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1 LICENSE AGREEMENT Static Control Components, Inc. (Static Control ) grants this limited license to the person, firm or corporation (hereinafter "User") downloading electronically or by printing this file to use Static Control s copyrighted documents in accordance with the terms of this agreement. If you agree with the terms of the license then you may download this information. If you do not agree with the terms of the license, then you are not authorized to use this information, and any use of it may be in violation of Static Control s copyrights or trademarks. TRADEMARKS The Static Control material herein may make reference to its own trademarks, or trademarks of others. Static Control grants a limited license to the User to use Static Control s trademarks in its internal documents and for its internal purposes on the following terms and conditions. Any use of Static Control s trademark must be used in a context which makes it clear that the product reference is a Static Control Components, Inc. product, and not a product from any source. The materials provided to the User may include reference to trademarks of others. Any use of the User makes of these marks should reference the owner of those marks. Nothing in this agreement constitutes any authorization by Static Control to use any of these trademarks in any context. COPYRIGHTS Static Control grants a limited license to the User to use the attached copyrighted documents. The permitted use of these documents is limited to internal purposes and needs of the company. The company is prohibited from using these copyrighted documents, or any part of them, including graphic elements, in any materials that are used outside the physical business location of the User. The User is prohibited from using any materials in any documents whether printed or electronic, which are distributed to any third party. The use of these copyrighted documents, or parts of them, including graphic elements, from these documents in marketing material, either print, electronic or web is prohibited. The sale, transfer, copying of these documents or any parts of these documents to any other party is prohibited. Static Control Components, Inc. retains all rights to its copyrighted documents, and any use of these documents by User should reference Static Control s copyrights, with the notice "copyright Static Control Components, Inc." Static Control reserves the right to cancel this license on 30-days written notice. All of the User s material incorporating Static Control s copyrighted documents shall be destroyed upon receipt of its notice of termination. The User may not distribute, share, and otherwise convey the copyrighted documents to any other persons, corporations or individuals. The User, by use of these documents, acknowledges Static Control s copyright in these materials. STATIC CONTROL DOES NOT GUARANTEE OR WARRANT DOWNLOADED INFORMATION The information User is downloading is published by Static Control in "as is" condition "with all faults". Static Control makes no representations or warranties of any kind concerning the quality, safety, or suitability of the downloadable materials, either express or implied, including without limitation any implied warranties of merchantability,fitness for a particular purpose, or non-infringement. Further, Static Control makes no representations or warranties as to the truth, accuracy or completeness of any statements, information or materials concerning items available for download. In no event will Static Control be liable for any indirect, punitive, special, incidental, or consequential damages however they may arise even if Static Control has been previously advised of the possibility of such damages. Version 1 11/03

2 R E M A N U F A C T U R I N G I N S T R U C T I O N S Samsung ML-1610/2010 Series Cartridges (Samsung ML2510/2570/1640/2240, Samsung SCX4321/4521/4725, Xerox Phaser 3117/3122/3124/3125/3200 MFP, Xerox WorkCentre PE-220, Dell 1100/1110) System Support Series 772 Tools & Supplies...2 Wirelines Conversion Chart...5 Separating the Two Sections...7 Disassembling the Hopper Reassembling the Hopper Disassembling the Waste Section..14 Reassembling the Waste Section...15 Reassembling the Two Sections...16 Heat Staked Cartridge Section Separating the Two Sections...17 Disassembling the Waste Section..18 Reassembling the Waste Section...19 Disassembling the Hopper...20 Reassembling the Hopper...21 Assembling the Two Sections Additional Information...24 Other System Support Series documents available in Adobe Acrobat format V

