BROTHER® HL-5200 • TN550 • 580

BROTHER ® HL-5200 • TN550 • 580
TONER CARTRIDGE REMANUFACTURING INSTRUCTIONS
BROTHER ® HL-5200 SERIES • TN550 • 580 TONER CARTRIDGE
(TN3145 • 3185 EUROPE)
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BROTHER
• TN550 1240/1650
• 1240/1650
580 CARTRIDGE• •REMANUFACTURING
UNINET
UNINETIMAGING
IMAGING
INC.
INC. HL-5200
• • BROTHER
BROTHER
DISASSEMBLING
ASSEMBLINGINSTRUCTIONS
THE
THETONER
TONERCARTRIDGE
CARTRIDGE
REMANUFACTURING THE BROTHER HL-5200 SERIES TONER CARTRIDGES
TN550/TN580 (TN3145/TN3185 EUROPE)
By Mike Josiah and the Technical Staff at UniNet
Released in November 2005, the Brother HL-5200 printer engine is based on a new 30ppm, true 1200 DPI laser engine. While
these cartridges are similar to the Brother HL-2030 (TN350) engines, there are enough differences that warrant its own
instructions. The first section of this article covers the theory behind these cartridges, with the first three paragraphs offering
interesting information on the reset gears and how they work. If you are not familiar with these Brother cartridges, it would be
best to read through this entire section. It may save you a few very frustrating hours.
CURRENT MACHINES RELEASED SO FAR ARE:
HL-5240
HL-5250DN
HL-5250DNT
HL-5270DN
HL-5280DW
DCP-8060
MFC 8860DN
There are two different yielding toner cartridges available for these machines: the TN550/580 (TN3130/3170 Europe,
TN3145/TN3185 Asia). The TN550 cartridge is rated for 3,500 pages at 5%. The TN580 is rated for 7,000 pages at 5%
coverage. The drum unit is new as well: part # DR520 (DR3100, DR3115) and is rated for 25,000 pages. It will be covered in a
future article.
Similar to the TN350, there is a reset gear that resets the printer. The TN550 reset gear is different from the TN350 though.
Like the TN350, the starter cartridges that come with new printers do not have this gear. There are actually two different reset
gears for TN550/580 cartridges, one for the low yield (550) that has one reset rib, and another for the high yield (580) that has
two reset ribs. These gears work by the gear train turning the reset gear and the ribs(s) of the gear press against a new toner
actuator bar in the machine. If one rib engages the actuator, it is sensed as a low yield cartridge, if two ribs engage the actuator,
it is sensed as a high yield cartridge. New rest gears are available.
An interesting point in the reset procedure is what happens in addition to the counter being reset. When the printer senses a new
toner cartridge, the bias voltage is set to 400 volts. As the cartridge is used, the bias voltage is reduced gradually down to about
300 volts. This process is necessary because according to Brother, a new toner cartridge has a tendency to print light. As the
cartridge is used, the density increases. To keep the density level even throughout its life, the density bias voltage is reduced
accordingly. This will also have to be true of any aftermarket toner. This is also why there are two different reset gears. For the low
life cartridge, the bias voltage is reduced over the life of 3,500 pages. For the high yield cartridge, the bias voltage is reduced
over 7000 pages. Each time a new cartridge is installed, the bias voltage is reset to 400 volts, and the cartridge page count is
reset to zero.
UPDATE: Though the initial TN550 and TN580 cartridges came with different reset gears, all cartridges to date have been
shipping with the TN580 or double ribbed reset gear. Apparently the differences between the two were not enough to justify using
the different gears. So depending on when your cartridge was made, a low yield cartridge may have a reset gear with one or two
ribs. It does not matter any longer either way.
As with previous Brother cartridges, the waste toner is repelled out of the drum cartridge and picked up by the developer roller in
the toner cartridge and brought back into supply chamber. That is why there will always be a good amount of toner left in the
supply chamber when the cartridge is finished. This remaining toner MUST be completely removed from the supply chamber
before adding new toner. Failure to do this will cause back grounding. In addition to contaminating the toner cartridge, this will
also contaminate the cleaning section of the drum cartridge, which in turn will contaminate the toner cartridge again. The
reasons for this are explained in the following cartridge theory section.
