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1060 lex optrareman

  1. 1. LICENSE AGREEMENTStatic Control Components, Inc. (Static Control) grants this limited license to the person, firm orcorporation (hereinafter "User") downloading electronically or by printing this file to use Static Control’scopyrighted documents in accordance with the terms of this agreement. If you agree with the terms ofthe 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 StaticControl’s copyrights or trademarks.TRADEMARKSThe 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 internaldocuments and for its internal purposes on the following terms and conditions. Any use of StaticControl’s trademark must be used in a context which makes it clear that the product reference is aStatic Control Components, Inc. product, and not a product from any source. The materials provided tothe User may include reference to trademarks of others. Any use of the User makes of these marksshould reference the owner of those marks. Nothing in this agreement constitutes any authorizationby Static Control to use any of these trademarks in any context.COPYRIGHTSStatic Control grants a limited license to the User to use the attached copyrighted documents. The per-mitted use of these documents is limited to internal purposes and needs of the company. The companyis 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 prohibitedfrom using any materials in any documents whether printed or electronic, which are distributed to anythird party. The use of these copyrighted documents, or parts of them, including graphic elements, fromthese 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 thesedocuments by User should reference Static Control’s copyrights, with the notice "copyright StaticControl Components, Inc."Static Control reserves the right to cancel this license on 30-days written notice. All of the User’smaterial incorporating Static Control’s copyrighted documents shall be destroyed upon receipt of itsnotice of termination.The User may not distribute, share, and otherwise convey the copyrighted documents to any otherpersons, 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 INFORMATIONThe 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, orsuitability of the downloadable materials, either express or implied, including without limitation anyimplied warranties of merchantability,fitness for a particular purpose, or non-infringement. Further, StaticControl makes no representations or warranties as to the truth, accuracy or completeness of any state-ments, information or materials concerning items available for download. In no event will Static Controlbe liable for any indirect, punitive, special, incidental, or consequential damages however they mayarise even if Static Control has been previously advised of the possibility of such damages. Version 1 11/03
  2. 2. www.scc-inc.comREMANUFACTURING INSTRUCTIONS Lexmark® Optra Series Cartridges System Support Series™ 1060 TOOLS & SUPPLIES ...........................2 WIRELINES ............................... 3 - 8 SEPARATING THE TWO SECTIONS .........9 DISASSEMBLING THE WASTE BIN .. 10 -12 REASSEMBLING THE WASTE BIN ... 13 -16 DISASSEMBLING THE TONER HOPPER ...................... 17 -21 REASSEMBLING THE TONER HOPPER ...................... 22 -25 REASSEMBLING THE TWO SECTIONS ....26 ADDITIONAL INFORMATION ...............27 Other System Support Series™ documents available in Adobe® Acrobat® format V.2 - 02.10
