BROTHER HL-2030 TN350 TN2000 TN2025
TONER CARTRIDGE REMANUFACTURING INSTRUCTIONS
BROTHER HL-2030 TN350 TN2000 TN2025 TONER CARTRIDGE

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BROTHER HL-2030 TN350 TN2000 TN2025 TONER CARTRIDGE REMANUFACTURING INSTRUCTIONS
REMANUFACTURING THE BROTHER HL-2030 TN350/TN2000/TN2025 TONER CARTRIDGES
By Mike Josiah and the Technical Staff at UniNet Released in January 2005, the Brother HL-2030 printer engine is based on a 20ppm, 1200 DPI laser engine. While it is similar to previous Brother engines, there are differences. Beside physically looking different, the toner is also new. The first section of this article covers the theory behind these cartridges. If you are already familiar with the pitfalls of the HL-1240 cartridges, there is nothing new in the theory here. If you are not however, it would be best to read through this section. It may save you a few very frustrating hours. MACHINES BASED ON THIS ENGINE With a retail price of $137.00 USD for the HL-2040, they are very popular: HL-2030, 2040, 2070N MFC-7020, 7220, 7225, 7420, 7820 DCP-7020 Intellifax 2820, 2920 Brother has only released one cartridge for these machines: the TN350 (TN2000 in Europe and TN2025 in Asia and Australia). The TN350 cartridge is rated for 2,500 pages at 5% coverage. The drum unit is new as well, part # DR350 (DR2000 Europe, DR2025 in Asia and Australia). It will be covered in a future article. One change for these cartridges is the presence of a flag gear that resets the printer. The starter cartridges that come with new printers do not have this gear. We are working on new flag gears, but until they become available, the starter cartridges cannot be remanufactured. 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 backgrounding. 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. 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 backgrounding. 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 backgrounding. As the toner cartridge reaches the end of it's 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 backgrounding. 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 printin 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). New fresh toner must be installed. 3. The drum unit needs to be taken apart and cleaned out with emphasis on the cleaning brush area. This is a very simple process but very necessary once contaminated. How to run test pages, printer troubleshooting, as well as common cartridge problems will be covered at the end of this article.
TOOLS REQUIRED 1. Toner approved vacuum 2. Phillips head screwdriver 3. Small common screwdriver 4. Needle nose pliers
SUPPLIES REQUIRED 1. Brother 2030 black toner (90g) 2. Lint free cotton cloths 3. Toner magnet cloths 4. White lithium grease
1. Vacuum the exterior of the cartridge.
2. 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.
3. On the non-gear side of the developer roller, remove the screw.
4. Locate the two tabs on the developer roller end plate and pry off.
5. On the gear side, remove the three screws and cover plate.
6. A white flag gear will fall off as the plate is removed. This flag resets the printer when the cartridge is installed. New starter cartridges do not have this flag gear. Until they are available, the starter cartridges cannot be remanufactured.
7. Remove the black plastic spacer from the developer roller shaft.
8. Remove the E-Ring and small gear.
9. Remove the developer roller.
10. 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.
11. Inspect the magnetic roller felts. If they are compressed, (shiny) roughen them up with a small screwdriver.

12. 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.
13. Clean the developer roller with a lint free cloth. Do not use any chemicals other than a dedicated cleaner for Brother rollers to clean the roller. A dry clean cloth will work fine.
14. Re-install the developer roller long shaft side to the gear side.
15. Install the small outside end plate and screw on the non-gear side. Make sure the clear plastic plug for the optical sensor is locked in the proper position.
16. Install the developer roller gear, c-ring, and black axle. Make sure all the other gears are meshing properly. You may have to release the white spacer on the mag shaft to get the gear back on.
17. Set the flag gear. Install the gear cover plate and three screws.
18. Fill the cartridge with Brother 2030 black toner.
19. Replace the fill plug. Wipe the cartridge down to remove any remaining toner dust.
20. Install the developer roller cover.
TEST PAGES 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 go off. 4. When the TONER LED comes on, release the GO button. 5. Press the GO button again and the printer will print out the test page. This can also be accomplished through the printer driver.
MACHINE TROUBLESHOOTING These machines have four LEDs to indicate the status or various problems. We have listed some of the more common ones here: Yellow TONER light blinking/ Green READY light on: Yellow TONER light on/ READY light out: Yellow DRUM light blinking/ Green READY light on: All lights blinking:

