HP4600 Toner Dis Assembly

8/2/2019 HP4600 Toner Dis Assembly

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Canon ImageClass C2500Canon LBP-2510HP Color LaserJet 4600HP Color LaserJet 4600 DNHP Color LaserJet 4600 DNTHP Color LaserJet 4600 HDNHP Color LaserJet 4650HP Color LaserJet 4650 NHP Color LaserJet 4650 DNHP Color LaserJet 4650 DNTHP Color LaserJet 4650 HDN

Part Number: C9720A BlackYield @ 5%: 9,000pgsPart Number: C9721A CyanYield @ 5%: 8,000pgsPart Number: C9722A YellowYield @ 5%: 8,000pgsPart Number: C9723A MagentaYield @ 5%: 8,000pgs

#1 Phillips Screwdriver

Small Flat Blade Screwdriver

Needlenose Pliers

1/8 Drill bit

Padding Powder

Soft Lint-Free Cloth

Cotton Swabs

Conductive Grease

Anhydrous Isopropyl Alcohol

Vacuum or Compressed Air

Technical Instructions Printers OEM Info Tools

E-mail: [email protected] Website: www.futuregraphicsllc.com

Step 1

Place the cartridge on the work bench sothe waste hopper is up and the blue cartridgehandles are facing you.(See Photo 1)

Photo 1

Step 2

Locate the square holes located (shown inPhoto 2 and Photo 3) on the top left and rightsides of the waste hopper.

Photo 2

Photo 3

P4600TECH

US 1 800 394.9900Intl +1 818 837.8100FAX 1 800 394.9910Intl +1 818 838.7047

DALLAS, USA

US 1 877 499.4989

Intl +1 972 840.4989FAX 1 877 774.1750Intl +1 972 840.1750

ATLANTA, USA

US 1 877 676.4223Intl +1 770 516.9488FAX 1 877 337.7976Intl +1 770 516.7794

MIAMI, USA

US 1 800 595.429Intl +1 305 594.3396FAX 1 800 522.8640Intl +1 305 594.3309

SANFORD,USA

US 1 800 786.9049Intl +1 919 775.4584

FAX 1 800 786.9049Intl +1 919 775.4584

TORONTO, CAN

CAN 1 877 848.0818Intl +1 905 712.9501FAX 1 877 772.6773Intl +1 905 712.9502

NEW YORK, USA

US 1 800 431.7884Intl +1 631 345.0121FAX 1 800 431.8812Intl +1 631345.0690

SYDNEY, AUS

AUS 1 800 003.100Intl +62 02 9648.2630FAX 1800 004.302Intl +62 02 9548.2635

BUENOS AIRES, ARG

ARG 0810 444.2656Intl +011 4583.5900FAX +011 4584.3100

MONTEVIDEO,URY

URY 02 902.7206Intl +5982 900.8358FAX +5982 908.3816

JOHANNESBURG, S.A.

S.A. +27 11 974.6155FAX +27 11 974.3593

MELBOURNE, AUS

AUS 1 800 003. 100Intl +62 03 9561.8102FAX 1 800 004.302Intl +62 03 9561-7751

CORPORATE

LOS ANGELES, USA


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Step 3

Using a 1/8 inch drill bit, drill a hole through tsquare holes on top of the waste hopper. Thole must be drilled at an angle so the drill hits the end of the cartridge pin, forcing the poutward. (See Photo 4)

NOTE: If the pins are not pushed out, inse

a small flat blade screwdriver into the drillholes and push the pin out the end of tcartridge. (See Photo #4b)

Photo 4

Photo 4b

Step 4

Flip the cartridge over so the toner hopperfacing up. Using diagonal cutters, remove tcartridge pins from each end of the cartridge(See Photos 5 & 6)

Photo 6

Photo 7

Step 5

Using a spring hook, release the tension sprithat holds the waste hopper to the toner hoper on the contact side of the cartridge.(See Photo 7)

Step 6

Lift the toner hopper away from the waste hoper. (See Photo 8)

Set the toner hopper aside.