  3. 3. TOOLS & SUPPLIES• Phillips Screwdriver• Small Slotted Screwdriver• Hook Tool (HTOOL)• Dry, Filtered, Compressed Air for Cleaning• 91-99% Isopropyl Alcohol Cotton-Tipped Swab (QTIP) Hook Tool (HTOOL)• Cotton-Tipped Swab (QTIP)• Felt/Foam Scraper Tool (FSTOOL)• Angle Blade Knife Tool (ABKTOOL)• Lint-free Swab (LFSWAB)• Lint-Free Cleaning Cloth (LFCCLOTH) Felt/Foam Scraper Tool (FSTOOL) Angle Blade Tool (ABTOOL)• Cartridge Sealant (CSEALANT)• Conductive Lubricant (CONCLUBE)• 4059 Hopper Fixture (4059HJIG)• Toner Vacuum (TONERVAC115) or (TONERVAC220) Lint-Free Cleaning Cloth• IBM®/Lexmark® Doctor Bar Putty - 4” Strip (LFCCLOTH) Lint--Free Foam Tip Swab (IBMDPUTTY) (LFSWAB) Toner Vacuum (TONERVAC115) or (TONERVAC220) Cartridge Sealant (CSEALANT) 4059 Hopper Fixture (4059JIG) Conductive Lubricant (CONCLUBE) IBM®/Lexmark® Doctor Bar Putty 4” Strip (IBMDPUTTY) SYSTEM SUPPORT SERIES™ 1060 PAGE 2
  4. 4. WIRELINES LEXMARK® OPTRA® S, OPTRA® Se, OPTRA® T, T520, T620, T630, T640 Toner Hopper - New Style Toner Reservoir Doctor Bar Doctor Bar Sealing Foam Hopper Vent Label Toner Paddle Encoder Wheel Toner Fill Hole Doctor Bar Retaining Tab Toner Hopper Cap Developer Roller Drive Gear Toner Hopper End Plate Developer Assembly Roller End Seal Toner Adder Doctor Bar Roller Retaining Tab Sealing Blade Support Toner Adder Roller Electrical Contact Leaf SpringDeveloper Roller Electrical Contact Doctor Bar Leaf Spring Position Doctor Bar Electrical Tab Contact Developer Roller Sealing Blade Developer Roller Teflon Developer Washer Roller Cover Developer Roller Developer Roller Shaft Contact Bushing Developer Roller Teflon Washer SYSTEM SUPPORT SERIES™ 1060 PAGE 3
  5. 5. WIRELINESLEXMARK® T520, T620, T630, T640 Waste Bin Drum Electrical Contact Drum Small Helical Gear Drum Large Helical Gear Torsion Spring OPC Drum Drum Large Helical Gear PCR Cleaning Assembly Base (not present on T640) Felt Support Blade (not present on T640) Hopper Tension Spring 4059 Wiper Blade Recovery Blade Drum Axle Retaining Drum Axle Ring Retaining Ring Drum Axle Hopper Chip Tension Spring Wiper Blade End Foam Laser Port Shutter Waste Bin Top Side View Laser Port Shutter SpringSYSTEM SUPPORT SERIES™ 1060 PAGE 4
  6. 6. WIRELINES LEXMARK® OPTRA® Se, OPTRA® T, T520, T620, T630 Toner Hopper - Old Style Toner Reservoir Doctor Bar Leaf Spring Doctor Bar Toner Paddle Encoder Wheel Doctor Bar Seal Strip Doctor Bar End Block Toner Fill Hole Doctor Bar Putty (Not Shown) Developer Roller Drive Gear Toner Hopper End Plate Toner Hopper Cap Assembly Developer Roller End Seal Doctor Bar End Block Toner Adder Doctor Bar Putty Roller (Not Shown) Inner Sealing BladeToner Adder Roller ElectricalContact Outer Sealing BladeDeveloper Roller Electrical Doctor Bar Electrical Developer Roller TeflonContact Contact Washer Developer Roller Developer Roller Teflon Washer Developer Roller Shaft Contact Bushing SYSTEM SUPPORT SERIES™ 1060 PAGE 5
  7. 7. WIRELINESLEXMARK® OPTRA® Se & OPTRA® T Waste Bin Drum Drum Small Electrical Helical Gear Drum Large Helical Gear Contact WashersDrum LargeHelical GearTorsionSpring OPC Drum PCR Cleaning Assembly Base Drum Large Helical Gear PCR Cleaning Felt Felt Support Blade Hopper Tension Spring Compatibility Tab (not shown) Wiper Blade with PCR Cleaning AssemblyRecovery Blade Drum Shutter Drum Axle Drum Axle Retaining Ring Retaining Ring Drum Axle Drum Small Helical Gear Washer Hopper Tension Wiper Blade Laser Port Spring End Foam Shutter Waste Bin Top Side View Chip Location Chip (old style) Chip (new style) Laser Port Shutter SpringSYSTEM SUPPORT SERIES™ 1060 PAGE 6
  8. 8. WIRELINES LEXMARK® OPTRA® S Hopper - Old Style Toner Reservoir Leaf Spring Doctor Bar Seal Toner Paddle Strip Encoder Wheel Doctor Bar Doctor Bar Toner End Block Fill Hole Developer Roller Drive Gear Doctor Bar Putty (Not Shown) Developer Toner Roller End Hopper Seal Cap Doctor Bar End Block Toner Adder Roller Inner Sealing BladeToner Adder RollerElectrical Contact Outer Sealing Blade Developer Roller Electrical Doctor Bar Electrical Contact Contact Developer Roller Plastic Washer Developer Roller Electrical Contact Bushing Developer Roller Developer Roller Plastic Developer Roller Shaft Bushing Washer SYSTEM SUPPORT SERIES™ 1060 PAGE 7
