ML1210

Technical Instructions
CORPORATE LOS ANGELES, USA
US 394.9900 Intl +837.8100 FAX 394.9910 Intl +838.7047

Machine Compatibility

Machine ML-1010 ML-1020 ML-1220 ML-1210 ML-1250 ML-1430 ML-4500 ML-4600 Lexmark E210 Par t #: P/N ML1210D3 P/N ML1210D3 P/N ML1210D3 P/N ML1210D3 P/N ML1210D3 P/N ML1210D3 P/N ML4500D3 P/N ML4500D3 P/N 10S0150

OEM Info

OEM Gram Load: 65 grams Yield @ 5%: 2,500 pgs Pages/Min.: 12 Resolution: 300/600 max
Phillips Screwdriver Small flat blade Screwdriver Supplies R equired: Cotton Swab 99% Alcohol Replacement Drum

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

Photo 1

Step 1
Using a Philips screwdriver, remove the four cartridge screws from the top corners of the cartridge. (See Photo 1)

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

BUENOS AIRES, ARG

ARG 0810 444.2656 Intl +011 4583.5900 FAX +011 4584.3100

Step 2

Photo 2

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
Locate the fifth screw located in the center of the cartridge on the waste hopper side. (See Photo 2) If the cartridge being remanufactured is a starter cartridge, this will be a regular Philips style screw. However if the cartridge is a replacement cartridge, a security screw is used instead of a Philips screw.

MONTEVIDEO, URY

URY 02 902.2001 Intl +5982 902.2001 FAX +5982 900.0858

Photo 3

Step 3
To remove the security screw, cut the thin wall that surrounds the screw. (See Photo 3)

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. 12/1/04

Website:
www.futuregraphicsllc.com

Photo 4

Samsung ML1210 Technical Instructions

Step 4

Using either diagonal cutters or needle nose pliers, grab the head of the screw and twist. (See Photo 4)

Photo 5

Photo 6

Step 5

Find the four locking tabs that hold the two halves of the cartridge together. (See Photo 5) To release the tabs, insert a small flat blade screwdriver into the tabs and carefully pry them apart. (See Photo 6)

Photo 7

Step 6
Lift the top cover up away from the cartridge. (See Photo 7) Clean the cover using dry compressed air or a vacuum.

Photo 8

NOTE: On some older cartridges, a metal plate covers the PCR and drum. Remove the two screws that hold the metal cover in place. (See Photo 8) Remove the cover.

Photo 9

Step 7
Using A Philips screwdriver, remove the three screws holding the cartridge end cap. (See Photo 9)
Need trust-worthy, detailed Technical Instructions for another engine? Visit: www.futuregraphicsllc.com

Photo 10

Step 8
Pull the end cap from the side of the cartridge. (See Photo 10)

Photo 11

Step 9
Remove the five gears from the end of the cartridge. (See Photo 11)

Photo 12

Step 10
Rotate the cartridge 180. Remove the three screws holding the cartridge end cap. (See Photo 12)

Photo 13

Step 11
Pull the end cap from the side of the cartridge. (See Photo 13)

Photo 14

Step 12
Lift out the PCR. (See Photo 14) Clean the PCR using a lint-free cloth.
Need help with a particular remanufacturing problem? Call the Technical Resource Center from 8am - 5pm PST: 800 394.9900

Photo 15

Step 13
Remove the two screws holding the wiper blade assembly. (See Photo 15) Lift the wiper blade assembly from the cartridge.

Photo 16

Photo 17

Step 14

Push up the drum drive gear from the bottom of the cartridge. (See Photo 16) Carefully lift the drum from the cartridge. (See Photo 17) NOTE: If you are going to reuse the drum, clean the drum using a dry lint free cloth and place the drum in a protected area away from the light.

Step 15

Photo 18
Dump the toner from the toner hopper. Using dry compressed air or a vacuum, clean the toner from the toner hopper.

Step 16

Using a small flat blade screwdriver, release the two locking tabs that hold the developer roller end cap to the side of the hopper. (See Photo 18 & 19)

Photo 19

Photo 20

Step 17

Slide the developer roller out from the side of the cartridge. (See Photo 20) Clean the developer roller using a lint-free cloth.

Photo 21

Step 18
Carefully clean the doctor blade using Acetone and a cotton swab. (See Photo 21) NOTE: If too much pressure is applied while cleaning the doctor blade, the blade could bend. If this occurs, a dark streak would appear running down the page.