Toner Low

Toner out
Drum life over soon Service call needed
When the GO button is pressed, a secondary set of errors will show: Yellow TONER light on: Yellow DRUM light on: Yellow TONER/Red PAPER lights on: Red PAPER light on: Fuser error Laser error Main Motor failure Engine PCB failure

Schedule of Brother original drivers
Monochrome Lasers Printer HL-2030 early December HL-2030R early December HL-2035 early December HL-2035R early December HL-2040 early December HL-2040R early December HL-2045 early December HL-2070N early December HL-2070NR early December HL-2075N early December HL-2140 end of October HL-2140R end of October HL-2150N end of October HL-2150NR end of October HL-2170W end of October HL-2170WR end of October HL-5240 early December HL-5240L early December HL-5250DN early December HL-5270DN early December HL-5280DW early December HL-5340D end of October HL-5350DN end of October HL-5350DNLT end of October HL-5370DW end of October HL-5370DWT end of October HL-5380DN end of October HL-6050 early December HL-6050D early December HL-6050DN early December HL-7050 early December HL-7050N early December HL-8050N early December Color Lasers Printer HL-2700CN end of October HL-3040CN late October HL-3070CW late October HL-4040CDN late November HL-4040CN late November HL-4050CDN late November HL-4070CDW late November Monochrome Laser Fax/ MFC/ DCP DCP-7010 early December DCP-7010L early December DCP-7010R early December DCP-7020 early December DCP-7025 early December DCP-7025R early December DCP-7030 early December DCP-7030R early December DCP-7040 early December DCP-7040R early December DCP-7045N early December DCP-7045NR early December DCP-8060 late December DCP-8065DN late December DCP-8070D late October DCP-8080DN late October DCP-8085DN late October FAX-2820 early December FAX-2920 early December FAX-2920R early December FAX-4100/FAX-4100e early December FAX-4750e early December FAX-5750e early December MFC-7220 early December MFC-7225N early December MFC-7320 early December MFC-7320R early December MFC-7340 early December MFC-7345N early December MFC-7420 early December MFC-7420R early December MFC-7440N early December MFC-7440NR early December MFC-7450 early December MFC-7820N early December MFC-7820NR early December MFC-7840N early December MFC-7840W early December MFC-7840WR early December MFC-8220 early December MFC-8370DN late October MFC-8380DN late October MFC-8460N late December MFC-8480DN late October late December MFC-8660DN MFC-8670DN late December late October MFC-8680DN MFC-8860DN late December MFC-8870DW late December MFC-8880DN late October MFC-8890DW late October Color Multifunction Machine DCP-9040CN early December DCP-9042CDN early December DCP-9045CDN early December MFC-9010CN late October MFC-9120CN late October MFC-9320CW late October MFC-9420CN end of October MFC-9440CN early December MFC-9450CDN early December MFC-9840CDW early December
* Not all models are available in all countries. * The schedule is subject to change.
Inkjet Fax/ MFC/ DCP DCP-115C late December DCP-116C late December DCP-117C late December DCP-120C late December DCP-130C end of October DCP-135C end of October DCP-145C early December DCP-150C end of October DCP-153C end of October DCP-155C end of October DCP-163C early December DCP-165C early December DCP-167C early December DCP-185C early December DCP-195C late October DCP-197C late October DCP-315CN late December DCP-330C end of October DCP-340CW late December DCP-350C end of October DCP-353C end of October DCP-357C end of October DCP-373CW late October DCP-375CW late October DCP-377CW late October DCP-383C early December DCP-385C early December DCP-387C early December DCP-540CN end of October DCP-560CN end of October DCP-585CW early December DCP-6690CW end of October DCP-750CW end of October DCP-770CW end of October FAX-1860C end of October FAX-1960C end of October FAX-2480C end of October FAX-2580C end of October MFC-215C late December MFC-230C end of October MFC-235C end of October MFC-240C end of October MFC-250C early December MFC-255CW late October MFC-260C end of October MFC-265C end of October MFC-290C early December MFC-295CN late October MFC-297C early December MFC-3360C end of October MFC-425CN late December MFC-440CN end of October MFC-465CN end of October MFC-490CW early December MFC-495CW late October MFC-5460CN end of October MFC-5490CN early December MFC-5860CN end of October MFC-5890CN end of October MFC-640CW late December MFC-6490CW end of October MFC-660CN end of October MFC-665CW end of October MFC-680CN end of October MFC-685CW end of October MFC-6890CDW late October MFC-790CW early December MFC-795CW late October MFC-820CW late December MFC-845CW end of October MFC-885CW end of October MFC-990CW early December