Refill Instructions
Canon AX and
HP-5L Cartridges

Theory

• The Toner Hopper
• The OPC (Organic Photo-Conductor) Drum
• The PCR (Primary Charge Roller)

Toner Hopper

The Toner is a fine powder composed of fine catridge particles. This toner allows waterproof printing after it has been printed on the paper. However, toner must be kept dry to work correctly.

MICR toner is special toner which retains a magnetic field. MICR toner is often used for printing checks.

If you find yourself with too light a print, you are probably low on toner.

Handling the Toner

• Avoid breathing the dust. Although most Toner is not poisonous, the dust can be quite irritating, especially if you have allergies or other breathing difficulties.
• Keep the Toner away from an open flame or hot spot, since it does burn.
• Keep the dust away from your eyes because the Toner can cause eye irritation.
• Keep the Toner dry and clean of any contaminations to avoid clumping of the toner.

OPC Drum

The OPC Drum is given a charge of static electricity by the PCR as it rotates. The drum is then written on by the laser which removes the static charge at points. The drum rotates further and attracts a coating of toner, which is deposited on the paper. Finally, another heated roller melts the catridge toner so that it fuses with the paper.

The OPC Drum has a typical life of 10,000 to 15,000 pages. As the OPC Drum grows old, it begins to show two signs of aging:

• It doesn't hold a charge well. This causes the printed pages to be light, even when plenty of toner is present.
• A distinctive mark appears on every printed page at intervals of about 3 to 4 inches. (The exact distance is the same every time for a given inkjet, and is the circumference of the OPC Drum).

Handling the OPC Drum

• Keep out of bright light and direct sunlight! Light gradually wears out an OPC Drum and should be avoided.
• Never touch the surface of the drum, since this can cause oil spots and scratches which will appear on your printed pages.
• Be careful to lay the Drum on a soft cloth.
• Always replace the wiper blade when you replace an OPC Drum.

PCR

The PCR applies the charge to the OPC Drum.

PCR's have a typical life of 25,000 to 35,000 pages. We also suggest that the PCR be gently wiped with a soft cotton cloth every 10,000 pages to remove OCR film that has accumulated on the PCR.

If the PCR is bad, the most common problem is that the printed page will have a regular mark every 1 to 1 and 1/2 inches (4 to 6 mm). The exact distance depends on the circumference of the PCR.

Handling the PCR

Instructions

Setup and Tools

• Choose a work area with good lighting and no breezes. But the work area should not be in direct sunlight.
• Spread out a newspaper to work on.
• You will need:
  • a small crosshead (Phillips) screwdriver
  • a small hexhead screwdriver or allen wrench may be needed instead for some cartridges.
  • a pair of pliers or side cutters.
  • The first time you may also need a 1 1/4th inch (33 mm) hole saw or wood drill bit and a drill. Optionally, you may use a 1 inch (25 mm) drill bit.
  • a small flathead screwdriver.
  • a small funnel.
  • a vacuum cleaner.
  • Several soft cotton cloths or towels.

Supplies

• Regular Black Toner, 1 bottle -- AX-A07500160
• Regular Black Toner, 4 bottles -- 4AX-A07500160
• Black MICR Toner, 1 bottle -- AXM-A07509160
• Black MICR Toner, 4 bottles -- 4AXM-A07509160
• OPC Drum -- Z00075004
• OPC Wiper -- Z01075001
• PCR -- Z21075000

Method for Refilling the Toner Cartridge

Part One

1. Separate the toner hopper from the OPC Drum holder by removing the metal pins on either end of the cartridge with a pair of pliers. Set aside the toner hopper.
2. Take the OPC Drum holder. You will need to partially disassemble this section since it contain the waste toner. If the waste toner section is not vacuumed, blobs of excess toner will begin to appear on your printed pages.
3. Remove the OPC Drum by removing the small axle which is located on the larger gear side of the OPC Drum with your pliers. Then use a small screwdriver to pry out the axle on the other side of the housing. You might locate the indention on the catridge color and use this as a pry point.
4. Remove the axle and then the OPC Drum. Set the OPC Drum aside on a towel and cover to protect from light.
5. Now, remove the PCR and place on a towel. You may gently wipe the PCR clean with a soft cloth or towel.
6. Next, remove the wiper blade by removing the two retaining screws. Check the wiper blade for damage and clean very gently with a soft cloth. Always replace the wiper blade when you replace the OPC Drum.
7. Carefully vacuum out the waste hopper.
8. Clean the metal contacts which hold the end of the PCR with a cotton swab if coated with toner. Use alcohol if particularly coated.
9. Reassemble the OPC Drum unit.
   1. Put the wiper blade back in place.
   2. Put the PCR back in place.
   3. Put the OPC Drum back in place.
   4. Cover with a towel to prevent light damage to the OPC Drum.

Part Two

Option A

1. The purpose of the next few steps is to expose the translucent plug through which we can refill the toner. These steps may not be needed on some units which have an accessible plug. If you are one of those lucky owners, go down a few steps and remove the plug. If you are not lucky, continue on....
2. Remove the screw which holds on the housing over the gears.
3. Carefully remove the housing to avoid damage to the catridge pins which are part of the housing.
4. Carefully remove the gears. Keep the order straight to make it easier to re-insert.
5. Drill a hole into the back of the gear housing using the 1.25 inch (33 mm) drill bit. The purpose of this hole is to allow you to remove the translucent plug which seals the toner hopper.
6. Remove the plug.
7. Using the funnel, fill the cartride with 1 bottle of toner.
8. Replace the plug.
9. Replace the gears in the proper order.
10. Replace the housing.
11. Reassemble the two pieces of the cartridge with the two metal pins.
12. Store the cartridge in a dry, dark place.

Option B

1. On the toner hopper section, locate a flat surface on the top or bottom of the cartridge far away from the drums.
2. Drill a 1 inch (25 mm) hole which you can later plug tightly with our provided translucent hopper cap.
3. Using the funnel, pour the contents of 1 bottle of toner into the cartridge.
4. Plug the hole.
5. Reassemble the two pieces of the cartridge with the two metal pins.
6. Store the cartridge in a dry, dark place.