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Remanufacturing the Lexmark X560 Toner Cartridges By Mike Josiah and the Technical Staff at Uninet Imaging

Mike Josiah Mike Josiah is the Technical Director at UniNet East Coast office, a global distributor of toner, Smartchips, OPC drums, and other toner remanufacturing components. Mr. Josiah is an industry veteran since 1987, and a member of ASTM committee F.05, the STMC Technician Certification committee, as well as an STMC trainer. He and his support team at UniNet contribute with technical articles to industry trade magazines, and conduct seminars at association meetings and tradeshows worldwide.

The Lexmark X560 Engine is a multi function 31 ppm Black and 20 ppm color engine that runs at 600 dpi (2400dpi image quality). The first page out is stated to be under 11 seconds and the printer runs off a 400 MHz processor. The memory comes standard at 384MB and is expandable to 1.4GB. These machines can print, scan, fax, copy and duplex. The chips on these cartridges need to be replaced each cycle. There are LY(Starter)cartridges and HY cartridges available. A LY cartridge cannot be made into a HY version as there are a set of gears in HY cartridges not present in Ly cartridge. HY cartridges use a second toner hopper based in the drum half of the cartridge. This hopper is present in the LY versions, but the necessary gears to move the toner are not. These cartridges have a chip that must be replaced each cycle. In addition, they also have gears on the supply hopper(s) that must be set correctly for the cartridge to work. The printers ship with a set of starter cartridges. Both the colors and the black are all rated for 4,000 pages. Current Machines based on the X560 engine are: Lexmark X560n



Lexmark X560dn The cartridges used in these machines are as follows: 0X560A2KG Black LY Cartridge (4000 pages) 0X560A2CG Cyan LY Cartridge (4000 pages) 0X560A2MG Magenta LY Cartridge (4000 pages) 0X560A2YG Yellow LY Cartridge (4000 pages) 0X560H2CG Cyan HY Cartridge (10,000 pages) $412.65 List 0X560H2MG Magenta HY Cartridge (10,000 pages) $412.65 List 0X560H2YG Yellow HY Cartridge (10,000 pages) $412.65 List 0X560H2KG Black HY Cartridge (10,000 pages) $278.25 List As you can see, these are extremely profitable cartridges to do. These cartridges use both toner and developer in the cartridges. This system is a little different so we are including the cartridge/printer theory here. Figure #1 shows the basic layout of the cartridges as they relate to the printer and also list the steps used in the printing process. These steps are covered in more detail below. In the first stage, the Primary Charge


Figure 1 Roller places a uniform negative DC voltage on the OPC drum surface. The amount of the negative DC voltage placed on the drum is controlled by the printer’s intensity setting. The PCR cleaning roller removes any toner or paper dust from the PCR. See Figure 2

Figure 2 In the second stage, each color’s laser beam is fired onto a set of fixed mirrors

$)*+,#!+!-.! ,) !"#$ %!&'(& Remanufacturing the Lexmark X560 Toner Cartridges

and then to the rotating mirror (called the scanner). As the mirror rotates, the beams are reflected into a set of focusing lenses. The beams then strike the drums surface, reducing the negative charge and leaving a latent electrostatic image on the drum. The areas where the lasers did not strike the drum will retain the higher negative charge. See Figures 3 & 4


blade, which uses pressure to keep the amount of toner on the roller constant. See Figure 5

Figure 7

Figure 5

Figure 3

As the laser exposed areas of the OPC Drum approach the developer roller, the toner particles are attracted to the drum’s surface due to the opposite voltage potentials of the toner, and laser exposed areas of the OPC drum. See Figure 6

process again. The static charge on the back of the paper is decreased with static charge eliminator. This helps stabilize the paper feed, and also prevents toner flares (spots) under low temperature and low humidity conditions. See Figure 8

Figure 8 Figure 4 The third or developing stage is where the toner is developed on the drum by the developing section (or supply chamber), which contains the toner and developer particles. The toner is moved from the hoppers by a series of agitators into the developer section where the augers and magnetic roller are located. The toner is brought out to the drum by the magnetic roller. The toner is also held onto and attracted to the magnetic roller by a negative DC bias voltage. This voltage is controlled by the printer’s intensity setting and causes either more or less toner to be attracted by the developer roller. This in turn will either increase or decrease the print density. The amount of toner on the magnetic roller is controlled by the doctor



Figure 6 The fourth stage is the transfer stage. This is where there are some large differences from monochrome printers and also from other color lasers. In the Primary transfer stage the transfer rollers which are located directly opposite each OPC drum, places a positive DC bias charge on the back of the Transfer Belt. Each toner cartridge has a separate transfer charge roller. As the paper moves through the machine, the image is transferred from the drum directly to the paper. This process is repeated for each color cartridge in the following order: Yellow, Magenta, Cyan, and Black. See Figure 7 The paper separates from the transfer belt as the belt turns back down to start the


