This document provides technical instructions for refurbishing Lexmark T640, T642, and T644 printer cartridges. It includes 30 steps with corresponding photos to guide removal and replacement of components like the toner hopper, drum, developer roller, doctor blade, and wiper blade. Specifications are provided for the printer models, cartridge part numbers, and yields. Tools and supplies needed to complete the refurbishing are also listed.

1. T640TECH
Technical Instructions Printers OEM Info Tools 1
CORPORATE See Last Page for Info. See Last Page for Info. See Last Page for Info.
LOS ANGELES, USA
US 1 800 394.9900
Int’l +1 818 837.8100
FAX 1 800 394.9910
Int’l +1 818 838.7047 Photo 1
Step 1
ATLANTA, USA
US 1 877 676.4223 Using a knife cut the yellow warranty sticker that
Int’l +1 678 919.1189 is attached to the toner and waste hopper.
FAX 1 877 337.7976
Int’l +1 770 516.7794
(See Photo 1)
KANSAS CITY, USA
US 1 913 871.1700
FAX 1 913 888.0626
MIAMI, USA
US 1 800 595.4297
Int’l +1 305 594.3396
FAX 1 800 522.8640 Photo 2
Int’l +1 305 594.3309 Step 2 & 3
NEW YORK, USA Using a spring hook release the tension springs
US 1 800 431.7884 that are attached to each side of the toner
Int’l +1 631 588.7300 hopper.
FAX 1 800 431.8812
Int’l +1 631 588.7333
(See in Photo 2 and Photo 3)
TORONTO, CAN
CAN 1 877 848.0818
Int’l +1 905 712.9501
FAX 1 877 772.6773
Int’l +1 905 712.9502
BUENOS AIRES, ARG Photo 3
ARG 0810 444.2656
Int’l +011 4583.5900
FAX +011 4584.3100
MELBOURNE, AUS
AUS 1 800 003. 100
Int’l +62 03 9561.8102
FAX 1 800 004.302
Int’l +62 03 9561-7751
SYDNEY, AUS
AUS 1 800 003.100
Int’l +62 02 9648.2630
FAX 1800 004.302
Int’l +62 02 9548.2635
MONTEVIDEO, URY Photo 4
URY 02 902.2001 Step 4
Int’l +5982 902.2001
FAX +5982 900.0858 Pull the developer roller drive gear from the end
JOHANNESBURG, S.A.
of the toner hopper.
S.A. +27 11 974.6155
FAX +27 11 974.3593
(See Photo 4)
SÃO PAULO, BRAZIL
Int’l +55 11 5524.8000
RAANANA, ISRAEL
ISR 09 760.12.39
Int’l +972 9760.12.39
ISR 052.38.555.82
Int’l +972 5238.555.82
E-mail: info@futuregraphicsllc.com Website: www.futuregraphicsllc.com
REV. 6/07/07

2. 2 Lexmark T640 Technical Instructions
Photo 8
Step 8
Holding the large gear end of the drum, pull the
axle from the drum. (See Photo 8)
Step 5
Grasp the toner hopper with the left
hand and the waste hopper side
plate with the right. Gently bend
the side plate way from the toner
hopper. (See Photo 5)
Photo 9
Step 9
Carefully lift the drum from the waste hopper.
Photo 5
(See Photo 9) If you plan on reusing the drum
place the drum in a protected area out of the
light.
Photo 10
Step 10
Place the waste hopper face up on the work-
bench. Using a knife cut the wiper blade seal-
ing foam.
Step 6 (See Photo 10)
Carefully lift the gear end of the
toner hopper up away from the
waste hopper. Separate the two
sections. (See Photo 6)
Photo 11
Step 11
Photo 6
Using a Philips screwdriver, remove the two
screws that hold the wiper blade.
(See Photo 11)
Step 12
Photo 12 Holding open the PCR shutter door, remove
the wiper blade from the waste hopper.
Step 7 (See Photo 12) Dump the waste toner from the
Set the toner hopper section aside. hopper. Clean the waste hopper using dry
Using a small flat blade screwdriver, compressed air or a vacuum.
remove the “e” ring that holds the
drum axle. (See Photo 7)
Photo 7
Photo 13
Step 13
Apply padding powder to the wiper blade.
Place the wiper blade onto the waste hopper
and install the two screws that hold the blade
in place.
(See Photo 13)

3. Lexmark T640 Instructions 3
Photo 14
Step 14
Apply the wiper blade sealing tape to the top of
the waste hopper.
(See Photo 14) Step 20
Rotate the developer roller bushing
counterclockwise. (See Photo 20)
Slide the bushing off the developer
Step 15 & 16 roller axle.
Apply padding powder to the drum. Place the
drum into the waste hopper. (See Photo 15)
Slide the drum axle through the drum starting
Photo 20
on the small gear end. (See Photo 16)
Photo 15 Photo 16
Photo 17
Step 17 Step 21
Using needle nose pliers, grab the leaf spring Lift up the shaft of the developer
towards its center. Carefully press downward, roller on the contact side of the
removing the spring from the spring’s locking toner hopper. Slide the shaft of the
cradle. (See Photo 17) Remove the leaf spring. developer roller from the gear end
of the toner hopper. (See Photo 21)
Remove the clear mylar shims from
the end of the developer roller.
Clean the developer roller using a
Photo 18
lint free cloth and a 50 /50 mixture
Step 18 of water and 99% Isopropyl
Alcohol. Make sure the developer
Pull the developer roller contact from the end roller is completely dry before it is
of the toner hopper. (See Photo 18) reinstalled in the toner hopper.
Photo 19
Step 19 Photo 21
Release the locking clip that holds the devel-
oper roller shield to the doctor blade stabilizer
bracket on the gear end of the hopper.
(See Photo 19) Slide the developer roller shield
from the post of the stabilizer bracket on the
contact end of the hopper. Set the shield aside.

