Rechargx Rx411 User manual

TonerRellKits.com ReChargX™RX411

ReChargX™ RX411 Instructions

For relling the Dell 593-BBKC (CVXGF/2RMPM) and

593-BBKD (P7RMX/PVTHG) toner cartridges

Dell 593-BBKC & 593-BBKD toner cartridge

ReChargX™ RX411 premium print toner rell kit

Tools needed to properly rell your cartridge using the

ReChargX™ RX411 toner rell kit.

ReChargX™ RX411 Instructions: Overview

The Dell 593-BBKC (CVXGF/2RMPM) and 593-

BBKD (P7RMX/PVTHG) are the cartridges frequently

found in the following Dell printer models (and all

other machines using the same “engine”):

E310dw E514dw

E515dn E515dw

The Dell 593-BBKC (CVXGF/2RMPM) Standard-

Yield and 593-BBKD (P7RMX/PVTHG) High-Yield

cartridges are easy to rell using our ReChargX™

RX411 premium print toner rell kit.

Included in the ReChargX™ RX411 Kit

• ReChargX™ RX411 instructions

• ReChargX™ RX411 premium print toner

• ReChargX™ RX411 reset gear & spring

• ReChargX™ RX411 toner hopper plug

• Residual toner bag

• Reminder labels (2)

• Toner bottle funnel spout

• “Toner grabber” cloth

• Work surface protector/newsprint

Required Tools

The toner rell process requires the use of the

following tools (which, if you need them, are available

in our ReChargX™ Brother tool kit):

• Small phillips-head screwdriver

• Small at-blade screwdriver

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Note: Please make certain the printer is powered

“ON” throughout the entire rell procedure. Failure to

do so may cause the printer to be unable to identify

that the cartridge has been relled.

Step 1: Prepare your work surface

Included in the ReChargXTM RX411 premium print

toner rell kit is a sheet of newsprint (Figure 1).

Unfold the sheet and lay it across your work surface.

The newsprint keeps your work surface clean and is

discarded after completing the relling process.

Step 2: Position the drum unit and toner

cartridge assembly

When you remove the cartridge from your printer the

drum unit will still be attached.

Position the assembly on your work surface so the

handle on the front of the toner cartridge (A) is facing

you and the green or blue tab (B) is on the left-hand

side (Figure 2).

Step 3: Separate the toner cartridge from the

drum unit assembly

Press and hold down the green or blue tab (A)

located on the left-hand side of the unit while lifting

up on the handle of the front of the toner cartridge

with your right hand (B) to separate the toner

cartridge from the drum unit (Figure 3).

Lift the toner cartridge up and off of the drum unit.

Note: Since the drum in the drum unit can be easily

scratched or damaged, put it out of harm’s way until

we are completely nished with the relling operation.

Step 4: Prepare the cartridge for relling

Position the cartridge on your work surface so the

handle (A) is facing toward you and the developer

roller (B) is facing away from you (Figure 4).

Figure 1: ReChargX™ newsprint work surface protector

Figure 2: Positioning the drum unit and toner cartridge assembly

Figure 3: Removing the cartridge from the drum unit

Figure 4: The toner cartridge in the correct orientation

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Step 5: Protect the developer roller

The developer roller along the front of the cartridge is

critical to the image production process and can be

damaged even by a ngerprint.

To protect the roller during relling we will cover it

with a sheet of paper.

Start with a piece of paper in “portrait” orientation,

then fold the 8.5” X 11” sheet in half (folding the

top edge over to meet the bottom edge) leaving an

8.5” X 5.5” sheet.

With the cartridge face up tape one of the long 8.5”

edges to the top of the cartridge (Figure 5-1).

Carefully fold the paper over the developer roller

(again, being careful not to touch the roller with your

ngers) and tape the other edge of the paper to the

bottom of the cartridge (Figure 5-2).

Step 6: Remove the cartridge end cap

Position the cartridge on your work surface so the

black plastic end cap (which covers the internal gears

of the cartridge) is facing upward and the handle of

the cartridge is on the right-hand side (Figure 6-1).

You now have access to the two screws which

secure the end cap to the cartridge (highlighted by

the arrows in Figure 6-1).

Using the phillips-head screwdriver remove the two

phillips-head screws (Figure 6-2 and Figure 6-3) and

set them aside for later use.

After removing the two phillips-head screws, lift the

black end cap up and away from the cartridge body

to expose the gear train and set the end cap aside.

