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Refill Instructions
Canon EX,
HP-4, HP-5 Cartridges

Including:
  • Apple LaserWriter 16/600
  • Apple LaserWriter Pro 600
  • Apple LaserWriter Pro 630
  • Apple M2473G/A Cartridges
  • Brother HL-960
  • Brother HP-1260
  • Brother HL-1660
  • Canon EP-E
  • Canon EX
  • Canon LBP-1260
  • Canon LBP-1260 Plus
  • Canon LBP-8 IV
  • Canon LBP-860
  • Canon LBP-EX
  • Canon P 270
  • Canon P 430
  • Canon R74-1003
  • DEC DECLaser 5100
  • DEC LN 09
  • HP Laser Jet 4
  • HP Laser Jet 4M
  • HP Laser Jet 4 Plus
  • HP Laser Jet 4M Plus
  • HP Laser Jet 5
  • HP Laser Jet 5M
  • HP Laser Jet 5N
  • HP Laser Jet 5Se
  • HP C2001A
  • HP C2021A
  • HP C2037A
  • HP 92298A Cartridge
  • HP C3973A Cartridge
  • HP 98e Cartridge
  • Lexmark 140198A Cartridge
  • Lexmark 140198X Cartridge
  • Printmaster TN-1400 Cartridge
  • Siemens 4821-P10
  • Siemens 4821-P15
Updated August 10, 1999

Theory

This cartridge, like most laser printer cartridges, contains three critical elements:
  • The Toner Hopper
  • The OPC (Organic Photo-Conductor) Drum
  • The PCR (Primary Charge Roller)

Toner Hopper

The Toner Hopper is where the Toner (ink powder) is kept. One of our refill bottles contains enough Toner to fill the Toner Hopper for roughly 3000 to 5000 pages -- the same as a new cartridge.

The Toner is a fine powder composed of fine plastic particles. This toner allows waterproof printing after it has been printed on the paper. However, toner must be kept dry to work correctly.

MICR toner is special toner which retains a magnetic field. MICR toner is often used for printing checks.

If you find yourself with too light a print, you are probably low on toner.

Handling the Toner

There are several cautions to handling Toner:
  • Avoid breathing the dust. Although most Toner is not poisonous, the dust can be quite irritating, especially if you have allergies or other breathing difficulties.
  • Keep the Toner away from an open flame or hot spot, since it does burn.
  • Keep the dust away from your eyes because the Toner can cause eye irritation.
  • Keep the Toner dry and clean of any contaminations to avoid clumping of the toner.

OPC Drum

The OPC Drum is the Green, Blue, or Red cylinder in the cartridge. It is typically about an inch (25 mm) in diameter, and is the width of a normal sheet of paper.

The OPC Drum is given a charge of static electricity by the PCR as it rotates. The drum is then written on by the laser which removes the static charge at points. The drum rotates further and attracts a coating of toner, which is deposited on the paper. Finally, another heated roller melts the plastic toner so that it fuses with the paper.

The OPC Drum has a typical life of 10,000 to 15,000 pages. As the OPC Drum grows old, it begins to show two signs of aging:

  • It doesn't hold a charge well. This causes the printed pages to be light, even when plenty of toner is present.
  • A distinctive mark appears on every printed page at intervals of about 3 to 4 inches. (The exact distance is the same every time for a given printer, and is the circumference of the OPC Drum).
If either of these conditions becomes annoying, it is time to change the OPC Drum.

Handling the OPC Drum

Follow these guidelines when handling the OPC Drum
  • Keep out of bright light and direct sunlight! Light gradually wears out an OPC Drum and should be avoided.
  • Never touch the surface of the drum, since this can cause oil spots and scratches which will appear on your printed pages.
  • Be careful to lay the Drum on a soft cloth.
  • Always replace the wiper blade when you replace an OPC Drum.

PCR

The PCR is a smaller roller, which is typically about 1/2 inch (10 to 15 mm) in diameter. It is usually black and is in contact with the OPC Drum.

The PCR applies the charge to the OPC Drum.

PCR's have a typical life of 25,000 to 35,000 pages. We also suggest that the PCR be gently wiped with a soft cotton cloth every 10,000 pages to remove OCR film that has accumulated on the PCR.

If the PCR is bad, the most common problem is that the printed page will have a regular mark every 1 to 1 and 1/2 inches (4 to 6 mm). The exact distance depends on the circumference of the PCR.