4. 4 Lexmark T640 Technical Instructions
Photo 25
Step 25
Slide the doctor blade under the doctor blade
contact fingers and into the two white locating
Step 22 brackets on each end of the toner hopper. Be
careful not to damage the sealing foam that
Slide the doctor blade downward
site behind the doctor blade.
towards the developer roller open-
(See Photo 25)
ing, removing the blade from its
white plastic holders located on
each side of the toner hopper.
(See Photo 21) Photo 26
Step 26
NOTE: Be careful not to bend the
Place the mylar shims onto the ends of the
doctor bar contact fingers. Clean
developer roller. Install the keyed end of the
the doctor blade first using dry
roller into the gear end of the toner hopper.
compressed air or a vacuum then
(See Photo 26)
using a cotton swab and acetone.
Photo 22
Photo 27
Step 27
Place the developer roller contact bushing
onto the end of the developer roller and install
the contact onto the end of the toner hopper.
(See Photo 27)
Step 23 Photo 28
Remove the toner sensor wheel and the Step 28
fill plug from the end of the toner hopper. Position one end of the leaf spring onto the
(See Photo 23) Clean the toner hopper
doctor bar. Using needle nose pliers carefully
using dry compressed air or a vacuum.
place the opposite end of the spring onto the
doctor bar.
(See Photo 28)
Photo 23
Photo 29
Step 29
Install the developer roller shield onto the toner
hopper. (See Photo 29) Fill the toner hopper
with toner. The fill weight will very depending
Step 24 on they type of cartridge you are building.
Clean the developer roller end seals
using a cotton swab and alcohol.
(See Photo 23)
Photo 30
Photo 24
Step 30
Place the fill plug and the toner sensor wheel
back onto the end of the toner hopper.
(See Photo 30)
E-mail: info@futuregraphicsllc.com Website: www.futuregraphicsllc.com

5. Lexmark T640 Technical Instructions 5
Photo 31
Step 31
Place the developer roller drive gear onto the
end of the roller. (See Photo 31) Step 36 & 37
Rotate the developer roller counter clock-wise
to ensure that the toner is evenly distributed Using needle nose pliers pull out
across the developer roller. the OEM chip. (See Photo 36)
Install a new chip into the cartridge.
(See Photo 37)
Test the cartridge
Photo 32
Step 32
Place the waste hopper top side down on the
workbench with the opening facing you. Place Photo 36
the gear end of the toner hopper into the waste
hopper.
(See Photo 32)
Photo 33
Step 33 & 34
Carefully pull the waste hopper side plate away
from the contact end of the toner hopper.
(See Photo 33) Position the contact end of the
toner hopper into the waste hopper.
Photo 36
(See Photo 34)
Photo 34
Photo 35
Step 35
Attach the toner hopper tension springs to
each end of the toner hopper.
(See Photo 35)

6. Lexmark T640 Technical Instructions 6
Tools & Supplies Needed: Models: T644 / T644dtn / T644n / T644tn
Tools Required: Technology: Laser
Knife Print Speed: Up to 50ppm
Needle-nose Pliers Resolution: 1200 Image Quality
Phillips Screwdriver Processor: 514MHz
Spring Hook Memory: 128 Std., 640 Max
Small Flat-blade Screwdriver Footprint: 16(H) x 16.6(W) x 20.6(D)
Duty Cycle: 250,000 pages per month
Supplies Required:
99% Isopropyl Alcohol Cartridge Part #: Yield:
Padding Powder 64015SA (std) Cartridge Return Program 6,000pgs
Wiper Blade Sealing Tape 64015HA (hy) Cartridge Return Program 21,000pgs
64415XA (xhy) Cartridge Return Program 32,000pgs
(For use in T642 / T644 Cartridges only)
Printer Information:
Models: T640 / T640dn / T640dtn / T640n / T640tn 64035SA (std) 6,000pgs
Technology: Laser 64035HA (hy) 21,000pgs
Print Speed: Up to 35ppm 64435XA (xhy) 32,000pgs
Resolution: 1200 Image Quality (For use in T642 / T644 Cartridges only)
Processor: 400MHz
Memory: 64MB Std., 576MB max 64004HA (hy) Cartridge return Program Label 21,000pgs
Footprint: 13.6(H) x 16.6(W) x 19.6(D) 64404XA (xhy) Cartridge Return Program Label 32,000pgs
Duty Cycle: 200,000 pages per month (For use in T642 / T644 Cartridges only)
Models: T642 / T642dtn / T642n / T642tn
Technology: Laser
Print Speed: Up to 45ppm
Resolution: 1200 Image Quality
Processor: 457MHz
Memory: 64MB Std., 576MB Max.
Footprint: 16(H) x 17.2(W) x 20.6(D)
Duty Cycle: 225,000 pages per month
Use of brand names and registered trademarks in this document are for descriptive purposes only and are the sole properties of their respective owners,
which are not affiliated with Future Graphics LLC. None of Future Graphics’ products are genuine Lexmark replacement parts and no affiliation or spon-
sorship is to be implied between Lexmark and Future Graphics.