Remanufacturing the Lexmark E120 Toner and Drum Cartridge
The Lexmark E120 was introduced in February 2006. The E120 engine is a new
low-cost engine that in some ways is a bit strange, but it works well, and will
most likely sell well too.
Josiah is teaching the HP CLJ 3600
Remanufacturing Lab at the 2006 World Expo. Click
here to view the educational sessions at this year's event.
The new machines are based on a Lexmark 19-ppm, 600-dpi engine. With a street
price of around $149 (as of March 2006), these machines should be very popular.
As with all Lexmark cartridges these days, they do have a chip that shuts the
cartridge down after use on the Return Program versions. The code in this chip
is new, and at the time of this writing new replacement chips are actively being
worked on, so check with you supplier for availability. There are also different
cartridges used for different regions of the world. It is too soon to say for
certain, but as with other new Lexmark series I think it is a safe guess that
it is the chips that are different.
The E120 Return Program cartridge as packaged.
The E120 Return Program cartridge.
The E120 drum unit.
There are two cartridges used for this engine, a toner and drum unit. The toner
cartridge is rated for 2,000 pages and the drum unit is rated for 25,000. No
high-yield cartridges are available at this time. These machines also have standard
and Return Program (Prebate) cartridges and all have chips. The Return Program
chips must be replaced each cycle. The drum units are the same worldwide. Instructions
for the drum cartridge are included in this article as well and they are simple
to do. Testing is ongoing, so at the time of this writing we do not know if
a drum or wiper blade will last another cycle. Preliminary tests indicate they
will, but not enough tests have been run to say for certain. There are no chips
on the drum units.
The drum units are installed and removed from the back of the printer, and the
toner from the front. This is a little strange but understandable as these machines
have such a small footprint. I just wonder what the customer reaction to it
New machines ship with a 500-page starter cartridge, so new owners will be looking
for cartridges fairly quickly.
A listing of the cartridges available and pricing are shown below.
Cartridges for Use in the U.S. and Canada (Part No./Type Yield/List
- 12026XW/Drum cartridge/25,000/$40*
- 12015SA/Return Program cartridge/2,000/ $86.75
- 12035SA/Standard cartridge/2,000/ $66.75
*Pricing in U.S. as of March 2006
Cartridges for Use in Europe, the Middle East and Africa
- 12026XW/Drum cartridge/25,000
- 12016SE/Return Program cartridge/2,000
- 12036SE/Standard cartridge/2,000
Cartridges for Use in Latin America
- 12026XW/Drum cartridge/25,000
- 12018SL/Return Program cartridge/2,000
- 12038SL/Standard cartridge/2,000
Cartridges for Use in the Asia Pacific Region
- 12026XW/Drum cartridge/25,000
- 12017SR/Return Program cartridge/2,000
- 12037SR/Standard cartridge/2,000
The only machines we have found so far based on this engine are the Lexmark
E120 and E120n.
How to take test prints as well as troubleshooting are covered at the end of
- Toner-approved vacuum.
- A small common screwdriver.
- A Phillips-head screwdriver.
- Needle-nose pliers.
- Lexmark E120 toner, 80 grams (preliminary weight testing is ongoing).
- Toner magnet cloths.
- Lint-free synthetic cotton 4-inch by 4-inch pads.
- 99 percent pure isopropyl alcohol.
- Cotton swabs.
Toner Cartridge Remanufacturing Instructions
1) Remove the fill plug from the right side of the cartridge (developer roller
facing away from you). Dump out any remaining toner from the hopper. See Figure 1.
2) On the left side, remove the two small screws and the gear cover. See Figure 2.
3) Remove the center screw on the developer roller cover. See Figure 3.
4) Lift up the developer roller cover from the center and remove. Be careful
not to damage the plastic pins on the cover. See Figures 4 and 5.
5) Remove the doctor blade spring. The doctor blade is now loose. Carefully
lift it out, watching the contact spring on the right side. Also, be careful
not to damage the retaining blade that is located under the doctor blade. See
Figures 6, 7 and 8.
6) On the large black drive gear there is a locking star washer pressed onto
the shaft. With a small pair of wire cutters, cut the old washer off and remove.
You can try to bend the different legs of the washer, but that is very time
consuming, and it is likely that at least one leg will break anyway and the
washer will still have to be replaced. See Figures 9 and 10.
7) Remove the large black drive gear. Make sure you don’t lose the small
flat washer that is under the star washer. See Figure 11.
8) On the white developer roller gear, take the tips of your small wire cutters
and place them into the two small holes. Spin the gear so the metal shaft is
in the slot on the opposite side of the gear. Remove the gear. See Figures 12
9) Remove all the gears. See Figures 14 and 15.
10) Remove the three screws and gear alignment plate. See Figures 16 and 17.
11) With a small flat-head jewelers screwdriver, pry off the metal lock from
the developer roller bushing. See Figure 18.