3 Tools & Supplies Lint-Free Foam Tip Swabs (LFSWAB) Lint-Free Cleaning Cloth (LFCCLOTH) Felt Foam Scraper (FSTOOL) Conductive Lubricant (CONCLUBE) Fuse (SCX4216FUSE) Cotton Swab (QTIP) Lubriplate Lubricant Phillips Screwdriver Dry, Filtered, Compressed Air for Cleaning Small Slotted Screwdriver Needle Nose Pliers 91-99% Isopropyl Alcohol Lint-Free Cleaning Cloth (LFCCLOTH) Felt Foam Scraper (FSTOOL) Lint-Free Tip Swabs (LFSWAB) Conductive Lubricant (CONCLUBE) Additional Tools for Cartridge Conversion Conversion End Plate (SAM1610CONVEPLT) Conversion Waste Bin (SAM1610CONVWBIN) Cotton Swabs (QTIP) Fuse (SCX4216FUSE) Additional Tools for Heat Staked Cartridge Section Curved Scraper Blade Tool (CFSTOOL) Foam Removal Tool (CSS-40) PX Retrofit Screws (PXSCREW) Drill 3/32 Drill Bit Curved Scraper Blade Tool (CSBTOOL) PX Retrofit Screws (PXSCREW) Foam Removal Tool (CSS-40) page 2 System Support Series 1058

4 Wirelines Developer Roller End Foams Contact Side End Plate Contact Spring Hopper Section Idler Gear Agitator Gear Developer Roller Drive Gear Developer Roller End Plate Doctor Blade Sealing Foam Doctor Blade Developer Roller Drive Side End Plate Adder Roller Drive Gear PCR OPC Drum Hopper Section Assembly p r o d u c t w i r e l i n e s System Support Series 772 page 3

5 Wirelines Wiper Blade End Felts Waste Bin Section Wiper Blade Sealing Foam Wiper Blade End Foam Recovery Blade Wiper Blade End Foam Wiper Blade Waste Bin Section p r o d u c t w i r e l i n e s System Support Series 772 page 4

6 End Plate Needed Conversion Waste Bin Needed Both End Plate & Waste Bin Needed Samsung ML ,000 pages ML-1610D2 Samsung ML-2010/2510/2570 3,000 pages ML-2010D3 Samsung SCX-4321/4521F MFP 3,000 pages SCX-4521D3 Dell 1100/1110 2,000 pages MFG.P/N GC502 Dell P/N Xerox Phaser 3117/3122/ 3124/3125 3,000 pages 106R01159 Xerox WorkCentre PE220 MFP 3,000 pages 013R00621 Xerox Phaser 3200MFP 3,000 pages 113R00730 Samsung SCX-4725FN 3,000 pages SCX-D4725A/XAA Samsung ML-1610/2010 Family Conversion Chart CONVERTING TO Chipped Cartridges Samsung ML ,000 pages ML-1610D2 Samsung ML-2010/2510/2570 3,000 pages ML-2010D3 Samsung SCX-4321/4521F MFP 3,000 pages SCX-4521D3 Dell 1100/1110 2,000 pages MFG.P/N GC502 Dell P/N Xerox Phaser 3117/3122/ 3124/3125 3,000 pages 106R01159 Xerox WorkCentre PE220 MFP 3,000 pages 013R00621 Xerox Phaser 3200MFP 3,000 pages 113R00730 Samsung SCX-4725FN 3,000 pages SCX-D4725A/XAA N/A Straight Remanufacture (Starter cart. will not hold 3K toner load 90g max.) (Starter cart. will not hold 3K toner load 90g max.) (Starter cart. will not hold 3K toner load 90g max.) (Starter cart. will not hold 3K toner load 90g max.) (Starter cart. will not hold 3K toner load 90g max.) (Starter cart. will not hold 3K toner load 90g max.) No Modification Required N/A Straight Remanufacture N/A Straight Remanufacture N/A Straight Remanufacture N/A Straight Remanufacture N/A Straight Remanufacture N/A Straight Remanufacture N/A Straight Remanufacture Samsung ML-1640/2240 1,500 pages MLT-D108S Highly Encrypted CONVERTING FROM Chipped Cartridges Samsung ML-1640/2240 1,500 pages MLT-D108S Highly Encrypted (Starter won t hold required toner load - 75g max) (Starter won t hold required toner load - 75g max) (Starter won t hold required toner load - 75g max) (Starter won t hold required toner load - 75g max) (Starter won t hold required toner load - 75g max) (Starter won t hold required toner load - 75g max) (Starter won t hold required toner load - 75g max) (Starter won t hold required toner load - 75g max) * - End Plate must accept installation of a chip to properly function in the corresponding printer ** - End Plate must have cartridge recognition contact to properly function in the corresponding printer. NOTE: 80g bottle is offered for remanufacturing ML-1640/2240- Starter will only hold 75g but this is enough to meet the 1500 pg yield. Standard Cart. Straight Remanufacture Correct End Plate Req d for Starter Cartridge* (See bottom) System Support Series 772 page 5

