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Version 1 11/03

Lexmark T520, T620, T630, T640 Series Printers
Remanufacturing Instructions
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 targeted 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 network-ready models
with duplex units standard. 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. Printers:
The Lexmark T630 family of monochrome
laser printers were released in April 2003 as
replacements for the T520 and & T620 series
(Summer 2001). Priced from $679 to $1,400 for
base models, the T630's print speeds ranged
from 35ppm (T630) to 45ppm (T634).
Multifunction versions were also available start-
ing at $2,750.
The T520 and T522 models were replaced by
the T630, with the T632 replacing the T620. The
T634 replaced the T622.
Lexmark T630/632/634
The T630, 632 and 634 printers all use the
same standard (5,000-page) and high-yield
(21,000- page) cartridges. An extra high-yield
(32,000-page) version is available for use in the
T632 and 634 only, with compatibility notches
preventing its use in the T630 printers. All of the
cartridges are chipped, and only one cartridge
version has been seen to date.
The cartridges present no new technology,
with nearly all the internal components being
borrowed from earlier models. Externally the
cartridges differ from their predecessors in the
placement of compatibility recesses, which pre-
vent the units from being usable in the previous
model printers.
Static Control has determined that Optra S,
Se and T cores can be successfully converted
into T630, 632 and 634 cartridges, and has devel-
oped a conversion kit for doing so.
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
Lexmarks, in nearly twin cartridges.
Cartridge Reference
System Support Series 424
Table of Contents
About the Printers Cartridges . . . . .1
Cartridge Page . . . . . . . . . . . . . . . . .3-4
Printer and Cartridge Info . . . . . .5-9
Tools & Supplies You Will Need . . .10
Compressed Air, Use of . . . . . . . . .10
Isopropyl Alcohol, Use of . . . . . . . .10
Old Style Hopper Wireline . . . . . . .11
Waste Bin Wireline . . . . . . . . . . . . . .12
New Style Hopper Wireline . . . . . . .13
Cartridge, Separation of . . . . . .14-15
Waste Bin, Disassembly of . . . .15-18
Waste Bin, Reassembly of . . . . .19-22
Toner Hopper, Disassembly of .23-28
Toner Hopper Reassembly of . .29-33
Filling the Hopper . . . . . . . . . . . .34-35
Cartridge, Reassembly of . . . . .36-37
Safeguarding Your Cartridges . . .37
www.scc-inc.com/imaging/Imaging.htm
Get the latest information
on the web at Static Controls
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 (Intl)
+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 7
July 2007
Lexmark T520, T620, T630, T640 Remanufacturing Instructions

Important: ONLY for use on:

1) Non-Prebate (Regular) cartridges (any brand).
2) IBM Return Program (Prebate) cartridges.

page 2 SSS424
Lexmark T520, T620, T630, T640 Remanufacturing Instructions

Lexmark T520/T620/T630/T640 series Cartridge Page

T520 T620

Available in Old and New Style Available in Old and New Style
Yield: Low Yield-7,500 High Yield-20,000 Yield: Low Yield-10,000 High Yield-30,000

T630

One notch

Available in Old and New Style Extra High Yield T632/T634

Yield: Low Yield-5,000 High Yield-21,000 Yield: 32,000

T640
One notch

Extra High Yield T644

Available in New Style only
Yield: 32,000
Yield: Low Yield-6,000 High Yield-21,000

page 3 SSS 424

Lexmark T520, T620, T630, T640 Remanufacturing Instructions

Determining Old Style versus New Style Hoppers

Old Style
Ridge

New Style
Cartridge has a smooth bottom

Old Style New Style

Held in with White
Putty Retaining Tabs

T640 New Style

Developer Roller Cover

page 4 SSS 424

 Lexmark T520, T620, T630, T640 Remanufacturing Instructions

Lexmark Printer and Cartridge Information

Lexmark T520 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
Prebate Yield Prebate (Labels)
Cartridge Part # (OEM): 12A6730 12A6830 12A6735 12A6835 12A6839
MSRP* *$160 $179 $469 $421 $421
Avg. Street Price:* $110 $128 $324 $271 $271
OEM Rated Page Yield: 7,500 7,500 20,000 20,000 20,000
(@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 December 2005 **Cartridge components are compatible, cartridges are not

Lexmark T620 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
Prebate Yield Prebate (Labels)
Cartridge Part # (OEM): 12A6760 12A6860 12A6765 12A6865 12A6869
MSRP: * $242 $192 $521 $471 $471
Avg. Street Price: * $193 $137 $360 $304 $304
OEM Rated Page Yield (@5%): 10,000 10,000 30,000 30,000 30,000

