DELL1100TECH

Technical Instructions
CORPORATE LOS ANGELES, USA
US 394.9900 Intl +837.8100 FAX 394.9910 Intl +838.7047
Cartridge Information See Last Page.
Tools & Supplies See Last Page.

Photo 1

Step 1
Having the handle of the cartridge facing you remove two Philips screws one from each side on the top of the cartridge. (Photo 1)

ATLANTA, USA

US 676.4223 Intl +919.1189 FAX 337.7976 Intl +516.7794

KANSAS CITY, USA

US 871.1700 FAX 888.0626

MIAMI, USA

US 595.4297 Intl +594.3396 FAX 522.8640 Intl +594.3309

Step 2

Grab the top of the cartridge that has the instruction label on it with both hands. Pull the cartridge top up and back towards yourself to remove. This is the waste hopper section of the cartridge and as it is removed may leak some toner. Turn the waste hopper over and place on the table with label facing down. (Photo 2)

Photo 2

NEW YORK, USA
US 431.7884 Intl +588.7300 FAX 431.8812 Intl +588.7333

TORONTO, CAN

CAN 848.0818 Intl +712.9501 FAX 772.6773 Intl +712.9502

Step 3

Place the toner hopper aside and protect from light. (Photo 3)

BUENOS AIRES, ARG

ARG 0810 444.2656 Intl +011 4583.5900 FAX +011 4584.3100

Photo 3

MELBOURNE, AUS
AUS 003. 100 Intl +9561.8102 FAX 004.302 Intl +9561-7751

SYDNEY, AUS

AUS 003.100 Intl +9648.2630 FAX 1800 004.302 Intl +9548.2635

Step 4

Take the waste hopper with the wiper blade facing you remove two Philips screws one from each side of the wiper blade. Lift the blade straight up from the waste hopper and visually inspect for damage. Clean the blade with compressed air and clean lint free cloth. Set blade aside. (Photo 4)

MONTEVIDEO, URY

URY 02 902.2001 Intl +5982 902.2001 FAX +5982 900.0858

Photo 4

JOHANNESBURG, S.A.
S.A. +974.6155 FAX +974.3593

SO PAULO, BRAZIL

Intl +5524.8000

RAANANA, ISRAEL

ISR 09 760.12.39 Intl +972 9760.12.39 ISR 052.38.555.82 Intl +972 5238.555.82
E-mail: info@futuregraphicsllc.com

REV. 10/10/05

Website:
www.futuregraphicsllc.com

Photo 7

Dell 1100 Technical Instructions

Step 7

Using a small flat blade screwdriver pry the end cap off carefully. The end caps contain the drum axles. (Photo 7)

Step 5

Clean the remaining waste toner from the waste hopper using a vacuum or compressed air. Careful not to damage the retaining blade in the waste hopper, opposite the wiper blade that was removed. Inspect the retaining blade after cleaning to insure that it is straight and not damaged. (Photo 5)

Photo 8

Step 8
Rotate the cartridge so that the opposite end is facing you with the handle of the cartridge to the left. Remove two Philips screws that are holding the end cap in place. Using a small flat blade screwdriver pry the end cap off carefully. (Photo 8)

Photo 5

Photo 9

Step 9

Rotate the cartridge so that the handle of the cartridge is facing you. Grasp the PCR shaft and slide it towards your left to remove it from the right PCR saddle. To remove the PCR from the left PCR saddle, lift the PCR up on the right side to clear movement and move towards the right to remove the PCR. (Photo 9)

Step 6

Taking the wiper blade that is to be installed pad the blade with padding powder. Reinstall the blade using two Philips screws one on each side of the blade. Place completed waste hopper aside. Set the toner hopper with the long handle towards your right and remove two Philips screws that are holding the end cap in place. (Photo 6)

Photo 10

Step 10
Remove the drum by pushing up on the helical gear with your finger enough to grab the entire gear. Pull the drum away slightly from the opposite side and lift completely out. Set the drum aside in a protective area. (Photo 10)

Photo 6

Photo 11

Step 11

Rotate the cartridge so that the handle is facing towards your left and remove the fill plug from the end cap. Clean out all remains of toner from the inside of the toner hopper. Place the fill plug aside for later. (Photo 11)

Photo 12

Step 12
On the cartridge end that contains the fill plug and electrical contacts, push up the wire that contacts the developer roller shaft. Release the clip that holds the black contact support plate by pushing the tab in from the outside of the cartridge. Gently pull forward on the plate to remove. (Photo 12)

