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Lexmark® T520/T522, T620/T622
IBM® InfoPrint® 1120/1125, 1130/1140
Remanufacturing Instructions
T520/T522
T620/T622
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, simpli-
fying the model numbering scheme. Many of the
features of the original Optra T-series were
retained, with these latest T-machines contain-
ing 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 perform-
ance 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 target-
ed 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 T-
series. 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 net-
work-ready models with duplex units stan-
dard. 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 1000-
series machines.
The specifications for IBM's Infoprint 1000-
series 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.
1120/1125
1130/1140
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
Cartridge Reference
System Support Series™ 424
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
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 Series™
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.
1.800.488.2426 (USA)
919.774.3808 (Int’l)
+44 (0) 118 923 8800 (UK)
info@scc-inc.com (USA e-mail)
info@scceurope.co.uk.(UK e-mail)
www.scc-inc.com/imaging/Imaging.htm
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.
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 offer-
ing that provides customers with an upfront discounted price on
select cartridges. This discount is based on a customer’s commit-
ment 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
z 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.
z The original Optra T-series cartridges utilized a drum shutter.
® brands, respective of the model compatibility.
The designs were changed with the release of the T-series, exclud-
ing this shutter and exposing the drum. IBM versions reflect the
same changes. Additional precautions should be used when han-
dling and packaging these cartridges to avoid light and impact
damage to the OPC drum.
page 2 SSS™424
z 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.
z Only two encoder wheels are used for all models of the car-
tridges. 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.
z The chip and wheel settings are matched. A non-Prebate/non-
Return 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 dis-
played.
z 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)
z Static Control’s Imaging Labs have determined that, with the
proper chips, the cartridges are interchangeable between the two
z Many of Optra S, Se and T cartridge components are compati-
ble with the T520/T522, T620/T622, as well as the IBM 1120/1125
and 1130/1140 cartridges. For more information, log onto www.scc-
inc.com/imaging/Imaging.htm.
 Lexmark® T520/T522, T620/T622 Remanufacturing Instructions
IBM 1120/1125, 1130/1140
®

Lexmark ® Printer and Cartridge Information

Lexmark® T500 Series
Printer Information
Printer Name: Price Introduced Print Speed
Lexmark® T520 (base) $699 July 2001 20ppm
Lexmark® T520d (duplex std) $799 July 2001 20ppm
Lexmark® T520n (network-ready) $1,049 July 2001 20ppm
Lexmark® T520dn (duplex/network-ready) $1,129 July 2001 20ppm
Lexmark® X520 MFP (print/copy/fax/scan) $1,999 June 2001 19ppm
Lexmark® T522 (base) $899 July 2001 25ppm
Lexmark® T522n (network-ready) $1,299 July 2001 25ppm
Lexmark® T522dn (duplex/network-ready) $1,549 July 2001 25ppm
Lexmark® X522 MFP (print/copy/fax/scan) $3,650 June 2001 24ppm

Cartridge Information
Cartridge Types: Standard Standard High High Yield High Yield MICR
Prebate Yield Prebate (Labels)
Cartridge Part # (OEM): 12A6730 12A6830 12A6735 12A6835 12A6839 STI-204520
MSRP* *$160 $179 $469 $421 $421 $350
Avg. Street Price:* $110 $128 $324 $271 $271 $240
OEM Rated Page Yield: 7,500 7,500 20,000 20,000 20,000 14,000
(@5%)

Model Compatibility
Lexmark® T520 (base) Lexmark® T522 (base) IBM® Infoprint® 1120/1125
Lexmark® T520d (duplex standard) Lexmark® T522n (network-ready) Unisys® UDS-130/UDS-132**
Lexmark® T520n (network-ready) Lexmark® T522dn (duplex/network-ready)
Lexmark® T520dn (duplex/network-ready) Lexmark® X522 MFP
Lexmark® X520 MFP
Prices as of February 2003 **Cartridge components are compatible, cartridges are not