Figure 5-1: Protecting the developer roller (front-side)

Figure 5-2: Protecting the developer roller (back-side)

Figure 6-1: Cartridge positioned with end cap facing up

Figure 6-2: Removing the cartridge end cap screws (1 of 2)

Figure 6-3: Removing the cartridge end cap screws (2 of 2)

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Dell uses a “page counting” mechanism (a

combination of gears and “ags”) to report to the

printer when the cartridge is either full or used.

Before we begin the rell procedure we will address

the components of the reset mechanism that either

have to be removed or replaced.

Without properly resetting/addressing these

mechanisms, even after the cartridge has been

relled the cartridge would still appear to the printer

as being empty resulting in a false “toner low” or

“toner empty” message.

Although the starter, standard-yield, and high-yield

toner cartridges are fundamentally the same, each

requires a slightly different process to reset the page

counting mechanism.

Skip forward to the appropriate page for the reset

procedures specic to your cartridge.

If you are working on a starter cartridge (the

cartridge included with the printer) proceed to page 5

and follow steps 7a-7c.

If you are working on a standard-yield cartridge

proceed to page 6 and follow steps 8a-8e.

If you are working on a high-yield cartridge,

proceed to page 8 and follow steps 9a-9e.

Figure A: The starter cartridge (with end cap removed)

Figure B: The standard-yield cartridge (with end cap removed)

Figure C: The high-yield cartridge (with end cap removed)

Identifying the toner cartridge type

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Preparing the starter cartridge for relling and resetting

Figure 7-1: The starter cartridge (end cap removed)

Figure 7-2: After removing the starter drive gear; before

removing the actuator gear

Figure 7-3: After removing the starter actuator gear; before

removing the toner hopper plug

Figure 7-4: Removing the starter toner hopper plug

Remove the components

Figure 7-1 shows the gear end of the TN starter

cartridge (the cartridge that came with the machine

when it was new) with the end cap removed.

The components you will be removing (to be replaced

with the new components which came with the

RX411 toner rell kit to convert your cartridge into a

high-yield cartridge) are the drive gear (A), actuator

gear (B) and toner hopper plug (C).

Step 7a: Remove the drive gear

To prepare for the resetting of the starter toner

cartridge and its conversion into the equivalent of the

high-yield cartridge, we start by removing the drive

gear (A) (Before: Figure 7-1; After: Figure 7-2).

Step 7b: Remove the actuator gear

With the drive gear removed, we can remove the

actuator gear (B) from the gear train (Before: Figure

7-2; After: Figure 7-3).

Step 7c: Remove the toner hopper plug

With the drive and actuator gears out of the way we

will remove the toner hopper plug (C).

Using the edge of the opening as support, wedge the

tip of a at-blade screwdriver between the lip of the

toner hopper opening and the toner hopper plug.

Then pry the plug up and out (Figure 7-4).

Now that we have removed the starter gears and

toner hopper plug, proceed to page 10 to continue

the process.

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Figure 8-1: The standard-yield cartridge (end cap removed)

Figure 8-2: After removing the reset spring; before removing the

reset gear

Figure 8-3: After removing the reset gear; before removing the

drive gear

Preparing the standard-yield cartridge for relling and resetting

Remove the components

Figure 8-1 shows the gear end of the standard-yield

toner cartridge with the end cap removed.

The components you will be removing (to be replaced

with the new components which came with the

RX411 toner rell kit to convert your cartridge into a

high-yield cartridge) are the drive gear (A), actuator

gear (B), reset gear (C), reset spring (D) and toner

hopper plug (E), which is located under the reset

gear and not visible in this gure.

Step 8a: Remove the reset spring

To begin the process of converting the standard-yield

into the high-yield, we start by removing the reset

spring (D) (Before: Figure 8-1; After: Figure 8-2).

Step 8b: Remove the reset gear

With the reset spring removed, you may now remove

the black reset gear (C) (Before: Figure 8-2; After:

Figure 8-3) which will expose the toner hopper plug.

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Figure 8-4: After removing the drive gear; before removing the

actuator gear

Figure 8-5: After removing the actuator gear; before removing

the toner hopper plug

Figure 8-6: Removing the toner hopper plug

Step 8c: Remove the drive gear

With the reset gear removed, we will now remove

the drive gear (A) from the gear train (Before: Figure

8-3; After: Figure 8-4).

Step 8d: Remove the actuator gear

With the drive gear removed we will now remove the

actuator gear (B) from its post (Before: Figure 8-4;

After: Figure 8-5).

Step 8e: Remove the toner hopper plug

With the drive, reset, and actuator gears out of the

way we now have access to the hopper plug (E).

