by Craig Rummler, Future Graphics

What Works

Remanufacturing the Samsung ML-6060/ML-1650 Toner Cartridge
n July 2000, NEC released a new family of printers, the SuperScript 1400, 1450, and the 1450N, which all use a new Samsung ML-6060 engine. Two months later, Xerox and IBM released the Xerox DocuPrint P1210 and the IBM InfoPrint 12, which also use the same Samsung engine. These machines are capable of printing 12 ppm and have a first-page-out speed of 14 seconds.
The new Samsung ML-6060 engine uses a new mono-component, all-in-one toner cartridge. Although the cartridges use the same internal components, a molding difference on the form of the waste hopper prevents the cartridges from being interchangeable in the different machines. Both Xerox and NEC sell cartridges of two different yieldsa 3,000-page standard yield cartridge and a 6,000-page high yield cartridgewhile 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 ppm and have a first-page-out time of 12 seconds. The cartridges for these printers are very similar to the ML6060; they use the same components, and the remanufacturing process is almost the same. The only difference in the remanufacturing process is in 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 produce 8,000 pages at 5 percent coverage with the high yield cartridge and 4,000 pages at 5 percent coverage with the low yield cartridge.
Tools & Supplies Needed:
Tools Required: Phillips-head Screwdriver Small, Flat-blade Screwdriver Supplies Required: Acetone Cotton Swab Lint-free Cloth Toner Seal

Figure 1

Craig Rummler, development engineer at Future Graphics, is responsible for new product development, customer technical support, and technical training. Having worked more than 12 years in the imaging supplies industry, Craig has a strong background in Lexmark and Canon cartridge parts development and engineering,as well as toner development and cartridge remanufacturing. Craig has worked with leading cartridge manufacturers, such as Nu-kote International, Laser Imaging and Earth Corporation.
www.i-itc.org June 2004 Imaging Spectrum Magazine 1
Rummler: Remanufacturing the Samsung ML6060 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 ML-6060 Samsung ML-6060 Samsung ML-6060 Samsung ML-6060 Samsung ML-6060 Samsung ML-6060 Samsung ML-6060 Samsung ML-6060 Samsung ML-6060 Samsung ML-6060 Samsung ML-6060 Samsung ML-6060 Samsung ML-6060 Samsung ML-1650 Samsung ML-1650 Samsung ML-1650 Samsung ML-1650 Samsung ML-1650

Photo 1

Remanufacturing Instructions
Steps 1 and 2: Place the cartridge upside down on the workbench. Slide open the drum shutter and pull the drum shutter arms from their positioning posts on each side of the cartridge. See Photos 1 and 2. Step 3: Place the cartridge on the workbench so that the waste hopper faces away from you. See Photo 3. Step 4: Using a Philips-head screwdriver, remove the two screws located on top of the cartridge next to the toner hopper. See Photo 4.

Photo 2

Photo 3

Photo 4

2 Imaging Spectrum Magazine June 2004 www.i-itc.org

Photo 5

Photo 6
Step 5: Pry the front of the toner hopper reservoir back. See Photo 5. Step 6: Lift the toner hopper reservoir away from the cartridge. See Photo 6. Clean the toner hopper reservoir using dry, compressed air or a vacuum. Step 7: Remove the three screws that hold the cartridge end cap to the toner hopper on the gear side of the cartridge. See Photo 7. Step 8: To remove the fourth screw from the end cap, rotate the screwdriver to the right. See Photo 8.

Photo 7

Photo 8
www.i-itc.org June 2004 Imaging Spectrum Magazine 3

Photo 9

Photo 10
Step 9: Slide the cartridge end cap from the side of the cartridge. See Photo 9. Step 10: 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. Steps 11 and 12: 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 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. Step 13: Remove the three gears from the side of the cartridge. See Photo 13.