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BROTHER
• TN550 1240/1650
• 1240/1650
580 CARTRIDGE• •REMANUFACTURING
UNINET
UNINETIMAGING
IMAGING
INC.
INC. HL-5200
• • BROTHER
BROTHER
DISASSEMBLING
ASSEMBLINGINSTRUCTIONS
THE
THETONER
TONERCARTRIDGE
CARTRIDGE
The cleaning section of the drum cartridge consists of a "cleaning brush" and a recovery blade. The cleaning brush has two
opposite charges placed on it during the print cycle. The first attracts any remaining toner off the drum. The second repels the
toner off the brush back onto the drum where it then transfers back into the toner cartridge. This is all done in a timing sequence
that does not interfere with the printing process. If the cleaning brush becomes contaminated with bad toner that will not charge,
the brush will not be able to clean itself, and back grounding will occur. It seems to be the nature of contaminated toner that it
will accept most of the charge to be cleaned off the drum, but it will not accept the charge that would allow the brush to clean
itself off at all. A properly working cleaning brush will at any given time have only a small amount of toner on it. Once
contaminated, toner will accumulate, which will only cause the problems to get worse.
Since the developer roller actually contacts the drum, some toner is transferred back into the supply of the toner cartridge. Once
you print with a bad toner cartridge, the drum unit will become contaminated. Even when you change out the toner with a good
properly recycled or new OEM cartridge, the drum unit will transfer some of the bad toner back into the good toner cartridge,
which will again cause back grounding. Both cartridges will be contaminated again.
The remaining "toner" in the toner cartridge is just below the bare minimum that can maintain the proper charge level. When the
change toner light comes on, the toner will not charge up to the proper level and will cause the back grounding. As the toner
cartridge reaches the end of its useful life, the printer senses the low charge level in the toner supply and will try to keep the
charge level up. This constant charging keeps an almost "empty" cartridge from back grounding. Once the printer cannot get the
remaining toner up to the minimum charge, the change toner light comes on. The cartridge at this point will still be printing
properly. If you were to take that same cartridge out of the machine for a few days, and then put it back in the printer with out
doing anything to it, the cartridge will shade. This will happen because the charge level that the printer was trying so hard to keep
up has dissipated out and the materials left can no longer accept a proper charge.
WHAT DOES THIS ALL MEAN?
1. Make sure that your cartridge technicians thoroughly clean out the supply chamber of the toner cartridge.
2. In the event that they forget and you have a shading cartridge, the toner must be completely cleaned out again (do not use the
same toner over!) and new fresh toner must be installed.
3. The drum unit has to be taken apart and cleaned out with emphasis on the cleaning brush area. This is a very simple process
but very necessary once it is contaminated.
According to the Brother service manual, there will be approximately 65-70g of toner left when the cartridge is spent. We have
confirmed this in our tests.
How to run test pages, printer troubleshooting, as well as common cartridge problems will be covered at the end of this article.
REQUIRED TOOLS
1. Toner approved vacuum
2. Phillips head screwdriver
3. Small common screwdriver
4. Needle nose pliers
REQUIRED SUPPLIES
1. Brother 5240 black toner (130g for TN550, 180g for TN580)
2. Reset gear for the starter cartridge
3. Lint free cotton cloths
4. Toner magnet cloths
5. White lithium grease
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© 2010 UniNet Imaging Inc. All trademark names and artwork are property of their respective owners. Product brand names mentioned are intended to show compatibility only.
UniNet Imaging does not warrant downloaded information. Unauthorized sale, reproduction or distribution of this article is prohibited. For additional support, please contact techsupport@uninetimaging.com
BROTHER
• TN550 1240/1650
• 1240/1650
580 CARTRIDGE• •REMANUFACTURING
UNINET
UNINETIMAGING
IMAGING
INC.
INC. HL-5200
• • BROTHER
BROTHER
DISASSEMBLING
ASSEMBLINGINSTRUCTIONS
THE
THETONER
TONERCARTRIDGE
CARTRIDGE
1. Vacuum the exterior of the cartridge. Remove the fill plug
from the toner cartridge. Dump the remaining toner and
vacuum/blow out the cartridge. Make sure that the gear area
is clean. Leaving any toner in the teeth of the gears may cause
a tooth to be damaged and cause a clicking noise. We have
found it best to use compressed air to clean them out, but to
also keep one hand over the gears to protect them.