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 December 2005
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 5

Lexmark T520, T620, T630, T640 Remanufacturing Instructions

Lexmark Printer and Cartridge Information

Lexmark T630 Series
Printer Information
Printer Name: Price Introduced Print Speed
Lexmark T630 (base) $769 April 2003 35ppm
Lexmark T630n (network-ready) $1,119 April 2003 35ppm
Lexmark T632 (base) $1059 April 2003 40ppm
Lexmark T632n $1,539 April 2003 40ppm
Lexmark T634 (base) $1,489 June 2003 45ppm
Lexmark T632n $1,879 June 2003 45ppm

Cartridge Information (T630)

Cartridge Types: Standard Standard High High Yield High Yield
Prebate Yield Prebate (Labels)
Cartridge Part # (OEM): 12A7360 12A7460 12A7362 12A7462 12A7468
MSRP* *$165 $115 $380 $330 $330
Avg. Street Price:* N/A $96 $329 $288 $268
OEM Rated Page Yield: 5,000 5,000 21,000 21,000 21,000
(@5%)

Model Compatibility
Lexmark T630/T630n/T630dn
Lexmark T632/T632n/T632tn/T632dtn/T632dtnf
Lexmark T634/T634n/T634tn/T634dtn/T634dtnf
Lexmark X630 MFP
Lexmark X632 MFP
Lexmark X632e MFP
Prices as of December 2005 **Cartridge components are compatible, cartridges are not

Important: ONLY for use on:

1) Non-Prebate (Regular) cartridges (any brand).
2) IBM Return Program (Prebate) cartridges.

page 6 SSS 424

 Lexmark T520, T620, T630, T640 Remanufacturing Instructions

Lexmark Printer and Cartridge Information

Lexmark T640 Series
Printer Information
Printer Name: Price Introduced Print Speed
Lexmark T640 (base) $699 June 2005 35ppm
Lexmark T640n (network-ready) $1,049 June 2005 35ppm
Lexmark T640tn $1,299 June 2005 35ppm
Lexmark T640dtn $1,329 June 2005 35ppm
Lexmark T640dtn $1,329 June 2005 35ppm
Lexmark T642 (base) $799 June 2005 45ppm
Lexmark T642n (network-ready) $1,149 June 2005 45ppm
Lexmark T642tn $1,399 June 2005 45ppm
Lexmark T642dtn n/a June 2005 45ppm
Lexmark T642dtnf $1,549 June 2005 45ppm
Lexmark T644 (base) $1,059 June 2005 50ppm
Lexmark T644n (network-ready) $1,539 June 2005 50ppm
Lexmark T644tn $1,779 June 2005 50ppm
Lexmark T644dtn $2,039 June 2005 50ppm
Lexmark T644dtnf $2,449 June 2005 50ppm

Cartridge Information
Cartridge Types: Standard Standard High High Yield High Yield Extra High
Prebate Yield Prebate (Labels) Yield (non-
retun)
Cartridge Part # (OEM): 64035SA 364015SA 64035HA 64015HA 64004HA
MSRP* *$185 $135 $380 $330 $330
OEM Rated Page Yield: 6,000 6,000 21,000 21,000 21,000
Cartridge Types Standard Standard High-Yield High-Yield Extra High Yield Extra High
(non-retun) (return) (non-return) (return) (return) Yield (non-
retun)
Cartridge Part # (OEM): 64035SA 64015SA 64035HA 64015HA 64415XA 64435XA
MSRP* *$185 $135 $380 $330 $355 $405
OEM Rated Page Yield: 6,000 6,000 21,000 21,000 32,000 32,000
Cartridge Types: Standard Standard High High Yield High Yield
Prebate Yield Prebate (Labels)
Cartridge Part # (OEM): 64035SA 64015SA 64035HA 64015HA 640004HA
MSRP* *$185 $135 $380 $330 $330
OEM Rated Page Yield: 6,000 6,000 21,000 21,000 21,000
(@5%)

Model Compatibility
Lexmark T640 series printers
Lexmark T642 series printers
Lexmark T644 series printers
IBM InfoPrint 1532 series printers
IBM InfoPrint 1552 series printers
IBM InfoPrint 1572 series printers
Prices as of December 2005 **Cartridge components are compatible, cartridges are not

Important: ONLY for use on:

