Future LBP-2460 Owner's manual

Canon LBP-2460
Data Products DD524
HP5Si, 5Si MX, 5Si Mopier
IBM Network Printer 24
Lexmark Optra N Model 240
QMS 2425-2425 EX
Troy 524
Part Number: C3909A
Gram Load: 840 grams
Yield @ 5%: 15,000 pgs
Pages/Min.: 24ppm
Resolution: 600 dpi
Needle Nose Pliers
Small Flat Blade Screwdriver
#2 Phillips Head Screwdriver
Small Hammer
Soft Lint-Free Cloth/ Damp Cloth
5/32” Drift Punch
Anhydrous Isopropyl Alcohol
800gms 5Si Toner
Nu-Finish (optional)
Damp Cloth
Technical Instructions Printers OEM Info Tools 1
Step 1
Locate and remove the cartridge clips on
both sides of the cartridge using your fin-
ger. Gently pry up on the clip until it pops
up.
(See Photo 1)
Photo 1
Photo 2a
Photo 2b
WXTECH
Step 2
Using a flat blade screwdriver, pry up on
the other clip and remove it.
(See Photo 2a)
NOTE: Itis very likely that these clips will
break while theyare being removed. If
these break, replace with aftermarket
part. You may need to use the springs
from the OEM clip.
(See Photo 2b)
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Photo 3
Step 4
Set the hopper aside. If you have a waste
hopper fixture, set the waste hopper in the
fixture. If not, place the waste hopper on
the table.
(See Photo 4)
Photo 5
Photo 6
Step 6
Removethe drum, blowoff excess toner
with compressed air and clean with iso-
propyl alcohol. Wrap the drum in a protec-
tive paper or cloth and set it aside in a dark,
protected place. (See Photo6)
NOTE: We were able to use the OEM drum
onceafter the Oem cycle with no loss in
density, however, you may choose to
recoat or replace the drum after the first
recharge.
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2WX Technical Instructions
Photo 4
Step 3
Just like the HP4 cartridge, the two halves
of the cartridge can now be separated.
(See Photo 3)
Step 5
The drum axle is a metal rod that goes
through the center of the drum end to
end. On the large gear end of the axle is a
small white plastic retaining ring. Using a
drift punch and a hammer, tap directly on
the shaft (large gear side) and drive it out
the other end. (See Photo 5)
NOTE: Make sure you don’t lose the retain-
ing ring. The ring fits intoagroove on the
drum shaft to hold the shaft in position.
Repeated removal will wear this ring and
the ring will no longer snap intoposition.
If the ring does not snap, replace it.
Photo 7
Step 7
Remove the primary charge roller from its
clips.Clean clips with isopropyl alcohol
and a cotton swab. Inspect the primary
charge roller for damage. Clean the pri-
marycharge roller with a mild soap and
water and set it aside.
(See Photo 7)
NOTE: We have had no problems using the
OEM primary charge roller three cycles in
mild weather climates.
Notes

Photo 9
Photo 12 Step 12
Apply padding powder to the OPC drum
and install. The big helical gear will go on
the right side of the waste hopper. Install
the drum axle only far enough to hold the
drum against the wiper blade. Rotate
drum so the wiper blade wipes the
padding powder off the drum.
(See Photo12)
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WX Technical Instructions 3
Photo 8 Step 8
Remove the two Phillips head screws hold-
ing the wiper blade and remove the blade.
Be careful not to break the plastic position-
ing posts.
(See Photo 8)
Step 9
Empty out the waste toner and clean felts
and foam with a vacuum or compressed
air.
(See Photo 9)
NOTE: Be careful not to damage felts,
foam or the mylar recovery blade, as this
can cause leaks. If the felts or foam are
damaged or worn, replace.
Step 13
Onceagain, remove the drum axle and the drum. Reinstall the primary charge roller
then reinstall the drum and drum axle.
NOTE: When reinstalling the drum axle, the axle slides through the drum from the
left side. Make sure you install the axle in the right way. The notched end of the axle
goes on the large gear end.
Photo10
Step 10
Apply OPC protector felt to the drum
shutter door. You will need to remove the
cartridge from the fixture.
(See Photo10)
Step 11
Apply padding powder on wiper blade
and reinstall.
NOTE: If you are going to use a new after-
market drum, always replace wiper blade.
Notes

Photo 14
Photo 17
Photo19
Photo 20
4WX Technical Instructions
Step 14
Install the retaining ring.
(See Photo 14)
Step 15
Set waste hopper aside and cover.
Step 16
If you have a toner hopper fixture, place
toner hopper in fixture or place toner
hopper on the workbench.
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Step 17
Remove the two screws holding the end
cap on the gear side of the toner hopper.
(See Photo 17)
Photo 18
Step 20
Turnthe cartridge around. Remove the
two screws that hold the other end cap
on and remove.
(See Photo 20)
Step 19
Slide the end cap off. Note the position of
the white gears, then remove the four
largest ones and set them aside.
(See Photo 19)
Step 18
Beforeremoving the end cap, lift the bias
strip off its positioning post next to the
doctor blade.
(See Photo 18)
Notes

