12015SA2,000 page Return Program TonerCartridge

12035SA2,000 page Toner Cartridge

12026XW25000 page Photoconductor Kit

Part Number: 23S0300Technology: LaserPrint Speed: Up to 20ppmResolution: 1200 image quality printingFirst page out: As fast as 8 secondsProcessor: 183 MHzMemory: 16MB (std./max)Footprint: 15.3W x 14D x 9.8HDuty Cycle: Up to 10,000 pages per month

Tools Needed:Needle nose pliersSmall Phillips screwdriver#2 Phillips screwdriverSmall flat blade screwdriver

Supplies Needed:99% AlcoholLint-free clothCotton swabsTonerDoctor bar (if needed)Drum (if needed)

Technical Instructions Printer Supplies. OEM Info Tools 1

E-mail: info@futuregraphicsllc.com Website: www.futuregraphicsllc.com

Step 1Remove the small Phillips screw that holds thedoctor blade positioning plate.(See Photo 1)

Photo 1

Step 2The doctor blade positioning plate has two align-ment pins on each side of the plate that holds thedoctor blade in the correct position. Carefullybend the plate and slide the alignment pins fromthe gear side of the toner hopper.(See Photo 2)

Photo 2

Photo 3

E120TECH

REV. 9/14/06

Step 3Slide the positioning plate toward the gear sideof the hopper to remove the alignment pins fromthe contact side of the toner hopper.(See Photo 3)

Toner Hopper Remanufacturing Instructions:

US 1 800 394.9900Int’l +1 818 837.8100FAX 1 800 394.9910Int’l +1 818 838.7047

KANSAS CITY, USAUS 1 913 871.1700FAX 1 913 888.0626

ATLANTA, USAUS 1 877 676.4223Int’l +1 678 919.1189FAX 1 877 337.7976Int’l +1 770 516.7794

MIAMI, USAUS 1 800 595.4297Int’l +1 305 594.3396FAX 1 800 522.8640Int’l +1 305 594.3309

TORONTO, CANCAN 1 877 848.0818Int’l +1 905 712.9501FAX 1 877 772.6773Int’l +1 905 712.9502

NEW YORK, USAUS 1 800 431.7884Int’l +1 631 588.7300FAX 1 800 431.8812Int’l +1 631 588.7333

SYDNEY, AUSAUS 1 800 003.100Int’l +62 02 9648.2630FAX 1800 004.302Int’l +62 02 9548.2635

BUENOS AIRES, ARGARG 0810 444.2656Int’l +011 4583.5900FAX +011 4584.3100

MONTEVIDEO, URYURY 02 902.2001Int’l +5982 902.2001FAX +5982 900.0858

JOHANNESBURG, S.A.S.A. +27 11 974.6155FAX +27 11 974.3593

MELBOURNE, AUSAUS 1 800 003. 100Int’l +62 03 9561.8102FAX 1 800 004.302Int’l +62 03 9561-7751

CORPORATELOS ANGELES, USA

SÃO PAULO, BRAZILInt’l +55 11 5524.8000

RAANANA, ISRAELISR 09 760.12.39Int’l +972 9760.12.39ISR 052.38.555.82Int’l +972 5238.555.82

Step 6Clean the doctor blade using dry compressedair. (Lexmark is using the new style doctorblades in the E120n cartridges. These bladeshave a foam core with a textured coated stripon the working edge.) Clean the blade using alint-free cloth and alcohol. (See Photo 7)

Photo 4

Step 7Rotate the toner hopper so the gear end is facing you. Using a spring hook, remove thelocking washer and the washer that holds theblack drive gear to the toner hopper.(See Photo 8)

Photo 6

Photo 7

Step 8Remove the gear.(See Photo 9)

Step 9Using a small flat blade screwdriver, removethe locking bar that holds developer rollerbushing. (See Photo 10)

Photo 8

Step 10Rotate the developer roller bushing counter-clockwise. (See Photo 11)

Photo 9

2 E120 Technical Instructions

Photo 5

Photo 10

Step 4Using needle nose pliers, grab theleaf spring towards its center.Carefully press downward, removingthe spring from the spring’s lockingcradle. (See Photo 4) Remove theleaf spring.

Step 5Lift the doctor blade from the gearside of the toner hopper. (See Photo5) Slide the contact end of the doctorblade out from the contact side ofthe toner hopper. (See Photo 5)NOTE: Be careful not to bend thedoctor blade contact while removingthe blade.

Photo 11

Photo 12Step 11Lift up the end of the roller and slide the developer roller bushing from the shaft of theroller. (See Photo 12)

Photo 14

Photo 15

Photo 16

Lexmark E120 Technical Instructions 3

Step 14Lift up the shaft of the developer roller on thecontact side of the toner hopper. Slide theshaft of the developer roller from the gear endof the toner hopper. (See Photo 15). Clean thedeveloper roller using distilled water and a lint-free cloth. (See Photo 16).NOTE: Make sure the developer roller is com-pletely dry before it is reinstalled in the tonerhopper.

Step 12Holding the developer roller in place, rotate thedeveloper roller drive gear clockwise. This willunlock the drive gear from the shaft of thedeveloper roller. (See Photo 13) NOTE: You mayneed to hold the shaft of the developer rollerusing needle nose pliers and rotate while hold-ing the drive gear in order to remove the rollersdrive gear.