Lexmark® T600 Series

Printer Information
Printer Name: Price Introduced Print Speed
Lexmark® T620 (base) $1,099 June 2001 30ppm
Lexmark® T620n (network-ready) $1,579 June 2001 30ppm
Lexmark® T620dn (duplex/network-ready) $1,939 June 2001 30ppm
Lexmark® T620in (internet-ready/network-ready) $1,699 Aug. 2001 30ppm
Lexmark® X620 MFP (print/copy/scan/fax) $8,710 Summer 2001 30ppm
Lexmark® T622 (base) $1,699 June 2001 40ppm
Lexmark® T622n (network-ready) $2,149 June 2001 40ppm
Lexmark® T622dn (duplex/network-ready) $2,449 June 2001 40ppm
Lexmark® T622in (internet-ready/network-ready) $2,199 Aug. 2001 40ppm

Cartridge Information
Cartridge Types: Standard Standard High High Yield High Yield MICR
Prebate Yield Prebate (Labels)
Cartridge Part # (OEM): 12A6760 12A6860 12A6765 12A6865 12A6869 STI-204070
MSRP: * $242 $192 $521 $471 $471 $350
Avg. Street Price: * $193 $137 $360 $304 $304 $240
OEM Rated Page Yield (@5%): 10,000 10,000 30,000 30,000 30,000 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

SSS™ 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: Price Introduced Print Speed
InfoPrint® 1120 $721 September 2001 20ppm
InfoPrint® 1120d $853 September 2001 20ppm
InfoPrint® 1120n $1,082 June 2001 20ppm
InfoPrint® 1120dn $1,221 June 2001 20ppm
InfoPrint® 1125 $928 June 2001 25ppm
InfoPrint® 1125n $1,340 June 2001 25ppm
InfoPrint® 1125dn $1,599 June 2001 25ppm

Cartridge Information
Cartridge Types: Starter Standard Standard High High Yield MICR MICR
Return Yield Return High Yield
Cartridge Part # (OEM): N/A 28P2491 28P2493 28P2492 28P2494 TBN-920M-I TBN-920MX-I
MSRP:* N/A $192 $144 $373 $325 $N/A N/A
Avg. Street Price:* N/A $175 $136 $325 $300 $299 $375
OEM Rated Page Yield (@5%): 5,000 7,500 7,500 20,000 20,000 7,500 20,000

Model Compatibility
IBM® Infoprint® 1120/1125
Lexmark® T520 (base) Lexmark® T522 (base)
Lexmark® T520d (duplex standard) Lexmark® T522n (network-ready)
Lexmark® T520n (network-ready) Lexmark® T522dn (duplex/network-ready)
Lexmark® T520dn (duplex/network-ready) Lexmark® X522 MFP
Lexmark® X520 MFP Unisys® UDS-130/UDS-132**

Prices as of February 2003 **Cartridge components are compatible, cartridges are not

IBM® InfoPrint® 1130/1140 Series

Printer Information
Printer Name: Price Introduced Print Speed
InfoPrint® 1130 $1,199 July 2001 30ppm
InfoPrint® 1130n $1,697 July 2001 30ppm
InfoPrint® 1130in $1,082 August 2001 30ppm
InfoPrint® 1130dn $1,999 July 2001 30ppm
InfoPrint® 1140 $1,759 July 2001 40ppm
InfoPrint® 1140n $2,217 July 2001 40ppm
InfoPrint® 1140in $2,270 August 2001 40ppm
InfoPrint® 1140dn $2,535 July 2001 40ppm

Cartridge Information
Cartridge Types: Starter Standard Standard High High Yield MICR
Return Yield Return
Cartridge Part # (OEM): N/A 28P2007 28P2009 28P2008 28P2010 TBN-930
MSRP:* N/A $279 $164 $414 $364 $N/A
Avg. Street Price:* N/A $214 $160 $398 $348 $406
OEM Rated Page Yield (@5%): 5,000 10,000 10,000 30,000 30,000 30,000

Model Compatibility
IBM® Infoprint® 1130/1140
Prices as of February 2003
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**

page 4 SSS™ 424

 Lexmark® T520/T522, T620/T622 Remanufacturing Instructions
IBM 1120/1125, 1130/1140
®

Tools and Supplies You Will Need

For Wiper Blade Replacement:

