Summit Laser Products - Samsung ML-1650 Toner Cartridges

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Overview Required Tools Required Supplies Disassembly Common Cartridge Problems Test Printing Cleaning the Printer Common Error Codes (Light Patterns)
Samsung ML-1650 Toner Cartridges

DOC-0310

OVERVIEW
The Samsung ML-1650, ML-1651N , Tektronix Phaser 3400, and Tally T9216 series of printers are based on a Samsung 17 ppm, 1200 dpi engine. This engine is an updated version of the Samsung ML-6060. As with the ML-6060, these cartridges are at the same time deceptively easy and deceptively difficult to remanufacture. I will explain more as we go through the process. The Samsung (ML-1650D8), Tektronix 3400 (106R00462) and Tally (043240) cartridges are rated for 8,000 pages at 5% coverage. Samsung and Tektronix also make the ML-1650D4, and 106R00461 cartridges respectively which are rated for 4,000 pages at 5%. Tally only has the high yield cartridge The Samsung machines have some interesting features that come standard with the machine. They can print multiple pages on one sheet, and print posters by breaking up the image into parts that overlap each other. The amount of overlap can be controlled by the user. Both of these functions are accessed through the driver. One important thing to watch out for is the toner save function. This is easily accidentally pressed as it has its own button on the control panel. If you are getting light print, check this out first. A complete list of the machines based on the ML-1650 engine is as follows: Samsung ML-1650 Samsung ML-1651N Tally T9216 Tally T9216N Tektronix (Xerox) Phaser 3400 Tektronix (Xerox) Phaser 3400B Tektronix (Xerox) Phaser 3400N Figures A and B show the difference between the Samsung and Tektronix cartridges. As the Tally machines are not sold in the US, I was not able to determine if the Tally and Samsung cartridges are interchangeable or not. More than likely, the notch on the front edge of the cartridge is in a different location. These cartridges are not interchangeable with any of the many Samsung versions currently produced.
http://www.summitechnologies.com/docs/0310/0310.asp

4/21/2008

Summit Laser Products - Samsung ML-1650 Toner Cartridges REQUIRED TOOLS
Toner approved vacuum. A small Common screw driver #1 Phillips head screwdriver Needle nose pliers Spring Hook

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REQUIRED SUPPLIES
1651 toner, 240g (For 8k cartridge) Wiper Blade (Check for availability) OPC Drum (ML-6060) Sealing Strip (P8e) Developer Roller (P8e) Dr. Blade (Check for availability) PCR (Check for availability) Kynar padding powder PCR Cleaner Conductive grease

DISASSEMBLY

1. Clean the exterior of the cartridge.
Place the cartridge with the handle facing up. Remove the top 2 screws. See Figure 1
Tilt the hopper away from the screw holes and remove. To prevent the tabs from breaking, it is best to tilt it 180 degrees from the start position. Vacuum both the hopper but leave the cartridge base alone. There is a sensor that can be ruined if the base of the hopper is vacuumed. See Figure 2 CAUTION: The upper half of the toner hopper is being removed. If there is a lot of toner left in the hopper, it will dump out all over!

FIGURE 1

FIGURE 2
4. Remove the screw on the front toner low sensor contact plate. See Figure 3

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Remove the two screws on the rear sensor plate. Remove the plate, sensor, and front contact plate. Note that the shorter screw is in the through hole, mounting directly to the sensor. See Figure 4

FIGURE 3

FIGURE 4
Note the hole in the toner hopper where the toner low sensor was located. Vacuum any remaining toner from the base of the hopper. This should be done after the sensor is removed to prevent it from being destroyed by the static fields normally generated while removing toner.
Locate both the drum cover arms and gently pry them off. Try to keep the springs on the arms to make re-assembly easier later. Remove the entire cover assembly. See Figures 5 & 6

FIGURE 5

FIGURE 6
Remove the two screws on the Waste chamber. Lift the waste chamber off the cartridge. See Figure 7 & 8

FIGURE 7

FIGURE 8
On the waste chamber, remove the two screws on the PCR clips. Remove the clips, and the PCR. Make sure you
note the orientation of the PCR as each side is different. See Figure 9

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Remove the two screws on the wiper blade. Remove the blade. Figure 10

FIGURE 9

11. Clean out the Waste chamber.

FIGURE 10

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
Clean the PCR. 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
Re install the Wiper Blade. New blades are at the time of this writing not available, but the OEM will easily last another cycle.
Reinstall the PCR and clips. Make sure that the long side of the PCR is to the left. Put the entire assy. aside. See Figure 11 Up to now this has been extremely easy. The next part on removing the drum had me going for a while. Its not that hard, just very different. If you have ever done an ML-6060, it is exactly the same.
Remove the three screws on the left side end cap (small drum gear side). Remove the end cap. This end cap tends to have a very tight fit. Take your time and work it off. See Figure 12.