2. On the NON-GEAR side of the developer roller, remove the
screw.
3. Remove the drum axle plate.
4. On the GEAR SIDE, remove the two screws and cover plate.
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BROTHER
• TN550 1240/1650
• 1240/1650
580 CARTRIDGE• •REMANUFACTURING
UNINET
UNINETIMAGING
IMAGING
INC.
INC. HL-5200
• • BROTHER
BROTHER
DISASSEMBLING
ASSEMBLINGINSTRUCTIONS
THE
THETONER
TONERCARTRIDGE
CARTRIDGE
5. The black spring-loaded reset gear may fall off as the plate
is removed. This gear resets the printer when the cartridge is
installed. New starter cartridges do not have this reset gear.
Until they are available, the starter cartridges cannot be
remanufactured.
6. Remove the black plastic spacer from the developer roller
shaft.
7. Remove the E-Ring, and small gear.
8. Remove all the remaining gears.
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© 2010 UniNet Imaging Inc. All trademark names and artwork are property of their respective owners. Product brand names mentioned are intended to show compatibility only.
UniNet Imaging does not warrant downloaded information. Unauthorized sale, reproduction or distribution of this article is prohibited. For additional support, please contact techsupport@uninetimaging.com
BROTHER
• TN550 1240/1650
• 1240/1650
580 CARTRIDGE• •REMANUFACTURING
UNINET
UNINETIMAGING
IMAGING
INC.
INC. HL-5200
• • BROTHER
BROTHER
DISASSEMBLING
ASSEMBLINGINSTRUCTIONS
THE
THETONER
TONERCARTRIDGE
CARTRIDGE
9. Remove the non-gear side end cap by gently prying it off.
10. On the gear side of the developer roller, press in on the locking tab and rotate the developer roller lock up.
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BROTHER
• TN550 1240/1650
• 1240/1650
580 CARTRIDGE• •REMANUFACTURING
UNINET
UNINETIMAGING
IMAGING
INC.
INC. HL-5200
• • BROTHER
BROTHER
DISASSEMBLING
ASSEMBLINGINSTRUCTIONS
THE
THETONER
TONERCARTRIDGE
CARTRIDGE
11. Remove the developer roller.
12. Vacuum the doctor blade and foam feed roller clean. We
do not recommend that the doctor blade be removed and the
developer roller felt seals will be disturbed. Once a new blade
is available, great care will have to be taken not to tear the
seals, causing a leak. The doctor blade can be easily cleaned
by blowing the excess toner off, and wiping down with a lint
free cloth. Be very careful not to leave any lint behind!
13. Inspect the magnetic roller felts. If they are compressed
(shiny), roughen them up with a small screwdriver.
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© 2010 UniNet Imaging Inc. All trademark names and artwork are property of their respective owners. Product brand names mentioned are intended to show compatibility only.
UniNet Imaging does not warrant downloaded information. Unauthorized sale, reproduction or distribution of this article is prohibited. For additional support, please contact techsupport@uninetimaging.com
BROTHER
• TN550 1240/1650
• 1240/1650
580 CARTRIDGE• •REMANUFACTURING
UNINET
UNINETIMAGING
IMAGING
INC.
INC. HL-5200
• • BROTHER
BROTHER
DISASSEMBLING
ASSEMBLINGINSTRUCTIONS
THE
THETONER
TONERCARTRIDGE
CARTRIDGE
14. Clean the developer roller with a lint free cloth. Do not use any chemicals other than a dedicated cleaner for the Brother rollers
to clean the roller. A dry clean cloth will work fine. Re-install the developer roller long shaft side to the gear side, and white lock
pointing up. Turn the lock towards the doctor blade until it locks in place.
15. Install the small outside end plate on the non-gear side.
Make sure the clear plastic plug for the optical sensor is locked in the proper position.
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© 2010 UniNet Imaging Inc. All trademark names and artwork are property of their respective owners. Product brand names mentioned are intended to show compatibility only.