1) Non-Prebate (Regular) cartridges (any brand).
2) IBM Return Program (Prebate) cartridges.

page 7 SSS 424

Lexmark T520, T620, T630, T640 Remanufacturing Instructions

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
Return Yield Return
Cartridge Part # (OEM): N/A 28P2491 28P2493 28P2492 28P2494
MSRP:* N/A $192 $144 $373 $325
Avg. Street Price:* N/A $175 $136 $325 $300
OEM Rated Page Yield (@5%): 5,000 7,500 7,500 20,000 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 December 2005 **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
Return Yield Return
Cartridge Part # (OEM): N/A 28P2007 28P2009 28P2008 28P2010
MSRP:* N/A $279 $164 $414 $364
Avg. Street Price:* N/A $214 $160 $398 $348
OEM Rated Page Yield (@5%): 5,000 10,000 10,000 30,000 30,000

Model Compatibility
IBM Infoprint 1130/1140
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)
Lexmark T622 (base)
Lexmark T622n (network-ready)
Lexmark T622dn (duplex/network-ready)
Lexmark T622in (internet-ready/network-ready)
Unisys UDS-134/UDS136**

Prices as of December 2005 **Cartridge components are compatible, cartridges are not

SSS 424 page 8

 Lexmark Lexmark T520, T620, T630, T640 Remanufacturing Instructions

IBM Printer and Cartridge Information

IBM InfoPrint 1532/1552/1572 Series

Printer Information
Printer Name: Price Introduced Print Speed
InfoPrint 1532 $1,132 July 2005 35ppm
InfoPrint 1552 $871 July 2005 45ppm
InfoPrint 1552n $871 July 2005 50ppm
InfoPrint 1572 $1,348 July 2005 n/a

Cartridge Information
Cartridge Types: Standard Standard High High Yield
Return Yield Return
Cartridge Part # (OEM): 75P6958 75P6959 75P6960 75P6961
MSRP:* $190 $128 $383 $320
OEM Rated Page Yield (@5%): 6,000 6,000 21,000 21,000

Model Compatibility
IBM Infoprint 1532/1552/1572
Lexmark T640 series printers
Lexmark T642 series printers
Lexmark T644 series printers
IBM InfoPrint 1532 series printers
IBM InfoPrint 1552 series printers
IBM InfoPrint 1572 series printers

