How to refill toner cartridges for Brother HL-2220, HL-2230 HL-2230D,HL-2240 HL-2240D,HL-2270 HL-2270D HL-2270DW HL-2270W HL-2280 HL-2280DW,MFC-7360, MFC-7460DN, MFC-7860DW,DCP-7060, DCP-7060D, DCP-7065DN AIO
Author: Tin Nguyen Views: 14588 Created: 2012-06-26 06:19 Last Updated: 2012-12-21 21:31 100 Rating/ 2 Voters
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How to reset the Brother TN-420 tn-450 toner cartridges 

Following these instruction Video to reset the cartridge will let you printer print another 100-300 pages before refilling the cartridges. make sure that you shake the cartridge before install it back into printer

How to refill the Brother TN-420-TN-450

Remanufacturing the Brother HL-2240/2270 Series Toner Cartridges TN-420 and TN-450

Released in November 2010, the Brother HL-2270 printer engine is based on a new 24/27-ppm, 1,200-dpi laser engine. These machines have a first page out in less than 8.5 seconds and come standard with 8MB or 32MB of memory, depending on the machine. The HL-2270DW printers also have duplexing built in. Our HL-2270DW machine came with a starter cartridge rated for 700 pages (a low-yield TN cartridge without a reset gear).

The first section of this article covers the theory behind these cartridges. The first three paragraphs have some interesting information on the reset gears and how they work. The rest is standard Brother theory. If you are not familiar with 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-2130 (Listed in service manual but not seen anywhere as of Nov. 10, 2010)

HL-2220 (Listed in service manual but not seen anywhere as of Nov. 10, 2010)






Besides the starter cartridge, there are two different yielding toner cartridges available for these machines: the TN-420/450 (TN-2210/2220 Europe). The TN-420 cartridge is rated for 1,200 pages at 5 percent; the TN-450 is rated for 2,600 pages at 5 percent. The drum unit is new as well; part number DR-420 (DR-2200 Europe) is rated for 12,000 pages. It will be covered in a future article.

The fuser assembly, paper-feed assembly and laser units all have a stated life of 50,000 pages. The printer itself is also rated for 50,000 pages, so basically when these parts are done, so is the printer.

There is a reset gear that resets the printer each time a new toner cartridge is installed. In our machine, the starter cartridge was marked just “TN” and had the reset gear section completely blocked off. See Figure 1.

 In order to recycle starter cartridges, the proper reset gear and the end cap must be replaced. Both the TN-420 and the TN-450 cartridges use different reset gears. The TN-420 gears have three flags on them versus two flags for the TN-450. That is how the machine knows if there is a standard or high-yield cartridge installed. New reset gears and an end cap are being developed so that low-yield cartridges can be made into high-yield and starter cartridges can be recycled into either one. See Figures 2 and 3.

These cartridges also use a completely new developer roller cover. See Figure 4.

An interesting point in the reset process is what happens in addition to the counter being reset. When the printer senses a new toner cartridge, the bias voltage is set to a high voltage. As the cartridge is used, the bias voltage is reduced down gradually. 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. Each time a new cartridge is installed, the bias voltage is reset to the high voltage point, and the cartridge page count is reset to zero. Since different yields would dictate different decreases in density over time, Brother uses different reset gears. This was also done in other Brother cartridges, but after awhile Brother just went with the high-yield gear for both cartridges. Time will tell what they will do with these cartridges.

Figure 5 shows how the toner and drum cartridges relate position-wise to the rest of the printer.

Basic Brother print theory

As with previous Brother cartridges, the waste toner is repelled out of the drum cartridge, picked up by the developer roller in the toner cartridge and brought back into the 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” (also known as a “charge felt”) 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 accept a charge, the brush will not be able to clean itself, and backgrounding 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 waste 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. It can be a vicious cycle.

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 backgrounding. 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 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 printing. However, if you were to take that same cartridge out of the machine for a few days, then put it back in the printer without 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’re left with a shading cartridge, the toner must be completely cleaned out again. Do not use the toner over! New, fresh toner MUST be installed.

3) The drum unit has to be taken apart and cleaned out, with emphasis placed on the charge brush. This is a very simple but very necessary process once it is contaminated.

According to our tests, there will be approximately 50 to 60 grams of toner left when the cartridge is spent. This is normal. As stated, however, the toner left is waste only and must be thrown out, or there will be backgrounding issues.

How to run test pages, printer troubleshooting, common cartridge problems and how to read the cartridge serial number will be covered at the end of this article.

Required supplies

  1. Toner-approved vacuum
  3. Small common screwdriver
  5. Phillips-head screwdriver
  7. Needle-nose pliers

Required tools

  1. Dedicated Brother HL-2270 black toner

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. Even though on these cartridges, the gears are covered, we have found it best to keep one hand over the gear side to protect them. See Figure 6.

3) On the non-gear side of the developer roller, remove two screws. Remove the two plastic arms. The smaller arm needs to be turned to release the lock. See Figures 7 and 8.

