XEROX ® PHASER 3635 MFP

TONER CARTRIDGE REMANUFACTURING INSTRUCTIONS

XEROX PHASER 3635 TONER CARTRIDGE

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 XEROX PHASER 3635 MFP TONER CARTRIDGE REMANUFACTURING INSTRUCTIONS

REMANUFACTURING THE XEROX

PHASER 3635 MFP TONER CARTRIDGE
By Mike Josiah and the Technical Staff at UniNet

First released in August 2008, the Xerox Phaser 3635 MFP printers are based on a 35ppm, 1200 DPI engine. The first page out
is rated under nine seconds, and the monthly duty cycle is up to 75,000 pages. Both model printers are print, copy, scan, fax,
and email capable.

These cartridges do not have a drum cover, and come new with a piece of heavy paper with foam glued to it taped around
the cartridge.

There are both low yield (5,000 pages) and high yield (10,000 pages) cartridges available. Each version of cartridge has its own
specific chip, but the cartridges themselves are identical. Methods to reset the OEM chips and/or new replacement chips should
be available as you read this. The chip covers are held in place by plastic rivets. To replace the chip, the rivets need to be cut off,
holes carefully drilled (not too deep or the cartridge will leak), and screws installed. This is definitely a cartridge where a reset box
is the way to go.

The printers, as well as the cartridges, are listed below.

LOW YIELD CARTRIDGE HIGH YIELD CARTRIDGE

108R00793 (5,000 pages) 108R00795 (10,000 pages)

PRINTER
Xerox Phaser 3635MFP/S
Xerox Phaser 3635MFP/X

Shown are the high yield and low yield cartridges. As you can see, they are identical so if you install the correct chip and
toner load, you can easily make a low yield a high yield cartridge.

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 XEROX PHASER 3635 MFP TONER CARTRIDGE REMANUFACTURING INSTRUCTIONS

REQUIRED TOOLS
1. Toner approved vacuum
2. A small common screwdriver
3. A Phillips head screwdriver
4. Needle nose pliers

REQUIRED SUPPLIES
1. Replacement toner for use in Xerox Phaser 3635 (135g for low yield, or 290g for high yield)
2. Replacement chip (high yield or low yield)
3. Replacement drum
4. Replacement wiper blade
5. Replacement doctor blade
6. Replacement developer roller
7. Replacement PCR
8. Conductive grease
9. Drum lubricating powder

1. Place the cartridge with the handle/supply chamber 2. Gently pry off the plastic drum axle bushing. Keep this
facing you. Remove the three screws on the right end cap. bushing with the appropriate end cap when removed. Each side
is different.

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 XEROX PHASER 3635 MFP TONER CARTRIDGE REMANUFACTURING INSTRUCTIONS

3. On the top edge of the end cap, there is a plastic tab.

Press in on the tab and remove the right end cap.

4. On the opposite side of the cartridge, remove the three 5. Gently pry off plastic drum axle bushing. Keep this bushing
screws on the left end cap. with the appropriate end cap when removed.

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 XEROX PHASER 3635 MFP TONER CARTRIDGE REMANUFACTURING INSTRUCTIONS

6. On the top edge of the end cap, there is a plastic tab.

Press in on the tab and remove the left end cap.

7. Lift off the roller cover. 8. Carefully pry off the side plastic tab to release the waste
chamber.

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 XEROX PHASER 3635 MFP TONER CARTRIDGE REMANUFACTURING INSTRUCTIONS

9. Remove the waste chamber. 10. On the supply hopper, remove the fill plug and dump out
any remaining toner.

11. Remove the developer roller drive gear; put a strip of tape across the remaining gears.

They do not need to be removed.

The tape will help keep them in place.

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 XEROX PHASER 3635 MFP TONER CARTRIDGE REMANUFACTURING INSTRUCTIONS

12. On the fill plug side, press in on the plastic tab and remove the spring and plastic bushing assembly.

13. Remove the developer roller. 14. Remove the two screws on the doctor blade.

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 XEROX PHASER 3635 MFP TONER CARTRIDGE REMANUFACTURING INSTRUCTIONS

15. Carefully pry off the doctor blade. 16. Clean out any remaining toner from the hopper.

This blade has a very tight fit, so work it off carefully. 17. Clean the doctor blade and foam seals. It is too early to say
exactly what chemical to use on the blade, but so far 99%
isopropyl alcohol seems to work.