  9. 9. WIRELINESLEXMARK® OPTRA® S Waste Bin Drum Small Helical Gear Drum Electrical Contact Drum Large Helical Gear Torsion Spring OPC Drum Drum Large Helical Gear Washers PCR Cleaning Assembly Base Drum Large Helical Gear PCR Cleaning Felt Felt Support Blade Hopper Tension Spring Wiper Blade with PCR Cleaning Assembly Recovery Blade Drum Shutter Drum Axle Retaining Ring Drum Axle Retaining Ring Drum Small Helical Gear Hopper Tension Spring Washer Drum Axle Laser Port Wiper Blade End Foam Waste Bin Top Side View Shutter Laser Port Shutter SpringSYSTEM SUPPORT SERIES™ 1060 PAGE 8
  10. 10. SEPARATING THE TWO SECTIONS For instructional purposes, a new style T630 cartridge is shown.1. Place the cartidge on your work surface with the top of 4. Once the contact end stabilizer post is clear from the the cartridge face down, the OPC facing up as shown waste section, pull the drive gear end of the waste in Figure 1. section away from the hopper, as shown in Figure 4. Figure 1 Figure 42. Using a hook tool or a pair of needle nose pliers, gently release the hopper tension springs from the posts on 5. Once the hopper is high enough to clear the end of the both sides of the cartridge, as shown in Figure 2. waste section, seperate the two sections. See Figure 5. Note: Do not overstretch or deform the springs. For easier reassembly the springs can be hooked onto the existing opening on the waste Hopper section. Hopper Tension Hopper Spring Tension Spring Figure 2a Figure 2b3. The hopper is secured to the waste section by two stabilizer posts that install in receptacles at each end of the waste section. To release the posts, carefully Waste Bin Figure 5 pull the contact end of the waste section away from the hopper, as shown in Figure 3. Figure 3 SYSTEM SUPPORT SERIES™ 1060 PAGE 9
  11. 11. DISASSEMBLING THE WASTE SECTION1. Position the waste section on your work surface as shown 4. While supporting the large helical gear end of the in Figure 6. OPC in one hand, remove the OPC axle from the small helical gear end of the OPC, as shown in Figure 9. Figure 62. For earlier style waste sections, lift the waste section Figure 9 slightly and move the shutter arms toward you to move the OPC shutter to it’s open position. See Figure 7. 5. Remove the OPC and the OPC washer from the waste bin section, as shown in Figure 10. Drum Note: Not all waste sections will have an OPC Shutter washer. This was only seen in earlier cartridges and is not present in recentShutter cartridges.Actuator Arm Figure 73. Using a small slotted screwdriver remove the retaining Figure 10 ring off the OPC axle on the large helical gear end as shown in Figure 8. 6. Carefully twist the torsion spring while pulling it off the large helical gear as shown in Figure 11. You may need to use a small slotted screwdriver to move the spring out in order to remove it. Washers Twist the spring while carefully pulling it off the hub Figure 8 Figure 11PAGE 10 SYSTEM SUPPORT SERIES™ 1060
  12. 12. DISASSEMBLING THE WASTE SECTION7. Using a small slotted screwdriver, remove the two plastic 10. Turn the waste section over as shown in Figure 15. A washers from the large helical gear. See Figure 12. thin foam sits between the wiper blade and the waste section. Note: Not all OPC’s will have gear washers. This was only seen in earlier cartridges and is not 11. Using an angled blade knife or similar cutting tool cut present in recent ones. through the thin foam as shown in Figure 15. Make sure to cut end to end. Figure 12 Figure 15 12. Turn the waste section on end and while holding the laser port shutter open remove the wiper blade as shown8. Inspect the recovery blade for damage, as shown in in Figure 16. Figure 13. If there is no obvious damage, the blade may be left in place. If replacement is needed, peel the blade off and clean the mounting area of the waste section with Drum 91-99% isopropyl alcohol. Shutter Recovery Blade Figure 16 Note: While removing the wiper blade, it may be Figure 13 possible that the left and right wiper blade end foams are removed as well. If they are damaged replace with new ones, otherwise reinstall into the waste section.9. Remove the screws from each end of the wiper blade, as shown in Figure 14. Wiper Blade End Foams Figure 17 Figure 14 SYSTEM SUPPORT SERIES™ 1060 PAGE 11