7 page 6 System Support Series 772

8 Separating the Two Sections For instructional purposes the Dell 1100 is shown throughout this instruction. 1. Remove the two screws from the front of the cartridge, as shown in Figure 1a. Remove 2 Screws 2. Separate the sections. Press the waste bin section down in the middle, then slide the waste bin away from the drum, see Figure 2. Note: A small amount of waste toner will fall from the waste bin when removed. Push Down Here Figure 1a Note: If heat stakes are in place of the screws, then refer to page 17 for remanufacturing instructions. See Figure 1b. Slide away from Drum Figure 2 Heat Stakes Figure 1b System Support Series 772 page 7

9 Disassembling the Hopper 1. Remove the two screws from the drive side end plate, see Figure 3. Remove Screws 4. Using a small slotted screwdriver, gently pry off the contact side end plate from the hopper, see Figure 6. Pry off End Plate Figure 3 Figure 6 2. Using a small slotted screwdriver, gently pry off the drive side end plate from the hopper, see Figure 4. Pry off End Plate 5. Grasp the PCR by the metal shaft on the contact side and slide towards the geared side and lift from the hopper, as shown in Figure 7. Note: Clean the PCR of any debris by using dry filtered compressed air and wiping it with a lint free cloth. Slide Figure 4 3. Remove the two screws from the contact side end plate, as shown in Figure 5. Lift Figure 7 6. Remove the drum by lifting it from the hopper section as shown in Figure 8. Remove Screws Figure 5 Lift Drum out by gears Figure 8 page 8 System Support Series 772

10 Disassembling the Hopper 7. Lift the spring off of the developer roller axle. Remove the spring from the contact side of the hopper, as shown in Figure 9. Remove the Spring Note: Remove the four gears on the drive side of the hopper, see Figure 12. Developer Roller Drive Gear Idler Gear Agitator Gear Adder Roller Drive Gear Figure 12 Figure 9 8. Remove the developer roller end plate. Release the tab on the bottom of the plate, as shown in Figure 10. Release Tab using small slotted screwdriver 10. Remove the developer roller from the hopper section. Lift the contact side of the developer roller from the cradle and remove the developer roller, see Figure 13. Note: Clean the developer roller with dry, filtered compressed air and then wipe with a lint free cloth. Figure Grasp the tab with needle nose pliers and remove from the hopper, as shown in Figure 11. Grasp and slide out plate Note: If cleaning the doctor blade then continue with step 11. If replacing the doctor blade then skip to step Using the wooden end of a cotton swab, rub along the working edge of the doctor blade to remove any embedded toner, as shown in Figure 14. Figure 13 Figure 11 Figure 14 System Support Series 772 page 9

11 Disassembling the Hopper 12. Remove two screws from the doctor blade and lift the doctor blade out of the hopper, see Figure 15. Remove the two screws from the Doctor Blade Figure Pry the hopper cap from the hopper. Using dry, filtered compressed air clean the excess toner from the hopper section, as shown in Figure 16. Clean the Hopper with Compressed Air Figure Inspect the felts, foams, and sealing blade for damage. Replace if there is any damage, see Figure 17. Inspect Felts, Foams, and Sealing Blade Figure 17 page 10 System Support Series 772

