Remanufacturing the Fuji-Xerox 12 Engine
IBM Network Printer 12, Xerox P12, Apple LaserWriter 12/640 PS, NEC 1200
The Fuji-Xerox® 12 (FJX12) engine was first introduced in 1996 in two printers: IBM® Network Printer 12 and Apple® LaserWriter® 12/640. The FJX12 engine features 12 page per minute print speed, 600 dots per inch print resolution and supports edge-to-edge printing, a key selling point for the IBM printer. Now in its fourth year of production, the FJX12 has established a significant worldwide installad base. The rapid acceptance of Fuji-Xerox engines by various original equipment manufacturers over the past few years is fueling Fuji-Xerox into becoming the leading engine supplier to OEMs.
About the Cartridge
The FJX12 cartridge can be considered a twin to the FJX17. Both share a compact design, use some of the same components and are relatively simple to remanufacture. The FJX12 cartridge separates into two distinct sections: waste bin and toner hopper. These sections are held together with two cartridge pins (one installed at each end of the cartridge) and one tension spring at the contact end.
The OEM cartridge pins can be removed by tapping them through the hopper and waste bin section pin casings to the interior of the cartridge. The pins should fall out of the cartridge through the laser port.
The waste bin section houses the OPC drum, PCR, wiper blade and recovery blade. The OPC drum contains two inserts to dampen drum vibrations that result in humming noises. Testing has indicated a considerable difference in noise generated when the cartridge is operated without the drum inserts. The amount of noise created is generally caused by the hardness of the PCR. Harder PCRs tend to generate more noise than softer ones. When using a replacement drum, we highly recommend using a drum with inserts in order to minimize any noise that may be potentially objectionable to your customers. The PCR also merits some caution regarding print problems in low humidity environments.
Sealing components in the waste bin include wiper blade sealing foam and wiper blade end foams (large and small). The wiper blade sealing foam is unique in that it fits into a channel in the waste bin, instead of adhering to a mounting surface with adhesive.
The hopper section houses a 270-gram toner load, mag roller and doctor blade. When testing aftermarket toners not specifically formulated for the FJX12, we observed fusing and light print problems. The melt rheology (melt flow characteristics) of the toners tested has not been compatible with the fusing temperatures of the fuser roller, causing the toner to easily flake off the printed page. A toner formulation specific to the FJX12 engine is required to maintain acceptable fusing performance and to minimize the occurrence of offsetting while simultaneously delivering the necessary solid image density performance.
Additional sealing components in the hopper include mag roller felts and doctor blade sealing foam. Like the wiper blade sealing foam in the waste bin section, the doctor blade sealing foam fits into a channel in the hopper body. This design facilitates foam removal and installation.
Both the mag roller and doctor blade show signs of wear after the OEM cartridge cycle. The doctor blade is somewhat different from the typical doctor blade design, but closely compares to the Fuji-Xerox XP15/20. The blade is comprised of white silicone applied to a stainless steel shim attached to the stamping.
Separating The Cartridge
Remove the hopper tension spring.
Position the cartridge on your work surface with the drum shutter facing upward (Fig. 1).
Fig. 1
Remove the hopper tension spring using a pair of needlenose pliers (Fig. 2).
Fig. 2
Remove the cartridge pins.
One cartridge pin is located adjacent to each drum axle. Using a 3/32" punch and hammer, carefully tap the pins to the inside of the cartridge as shown in Figs. 3 and 4. The pins should fall out of the cartridge through the laser port.
Fig. 3
Fig. 4
Separate the cartridge (Fig. 5).
Fig. 5
IMPORTANT If you remove OEM cartridge pins, make sure the pins are completely removed from the cartridge. The pins may remain in the casing in the toner hopper section (Fig. 6).
Fig. 6
Disassembling The Waste Bin Section
Secure drum shutter.
Open the drum shutter as indicated by the arrow in Fig. 7. Use a piece of tape to secure the shutter in place.
Fig. 7
Remove the drum axles from each end of the waste bin (Figs. 8-11).
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Remove the drum.
For best results, we recommend replacing the OEM drum after the OEM cycle.
Note that the drum contains two drum inserts, used to dampen drum vibrations during cartridge operation.
To avoid touching the surface of the drum, grasp the drum by the gears. (Fig. 12).
Fig. 12
IMPORTANT If you plan to reuse the drum, store it in an area that is protected from light and impact damage.
Remove the PCR.
Handle the PCR by the shaft or use clean latex gloves (Fig. 13). If you plan to reuse the PCR, store it on a flat uniform surface.
Fig. 13
CAUTION Do not stack or lay anything on top of the PCRs, wrap PCRs with rubber bands or touch the surface of the PCR with your bare hands.
Remove the wiper blade.
Remove two screws from the stamping as shown in Fig. 14 and lift the blade from the waste bin as shown in Fig. 15.