Prices as of June 2005 **Cartridge components are compatible, cartridges are not

page 9 SSS 424

Lexmark T520, T620, T630, T640 Remanufacturing Instructions
Tools and Supplies You Will Use
Tools and Supplies
Items Recommended for Basic Remanufacturing:
Phillips Screwdriver
Small Flat-blade Screwdriver
Needlenose Pliers or
Hook Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .HTOOL
Ionized Compressed Air for Cleaning . . . . . . . .AIRGUNSET
91-99% Isopropyl Alcohol . . . . . . . . . . . . . . . . . . . . . . . . .(Below)
Cotton-Tipped Applicator . . . . . . . . . . . . . . . . . . . . . . . . . .Q-TIP
Sealing Wax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CSEALANT
Lint-free Cleaning Cloth . . . . . . . . . . . . . . . . . . . . . . .LFCCLOTH
Felt/Foam Scraper Tool . . . . . . . . . . . . . . . . . . . . . . . . . .FSTOOL
Hopper Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4059HJIG
Odyssey OPC Drum (with gears) . . . . . . .OS4059DRGR-PNP
Toner:
270g Bottle, T520/T522 . . . . . . . . . . . . . . . . . . . . . . .LT520-270B
635g Bottle, T520/T522 . . . . . . . . . . . . . . . . . . . . . . .LT520-635B
280g Bottle T620/T622 . . . . . . . . . . . . . . . . . . . . . . . .LT620-280B
855g Bottle T620/T622 . . . . . . . . . . . . . . . . . . . . . . . .LT620-855B
490g Bottle T630/632/634 . . . . . . . . . . . . . . . . .LT630-490B-OS
715g Bottle T630/632/634 . . . . . . . . . . . . . . . . .LT630-715B-OS
T640 Bottle T640/642/644 . . . . . . . . . . . . . . . . .LT640-600B-OS
T640 Bottle T640/642/644 . . . . . . . . . . . . . . . .LT640-900B-OS
For Doctor Bar and Leaf Spring Replacement
Doctor Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OSLEXDBAR*
Use of Isopropyl Alcohol
For best results, we recommend using ONLY 91-99% for clean-
ing as directed in these instructions. 91% isopropyl alcohol is
available at most major drug stores; 99% isopropyl alcohol is
available through distributors of chemical products. Follow
the alcohol manufacturer's safety instructions.
page 10 SSS 424
Leaf Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OPTTDBARSPG*
*Not qualified for use in LT640/642/644
For Recovery Blade Replacement:
PolyBlade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PRECB-4059
Insertion Tool (PolyBlade) . . . . . . . . . . . . . . . . . . . .RBIKIT-PBL
Mylar-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4059RECBLADE
Insertion Tool (Mylar) . . . . . . . . . . . . . . . . . . . . . . . . . . .RBITOOL
For Wiper Blade Replacement:
Wiper Blade (blade only) . . . . . . . . . . . . . . . . . . . . . . .4059BLADE
Wiper Blade
(w/PCR Cleaning Assembly) . . . . . . . . . . . . .4059BLADE-AS
Wiper Blade Sealing Strip . . . . . . . . . . . . . . . . . .4059WBSSTRIP
Shallow trough for dipping the wiper blade
Replacement Instructions . . . . . . . . . . . . . . . . . . . . . . . . .SSS #8
For Developer Roller Sealing Blade Replacement:
Developer Roller Sealing Blade Kit . . . . . . . . . . .4059DRSBKIT
Inner Sealing Blade . . . . . . . . . . . . . . . . . . . . . . . .4059INSB-TAB
Outer Sealing Blade . . . . . . . . . . . . . . . . . . . . . . . . . .4059OUTSB
Replacement Instructions . . . . . . . . . . . . . . . . . . . . . . .SSS #149
New Style Sealing Blade . . . . . . . . . . . . . . . . . .4059DRSBLD-NS
For more information about other replacement components
available for these cartridges, contact a member of your
Static Support Team, or visit our Web site at
www.scc-inc.com/imaging/Imaging.htm
Use of Compressed Air
As of April 28, 1971, the Occupational Safety & Health
Administration (OSHA) Standard, 29 CFR 1910.242 paragraphs
a & b for general industry requires effective chip guarding and
personal protective equipment (PPE) when using compressed
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.
product wirelines Lexmark T520, T620, T630
Old Style

Doctor Bar Leaf Spring Toner Reservoir

OPTTDBARSPG

Doctor Bar
OSLEXDBAR

Doctor Bar Seal Strip

Toner Paddle Encoder Wheel IBMDBSTRIP
Doctor Bar End Block

Toner Fill Hole

Doctor Bar Putty(Not Shown)
IBMDBARPUTTY

Developer Roller
Drive Gear

Toner Hopper End Plate Assembly

Toner Hopper Cap

Developer Roller End Seal

Doctor Bar End Block Toner Adder Roller

Inner Sealing Blade

Inner Sealing Blade w/Tab
4059INSB-TAB
Toner Adder Roller Electrical Contact
Outer Sealing Blade
4059OUTSB

Developer Roller Electrical Contact Doctor Bar Electrical Contact Developer Roller Teflon Washer
IBMWASHER

Developer Roller

Developer Roller Teflon Washer

IBMWASHER
Developer Roller Shaft Contact Bushing

Toner
p r o d u c tHopper
w i r e l i n e Assembly
s

SSS 424 page 11

Lexmark T520, T620, T630 product wirelines

Drum Electrical Contact

OPC Drum Drum Small Helical Gear
Odyssey 4059 Drum/Gears-Paper - No Powder
OS4059DRGR-PNP
Drum Large Helical Gear Torsion Spring
4059GTSPRING

Drum Large Helical Gear PCR Cleaning Assembly Base

Hopper Tension Spring

4059HTS
Felt Support Blade

4059 Wiper Blade

4059BLADE-AS (With PCR Cleaning Assembly)
4059BLADE (Wiper Blade Only)
Wiper Blade Sealing Strip (Not Shown)
4059WBSSTRIP

Recovery Blade
PRECB-4059 (PolyBlade)
4059RECBLADE (Mylar)

Drum Axle Retaining Ring Drum Axle Retaining Ring

4059DRAXRING 4059DRAXRING

Drum Axle
Hopper Tension Spring
Chip 4059HTS Wiper Blade End Foam
4059WBEFOAM

Laser Port Shutter

Waste Bin Top Side View

Waste
p r o d u c t Bin
w i r eAssembly
lines
Laser Port Shutter Spring
4059LSSPRING

page 12 SSS 424

Lexmark T520, T620, T630, T640
product wirelines
New Style Toner Reservoir Lexmark T620/622 Toner, 280g Bottle
Lexmark T520/522 Toner, 270g Bottle LT620-280B
LT520-270B Lexmark T620/622 Toner, 855g Bottle
Lexmark T520/522 Toner, 635g Bottle LT620-855B
LT520-635B Lexmark T620/622 SecureRite MICR
Lexmark T520/522 SecureRITE MICR Toner, 640g Bottle
Toner, 635g Bottle LT620-640-MICR
LT520-635B-MICR
Doctor Bar
OSLEXDBAR