12) Turn the developer roller bushing so the plastic tab is facing up. See Figure
13) Lift the developer roller out of the cartridge. The bushing will come off
with the roller. See Figure 20.
14) Clean out any remaining toner from the hopper. Make sure the developer roller
retaining blade does not get damaged. See Figure 21.
15) Wipe the developer roller down with a clean, lint-free cloth. Testing is
ongoing, but for now, do not use any chemicals to clean it.
16) Reinstall the developer roller. Spin the plastic bushing so it is locked
in place. Install the metal locking bar; note that the left side fits into the
small notch and the right side is flush with the hub. If the small metal plate
falls off the bushing, replace it. See Figures 22, 23 and 24.
17) Install the gear axle plate and three screws. See Figure 25.
18) Install the gears. The large gear with the long shaft fits onto the toner
agitator bar inside the hopper. Spin it a few times and listen to make sure
it is engaged properly. On the large drive gear, make sure the flat washer is
in place and install a new star lock washer. Make sure the lock washer is pressed
down fully against the base of the gear. Finally, on the developer roller drive
gear, spin the gear by the two small holes while holding the developer roller
in place. This will lock the gear onto the shaft. See Figures 26, 27 and 28.
19) Clean the doctor blade and install. Make sure the metal tab on the right
side fits into its slot. See Figure 29.
20) Install the doctor blade spring. See Figure 30.
21) Install the developer roller cover and screw. See Figure 31.
22) Install the gear cover and two screws. See Figure 32.
23) Fill the hopper with E120 toner and replace the fill plug. See Figure 33.
24) Replace the chip. See Figure 34.
25) If the cartridge cover is available, wrap the cartridge as indicated. This
cover helps protect the developer roller from damage. Aftermarket covers are
in development. See Figure 35.
Drum Cartridge Remanufacturing Instructions
26) On the gear side of the drum unit, remove the e-ring from the drum axle
shaft. See Figure 36.
27) Slide the drum axle out from the drum. See Figure 37.
28) Remove the drum. See Figure 38.
29) From the right (gear) side, remove the PCR assembly. (The spring loaded
holder may come with it.) See Figure 39.
30) Remove the two screws from the wiper blade and remove the blade. See Figure 40.
31) Clean out the waste toner.
32) Clean and coat the edge of the wiper blade with your preferred lubricant.
Install the blade and two screws. See Figure 41.
33) Clean the PCR and install. Make sure the black spacers are oriented toward
the back of the wiper blade as shown. See Figure 42.
34) Coat the drum with your preferred lubricant and install the drum. Make sure
the small spring on the non-gear side fits into the slot in the plastic cartridge
wall. See Figures 43 and 44.
35) Install the drum axle shaft from the gear side of the drum. Install the
e-ring. See Figure 45.
Printing Test Pages
With the printer at the ready state, press the CONTINUE button. The printer
will print the menu settings page and network setup page if so configured.
Repetitive defect chart
- Lower Fuser Roller (Printer) 17.8 millimeters
- Toner Feed Roller (Toner Cart.) 18.7 millimeters
- PCR (Drum Cart.) 29.0 millimeters
- Paper Pinch Roller (Printer) 30.4 millimeters
- Developer Roller (Toner Cart.) 36.1 millimeters
- Fuser Exit Roller (Printer) 37.9 millimeters
- Transfer Roller (Printer) 48.1 millimeters
- Paper Feed Roller (Printer) 56.2 millimeters
- Upper Fuser Roller (Printer) 62.2 millimeters
- Drum (Drum Cart.) 74.1 millimeters
- Paper Pickup Roller (Printer) 92.4 millimeters
Printer Error Codes (Light Sequences)
The E120 does not have an LCD display. It has a panel of lights to indicate
problems. Some of the more common are listed below. In some cases, the same
sequence of one light on and another blinking will have different meanings.
The difference is the number of times the blinking light blinks. The first four
sequences listed will give you a good idea of what I mean.
- Error Light On, Ready Light Blinking (4x): Cartridge region mismatch. Wrong
chip is installed on the cartridge.
- Error Light On, Ready Light Blinking (3x): Missing/defective cartridge.
- Error Light On, Ready Light Blinking (1x): Door open.
- Error Light On, Ready Light Blinking (8x): Toner low.
- Error Light Blinking, Ready Light Blinking (1x): Replace the drum unit.
Some light sequences have a primary and secondary sequence. The secondary sequence
can be seen by pressing the CONTINUE button twice quickly.
Here is an example of the primary and secondary sequence:
Primary: Toner Low Light On, Error Light Blinking. Secondary: Toner Low Light
On, Paper Jam Light Blinking, Error Light On: Missing/defective cartridge.
Most of the others deal with various paper jams. All are listed in the user
Contact Mike Josiah and the technical staff of Summit Technologies at (631)
218-8376 or visit www.summitechnologies.com.
This article originally appeared in the May 2006 issue of Recharger.