OEM cartridges come with a shipping lock, which creates a separation between the developer roller and OPC drum so that these components are not in contact during shipping. Static Control offers an OEM-type shipping lock that installs easily on remanufactured cartridges (FIG 87), with an instruction card that prompts the end-user to remove the lock before installing the unit in the printer (4059SLOCK).
Shipping lock in place
FIG 87
SSSTM 424 page 27
Technology and Support You Can Rely On!
We realize that the success of your business directly affects the success of Static Control. It's no longer a matter of keeping up with your competition, but surpassing them. That is why we invest so much time and effort in the technology necessary for your business to address new market opportunities quickly, and with confidence. Where monochrome once ruled the industry, color is now emerging and taking a foothold. It is our pledge to you, our customer, to do all we can to help you move into this new opportunity and others, as quickly and effortlessly as possible. We will continue to support monochrome markets, while building a comprehensive color technology library for your reference, along with products to support your growing business. Together we can build a partnership for a successful future.
STATIC CONTROL
SCC Imaging Division
3010 Lee Avenue · PO Box 152 · Sanford, NC 27331 US/Can 800.488.2426 · US/Can Fax 800.488.2452 Int'l 919.774.3808 · Int'l Fax 919.774.1287 www.scc-inc.com/imaging/Imaging.htm
Static Control Components (Europe) Limited
Unit 30, Worton Drive Reading · Berkshire RG2 OTG · United Kingdom Tel +44 (0) 118.923.8800 · Fax +44 (0) 118.923.8811 www.scc-inc.com/imaging/Imaging.htm
© 2003 Static Control Components, Inc. All rights reserved worldwide. The stylized S and Odyssey are registered trademarks, and Polyblade, SSS, Static Control and System Support Series are trademarks of Static Control Components Inc. All other brand and product names are trademarks or registered trademarks of their respective companies. Adobe, Acrobat and the Acrobat logo are registered trademarks of Adobe Systems Incorporated.