12 Reassembling the Hopper 1. Install the doctor blade and secure with two screws, as shown in Figure Install the contact side spring to the post on the hopper, and place the end of the spring onto the developer roller axle, as shown in Figures 21a, b and c. Slide onto post Install Doctor Blade and secure with two screws Figure 18 Figure 21a 2. Slide the longer keyed shaft of the developer roller into the geared side of the hopper section and place the non-keyed end into the cradle, see Figure 19. Fit top of spring into notch on the Doctor Blade Place on Developer Roller Axle Place into cradle Slide into slot Figure 21c Figure 21b Figure Install the developer roller plate, and be sure to lock the locking tab, see Figure Install the gears on the drive side of the hopper, as shown in Figure 22. Idler Gear (3) Be sure to secure the locking tab Developer Drive Roller Gear (4) Agitator Drive Gear (1) Slide in plate Figure 20 Adder Roller Drive Gear (2) Figure 22 System Support Series 772 page 11

13 Reassembling the Hopper 6. Grasp the drum by the geared side, and gently place the drum into the cradle, as shown in Figure Using a cotton swab dampened with 91-99% isopropyl alcohol clean the toner from the contact side and the drive side end plate contacts and bushings, see Figures 26 and 27. Clean toner from the Contacts and Drum Axle Gently place Drum into Cradle Figure 23 Note: Be sure to apply conductive lubricant to the contact side PCR saddle. 7. Install the PCR. Slide the long shaft into the drive side PCR saddle and then fit the short shaft into the contact side PCR saddle, as shown in Figure 24. PCR Saddles Clean toner from the Drum Axle and bushings Figure 26 Figure 27 Figure Fill with qualified toner and replace the hopper cap, see Figure 25. Note: If converting a non-chipped cartridge into a chipped cartridge or converting a chipped cartridge to a non-chipped cartridge, refer to the conversion chart (page 5) for more information. Fill with toner Figure 25 page 12 System Support Series 772

14 Reassembling the Hopper 10. Using a cotton swab, apply lubricant to the drive side end plate bushings and the drum axle, as shown in Figure Attach the contact side end plate to the hopper and secure with two screws, see Figure 31. Apply lubricant to the drum axle and bushings Secure with two Screws Figure 28 Figure Using a cotton swab, apply conductive lubricant to the contact side end plate contacts and the drum axle, as shown in Figure 29. Refer to System Support Series #855 or #963 for chip installation instructions. Apply conductive lubricant to the contacts and drum axle Figure Attach the drive side end plate to the hopper and secure with two screws, as shown in Figure 30. Secure with two Screws Figure 30 System Support Series 772 page 13

15 Disassembling the Waste Section 1. Remove the two screws from the wiper blade and lift the wiper blade from the waste bin, see Figure Inspect the felts, foams and recovery blade for damage, see Figure 34. Replace if necessary. Remove the two screws from the Wiper Blade and lift from the Waste Bin Inspect Wiper Blade End Felts/Foams Figure 32 Note: If converting a cartridge to fit into an undesignated printer, then refer to the conversion chart (page 5). Inspect the Recovery Blade Inspect Wiper Blade Sealing Foam Figure Using dry, filtered compressed air, clean the excess toner from the waste bin, as shown in Figure 33. Clean excess toner from the Waste Bin with compressed air Figure 33 page 14 System Support Series 772

16 Reassembling the Waste Section Note: If converting between families (ie. Samsung to Dell ), refer to the conversion chart (page 5) for more information. 1. Install the wiper blade into the waste bin and secure with two screws, see Figure 35. Note: Be sure to dip the working edge of the wiper blade in trough of qualified toner. Tap the metal stamping with a screwdriver to knock off any excess. Install wiper blade and secure with two screws Figure 35 System Support Series 772 page 15

17 Reassembling the Two Sections 1. Fit the waste bin to the hopper section, be sure to fit the pegs into the slots and secure with two screws, as shown in Figure 36. Fit sections together, slide pegs into slots Figure Remove the fuse from the front of the cartridge and replace with a new fuse, see Figure 37. Note: For fused applications only. Remove fuse Figure 37 page 16 System Support Series 772