FIGURE 11

FIGURE 12
Remove the three screws indicated on the right side end cap. The fourth screw located in the raised lip (Colorized), is screwed into the drum axle, and uses a left hand thread. Make sure you turn that screw to the right to remove it. Keep this screw separate so it doesnt get mixed up. It may be necessary to hold the opposite side of the drum shaft to keep it from spinning while removing the screw. See Figure 13.
NOTE: Although the drum axle pin looks like it should come out, it doesnt. The drum axle has a slug/silencer attached to it inside the drum. To remove the drum, do the following:

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Note the location of the gears and gear plate on the large gear side of the cartridge. Remove the Metal plate and gears. A drive belt will come loose as the plate is removed. This belt runs between the developer roller gear and the smaller of the two gears that stay on the gear plate. This belt presumably keeps the delivery of toner to the developer roller and from the developer roller to the drum smoother. A smooth turning developer roller will produce much more even gray scales. Make sure to note the orientation of the remaining gears as they are now loose. Remove the remaining gears. See Figures 14 & 15

From the large gear side, push the axle in as far as it will go. Lift up the large gear side, and press the axle back over from the small gear side, until the drum is released. See Figure 16. We have removed the gear from an OEM drum to show the axle/silencer combo. New replacement drums come with the small drive gear installed, and the large gear just pressed in the drum, not glued. If the drum is being replaced, dont forget to glue this gear in place! See Figure 17

FIGURE 13

FIGURE 14

FIGURE 15

FIGURE 16
To clean the Dr. Blade (Highly recommended), the developer roller must be removed. These blades tend to get toner built up on them that can cause light streaks if not cleaned properly.
Locate the plastic plate the locks the developer roller in place. See Figure 18

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FIGURE 17

FIGURE 18

From the bottom of the cartridge, press in on the tab to release the plate. See Figure 19
Slide the plate forward so that the small tab at the top of the plate is free. Remove the plate. See Figure 20

FIGURE 19

FIGURE 20
Slide the developer roller out of the cartridge. See Figure 21
Clean the Dr. Blade. It can be removed to clean, but is not necessary. If you do remove it, be very careful not to tear the foam seals that attach to it. The P8e blade looks similar, but is just different enough not to fit correctly. See Figure 22

FIGURE 21

FIGURE 22
Clean the developer roller with a clean lint free cloth. Install back into the cartridge. Keep the longer shaft side to the gear side of the cartridge. See Figure 23
Re-install the locking plate over the developer roller shaft. Make sure that the top tab fits behind the frame. See

Figure 24

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FIGURE 23

FIGURE 24
Install new drum axle and gears. Make sure you glue in the gears. The screw hole side of the axle is on the large gear side. See Figure 25
Re-install the loose gears, and belt onto the developer roller gear. As the metal plate with gears is inserted, slide the loose end of the belt over the front double gear. See Figures 26 & 27

Install the end cap and the four screws. Make sure that the machined left hand threaded screw is in the drum axle shaft. See Figure 28

FIGURE 25

FIGURE 26

FIGURE 27

FIGURE 28
Re-install the waste chamber and screws. Make sure that the end of the PCR shaft fits through the hole in the cartridge wall. See Figure 29.

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Install the toner sensor, cover, and two screws on the base of the toner hopper. Make sure that the short screw is in the through hole, mounting directly to the sensor. See Figures 30 & 31
Route the wires as shown, install the contact plate and screw. Make sure that the front tabs lock in place. Figures 32, 33 & 34

FIGURE 29

FIGURE 30

FIGURE 31

FIGURE 32

FIGURE 33

33. Install the seal on the toner hopper. See Figure 35

FIGURE 34

34. Remove the fill plug on the toner hopper and fill the hopper with the correct toner. Re-install the fill plug. This plug is made with a hard plastic, if it gets damaged; put a small bead of silicon around the lip to seal the cavity. See Figure 36