Photo 8

Step 7

Using a small Phillips screwdriver, remove tscrew that holds the blue cartridge handles each end of the waste hopper.(See Photos 9 & 10)

Photo 9

2 HP4600 Technical Instructions

Photo 5

Notes

Photo 10


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Photo 12

Step 11

Grab the drum drive hub located on the drumaxle and pull the axle out from the drum.(See Photo 14)

NOTE: It maybe necessary to tap the drumaxle out from the contact side of the cartridge.The drum axle bearing may come out when thedrum axle is removed from the hopper. If not,remove the drum axle bearing from the contactside of the waste hopper.(See Photo 15)

Photo 13

Photo 14

HP4600 Technical Instructions

Step 10

Remove the washer from the drum axle.(See Photo 13)

Step 8

Remove the blue cartridge handle and the ten-sion spring from the contact side of the wastehopper.(See Photo 11)

Photo 11

Step 9

Using a spring hook, pull the tines holding thelock washer to the drum axle.(See Photo 12)

Pull on each tine one at a time until the washeris removed.

Notes

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Photo 15


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Photo 17

Photo 18

Photo 19

Photo 20

Photo 21

Photo 22

Photo 16



Step 12

Carefully lift the drum out from thewaste hopper.(See Photo 16)

Step 13

Pull the drum shutter bar out of itspositioning hole on the contact sideof the waste hopper.(See Photo 17)

Step 14

Remove the drum shutter bar from the geside of the hopper.(See Photo 18)

Step 15

Remove the drum shutter from the drum shuarm.(See Photo 19)

Step 16

Remove the PCR. (See Photo 20)Clean the PCR using a lint-free cloth.

If needed, water can also be used to clean tPCR.

Step 17

Carefully bend back the brown film on twiper blade to access the screws holding twiper blade. Remove the two screws usingPhillips screwdriver.(See Photo 21)

Step 18

Lift one end of the wiper blade and pull tblade away from the sealing foam.(See Photo 22)

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Photo 26

Photo 24

Step 24

Install the cleaned PCR into the hopper.(See Photo 27)

Photo 25

Photo 27


Step 22

Apply the wiper blade sealing foam to thewaste hopper.(See Photo 25)

Step 19

Dump the waste toner from the hopper. Usinga vacuum or dry compressed air, clean out the

waste hopper.

Step 20

Remove the OEM wiper blade sealing foam.(See Photo 23)

Photo 23

Step 23

Apply padding powder to the new wiper blade.Install the blade and the two screws that holdthe blade in place.(See Photo 26)

Step 21

Clean the waste hopper using a dry lint-freecloth. Apply the wiper blade sealing end foamsonto the waste hopper at each end of thewaste hopper.(See Photo 24)

Notes

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Photo 29

Photo 31

Photo 32

Photo 33

Photo 34

Photo 28



Step 25

Apply padding powder to the OPCdrum. Place the drum into thewaste hopper so the drive hub is onthe gear side of the hopper.(See Photo 28)

Step 26

Slide the drum axle through thedrum, starting on the gear side.(See Photo 29)

NOTE: Make sure the bearing onthe drive hub side of the drum axleis seated properly in the side of thewaste hopper.

Step 28

Place the small looped end of the tensiospring over the spring post.(See Photo 31)

Step 29

Install the blue cartridge handle on the contaend of the hopper and install the small screthat holds the handles on each side of twaste hopper.(See Photo 32)

Step 30

Install the drum shutter post into the drushutter arm. Install the drum shutter bar inthe alignment holes on each side of the hoper. (See Photo 33)

Step 31

Set the waste hopper aside and cover.

Step 32

Remove the screw holding the contact ecap to the toner hopper.(See Photo 34)

Photo 30

Step 27

Install the drum axle bearing, the washer athe lock washer to the drum axle on the cotact side of the hopper. (See Photo 30)

Rotate the drum 5-10 revolutions. Clean tpadding powder off the PCR using a dry lin

free cloth.


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Photo 37

Photo 38


Step 35

Rotate the cartridge 180. Remove the twoscrews holding the gear housing end cap tothe toner hopper. (See Photo 38) Remove thegear housing end cap.

Step 34

Remove the two screws that hold the developerroller end cap to the toner hopper.(See Photo 36)

Remove the end cap.