Tools and Supplies • Wiper Blade (blade only) . . . . . . . . . . . . . . . . . . . . .4059BLADE
• Wiper Blade
Items Recommended for Basic Remanufacturing:
(w/PCR Cleaning Assembly) . . . . . . . . . . . .4059BLADE-AS
• Phillips Screwdriver
• Wiper Blade Sealing Strip . . . . . . . . . . . . . . . . .4059WBSSTRIP
• Small Flat-blade Screwdriver
• Wiper Blade Adhesive Strip . . . . . . . . . . . . .(4059WBASTRIP)
• Needlenose Pliers or
• Shallow trough for dipping the wiper blade
Hook Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .HTOOL
• Replacement Instructions . . . . . . . . . . . . . . . . . . . . . . .SSS™ #8
• Ionized Compressed Air for Cleaning . . . . . . . .AIRGUNSET
• 91-99% Isopropyl Alcohol . . . . . . . . . . . . . . . . . . . . . . . .(Below)
For Developer Roller Sealing Blade Replacement:
• Cotton-Tipped Applicator . . . . . . . . . . . . . . . . . . . . . . . . .Q-TIP
• Developer Roller Sealing Blade Kit . . . . . . . . . .4059DRSBKIT
• Lint-free Cleaning Cloth . . . . . . . . . . . . . . . . . . . . . .LFCCLOTH
• Inner Sealing Blade . . . . . . . . . . . . . . . . . . . . . . .4059INSB-TAB
• Felt/Foam Scraper Tool . . . . . . . . . . . . . . . . . . . . . . . . .FSTOOL
• Outer Sealing Blade . . . . . . . . . . . . . . . . . . . . . . . . .4059OUTSB
• Hopper Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4059HJIG
• Replacement Instructions . . . . . . . . . . . . . . . . . . . . . .SSS™ #149
• Odyssey® OPC Drum (with gears) . . . . . . . .OS4059DRG-PNP
• Toner:
For Doctor Bar Replacement:
270g Bottle, T520/T522 . . . . . . . . . . . . . . . . . . . . . .LT520-270B
• Odyssey® Doctor Bar Installation Kit . . . . . . .IBMDBARKIT-4
635g Bottle, T520/T522 . . . . . . . . . . . . . . . . . . . . . .LT520-635B
Contains 1 Seal Strip, Putty
280g Bottle T620/T622 . . . . . . . . . . . . . . . . . . . . . . .LT620-280B
• Odyssey® Doctor Bar w/ Leaf Spring . . .(OSIBMDBAR-4059)
855g Bottle T620/T622 . . . . . . . . . . . . . . . . . . . . . . .LT620-855B
• Replacement Instructions . . . . . . . . . . . . . . . . . . . . . .SSS™ #151
For Recovery Blade Replacement:
• PolyBlade™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PRECB-4059 For more information about other replacement components
• Insertion Tool (PolyBlade™) . . . . . . . . . . . . . . . . . . .RBIKIT-PBL available for these cartridges, contact a member of your
• Mylar-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4059RECBLADE Static Support Team, or visit our Web site at
• Insertion Tool (Mylar) . . . . . . . . . . . . . . . . . . . . . . . . .RBITOOL www.scc-inc.com/imaging/Imaging.htm

Use of Isopropyl Alcohol Use of Compressed Air

For best results, we recommend using ONLY 91-99% for clean-
As of April 28, 1971, the Occupational Safety & Health
ing as directed in these instructions. 91% isopropyl alcohol is
Administration (OSHA) Standard, 29 CFR 1910.242 paragraphs
available at most major drug stores; 99% isopropyl alcohol is
a & b for general industry requires effective chip guarding and
available through distributors of chemical products. Follow
personal protective equipment (PPE) when using compressed
the alcohol manufacturer's safety instructions.
air. When cleaning residual toner particles from cartridges
using a compressed air system, you must use air nozzles meet-
ing 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.

SSS™ 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 Using SCC’s Hook Tool (HTOOL) or a pair of needlenose pliers,
Place the cartridge on your work surface with the top of the car- gently release the hopper tension spring from the post on the
tridge face-down, drum up (FIG 1). opposite side of the cartridge (FIG 3).

