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Spring Hook

Philips Screwdriver

Small Flat blade Screwdriver

X-Acto Knife

Technical Instructions Supplies Tools

E-mail: [email protected] Website: www.futuregraphicsllc.com

EWLEXMARKT520TECH

Photo 3

Photo 2

Step 2

Using a small flat blade screwdriver, pry the

developer roller drive gear from the shaft of

the roller. (See Photo 2)

Step 3

Rotate the cartridge so the toner hopper

label faces you.Using needle nose pliers or a

spring hook,remove the tension springs from

each side of the toner hopper.

(See Photo 3 and Photo 4)

Photo 1

Step 1

Place the cartridge upside down on the work

bench so the drum faces up and the gear end

of the toner hopper is facing towards you.(See Photo 1)

Toner

Drum

Lint free cloth

99% Isopropyl Alcohol

Cotton Swabs

Wiper Blade

Photo 4

REV. 1/25/05

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Photo 9

Photo 5

Step 4

While holding onto the toner hopper wi

your left hand, carefully bend the was

hopper away from the gear side of the ton

hopper using your right hand. Lift the rig

side of the toner hopper up away from th

waste hopper. (See Photo 5)

Step 5

Separate the toner hopper and waste hopp

(See Photo 6) Set the toner hopper aside.

Photo 6

Photo 7

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2 New Lexmark T520 Technical Instruction

Photo 8

Step 7

While holding onto the drive gear on t

drum, slide the drum axle out from the sm

(contact) gear end of the waste hopper.

(See Photo 8)

Step 6

Using a small flat blade screwdriver remo

the “C” clip from the drum axle on the dr

gear end of the drum. (See Photo 7)

Step 8

Lift the drum from the waste hoppe

(See Photo 9) If you plan on reusing th

drum, place the drum in a protected are

and out of the light.

Notes

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Step 10

Once again place the waste hopper flat on

the work bench. Using a Philips screwdriver

remove the two screws that hold the wiper

blade to the waste hopper. (See Photo 11)

Step 13

Apply padding powder to the new wiper

blade. Place the new blade onto the waste

hopper and install the two screws that hold

the blade in place. (See Photo 13)

Step 14

Flip the waste hopper over. Place a strip of

sealing tape over the area where the wiper

blade and waste hopper meet.

(See Photo 14)

Photo 12

Photo 13

Need help with a particular remanu-

facturing problem? Call the Technical Resource Center from

8am - 5pm PST: 800 394.9900

New Lexmark T520 Technical Instructions

Step 9

Lift the waste hopper by the handle so the

hopper is up on its end.Using a X-Acto knife

cut the wiper blade sealing foam that

attaches the wiper blade to the waste

hopper.(See Photo 10)

Photo 14

Step 11

Using a small flat blade screwdriver pry the

wiper blade away from the waste hopper.

(See Photo 12) Remove the wiper blade.

Step 12

Dump the waste toner from the hopper.

Using dry compressed air or a vacuum,

clean the waste hopper.Visually inspect the

waste hopper recovery blade. If the blade is

wavy, nicked, or torn the blade will have to

be replaced.

Photo 10

Photo 11

Photo 15

Foto 16

Step 15

Apply padding powder to t

drum. Place the drum into t

waste hopper. (See Photo 15)

Step 16

Slide the drum axle through t

drum starting from the small (co

tact) gear side of the waste ho

per. (See Photo 16)

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Photo 20

Photo 21

Photo 22

Photo 23



Step 20

Carefully remove the doctor blade tensio

spring from the hopper.

(See Photo 19)

NOTE: Do not let the tension spring slip a

hit the developer roller. This will scratch t

roller and could cause print defects.

Step 24

Remove the mylar shims from the ends of t

developer roller (See Photo 23)

Clean the shims using a lint free cloth.

Step 22

Slide the brass developer roller conta

bearing from the end of the hopper.

(See Photo 21)

Step 23

While holding the shaft of the develop

roller, lift the roller out from the hopper an

slide the developer roller axle out from th

toner hopper gear end plate.

(See Photo 22)

Step 21

Remove the developer roller contact from t

side of the toner hopper.

(See Photo 20)

Photo 19

Photo 17

Photo 18

Step 17

Install the “C” clip onto the drum

axle. (See Photo 17)

Step 18

Set the waste hopper aside in a

protected area out of the light.

Step 19

Remove the two square white plas-

tic tabs that secure the doctor

blade tension spring in place.

(See Photo 18) These plastic tabsare new to the Lexmark cartridges

and are used to prevent the ten-

sion spring from moving during

shipping. It is recommended that

they be reinstalled during the

assembly process.

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Step 26

To remove the doctor blade press down on the

ends of the blade. (See Photo 26)

NOTE: To ensure the best print quality when

remanufacturing the new style cartridges it is

important that the doctor bar is replaced.

When remanufacturing the old style cartridgesit was possible the flip the doctor bar around

giving you a new unworn surface area on the

bar. With the new style cartridges the doctor

bar wears in the center of the bar so flipping

the bar is not an option.