NOTE: The screws that hold the developer rollerend cap have a flat head and are different thatthe other screws used on the cartridge. Be surethe correct screws are used during reassembly.The developer roller end cap has a small bearingthat sits inside the end cap. Do not lose thebearing. (See Photo 37)

Photo 36

Photo 39

Step 36

Remove the five loose gears from the side ofthe hopper.(See Photo 39)

Photo 41

Photo 40

Step 37

Release the locking clip that holtoner hopper agitator drive gear the agitator bar. (See Photo 4Remove the gear.

Step 38

Remove the two screws holding tdeveloper roller end cap to ttoner hopper. (See Photo 41)Remove the end cap.NOTE: Do not lose the bearing thsits in the developer roller end ca(See Photo 42)

Photo 42

Photo 35

Step 33

Using a small flat blade screwdriver, releasethe locking clip that holds the contact end capto the toner hopper.(See Photo 34)

Remove the contact end cap.


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Photo 45

Photo 46

Photo 47

Photo 48



Step 41

Remove the white bushings from the ends the developer roller. (See Photo 45) Clean tbushings with a dry lint-free cloth and alcoh

Step 42Install the drive gear end of the developer rolaxle into a drill and tighten the chuck. Clethe developer roller using a lint-free cloth a99% Alcohol while the roller is rotating in tdrill. Once the roller is clean, go over the rolagain using distilled water and a lint-free cloMake several passes. Dry the roller using a dlint-free cloth. (See Photo 46)

NOTE: The surface of the developer roller mchange and become wrinkled. If propecleaned, the developer roller will go back to original state when finished with the cleani

process.

Step 43

Remove the two screws holding the doctor b(See Photo 47)

NOTE: On some of the old HP4600 cartridgthe doctor blades are adhered to the developroller end felts. If so, insert an angled knbehind the ends of the doctor blade and carfully cut the doctor blade free. (See Photo 48

Step 44

Remove the doctor blade from the toner hoper. (See Photo 49) Clean the doctor blausing dry compressed air.

Photo 43

Step 39

Grab the toner charge roller by theends and remove the roller from thehopper. (See Photo 43) Clean theroller using dry compressed air.

NOTE: Some Newer cartridgesfrom HP do not have a toner chargeroller. If the TCR is not present skipthis step.

Step 40

Carefully lift out the developer roller.(See Photo 44)

Photo 44 Photo 49


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Photo 51

Step 50

Place the cleaned doctor bar onto the hopper.Install the two screws that hold the blade inplace.(See Photo 53)

Step 51

Apply a small amount of toner to a lint-freecloth. Wipe toner onto the developer roller tohelp prevent dry start. (See Photo 54)

Photo 52

Photo 53


Step 48

Using dry compressed air clean out the tonerhopper.NOTE: Do not damage the toner supply roller.Visually inspect the roller for flat spots. If flatspots are found the feed roller will have to bereplaced.

Step 49

Place the sealing felt washers onto the end ofthe supply roller axle. (See Photo 52)

Step 45

Place the doctor blade onto flat surface or acleaning fixture. (See Photo 50) Clean the doc-tor blade using a lint free cloth and 99%

Alcohol. NOTE: Do not use pressure to cleanthe surface of the doctor blade. Wipe the sur-face of the blade till all the toner build up isremoved from the blade. NOTE: Do not bend

the doctor blade. Visually inspect the doctorblade before reinstalling the blade onto thecartridge.

Photo 50

Step 46

Remove the sealing felt washers from the axleof the toner supply roller.

(See Photo 51)

Step 47

Remove the toner hopper fill plug.

Photo 54

Photo 55

Step 52

Place the developer roller bearinonto the ends of the roller. Plathe developer roller onto the to

hopper.(See Photo 55)

Step 53

Slide the developer roller end conto the gear side of the toner hoper. Install the two screws that hothe end cap in place.(See Photo 56)

Photo 56


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Photo 59

Photo 60

Photo 61

Photo 62

Photo 63



Step 56

Place the gears onto the end of the tonehopper.(See Photo 59)

Step 57

Place the gear assembly end cap onto the eof the hopper. Install the two screws that hothe end cap in place.(See Photo 60)

Rotate the developer roller 5-10 revolutions.