Step 17

Place the cartridge with the cartridge handle facing you and the handle extended outward. On the right side push the electrical contact wire forward and to the right to rest just out of the way of the Dr. Bar so that you can install the blade. Install the blade by lining up the location pins on each side and coming straight down. Hold in place by inserting the two Philips screws one on each side of the Dr. Bar. Move the electrical contact wire back into position. (Photo 17)

Photo 13

Step 13
Remove the developer roller drive gear from the developer roller using a small flat blade screwdriver to push with. The center idle gear in the gear train is loose and can fall off so take it off and place aside. The smaller helical diameter teeth face inward. (Photo 13)

Photo 17 Photo 14

Step 14
Remove the developer roller by holding the metal shaft on either end and pulling upward. (Photo 14)

Step 15

Start by placing the cartridge with the cartridge handle facing you and the handle extended outward. Remove two Philips screws one from each side of the Dr. Bar. Lift carefully from the left side up off the location pin just enough to clear it. Holding the Dr. Bar steady work towards the right and lift straight up off the locator pin and back towards you. This will allow the electrical contact wire to rest in the tab slot of the cartridge. Clean with 99% Isopropyl alcohol and a lint free cloth. (Photo 15)

Photo 15

Step 18
Holding the developer by the shaft on each side position and install the developer roller. Push down with just a little pressure to set and replace the developer roller idle and drive gear. (Photo 17)

Photo 18 Photo 16

Step 16
Clean the toner hopper area which includes the toner feed roller, developer roller recovery blade, sealing felts, PCR saddles and toner tank area. Be very careful not to damage these parts by using too strong of an air flow. (Photo 16)

Photo 21

Step 21

Place the cartridge with the cartridge handle facing you and the handle extended outward. Place the drum into the cartridge with the helical gear to your right. (Photo 21)

Step 19

Moving to the electrical contact end of the cartridge push the electrical contact wire up out of the way and replace the black contact support plate by pushing the black contact support plate in until it latches. Bring the electrical contact wire down and in contact with the metal shaft end of the developer roller. (Photo 19)

Step 22

Photo 22
With the longer shaft of the PCR on your left side install the shaft into the left side PCR saddle enough so that you can clear the right side of the cartridge. Pull the right side saddle up enough so that you can push the PCR towards your right and into the saddle until it stops. Place a little conductive grease on contact of PCR saddle before installing. (Photo 22)

Photo 19

Step 23

Photo 23

Set the toner hopper with the long handle towards your right and install the end cap and the two Philips screws to hold the end cap in place. (Photo 23)

Step 24 Step 20

Now fill the toner into the toner hopper and replace the fill plug. (Photo 20)

Photo 24

Rotate the cartridge so that the opposite end is facing you with the handle of the cartridge to the left. Install the end cap and the two Philips screws to hold the end cap in place. Place a little conductive grease on contacts as applicable. (Photo 24)

Photo 20

Step 25

Photo 25

Place the cartridge with the cartridge handle facing you and the handle extended outward. Taking the waste hopper with the label up and embossed arrows pointing away from you place the tabs on each side into the slots and tilt forward. Hold in place using Philips screws one on each side. (Photo 25)

Photo 26

Step 26
Replace the fuse. The fuse is located on the right side of the cartridge with the cartridge handle facing away from you. The fuse is blown when installed into the printer to reset the counter/flag. (Photo 26)

Website: www.futuregraphicsllc.com
Remanufacturing the Dell 1100 / Samsung ML-2010D3 Laser Cartridges
Tools Small flat blade screwdriver Philips screwdriver number 2 Small needle nose pliers (for fuse replacement) Supplies Cotton swabs 99% isopropyl Alcohol Conductive Grease Replacement Drum Replacement fuse Toner The Dell Laser Printer 1100 monochrome printer has a small foot print design at 11.7 x 8.54 x 14.1 and prints at a speed of 15 pages per minute. Its design and price makes it a good choice for home and small offices selling online at $99.00. The printer when purchased from Dell also comes with 24/7 toll free technical support and one year exchange program. The printer ships with a starter cartridge rated for 1k page use and the replacement cartridge is rated at 2k pages. The Dell replacement part number is 310-6640. Samsung ML-2010 printer is the engine design and takes the replacement cartridge ML-2010D3 rated at 3k pages.
This cartridge is the same as the Dell replacement cartridge with the exception that the key (cutout on the waste hopper is in a different location) so that you can not put this cartridge into the Dell and visa versa.
Future Graphics (FG) is a distributor of compatible replacement parts and products for imagining equipment. None of FG's products are genuine OEM replacement parts and no affiliation or sponsorship is to be implied between FG and any OEM.