In the fifth stage, the image is then fused onto the paper by the fuser assembly. The fuser Assembly is comprised of the upper heating assembly and lower pressure roller. The lower pressure roller presses the page up into the upper heating assembly which then melts the toner into the paper. This heating assembly is based on older technology. It uses a heat lamp and a pressure roller assembly and not the

Figure 9

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ceramic heaters that many machines now use. See Figure 9 OPC Drum Cleaning: The drum is cleaned after the image is transferred to the paper by the wiper blade. This part is fairly standard; the wiper blade scrapes the toner off the drum, and the recovery blade guides it into the waste chamber. These machines also have an erase lamp to remove any residual charges from the drum and allow the wiper blade to clean better. See Figure 10

Figure 10

Figure 11

Figure 15

Figure 12

Figure 16

cap on the contact side. See Figure 13

Cartridge troubleshooting will be covered at the end of this article. Supplies required: Dedicated Lexmark X560 color toner (HY or LY) Dedicated Lexmark X560 color developer (HY or LY) Replacement chip (HY or LY) Dedicated OPC drum Drum cover Toner seal Developer seal Fill hole seal

Figure 13 3) Remove the screw from the white end cap. See Figure 14

Figure 17

Tools Required Phillips head screwdriver Small common screw driver Jewelers screwdriver set Spring Hook Vacuum approved for toner 1) Remove the two springs from either side to the cartridge. The contact side is easier to remove if the cartridge is upside down. See Figures 11 & 12 2) Remove the screw from the black end

5) Remove the black and cap by prying up the tab to release it, press down on the lower contact plate and pry up around the bottom edges. The end cap will come free. It’s important to press the lower contact plate down so it does not become

Figure 14 4) Remove the white end cap by prying up on the tab as shown. See Figures 15 & 16


Figure 18


$)*+,#!+!-.! ,) !"#$ %!&'(& Remanufacturing the Lexmark X560 Toner Cartridges


damaged. Two white gears will come off with the end cap. It is best to store them on their respective shafts as shown. See Figures 17, 18, 19 & 20

Figure 22

Figure 26 28.

Figure 19

Figure 23 Figure 27

Figure 20 6) Remove the Single gear with the black axle as shown. Do not remove the 3 remaining gears as they are attached inside the hopper. See Figure 21

Figure 24 Figure 28

See Figure 25

12) Remove the Mag. Roller support bearings from both sides. See Figure’s 29 & 30.

Figure 21 7) Separate the two halves. See Figure 22 8) On the toner hopper, remove the magnetic roller clip by lifting up the 2 small tabs from the plastic shaft. Turn the contact towards the flat side of the mag. roller shaft and remove. See Figures 23 & 24 9) Remove the large Mag. roller drive gear.



Figure 25 10) Remove the front auger drive gear so the bearing can be removed. See Figure 26 11) Remove the round bearings from both sides of the mag. roller. See Figures 27 &


Figure 29 13) Lift the mag. Roller out by lifting it up

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15) Clean out all remaining toner and developer. 16) Install the mag. Roller long shaft side first. See Figure 34

Figure 30

Figure 37

from the short shaft side See Figure 31

Figure 34 17) Install the support bearings on both sides of the cartridge. Make sure the tab on the bushing is set in its slot as shown. See Figures 35 & 36 Figure 38 Figure 31

of the shaft and turn the whole assembly until it fits in place. See Figures 39 & 40

14) Remove the Toner hopper sealing strip, and the developer chamber sealing strip. New seals are now available so there is no need to re-use them. See Figures 32 & 33.

Figure 35

Figure 39

Figure 32 Figure 36

Figure 33

18) Install the round bearings on both sides of the Mag. Roller. See Figure 37 19) Install the front auger gear. Make sure it is installed correctly. It must mesh properly with the auger or print voids will occur. See Figure 38 20) Install the mag. Roller contact. Set the fingers so they are contacting the flat side


Figure 40 21) Place a piece of paper across the developer chamber opening so it blocks the mag. Roller. Fill the chamber with the dedicated developer. Remove the ,-./0,1-&()&222292223-.-45-,22267882229


$)*+,#!+!-.! ,) !"#$ %!&'(& Remanufacturing the Lexmark X560 Toner Cartridges

paper. The paper makes it simpler to fill the chamber by blocking off the mag. Roller. See Figure 41


instructions in step 46) See Figures 43 & 44 NOTE: Do NOT mix the developer with the toner. They must be separate inside the cartridge for the system to work correctly. Place the toner chamber aside

Figure 47

Figure 41 22) Clean the edge of the developer chamber opening with a cotton swab dipped in alcohol. Install the new seal. See Figure 42