Photo22
Photo 23
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WX Technical Instructions 5
Photo 21a
Photo 21b
Step 23
Turn the cartridge around to the gear
side once again. Remove the two other
gears. Remember which gear goes
where. These gears turn the toner paddle
bars inside the toner hopper. The bars
will fall into the toner hopper. Remove
these toner paddle bars from inside the
toner hopper.(See Photo23)
Step 21
Lift out mag roller. Remove the mag roller
stabilizer, mag roller sleeve bearing and
mag roller sleeve bushing from the non-
gear side of the mag roller and clean.
(See Photo 21a and 21b)
Use compressed air or a vacuum and
remove the extra toner off the mag roller.
Use mag roller cleaner to remove any
residue built up on mag roller.
NOTE: If you are going to have your mag
rollers coated or replaced, you’ll need to
remove the mag roller contact, the gear,
mag roller stabilizer, the bearing and the
bushing from the other side of the mag
roller.
To remove the gear off the mag roller, use
avery small flat blade screwdriver to pry
back the prong on the gear. Remove the
non-gear side hub and send in mag roller
to be coated.
The mag roller bearings have a difference
in the inner diameter size and are not
interchangeable. HP also made two dif-
ferentmag rollers. The only difference is
in the length of the shaftand the hub.It
is very important to keep the parts
together. The long shaft uses a shorter
hub. When the mag rollers are put
together correctly, they can be used inter-
changeably in different cartridges.
Step 22
Remove the two screws that hold the
doctor blade and lift it out. Clean and set
aside.The doctor blade can wear out
after a few cycles, check and replace if
necessary.
(See Photo 22)
Notes

Photo 24
Photo 25
6WX Technical Instructions
Step 25
Remove toner sensing bar. Make sure you
don’t lose the toner sensor bar seal. Clean
the sensor bar with a cloth and alcohol.
NOTE: Do not bend the sensor bar.
(See Photo 25)
Step 24
The bars are the same so don’t worry
about getting them mixed up. Also,
remove the toner paddle bar felt washers.
Look at the washers to make sure toner is
not leaking through them. After a few
cycles, these felt washers will wear out
and need to be replaced.
(See Photo 24)
Photo 26
Photo 27
Photo 28a
Step 26
Removeleftover toner and clean the felts
and foam seals with compressed air or
vacuum. Be careful not todamage anyof
the foam, felt strips, or the thin mylar strip
on the bottom lip of the toner hopper. If
these aredamaged,the cartridge will
leak.
(See Photo 26)
Step 27
At this point, if you are not going to seal
this cartridge, you can fill it with toner
now through the mag roller opening
then start reassembling cartridge.
(See Photo 27)
If you wish to split and seal the toner hop-
per first, proceed to the next step.
Step 28
Place cartridge in splitter fixture. Hold
cartridge in place and slide cutting unit
along the guide toensureagood clean
split.
(See Photo 28a)
Notes

Photo 29
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WX Technical Instructions 7
Photo 28b
Step 29
Use a razor knife to cut off plastic posts at
the base on the non-plug side of the car-
tridge. These are removed so a seal can
be used.
(See Photo 29)
Step 28 cont.
NOTE: The two halves of the toner hopper
are still held together by two pins.
Carefully pull the two halves apart.
(See Photo 28b)
Photo 30
Step 30
Using needle nose pliers,pinch the retain-
ing clips of the agitator, and removethe
agitator drive assembly. Remove the
toner agitator felt washer. If toner is leak-
ing through opening, replace the washer.
(See Photo 30)
Photo31
Step 31
Use isopropyl alcohol and clean surface
of toner hopper where cartridge was
split.
(See Photo 31)
Photo 32
Step 32
Remove backing from the seal. With the
tail of the seal on the leftside of the car-
tridge (the plug side), adhereseal tothe
toner hopper.
(See Photo 32)
NOTE: Use your finger to press around
the seal tomakesureof a good adhesion.
Notes

Photo 33
Photo 34
8WX Technical Instructions
Step 34
Use compressed air or a vacuum and
clean the toner hopper seal channel end
foam on the back of the mag roller sec-
tion. Wipe off the back of the mag roller
section.
(See Photo 34)
NOTE: If these foam pads are damaged,
they need to be replaced.
Step 33
Remove fill plug and fill with toner.
(See Photo 33)
Photo 35
Photo 36
Photo 37
Step 35
These foam strips stop the cartridge from
leaking after it has been split. The foam
strips areapplied rightacross the seal
channel end foam.
(See Photo35)
Step 36
Fold the seal back across the toner hop-
per. Now re-join the mag roller section
and the toner hopper section.
(See Photo 36)
NOTE: The posts on the mag roller section
needs to fit back into the holes on the
toner hopper section.
Step 37
Using the toner hopper clips, clip the two
sections together.
(See Photo37)
Notes

Photo 39
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WX Technical Instructions 9
Photo 38
Step 39
Put a little fresh toner on the doctor blade
and reinstall.
(See Photo 39)
Step 38
Reinstall the toner paddle bar felts and
the bar gears that hold them in. Then
install toner sensor bar.
(See Photo 38)
Photo 40
Step 40
Place the mag roller bushing, mag roller
bearing, and the mag roller stabilizer back
on the mag roller. Install mag roller back
onto toner hopper.
(See Photo 40)
Photo41
Step 41
Reinstall all the gears on the toner hop-
per.
(See Photo 41)
Photo 42
Step 42
Now install the gear side end cap, align-
ing the “flat sided shaft” of the magnet
with its “D” shaped hole and the position-
ing pins through the mag roller stabilizer
holes and then press down. Install two
Phillips head screws. Align the metal bias
strap tothe plastic pin next to the doctor
blade and press into position so thatit
contacts the doctor blade.
(See Photo 42)
Notes

Photo 43
Photo 45
10 WX Technical Instructions
Step 45
Snap the OEM or aftermarket cartridge
clip back into position.
(See Photo 45)
Step 43
Do the same with the end cap on the
other side and apply pull tab to seal.
(See Photo 43)
Step 44
Align the toner hopper and waste hopper
assemblies together.
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Notes
Future Graphics (FG) is a distributor of compatible replacement parts and products for imagining equipment. None of FG's
products aregenuine OEM replacement parts and no affiliation or sponsorship is to be implied between FG and any OEM.