Photo 13

Step 13Remove the developer roller drive gear from theshaft of the roller.(See Photo 14)

Photo 17

Photo 21

Photo 19

Step 18While holding the developer rollerby the shaft, install the keyed endof the shaft into the gear end of thetoner hopper. (See Photos 19)

Step 19Lift up on the shaft of the developerroller. Install the bushing on to theend of the developer roller. Rotatethe developer roller clockwise,locking the bushing in place. (See Photo 20)

Step 15Remove the warranty sticker covering the tonerhopper fill plug. Remove the fill plug from thetoner hopper. (See Photo 17)

Step 16Dump the remaining toner from the toner hopper. Clean the hopper using dry,compressed air or a vacuum.

Photo 18

Photo 20

Step 17Clean the developer roller end seals using acotton swab and alcohol.(See Photo 18)

Step 20Place the locking bar onto the endof the developer roller bushing.(See Photo 21)

Photo 22

Photo 23

Photo 24

Photo 25

4 Lexmark E120 Technical Instructions

E-mail: info@futuregraphicsllc.com Website: www.futuregraphicsllc.com

Step 21Install the white developer rollerdrive gear onto the shaft of theroller. Rotate the gear counter-clockwise to lock the gear onto theshaft of the developer roller. (See Photo 22)

Step 22Place the black drive gear onto thealignment post on the gear end ofthe toner hopper. Install the washerand locking washer onto the align-ment post. (See Photo 23)

Step 24Position one end of the leaf spring onto thedoctor bar. Using needle nose pliers, carefullyplace the opposite end of the spring onto thedoctor bar. (See Photo 25)

Step 25Slide the two alignment pins on the left side ofthe positioning plate into the two holes on thecontact side of the toner hopper. (See Photo 26)

Step 26Carefully bend the plate and slide the twoalignment pins into the two alignment holes onthe gear end of the toner hopper. (See Photo 27)

Step 27Install the small Phillips screw that holds thepositioning plate in place. (See Photo 28)

Step 28Fill the toner hopper with toner. Place the fillplug back onto the toner hopper.

Step 29Remove the Phillips screw that holds the cartridge chip that sits atop the toner hopper.Remove the chip.(See Photo 29)

Photo 26

Photo 29

Photo 27

Photo 28

Step 23Install the cleaned or new doctor baronto the toner hopper, making surethe positioning post on the doctorbar is properly seated into the endof the toner hopper. (See Photo 24)NOTE: Make sure the doctor bladecontact is touching the doctorblade.

Step 4Carefully lift out the PCR. (See Photo 4)Remove the two spacers from the shaft of thePCR. (See Photo 5). Clean the PCR using alint-free cloth and distilled water.

Photo 30

Lexmark E120 Technical Instructions 5

Step 2Slide the drum axle from the drum on theopposite side of the waste hopper. (See Photo 2)

Step 30Place a new chip onto the toner hopper andinstall the screw that holds the chip in place.(See Photo 30) Post-test your cartridge.

Step 3Carefully lift out the drum. (See Photo 3) Cleanthe drum using a soft cloth. Place the drum ina protected area away from the light.

Step 1Using a small flat blade screwdriver removethe E-ring from the drum axle.(See Photo 1)

Photo 1

Photo 2

Photo 3

Photo 4

Step 5Remove the two screws that holdthe wiper blade. (See Photo 6)

Photo 6

Photo 7

Remanufacturing the E120n Drum Unit:

Photo 5

Step 6Lift out the wiper blade. (See Photo7) Clean the wiper blade and thewaste hopper using dry compressedair or a vacuum. NOTE: Be careful not to lose thewiper blade end foams that sit oneach side of the waste hopper.

Step 7Apply padding powder to the wiperblade. Place the wiper blade ontothe waste hopper and install the twoscrews that hold the blade in place.(See Photo 8)

Photo 8

6 Lexmark E120 Technical Instructions

Photo 9

Photo 10

Photo 11

Photo 12

E-mail: info@futuregraphicsllc.com Website: www.futuregraphicsllc.com

Step 8Clean the PCR saddles using a cotton swab and alcohol. (See Photo 9)

Step 9Place the spacers onto the shaft ofthe PCR (See Photo 10)

Step 11Install the loop of the drum’s torsion spring,located on the non-gear side of the drum, intothe slot on the side of the waste hopper.(See Photo 12)

Step 12Slide the drum axle through the drum startingon the non-gear side of the drum.(See Photo 13)

Step 13Install the E-ring onto the end of the drum axle.(See Photo 14)

Step 14Post-test the drum unit.

Step 15Rotate the spacers on each end of the PCR sothe legs of the spacer are facing up. (See Photo 15) This will pull the PCR awayfrom the drum and prevent flat spots for form-ing on the PCR.

Drum Reset Procedures:

Step 1: Open the front door and hold theCancel button until all lights begin to cycle.

Step 2: Close the front door. The warningclears and the counter resets to zero.

Step 3: Press Continue to resume printing.

Photo 13

Photo 14

Photo 15

Step 10Install the PCR into the saddles.(See Photo 11)