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FIGURE 35

FIGURE 36

Slide the seal pull tab under the foam seal and out the cartridge wall. See Figure 37
Install the hopper back on to the cartridge. Start with the hopper upside down, slide the tabs in place, and rotate it until it is in place. Install the two screws. See Figures 38 & 39
Clean the contacts on the left end cap. Re-install the conductive grease. Install the end cap making sure the seal tab is inserted through the slot. See Figure 40

FIGURE 37

FIGURE 38

FIGURE 39

FIGURE 40
Install the drum cover. Press the spring tab into the slot in the end cap to set the spring tension. See Figure 41

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FIGURE 41
COMMON CARTRIDGE PROBLEMS
Light print overall: Check to see if the toner save mode is on. (Button is easy to accidentally press as it is on the control panel.) 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, or as ghosting where part of a previously printed area is repeated. 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 3 times per page. Any drum defects will repeat 3 times per page. Light Damaged Drum: This will show up as a shaded area on the test print that should be white. Again this will repeat 3 times per page. 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.

TEST PRINTING

On the front panel of the printer there is a DEMO button. By pressing this button for different lengths of time, different pages will print. Demo Page: Press and hold this button for about 2 seconds until the control panel lights blink SLOWLY. A demo page that has both text and graphics will print out Configuration Page: Press and hold this button for about 6 seconds until the control panel lights blink RAPIDLY. A configuration page containing most of the printers settings will print out. Printing a Cleaning Page: Press and hold the DEMO button for about 10 seconds until the control panel lights STAY ON. The printer will run through a cleaning process, and print out a blank page. (This usually takes a while.) The process is done at this point; the printed page does not get run through again.

CLEANING THE PRINTER

Not much of the machine is accessible. All that can be done easily is to vacuum the interior and wipe the lens down with a
clean lint free cloth. The lens is located on the bottom of the top cover directly below the cartridge cover.

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COMMON ERROR CODES (LIGHT PATTERNS)
The error light patterns are not very helpful for anything besides a paper jam, but here they are: Paper Jam: Paper LED is on, Error LED is on Cover open/no cartridge: The error LED is on steady Internal system error: All four LEDs blink in sequence, at a high rate of speed. See next error. Engine error: Same as above, all four LEDs blink in sequence, at a high rate of speed. This can be caused by a memory crash, Main board or fuser error!
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.
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ML6060/1650HTECH

Technical Instructions

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

Printers

See Last Page

OEM Info

Tools & Supplies 1
Philips Screwdriver Small Flat blade Screwdriver Cotton swab Alcohol Lint free cloth Toner Seal

ATLANTA, USA

US 676.4223 Intl +919.1189 FAX 337.7976 Intl +516.7794

KANSAS CITY, USA

US 871.1700 FAX 888.0626

Photo 1

MIAMI, USA
US 595.4297 Intl +594.3396 FAX 522.8640 Intl +594.3309

Step 1

Place the cartridge upside down on the work bench. Slide open the drum shutter and pull the drum shutter arms from their positioning posts on each side of the cartridge. (See Photos 1 & 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

Photo 2

BUENOS AIRES, ARG
ARG 0810 444.2656 Intl +011 4583.5900 FAX +011 4584.3100

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

MONTEVIDEO, URY

URY 02 902.2001 Intl +5982 902.2001 FAX +5982 900.0858

Photo 3

Step 2
Place the cartridge on the work bench so the waste hopper is facing away from you. (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. 2/23/05

Website:
www.futuregraphicsllc.com

Photo 4

ML-6060/1650 Technical Instructions

Step 3

Using a Philips screwdriver remove the two screws located on top of the cartridge next to the toner hopper. (See Photo 4)

Photo 5

Step 4
Pry the front of the toner hopper reservoir back. (See Photo 5)

Photo 6

Step 5
Lift the toner hopper reservoir away from the cartridge. (See Photo 6) Clean the toner hopper reservoir using dry compressed air or a vacuum.

Photo 7

Step 6
Remove the three screws that hold the cartridge end cap to the toner hopper on the gear side of the cartridge. (See Photo 7)

Photo 8

Step 7
To remove the fourth screw from the end cap rotate the screwdriver to the right. (See Photo 8)
Need trust-worthy, detailed Technical Instructions for another engine? Visit: www.futuregraphicsllc.com

Photo 9

Step 8
Side the cartridge end cap from the side of the cartridge. (See Photo 9)

Photo 10

Step 9
Pull the metal gear housing plate from the side of the cartridge. (See Photo 10) NOTE: Two gears may stay attached to the gear housing end plate.