Photo 22

Step 19
Slide the cleaned developer roller back into the cartridge. (See Photo 22)

Photo 23

Step 20
Install the developer roller end plate. Press the end plate until the two locking tabs are pushed into place. (See Photo 23)

Photo 24

Step 21
Install the five gears on the end of the cartridge. (See Photo 24)

Photo 25

Step 22
Carefully place the drum into the cartridge. (See Photo 25)

Photo 26

Step 23
Place the wiper blade assembly into the cartridge. Install the two screws that hold the wiper blade assembly in place. (See Photo 26)

Photo 27

Step 24
Install the cartridge end cap on the gear end of the cartridge. Install the three screws that hold the end cap. (See Photo 27)

Photo 28

Step 25
Install the non-gear end of the PCR into the saddle clip on the cartridge end plate. (See Photo 28)

Photo 29

Step 26
Slide the cartridge end cap onto the opposite end of the cartridge. Lift up on the PCR saddle and install the PCR axle into the saddle clip. (See Photo 29)

Photo 30

Step 27
Install the three screws that hold the end cap. (See Photo 30)

Photo 31

Step 28
Step 28: Fill the cartridge with toner. (See Photo 31) NOTE: If the cartridge being remanufactured had a metal plate that covered the PCR and drum, place the metal plate back onto the cartridge at this time. Install the two screws that holds the plate in place. See Photo 32)

Photo 32

Photo 33

Step 29

Place the top of the cartridge onto the cartridge. Press down on the top of the cartridge until it snaps into place. Install five screws into the cartridge. (See Photo 33)

Step 30

Test the cartridge.
Remanufacturing the Samsung ML1210
Released in 2001, the Samsung ML-1210 engine was utilized by Lexmark in the E210 and by Samsung in the ML-1010, 1220M, 1210, 1220M, 1250, 1430, 4500, and the ML-4600 series of printers. The Samsung ML-1210 engine is capable of printing 12 pages per minute at 600dpi and is rated at a 5,000 page duty cycle. These printers were discontinued back in 2002 but are still fairly popular amongst remanufactures. cartridge P/N ML1210D3. The ML-4500 and the 4600 use P/N ML4500D3. The part number for the Lexmark version cartridge is 1OS0150. One unique feature of this engine is the use of a toner that is stated to have 100% transfer efficiency. The waste hopper has no real chamber that could hold a large amount of waste. The use of a toner that wasnt close to having 100% transfer efficiency would overload the chamber and result in toner leaking from the so called waste hopper. Lastly, the wiper blade is a mylar strip that resembles a recovery blade, not a wiper blade.
The all-in-one cartridge holds 65 grams of toner and yields only 2,500 pages at 5% coverage. Two sepatate part numbers are given for the Samsung cartridges. The ML-1010, 1020M, 1210, M1220, 1250, and 1430 printers use
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.

Summit Laser Products - Samsung ML-1210 / Lexmark E-210 Toner Cartridges

Page 1 of 10

New Arrivals!

Company Info

Publications

Special Features

Contact Us
Overview Required Tools Required Supplies Disassembly Printing a Test Page Common Cartridge Problems Common Printer Problems Printer Modification

Recommended Supplies

Samsung ML-1210 / Lexmark E-210 Toner Cartridges

DOC-0288

OVERVIEW
First released in July 2001, the Lexmark E210, Samsung ML-1010, 1210, 4500, and 4600 printers are all based on the Samsung MLppm, 1200 dpi engine. The various models listed all use the same supplies to recycle, however we cannot confirm that they are all interchangeable. The Samsung versions have proved very difficult to find. See Figure 1 for the Lexmark Version. The cartridge is an All in one type cartridge, (it houses the toner supply, OPC drum, and waste chamber). The standard cartridge comes new with 65g toner, and is rated for 2,500 pages at 5% coverage. The Samsung part # is ML-1210D3/XAR (ML-4500D3 for the ML-4500/4600) The Lexmark part # is 10S0150 These cartridges are unique in a number of different ways, the first is that they do not have a drum cover, and come new with a piece of heavy paper taped around the cartridge. (See Figure 2) Second is that they do not use a seal. (All new cartridges opened so far have shown some toner leakage that would have shown on any prints). Lastly there is a screw on the top center that is a "One Way" Security type screw. This screw calls for a special driver to remove it, unfortunately these screws seem to be a specialty item made for Lexmark. It can also be done with wire cutters, not as neatly, but not that hard to do either. This will be gone over later in the procedure.
http://www.summitechnologies.com/docs/0288/0288.asp

4/21/2008

Page 2 of 10

FIGURE 1

FIGURE 2
The Starter cartridge that comes with the Printer has two major differences from the replacement cartridge. 1) These cartridges do not use a "One Way" security screw, and 2) they have a fill plug. The replacement cartridge has a plastic wall in place of the fill plug that is held in place by another "One way" screw. Clearly the replacement cartridges were designed to annoy Re-manufacturers. See Figures 3, 4, and 5.

