Recharger Magazine

Technical Step-by-Step

Remanufacturing the Samsung ML-1860 Toner Cartridge

• By Mike Josiah
• Jul 01, 2012

First released in May 2011, the Samsung ML-1860 series of printers is based on a 19-ppm, 1,200-dpi engine.

Other than the toner cartridge, all the other consumables (fuser, transfer roller, paper pickup rollers) are rated for 30,000 pages. That, coincidentally, is also the rated life for the printer. It seems Samsung considers these models throwaway machines.
Figure A shows the basic printer/cartridge position layout.

These cartridges do not have a built-in drum cover but do come new with a black plastic cover. See Figure 1.

The replacement cartridge itself is rated for 1,500 pages at 5 percent coverage (ISO 19752). The starter cartridge is rated for 700 pages.
Printers based on this engine:
Samsung ML-1660
Samsung ML-1665
Samsung ML-1670
Samsung ML-1675
Samsung ML-1860
Samsung ML-1865
Samsung SCX-3200
Samsung SCX-3205.
Cartridge:
MLT-D104S, MLT0D0142S (Europe)

Required Tools

1. Toner-approved vacuum
2. Small common screwdriver
3. Phillips-head screwdriver
4. Needle-nose pliers
5. Square X-Acto type blade
6. Chisel blade
7. Jewelers screwdriver

Required Supplies

1. Replacement toner for use in the Samsung ML-1860
2. Replacement chip
3. Conductive grease
4. Drum lubricating powder
5. 99% isopropyl alcohol
6. Cotton swabs
7. Acetone
8. PCR cleaner

1) Place the cartridge with the handle facing away from you. Slice off the three plastic rivets with a square X-Acto type blade on the contact end cap. See Figures 2 and 2a.

2) Gently pry off the end cap. See Figure 3.

3) On the opposite side of the cartridge, slice off the three plastic rivets with a square X-Acto type blade. See Figure 4.

4) Gently pry off the end cap. See Figure 5.

5) Locate the two rivets on each side on the top of the cartridge. Slice them off with a chisel blade. See Figures 6 and 7.

6) Lift off the waste chamber. See Figure 8.

7) Remove the PCR. See Figure 9.

8) Remove the two screws and wiper blade from the waste chamber. See Figures 10 and 11.

9) Clean out any remaining toner from the waste chamber. Be careful to keep the WB seal clean. See Figure 12.

10) Reinstall the wiper blade and two screws. See Figure 13.

11) Clean the PCR with your normal PCR cleaner and install in the cartridge. See Figure 14.

Warning: Do not clean the OEM PCR with alcohol, as this will remove the conductive coating from the roller. If the PCR is an aftermarket one, follow the cleaning methods recommended by the manufacturer. If the PCR is an OEM one, we recommend it be cleaned with your standard PCR cleaner.

12) To remove the OPC drum, slide the axle out from the gear side of the drum. Remove the drum. See Figures 15 and 16.

13) Remove the five gears as shown and place aside. Leave the developer roller gear on its shaft. See Figures 17 and 18.

14) Remove the developer roller by lifting it out from the nongear side. See Figure 19.

15) Carefully pry out the fill plug. It fits tightly and is easily damaged. Work a small jewelers screwdriver around the edge until the plug comes free. See Figure 20.

16) Clean out any remaining toner from the hopper.

17) Remove the two screws on the doctor blade. The blade was left in place to protect the DB seal. If toner gets on this seal, it will not work, and the cartridge will leak. It can be replaced with silicone, but it’s easier to just keep it clean by leaving the DB on as long as possible when cleaning. See Figures 21 and 22.

Note: It is highly recommended that the doctor blade be cleaned. Failure to do so will cause streaking. Dampen a cotton swab with alcohol and clean the blade. Be careful not to press too hard, as that can damage the blade. If the blade has a heavy buildup of toner on it, clean it with acetone, then alcohol.

18) Clean the feed roller and any remaining toner from the hopper. See Figure 23.

19) Reinstall the doctor blade and two screws. See Figure 24.

20) Install the developer roller, geared end to the gear side of the cartridge. See Figure 25.

21) Install the drum.

22) Install the drum axle through the gear side. Keep the keyed end toward the gear. See Figure 26.

23) Install the five gears as shown in the order indicated. See Figure 27.

24) Fill the hopper with the appropriate toner. Replace the fill plug and check for leaks. See Figure 28.

25) Place the two halves together. Make sure the top two rivets snap in place. See Figure 29.

26) Drill two small holes in the rivets and insert the screws. See Figures 30 and 31.

27) Install the gear-side end cap. Make sure the drum axle fits correctly in its slot by turning it from the opposite side until it locks in place. See Figure 32.

28) Drill a hole where the three rivets were and install the screws. See Figures 33 and 34.

29) Install the replacement chip on the contact end cap by sliding it out from the inside of the end cap. Replace the chip, making sure it’s seated properly. See Figures 35 and 36.

30) Install the remaining end cap. Drill three holes and install the screws. See Figures 37 and 38.

31) Install the drum cover on the cartridge. See Figure 39.

Taking test prints

Demo page
Press and hold the Print Screen button for 10 seconds until all the green LED lights blink rapidly. A demo page and configuration page will print.

Repetitive Defect Chart

Upper fuser roller	77.5 mm
Lower fuser roller	75.4 mm
OPC drum	47.0 mm
Supply roller	47.0 mm
Transfer roller	39.2 mm
Developer roller	35.1 mm
PCR	26.7 mm

Printer error codes

Error Code	Error Message
C1-1110	Prepare new toner cartridge.
C1-1120	Replace with new toner cartridge.
C1-1130	End of life; replace with new toner cartridge.
C1-1411	Toner cartridge is not installed. Install the cartridge.
C1-1512	Toner cartridge is not compatible.
M1-1013	Paper jam in tray.
M1-5012	Paper is empty in tray. Load paper.
M2-1114	Paper jam inside of machine.
S2-4110	Door is open. Close the door.
U1-2113	Fuser Unit Failure #U1-2113. Please turn off, then on.
U1-2131	Fuser Unit Failure #U1-2131. Please turn off, then on.
U1-2141	Fuser Unit Failure #U1-2141. Please turn off, then on.
U2-5111	Black LSU Unit Failure #U2-5111. Please turn off, then on.
U2-5113	Black LSU Unit Failure #U2-5113. Please turn off, then on.

This article originally appeared in the July 2012 issue of Recharger.