THE SAMSUNG ML-2010 TONER CARTRIDGE

DOC# 0367

By Mike Josiah and the Technical Staff at Summit Technologies
SAMSUNG ML-2010 TONER CARTRIDGE REMANUFACTURING INSTRUCTIONS

Page 1

USA Sales: T 800.221.3516 F 888.791.9188 International Sales: T +1 631.590.1040 F +1 631.218.3285 www.summitechnologies.com
Remanufacturing the Samsung ML-2010 Toner Cartridge
The Samsung ML2010 Toner Cartridge
irst released in July 2005, the Samsung ML-2010 printers are based on a 20ppm, 1200 x 600 dpi engine.
These cartridges are based on the new engine/cartridge design of the ML-1610 (Dell 1100). The cartridges have a huge handle which folds over the cartridge when installed. The good news here is that for at least the Samsung ML-2010 version, there is NOT a fuse or Chip used to reset the machine. There is a fuse clip however. It is possible that one of the soon to be released Xerox or other Samsung cartridges will use one. These cartridges do not have a drum cover, and come new with a piece of heavy paper taped around the cartridge. All new cartridges opened so far have shown some toner leakage on the drum that would have shown on any prints. The replacement cartridge it self is rated for 3,000 pages at 5% coverage (ISO 19752). The starter cartridge is rated for 1000 pages. Printer Samsung ML-2010 Samsung SCX-4321 Series Samsung SCX-4521 Series SEE Samsung SP20MPP Cartridge ML-2010D3 SCX4521D3/SEE SCX4521D3/ Not released as
of 9/19/2005 Samsung SP20MPU of 9/19/2005 Xerox Phaser 3117 Xerox Phaser 3122
Not released as 106R01159 106R01159
Possible other machines based on the ML-2010 engine: Not confirmed, but likely. Printer Xerox WorkCentre PE-220 of 9/19/2005 Xerox CopyCentre PE-220 of 9/19/2005 Required Tools 1) Toner approved vacuum. 2) A small Common screw driver 3) A Phillips head screwdriver 4) Needle nose pliers Required Supplies Samsung 2010 Toner 85g Conductive Grease Drum lubricating powder Cartridge Not released as Not released as

Page 2

1) Place the cartridge with the handle facing away from you. Remove the 2 screws on the left end cap. See Figure 1

Figure 1

4) Lift up and remove the waste chamber from the cartridge. Make sure the tab on the right side slide out of the slot. If you try to lift the cover off with out sliding the tab out, it will break off. See Figure 4
2) Gently pry off the left end cap. See Figure 2

Figure 4

5) Remove the two screws and wiper blade from the waste chamber. See Figures 5 & 6

Figure 5 Figure 2

3) On the front edge of the cartridge, there are two screws, remove them. See Figure 3

Figure 6

6) Clean out any remaining toner from the waste chamber. 7) Re-install the wiper blade and two screws. Place the waste chamber aside. See Figure 7

Figure 3

Figure 7

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8) Remove the two screws from the right side end cap. Carefully pry off the end cap. See Figure 8
11) Remove the OPC drum. See Figure 11

Figure 11 Figure 8

9) Remove the 4 gears, and place aside. See Figure 9 12) Carefully pry out the fill plug. It fits tight and is easily damaged. Work a small jewelers screwdriver around the edge until the plug comes free. See Figure 12

Figure 9

10) Slide the PCR away from the contact side, lift up and remove. See Figure 10

Figure 12

13) Clean out any remaining toner from the hopper. 14) Gently pry out the roller plate from the cartridge by pressing in on a tab located on the bottom of the cartridge. There is a spring that is in contact with the developer roller shaft. Move the tail of the spring up so that as the plate is lifted out, it will fall behind it. See Figures 13 & 14

Figure 10

Clean the PCR with your normal PCR cleaner. WARNING: Do not clean the OEM PCR with alcohol, as this will remove the conductive coating from the roller. If the PCR is an aftermarket, follow the cleaning methods recommended by the manufacturer. If the PCR is an OEM, we recommend it be cleaned with your standard PCR cleaner.