Wedge the tip of a at-blade screwdriver between the

lip of the toner hopper opening and the toner hopper

plug. Then pry the plug up and out (Figure 8-6).

Now that we have removed the spring, gears, and

toner hopper plug, proceed to page 10 to continue

the rell process.

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Figure 9-1: The high-yield cartridge (end cap removed)

Figure 9-2: After removing the reset spring; before removing the

reset gear

Figure 9-3: After removing the reset gear; before removing the

drive gear

Preparing the high-yield cartridge for relling and resetting

Remove the components

Figure 9-1 shows the gear end of the high-yield toner

cartridge with the end cap removed.

The parts you will be working with are the drive gear

(A), actuator gear (B), reset gear (C), reset spring (D)

and toner hopper plug (E), which is located under the

reset gear and not visible in this view.

Step 9a: Remove the reset spring

To prepare for the resetting we start by removing the

cartridge reset spring (D) (Before: Figure 9-1; After:

Figure 9-2).

Step 9b: Remove the reset gear

With the reset spring removed we will now remove

the reset gear (C) which will expose the toner hopper

plug (Before: Figure 9-2; After: Figure 9-3).

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Figure 9-4: After removing the drive gear; before removing the

actuator gear

Figure 9-5: After removing the actuator gear; before removing

the toner hopper plug

Figure 9-6: Removing the toner hopper plug

Step 9c: Remove the drive gear

With the reset gear out of the way, we will now

remove the drive gear (A) from the cartridge gear

train (Before: Figure 9-3; After: Figure 9-4).

Step 9d: Remove the actuator gear

With the drive gear removed, we will now remove

the actuator gear (B) (Before: Figure 9-4; After:

Figure 9-5).

Step 9e: Remove the toner hopper plug

With the reset spring and the reset, drive and

actuator gears out of the way, we will now remove

the toner hopper plug (E) (Figure 9-6).

Wedge the tip of a at-blade screwdriver between the

lip of the toner hopper opening and the toner hopper

plug. Then pry the plug up and out.

Now that we have removed the spring, gears, and

toner hopper plug, proceed to page 10 to continue

the process.

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Figure 10-1: Inserting cartridge into zip-top bag

Figure 10-2: Dumping out the remaining toner

Preparing the cartridges for relling and resetting

Step 10: Remove the remaining toner

Prior to adding “fresh” toner, we must remove the

residual “old” toner.

On the rst rell of your toner cartridge, the new toner

should not be combined with whatever quantity of

toner that remains in the hopper.

Failure to remove the remaining toner will result in

splotching, smudging, hazing, and other print defects.

Note: This step does not need to be performed on

subsequent rells when fresh ReChargX™ toner is

being added to the existing ReChargX™ toner.

Insert the toner hopper opening end of the cartridge

into the plastic zip-top bag which is included in the

ReChargX™ RX411 toner rell kit (Figure 10-1).

Carefully pour out as much of the residual toner as

possible (tapping along the side of the cartridge helps

to keep the toner owing) (Figure 10-2).

If the toner stops owing, stand the cartridge upright

(with the toner hopper hole facing up) and then put

the end of the cartridge back into the bag and

continue the emptying process.

With the majority of the toner removed, remove the

cartridge from the bag. Seal the bag and discard it.

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Step 11: Add the ReChargX™ RX411 premium

print toner to the toner hopper

Before starting the toner hopper relling process

(and after verifying the bottle cap is screwed rmly in

place), gently rock or shake the bottle back-and-forth

several times to ensure the toner will ow smoothly

(the toner can settle and compact during storage).

Remove the original cap from the toner bottle and

attach the clear, plastic dispenser spout from the

ReChargX™ RX411 premium print toner rell kit.

For the easiest, quickest and most mess-free relling,

tilt the end of the cartridge up with the toner hopper

hole at a 45 degree angle and slowly angle the

dispenser spout on the bottle of toner to meet up

with the hole (Figure 11). Tilting the bottle up a little

more will start the toner owing into the toner hopper.

Pour the toner slowly. RESIST ALL TEMPTATION

TO SQUEEZE THE BOTTLE to increase the ow

of toner. The likelihood of toner escaping under

pressure greatly increases when the bottle is

squeezed while lling the cartridge. If the toner

stops owing, return the bottle to the upright

position and restart the lling process.

Fill the cartridge until the hopper appears to be full.

Any toner remaining in the bottle can be used at a

later date after you have completed a signicant

amount of printing.

