Remanufacturing Instructions

LexmarkTM Optra "S" Remanufacturing Instructions...

Optra® S

Reference Information:
Regular Low Yield (7,500 Pages) - 1382620
Regular High Yield (17,600 Pages) -1382625
Prebate Low Yield (7,500 Pages) - 1382920
Prebate High Yield (17,600 Pages) -1382925

Recommended Tools:
Spring Removal Hook
Phillips Screwdriver
Jewelers Screwdriver

Optra "S" Cartridge

Disassembly Instructions:

Cartridge Shell
1. Place cartridge on its top with the drum shutter away from you.

2. Unhook the springs from the left and right sides of the toner hopper (Fig. 1A).

3. Remove the developer roller drive gear (See Fig.1B).

4. Pry the sides of the cartridge shell outward to free the retaining pins on the

left and right sides of the toner hopper (Figs. 2A & 2B).

Figure 1A

5. Lift the toner hopper back and up to remove, then set aside.

6. Note the differences in the OPC gears (Fig. 3). The gear without the stem is

the contact gear. With the OPC facing up and the stem gear on the left, re-
move the e-ring from the right side of the drum shaft. Now gently pull the
drum shaft to the left until it is free of the cartridge. While the shaft is being
removed, ensure the OPC does not move or get scratched. A flat, white
mylar spacer bushing is located on the contact side of the OPC. Retain this
spacer for use during reassembly. Clean, inspect and lubricate the OPC.

Figure 1B

Replace if necessary (Oasis Part #5088). Protect the OPC from light as it is
photoconductive and can be damaged by overexposure to light. Also note
(Fig. 3), some OPCs have a simple spring clutch which is designed to prevent
the OPC

from rotating backwards.

7. Locate and remove the two screws on the wiper blade (Fig. 4A). Invert the

cartridge (right side up) to locate and remove the mylar strip across the top of
the wiper blade (Fig. 4B). The mylar strip prevents leakage over the top of the
wiper blade. Remove the wiper blade. Clean, inspect and lubricate the blade.
Replace if necessary. Vacuum excess toner from the waste hopper
carefully to avoid damaging the recovery blade. If removal of the recovery

Figure 2A

blade is required, lift one corner and slowly remove it from the surface of the
waste hopper. Remove all residual adhesive from the surface area. To
install a new recovery blade (Oasis part #884), peel the backing and apply it
to the area ensuring there are no wrinkles or creases. Set the cartridge shell aside.

Toner Hopper

8. Place the toner hopper on the work surface with the developer roller toward

you and the hopper plug to the left. Remove the doctor blade tension spring

Figure 2B

by pulling the two out swept arms away from the cartridge (Fig. 5A). Remove
the developer roller contact from the cartridge by sliding it off to the left side

Oasis Imaging Products, Inc. Technical Support: (888) 627-6555

of the cartridge (Fig. 5B). Remove the developer roller retaining bushing by
sliding it off to the left side of the cartridge (Fig. 5B). Remove the developer
roller from the cartridge by lifting the left side slightly and pulling the roller to
the left while gently rotating the roller back and forth until it is free. Retain the
flat, white mylar spacers from each end of the roller for use during
reassembly. Clean and inspect the roller.

9. In the development area, there are two black mylar strips behind and below

the developer roller (Fig. 6). Inspect these strips carefully. If damaged, pro-

Figure 3

ceed to the Inner / Outer Mylar portion of these instructions. There is also a
coarse foam delivery roller in the development area (Fig. 6). Gently blow off
the roller with compressed air to remove residual toner.

10. Remove the hopper cap to clean the inside of the toner hopper. Use caution

when vacuuming to avoid the agitator inside the toner hopper. There is a
slotted wheel which partially obscures the hopper plug. This wheel is easily
removed by pulling it off the cartridge (NOTE: Reach behind the wheel face
with your finger tips to the center hub or the wheel face could snap).

Figure 4A

11. Clean all electrical contacts with cotton swabs and alcohol and ensure all

residual toner is removed prior to filling the toner hopper. A small amount of
conductive grease (Oasis Part #592) should be applied to the ground contact
inside the OPC and also on the developer roller contact previously removed.
The doctor blade's metering edge should be thoroughly cleaned. Any toner
remaining in this area could result in poor print quality.

Reassembly

Figure 4B

12. Place the cartridge shell up-side-down on the work surface with the waste

hopper away from you. Install the wiper blade and secure the two screws
which hold it in place. Check the PCR shutter operation.

13. Insert the OPC shaft approximately 1/4 inch into the right side of the shell

And place the flat, white mylar spacer over the end of the shaft (Fig. 7).
Carefully place the OPC in the cartridge with the contact gear on the right
side, then push the shaft fully through to the left side and replace the e-ring
(Oasis Part #1196). Turn the cartridge back over. Apply a mylar strip over
the top of the wiper blade and the cartridge to avoid leakage from the waste
hopper (see fig. 4B).

Figure 5A

14. Place the toner hopper on the work surface with the development chamber

facing you. With a flat mylar spacer on each side, install the developer roller
with keyed or D shaped shaft to the right. Replace the retaining bushing
and the contact (see fig. 5B). Replace the doctor blade tension spring (see
fig. 5A).

15. Fill the toner hopper with toner (Oasis Part #1428), then replace hopper cap.

Replace the slotted wheel taking into account the position of the D shaped
shaft on which it sits.

Figure 5B

16. Place the cartridge shell up-side-down on the work surface with the waste

hopper away from you. Secure the two long springs to the sides and out of
the way of the toner hopper (Fig. 8).

17. Holding the toner hopper up-side-down, insert the cartridge guides (Fig. 9)

into the guide tracks (Fig. 8) in the cartridge shell. When the guides are fully
inserted, lower the toner hopper until the retaining pins are resting on the cart-
ridge shell. Gently pry the sides of the shell outward until the retaining pins
drop into the retaining slots in the cartridge shell. Secure the ends of the long
springs to the left and right sides of the toner hopper. Replace the developer

Figure 6

roller drive gear.

Lexmark® Optra "S" Remanufacturing Instructions...

Inner/Outer Mylar and Developer Roller Saddles
with the Developer Roller Previously Removed

In the development area, there are two black mylar strips behind and below
The developer roller (see Fig. 6). Inspect these strips carefully. If damaged, peel
them off the cartridge and remove any residual adhesive. Remove the backing
from the replacement inner mylar (Oasis Part #886) and carefully apply it to the
inner surface area. Next, remove the backing from the replacement outer mylar
(Oasis Part #896) and carefully apply it to the outer surface area. In the develop-

Figure 7

ment area, there are two white rubber saddles; one on each end (Fig. 10). If these
channels are damaged or worn, toner leakage from the ends of the developer
roller may occur.

Figure 8

Figure 9

Figure 10

© 2001 Oasis Imaging Products, Inc. Any attempt to reproduce any part of these instructions without the written consent of Oasis Imaging
Products, Inc. may result in legal action. All registered trademarks are the property of their respective owners.