Remove
spring from
post

FIG 1 FIG 3

2. Release the hopper tension springs 3. Remove the developer roller drive gear
Using SCC’s Hook Tool (HTOOL) or a pair of needlenose pliers, Using a small flat-blade screwdriver, carefully pry the developer
gently release the hopper tension spring from the post on one roller drive gear away from the cartridge. Remove the gear by
side of the cartridge (FIG 2). 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 SSS™ 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 sec-
tion. 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 hop-
per away from the waste bin until the post is free from the
receptacle (FIG 6).
Flex the drive gear end of the waste
bin away from the hopper
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

Hopper
Stabilizer Post Stabilizer Post
Receptacle Hopper
Stabilizer Post
FIG 7

FIG 5
Separate the two halves of the cartridge.

FIG 6

Disassembly of the Waste Bin

1. Remove the drum Using a flat-blade screwdriver, slide the retaining ring (E-ring)
Position the waste bin section on your work surface with the top off the drum axle on the small helical gear end (FIG 9).
of the waste bin face down, drum up (FIG 8).
Retaining Small Helical
E-ring Gear

FIG 9
FIG 8
Retaining
E-Ring

SSS™ 424 page 7

 Lexmark® T520/T522, T620/T622 Remanufacturing Instructions
IBM 1120/1125, 1130/1140
®

A torsion spring is located on a hub on the large helical gear

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.
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
While supporting the small helical gear end of the drum in one spring out enough to grasp it in your fingers.
hand, remove the drum axle from the large helical gear end of
the drum (FIG 10).
Drum Large Helical
Axle Gear

Twist the spring

while carefully
Remove axle in this pulling it
direction off the hub
FIG 12
FIG 10

Lift the drum by the small helical gear and remove the drum NOTE Take care not to stretch or otherwise distort the tor-
from the waste bin (FIG 11). sion 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.
Recovery
FIG 11 Blade

NOTE For best results, Static Control recommends replacing

the OPC drum after the OEM cycle and after each remanu-
facturing cycle. A replacement drum with gears is available
from Static Control. FIG 13

page 8 SSS™ 424

 Lexmark® T520/T522, T620/T622 Remanufacturing Instructions
IBM 1120/1125, 1130/1140
®

NOTE Once the recovery blade is removed, it should not be NOTE This foam seal must be cut through before removal of
reused. Both mylar (4059RECBLADE) and PolyBlade™ the wiper blade. A small flat-blade screwdriver works well
(PRECB-4059) recovery blades are available from Static for this and poses less risk than using a sharp blade.
Control.

3. Remove the wiper blade and PCR cleaning assembly

Static Control recommends that the wiper blade, with attached Using a small flat-blade screwdriver, cut through the area
PCR cleaning assembly and PCR cleaning felt, be replaced with (foam) where the wiper blade stamping butts against the body
each remanufacturing cycle (FIG 14). of the waste bin (FIG 16).

PCR Cleaning
Wiper Blade
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

FIG 16
NOTE Starter cartridges may not have PCR felts.

Turn the waste bin over. A thin foam seal is attached between
the wiper blade stamping and the plastic waste bin housing NOTE If remanufacturing a second (or subsequent) cycle car-
(FIG 15). tridge, there may be a clear sealing tape over the area of the
foam seal. In this case, the foam has already been cut
Wiper Blade through.
Foam
If tape is present, it should be removed before proceeding.

FIG 15

SSS™ 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 Turn the waste bin on end, and while holding the laser port
not to damage the wiper blade end foams which may be shutter open, remove the wiper blade (FIG 19).
attached at each end of the seal tape (FIG 17).

Remove Wiper Blade

tape

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 SSS™ 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).
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).
With the printed side of the tool up and the brown paper back-
ing 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).
Center the blade
end-to-end

FIG 21

Recovery blade on lip

of the waste bin While holding the blade in place in the tool, carefully peel the
FIG 20 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 Once the brown paper backing has been removed, DO

NOT touch the adhesive.

After making sure the lip of the waste bin is clean, dry and
smooth, secure the waste bin so that both hands are free.