Figure 44 24) On the drum chamber, remove the “E� ring from the contact or hub side of the drum. See Figure 45 Figure 48 28) Remove the PCR cleaning roller, vacuum or blow any toner from the roller. See Figure 49

Figure 42 23) For low yield cartridges, fill the toner chamber now. Clean the edge of the chamber with alcohol and install the new seal. HY cartridges have two chambers so it is easier for them to be filled later. Both chambers should be filled at the same time in order to get the correct amount in each. (They will be filled at the end of these

Figure 45 25) Pull the axle out from the gear side of the drum so that the inner drum ground contacts are not damaged. See Figure 46

Figure 49 29) Remove the two PCR/PCR Cleaning roller holders, carefully pry them up from

Figure 46 26) Remove the drum. See Figure 47 Figure 43



27) Remove the PCR and clean with a lint free cloth. See Figure 48


Figure 50

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the sides. Clean them with a cotton swab and alcohol. See Figure 50 30) HY cartridges have a seal and set of gears for the additional augers. Remove the seal and clean out any remaining toner. See Figure 51

Figure 54

Figure 57

34) Install the cleaned PCR/PCR Cleaning roller holders. See Figure 55

Figure 51 31) Remove the 2 screws and the wiper blade. Clean out any toner from the waste chamber. See Figure 52 Figure 58

Figure 55 35) Install the cleaned PCR cleaning roller. See Figure 56

Figure 52

Figure 59

32) Coat the wiper blade with your preferred lubricant and install. Install the two screws. See Figure 53 Figure 56

Figure 53 33) Clean the PCR holders and PCR cleaning roller holders with a cotton swab and alcohol. See Figure 54

36) Install the cleaned PCR. Place a small amount of new conductive grease on the black holder side. See Figure 57 37) Install the drum. See Figure 58 38) Install the drum axle from the hub side. See Figure 59 39) Install the E ring. See Figure 60 40) On the toner hopper, install the white auger gear as shown. At this point the remaining gears must also be set properly. If the cartridge is a HY the top 2 gears


Figure 60 must point to the arrows on the cartridge as shown. For all cartridges on the lower half, the gears must be pointing to the arrow and gear as shown See Figure 61 41) Install the developer roller drive gear. See Figure 62



$)*+,#!+!-.! ,) !"#$ %!&'(& Remanufacturing the Lexmark X560 Toner Cartridges


Figures 64, 65 & 66

Figure 61

Figure 69 Figure 65

46) If you have a HY cartridge, fill the upper (Drum Unit) and lower (Toner) hoppers now. We have found it best to fill the upper hopper with Âź of the bottle and the rest in the lower hopper. See Figure 70

Figure 62 42) Place the two halves together. See Figure 63

Figure 66 44) Install the white end cap and screw. See Figure 67

Figure 70 47) Remove the old chip by prying out and lifting up on the black plastic holder. Remove the old chip from the holder and slide the new chip into the rails. Make sure it snaps into place. See Figures 71, 72 & 73 Figure 63 Figure 67 43) With the two gears placed on the black end cap. Install the end cap. Make sure the tab locks in place. Install the screw. See

45) Install the springs on both sides of the cartridge. See Figures 68 & 69

Figure 71 48) Install the chip holder assembly onto the hopper. See Figure 74 49) Install the drum cover. See Figure 75 Figure 64



Figure 68


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Repetitive Defect Chart

Figure 72

Figure 74

Figure 73

Figure 75

OPC drum 75.4mm PCR 28.3mm PCR cleaning roller 25.1mm Black & color Mag. roller sleeve 27.9mm 1st primary transfer roller 31.4mm Drive roller transfer unit 56.9mm Upper fuser roller 82.7mm Fuser drive belt 94.2mm Pinch roller fuser assy. 18.8mm Exit roller fuser assy. 43.1mm Exit pinch roller fuser assy. 31.4mm

Remanufacturing the Dell 1230 Color Toner Cartridges By Mike Josiah and the Technical Staff at Uninet Imaging The Dell 1230 printers are based on a 16ppm black and 4ppm color Samsung engine. It has a first page out in less than 14 seconds and a maximum resolution of 2400 x 600 dpi. The printer comes standard with 32MB of Ram, a USB 2.0 interface, and has a monthly duty cycle of 20,000 pages/month. These machines have a very small footprint at 15.3” x 12.3” The machines are small and the toner cartridges are also small The Cartridges used in this series are as follows: 330-3012 Black 1,500 pages $57.99* 330-3015 Cyan 1,000 pages $51.99* 330-3014 Magenta 1,000 pages $51.99* 330-3013 Yellow 1,000 pages 451.99* 330-3017 Drum unit 24,000 pages black, 6,000 color

$99.99* 330-3016.1 Waste Container 10,000 pages black, 2,500 pages color $16.99* *Pricing as of 1/19/2011 New printer’s ship with starter cartridges rated for 700 pages both black and color. Figure A shows the complete printing process as it pertains to this engine.