Figure 13

Page 4

Figure 14

16) Remove the Developer Roller by lifting it out. See Figure 15

Figure 17

It is highly recommended that the Doctor Blade be cleaned. Failure to do so will cause streaking. Dampen a cotton swab with alcohol, and clean the blade. Be careful not to press too hard and damage the blade. If the blade has a heavy buildup of toner on it, clean it with Acetone, and then alcohol. 18) Clean the feed roller and any remaining toner from the hopper. See Figure 18

Figure 15

17) Remove the 2 screws on the doctor blade. On the fill plug side of the blade, there is the other tail of the spring. Lift it up while removing the doctor blade so it is not damaged. See Figures 16 & 17

Figure 18

19) Re-install the doctor blade and two screws. Make sure the tail of the spring fits into the proper slot. See Figures 19 & 20

Figure 19

Figure 16

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Figure 20
20) Install the developer roller, keyed end to the gear side of the cartridge. See Figure 21

Figure 23

23) Install the 4 gears as shown. See Figure 24

Figure 21

21) Install the roller plate. Route the tail of the spring so that it sits on top of the plate and is in contact with the shaft of the developer roller. Lock the plate in place with the tab. See Figures 22 & 23

Figure 24

24) Install the drum in place. See Figure 25

Figure 25

Figure 22
25) Clean out the old conductive grease from the PCR contact hub and replace with new. A small amount of grease is fine, more is not better when it comes to

Page 6

conductive grease. See Figure 26

Figure 26

28) Install the gear side end cap, and 2 screws. Make sure the PCR fits correctly in its holder, and all the gears are aligned. See Figure 29
26) Install the PCR by sliding it through the non contact side, and into the contact hub. See Figure 27

Figure 29

29) Install the waste chamber by sliding the tab through the slot in the end cap. Rotate it down, and install the two screws. See Figures 30 & 31

Figure 27

Figure 30
27) Fill the hopper with the appropriate toner. Replace the fill plug, check for leaks. See Figure 28

Figure 28

Figure 31

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30) Install the remaining end cap and two screws. Make sure the end cap sits flush with the rest of the cartridge. See Figures 32 & 33
Printing Test Pages: Demo Page Press and hold the CANCEL button for 2 seconds until all the LEDs blink slowly. A demo page will print out Common Cartridge Problems Repetitive Defect Chart PCR Developer Roller OPC Drum 38mm 44mm 75mm

Figure 32 Figure 33

A Dirty or Bad Primary Charge Roller (PCR); located Inside the cartridge, this will show on the test print as vertical gray streaks down the page, as a gray background throughout the page, as ghosting where part of a previously printed area is repeated, or as a mark that repeats every 38mm. Dirty PCR Connection; This will show as horizontal dark black bars across the page, or as shading throughout the page. Scratched Drum; This is shown by a very thin, perfectly straight line that runs from the top to the bottom of the test page. Chipped Drum; This will show as a dot or series of dots that repeat every 75mm.

31) If your cartridge has a fuse, it needs to be replaced. Replace the fuse located on the right front of the cartridge (with the handle away from you. The ML-2010 does not use a fuse, and no other machines/cartridges are available yet (9/2005), but the slot for a fuse is there so it is possible that some of these cartridges will use one. See Figure 34
Light Damaged Drum; This will show up as a shaded area on the test print that should be white. Again this will repeat every 75mm. Bad Wiper Blade; This will show as either a gray line approximately 1/8" thick, or as shading across the entire page. In either case there will be a film of toner on the drum surface. Bad Developer Roller; This will show up as light print or as a mark that repeats every 44mm Machine Error Codes: These machines do not have a display panel. They use a series of LEDs to indicate a problem. There are two lights on the control panel, the ONLINE/ERROR, and the TONER SAVE lights. The TONER SAVE light is a Green LED, and the ONLINE/ERROR LED is a two color LED, Red and Green.

Figure 34

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The user manual for these machines only has very basic information listed as follows: If both lights are blinking, the machine has problems and needs service. (Dont you just love these helpful notes!) If the On Line/Error light is on steady red, and the toner save is off, there could be a number of problems. Either there is a paper jam, the front cover is open, the paper tray is empty, or the toner cartridge is empty. The Transfer roller, paper pickup roller, and the fuser are all rated for 50,000 pages

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