SSS™ 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).
Recovery blade
attached to installation
tool
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).
Remove all
ripples and air
pockets
FIG 24
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 PolyBlade™, use your fingers to carefully
peel the white reinforcement paper from the recovery blade.
page 12 SSS™ 424
2. Install the wiper blade
NOTE A small amount of lubricant applied to the working
edge of the blade will help prevent blade “flip overs” dur-
ing the first drum rotations.
Static Control recommends the use of a system-quali-
fied toner for this purpose, since Kynar lubricating pow-
der (normally recommended for use in Canon® car-
tridges) 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 25
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.
Cartridge
Handle PCR Cleaning
Assembly
Laser port
shutter
Wiper Blade
Stamping FIG 26
 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 damp-
ened with 91-99% isopropyl alcohol, clean the base of the wiper Use your finger to smooth out any air bubbles or wrinkles in the
blade and the area of the waste bin housing (FIG 28). 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 NOTE Do not place the seal strip over the laser port shutter.
leakage.

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.

SSS™ 424 page 13

 Lexmark® T520/T522, T620/T622 Remanufacturing Instructions
IBM 1120/1125, 1130/1140
®

4. Replace the drum While supporting the drum with one hand, insert the drum axle.
Static Control recommends replacing the OPC drum after the Carefully slide it in along the entire length of the drum (FIG 33).
OEM and each remanufacturing cycle.
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 replace-
Hook toward ment retaining ring is available from Static Control.
the outside
FIG 31
Retaining
Ring

NOTE To prevent damage to the drum electrical contact

(installed in the small helical gear) always install the drum Notch
axle through the small helical gear end of the drum.

FIG 34

5. Rotate the drum

Rotating the drum will help lubricate the wiper blade and pre-
Place the drum in the waste bin section with the small helical vent blade “flip overs”. The toner removed from the drum by
gear at the non-contact end of the waste bin (FIG 32). the wiper blade will fall into the waste bin.
Small Helical
Gear Rotate the drum at least six full rotations in its normal operat-
ing direction (FIG 35).

FIG 32

FIG 35

page 14 SSS™ 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.
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.

Using a small flat-blade screwdriver, pry the encoder wheel off Doctor Bar
from the base of the wheel (FIG 36). Place the encoder wheel in Leaf Spring
an area where it is protected from impact damage.

Up nly
Side
ce
Air Ois Surfa
sed
This pres On Th
Com ids
With Use Liqu
Clean h Or
Touc
D o Not

Leaf Spring
Feet FIG 38

FIG 36
NOTE 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
NOTE To avoid damaging the encoder wheel (warp, crack installed position.
or break), do not pull on its edges to remove it from the
hopper.

3. Remove the doctor bar

2. Remove the doctor bar leaf spring The amount of doctor bar putty used is critical. Too little and
Using needlenose pliers, remove the plastic doctor bar end toner leakage will result. Too much and it will work its way
blocks (if present) located on each end of the leaf spring (FIG 37). behind the doctor bar onto the developer roller, damaging both
and causing print defects.
Doctor Bar
End Blocks 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.

Sid e seUdpAir OisnlySurface

Thitis pres On Th
Com ids
W h Use Liqu
Clean h Or
ot Touc
Do N

Doctor
Leaf Bar
Spring Developer
Roller FIG 37 Up Only ce
Sidessed Air is Surfa
ThithisCompLiqreuids On Th
nW
Clea h Or Us
e
t Touc
Do No

Remove the putty

from each end of
NOTE ALWAYS remove the doctor bar and leaf spring the doctor bar
before removing the developer roller. FIG 39

SSS™ 424 page 15

 Lexmark® T520/T522, T620/T622 Remanufacturing Instructions
IBM 1120/1125, 1130/1140
®

Carefully remove the doctor bar from the hopper by lifting it

NOTE The use of too much doctor bar putty is a common straight up and out (FIG 42).
cause of doctor bar and developer roller contamination and
resulting failures in remanufactured cartridges. Remember
HINT: If not wearing gloves, a strip of tape placed on the doctor
to notice how much putty you remove. Do not reuse what is
bar will act as a “handle” and help you to avoid touching the
removed - it is already contaminated with toner.
developer roller with your bare fingers.