Doctor Bar Sealing Foam

4059DBARSFM-NS Hopper Vent Label

Toner Paddle Encoder Wheel

Toner Fill Hole

Doctor Bar Retaining Tab

Toner Hopper Cap

WXHCAP

Developer Roller Drive Gear

Toner Hopper End

Plate Assembly
Developer Roller
End Seal

Toner Adder Roller

Doctor Bar Retaining Tab
Sealing Blade Support

Toner Adder Roller Electrical Contact

Leaf Spring
OPTTDBARSPG
Developer Roller Electrical Contact
Doctor Bar Leaf Spring
Position Tab
Doctor Bar Electrical Contact OPTMSPRGTAB

Developer Roller Sealing Blade

4059DRSB-NS

Developer Roller Teflon Washer

Developer Roller Cover IBMWASHER
(Present in T640 Series only)

Developer Roller
Developer Roller Shaft
Contact Bushing

Developer Roller Teflon Washer

IBMWASHER

Toner Hopper Assembly

product wirelines
page 13 SSS 424
 Lexmark T520, T620, T630, T640 Remanufacturing Instructions

Separation of the Cartridge

The steps for remanufacturing both Lexmark and IBM cartridges are the same. The Lexmark T520 model is shown in all
photos.

1. Position the cartridge Using SCCs 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 SCCs 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 14 SSS 424

 Lexmark T520, T620, T630, T640 Remanufacturing Instructions

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 15

Lexmark T520, T620, T630, T640 Remanufacturing Instructions

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 16 SSS 424

 Lexmark T520, T620, T630, T640 Remanufacturing Instructions

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.

Using a small flat-blade screwdriver, cut through the area

(foam) where the wiper blade stamping butts against the body
3. Remove the wiper blade and PCR cleaning assembly
of the waste bin (FIG 16).
Static Control recommends that the wiper blade, with attached
PCR cleaning assembly and PCR cleaning felt, be replaced with
each remanufacturing cycle (FIG 14).

PCR Cleaning CAUTION If using an instrument with a sharp blade, use

Wiper Blade extreme care. Severe injury may result from misuse.
Assembly Base

PCR Cleaning
Felt
Wiper Blade
Stamping
FIG 14

FIG 16

NOTE Starter cartridges may not have PCR felts. A T640

cartridge will not have PCR felts.

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

FIG 15

SSS 424 page 17

Lexmark T520, T620, T630, T640 Remanufacturing Instructions

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

NOTE The Wiper Blade End Foams may be pulled from the
Waste Bin with the removal of the Wiper Blade.

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).

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.

Remove two
Phillips screws FIG 18

page 18 SSS 424

 Lexmark T520, T620, T630, T640 Remanufacturing Instructions

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 19

Lexmark T520, T620, T630, T640 Remanufacturing Instructions

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
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 working edge of the blade in a long, shallow trough con-
taining only toner system-qualified for use in the cartridge you
are remanufacturing (FIG 25). Repeat once to insure even
coverage.

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). FIG 25

Remove all
ripples and air NOTE Use only toner qualified for use in the cartridge you
pockets 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.

FIG 24 Cartridge
Handle Laser port PCR Cleaning
shutter Assembly

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 Wiper Blade
peel the white reinforcement paper from the recovery blade. Stamping FIG 26

page 20 SSS 424

 Lexmark T520, T620, T630, T640 Remanufacturing Instructions

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 21

 Lexmark T520, T620, T630, T640 Remanufacturing Instructions

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 (4059GTSPRING) 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
axle through the small helical gear end of the drum.

Place the drum in the waste bin section with the small helical
Notch
gear at the non-contact end of the waste bin (FIG 32).

Small Helical
FIG 34
Gear
5. Rotate the drum
Rotating the drum will help lubricate the wiper blade and pre-
vent blade flip overs. The toner removed from the drum by
the wiper blade will fall into the waste bin.

Rotate the drum at least six full rotations in its normal operat-
ing direction (FIG 35).

