NEWLEXMARKT520TECH

Technical Instructions

Tools
Spring Hook
Philips Screwdriver
Small Flat blade Screwdriver
X-Acto Knife

Toner
Drum
Lint free cloth
99% Isopropyl Alcohol
Cotton Swabs
Wiper Blade

CORPORATE
LOS ANGELES, USA
US 1 800 394.9900
Intl +1 818 837.8100
FAX 1 800 394.9910
Intl +1 818 838.7047

ATLANTA, USA
US 1 877 676.4223
Intl +1 678 919.1189
FAX 1 877 337.7976
Intl +1 770 516.7794

Supplies

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)

KANSAS CITY, USA

US 1 913 871.1700
FAX 1 913 888.0626

MIAMI, USA
US 1 800 595.4297
Intl +1 305 594.3396
FAX 1 800 522.8640
Intl +1 305 594.3309

NEW YORK, USA

US 1 800 431.7884
Intl +1 631 588.7300
FAX 1 800 431.8812
Intl +1 631 588.7333

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)

TORONTO, CAN
CAN 1 877 848.0818
Intl +1 905 712.9501
FAX 1 877 772.6773
Intl +1 905 712.9502

BUENOS AIRES, ARG

ARG 0810 444.2656
Intl +011 4583.5900
FAX +011 4584.3100

MELBOURNE, AUS

Photo 3

AUS 1 800 003. 100

Intl +62 03 9561.8102
FAX 1 800 004.302
Intl +62 03 9561-7751

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)

SYDNEY, AUS
AUS 1 800 003.100
Intl +62 02 9648.2630
FAX 1800 004.302
Intl +62 02 9548.2635

MONTEVIDEO, URY
URY 02 902.2001
Intl +5982 902.2001
FAX +5982 900.0858

Photo 4

JOHANNESBURG, S.A.
S.A. +27 11 974.6155
FAX +27 11 974.3593

SO PAULO, BRAZIL
Intl +55 11 5524.8000

RAANANA, ISRAEL
ISR 09 760.12.39
Intl +972 9760.12.39
ISR 052.38.555.82
Intl +972 5238.555.82

E-mail: info@futuregraphicsllc.com
REV. 1/25/05

Website:

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New Lexmark T520 Technical Instructions

Photo 5

Step 4
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. Lift the right
side of the toner hopper up away from the
waste hopper. (See Photo 5)

Notes

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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New Lexmark T520 Technical Instructions

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
attaches the wiper blade to the waste
hopper. (See Photo 10)

Photo 11

Step 15
Apply padding powder to the
drum. Place the drum into the
waste hopper. (See Photo 15)

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)

Photo 15

Step 11
Photo 12

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 13

Step 13

Step 16
Slide the drum axle through the
drum starting from the small (contact) gear side of the waste hopper. (See Photo 16)

Foto 16

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 remanufacturing problem?
Call the Technical Resource Center from
8am - 5pm PST: 800 394.9900

New Lexmark T520 Technical Instructions

Photo 19

Step 20
Carefully remove the doctor blade tension
spring from the hopper.
(See Photo 19)

Step 17
Install the C clip onto the drum
axle. (See Photo 17)

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 20

Step 21
Remove the developer roller contact from the
side of the toner hopper.
(See Photo 20)

Step 18

Photo 21

Step 22

Set the waste hopper aside in a

protected area out of the light.

Slide the brass developer roller contact

bearing from the end of the hopper.
(See Photo 21)

Step 19
Remove the two square white plastic tabs that secure the doctor
blade tension spring in place.
(See Photo 18) These plastic tabs
are new to the Lexmark cartridges
and are used to prevent the tension spring from moving during
shipping. It is recommended that
they be reinstalled during the
assembly process.

Photo 18

Step 23
While holding the shaft of the developer
roller, lift the roller out from the hopper and
slide the developer roller axle out from the
toner hopper gear end plate.
(See Photo 22)

Photo 22

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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New Lexmark T520 Technical Instructions

Photo 24

Step 25

Photo 25

Photo 26

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)

Step 29
Dump out the toner from the toner
hopper. Using dry compressed
air or a vacuum clean the toner
hopper. NOTE: Make sure you clean
the doctor bar sealing foam well.

Step 30
Clean the developer roller end
sealing gills using a swab and
alcohol. (See Photo 29)
NOTE: The gills on the new style
cartridges are different than those
on the old style cartridges. They
are narrower and there are more of
them. Cleaning the gills will help
prevent toner from leaking out
from the ends of the developer
roller.

Step 26
To remove the doctor blade press down on the
ends of the blade. (See Photo 26)

Photo 27

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
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 27
Pull the encoder wheel off the end of the
toner hopper. (See Photo 27)

Photo 28

Step 28
Remove the fill plug from the side of the
hopper. (See Photo 28)
NOTE: The fill plugs on the new style
cartridges dont 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.

Photo 29

Step 31
Visually inspect the inner toner
hopper sealing blade. If the blade is
damaged it will cause leaking and
must be replaced. The inner toner
hopper sealing blade is now
attached to a plastic support piece
that serves as the outer toner
hopper blade. To replace the blade
pry the plastic support piece out
from the toner hopper. Attach the
new inner sealing blade to the
plastic support piece and attach
the support piece to the toner
hopper.
Need help with a particular remanufacturing problem?
Call the Technical Resource Center from
8am - 5pm PST: 800 394.9900

New Lexmark T520 Technical Instructions

Photo 30

Step 32
Slide the new doctor bar under the white
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)

Notes

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
Vstamp 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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New Lexmark T520 Technical Instructions

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
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

Photo 37

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)

Photo 38

Step 40

Step 42
Test the cartridge.

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 remanufacturing problem?

Call the Technical Resource Center from
8am - 5pm PST: 800 394.9900

Our friends in Kentucky have been at it again, making changes to

older established products. This time its not printer firmware thats
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 cartridges. 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 surface, no longer works. Except for this, the changes appear to actually 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 easier to remanufacture for Lexmarks 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.

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