International Imaging Technology Council

What Works

by Craig Rummler, Future Graphics

Editors note: A full discussion of this printer appeared in the June

2006 issue of Imaging Spectrum. For more details about the
printer, please refer to that article, A First Look at the New
Lexmark E120n. The cartridge remanufacturing instructions are presented here.
Printer Information:
Part Number:
23S0300 (U.S.)
Technology:
Laser
Print Speed:
Up to 20 ppm
Resolution:
1200 image quality printing
First page out:
As fast as 8 seconds
Processor:
183 MHz
Memory:
16MB (std./max)
Footprint:
15.3W x 14D x 9.8H
Duty Cycle:
Up to 10,000 pages per month

IMAGING SPECTRUM MAGAZINE

Remanufacturing the Lexmark E120n

Printer Supplies:
12015SA
2,000 page Return Program Toner Cartridge
12035SA
2,000 page Toner Cartridge
12026XW
25,000 page Photoconductor Kit

Toner Hopper Remanufacturing Instructions:

Copyright 2006 Imaging Spectrum and its licensors.All rights reserved.

Step 1:
Remove the small Phillips screw that holds the doctor blade positioning plate. See Photo 1.

Tools & Supplies Needed:

Tools Required:
Needle-nose Pliers
Small Phillips Screwdriver
#2 Phillips Screwdriver
Small flat-blade Screwdriver

Supplies Required:
99% Alcohol
Cotton Swabs
Doctor Bar (if needed)
Drum (if needed)
Lint-free Cloth
Padding Powder
Toner

Craig Rummler, development engineer at Future Graphics, is responsible for new product
development, customer technical support and technical training. Having worked more than
17 years in the imaging supplies industry, Rummler has a strong background in Lexmark and
Canon cartridge parts development and engineering, as well as toner development and cartridge
remanufacturing. He has worked with leading cartridge manufacturers,
such as Nu-kote International, Laser Imaging and Earth Corporation.

Photo 1

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What Works

Photo 2

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Step 2:
The doctor blade positioning plate has two alignment pins on each side
of the plate that holds the doctor blade in the correct position. Carefully
bend the plate and slide the alignment pins from the gear side of the toner
hopper. See Photo 2.
Step 3:
Slide the positioning plate toward the gear side of the hopper to remove
the alignment pins from the contact side of the toner hopper.
See Photo 3.
Step 4:
Using needle-nose pliers, grab the leaf spring towards its center. Carefully press downward, removing the spring from the springs locking cradle.
See Photo 4. Remove the leaf spring.
Steps 5 and 6:
Lift the doctor blade from the gear side of the toner hopper. See Photo 5.
Slide the contact end of the doctor blade out from the contact side of the
toner hopper. See Photo 6.

Photo 3

Photo 4

Note: Be careful not to bend the doctor blade contact while removing the
blade.

Photo 5

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Rummler: Remanufacturing the Lexmark E120n

Photo 6

Photo 7

Step 7:
Clean the doctor blade using dry, compressed air. (Lexmark is using the
new style doctor blades in the E120n cartridges. These blades have a foam
core with a textured, coated strip on the working edge.) Clean the blade
using a lint-free cloth and alcohol. See Photo 7.
Step 8:
Rotate the toner hopper so the gear end is facing you. Using a spring
hook, remove the locking washer and the washer that holds the black
drive gear to the toner hopper. See Photo 8.
Step 9:
Remove the gear. See Photo 9.
Step 10:
Using a small, flat-blade screwdriver, remove the locking bar that holds
the developer roller bushing. See Photo 10.

Photo 9

Photo 8

Photo 10

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What Works

Photo 11

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Step 11:
Rotate the developer roller bushing counterclockwise. See Photo 11.
Step 12:
Lift up the end of the roller and slide the developer roller bushing from
the shaft of the roller. See Photo 12.
Step 13:
Holding the developer roller in place, rotate the developer roller drive
gear clockwise. This will unlock the drive gear from the shaft of the developer roller. See Photo 13.
Note: You may need to grab the shaft of the developer roller using
needle-nose pliers and rotate the developer roller while holding the drive
gear in order to remove the rollers drive gear.

Photo 12

Photo 13

Step 14:
Remove the developer roller drive gear from the shaft of the roller.
See Photo 14.

Photo 14

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Rummler: Remanufacturing the Lexmark E120n

Photo 15

Photo 16

Steps 15 and 16:

Lift up the shaft of the developer roller on the contact side of the toner
hopper. Slide the shaft of the developer roller from the gear end of the
toner hopper. See Photo 15. Clean the developer roller using distilled
water and a lint-free cloth. See Photo 16.
Note: Make sure the developer roller is completely dry before it is reinstalled in the toner hopper.
Step 17:
Remove the warranty sticker covering the toner hopper fill plug. Remove
the fill plug from the toner hopper. See Photo 17. Dump the remaining
toner from the toner hopper. Clean the hopper using dry, compressed air
or a vacuum.
Step 18:
Clean the developer roller end seals using a cotton swab and alcohol.
See Photo 18.