FIG 32

NOTE Drum Axle will build-up Oxidation, and need to be

cleaned. Clean the Drum Axle using an emory cloth or
steel wool and be sure that all the Oxidation is removed.

FIG 35

page 22 SSS 424

 Lexmark T520, T620, T630, T640 Remanufacturing Instructions

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.

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.
OLD STYLE CARTRIDGES
For visual reference a T630 cartridge is shown.

2. Remove the doctor bar leaf spring 3A. Using the Felt/Foam Scraper Tool, carefully remove the
Using needlenose pliers, remove the plastic doctor bar end putty from each end of the Doctor Bar (FIG39). Note the
blocks (if present) located on each end of the leaf spring (FIG 37). amount of putty removed and discard it.

Doctor Bar Note: Do not reuse what is removed. It is already con-

End Blocks taminated with toner.For visual reference a T630
cartridge is shown.

Doctor
Leaf Bar
Spring Developer
Roller FIG 37

Putty

NOTE ALWAYS remove the doctor bar and leaf spring Figure 39
before removing the developer roller.

SSS 424 page 23

 Lexmark T520/522, T620/622,
T630/632/634, T640/642/644 Remanufacturing Instructions
Lexmark T520, T620, T630, T640 Remanufacturing Instructions

NOTE The use of too much doctor bar putty is a common NEW STYLE CARTRIDGES
cause of doctor bar and developer roller contamination and
resulting failures in remanufactured cartridges. Remember T640 shown for technichal reasons, may differ slightly from your
to notice how much putty you remove. Do not reuse what is cartridge.
removed - it is already contaminated with toner.
3B. Remove the Developer Roller cover if present,
4. Using the Felt/Foam Scraper Tool, peel up one end of the (FIG42 & 43).
Doctor Bar Sealing Strip. Grasp the strip with needlenose
pliers and remove it slowly so that the adhesive remains on
Remove Developer
the strip (FIG 40).
Roller Cover

Slide Off Developer

FIG 42
Roller Cover

FIG 40
FIG 43
NOTEThe doctor bar may need to be held in place while
removing the sealing strip. Remove the Doctor Bar retaining tabs from each side of the
cartridge (FIG 44).
Carefully remove the doctor bar from the hopper by lifting it
straight up and out (FIG 41).
Remove each
HINT: If not wearing gloves, a strip of tape placed on the doctor Retaining Tab
bar will act as a handle and help you to avoid touching the
developer roller with your bare fingers.

FIG 44

Figure 41

page 24 SSS 424

 Lexmark T520, T620, T630, T640 Remanufacturing Instructions

Remove the Doctor Bar from the cartridge (FIG 45). 4. Remove the developer roller

Lift out the

Doctor Bar NOTE Do not touch the surface of the developer roller with
your fingers. Use gloves or other protective materials.

Rotate the brass bushing upward to remove it from the cartridge

(FIG 46a)(FIG46b).

FIG 45

Developer
Roller

Electrical
Contact
Bushing
FIG 46a

Housing
Plastic
Washer

FIG 46b

page 25 SSS 424

Lexmark T520, T620, T630, T640 Remanufacturing Instructions

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 47). 99% isopropyl alcohol (FIG 50).

Developer
Roller
Developer Roller FIG 50
Shaft
FIG 47

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 48).

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 51).

Move forward
and out Push in until flush
with housing
FIG 48
Do not
damage
latching
Remove the plastic washers from each end of the developer clips
roller (FIG 49). FIG 51

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 49

SSS 424 page 26

 Lexmark T520, T620, T630, T640 Remanufacturing Instructions

Clean the hopper cap using ionized, dry, filtered, compressed
air. Be sure to clean the filter in the cap (FIG 52).
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 54).

Filter
Outer
Sealing
FIG 52 Blade
Inner Sealing
Blade with Tabs
& Caulk FIG 54
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 NOTE Both inner and outer blades are made of polyester and
embedded in the surface of the toner adder roller. For best have poor memory, meaning that once bent or kinked they
results, Static Control recommends cleaning the toner adder do not return to their original configuration. Damaged blades
roller each remanufacturing cycle to remove compacted toner. 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-
Using ionized, dry, filtered, compressed air clean the toner
er blades only when they are damaged or are loose.
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 53).

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 53

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

developer roller sealing blades with the air gun nozzle.

SSS 424 page 27

Lexmark T520, T620, T630, T640 Remanufacturing Instructions

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 55).