18 Separating the Two Sections - heat staked For instructional purposes the Samsung ML-2010 is shown. There are currently no cartridge conversions available for heat staked cartridges. 1. Using the foam removal tool, scrape off the heat stakes located on the end plates and on top of the waste section as shown in Figure 38a & 38b. Heat Stakes Locking Tab Figure 38a Figure 39b Heat Stakes 3. Remove the waste section by lifting the waste section straight up. See Figure 40. Note: A small amount of waste toner may fall from the waste section when removed. Figure 38b 2. Using a small slotted screwdriver or the felt/foam scraper tool, release the locking tabs on the back and bottom of the drive and contact side end plates and remove. See Figure 39a & 39b. Note: A small slotted screwdriver may be needed to help pry the end plates off. Figure 40 Locking Tab Figure 39a System Support Series 772 page 17

19 Disassembling the Waste Section - heat staked 1. Remove the PCR by sliding the ends of the PCR out of the saddles. See Figure 41. Clean the PCR of any debris by using dry filtered compressed air and wiping it with a lint free cloth. 3. Remove the two screws from the wiper blade and lift the wiper blade from the waste section as shown in Figure 43. Screws PCR Figure 41 Figure Remove the contact side saddle by slightly rotating it clockwise to release the locking tab and then sliding it away from the waste section. See Figure 42. Note: The non-contact side saddle can be removed the same way except rotate the saddle counterclockwise. Only one saddle needs to be removed in order to remove the wiper blade. 4. Using dry filtered compressed air, clean the waste toner from the waste section as shown in Figure 44. Contact Side Saddle Figure 44 Figure 42 page 18 System Support Series 772

20 Reassembling the Waste Section - heat staked 1. Dip the working edge of the wiper blade into qualified toner before installing onto the waste section. 4. Install the PCR into the saddles with the shorter end of the PCR shaft on the contact side as shown in Figure Using two screws, secure the wiper blade to the waste section as shown in Figure 45. Screws PCR Figure 47 Figure Install the contact side saddle by sliding it onto the waste section as shown in Figure 46. Make sure that the saddle is securely locked into place. Clean the PCR contact on the saddle with a Q-tip dampened in 91-99% isopropyl alcohol. Contact Side Saddle Figure 46 System Support Series 772 page 19

21 Disassembling the Hopper - heat staked 1. Remove the drum by lifting it from the hopper section as shown in Figure Use the wooden end of a cotton swab to clean the working edge of the doctor blade as shown in Figure 52. Figure Remove the gears on the drive side to insure that they are not lost during cleaning as shown in Figure 49. Figure Use a small slotted screwdriver to pry the hopper cap from the hopper. See Figure 53. Using dry, filtered compressed air to clean any excess toner from the hopper section. Hopper Cap Figure Remove the developer roller by first sliding the contact side away from the hopper and then lifting up. Then slide the keyed drive side away from the hopper and lift it to remove the developer roller from the hopper section. Clean the developer roller using dry, filtered compressed air and then wipe with a lint free cloth. Figure Use a felt/foam scraper tool to fluff the felts on each end of the hopper section to prevent toner from leaking as shown in Figure 54. Felt Figure Remove the two screws securing the doctor blade and then remove the doctor blade from the hopper section as shown in Figure 51. Clean the doctor blade using dry filtered compressed air. Figure 54 Screws Figure 51 page 20 System Support Series 772

22 Reassembling the Hopper - heat staked 1. Install the doctor blade and secure it with two screws as shown in Figure Install the gears on the drive side of the hopper section as shown in Figure 57. Screws Figure 55 Figure Install the keyed end (Figure 56a) of the developer roller into its slot on the geared side of the hopper section and then install the non-keyed side of the developer roller into its slot on the contact side of the hopper section. See Figure 56b. Keyed End 4. Install the drum by placing it in the hopper section as shown in Figure 58. Figure 56a Figure 58 Figure 56b System Support Series 772 page 21