Using the felt/foam scraper tool, peel up one end of the doctor
bar sealing strip (FIG 40).

p ly ce
e U Air On Surfa
SidpressedOn This
ThithisCoemLiquids
n W Us
Cleauch Or
To
Not
Do

Up r Only rface
Side sed Ai This Su
ThithisComLiprquesids On
nW e
Cleauch Or Us
t To
Do No

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).
4. Remove the developer roller

Sid e seUdpAir OisnlySurface

Thitis pres On Th

D
Clean
o Not
To uc h Or
Com ids
W h Use Liqu
NOTE 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

NOTEThe doctor bar may need to be held in place while Electrical

removing the sealing strip. Contact
Bushing
FIG 43

page 16 SSS™ 424

 Lexmark® T520/T522, T620/T622 Remanufacturing Instructions
IBM 1120/1125, 1130/1140
®

While handling only the developer roller shaft, carefully move Remove any conductive grease from the developer roller shaft
the end of the developer roller forward and away from the using a lint-free cloth or cotton-tipped swab dampened with 91-
hopper (FIG 44). 99% isopropyl alcohol (FIG 47).

Developer
Roller
Developer Roller FIG 47
Shaft
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
NOTE Do not apply alcohol to any part of the developer roller
other than the shaft.
shaft on the geared side until your finger is flush with the car-
tridge housing and remove the developer roller from the hopper
section (FIG 45).

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
Do not
damage
latching
Remove the plastic washers from each end of the developer clips
roller (FIG 46). 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

SSS™ 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
FIG 49 Blade
Inner Sealing
Blade with Tabs
& Caulk FIG 51
6. Clean the toner hopper
Dump any remaining toner from the hopper and clean the
hopper with ionized, dry, filtered, compressed air.

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.
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).
NOTE 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 develop-
er blades only when they are damaged or are loose
(4059INSB/4059OUTSB).

Toner Adder Gasket

Roller Seal
Gasket If the inner and outer developer roller sealing blades need to be
Seal replaced, refer to System Support Series™ 149, “How to install
your 4059 Developer Roller Sealing Blades”.

If the sealing blades do not need replacing at this time, carefully

Outer
Sealing clean them using ionized, dry, filtered, compressed air.
Inner Sealing Blade
Blade with
Tabs & Caulk FIG 50

NOTE Be careful not to touch the toner adder roller or the

developer roller sealing blades with the air gun nozzle.

SSS™ 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

11. Clean the developer roller

FIG 52
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% iso-
propyl alcohol, clean the developer roller contact on the car-
tridge (FIG 53).

Developer
Roller
Electrical
Contact

FIG 56

FIG 53
NOTE Oils from your skin will adhere to the developer roller
surface, resulting in print defects. Do not touch the surface of
10. Clean the doctor bar support areas the developer roller with your bare skin, and take care not to
Using 91%-99% isopropyl alcohol and a cotton-tipped applicator, nick the surface of the roller with the air gun.
remove any toner and/or putty from the slots (both ends of car-
tridge) where the doctor bar will rest (FIG 54 & 55).

FIG 54

SSS™ 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 the contact end of the developer roller (FIG 59). Make
Install one plastic washer on each end of the developer roller sure the plastic washer fits inside the cartridge housing.
shaft (FIG 57). If lost or damaged, replacement washers can be
obtained from Static Control (IBMWASHER).

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
Developer
not help reduce toner leakage, and may actually contribute
Roller
to other print defects.

2. Install the developer roller

Insert the keyed end of the developer roller shaft into the non- This
Side
Up
ressedOn Thi
Comp uids
With e Liq
Cleanch Or Us
t Tou
ly
Air Ons Surfa
ce

Do No

contact end of the hopper (FIG 58).