Seals are located at each

end of the hopper

FIG 58

11. Clean the developer roller

FIG 55
Clean the developer roller with ionized, dry, filtered, compressed
air (FIG 59). 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 56).

Developer
Roller
Electrical
Contact

FIG 59

FIG 56
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 57 & 58).

FIG 57

SSS 424 page 28

 Lexmark T520, T620, T630, T640 Remanufacturing Instructions

Reassembly of the Hopper Section

1. Apply a small amount of Sealing Wax to edge of the Doctor

Blade Sealing Foam and the Developer Roller End Seals as well
as the edge of the Sealing Blade, see Figure 60.

a. Repeat Step 1 for the Contact Side.

Note: Lift the Doctor Bar Electrical Contact on the Contact Insert the keyed end of the
side, to apply wax. Be sure not to bend back to far or it shaft into the non-contact end
will not come in to contact with the Doctor Bar. of the cartridge

FIG 61
Sealing
Wax

FIG 60

Install the contact end of the developer roller (FIG 62). Make
sure the plastic washer fits inside the cartridge housing.

1. Install the plastic developer roller washers

Install one plastic washer on each end of the developer roller
shaft (FIG 60). If lost or damaged, replacement washers can be
obtained from Static Control.

Housing
Plastic
Washer

FIG 62

Replace the brass electrical contact bushing on the contact end

of the developer roller shaft (FIG 63).

Developer
FIG 60
Roller

NOTE Washers are to help reduce friction only and not for
sealing purposes. Using more than one washer per end will
not help reduce toner leakage, and may actually contribute
to other print defects.

2. Install the developer roller Electrical

Insert the keyed end of the developer roller shaft into the non- Contact
Bushing
contact end of the hopper (FIG 61). FIG 63

page 29 SSS 424

Lexmark T520, T620, T630, T640 Remanufacturing Instructions

3. Install the doctor bar

Static Control recommends replacing the OEM doctor bar with
a new Odyssey doctor bar and leaf spring. The Doctor Bar
Installation Kit includes doctor bar putty, seal strip and detailed
instructions that make installation quick and easy NOTE Be extremely careful not to damage the developer
(doctor bar and springs sold separately from kit). roller while removing or installing the doctor bar.

The Doctor Bar should be installed with the working edge (dull
gray finish) (FIG 64a) in contact with the Developer Roller. The
other side of the Doctor Bar is shiny (FIG 64b).
Working Edge
of Doctor Bar
OLD STYLE CARTRIDGES
Carefully install the Doctor Bar into the cartridge (FIG 66).
Make sure to not damage the contact. Make sure working edge
is in contact with Developer Roller.

Contact

Shiny Edge of
Doctor Bar FIG 64a

FIG 66

FIG 64b

NOTE Always wear gloves when working with the Odyssey Clean the doctor bar sealing strip mounting surface (the lip of
Doctor Bar, and take care not to damage the working edge the hopper and the top edge of the doctor bar) with 91%-99%
of the bar. isopropyl alcohol and a cotton-tipped applicator (FIG 67). Allow
the alcohol to dry completely.
If remanufacturing an old style hopper with an Odyssey Doctor
Bar already installed, the bar can be re-used one time. Simply
turn the bar end-to-end for a second cycle (FIG 65). DO NOT flip
top-to-bottom. The working surface of the bar must face the
developer roller.

FIG 67

Worn side of doctor bar NOTE DO NOT saturate the cotton on the applicator. Excess
FIG 65 alcohol can run down the back side of the bar, into the toner.

SSS 424 page 30

 Lexmark T520, T620, T630, T640 Remanufacturing Instructions
Expose the doctor bar sealing strip adhesive by peeling off and
folding back 1 to 2 inches of the dull white paper backing from
one end of the doctor bar sealing strip (FIG 68). Place the end of
the Doctor Bar Sealing Strip flush with the end of the Doctor
Bar and flush against the hopper.
HINT: Carefully press the strip into place, peeling the backing
off slowly as you progress. You may want to use your felt/foam
scraper tool to press the strip into place, smoothing out any
wrinkles and air pockets.
Sealing
Strip
FIG 68
Remove the white reinforcement paper (FIG 69). Smooth out any
additional wrinkles and air pockets that still remain. Smooth
Doctor Bar Sealing Strip from left to right or right to left.
Reinforcement Paper
FIG 69
page 31 SSS 424
NOTE DO NOT seal the ends of the doctor bar with rigid
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
doctor bar.
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.
NOTE Be careful not to get any of the putty on the
developer roller.
After insuring that all toner has been removed from the corners,
apply a small amount of fresh doctor bar putty (approximately
the same amount you removed at the beginning of the instruc-
tions) in each corner at the end of the doctor bar to complete
the seal. Use a small flat-head screwdriver or felt/foam scraper
tool to press the putty in place where the bar and hopper meet
(FIG 70).
FIG 70
Lexmark T520, T620, T630, T640 Remanufacturing Instructions

If present, replace the Developer Roller Cover (FIG 73).