23 Assembling the Two Sections - heat staked 1. Place the waste section on top of the hopper section as shown in Figure Using a lint free swab, apply conductive lubricant to the contact side end plate contacts and drum axle as shown in Figure 62. Lubricate Figure Using a cotton swab dampened with 91-99% isopropyl alcohol, clean the toner from the contact side and the drive side end plate contacts and bushings as shown in Figure 60a & 60b. Figure Attach the drive side end plate to the cartridge as shown in Figure 63a. Ensure that the locking tabs are securely locked into place. See Figure 63b and 63c. Clean Figure 60a Figure 63a Clean Locking Tab Locking Tab Figure 63b Figure 63c Figure 60b 3. Using a lint free swab, apply lubricant to the drive side end plate bushings and the drum axle as shown in Figure Fill the cartridge with qualified toner and install the hopper cap as shown in Figure 64. Lubricate Figure 61 Figure 64 page 22 System Support Series 772

24 Assembling the Two Sections - Heat Staked 7. Attach the contact side end plate to the cartridge as shown in Figure 65a. Ensure that the locking tabs are securely locked into place. See Figure 65b and 65c. 9. Secure the waste section and the end plates using screws as shown in Figure 67a, 67b, 67c and 67d. Screw Screw Figure 65a Figure 67a Figure 67b Locking Tab Locking Tab Screws Screws Figure 65b Figure 65c Refer to System Support Series #855 or #963 for chip installation instructions. Figure 67c Figure 67d Steps 8-9 are OPTIONAL. If the locking tabs on the end plates are damaged or if the cartridge requires a more secure assembly, then follow steps 8-9. Otherwise, skip to step Using a 3/32 drill bit, drill the cartridge through the center of the heat stakes on the waste section and on each end plate as shown in Figure 66. Be sure to drill precisely in the middle of the heat stakes or you could risk damaging the cartridge and you may not be able to attach the waste section and end plates properly. 10. Remove the fuse from the top of the cartridge and replace with a new fuse as shown in Figure 68. Fuse Drill Figure 68 Note: This only applies for fused applications. Figure 66 System Support Series 772 page 23

25 Additional Information Use of Compressed Air As of April 28, 1971, the Occupational Safety & Health Administration (OSHA) Standard, 29 CFR paragraphs a & b for general industry requires effective chip guarding and personal protective equipment (PPE) when using compressed air. When cleaning residual toner particles from cartridges using a compressed air system, you must use air nozzles meeting OSHA requirements. Air nozzles that regulate air pressure to a maximum of 30 psi comply with this standard. Refer to the OSHA publication for any updates or changes that have occurred since the date noted above. Illustrations The illustrations and photos in this document might differ slightly from your cartridge. Every effort is made to include the most up-to-date photos and illustrations at the time of printing. The OEM may make changes, which were not available at the time of printing. Safety Information Always wear eye protection while operating power tools. Always wear eye protection and protective clothing while working with toner and or other chemicals. Do not swallow or ingest toner, isopropyl alcohol, toner dust or any chemicals or materials used in the process of remanufacturing. page 24 System Support Series 772

26 Moving at the speed of new technology The development of cartridge imaging systems is the primary mission of our Imaging Labs. Through extensive testing and research, we develop the optimum combination of matched components for each cartridge system. Our engineering and manufacturing expertise provides us with total control in design, quality and development to produce products from the ground up. The result is a system of components that seamlessly work together in each cartridge application. This dedication and commitment results in integrated cartridge systems that Static Control fully supports, allowing you to quickly attack new market opportunities with complete confidence in the reliability and performance of your cartridges Lee Avenue PO Box 152 Sanford, NC US/Can US/Can Fax Int l Int l Fax Static Control Components (Europe) Limited Unit 30, Worton Grange Reading Berkshire RG2 0TG United Kingdom Tel +44 (0) Fax +44 (0) Static Control Components, Inc. All rights reserved worldwide. The stylized S is a registered trademark, and Static Control and Multi-Tracker are trademarks of Static Control Components, Inc. All other brand and product names are trademarks or registered trademarks of their respective companies.