UniNet Imaging does not warrant downloaded information. Unauthorized sale, reproduction or distribution of this article is prohibited. For additional support, please contact techsupport@uninetimaging.com
BROTHER
• TN550 1240/1650
• 1240/1650
580 CARTRIDGE• •REMANUFACTURING
UNINET
UNINETIMAGING
IMAGING
INC.
INC. HL-5200
• • BROTHER
BROTHER
DISASSEMBLING
ASSEMBLINGINSTRUCTIONS
THE
THETONER
TONERCARTRIDGE
CARTRIDGE
16. Clean the gears, making sure that they have no toner on
them. This is a good time to also check the gear shafts to
make sure there is enough grease. If the shafts appear dry, or
the grease is contaminated with toner, clean the shaft and
inside of the gear. Replace the grease with white lithium
grease.
17. Install the developer roller gear, c-ring, black axle and the rest of the gears.
Make sure all the gears are meshing properly.
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© 2010 UniNet Imaging Inc. All trademark names and artwork are property of their respective owners. Product brand names mentioned are intended to show compatibility only.
UniNet Imaging does not warrant downloaded information. Unauthorized sale, reproduction or distribution of this article is prohibited. For additional support, please contact techsupport@uninetimaging.com
BROTHER
• TN550 1240/1650
• 1240/1650
580 CARTRIDGE• •REMANUFACTURING
UNINET
UNINETIMAGING
IMAGING
INC.
INC. HL-5200
• • BROTHER
BROTHER
DISASSEMBLING
ASSEMBLINGINSTRUCTIONS
THE
THETONER
TONERCARTRIDGE
CARTRIDGE
18. Set the reset gear and spring as shown. The straight tail of the spring fits into a notch at the base of the gear shaft.
The teeth of the reset gear should start to mesh with the other gear as shown.
19. Install the gear cover plate, and two screws.
20. Install the drum axle plate on the non gear side and screw.
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© 2010 UniNet Imaging Inc. All trademark names and artwork are property of their respective owners. Product brand names mentioned are intended to show compatibility only.
UniNet Imaging does not warrant downloaded information. Unauthorized sale, reproduction or distribution of this article is prohibited. For additional support, please contact techsupport@uninetimaging.com
BROTHER
• TN550 1240/1650
• 1240/1650
580 CARTRIDGE• •REMANUFACTURING
UNINET
UNINETIMAGING
IMAGING
INC.
INC. HL-5200
• • BROTHER
BROTHER
DISASSEMBLING
ASSEMBLINGINSTRUCTIONS
THE
THETONER
TONERCARTRIDGE
CARTRIDGE
21. Fill the cartridge with Brother 5200 black toner.
22. Replace the fill plug.
Wipe the cartridge down to remove any remaining toner dust.
23. Install the developer roller cover.
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© 2010 UniNet Imaging Inc. All trademark names and artwork are property of their respective owners. Product brand names mentioned are intended to show compatibility only.
UniNet Imaging does not warrant downloaded information. Unauthorized sale, reproduction or distribution of this article is prohibited. For additional support, please contact techsupport@uninetimaging.com
BROTHER
• TN550 1240/1650
• 1240/1650
580 CARTRIDGE• •REMANUFACTURING
UNINET
UNINETIMAGING
IMAGING
INC.
INC. HL-5200
• • BROTHER
BROTHER
DISASSEMBLING
ASSEMBLINGINSTRUCTIONS
THE
THETONER
TONERCARTRIDGE
CARTRIDGE
TEST PAGES
HL-5240/5250 only:
1. To print a test page from these machines, first turn the machine off.
2. Press and hold the GO button and turn the printer back on.
3. All the LEDs will light up and turn off, except for the Status light which stays on.
Release the GO button, all the LEDs should turn off.
5. Press the GO button:
once: The printer will print out the test page.
twice: Print Fonts
3 times: Hex Dump
4 times: -8X various factory resets/tests. See service manual for more info
9 times: Test sample page
HL-5270/5280 only:
1. To print a test page from these machines, first turn the machine off.
2. Press and hold the GO Button and turn the printer back on.
3. The message USERS MODE appears on the display with an orange backlight
4. Release the GO button. All the LEDs should go off.
5. Press the GO button:
once: The printer will print out the test page.
