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Remanufacturing the Xerox Phaser 4510

• By Mike Josiah
• Nov 01, 2007

First introduced in April 2007, the Phaser 4510 machine is based on a 45-ppm, 1,200-dpi Fuji-Xerox laser printer engine. There are two cartridges available; the LY 113R00711 is rated for 10,000 pages, and the HY 113R00712 is rated for 19,000 pages. The first page out is stated to be under eight seconds. The processor is 533Mhz, and they all come standard with 128MB RAM with a max of 512MB. These machines tend to be used as workgroup printers, so if you have a customer that has one, the cartridge volume will be on the high side.

With the list prices of these cartridges at $159.99 for the low-yield and $224.99 for the high-yield, they are a nice profitable cartridge to do. Though they are a bit unique in their construction, they are fairly easy to remanufacture.

While this cartridge looks very similar to the Phaser 4500 from the outside, it is very different. This is especially true for the toner and chips. The chip itself is an RF type and is a black round disk that fits into the side of the cartridge.

Like the Phaser 4500, the LY and HY use white plastic pins located on each side of the cartridge that lock the two halves of the cartridge in place. The heads of these pins have a one-way screw head on them. See Figure 1. We have contacted multiple specialty screw manufacturers to see if a special tool is available, but were unable to find one. They can be removed by inserting a one-inch No. 6 or No. 8 wood screw into the center of the pin. You can then twist the pin to release the two small tabs and pull it out. The text below will go into more detail on this.

The machines that are based on the Xerox 4510 engine are as follows:

• Phaser 4510
• Phaser 4510 B
• Phaser 4510 N
• Phaser 4510 DT
• Phaser 4510 DX

How to run test prints as well as printer error codes will be discussed at the end of this article.

Remanufacturing instructions

1) On either side of the cartridge is a white plastic pin with one-way screw heads. These pins hold and lock the halves together. As mentioned above, specialty drivers to remove them are not available, so the only way as of now to remove them is to insert a one-inch No. 6 or No. 8 wood screw into the center of the pin. Once the screw has been inserted, turn the pin/screw so that the two small tabs in the pin are free. Remove the pin. See Figures 2, 3 and 4.

2) Remove the spring from the right (fill plug) side of the cartridge. Separate the halves by lifting the waste chamber straight up and off the supply chamber. See Figures 5 and 6.

3) Remove the two screws and metal drum axle pin from left side of the cartridge. See Figure 7.

4) Remove the two screws and plastic drum bushing from the right side of the cartridge. See Figure 8.

5) Remove the drum. See Figure 9.

6) Remove the PCR from its holders. See Figure 10.

7) Remove the two screws and wiper blade. This blade has a very tight fit. Be careful not to break the alignment pins. See Figure 11.

8) Clean out the waste chamber. Be very careful not to lose or damage the foam wiper blade seal. See Figure 12.

9) Coat the wiper blade with your preferred lubricant, and install in the cartridge. As stated previously, this blade has a very tight fit. Be careful not to break the alignment pins. Install the two long screws — the four short screws are for the drum axle pins only. See Figure 13.

10) Clean the PCR contacts with a cotton swab and alcohol. Place a small amount of conductive grease on the black PCR holder. See Figure 14.

11) Clean the PCR with your preferred PCR cleaner, and install in the holders. See Figure 15.

12) Install the drum, axle pins, and screws. Make sure that there is clean conductive grease on the drum axle pin shaft. See Figure 16.

13) While the cartridge is apart is the best time to remove the old chip. Press in on the two tabs from the inside wall of the cartridge, and remove the chip. See Figures 17 and 18.

14) With a small jewelers screwdriver, pry out the upper fill plug (see Figure 17 again). Dump out any remaining toner from the upper hopper. See Figure 19.

15) With the same jewelers screwdriver, pry out the lower fill plug and dump out any remaining toner from the lower section. See Figure 20.

16) On the side opposite the fill plug, remove the two screws, the end cap and gears as shown. Leave the top large white gear in place. See Figures 21, 22 and 23.

17) Lift up the locking arm on the right side of the magnetic roller. With the keyed shaft of the magnetic roller free, lift up on the keyed end by the locking arm. Pull the entire magnetic roller assembly free. See Figures 24 and 25.

18) Remove the two screws and doctor blade. Watch out for the alignment pins. Clean out any remaining toner. See Figure 26.

19) Remove the four screws that hold the upper supply section to the lower. Remove the upper section. See Figures 27, 28 and 29.

20) Remove the two agitators from the lower hopper and clean them off. See Figures 30 and 31.

21) Thoroughly clean out both the lower and upper chambers. Be careful not to lose or damage the square foam seals on the lower chamber. See Figure 32.

22) Install the two agitators. Make sure the rectangle hole is towards the top of the cartridge. See Figures 33 and 34.

23) Place the upper chamber onto the lower, and install the four screws. See Figures 35 and 36.

24) If you are installing a seal, remove the seal plug on the lower section by pressing in on the side tab. See Figure 37.

25) Install the seal. Make sure the seal tab is slid into the seal tab slot. See Figure 38.

26) Install the seal plug. See Figure 39.

27) Install the cleaned doctor blade and two screws. Be careful not to damage the alignment pins. See Figure 40.

28) Clean the magnetic roller assembly with a dedicated magnetic roller cleaner. Install the assembly left side (round shaft) first. Make sure the locking arm is firmly locked in place. See Figures 41 and 42.

29) Install the gears in the order shown. Install the end cap and two screws. See Figures 43 and 44.

30) Install the lower fill plug. See Figure 45.

31) Fill with 820 grams of Phaser 4510 toner in the upper chamber. See Figure 46.

32) Install the upper fill plug, check for leaks. See Figure 47.

33) Install the toner supply section onto the waste chamber. Make sure the spring on the supply hopper fits into the plastic ring on the waste hopper. See Figure 48.

34) Install the two white plastic locking pins. See Figure 49.

35) Install the spring onto the outside of the cartridge. See Figure 50.

36) Replace the RF chip. Line the two tabs on the back of the chip with the slots, and snap into place. See Figure 51.

Cartridge defect listing

We have found no strange defects related to these cartridges. The following is a list of repetitive defects for the more common failures.

• 94.4mm OPC drum
• 94.2mm Fuser assembly
• 52mm Magnetic roller
• 51mm Transfer roller
• 38mm PCR

Running test pages

• Press the MENU button until "TROUBLESHOOTING” is displayed.
• Press the OK button.
• Select "PRINT QUALITY PROBLEMS.”
• Press the OK button.
• Select "TEST PRINTS.”
• Press the OK button.
• A series of test pages will then print out.

Machine error codes

The error codes in these machines follow the trend of using all English messages (no number codes). There is no need to list them here. It should be noted however that for many errors there are two levels of error codes. If there is a secondary code, the primary will tell you which button to press to get the second. Usually it is the HELP button.