Manual utilizado nos modelos Lexmark T520 | T522.

1. NEWLEXMARKT520TECH
Technical Instructions Supplies Tools 1
CORPORATE Toner Spring Hook
LOS ANGELES, USA Drum Philips Screwdriver
US 1 800 394.9900
Int’l +1 818 837.8100 Lint free cloth Small Flat blade Screwdriver
FAX 1 800 394.9910 99% Isopropyl Alcohol X-Acto Knife
Int’l +1 818 838.7047 Cotton Swabs
Wiper Blade
ATLANTA, USA
US 1 877 676.4223
Int’l +1 678 919.1189
FAX 1 877 337.7976 Photo 1
Int’l +1 770 516.7794
Step 1
KANSAS CITY, USA Place the cartridge upside down on the work
US 1 913 871.1700
FAX 1 913 888.0626
bench so the drum faces up and the gear end
of the toner hopper is facing towards you.
MIAMI, USA (See Photo 1)
US 1 800 595.4297
Int’l +1 305 594.3396
FAX 1 800 522.8640
Int’l +1 305 594.3309
NEW YORK, USA
US 1 800 431.7884
Int’l +1 631 588.7300 Photo 2
FAX 1 800 431.8812
Int’l +1 631 588.7333 Step 2
TORONTO, CAN Using a small flat blade screwdriver, pry the
CAN 1 877 848.0818 developer roller drive gear from the shaft of
Int’l +1 905 712.9501
FAX 1 877 772.6773 the roller. (See Photo 2)
Int’l +1 905 712.9502
BUENOS AIRES, ARG
ARG 0810 444.2656
Int’l +011 4583.5900
FAX +011 4584.3100
MELBOURNE, AUS Photo 3
AUS 1 800 003. 100 Step 3
Int’l +62 03 9561.8102
FAX 1 800 004.302 Rotate the cartridge so the toner hopper
Int’l +62 03 9561-7751 label faces you. Using needle nose pliers or a
SYDNEY, AUS spring hook, remove the tension springs from
AUS 1 800 003.100 each side of the toner hopper.
Int’l +62 02 9648.2630 (See Photo 3 and Photo 4)
FAX 1800 004.302
Int’l +62 02 9548.2635
MONTEVIDEO, URY
URY 02 902.2001
Int’l +5982 902.2001
FAX +5982 900.0858 Photo 4
JOHANNESBURG, S.A.
S.A. +27 11 974.6155
FAX +27 11 974.3593
SÃO PAULO, BRAZIL
Int’l +55 11 5524.8000
RAANANA, ISRAEL
ISR 09 760.12.39
Int’l +972 9760.12.39
ISR 052.38.555.82
Int’l +972 5238.555.82
E-mail: info@futuregraphicsllc.com Website: www.futuregraphicsllc.com
REV. 1/25/05

2. 2 New Lexmark T520 Technical Instructions
Photo 5
Step 4
While holding onto the toner hopper with
your left hand, carefully bend the waste
Notes hopper away from the gear side of the toner
hopper using your right hand. Lift the right
side of the toner hopper up away from the
waste hopper. (See Photo 5)
Photo 6
Step 5
Separate the toner hopper and waste hopper.
(See Photo 6) Set the toner hopper aside.
Photo 7
Step 6
Using a small flat blade screwdriver remove
the “C” clip from the drum axle on the drive
gear end of the drum. (See Photo 7)
Photo 8
Step 7
While holding onto the drive gear on the
drum, slide the drum axle out from the small
(contact) gear end of the waste hopper.
(See Photo 8)
Photo 9
Step 8
Lift the drum from the waste hopper.
(See Photo 9) If you plan on reusing the
drum, place the drum in a protected area
and out of the light.
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3. New Lexmark T520 Technical Instructions 3
Photo 10
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 Step 15
attaches the wiper blade to the waste
Apply padding powder to the
hopper. (See Photo 10)
drum. Place the drum into the
waste hopper. (See Photo 15)
Photo 11
Step 10
Once again place the waste hopper flat on
Photo 15
the work bench. Using a Philips screwdriver
remove the two screws that hold the wiper
blade to the waste hopper. (See Photo 11)
Step 11
Using a small flat blade screwdriver pry the
Photo 12 wiper blade away from the waste hopper.
(See Photo 12) Remove the wiper blade.
Step 16
Step 12
Slide the drum axle through the
Dump the waste toner from the hopper. drum starting from the small (con-
Using dry compressed air or a vacuum, tact) gear side of the waste hop-
clean the waste hopper. Visually inspect the per. (See Photo 16)
waste hopper recovery blade. If the blade is
wavy, nicked, or torn the blade will have to
be replaced.
Photo 13 Foto 16
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)
Photo 14
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)
Need help with a particular remanu-
facturing problem?
Call the Technical Resource Center from
8am - 5pm PST: 800 394.9900