  13. 13. DISASSEMBLING THE WASTE SECTION13. Dump remaining toner from the waste section and clean using dry, filtered compressed air. See Figure 18. Note: Waste toner may have become melted into the bottom of the waste section, this is normal. Using a small slotted screwdriver, lightly scrape until all toner is loose and can be removed with compressed air. Figure 18PAGE 12 SYSTEM SUPPORT SERIES™ 1060
  14. 14. REASSEMBLING THE WASTE SECTION Note: Recovery blades can be installed either by hand or using an installation tool. The following1. Position the waste section on your work surface as shown steps will be using the recommended tool in Figure 19. method. 5. Install the blade into the installation tool as shown in Figure 22. Slide the blade back and forth to make sure it is fully seated in the slot. Center the blade in the tool. Note the location of the adhesive side of the blade in relation to the tool. Figure 192. For earlier style waste sections, lift the waste section slightly and rotate the shutter arm to move the OPC shutter to the open position, as shown in Figure 20. Figure 22 Drum Shutter 6. While holding the blade in place, carefullly peel the paper backing from the adhesive side as shown in Figure 23. Shutter Actuator Arm Figure 20 Figure 233. If the original recovery blade was retained, move to step #8 , otherwise move to next step #4. 7. Hold the installation tool with both hands as shown in4. Make sure the mounting location is completely clean Figure 24. Position the tool and blade over the mounting including adhesive materal. If needed, clean the mounting location, make sure the adhesive is toward the waste location with 91-99% isopropyl alcohol as shown in Figure section and the blade is flush with the edge of the lip. 21. Note: If the blade extends past the lip of the waste section, paper jams and possible toner leakage will occur. When the blade is positioned correctly, roll the installation tool down so the blade adhesive adheres to the mounting surface, and the blade pulls free of the tool. Figure 21 Note: The use of solvents other than alcohol may affect the bond between the adhesive and the mounting location. DO NOT use a scraper tool on the mounting surface. Figure 24 SYSTEM SUPPORT SERIES™ 1060 PAGE 13
  15. 15. REASSEMBLING THE WASTE BIN8. Using your finger, gently smooth the blade in place from 11. Turn the waste section over. Using a lint free cloth the center outward to the ends to remove any ripples or dampened with 91-99% isoproply alcohol, clean the air pockets as shown in Figure 25. waste bin as shown in Figure 28. Note: If a polyblade was installed carefully peel the reinforcement paper away now. Figure 28 Figure 25 12. After the area has dried completely, peel the backing from the wiper blade sealing strip. Place the strip in position over the area that was cut. See Figure 29.9. Dip the edge of the wiper blade in qualified toner before installation in the waste section. Insure even coverage. See Figure 26. Figure 29 Figure 2610. Position the waste section as shown in Figure 27. Open the laser port shutter and install the wiper blade. Secure 13. Begin where the wiper blade end foam is visible between the wiper blade using two screws. the wiper blade and waste section as shown in Figure 30. Gradually work the sealing strip along the waste section using your finger to smooth out any air bubbles or wrinkles as shown in Figure 30. Figure 27 Figure 30PAGE 14 SYSTEM SUPPORT SERIES™ 1060