Electrical
Contact
Bushing
FIG 60

3. Install the doctor bar

Insert the keyed end of the
shaft into the non-contact end
of the cartridge
FIG 58
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 SSS™ 424

 Lexmark® T520/T522, T620/T622 Remanufacturing Instructions
IBM 1120/1125, 1130/1140
®

For initial installations, Static Control’s Odyssey® Doctor Bar Carefully place the Odyssey® Doctor Bar into the slots where it
should be installed with the printed side facing the outside of will rest. Unless flipping the bar for a second cycle, the doctor
the hopper (FIG 61). The working surface of the bar must face bar should be installed with the printed side up [see note print-
the developer roller. ed on bar] (FIG 63).
Installation
Slots

p
S ide U ir On
ly
Up
TChoismpressseOdnAThis Surfa
ce nly
Side
ce
Air Ois Surfa
sed
n With Liquid This pres On Th
Com ids
Clea uch Or Use With Use Liqu
To Cleanuc h Or
Do Not o Not
To
D

Working edge Doctor

of doctor bar Bar

FIG 61 FIG 63

Clean the doctor bar sealing strip mounting surface (the lip of
NOTE Always wear gloves when working with the Odyssey® the hopper and the top edge of the doctor bar) with 91%-99%
Doctor Bar, and take care not to damage the working edge isopropyl alcohol and a cotton-tipped applicator (FIG 64). Allow
of the bar. the alcohol to dry completely.
Cotton
Lip of the Swab
hopper

If remanufacturing a cartridge with an Odyssey® Doctor Bar Top edge of

already installed, the bar can be re-used one time. Simply turn the doctor bar
the bar end-to-end for a second cycle (FIG 62). DO NOT flip top-
to-bottom. The working surface of the bar must face the
developer roller.

Up Only rface
Sidessed AirThis Su
Worn side of doctor bar n
ThitihsComLpiqreuids On
W s e
FIG 64
Clea h Or U

This Side Up
Clean With Compressed Air Only
Do Not Touch Or Use Liquids On This Surface

NOTE DO NOT saturate the cotton on the applicator. Excess

alcohol can run down the back side of the bar, into the toner.
Working Unused side of doctor bar
edge of (install with unprinted side facing you)
doctor bar
FIG 62

NOTE Be extremely careful not to damage the developer

roller while removing or installing the doctor bar.

SSS™ 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).
Exposed
Adhesive
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.
Using a flat-head screwdriver, peel up one corner of the white
reinforcement paper (FIG 68).

White Paper
Reinforcement

Brown
Backing
FIG 65

Up Only ce
Side sed Air is Surfa
Place the end of the sealing strip flush with the end of the doc- ThithisComLiprquesids On Th
nW
Clea h Or Us
t Touc
e

Do No

tor 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
Sealing Flush against the
Strip Up Only rface hopper White Paper
Side sed Air his Su
ThitihsComLpiqreuids On
s T

nW
Cleauch Or U
se
Reinforcement
ot To
Do N
FIG 66

Up Only ce
Side sed Air is Surfa
ThithisComLiprquesids On Th
nW e
Clea h Or Us
t Touc
Carefully press the strip into place, peeling the backing off slow- Do No

ly as you progress. You may want to use your felt/foam scraper

FIG 69
tool to press the strip into place, smoothing out any wrinkles
and air pockets (FIG 67).

Sealing Strip Felt/Foam NOTE DO NOT seal the ends of the doctor bar with rigid
Scraper Tool caulking or glue. This can change or eliminate the down-
force exerted on the doctor bar by the leaf spring, trans-
forming the bar into a “fixed” rather than a “spring-loaded”
Up nly
doctor bar.
Side ir O urface
ed A is S
This ress n Th
omp ids O
ith Cse Liqu
nW
Cleauch Or U
To
Do Not

Brown Backing NOTE 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.
FIG 67

page 22 SSS™ 424

 Lexmark® T520/T522, T620/T622 Remanufacturing Instructions
IBM 1120/1125, 1130/1140
®

After insuring that all toner has been removed from the corners, While holding one end of the leaf spring in each hand, insert the
apply a small amount of fresh doctor bar putty (approximately center bend into the plastic seat on the hopper (FIG 72).
the same amount you removed at the beginning of the instruc-
tions) in each corner at the end of the doctor bar to complete Center bend
the seal. Use a small flat-head screwdriver or felt/foam scraper positioned in
tool to press the putty in place where the bar and hopper meet plastic seat
(FIG 70).

