There are different methods employed in the replenishment of a cartridge's toner supply. Some cartridges require only the removal of the fill plug to access the toner chamber. Other cartridges, particularly the melt and pour types, are not designed with a fill hole. Therefore, a refill tool is required to create a fill hole and gain access to the toner chamber. The fill hole serves as an access point to the waste chamber and as inlet hole for the toner chamber.
An example of a melt and pour toner cartridge is the HP Q6000A, which loads the HP 1600, 2600, 2600N and 2605 laser printers. To administer the replenishment of the cartridge's toner supply, the process is outlined as follows:
Soldering Kit
First of all, purchase a refill tool, which is an improved version of a soldering iron with a cylindrical copper tip that is 18mm to 20mm in diameter (instead of the usual conical tip). When plugged to the electrical outlet, the copper tip heats-up sufficiently to allow the carving of a hole on the polymer surface of the toner cartridge. This is a one-time purchase of around because the refill tool can still be utilized in subsequent refills. To proceed with replenishment, secure a compatible refill product such as the HP 2600 toner refill kit. The compatible consumable is retailed at .95 and rated for the same yield as the OEM cartridge. Upon receipt of the package, check the contents and verify if all the tools pertinent to the refill are supplied with the kit; which includes 1 bottle of replacement toner powder, a pair of latex gloves, toner wipes, funnel cap and the instruction manual. Always conduct refills in a properly ventilated and lighted area. If possible work on a workbench or a table with a trash bin nearby. Line portions of the table and floor space underneath with old newspapers. This is just a precautionary measure in the event of toner spills, which rarely happens. Place the empty cartridge on the table and mark the precise location of the hole. Read the instruction manual for reference. Retrieve the refill tool, place it on the tool stand and plug the device to an electrical outlet. The device should be left to heat-up for 3 to5 minutes. Grab the handle of the now heated refill tool and vertically aim the tip over the marked spot. Push down the refill tool gently over the polymer casing and carve a hole to reveal the toner chamber. Withdraw the refill tool, place it back on the tool stand, unplug the devise and let it cool down. Inspect the hole, retrieve whatever loose plastic material found inside the chamber and dump old toner (whatever is left) into the trash bin. If necessary use a toner vacuum to completely relieve the chamber of toner residues. Next pour in the replacement toner - screw on the funnel cap over the rim of the toner bottle and let toner flow freely into the toner chamber. Using toner wipes, clean the cartridge's surface from toner residues. Seal the fill hole with duct tape or electrical tape to avoid toner leaks. Open the cavity housing the lockout chip, retrieve the old chip and set in place the new reset chip.
This completes the refill process. But before loading the cartridge back to the printer, it needs a little shake to distribute toner evenly. The toner cartridge can now be loaded to the printer and run a test print. The ensuing printouts should be clear crisp and razor sharp as expected from a compatible HP 2600 toner refill kit, similar to the OEM toner.