  16. 16. REASSEMBLING THE WASTE BIN14. If the original OPC had the two plastic washers, install 17. Place a small amount of conductive lubricant onto the onto the large helical gear at this time as shown in Figure drum axle where the previous OPC made contact as 31. shown in Figure 34. Figure 31 Figure 34 18. Place the end of the drum axle with no retaining ring in15. Install the torsion spring from the original OPC onto the the waste section as shown in Figure 35. large helical gear as shown in Figure 32. Carefully twist the torsion spring while installing onto the gear. Washers Twist the spring while carefully pushing it onto the hub Figure 35 Figure 32 19. Install the OPC washer (for eariler style cartridges), on the end of the axle once initially inserted into the waste section as shown in Figure 36.16. Position the waste section on your work surface as shown in Figure 33. Figure 36 Figure 33 SYSTEM SUPPORT SERIES™ 1060 PAGE 15
  17. 17. REASSEMBLING THE WASTE BIN20. Place the OPC in the waste section as shown in Figure 22. Install the retaining ring on the other end of the OPC axle 37a. Verify that the torsion spring on the large helical as shown in Figure 39. gear is installed into the opening on the waste section as shown in Figure 37b. Figure 39 Figure 37a Note: Two types of retaining rings have been seen on various cartridges. Each OPC axle is match to a certain one, these can not be interchanged. See Figure 40 for the two types. Figure 37b Figure 40 23. Rotate the OPC at least three full rotations by the large and small helical gears to prelubricate the OPC as shown in Figure 41.21. While supporting the OPC by the large helical gear insert Note: It may be necessary to rock the OPC back and the drum axle. Carefully slide it in until the retaining ring forth initally before the OPC will rotate in the stops the axle from being pushed any further as shown in normal operating direction. Figure 38. Figure 41 Figure 38 Note: Cover the waste section so the OPC does not get light damage while remanufacturing the hopper section.PAGE 16 SYSTEM SUPPORT SERIES™ 1060
  18. 18. DISASSEMBLY OF THE TONER HOPPER1. Using a small slotted screwdriver, pry the encoder wheel 4. While keeping the feet of the leaf spring in place, gently off by the base of the wheel as shown in Figure 42. press down on the center of the spring to release it from the spring seat as shown in Figure 45. Note: Care must be taken to not let the leaf spring snap into the developer roller. Do not leave the leaf spring installed in the hopper when the developer roller is not present. Figure 422. Remove the developer roller drive gear as shown in Figure 43. You may need to use a small slotted screwdriver to pry the gear off the developer roller shaft. Figure 45 Old Style Cartridges ONLY for steps 5-7 (for New Style Cartridges skip to step 8) 5. Using the felt/foam scraper tool, remove the putty from each end of the doctor bar as shown in Figure 46. Figure 433. Using needle nose pliers remove the plastic doctor bar end blocks (if present) located on each end of the leaf spring as shown in Figure 44. Discard as they will not be used later. Figure 46 Note: Do not reuse the putty as it may be contaminated, however note the amount that was removed for later. Figure 44 SYSTEM SUPPORT SERIES™ 1060 PAGE 17
  19. 19. DISASSEMBLING THE TONER HOPPER New Style Cartridges ONLY for step 8-10 (for Old Style Cartridges go to step 4)6. Using the felt/foam scraper tool peel up one end of the 8. If present, remove the developer roller cover by doctor bar sealing strip as shown in Figure 47a. Grasp releasing the locking tab (Figure 49a) and then sliding the strip and remove it slowly so that the adhesive the cover towards the contact side as shown in Figure remains on the strip as shown in Figure 47b. 49b. Locking Tab Figure 47a Figure 49a Developer Roller Cover Figure 47b Figure 49b7. Carefully remove the doctor bar from the hopper by lifting straight up and out as shown in Figure 48. 9. Remove the doctor bar retaining tabs from each side of the cartridge as shown in Figure 50a & 50b. Figure 48 Figure 50a Figure 50bSYSTEM SUPPORT SERIES™ 1060 PAGE 18