Fig. 14
Fig. 15
For best results, replace the wiper blade each time you replace the drum.
Clean the waste bin.
Empty the bulk of the waste toner and clean the waste bin with dry, filtered compressed air (Fig. 16). Direct compressed air on and around the wiper blade sealing foam and end foams to remove toner and debris from the foam material. Be careful not to damage the recovery blade. Clean PCR saddles (Fig. 17).
Fig. 16
Fig. 17
Clean toner residue from the saddles using a lint-free swab dampened with isopropyl alcohol.
Inspect the sealing components in the waste bin (Fig. 18).
Fig. 18
Foam material, such as wiper blade sealing foam and wiper blade end foams, should have a smooth surface and be secured to the cartridge itself. Replace foam components that are ripped, pitted or missing.
The recovery blade surface should appear smooth and flat with no kinks or waviness along the edge. Replace the recovery blade if it is damaged, dislodged or missing.
Install a drum shutter felt.
The drum shutter felt is an aftermarket component installed on the interior surface of the shutter to protect the drum from nicks and scratches during shipping and handling.
Remove the release liner from the felt (Fig. 19).
Fig. 19
Position the shutter so that the interior surface of the shutter is facing upward. Center the felt on the drum shutter as shown in Fig. 20.
Fig. 20
Disassembling The Toner Hopper Section
Remove the mag roller end plate.
Remove two Phillips screws and then remove the end plate (Figs. 21 and 22).
Fig. 21
Fig. 22
Remove the gear housing end plate.
Remove three Phillips screws and then the end plate (Figs. 23 and 24).
Fig. 23
Fig. 24
Remove the mag roller drive gear (Fig. 25).
Fig. 25
Remove the idler gears (Figs. 26 and 27).
Fig. 26
Fig. 27
Remove the mag roller.
Grasp each end of the mag roller as shown in Fig. 28 and lift from the hopper. If you plan to reuse the mag roller, store it on a soft, clean surface.
Fig. 28
CAUTION Do not touch the surface of the mag roller with your fingers or scratch the surface. Store the mag roller on a soft surface, and DO NOT stack the rollers on top of each other.
Remove the mag roller bushings from the mag roller (Fig. 29).
Fig. 29
Remove the doctor blade.
Remove two screws from the stamping (Fig. 30), then carefully remove the blade from the hopper (Fig. 31).
Fig. 30
Fig. 31
Clean the hopper with dry, filtered compressed air.
Direct compressed air on and around foam and felt components to remove as much toner and debris as possible (Fig. 32). Refer to Fig. 33 for the location of the foam and felt materials.
Fig. 32
Inspect the sealing components in the hopper section and replace as required (Fig. 33).
Fig. 33
Foam components such as the doctor blade end foams and doctor blade sealing foam should display a smooth, clean surface. Make sure the foam materials are secured in the correct position.
Mag roller felts should display a plush surface. Make sure the felts are securely adhered to the mag roller saddles. Replace the felts if the surface appears shiny and compacted with toner.
If you plan to seal the toner hopper, install the seal before continuing to the next section.
If you don't install a seal, fill the hopper through the toner port with 270 grams of toner and reassemble the hopper using the instructions in the following section.
Assembling The Toner Hopper Section
Clean the doctor blade.
Clean the doctor blade with dry, filtered compressed air (Fig. 34). Clean the working edge of the blade with isopropyl alcohol (91%-99%).
Fig. 34
Install the doctor blade.
Position the blade stamping on the locating posts and secure the blade with two Phillips screws (Fig. 35).
Fig. 35
Clean the mag roller.
Clean the surface of the roller with dry, filtered compressed air only (Fig. 36).
Fig. 36
CAUTION Do not scratch the coated area of the roller with the air nozzle or touch the mag roller surface with your bare fingers.
Clean the mag roller bushings.
Clean the bushings with a lint-free swab or lint-free cloth (Fig. 37).
Fig. 37
Install a mag roller bushing on each end of the mag roller (Fig. 38).
Fig. 38
Install the mag roller.
Position the mag roller with the metal axle at the right end of the toner hopper (Fig. 39).
Fig. 39
Install the idler gears (Figs. 40 and 41).
Fig. 40
Fig. 41
Install the mag roller drive gear (Fig. 42).
Note the orientation of the gear as shown in Fig. 43.
Fig. 42
Fig. 43
Clean the electrical contact on mag roller end plate.
Clean toner and debris from the electrical contact using a lint-free swab dampened with isopropyl alcohol (Fig. 44).
Fig. 44
Apply a thin layer of conductive cartridge lubricant to the mag roller electrical contact (Fig. 45).
Fig. 45
Use the wooden end of a swab as an applicator.
Install the gear housing end plate (Fig. 46).
Fig. 46
Note that the mag roller axle is keyed and fits into a positioner bushing in the end plate. Rotate the magnet at the right end of the hopper to help position the keyed axle in the end plate positioner bushing. Secure the end plate with two Phillips screws (Fig. 47).