Replace
putty in
each corner

Up Only ace FIG 72

Side sed Air is Surf
ThithisComLiprquesids On Th
nW se
Clea h Or U
uc
ot To
Do N

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 num-
ber 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-
Push up on the ends of
ment doctor bars are stamped with either “T5” (T520/522, the spring until they
1120/1125) or “T6” (T620/622, 1130/1140) (FIG 71). seat on top of the
doctor bar FIG 73

Identification
Marks T6
5T6
9V

T5
SCC Replacement
59
VT5
T620/T622, 1130/1140
SCC Replacement Leaf Spring
T520/T522, 1120/1125
Leaf Spring FIG 71

SSS™ 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 NOTE Over-filling the toner hopper will flood the develop-
hopper (FIG 74). To make filling easier, Static Control recom- ment station, defeating this system. Use only the amount of
mends using a funnel attachment on the toner bottle. 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 latch-
ing 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 FIG 76
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 sys-
tem prevents excess toner from flowing over the wall and
flooding the development station, insuring that the maxi-
mum toner load for the desired page yield is maintained,
avoiding a number of potential print defects (FIG 75). 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.

Standard and High-Yield Prebate/Return Program cartridge

Toner Reservoir
Development wheels are black and have the code 12A0110 stamped on their
(Hopper)
Toner Station surface. Standard and High-Yield Non-Prebate/Non-Return
Metering Bar Program cartridge wheels are white and are stamped with
Arm 12A0601 (FIG 77).
Paddle
Prebate/Return Program Non-Prebate/non-Return
wheel Program wheel
Toner
Level Wall

FIG 75

FIG 77

page 24 SSS™ 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, With one hand, hold the spring-loaded gear in place. With the
there is a spring-loaded gear that resembles the “Pacman” char- other hand, press down on the center of the wheel until it is fully
acter, which is another part of the cartridge’s toner sensing sys- secured on the axle (FIG 80).
tem (FIG 78). This gear can pop out of alignment if not held in
place on the shaft when the encoder wheel is installed, resulting Press on the center of
in either a “toner sensor” error message or a “32 Unsupported the wheel
Print Cartridge” error message.

Encoder
Spring Loaded Wheel / Toner
“Pacman” Gear 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 car-
tridge (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 Toner Agitator

Paddle Axle
Wheel

Wheel
Base
FIG 79

SSS™ 424 page 25

 Lexmark® T520/T522, T620/T622 Remanufacturing Instructions
IBM 1120/1125, 1130/1140
®

Reassembly of the Cartridge

1. Reassemble the sections 2. Install the hopper tension springs
Position the waste bin section on your work surface with the Using Static Control’s Hook Tool (HTOOL) or a pair of
drum face up (FIG 81). needlenose pliers, attach the tension springs to the spring posts
on each end of the cartridge (FIG 84).

Spring
Post

FIG 81 FIG 84

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).

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 avail-
able 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 3. Install the drive gear
receptacle in the waste bin (FIG 83). Install the developer roller drive gear on the end of the develop-
er roller shaft (FIG 85).

Developer Roller
Drive Gear

FIG 83

FIG 85

page 26 SSS™ 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 Shipping lock in

The design of the hopper and waste bin sections allows the place
potential for impact damage to the OPC drum and developer
roller anytime the cartridge is being moved, and especially dur-
ing shipping. This damage can result in print defects. OEM car-
tridges come with a shipping lock, which creates a separation
between the developer roller and OPC drum so that these com-
ponents are not in contact during shipping. Static Control offers
an OEM-type shipping lock that installs easily on remanufac-
tured cartridges (FIG 87), with an instruction card that prompts
the end-user to remove the lock before installing the unit in the
printer (4059SLOCK). FIG 87

SSS™ 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 keep-
ing up with your competition, but surpassing them. That is why we invest so much time and effort in the technology neces-
sary 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 cus-
tomer, 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 Static Control Components (Europe) Limited
3010 Lee Avenue • PO Box 152 • Sanford, NC 27331 Unit 30, Worton Drive
US/Can 800.488.2426 • US/Can Fax 800.488.2452 Reading • Berkshire RG2 OTG • United Kingdom
Int’l 919.774.3808 • Int’l Fax 919.774.1287 Tel +44 (0) 118.923.8800 • Fax +44 (0) 118.923.8811
www.scc-inc.com/imaging/Imaging.htm 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.