Photo 11

Step 10
A white bearing may be found on the shaft of the toner hopper supply roller. Slide the bearing from the supply roller shaft. (See Photo 11) If it the bearing is not on the shaft check the cartridge end cap. (See Photo 12) It is important that this bearing be present during the reassembly of the cartridge.

Photo 12

Photo 13

Step 11

Remove the three gears from the side of the cartridge. (See Photo 13)

Photo 14

Step 12
Rotate the cartridge 180. Remove the three screws that hold the contact end cap to the cartridge. (See Photo 14)

Photo 15

Step 13
Slide the end cap from the side of the cartridge. (See Photo 15) NOTE: A white bearing may be found on the shaft of the supply roller. Remove the bearing. (See Photo 16) If the bearing is not present check the cartridge end cap. (See Photo 17)

Photo 17

Photo 16
It is important that this bearing be present during the reassembly of the cartridge.

Photo 18

Step 14
NOTE: On some cartridges the drum axle can be removed at this time. Grab the drum axle on the contact side and slide the axle out of the cartridge. (See Photo 18) If the axle cannot be removed at this time continue to the next step.

Photo 19

Step 15
Remove the two screws holding the waste hopper to the cartridge. (See Photo #19)

Photo 20

Step 16
Lift up on the waste hopper and remove the hopper from the cartridge. (See Photo 20)

Photo 21

Step 17
If the drum axle has already been removed lift out the drum. If the drum axle cannot be removed from the drum slide the axle out as far as possible from the drive gear end. (See Photo 21) Lift the small gear end of the drum up out of the cartridge and slide the drum axle out from the end of the cartridge. (See Photo 22)

Photo 22

NOTE: If the drum being used is damaged and the axle cannot be removed from the drum by simply pulling the axle out, remove the small gear from the end of the drum. Install the drum axle into the new drum and glue the gear into place.

Photo 23

Step 18
Using a Philips screwdriver, remove the two screws holding the PCR to the waste hopper. (See Photo 23) Remove the PCR. Clean the PCR using a dry lint free cloth.

Photo 24

Step 19
Remove the two screws holding the wiper blade. (See Photo 24) Clean the wiper blade with dry compressed air.

Photo 25

Step 20
Dump out the waste hopper. Clean the waste hopper using dry compressed air or a vacuum.

Step 21

Apply padding powder to the wiper blade. Place the blade onto the waste hopper. Install the two screws that hold the wiper blade in place. (See Photo 25)

Photo 26

Step 22
Place the cleaned PCR into the PCR saddles. The rounded end of the PCR is the contact side of the roller. Place the PCR onto the waste hopper so the contact end sticks out the side of the hopper. (See Photo 26)

Photo 27

Step 23
Install the two screws that hold the PCR saddles in place. See Photo 27)

Photo 28

Step 24
Remove the developer roller drive gear from the side of the cartridge. (See Photo 28)

Photo 29

Step 25
Dump out the remaining toner from the toner hopper. Clean the hopper using dry compressed air or a vacuum.

Step 26

Release the clip the holds the developer roller end cap to the cartridge. (See Photo 29)

Photo 30

Step 27
Remove the end cap from the hopper. (See Photo 30)

Photo 31

Step 28
Slide the developer roller out from the side of the cartridge. (See Photo 31)

Photo 32

Step 29
Clean the developer roller using a dry lint free cloth.

Step 30

Carefully clean the doctor blade using Acetone and a cotton swab. (See Photo 32)

Photo 33

Step 31
Slide the developer roller back into the cartridge. Move the contact spring onto the developer roller axle. (See Photo 33)

Photo 34

Step 32
Install the developer roller end plate onto the cartridge. (See Photo 34) NOTE: Make sure the end plate snaps into place.

Photo 35

Step 33
Place the developer roller drive gear onto the rollers axle. (See Photo 35)

Step 34

Photo 37 Photo 36
Apply padding powder to the drum. Install the drum into the cartridge. (See Photo 36) If the drum axle is installed in the drum slide the axle out from the small gear end as far as possible. Install the drum axle into the side of the cartridge. (See Photo 37) Carefully lower the drive gear end of the drum into the cartridge and slide the drum axle back into the drum.