Handling the PCR

While the PCR is less sensitive than the OPC Drum, you still must handle it gently. Do not touch the surface of the PCR.

Instructions

Warning-Follow all the instructions carefully!
(or you'll make a mess!)

Setup and Tools

  • Choose a work area with good lighting and no breezes. But the work area should not be in direct sunlight.
  • Spread out a newspaper to work on.
  • You will need:
    • a small crosshead (Phillips) screwdriver
    • a small hexhead screwdriver or allen wrench may be needed instead for some cartridges.
    • The first time you will also need a 1 and 1/4th inch (33mm) hole saw or wood drill bit and a drill. Optionally, you can use a 1 inch (25 mm) drill bit.
    • a small flathead screwdriver.
    • a small funnel.
    • a vacuum cleaner.
    • Several soft cotton cloths or towels.

Supplies

  • Regular Black Toner, single bottle -- A04000380
  • Regular Black Toner, set of 4 bottles -- A04000380-4
  • Black MICR Toner, single bottle -- A04009340
  • Black MICR Toner, set of 4 bottles -- A04009340-4
  • OPC Drum -- Z00040204
  • OPC Wiper -- Z01040001
  • PCR -- Z21040000

Method for Refilling the Toner Cartridge

Part One

  1. Separate the toner hopper from the OPC Drum holder by removing the two spring clip screws on the top with the screwdriver. Lift the spring clips out or pry them up carefully with a small flathead screwdriver. The two halves should easily pull apart. Set aside the toner hopper.
  2. Take the OPC Drum holder. You will need to partially disassemble this section since it contain the waste toner. If the waste toner section is not vacuumed, blobs of excess toner will begin to appear on your printed pages.
  3. Remove the OPC Drum by removing the two screws on which retain the axle. The screws are on the metal plate at the end of the OPC Drum. (Note that these screws are different from the other screws used in the cartridge). After the screws have been removed, remove the axle and then the OPC Drum. Set the OPC Drum aside on a towel and cover to protect from light.
  4. Now, remove the PCR and place on a towel. You may gently wipe the PCR clean with a soft cloth or towel.
  5. Next, remove the wiper blade by removing the two retaining screws. Check the wiper blade for damage and clean very gently with a soft cloth. Always replace the wiper blade when you replace the OPC Drum.
  6. Carefully vacuum out the waste hopper.
  7. Clean the metal contacts which hold the end of the PCR with a cotton swab if coated with toner. Use alcohol if particularly coated.
  8. Reassemble the OPC Drum unit.
    1. Put the wiper blade back in place.
    2. Put the PCR back in place.
    3. Put the OPC Drum back in place.
    4. Cover with a towel to prevent light damage to the OPC Drum.

Part Two

Option A
  1. Remove the screw which holds on the housing over the gears.
  2. Carefully remove the housing to avoid damage to the plastic pins which are part of the housing.
  3. Carefully remove the gears. Keep the order straight to make it easier to re-insert.
  4. Drill a hole into the back of the gear housing using the 1 1/4th inch (33mm) drill bit. The purpose of this hole is to allow you to remove the translucent plug which seals the toner hopper.
  5. Remove the plug.
  6. Using the funnel, fill the cartride with 1 bottle of toner.
  7. Replace the plug.
  8. Replace the gears in the proper order.
  9. Replace the housing.
  10. Reassemble the two pieces of the cartridge with the two springe clips.
  11. Store the cartridge in a dry, dark place.
Option B
  1. On the toner hopper section, locate a flat surface on the top or bottom of the cartridge far away from the drums.
  2. Drill a 1 inch (25 mm) hole which you can later plug tightly.
  3. Using the funnel, pour the contents of 1 bottle of toner into the cartridge.
  4. Plug the hole.
  5. Reassemble the two pieces of the cartridge with the two springe clips.
  6. Store the cartridge in a dry, dark place.

To Place A Toner Order

You can telephone us at 1-888-728-2465 (USA Tollfree) or 1+740-374-9949. You can also Order Online or by other ways including by Fax, or by Postal Mail, or by EMAIL.

ACSI Bulk Inks also supplies bulk ink for refilling inkjet cartridges.
Check our main ink page at http://www.oddparts.com/oddparts/ink.


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Copyright 1999, Automation Consulting & Supply, Inc.
Contact us at 1-304-622-5086 or email us at Order Email.
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