Photo 17

Photo 18

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Photo 19
Step 19:
While holding the developer roller by the shaft, install the keyed end of
the shaft into the gear end of the toner hopper. See Photo 19.
Step 20:
Lift up on the shaft of the developer roller. Install the bushing on to the
end of the developer roller. Rotate the developer roller clockwise, locking
the bushing in place. See Photo 20.
Step 21:
Place the locking bar onto the end of the developer roller bushing.
See Photo 21.

Photo 20

Photo 21

Step 22:
Install the white developer roller drive gear onto the shaft of the roller.
Rotate the gear counterclockwise to lock the gear onto the shaft of the
developer roller. See Photo 22.

Photo 22

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Rummler: Remanufacturing the Lexmark E120n

Photo 23

Photo 24

Step 23:
Place the black drive gear onto the alignment post on the gear end of the
toner hopper. Install the washer and locking washer onto the alignment
post. See Photo 23.
Step 24:
Install the cleaned or new doctor bar onto the toner hopper, making sure
the positioning post on the doctor bar is properly seated into the end of
the toner hopper. See Photo 24.
Note: Make sure the doctor blade contact is touching the doctor blade.
Step 25:
Position one end of the leaf spring onto the doctor bar. Using needle-nose
pliers, carefully place the opposite end of the spring onto the doctor bar.
See Photo 25.

Photo 25

Step 26:
Slide the two alignment pins on the left side of the positioning plate into
the two holes on the contact side of the toner hopper. See Photo 26.

Photo 26

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Photo 27
Step 27:
Carefully bend the plate and slide the two alignment pins into the two
alignment holes on the gear end of the toner hopper. See Photo 27.
Step 28:
Install the small Phillips screw that holds the positioning plate in place.
See Photo 28. Fill the toner hopper with toner. Place the fill plug back
onto the toner hopper.
Step 29:
Remove the Phillips screw that holds the cartridge chip that sits atop the
toner hopper. Remove the chip. See Photo 29.
Step 30:
Place a new chip onto the toner hopper and install the screw that holds
the chip in place. See Photo 30. Post-test your cartridge.

Photo 28

Photo 29

Photo 30

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Rummler: Remanufacturing the Lexmark E120n

Photo 1

Photo 2

Remanufacturing the E120n Drum Unit:

Step 1:
Using a small, flat-blade screwdriver, remove the E-ring from the drum
axle. See Photo 1.
Step 2:
Slide the drum axle from the drum on the opposite side of the waste hopper. See Photo 2.
Step 3:
Carefully lift out the drum. See Photo 3. Clean the drum using a soft
cloth. Place the drum in a protected area away from the light.
Steps 4 and 5:
Carefully lift out the PCR. See Photo 4. Remove the two spacers from the
shaft of the PCR. See Photo 5. Clean the PCR using a lint-free cloth and
distilled water.

Photo 4

Photo 3

Photo 5

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International Imaging Technology Council

Photo 6
Step 6:
Remove the two screws that hold the wiper blade. See Photo 6.
Step 7:
Lift out the wiper blade. See Photo 7. Clean the wiper blade and the waste
hopper using dry, compressed air or a vacuum.
Note: Be careful not to lose the wiper blade end foams that sit on each
side of the waste hopper.
Step 8:
Apply padding powder to the wiper blade. Place the wiper blade onto the
waste hopper and install the two screws that hold the blade in place.
See Photo 8.

Photo 7

Photo 8

Step 9:
Clean the PCR saddles using a cotton swab and alcohol. See Photo 9.

Photo 9

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Rummler: Remanufacturing the Lexmark E120n

Photo 10

Photo 11

Step 10:
Place the spacers onto the shaft of the PCR as shown in Photo 10.
Step 11:
Install the PCR into the saddles. See Photo 11.
Step 12:
Install the loop of the drums torsion spring, located on the non-gear side
of the drum, into the slot on the side of the waste hopper. See Photo 12.
Step 13:
Slide the drum axle through the drum starting on the non-gear side of the
drum. See Photo 13.
Step 14:
Install the E-ring onto the end of the drum axle. See Photo 14.
Post-test the drum unit.

Photo 13

Photo 12

Photo 14

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Step 15:
Rotate the spacers on each end of the PCR so the legs of the spacer are
facing up. See Photo 15. This will pull the PCR away from the drum and
prevent flat spots for forming on the PCR.

Drum Reset Procedures:

Step 1:
Open the front door and hold the Cancel button until all lights begin to
cycle.
Step 2:
Close the front door. The warning clears and the counter resets to zero.

Photo 15

Step 3:
Press Continue to resume printing.

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