18. Replace the doctor blade and two screws. 19. Clean and install the developer roller, long shaft side to the
gear side first.

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 XEROX PHASER 3635 MFP TONER CARTRIDGE REMANUFACTURING INSTRUCTIONS

20. Snap the spring and plastic bushing assembly in place.

Make sure the tail of the spring is set properly.

21. Install the drive gear on the developer roller. 22. Fill the hopper with 135g or 290g of new replacement toner
for use in Phaser 3635. Check for leaks.

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 XEROX PHASER 3635 MFP TONER CARTRIDGE REMANUFACTURING INSTRUCTIONS

23. On the waste hopper, remove the E-ring from the drum axle. 24. Slide the drum axle out from the side opposite the E-ring.

25. Remove the OPC drum.

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 XEROX PHASER 3635 MFP TONER CARTRIDGE REMANUFACTURING INSTRUCTIONS

26. Slide the PCR to the non-contact side.

Remove the PCR.

27. Remove the two screws and the wiper blade. 29. Coat the new wiper blade with your preferred lubricant.
Install the new wiper blade and two screws. The tail of the wiper
28. Clean out all the toner from the hopper. blade should face up.

It is interesting to note that on new cartridges, some toner is in 30. Clean the PCR with your preferred PCR cleaner.
the waste hopper. Apparently these cartridges are being tested
before they are shipped, or the drum was lubricated with toner. 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, follow the cleaning methods recommended by
the manufacturer. If the PCR is an OEM, we recommend it be
cleaned with your standard PCR cleaner.

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 XEROX PHASER 3635 MFP TONER CARTRIDGE REMANUFACTURING INSTRUCTIONS

31. Clean the old conductive grease off the PCR shaft, 32. Install the PCR by sliding the long shaft side through the
and contact. Replace with new. non-contact side. Bring it back to fit into the contact side.

33. Coat the OPC drum with your preferred lubricant and install
the drum.

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 XEROX PHASER 3635 MFP TONER CARTRIDGE REMANUFACTURING INSTRUCTIONS

34. Install the drum axle, small drum gear side first.

Make sure that the E-ring groove ends up on the small drum gear side.

35. Install the E-ring. 36. Install the waste hopper on to the supply chamber.

Make sure that the tabs lock into place on the side wall.

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 XEROX PHASER 3635 MFP TONER CARTRIDGE REMANUFACTURING INSTRUCTIONS

37. Install the roller assembly.

38. Install the right side end cap and three screws.

Make sure the top rear tab locks in place.

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 XEROX PHASER 3635 MFP TONER CARTRIDGE REMANUFACTURING INSTRUCTIONS

39. Press the drum axle bushing in place. Set it so the small
tab is at the end of the groove; make sure it is fully seated.
The two small bushings are different. Make sure you have the
correct bushing for this side.

40. Remove the tape from the gears, and install the left side end cap and three screws.

Make sure the top rear tab locks in place.

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 XEROX PHASER 3635 MFP TONER CARTRIDGE REMANUFACTURING INSTRUCTIONS

41. Press the drum axle bushing in place. Set it so the small
tab is at the end of the groove; make sure it is fully seated.
The two small bushings are different. Make sure you have the
correct bushing for this side.

42. The chip is held in place by plastic rivets. It must be reset/replaced for the cartridge to work. Resetting is the easiest method,
(see left photo) but it can be replaced by cutting the plastic rivets, drilling two holes, and setting two self tapping screws in place.

© 2015 UniNet Imaging Inc. All trademark names and artwork are property of their respective owners. Product brand names mentioned are intended to show compatibility only.
UniNet Imaging does not warrant downloaded information. Unauthorized sale, reproduction or distribution of this article is prohibited. For additional support, please contact [email protected] www.uninetimaging.com
 XEROX PHASER 3635 MFP TONER CARTRIDGE REMANUFACTURING INSTRUCTIONS

PRINTING TEST PAGES

As these machines are copiers, the easiest way is to just make a copy of a suitable test page.

REPETITIVE DEFECT CHART

OPC drum: 75.5 mm
Supply roller: 44.9 mm
PCR: 37.7 mm
Developer roller: 35.2 mm

© 2015 UniNet Imaging Inc. All trademark names and artwork are property of their respective owners. Product brand names mentioned are intended to show compatibility only.
UniNet Imaging does not warrant downloaded information. Unauthorized sale, reproduction or distribution of this article is prohibited. For additional support, please contact [email protected] www.uninetimaging.com