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How To Properly Remanufacture Your Brother TN540 Toner Cartridges For The HL-5100 In Just 23 Steps

   By: Joseph Mercado

Here we have the Brother TN-540 toner cartridge which has been around since May of 2004. This toner is designed to fit into the Brother HL-5150 printer which is based a 21 page per minute and 1200 dots per inch LaserJet engine.

This engine is actually and upscale to the HL-1240, using the TN-460 cartridge. The primary difference is that the toner from the TN-460 toner is not engineered to be used in the TN-540 neither the TN 570 cartridge. Yet, the print engines share similar foundations.

The TN-540 is the low yield cartridge and the TN-570 is the high yield cartridge for the following Brother LaserJet printer models:


This TN-540 cartridge will yield up to 3,500 pages when printing at 5% coverage on A4 - Letter sized paper. The TN-570 toner cartridge will yield up to 6,700 pages when printing at 5% coverage on the same paper as the TN-540.

Let's get straight to the point, no beating around the bush during this lecture.

First, you will need the necessary Tools & Supplies Required:

Tools & Supplies Required:

•#1 Phillips Head Screwdriver (tool)
•Phillips Head Jeweler's Screwdriver (tool)
•Small Flat Blade Screwdriver (tool)
•Lint-free Cotton Cloths (supply)
•Toner Magnetic Cloths (supply)
•White Lithium Grease (supply)

Below are your 22 easy steps to know how to remanufacture your Brother TN 540 and TN 570 toner cartridges.

Here you will also be provided with the OEM information part numbers;

Part #'s:

•TN-540 (low yield)
•TN-570 (high yield)

Step-by-Step “How-to-Remanufacture the Brother TN-540/570” Instructions:

Step #1:

•First thing first, vacuum the outside part of the cartridge, removing any excess toner. Simply remove the fill plug which is located on the bottom left hand side of the cartridge itself. Deposit the excess toner and vacuum out the cartridge. Be sure that the gear area is spotless. If you leave any toner in the teeth of the gears, it may ruin it and could create a clicking noise. You are better of suing compressed air which will get the job done cleaner and faster. Just keep your hand over the gears so no dust particles get in there.

Step #2:

•The side with no gear, where the static roller is, take off the black spring loaded plastic axle.

Step #3:

•Find the three tabs on the static roller end plate and remove them gently.

Step #4:

•Back to the gear side, remove the two screws that are holding the cover plate and remove the cover plate at that point.

Step #5:

•Gently remove the plastic axle.

Step #6:

•Now take off the e-ring and small gear.

Step #7:

•As for the doctor blade side of the static roller, there will be another small plate. It's located on the end of the roller and inside the plastic wall of the cartridge.

Step #8:

•From the outside wall, locate a small, round hole. With your pointer finger, press the round tab located inside the hole. As you're pressing in, turn the plate up so that the plate and roller are absolutely free.

Step #9:

•You should now be able to remove the static roller assembly.

Step #10:

•Using your air compressed vacuum, clean the doctor blade and foam feed roller. It's not recommended removing the doctor blade because you may disturb the static roller felt seals which are delicate. Once a new blade is on hand, your special care will be needed since you do not want to tear the seals. This would end up causing a leak in the cartridge. The doctor blade is easily cleaned, all you have to do is blow off the excess toner dust and wipe it down with your lint-free cloth. Please make sure you don't leave any lint behind.

Step #11:

•Time for inspection! Carefully inspect the magnetic roller felts. If they are compressed (shiny), then use a small screwdriver to tighten them.

Step #12:

•Now you need to clean your gears, make sure that the fine-toothed gears have no toner on them. This is a good time to check that the gears have enough grease on them. If for some reason the shafts appear dry or the grease is contaminated with toner, you need to clean both the inside of the gear and the shaft.

Step #13:

•Again, clean the static roller with a lint-free cloth. Do not use the chemicals to clean the roller. A nice dry, clean, non-smelly cloth will work just fine.

Step #14:

•Re-install the static roller inside the end plate first. The inside plate needs to be rotated so that it locks in place.

Steps #15 and #16:

•You have to install the small outside end plate and both the spring-loaded white axle and non-spring axle.

Steps #17, #18, & #19:

•It's about that time; you can now install the static roller gear, e-ring, and white axle. Make sure all the other gears are meshing properly.

Step #20:

•Then, install the gear cover plate and its two screws.

Step #21:

•Finally, you can fill the cartridge with Brother 5150 black toner – 140 grams for the TN-540 (TN-3030) and as for the TN-570 it uses 200 grams of toner (TN-3060).

Step #22:

•At last, you can replace the fill plug. I also recommend cleaning down the toner cartridges in case there is any left over toner dust.

Step #23:

•Test the cartridge. For this cartridge model, there are no reset fuses or procedures the Brother TN-540 or the TN-570.

Congratulations! You've now just completed your Brother TN540/570 cartridge put together project. This information is provided to you to both educate and improve your knowledge in the technical area within the remanufacturing industry.

In description of, Joseph Mercado is known as The Internet Marketing Tyrant. He specializes in the consumable market involving studies on your Brother toner cartridges;

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