  20. 20. DISASSEMBLING THE TONER HOPPER10. Remove the doctor bar from the cartridge as shown in 12. While handling only the developer roller shaft, carefully Figure 51. move the developer roller out and away from the hopper section as shown in Figure 55. Figure 55 Figure 51 13. Remove the plastic washers from each end of the developer roller as shown in Figure 56. Note: Mark the side of the bar that was facing outward for reference later if reusing the OEM steel doctor bar. Some newer style cartridges utilize a “stamped” style doctor bar. See Figures 52 & 53 for reference. OEM Steel Doctor Bar Figure 56 Figure 52 “Stamped” Style Doctor Bar 14. Using a small slotted screwdriver remove the hopper cap as shown in Figure 57. Figure 5311. Rotate the brass bushing upward and slide away from the cartridge as shown in Figure 54. Figure 57 Note: Earlier style hoppers will have a vented cap, clean the cap with compressed air. Figure 54 SYSTEM SUPPORT SERIES™ 1060 PAGE 19
  21. 21. DISASSEMBLING THE TONER HOPPER15. Dump any remaining toner from the hopper section and 17. Using a dry lint free cloth or lint free foam tipped swab, clean using compressed air. See Figure 58. clean toner and sealant from the developer roller end seals at each end of the hopper section as shown in Figure 60a & 60b. Note: It is important to completely clean the developer roller end seals. Figure 58 Note: Light print problems can occur if toner is left embedded in the toner adder roller. For best results clean the toner adder roller thoroughly Figure 60b Figure 60a with compressed air and/or a toner vacuum. The adder roller can be rotated freely spinning the gears on the end of the hopper section. 18. Using a cotton tipped swab and 91-99% isopropyl alcohol, clean the hopper section contacts as shown in Figure 61. Doctor Bar Contact16. Inspect the developer roller inner and outer sealing Adder blades for damage as shown in Figure 59. If the blades Roller need to be replaced, refer to System Support Series™ Contact #149 for an old style cartridge and #669 for a new style cartridge. Developer Roller Contact Figure 61 19. Using a cotton tipped swab and 91-99% isopropyl Outer Sealing Inner Sealing alcohol, clean any toner and/or putty from the doctor Blade Blade bar slots on both end of the hopper section as shown in Figure 62a & 62b. (Old Style Cartridge Only) Figure 59 Figure 62a Figure 62bPAGE 20 SYSTEM SUPPORT SERIES™ 1060
  22. 22. DISASSEMBLING THE TONER HOPPER20. Clean the developer roller with compressed air. Clean the roller shafts using a lint free cloth and 91-99% isopropyl alcohol. Note: If needed, the roller can be cleaned with 91-99% isopropyl alcohol followed by deionized water and finally compressed air. DO NOT touch the developer roller surface with your bare hands.21. Clean the developer roller washers with a lint free cloth. SYSTEM SUPPORT SERIES™ 1060 PAGE 21
  23. 23. REASSEMBLING THE TONER HOPPER1. Using a lint free foam tipped swab, apply a thin coat of 4. Insert the non-keyed end of the developer roller shaft into cartridge sealant to the left and right developer roller end the contact end of the hopper section as shown in Figure seals and walls as shown in Figure 63a & 63b. 67. Note: Too much sealant will cause print defects and cause premature cartridge failure. Figure 67 5. Replace the developer roller shaft contact bushing as shown in Figure 68. Rotate the bushing as shown to lock Figure 63a Figure 63b the developer roller in place. Ensure that the developer roller bushing is making good contact with the developer2. Prior to installing the developer roller washers onto the roller contact. roller, apply a thin coat