4) Remove the drum axle plate by lifting up on the two tabs as indicated, then prying the plate off. See Figures 9 and 10.

5) On the gear side, remove the two screws and cover plate. See Figure 11.

6) The reset gear is spring-loaded and must be positioned correctly for the printer to accept a new cartridge. Our printer came with a starter cartridge that did not have a reset gear, and the end cap prevented the addition of a new reset gear. Starter cartridges will need to have a reset gear and replacement end cap before they can be used. As stated above, the TN-420 and TN-450 cartridges both have different reset gears. All three types are shown here in Figures 12, 13 and 14.

7) Remove the black plastic spacer from the developer roller shaft. Press in on the back tab to release. See Figures 15 and 16.

8) Remove the E-ring. See Figure 17.

9) Remove all the remaining gears. Don’t lose the reset gear spring. See Figures 18 and 19.

10) On the gear side of the developer roller, press in on the locking tab and rotate the developer roller lock up. See Figures 20 and 21.

11) Remove the developer roller. See Figure 22.

12) Remove the two doctor blade screws and the doctor blade. Unlike previous TN cartridges, the DB is not physically attached to the seals, so it can be removed for cleaning. See Figures 23 and 24.

13) Completely remove all remaining toner from the toner hopper, foam feed roller and doctor blade foam seals. See Figure 25.

14) Inspect the magnetic roller felts. If they are compressed (shiny), rough them up with a small screwdriver. See Figure 26.

15) Carefully wipe the doctor blade down with a lint-free cloth, being very careful not to bend or damage the blade in any way. Install the blade and two screws. See Figure 27.

16) Clean the developer roller with a lint-free cloth and a dedicated Brother developer roller cleaner. Do not use any chemicals other than a dedicated cleaner for Brother rollers to clean the roller.

17) Reinstall the developer roller long-shaft side to the gear side with the white lock pointing up. Turn the lock toward the doctor blade until it locks in place. See Figures 28 and 29.

18) Install the non-gear-side axle plate. Make sure the tabs lock in place. See Figures 30 and 31.

20) Install the developer roller gear, E-ring, black axle spacer and the rest of the gears in the order shown. Make sure all the gears are meshing properly. See Figures 32 and 33.

21) Set the reset gear spring as shown. See Figure 34.

22) Depending on the cartridge you have, set the reset gears as shown. See Figure 35 for the TN-420 and Figure 36 for the TN-450. Note that the gear teeth are not meshed when set. This is how it should be. The gear is spring-loaded and will turn when driven by the printer. See Figure 37.

23) Install the gear cover plate and two screws. See Figure 38 for the TN-420 and Figure 39 for the TN-450. Make sure the black arrow on the cover is aligned with the white arrow marked “3” on the TN-420 gear and “1” on the TN-450 gear.

24) On the non-gear side, install the two plastic arms and screws. The smaller arm should be installed last and has to be turned from the bottom up so that the lock engages. See Figures 40 and 41.

25) Fill the cartridge with the proper load of Brother HL-2270 black toner (high-yield or low-yield). See Figure 42.

26) Replace the fill plug. See Figure 43.

27) Wipe the cartridge down to remove any remaining toner dust.

28) Install the developer roller cover. See Figure 44.

Test pages

Press the “GO” button three times within three seconds with the front cover closed and the ready light on. A printer settings page will print.

Defect chart

OPC drum: 94.2mm

Upper fuser roller: 53.4mm

Lower pressure roller: 78.5mm

Developer roller: 32.5mm

NOTE: If you are experiencing horizontal black streaks and changing cartridges does not help, look in the bottom of the paper tray. There is a small metal ground terminal. If it gets bent or dirty, it can cause this. See Figure 45.

    Please make sure the reset gear like picture below

Rss Comments 4
  • #
    [ Pat]: tn450 2013-03-27 00:35

    Nice idea but it just does not work. Cleaned reassembled instaled gear and spring. Toner reinstaled and toner change light is still on.

  • #
    [ jots]: Excellent write up for Brother Toner Cartridge reset 2012-11-13 09:36

    Thanks for your service. This should benefit many users trying to refill the cartridge.

  • #
    [ Mike]: Remanufacturing the Brother HL-2240/2270 Series Toner Cartridges TN-420 and TN-450 2012-09-20 23:44

    I would suggest using line drawings rather than photography because the lighting in the photography hides the details you speak of in the text. i.e. pictures 38 & 39. The text says to set the Gear Reset Spring (see picture 34) In Picture 34, I cannot see the Gear Reset Spring. Things like this are confusing to me. I bought your Toner Reset Gear for the Brother DCP 7065DN because your eBay add implied it would include easy to follow instructions.

  • #
    [Tin Nguyen]: Re: Remanufacturing the Brother HL-2240/2270 Series Toner Cartridges TN-420 and TN-450 2012-11-16 21:20

    I will post up some more picture later for the reset gear section

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