Remanufacturing Instructions

Lexmark OptraTM E Remanufacturing Instructions...

OptraTM E

Reference Information:

Materials Needed:

OEM Part Numbers:

Toner (90 g)

Toner hopper: 69G8256

OPC (if needed)

OPC unit: 69G8257

Lint-free, wax-free cloths

OEM Yields:

Cotton swabs

(G256) 3,000 pages @ 5%

Conductive Grease

(G257) 20,000 pages @ 5%

Recommended Tools:

Approximate Remanufacturing Time:

Phillips head screwdriver

Toner Hopper- 25 min.

Spring hook

OPC Unit- 20 min.

Needle-nose pliers

Optra E Cartridge

Introduction
The Lexmark OPTRA ETM laser printer uses a two component system to con-
duct printing operations. While these two cartridges are relatively new, the
technology they employ is not. Many of the components in these two hoppers are
similar to those found in the Epson ActionLaserTM 1000/1500. This is not
surprising since the engine is a MinoltaTM design. The developer roller assembly
consists of a foam substrate within a thin, flexible plastic sleeve. The doctor
blade, like that in the EpsonTM, is a T-shaped aluminum configuration which is
very susceptible to scratches and dings. The OPC unit has a charge roller which
vaguely resembles the charge brush assembly also found in the EpsonTM. The

Figure 1

charge roller is functionally similar to that found in an EX, but is physically
different from anything on the market to date. Another oddity of the OPTRATM E
OPC unit is the fact that there is no waste hopper associated with it. Apparently
no waste toner is produced during printing with the OEM product.

Disassembly Instructions - Toner Hopper

1. With the developer roller facing you, locate and remove the hopper plug on

Figure 2

the left side of the cartridge (FIG 1). Remove the plug and evacuate all
remaining toner from the hopper. Be careful to avoid damaging internal
hopper components.

2. Lift up the shutter assembly and hook it over the handle on top of the cartridge.

It will be necessary to move the left arm of the assembly out slightly to avoid
damaging the stops (FIG 2).

3. Using a spring hook, free the top of the springs on the face of the toner

hopper (FIG 3). Do not allow the springs to scratch the surface of the
developer roller. On each end of the developer roller there are retaining

Figure 3

bushings, each with a finger pointing in toward the center of the hopper
(FIG 4). Gently rotate the bushings (fingers) toward you until they are free,
and then remove them. The developer roller is now free and can be removed.
Utmost care must be taken to avoid damaging the delicate surface of the
roller; even a slight scratch can impair print quality. On each end of the
developer roller you will find clear (or white) mylar spacers. Save the spacers
for use during reassembly.

4. Carefully remove the developer sleeve from the foam substrate and place it

over a wooden or metal dowel (an EX size mag sleeve or PCR will work as

Figure 4

a substitute for support during cleaning (FIG 5). Gently clean the surface of

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the sleeve with 99% Isopropyl Alcohol and a clean, lint-free cloth. The
developer roller sleeve is very delicate and great care must be taken to avoid
scratching or crimping it. It is important to remove the sleeve from the subs-
trate prior to cleaning it because if any alcohol contaminates the substrate, it
will be unusable. To clean the substrate, gently blow it off with compressed
air. Place the sleeve back on the substrate, replace the mylar spacers and
set the entire assembly aside.

5. Remove any residual toner from the development area (located behind the

developer roller) to prevent cross contamination. Note: The black mylar strip

Figure 5

along the bottom and the clear mylar strip on the inside (FIG 6) are easily
damaged.

Reassembly - Toner Hopper

6. Replace the developer roller assembly ensuring the top of the mylar

spring catch protrudes over the top of the roller (FIG 7). When replacing the
retaining bushings, take note of the small tab on the inside face of the left
bushing and the corresponding slot on the cartridge (FIG 8). Both bushings
must be placed on the developer roller shaft with the fingers slightly forward.

Figure 6

Lock the roller in place by rotating the fingers back toward the cartridge.

7. Affix one end of each spring to the mylar spring catch and the other end to the

cartridge face. The mylar catch goes over the top of the bushing fingers hold-
ing them in place (FIG 9).

8. Fill the cartridge with 90 grams of a quality toner and then replace the hopper

plug. Wipe residual toner from all exposed surfaces of the cartridge
(especially the contact points). The toner hopper is now ready for use.

Disassembly - OPC Unit

Figure 7

9. Hold the OPC unit by the large tabs with the copper contact end to the right.

Remove the two screws that hold the shutter bracket in place on each end of
the cartridge (FIG 10a & 10b).

10. On the right end of the OPC unit, remove the screw holding the copper con-

tact and the OPC axle in place. Next, remove the diode (located beneath the
copper contact FIG 11). Then use

a small flat tipped screwdriver to remove

the OPC axle plate.

11. Holding the shutter open, grasp the non-geared end of the OPC with a clean,

Figure 8

dry, lint-free cloth and carefully remove it from the cartridge. Clean, and
inspect but DO NOT LUBRICATE THE OPC. Replace if necessary.

12. Carefully remove the charge brush roller by moving the roller toward the non-

gear end and then lifting the geared end up and out (FIG 12). Using low
pressure air, gently blow residual debris from the surface of the roller. Set
the roller aside. With a dry, clean, lint-free cloth, remove residue from all
surfaces of the OPC unit housing.

Reassembly - OPC Unit

13. Insert the non-geared end of the charge roller into the contact end of the OPC

unit, and slowly lower the geared end into the charge roller trough.

Figure 9

14. Insert the geared end of the OPC into the OPC unit (the gears of the

OPC and the charge roller should be on the same end). Then lower the non-
geared end into the unit.

Lexmark OptraTM E Remanufacturing Instructions...

15. Replace the axle plate on the contact end of the cartridge so that the axle pin

is inserted into the OPC, and the end of the charge roller protrudes through the
circular hole in the axle plate (FIG 13). Glue the diode in place ensuring
proper polarization. Place the copper contact over the diode and secure in
place with one screw.

16. Place the shutter bracket on the cartridge and secure in place with one screw

on each end. The OPC unit is now ready for use.

Figure 10a

Figure 10b

Figure 11

Figure 12

Figure 13

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