Step 28

Remove the fill plug from the side of the

hopper.(See Photo 28)

NOTE: The fill plugs on the new style

cartridges don’t have the filters on them like

the old style cartridges. A vent has been

added to the top of the toner hopper and

covered with tape.

Step 27

Pull the encoder wheel off the end of the

toner hopper. (See Photo 27)



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Step 25

To clean the developer roller to take a lint

free cloth, add a small amount of alcohol,

then soak the cloth with distilled water.

Place the axle of the developer roller into a

drill.Clean the roller using the lint free cloth

while the roller is rotating in the drill.

(See Photo 24)NOTE: DO NOT USE straight alcohol to

clean the developer roller. Straight alcohol

will cause the roller to swell and could

cause the roller to crack.

NOTE: Removal of the doctor blade in the

new style cartridges is easier due to the fact

that no sealing tape or putty is used to hold

the blade in place. A foam strip has been

added behind the doctor blade to prevent

toner leaking. The doctor blade is held in

place by two white plastic tabs found on

each end of the toner hopper.

(See Photo 25)

Photo 24

Photo 29

Step 30

Clean the developer roller e

sealing gills using a swab a

alcohol. (See Photo 29)

NOTE: The gills on the new st

cartridges are different than tho

on the old style cartridges. Th

are narrower and there are more

them. Cleaning the gills will he

prevent toner from leaking o

from the ends of the develop

roller.

Photo 25

Photo 26

Photo 27

Photo 28

Step 29

Dump out the toner from the to

hopper. Using dry compress

air or a vacuum clean the to

hopper. NOTE: Make sure you cle

the doctor bar sealing foam well

Step 31

Visually inspect the inner ton

hopper sealing blade. If the blad

damaged it will cause leaking a

must be replaced. The inner to

hopper sealing blade is n

attached to a plastic support pie

that serves as the outer to

hopper blade.To replace the bla

pry the plastic support piece o

from the toner hopper. Attach

new inner sealing blade to t

plastic support piece and atta

the support piece to the ton

hopper.

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Step 32

Slide the new doctor bar under the whi

plastic tabs on each side of the toner hopp

Lift the doctor bar contact and push the b

up till the bar is positioned against the la

two posts of the plastic tabs. (See Photo 30

Step 33

Place the two mylar shims on the ends of t

developer roller. Slide the keyed end of t

developer roller axle into the gear assemb

end plate.(See Photo 31)

Step 34

Install the brass contact bearing onto t

opposite end of the developer roller ax

Slide the developer roller contact into plac

(See Photo 32)

Step 35

Reinstall the doctor bar tension spring so th

“V” stamp on the spring points away from t

toner hopper. Place the white plastic ta

onto the doctor bar next to the ends of t

spring. (See Photo 33)

Step 36

Fill the toner hopper with the correct amou

of toner. (See Photo 34) Reinstall the ton

hopper fill plug.

Photo 30

Photo 31

Photo 32

Photo 33

Photo 34

Notes

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Step 37

Place the encoder wheel onto the toner

hopper agitator shaft. (See Photo 35)

Step 38

Place the waste hopper top down on the

work bench with the waste hopper away

from you.Turn the toner hopper upside down

install the left side of the toner hopper first.

(See Photo 36)

Photo 40

Step 39

While holding onto the toner hopper with your

left hand, carefully bend the waste hopper

away from the gear side of the toner hopper

using your right hand. Push the right side of

the toner hopper toward the waste hopper.

(See Photo 37)

Step 40

Using a spring hook reattach the tension

springs to each end of the toner hopper.

(See Photo 38 and 39)



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Photo 35

Photo 36

Photo 37

Photo 38

Photo 39

Step 41

Install the developer roller dr

gear onto the developer roller ax

(See Photo 40)

Step 42

Test the cartridge.

Notes

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Our friends in Kentucky have been at it again, making changes toolder established products.This time it’s not printer firmware that’s

been changed but rather the construction of the cartridges used in

he Optra S, Optra Se3455, Optra T, T520/522 and T620/622 family of

printers.

The changes were made to the toner hopper section of these car-

ridges.The most significant change is that the angle of the doctor

bar has been altered. This results in a centered contact with the

developer roller rather than the offset contact found in the older

tyle cartridges. For the remanufacturer, this means that the trick of

lipping one-time-used doctor bars to get an unworn contact sur-

ace, no longer works. Except for this, the changes appear to actual-

y simplify the remanufacturing process rather than hinder it. As forhe reasoning behind the changes, they were most likely made to

eliminate lingering quality issues with the OEM cartridges, reduce

manufacturing costs and perhaps to even make the cartridges easi-

er to remanufacture for Lexmark’s own Return Cartridge Program

formerly Prebate).

Though the changes Lexmark made to the Optra S style cartridges

elate only to the toner hopper, this How To article covers the entire

emanufacturing process.


Future Graphics (FG) is a distributor of compatible replacement parts and products for imagining equipment.

None of FG's products are genuine OEM replacement parts and no affiliation or sponsorship is to be implied between FG and any OEM.

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