IBM 4019, 4028, 4029 Service Manual
IBM 4019
IBM 4028
IBM 4029
BDT Ergoprint 510, 610II
Unisys AP 9025, 9210
HIgh Yield
Part Number: 1380200
Gram Load: 300 grams
Yield @ 5%: 7,000
Pages per min.:5/10 ppm
Resolution: 300dpi
HIgh Yield Plus
Part Number: 1380520
Gram Load: 450 grams
Yield @ 5%: 9500
Pages per min.:5/10 ppm
Resolution: 300dpi
#1 Phillips Head Screwdriver
Small Flat Blade Screwdriver
Needle Nose Pliers
Anhydrous Isopropyl Alcohol
Damp Cloth
Soft Lint-Free Cloth
Cotton Swabs
Drill
3/32” Drill Bit
Razor Knife
Nipper PLiers
Rubber Cement
Teflon Shims for Electrostatic Roller
Waste Hopper Strip
Plastic Toner Hopper Cover
Tap e(p vc )
Toner Hopper Replacement Mylars (A&B)
Technical Instructions Printers OEM Info Tools 1
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4019 TECH
Step 1
Place the cartridge top down on the table
with the drum alignment side plate facing you. For the plastic side plates, drill
three 3/32" holes. These holes are for
screws used in final assembly. For the
metal side plate, drill out the middle of
each plastic rivet head.
(See Photo 1b)
Photo 1a
The 4019 has a standard cartridge holding 300 grams of toner and yielding 7,000
pages, and a plus cartridge that holds 450 grams of toner and yields 9500 pages at
5% coverage.
The 4019 uses a corona wire to charge the drum while the 4039 and 4049 use the
newer PCR technology.
There are two different side plates on the 4019 cartridge and two different drum
gear types. The older side plate (bottom left) is metal, compared with the newer
plastic part (bottom right). In the older unit, the metal spindle fits inside the drum
gear,while the newer drum gear has a plastic spindle that fits inside the plastic side
plate.
(See Photo 1a)
Photo 1b
Step 2
Cut off the four heads of the black plastic
rivets (shown in white in Photo #2) with a
razor knife or flush cut nipper pliers.
(See Photo 2)
Photo 2
Step 4
Move the drum shutter rod aside and
remove the drum alignment plate by
pulling it straight out.
(See Photo 4)
Photo 3
Photo 4
Step 5
Using Needle Nose pliers, disconnect the
toner hopper tension springs.
(See Photo 5)
Photo 5
Photo 6
2IBM 4019 Technical Instructions
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Step 6
Turn the cartridge 180° and remove the
toner hopper guide pin from the rectangular hole.
(See Photo 6)
Step 3
Remove the OPC drum cover from the
shutter rod using a small flat blade screwdriver.
(See Photo 3)
Step 9
Lift the alignment plate side of the cartridge enough to expose the lock tab on
the top of the waste hopper and gently
pry the tab with a small flat blade screwdriver, to release the toner hopper.
(See Photo 9a)
Now lift the toner hopper and separate it
from the waste hopper.
(See Photo 9b)
NOTE:An arrow points to the tab being
pulled down by the screwdriver.
Photo 9a
Photo 9b
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IBM 4019 Technical Instructions 3
Photo 7
Step 7
Rotate the cartridge 180° again, pull back
the toner hopper with one hand, and
remove the OPC drum with the other.
Wrap the drum in protective cloth or
paper and put it aside until later. You can
usually use the OEM drum one more
cycle after the original OEM cycle.
(See Photo 7)
Photo 8
Photo 10
Step 10
Now,set the toner hopper aside and
remove the waste hopper mylar strip
(recovery blade) opposite the wiper blade.
Dump out the waste toner and clean the
waste hopper with either compressed air
or vacuum.
(See Photo 10)
Step 8
Remove the drum clutch gear assembly
and set it aside.
(See Photo 8)
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