FIGURE 3

FIGURE 4

FIGURE 5

The entire waste system in this cartridge is a similar to the P8e. The waste chamber is very small and the wiper blade is very flimsy. Unlike the P8e, the wiper blade also has a foam PCR cleaner attached to it. This cartridge is listed as having a 100% transfer efficiency. Since there is a waste chamber and wiper blade present, that is clearly not the case, but from what we have seen, it is very close. These cartridges also have the same PCR problems as the P8e, so it would be wise to have a few spare new PCRs in stock. The printers themselves can be easily modified to allow testing of all the different versions of these cartridges. See the printer modification section at the end of this article.

Summit Laser Products - Samsung ML-1210 / Lexmark E-210 Toner Cartridges REQUIRED TOOLS
Toner approved vacuum. A small Common screw driver A Phillips head screwdriver Needle nose pliers Security screwdriver (If available), or flush cutting wire cutters

Page 3 of 10

REQUIRED SUPPLIES
65g TonerNew PCR (Optional) New Mag Roller sleeve (Optional) New Drum (Recommended) New Wiper Blade (In development) NOTE: The OEM wiper blade will usually last one cycle with no problems. As stated above, the biggest problem with these cartridges is the OEM PCR.

DISASSEMBLY

1. 2. Place the cartridge with the handle facing up. Remove the 4 top corner screws. See Figure 6 Also on top of the cartridge in the center, is the security screw. We are continuing to try and source the driver bit for these screws. We have contacted numerous companies that specialize in security screws; no one has ever seen a screw like this! At this time it is safe to say that a driver for these screws is not available. Lexmark Strikes again! The best way to remove the screw at this time is to take the pair of flush cutting wire cutters, and cut the plastic ring around the screw away. Grab the screw with the cutters, twist and remove. Not a pretty solution, but effective. We are continuing to look for a driver and will send out a news release when we find them. See Figures 7 & 8 The screw looks like it takes a "Tri-Wing", or "Tri-Groove" tool, it doesnt. It is actually almost a REVERSE combination of the two. Instead of being recessed, it is raised, with small recesses on top. 3. Underneath the handle of the cartridge, there are 2 plastic tabs GENTLY press them in, and pry the cover off. See Figure 9 CAUTION: The upper half of the toner hopper is being removed. If there is a lot of toner left in the hopper, it can dump out all over! Vacuum the hopper clean.

FIGURE 6

FIGURE 7

Page 4 of 10

FIGURE 8

FIGURE 9

4. 5. 6.
Remove the two screws on the metal brace, and the brace. See Figure 10 With the toner hopper facing away from you, remove the three screws on the right side end cap. Remove the end cap. See Figure 11 & 12 Also on the right side there is a series of gears under the end cap. Make a note of the location of each gear. If you are careful, it is not necessary to remove them. See Figure 13

FIGURE 10

FIGURE 11

FIGURE 12

FIGURE 13
Remove the PCR. Figure 14 Clean the PCR with your normal PCR cleaner.

Page 5 of 10

WARNING: Do not clean the OEM PCR with alcohol, as this will remove the conductive coating on the roller. IF the PCR is an after market, follow the cleaning methods recommended by the manufacturer. If the PCR is an OEM, we recommended it be cleaned with your standard PCR cleaner 9. 10. With the toner hopper away from you, remove the three screws on the left side end cap. Remove the end cap. See Figure 15 There are 2 screws on the Wiper Blade/PCR cleaner Assy. Remove them and gently pry the blade up. Be very careful not to break off the alignment tabs. We have found it best to lift up from both sides when removing this blade. See Figures 16 & 17 NOTE: As stated in the beginning of this document, the Wiper Blade in this cartridge is very flimsy. It actually looks more like a doctor blade than a wiper blade! Since the transfer efficiency of this cartridge is very high. The wiper blade does not work as hard as in a normal cartridge. Since it is so delicate, we recommend that it be changed each cycle. It is also very important that the PCR cleaner be cleaned. Vacuum or blow off any residual toner from the foam. NOTE: Be very careful not to damage or distort the thin Mylar Recovery Blade next to the wiper blade. If this blade is bent or damaged in any way, it should be replaced.