of cartridge sealant to both sides as shown in Figure 65. Install one plastic washer on each end of the developer roller shaft. Developer Roller Developer Roller Contact Bushing Figure 68 Old Style Cartridges ONLY for steps 6 -12 (for New Style Cartridges skip to step 13) Figure 64 6. Install the doctor bar into the hopper section as shown in Figure 69. Make sure the working edge (dull finish) is facing the direction of the developer roller, refer to Figure3. Insert the keyed end of the developer roller shaft into the 70 & 71. non-contact end of the hopper section as shown in Figure 66. Make sure to slide the developer roller into the hopper section completely until the developer roller washer comes into contact with the hopper section. Figure 69 Figure 66PAGE 22 SYSTEM SUPPORT SERIES™ 1060
  24. 24. REASSEMBLING THE TONER HOPPER Working Edge Shiny Edge of 9. Place the end of the sealing strip flush with the end of the Doctor Bar doctor bar and flush against the hopper section as shown of Doctor Bar in Figure 74. Figure 70 Figure 71 Note: If reusing the OEM steel doctor bar, make sure the side marked out earlier is now facing inward. This rotates the bar to a new working surface. The OEM stamped doctor bar can not be rotated. Figure 747. Clean the doctor bar sealing strip mounting surface (the 10. Carefully press the strip into place, peeling the backing lip of the hopper section and top edge of the bar) with off slowly as you progress as shown in Figure 75. You a cotton tipped swab and 91-99% isopropyl alcohol as may want to use a felt/foam scraper tool to press the shown in Figure 72. strip into place smoothing out any wrinkles and air pockets. Figure 75 Figure 72 Note: It may be necessary to cut 1/8” from the end of8. Expose the doctor bar sealing strip adhesive by peeling the sealing strip so it will fit completely. This strip off and folding back 1 to 2 inches of the dull white paper is used in multiple applications. backing from one end as shown in Figure 73. 11. Remove the white reinforcement paper as shown in Figure 76. Smooth out any additional wrinkles and air pockets from left to right or right to left. Figure 73 Figure 76 PAGE 23 SYSTEM SUPPORT SERIES™ 1060
  25. 25. REASSEMBLING THE TONER HOPPER12. Apply a small amount of fresh doctor bar putty (approximately the same amount you removed at the 15. Replace the developer roller cover as shown in Figure 81. beginning) in each corner at the end of the doctor bar as (T640/42/44 application only) shown in Figure 77. Press the putty in place where the seal and hopper section meet. Figure 81 Figure 77 Note: When installing a new Static Control doctor bar, it is recommended to replace the OEM leaf spring with an application specific Static ControlNew Style Cartridges ONLY for steps 13-15 leaf spring. (for Old Style Cartridges go back to step 6)13. Place the doctor bar up against the doctor bar sealing foam as shown in Figure 78. 16. While holding one end of the leaf spring feet in each hand, insert the center bend into the plastic seat on the hopper section as shown in Figure 82. Figure 78 Note: For additional information, refer to technical Figure 82 bulletins 1405 & 1836 on Lexmark doctor bars. 17. Using minimal pressure push up on the ends of the leaf14. Replace the left and right doctor bar retaining tabs as spring feet until they can be positioned onto the top of the shown in Figure 79 & 80. doctor bar as shown in Figure 83. Figure 83 Figure 79 Figure 80PAGE 24 SYSTEM SUPPORT SERIES™ 1060