4. 4 New Lexmark T520 Technical Instructions
Photo 19
Step 20
Carefully remove the doctor blade tension
spring from the hopper.
Step 17
(See Photo 19)
Install the “C” clip onto the drum
axle. (See Photo 17) NOTE: Do not let the tension spring slip and
hit the developer roller. This will scratch the
roller and could cause print defects.
Photo 17 Photo 20
Step 21
Remove the developer roller contact from the
side of the toner hopper.
(See Photo 20)
Photo 21
Step 18
Set the waste hopper aside in a Step 22
protected area out of the light. Slide the brass developer roller contact
bearing from the end of the hopper.
Step 19 (See Photo 21)
Remove the two square white plas-
tic tabs that secure the doctor
blade tension spring in place.
(See Photo 18) These plastic tabs
are new to the Lexmark cartridges Step 23
and are used to prevent the ten- Photo 22 While holding the shaft of the developer
sion spring from moving during roller, lift the roller out from the hopper and
shipping. It is recommended that slide the developer roller axle out from the
they be reinstalled during the toner hopper gear end plate.
assembly process. (See Photo 22)
Photo 18 Photo 23
Step 24
Remove the mylar shims from the ends of the
developer roller (See Photo 23)
Clean the shims using a lint free cloth.
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5. New Lexmark T520 Technical Instructions 5
Photo 24
Step 25
To clean the developer roller to take a lint
free cloth, add a small amount of alcohol, Step 29
then soak the cloth with distilled water. Dump out the toner from the toner
Place the axle of the developer roller into a hopper. Using dry compressed
drill. Clean the roller using the lint free cloth air or a vacuum clean the toner
while the roller is rotating in the drill. hopper. NOTE: Make sure you clean
(See Photo 24) the doctor bar sealing foam well.
NOTE: DO NOT USE straight alcohol to
clean the developer roller. Straight alcohol
will cause the roller to swell and could
Photo 25
cause the roller to crack. Step 30
Clean the developer roller end
NOTE: Removal of the doctor blade in the sealing gills using a swab and
new style cartridges is easier due to the fact alcohol. (See Photo 29)
that no sealing tape or putty is used to hold
the blade in place. A foam strip has been NOTE: The gills on the new style
added behind the doctor blade to prevent cartridges are different than those
toner leaking. The doctor blade is held in on the old style cartridges. They
place by two white plastic tabs found on are narrower and there are more of
each end of the toner hopper. them. Cleaning the gills will help
(See Photo 25) prevent toner from leaking out
Photo 26
from the ends of the developer
roller.
Step 26
To remove the doctor blade press down on the
Photo 29
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 cartridges
it was possible the flip the doctor bar around
Photo 27 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 31
Visually inspect the inner toner
hopper sealing blade. If the blade is
Step 27 damaged it will cause leaking and
must be replaced. The inner toner
Pull the encoder wheel off the end of the
hopper sealing blade is now
toner hopper. (See Photo 27)
attached to a plastic support piece
that serves as the outer toner
hopper blade. To replace the blade
Photo 28 pry the plastic support piece out
Step 28 from the toner hopper. Attach the
Remove the fill plug from the side of the new inner sealing blade to the
hopper. (See Photo 28) plastic support piece and attach
the support piece to the toner
NOTE: The fill plugs on the new style hopper.
cartridges don’t have the filters on them like
the old style cartridges. A vent has been Need help with a particular remanu-
added to the top of the toner hopper and facturing problem?
covered with tape. Call the Technical Resource Center from
8am - 5pm PST: 800 394.9900

6. 6 New Lexmark T520 Technical Instructions
Photo 30
Step 32
Slide the new doctor bar under the white
Notes plastic tabs on each side of the toner hopper.
Lift the doctor bar contact and push the bar
up till the bar is positioned against the last
two posts of the plastic tabs. (See Photo 30)
Photo 31
Step 33
Place the two mylar shims on the ends of the
developer roller. Slide the keyed end of the
developer roller axle into the gear assembly
end plate. (See Photo 31)
Photo 32
Step 34
Install the brass contact bearing onto the
opposite end of the developer roller axle.
Slide the developer roller contact into place.
(See Photo 32)
Photo 33
Step 35
Reinstall the doctor bar tension spring so the
“V”stamp on the spring points away from the
toner hopper. Place the white plastic tabs
onto the doctor bar next to the ends of the
spring. (See Photo 33)
Photo 34
Step 36
Fill the toner hopper with the correct amount
of toner. (See Photo 34) Reinstall the toner
hopper fill plug.
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7. New Lexmark T520 Technical Instructions 7
Photo 35
Step 37
Place the encoder wheel onto the toner
hopper agitator shaft. (See Photo 35)
Step 41
Install the developer roller drive
gear onto the developer roller axle.
(See Photo 40)
Photo 36
Step 38
Photo 40
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 37
Step 39
While holding onto the toner hopper with your
left hand, carefully bend the waste hopper Step 42
away from the gear side of the toner hopper Test the cartridge.
using your right hand. Push the right side of
the toner hopper toward the waste hopper.
(See Photo 37)
Photo 38
Step 40
Notes
Using a spring hook reattach the tension
springs to each end of the toner hopper.
(See Photo 38 and 39)
Photo 39
Need help with a particular remanu-
facturing problem?
Call the Technical Resource Center from
8am - 5pm PST: 800 394.9900

8. Our friends in Kentucky have been at it again, making changes to
older established products. This time it’s not printer firmware that’s
been changed but rather the construction of the cartridges used in
the 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-
tridges. 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
style cartridges. For the remanufacturer, this means that the trick of
flipping one-time-used doctor bars to get an unworn contact sur-
face, no longer works. Except for this, the changes appear to actual-
ly simplify the remanufacturing process rather than hinder it. As for
the 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
relate only to the toner hopper, this How To article covers the entire
remanufacturing 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.
E-mail: info@futuregraphicsllc.com Website: www.futuregraphicsllc.com