Photo 38

Step 35
Carefully place the waste hopper into the cartridge. Install the two screws that hold the waste hopper in place. (See Photo 38)

Photo 39

Step 36
If the drum axle is not attached to the drum, slide the drum axle into the drum starting on the gear side so the screw hole in the axle is visible on the gear side. (See Photo 39)

Photo 40

Step 37
Install the three toner hopper agitator gears. (See Photo 40)

Photo 41

Step 38
Install the white bearing onto the supply roller axle.

Step 43

(See Photo 41) Slide the contact end cap onto the cartridge. Install the three screws that hold the end cap in place. (See Photo 46)

Photo 42

Step 39
Place the metal gear housing plate onto the side of the cartridge. (See Photo 42)

Photo 46

Photo 43

Step 40

Slide the cartridge end cap onto the cartridge. Install the three screws that hold the end cap in place. (See Photo 43)

Step 44

Push the fill plug out of the toner hopper reservoir from the inside of the hopper. Apply a seal to the toner hopper and fill with toner. (See Photo 47)

Photo 44

Step 41
Install the small threaded screw into the drum axle. (See Photo 44) NOTE: Remember to rotate the screw to the left to install.

Photo 47

Photo 45

Step 42

Rotate the cartridge 180. Install the white bearing onto the supply roller axle. (See Photo 45)

Step 45

Pour some toner into the hopper for testing.

Photo 48

Step 46
Slide the tail of the seal under the toner hopper sealing end foam and out through the seal exit port on the side of the cartridge. (See Photo 48)

Photo 49

Step 47
Lock the latches on the back of the cartridge and toner hopper reservoir. (See Photo 49)

Photo 50

Step 48
Rotate the toner reservoir down onto the cartridge. Install the two screws that hold the toner hopper reservoir to the cartridge. (See Photo 50)

Photo 51

Step 49
Install the drum shutter arms onto the cartridge end caps. Install the drum shutter onto the shutter arms. (See Photo 51)

Step 50

Test cartridge.
In July of 2000, NEC released a new family of printers, the SuperScript 1400, 1450, and the 1450N all using a new Samsung ML-6060 engine. Two months later Xerox and IBM released the Xerox DocuPrint P1210 and the IBM InfoPrint 12 each using the same Samsung engine. These machines are capable of printing 12 pages per minute and have a first page out speed of 14 seconds. The new Samsung ML-6060 engine utilizes a new monocomponent, all-in-one toner cartridge. Even though the cartridges use the same internal components, a molding difference on the from of the waste hopper prevents the cartridges from being used in the different machines. Both Xerox and NEC sell two different yield cartridges, a 3,000 pages standard yield cartridge and a 6,000 page high yield cartridge, while IBM only sells the high yield version. In 2001 Xerox and Samsung released another series of printers using the Samsung ML-1650 engine. The Xerox Phaser 3400, 3400B, 3400N and the Samsung ML1650, 1651N printers print 17 pages per minute and have a first page out time of 12 seconds. The cartridges for these printers are very similar to the ML6060, they use same components and the remanufacturing

process is almost the same. The only difference in the process has to do with the gear assembly that turns the developer roller. A small drive belt is found on the gear and must be placed back onto the drive gear during the reassembly of the cartridge. See Figure 1. The ML1650 cartridges also hold more toner than the ML6060 and can 8,000 pages at 5% coverage with the high yield cartridge and 4,000 pages at 5% coverage with the low yield cartridge
Machine Model IBM Infoprint 12 NEC Superscript 1400 NEC Superscript 1450 NEC Superscript 1450N Samsung ML-1440 Samsung ML-1450 Samsung ML-1451N Samsung ML-6040 Samsung ML-6060 Samsung ML-6060N Samsung ML-6060S Xerox Docuprint P1210 Xerox Phaser 3310 Samsung ML-1650 Samsung ML-1651N Xerox Phaser 3400 Xerox Phaser 3400B Xerox Phaser 3400N
OEM Number 01P6897 20-150 20-150 20-150 ML6060D6 ML6060D6 ML6060D6 ML6060D6 ML6060D6 ML6060D6 ML6060D6 106R442 106R646 ML1650D8 ML1650D8 106R462 106R462 106R462
Engine Samsung Samsung Samsung Samsung Samsung Samsung Samsung Samsung Samsung Samsung Samsung Samsung Samsung Samsung Samsung Samsung Samsung Samsung
ML-6060 ML-6060 ML-6060 ML-6060 ML-6060 ML-6060 ML-6060 ML-6060 ML-6060 ML-6060 ML-6060 ML-6060 ML-6060 ML-1650 ML-1650 ML-1650 ML-1650 ML-1650
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.