Cartridge trouble shooting as well as how to run test pages will be covered at the end of this instruction. Tools needed Phillips head screwdriver Small common screwdriver Needle nose pliers Toner approved vacuum Supplies needed

Figure A


Dedicated Dell 1230 color toner Replacement chip Cotton swabs 1. With the gear side of the cartridge on your the left side, remove the two Phillips screws holding the end cap. See Figure 1 2. Pry open the cover carefully with the small screwdriver and remove it. Clean

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$)*+,#!+!-.! ,) !"#$ %!&'(& Remanufacturing the Dell 1230 Color Toner Cartridges


identical. The gear side screws are shorter and have a fine thread. See Figure 4 5. Remove the gear cover. Note that the large double gear comes out together with the cover. See Figure 5

7. Lift the cover/doctor blade from the left side to allow the right side to slide out first before taking it off the cartridge. See Figure 8

Figure 1 the metal bushings with a cotton swab. See Figure 2 Figure 8 Figure 5

Figure 2 3. Remove the right side end cap in the same way. See Figure 3

6. Remove the four screws from the top of the metal cover. The cover also acts as a doctor blade for the roller. Note the two cover plates on each side; the one on the left side is larger than the other. NOTE: Be very careful when removing the cover to protect the edge of the doctor blade. Any dent or mark on the doctor blade edge will seriously affect the quality of the print and possibly ruin the cartridge. See Figures 6 and 7

8. Remove the green separator bushing on the right side of the developer roller, slide the roller out. Be careful not to lose the gear from the opposite side of the roller as it will become loose as also will the remaining green bushing. See Figures 9 & 10

Figure 9

Figure 3 4. Note that the screws removed are not

Figure 6

Figure 10

Figure 4



Figure 7


9. Clean the developer roller with your favorite cleaner and wipe it down with a soft lint-free cloth. Vacuum the entire developing area including the seals of the cover/doctor blade. See Figure 11

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12. Vacuum the chamber clean. See Figure 15

Figure 11 10. On the right side of the cartridge pry open the lid of the toner load port. See Figure 12

Figure 18 Figure 15 13. Install the developer roller with the respective green separation bushing in position and insert the shaft through the support, then lock the other end in place. See Figures 16 & 17

Figure 19

Figure 12 11. Remove the plug of the loading port with needle nose pliers. See Figure 13 &14 Figure 16

Figure 20 install the cover with the metal bushings properly lubricated with a small quantity of conductive grease and tighten with the screw. See Figures 21 & 22 Figure 13 Figure 17

Figure 14

14. Install the gear cover making sure the gears fit properly on their respective shafts. See Figure 18 15. Install the cover with the short one with fine threaded screw in the center of the gear as shown. See Figure 19 16. Install the opposite side cover with the larger screw as shown. See Figure 20 17. On the left side of the cartridge


Figure 21 18. Carefully clean the cover/doctor blade and position it in an angle to insert it ,-./0,1-&()&222292223-.-45-,22267882229 #)

$)*+,#!+!-.! ,) !"#$ %!&'(& Remanufacturing the Dell 1230 Color Toner Cartridges


surface of the OEM chip (starter or standard chip). Peel off the adhesive backing from the new aftermarket chip and place it ON TOP of the OEM chip. The OEM is NOT removed. See Figure 31

Figure 22

Figure 26

in the slot at the right, and then drop it

19. Fill the cartridges with dedicated Dell

in place at the left. Fit the individual seal

1230 toner. Install the fill plug and install

presses in the proper places and secure with

the cover in place. See Figures 27, 28 & 29

the four screws. See Figures 23, 24, 25 & 26

Figure 31 21. Install the Developer roller cover. See Figure 32

Figure 27 Figure 23

Figure 32 Repetitive Defect Chart:

Figure 28 Figure 24

OPC Drum Upper Fuser 2nd Transfer Lower Fuser 1st Transfer PCR Toner feed Developer

Roller Roller Roller Roller roller roller

188.5mm 86.4mm 54.64mm 50.3mm 43.8mm 37.7mm 32.7mm 26.0mm

Printing test pages:

Figure 29 Figure 25



20. Replace the chip: With a clean swab, remove any toner that may be on the


Demo Page: With the printer in the Ready Mode, Press and hold the STOP button for 2 seconds. The demo page will print out Configuration Page: With the printer in the Ready Mode, Press and hold the STOP button for 5 seconds. The configuration page will print out.

Remanufacturing the Dell 1230 Color Toner Cartridges