NEW STYLE CARTRIDGES
Place the Doctor Bar up against the Docto Bar Sealing Foam
(FIG 71).

Developer Roller
Replace the
Cover
Doctor Bar

FIG 73

FIG 71

Replace the two Doctor Bar retaining tabs (FIG 72).

Doctor Bar
Retaining Tab

FIG 72

SSS 424 page 32

 Lexmark T520, T620, T630, T640 Remanufacturing Instructions

4. Install the doctor bar leaf spring While holding one end of the leaf spring in each hand, insert the
When installing a new SCC Odyssey Doctor Bar, the old leaf center bend into the plastic seat on the hopper (FIG 74).
spring must be replaced SCCs Oprta T Doctor Bar Leaf
Spring (OPTTDBARSPG) which is specifically designed for Center bend
your cartridge. positioned in
plastic seat

FIG 74

Using minimal pressure, push up on the ends of the spring until

they can be positioned onto the top of the doctor bar (FIG 75).
The arrow on the spring should point toward you with the num-
ber upright.

Push up on the ends of

the spring until they
seat on top of the
doctor bar FIG 75

page 33 SSS 424

 Lexmark T520, T620, T630, T640 Remanufacturing Instructions

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-
ment station, defeating this system. Use only the amount of
hopper (FIG 76). To make filling easier, Static Control recom- toner specified for your particular cartridge.
mends using a funnel attachment on the toner bottle.
2. Install the hopper cap
Install the hopper cap assembly (FIG 78), making sure the latch-
Use funnel ing clips are secured to the cap.
attachment
for filling Latching
Clips

FIG 76

NOTE As the toner paddle moves back and forth inside the
hopper it pushes toner toward the development station. An
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 77).
FIG 78
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, T620/T622 and
IBM 1120/1125, 1130/1140 cartridges.
Standard and High-Yield IBM Return Program(Prebate) car-
tridge wheels are black. Standard and High-Yield Non-
Prebate/Non-Return Program cartridge wheels are white (FIG
79).

Important: ONLY for use on:

Toner Reservoir 1) Non-Prebate (Regular) cartridges (any brand).
Development
(Hopper)
Toner Station 2) IBM Return Program (Prebate) cartridges.
Metering Bar
Arm
Paddle
IBM Return Program (Prebate) Non-Prebate/non-Return
wheel Program wheel
Toner
Level Wall

FIG 77

FIG 79

page 34 SSS 424

 Lexmark T520, T620, T630, T640 Remanufacturing Instructions

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 cartridges toner sensing sys- secured on the axle (FIG 82).
tem (FIG 80). 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
Wheel / Toner
Agitator
Paddle Axle

FIG 82

Spring Loaded
Pacman Gear
FIG 80

NOTE Make sure the encoder wheel you are installing is the
correct wheel for your cartridge. If installed on the wrong car-
tridge (IBM Return Program (Prebate) on Non-Prebate/Non-
Return Program, and vise-versa), the error message
Unsupported Print Cartridge will be displayed when the car-
tridge 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 81). Do not press the wheel in place at this time.

Encoder Toner Agitator

Paddle Axle
Wheel

Wheel
Base
FIG 81

SSS 424 page 35

 Lexmark T520, T620, T630, T640 Remanufacturing Instructions

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 Controls Hook Tool (HTOOL) or a pair of
drum face up (FIG 83). needlenose pliers, attach the tension springs to the spring posts
on each end of the cartridge (FIG 86).

Spring
Post

FIG 83 FIG 86

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 84).

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 84

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 85). Install the developer roller drive gear on the end of the develop-
er roller shaft (FIG 87).

Developer Roller
Drive Gear

FIG 85

FIG 87

page 36 SSS 424

 Lexmark T520, T620, T630, T640 Remanufacturing Instructions

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 88). 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 88

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 89), with an instruction card that prompts
the end-user to remove the lock before installing the unit in the
printer (4059SLOCK). FIG 89

SSS 424 page 37

 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
Intl 919.774.3808 Intl 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

2005 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.