  26. 26. REASSEMBLING THE TONER HOPPER Note: The “V” on the spring should point toward you 20. Fill the hopper section with approved toner as shown in with the number upright as shown in Figure 84. Figure 87. Number Figure 84 Figure 8718. Install the developer roller drive gear as shown in Figure Note: Overfilling the hopper section can cause 85. premature “Toner Low”. 21. Install the hopper cap as shown in Figure 88. Figure 85 Figure 8819. Rotate the developer roller toward you as shown in Figure 86. This will smooth out the cartridge sealant added earlier and create a complete seal. 22. Install the encoder wheel as shown in Figure 89. Align Note: Cartridge sealant should be present on each the key of the axle with the key in the base of the wheel end of the developer roller, but out of the paper and place the encoder wheel on the toner agitator paddle path after this step. axle. Press down on the center of the wheel. Cartridge Sealant Figure 89 Figure 86 SYSTEM SUPPORT SERIES™ 1060 PAGE 25
  27. 27. REASSEMBLING THE TWO SECTIONS1. Position the waste section on your work surface with the 4. Using a hook tool or a pair of needle nose pliers, attach drum facing up as shown in Figure 90. the tension springs to the spring posts on each end of the cartridge as shown in Figure 93a & 93b. Note: Always replace the hopper tension springs in pairs. Hopper Tension Hopper Spring Tension Spring Figure 902. Being careful not to scratch the OPC, install the drive gear end of the hopper section first by positioning the stabilizer Figure 93a Figure 93b post in the receptacle in the waste section as shown in Figure 91. Refer to the seperate System Support Series on removal and installation of the chip for appropriate chip needed for the cartridge. Figure 913. At the opposite end of the cartridge, carefully pull the end of the waste section outward and position the right stabilizer post in the receptacle in the waste section as shown in Figure 92. Figure 92PAGE 26 SYSTEM SUPPORT SERIES™ 1060
  28. 28. ADDITIONAL INFORMATIONUse of Compressed Air IllustrationsAs of April 28, 1971, the Occupational Safety & Health The illustrations and photos in this document might differAdministration (OSHA) Standard, 29 CFR 1910.242 slightly from your cartridge. Every effort is made to includeparagraphs a & b for general industry requires effective the most up to date photos and illustrations at the time ofchip guarding and personal protective equipment (PPE) printing. However, the OEM may make changes which werewhen using compressed air. When cleaning residual toner not availableparticles from cartridges using a compressed air system, at the time of printing.you must use air nozzles meeting OSHA requirements. Airnozzles that regulate air pressure to a maximum of 30 psi Safety Informationcomply with this standard. Refer to the OSHA publication • Always wear eye protection while operatingfor any updates or changes that have occurred since the power tools.date noted above. • 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. SYSTEM SUPPORT SERIES™ 1060 PAGE 27
  29. 29. MOVING AT THE SPEED OF NEW TECHNOLOGYThe development of cartridge imaging systems is the primary mission of our Imaging Labs. Through extensivetesting and research, we develop the optimum combination of matched components for each cartridge system. Ourengineering and manufacturing expertise provides us with total control in design, quality and development to produceproducts from the ground up. The result is a system of components that seamlessly work together in each cartridgeapplication.This dedication and commitment results in integrated cartridge systems that Static Control fully supports, allowingyou to quickly attack new market opportunities with complete confidence in the reliability and performance of yourcartridges. 3010 Lee Avenue • PO Box 152 • Sanford, NC 27331 Static Control Components (Europe) Limited US/Can 800.488.2426 Unit 30, Worton Grange US/Can Fax 800.488.2452 Reading • Berkshire RG2 0TG • United Kingdom Int’l 919.774.3808 • Int’l Fax 919.774.1287 Tel +44 (0) 118 923 8800 • Fax +44 (0) 118 923 8811 www.scc-inc.com www.scceurope.co.uk © 2010 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.

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