FIGURE 14

FIGURE 15

FIGURE 16

FIGURE 17

11. 12. 13. 14. 15.

With the Wiper Blade removed the drum can easily be removed by lifting it out. See Figure 18 Clean out any remaining toner from the cartridge. Remove all the Gears from the right side. See Figure 19 Press in on the top tab of the roller plate to release it. See Figure 20 Press in on the bottom tab of the roller plate to release it. See Figure 21

Page 6 of 10

FIGURE 18

FIGURE 19

FIGURE 20

FIGURE 21

16. 17. 18.
Gently pry out the roller plate from the cartridge. See Figure 22 Remove the Developer Roller. Be careful not to lose the spring on the opposite side of the roller. It is highly recommended that the Doctor Blade be cleaned. Failure to do so will cause streaking. The Doctor Blade can be cleaned with out removing it. 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. Removing the blade is difficult because of the foam seals attached. If the seals are torn, the cartridge will leak. That is why we do not recommend it. Once replacement Dr. Blades are available, they will have to come with replacement foam. See Figure 23 Replace the Developer roller, roller plate and gears. If no grease is left or it is contaminated with toner, clean it all off, and replace it with white lithium grease. Be sure to clean and grease the gear shafts, and inside the gear. Replace the spring on the opposite side of the cartridge. See Figure 24 Install the cleaned wiper Blade/PCR cleaner Assy. and two brass colored screws. See Figure 25

19. 20. 21.

FIGURE 22

FIGURE 23

Page 7 of 10

FIGURE 24

FIGURE 25

22. 23. 24. 25.

Install the drum back in place. See Figure 26 Replace the left side end cap and three screws. See Figure 27 Install the PCR. See Figure 28 Install the right side end cap and screws. Make sure the PCR fits correctly in its holder. See Figure 29

FIGURE 26

FIGURE 27

FIGURE 28

FIGURE 29
Replace the metal brace and two screws. See Figure 30
27. 28. 29. Fill the hopper with 65g of the 210 toner. See Figure 31 Carefully snap the cover on making sure all the tabs lock in place. See Figure 32

Page 8 of 10

Install the five screws in the top cover. It is not recommended that the security screw be reused, unless you have the driver. Normal Canon screws work fine.

FIGURE 30

FIGURE 31

FIGURE 32

PRINTING A TEST PAGE
Once the machine has warmed up and is ready, press and hold the right button down until all the lights flash. A demo page will print out that also has the printer configuration,(Page count, Memory etc).
COMMON CARTRIDGE PROBLEMS
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 37mm. 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. 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 32mm

Page 9 of 10

COMMON PRINTER PROBLEMS
Bad Upper Fuser Roller; Marks repeat every 58mm Bad Lower Fuser Roller; Marks repeat every 60mm Bad Transfer Roller; Marks repeat every 47mm The front panel lights designate all printer errors. Most codes are very similar to each other; it is the timing of the lights that makes the difference. It is recommended that the service manual be purchased if you are going to repair these machines.

PRINTER MODIFICATION

It is very simple to modify these printers so that they accept all versions of these cartridges for testing. That being said, please be aware that this will almost certainly void the warranty of the machine. Perform the following modification at your own risk. 1. 2. Remove the two top silver screws. The top cover will come loose. Lift up and remove the top cover. See Figure 33 Remove the three black screws from the laser unit. Carefully flip up the laser unit so that the metal tab is exposed. See Figure 34 You can see that with a total of eight slots, and the possibility of using more than one tab at a time, Samsung has quite a few options for cartridge variations! 3. Remove the tab screw and tab. See Figures 35 and 36.

FIGURE 33

FIGURE 34

Page 10 of 10

FIGURE 35

FIGURE 36

Replace the laser unit. Make sure that the alignment tabs are in their proper location, and that the cables are snug. Install the three screws. Install the top cover. Make sure that the back section of the cover is locked in place. Install the two silver screws. The machine is modified! Run a few test pages to ensure all is aligned properly.

2003 Summit Laser Products, Inc. Any attempt to reproduce any part of these instructions without the written consent of Summit Laser Products, Inc is prohibited. All registered trademarks are the property of their respective owners.

RECOMMENDED SUPPLIES

Microsoft OLE DB Provider for ODBC Drivers error '80004005' [Microsoft][ODBC Microsoft Access Driver]General error Unable to open registry key 'Temporary (volatile) Jet DSN for process 0xc5c Thread 0x268c DBC 0x86205a4 Jet'. /script/catSearch.asp, line 58