Photo 11

Photo 12

Photo 13

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Photo 14

Step 14: Rotate the cartridge 180 degrees. Remove the three screws that hold the contact end cap to the cartridge. See Photo 14. Steps 15, 16 and 17: 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. It is important that this bearing be present during the reassembly of the cartridge. Step 18: 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 15

Photo 16

Photo 17

Photo 18
www.i-itc.org June 2004 Imaging Spectrum Magazine 5

Photo 19

Step 19: Remove the two screws holding the waste hopper to the cartridge. See Photo 19. Step 20: Lift the waste hopper and remove from the cartridge. See Photo 20. Steps 21 and 22: 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 and slide the drum axle out from the end of the cartridge. See 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 20

Photo 21

Photo 22

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Photo 23

Step 23: Using a Philips-head 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. Step 24: Remove the two screws holding the wiper blade. See Photo 24. Clean the wiper blade with dry, compressed air. Step 25: Dump out the waste hopper. Clean the waste hopper using dry, compressed air or a vacuum. Apply padding powder to the wiper blade. Place the blade on the waste hopper. Install the two screws that hold the wiper blade in place. See Photo 25. Step 26: Place the cleaned PCR into the PCR saddles. The rounded end of the PCR is the contact side of the roller. Place the PCR on the waste hopper so that the contact end sticks out of the side of the hopper. See Photo 26.

Photo 24

Photo 25

Photo 26

www.i-itc.org June 2004 Imaging Spectrum Magazine 7

Photo 27

Step 27: Install the two screws that hold the PCR saddles in place See Photo 27. Step 28: Remove the developer roller drive gear from the side of the cartridge. See Photo 28. Step 29: Empty the remaining toner from the toner hopper. Clean the hopper using dry, compressed air or a vacuum. Release the clip the holds the developer roller end cap to the cartridge. See Photo 29. Step 30: Remove the end cap from the hopper. See Photo 30.

Photo 28

Photo 29

Photo 30

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Photo 31

Step 31: Slide the developer roller out from the side of the cartridge. See Photo 31. Step 32: Clean the developer roller using a dry, lint-free cloth. Carefully clean the doctor blade using Acetone and a cotton swab. See Photo 32. Step 33: Slide the developer roller back into the cartridge. Move the contact spring onto the developer roller axle. See Photo 33. Step 34: Install the developer roller end plate on the cartridge. See Photo 34. Note: Make sure the end plate snaps into place.

Photo 32

Photo 33

Photo 34

www.i-itc.org June 2004 Imaging Spectrum Magazine 9

Photo 35

Step 35: Place the developer roller drive gear on the rollers axle. See Photo 35. Steps 36 and 37: Apply padding powder to the drum. Install the drum in the cartridge. See Photo 36. If the drum axle is installed in the drum, slide the axle as far as possible from the small gear end. Install the drum axle in the side of the cartridge. See Photo 37. Carefully lower the drive gear end of the drum in the cartridge and slide the drum axle back into the drum. Step 38: Carefully place the waste hopper in the cartridge. Install the two screws that hold the waste hopper in place. See Photo 38.

Photo 36

Photo 37

Photo 38

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Photo 39

Step 39: If the drum axle is not attached to the drum, slide the drum axle into the drum starting on the gear side so that the screw hole in the axle is visible on the gear side. See Photo 39. Step 40: Install the three toner-hopper agitator gears. See Photo 40. Step 41: Install the white bearing on the supply roller axle. See Photo 41. Step 42: Place the metal gear housing plate on the side of the cartridge.See Photo 42. Step 43: Slide the cartridge end cap onto the cartridge. Install the three screws that hold the end cap in place. See Photo 43.

Photo 40

Photo 41

Photo 42

Photo 43
www.i-itc.org June 2004 Imaging Spectrum Magazine 11

Photo 44

Step 44: Install the small threaded screw in the drum axle. See Photo 44. Note: Remember to rotate the screw to the left to install. Step 45: Rotate the cartridge 180 degrees. Install the white bearing on the supply roller axle. See Photo 45. Step 46: Slide the contact end cap onto the cartridge. Install the three screws that hold the end cap in place. See Photo 46. Step 47: From the inside of the hopper, push the fill plug out of the toner hopper reservoir. Apply a seal to the toner hopper and fill with toner. See Photo 47. Pour some toner into the hopper for testing.

Photo 45

Photo 46

Photo 47

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Photo 48

Step 48: 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. Step 49: Lock the latches on the back of the cartridge and toner hopper reservoir. See Photo 49. Step 50: Rotate the toner reservoir down onto the cartridge. Install the two screws that hold the toner hopper reservoir to the cartridge. See Photo 50. Step 51: Install the drum shutter arms on the cartridge end caps. Install the drum shutter on the shutter arms. See Photo 51. Test cartridge.

Photo 49

Photo 50

Photo 51

www.i-itc.org June 2004 Imaging Spectrum Magazine 13

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.