Fig. 47
Install the mag roller end plate (Fig. 48).
Secure the end plate with three Phillips screws (Fig. 49).
Fig. 48
Fig. 49
Assembling The Waste Bin Section
Clean the wiper blade.
If you plan to reuse the wiper blade, clean it with dry, filtered compressed air (Fig. 50).
Fig. 50
CAUTION For best results, we do not recommend using alcohol or any alcohol-based solvent to clean the polyurethane blade. To avoid damage to the working edge of the blade, Static Control recommends using only dry, filtered compressed air to clean the wiper blade.
Pad the wiper blade.
Kynar Lubricating Powder applied to the working edge of the blade will help prevent blade "flip overs" during the first drum rotations of the remanufactured cartridge. Pad the wiper blade regardless of whether you are installing a new replacement blade or reusing the old blade.
Dip the edge of the blade in a long, shallow container of lubricating powder as shown in Fig. 51. Examine the length of blade to ensure even coverage. Repeat.
Fig. 51
Install the wiper blade
Position the stamping over the locating posts in the waste bin (Fig. 52). Secure the blade with two Phillips screws (Fig. 53).
Fig. 52
Fig. 53
Clean and inspect the PCR.
If you are reusing an OEM PCR, clean the roller using a soft, lint-free cloth dampened with water.
Gently wipe the PCR in one direction. Be careful not to pinch or dent the surface of the PCR, as the material has poor memory (Fig. 54).
Fig. 54
Apply conductive cartridge lubricant to the PCR saddle at the contact end of the cartridge (Fig. 55).
Fig. 55
Note that the saddle at the contact end of the cartridge is black. Apply the lubricant sparingly.
Install the PCR (Fig. 56).
Fig. 56
Make sure the PCR shafts fit securely in the PCR saddles.
Clean and inspect the drum (Fig. 57).
Fig. 57
If you plan to reuse the drum, clean it with dry, filtered, compressed air.
Inspect the drum for deep concentric wear lines or cracks in the coating and replace the drum as required. Drum inserts, installed in the OEM drum, are required for proper cartridge operation.
CAUTION For best results, we do not recommend using cleaning agents or coatings on the drum. Be careful not to nick the surface of the drum with the air nozzle.
Pad the drum.
Pad the coated area of the drum with Kynar Lubricating Powder (Fig. 58); avoid getting Kynar on the drum gear.
Fig. 58
Install the drum.
Place the drum in the waste bin with the helical gear on the right end of the waste bin (adjacent to the white PCR saddle) as shown in Fig. 59.
Fig. 59
Install the drum hub disk axle.
The plastic drum axle, which contains a metal contact, is installed at the drum hub disk end of the waste bin (Figs. 60 and 61).
Fig. 60
Fig. 61
Two screw lengths are used in the FJX12 application. Be sure to use the short screws to secure the drum axles (Figs. 62 and 63). The long screws will puncture the waste bin housing.
Fig. 62
Fig. 63
Install the drum helical gear axle.
The metal drum axle is installed at the helical gear end of the waste bin (Figs. 64 and 65). Secure axle with two screws (Fig. 66).
Fig. 64
Fig. 65
Fig. 66
Rotate the drum.
Rotate the drum in its normal rotational direction, as indicated by the arrow in Fig. 67, at least 6 full drum rotations. Rotating the drum will help lubricate the wiper blade and prevent the potential of blade "flip overs". Lubricating powder wiped from the drum by the wiper blade will deposit in the waste bin.
Fig. 67
Wipe lubricating powder from the PCR.
After you have rotated the drum to remove the lubricating powder, rotate the drum again in small increments in order to clean the powder from the PCR. As you rotate the drum in its normal rotational direction, wipe the powder from the PCR with a lint-free cloth.
You can also use dry, filtered compressed air rather than the cloth to remove the powder from the PCR.
IMPORTANT Make sure there is no lubricating powder present on the PCR, otherwise repeating voids in solid print areas at the PCR interval may result.
Assembling The Cartridge
Bring the two cartridge sections together as shown in Fig. 69.
Fig. 69
The hopper section should seat in the waste bin section as shown by the arrows in Fig. 70.
Install cartridge pins at each end of the cartridge (Fig. 71).
Fig. 70
Fig. 71
Attach the hopper tension spring (Fig. 72).
Use a pair of needlenose pliers to install the spring on the spring posts. Take care when installing, a stretched hopper tension spring can contribute to light print defects.
Fig. 72
Click to view enlarged photo. 
Click to view enlarged photo.
For further information, contact Static Control Components at 800-488-2426, 919-774-3808 or fax 800-488-2452, 919-774-1287. The company website can be accessed at www.scc-inc.com.
This article originally appeared in the January 2000 issue of Recharger.