Step 12: Activate the toner grabber cloth

Take the orange toner grabber cloth from the

ReChargX™ RX411 premium print toner rell kit and

stretch it along both dimensions; the cloth will stretch

considerably in one dimension and not the other

(Figure 12). Stretching the toner grabber cloth

activates the toner retaining substance embedded

within the cloth which gives it the ability to pick up

and retain toner.

Note: Only use the toner grabber cloth on the exterior

of the cartridge. Do not use the cloth to clean any of

the internal components or the drum as the toner

grabber will leave a residue on those critical image

production components which will affect the quality of

the print output.

Figure 11: Adding toner to the toner hopper

Figure 12: Stretching the “toner grabber” cloth

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Step 13: Clean the area around the toner

hopper opening

For the replacement toner hopper plug to seal

properly, the area around the toner hopper opening

must be cleaned with the toner grabber cloth before

the plug is inserted (Figure 13).

Step 14: Insert the toner hopper plug

Now that the area around the toner hopper opening

is clean, place the replacement plug (E) over the

hopper hole (Figure 14-1).

Press rmly on the plug to ensure the plug is seated

rmly in the hopper hole (Figure 14-2).

Figure 13: Cleaning the area around the toner hopper opening

Figure 14-1: Replacing the toner hopper plug

Figure 14-2: Firmly seating the toner hopper plug

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Step 15: Install the actuator gear on the

toner cartridge

The position of the gear must be placed properly in

order for the toner cartridge to reset the toner “low” or

“out” message.

Use your ngers to turn the actuator gear (B) in a

clockwise motion (2 - 3 times) so the middle opening

(attached to the post) appears as a “D” when facing

toward you (Figure 15).

Step 16: Install the drive gear

With the actuator gear in place, we will now install the

drive gear (A) into the gear train (Figure 16).

Step 17: Install the reset gear

With the drive gear in place, we will now install the

reset gear (C) (included in the ReChargX™ RX411

rell kit) over the post that is protruding from the toner

hopper plug (Figure 15).

Figure 15: Installing the actuator gear

Figure 16: Installing the drive gear

Figure 17: Installing the reset gear

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Step 18: Add the reset spring & verify placement

Now that the gear has been installed, place the

spring (D) over the post of the gear (Figure 18).

With the drive gear (A), actuator gear (B), reset gear

(C), reset spring (D) and toner hopper plug (E) (not

shown), installed on the cartridge verify your cartridge

looks the same as Figure 19.

Step 19: Secure the end cap to the cartridge

Now that you have veried the gears and springs

have been added to the cartridge and are in proper

orientation lower the end cap over the gear train and

secure it in place with the two small phillips-head

screws highlighted by the arrows (Figure 20).

Step 20: Remove the protective paper

In the nal step of the relling process carefully

remove the protective paper (Figure 21) and make

certain you do not accidentally touch the developer

roller once the paper has been removed.

Figure 18: Applying the reset spring

Figure 19: Final position of the gears and spring

Figure 20: Securing the end cap to the cartridge

Figure 21: Removing the protective paper

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Step 21: Reinstall the toner cartridge into

the drum unit

To complete the entire operation, carefully reinstall

the toner cartridge into the drum unit (making certain

it clicks back into place). With the toner cartridge

rmly installed in the drum unit (Figure 22) insert the

entire assembly into the printer.

Congratulations - You are nished!

Congratulations, you have successfully relled your

toner cartridge and replaced the gears saving an

average of 70% in the process versus the MSRP at

the “ofce superstores.”

In the case of the 593-BBKD (P7RMX/PVTHG), to

which you were able to upgrade to, that’s a whopping

$51.04 in your pocket for only a few minutes work!

- End of ReChargX™ RX411 Instructions -

TonerRellKits.com technical support and

customer 100% satisfaction pledge

Our number one goal is to earn your long-term

business. If you are not 100% satised with every

aspect of your interaction with our company (our

web site, ordering process, delivery process, relling

process (instructions, tools, components, etc.),

packaging, quality of the print output, customer

service, technical support or anything else...

We need to hear from you NOW!

We are available Monday through Friday, from 9am

until 5pm Eastern Time (except for legal holidays)

and are always ready, willing and happy to answer

any of your questions or comments via customer

service or technical support.

By telephone, please call us at 352.343.7533 or

800.527.3712 (800LASER12)

We are also available via the “Live Chat” button on

every page of our web site during the same hours.

You may also submit a technical support ticket after

hours by navigating to:

www.TonerRellKits.com/Tech_Support.php

Figure 22: Reinstalling the drum unit and cartridge assembly

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