twice: Print Fonts
3 times: Hex Dump
4 times: -8X various factory resets/tests. See service manual for more info
9 times: Test sample page
MACHINE TROUBLESHOOTING
The HL-5240/5250 machines have four LED’s to indicate the status or various problems. The HL-5270/5280 machines have an
LCD display and list the errors in plain English. We have listed some of the more common LED errors for the 5240/5250 here:
Toner light blinking / status light green:
Toner light on / status light out:
Drum light blinking / green status tight on:
DEFECT CHART
Paper feed Roller
Transfer roller
OPC Drum
Upper fuser roller
Lower Pressure roller
Developer roller
Toner low
Toner out
Drum life over soon
44.0mm
48.2mm
94.2mm
78.5mm
78.5mm
42.7mm
Maintenance kit which includes the fuser, paper feed rollers and the laser unit all have a life of 100,000 pages.
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© 2010 UniNet Imaging Inc. All trademark names and artwork are property of their respective owners. Product brand names mentioned are intended to show compatibility only.
UniNet Imaging does not warrant downloaded information. Unauthorized sale, reproduction or distribution of this article is prohibited. For additional support, please contact techsupport@uninetimaging.com
BROTHER
• TN550 1240/1650
• 1240/1650
580 CARTRIDGE• •REMANUFACTURING
UNINET
UNINETIMAGING
IMAGING
INC.
INC. HL-5200
• • BROTHER
BROTHER
DISASSEMBLING
ASSEMBLINGINSTRUCTIONS
THE
THETONER
TONERCARTRIDGE
CARTRIDGE
COMMON TONER CARTRIDGE PROBLEMS
As some problems can be caused by both the toner cartridge as well as the drum cartridge, we have listed both here:
Backgrounding (toner and drum cartridge):
By far the most common problem with these cartridges, there are three major common causes:
1. The first is contaminated toner. If the old toner in the toner cartridge was not fully cleaned out, a shaded background will result
usually over the entire page. This can also be caused by a contaminated cleaning brush in the drum cartridge, which is directly
related to a bad toner cartridge (see cartridge theory at the beginning of this article).
2. If the developer roller in the toner cartridge is worn, it will tend to pull too much toner, and backgrounding will result.
This normally happens only on cartridges that have been recycled a few times. A normal roller will have a somewhat mottled look,
and the texture should be smooth. If the roller has lines, small cracks, or just doesn’t look right, don’t use it. A dirty developer
roller can also cause this. If the roller has a white or bluish coating, it must be cleaned. Be sure to use only a dedicated Brother
developer roller cleaner. Any other type of cleaner will probably react with the toner and cause another set of problems.
3. Another backgrounding issue can result from the toner being used. Not all aftermarket toners will work together. This is
because there is always a small amount of toner left on the drum cartridge cleaning brush. Most aftermarket toners will work over
the OEM, but not all will work over another aftermarket toner. If your cartridges work in house but background out in the field, it
can be that the drum unit has failed, or that another aftermarket toner was used previous to yours. Check with your vendor to
make sure that your toner will work on top of another (all) aftermarket brand(s).
Dark black vertical streaks (drum cartridge):
This is normally caused by either a dirty primary corona wire, or the corona wire cleaner is not in its "home" position on the left
side of the cartridge.
Gray vertical streaks:
This is normally caused by a groove in the developer roller.
If the roller has a groove worn in it, it must be either replaced or re-surfaced by a company that specializes in this.
Light print (drum cartridge):
This can be caused by a dirty or worn transfer roller. These rollers are located inside the cartridge.
In our tests, they should last at least two cycles.
Black or white horizontal lines (toner and drum cartridge):
Black lines normally appear when there is a build-up of toner.
White lines appear when there is a dead spot or contamination of the roller.
Solid black pages (drum cartridge):
Bad drum ground contact, probably from the drum axle shaft to the contact gear inside the drum.
Perfectly straight thin black lines down the page (drum cartridge):
This is resulted from a scratched drum.
Black dots that repeat every 94.2mm (drum cartridge):
Bad drum or something is stuck to the drum surface.
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© 2010 UniNet Imaging Inc. All trademark names and artwork are property of their respective owners. Product brand names mentioned are intended to show compatibility only.
UniNet Imaging does not warrant downloaded information. Unauthorized sale, reproduction or distribution of this article is prohibited. For additional support, please contact techsupport@uninetimaging.com