Step 58

Fill the toner hopper with toner. Install the plug. Once the toner hopper is filled, rotate tdeveloper again. Check for toner build between the developer roller and doctor bladIf present, a problem occurred during tcleaning process. Recheck the developer rol

and doctor blade.

Step 59Place the contact end cap onto the hoppeInstall the screw that holds the end cap place. (See Photo 61)

Step 60

Place the waste hopper on the work bench the drum is facing up. Place the toner hoppso it is under the blade on the drum shutt(See Photo 62)

Check the tension spring on the back the hopper it must sit flat against the tonhopper. (See Photo 63)

Photo 57

Photo 58

Step 54

If present in the cartridge, install thetoner charge roller into the whitebearing in the developer roller end

cap. (See Photo 57)

NOTE: Insert the end of the tonercharge roller that is marked on theaxle into the gear end of the hopper.

Step 55

Slide the developer roller end capon the contact side of the hopper.

Make sure the axle of the tonercharge roller fits into the whitebearing in the end cap. Install thetwo silver screws that hold the endcap on.(See Photo 58)


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Photo 64

Photo 65

Photo 66

Step 61

Install the cartridge pins in each side of thecartridge.NOTE: The large pin goes on the gear end ofthe cartridge. (See Photos 64 & 65)

Step 62

Attach the tension spring to the contact side ofthe toner hopper. (See Photo 66)

Photo 67

Step 63

Replace the cartridge chip. (See Photo 67)


Notes


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First occurence of print defect

14 mm

33 mm

38 mm

39 mm

63 mm

75 mm

94 mm

107 mm

Roller Distance Type of Defect Replacement Par

A toner charging roller 14 mm print cartridge

B developing cylinder 33 mm defect on front of paper print cartridge

C primary charging roller 38 mm blank spots print cartridge

D toner feed roller 39 mm print cartridge

E media attaching roller 38 mm defect on front of paper ETB

F fuser pressure roller 63 mm poor fusing fuser

G photosensitive drum or transfer rollers 75 mm Replace any print

(center-to-center distance) cartridges that have a

damaged photosensit

drum. Replace the ET

H photosensitive drum 94 mm defect on front of paper print cartridge

blank spots

J fuser sleeve 107 mm poor spots fuser

Repetitve defect troubleshooting


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In June 2002, HP released the ColorLaserJet 4600 series of printers designedo replace the outdated HP4500 and

HP4550 series printers. Capable of print-ng 17 pages per minute in both full colorand monochrome at a resolution of 600dpi (HP ImageREt 2400) and a first pageout speed of 17.5 seconds, the HP4600out performs the HP4500 in every way.

At a starting price of $2,600, the

HP4600 is priced $400 less than thestarting price of the HP4500 when it waseleased back in October 1998.In order to reach the print performance

ound using the HP4600, HewlettPackard used technology that we havenot seen from them.

A completely new development systemusing contact type developer rollers andoner charge rollers is found in the 4600

cartridges. This development systemesembles more the non-magnetic

contact systems found in Lexmark tonercartridges than the classic Canon/HPumping development used in all of theirprevious printer models.

Four-color registration is done directlyon the print media eliminating thentermediate transfer belt found in earliercolor printers. In preparation for tonerransfer, the paper is attached to an

electrostatic transport belt (ETB) thatcontrols the paper movement sufficientlyo allow for direct to paper 4-coloregistration.

For lower power consumption andaster heat-up times, Canon/Hp hasntroduced an induction coil type fuserassembly in this printer.

The toner cartridges are hinged so thata cam mechanism in the printer candisengage the developer rollers fromhe OPC drums. This allows for a

monochrome-printing mode where onlythe black cartridge developer roller isengaged. All four developers are disen-gaged during ETB cleaning as well asprimary and toner charge roller cleaningoperations. The printer automaticallyinitiates cleaning operations at intervalsof 51, 90 and 140 pages (after the print

job is completed).

The HP4600 uses two active calibra-tion sensors that (left and right) readreflected light from density patchesdeveloped directly on the ETB for adjust-ing print density and halftone quality.Calibration routines occur at variousautomatic intervals. The HP4500 printerused only one calibration sensor.

A wireless rfid type memory chip, likethe chips on the HP4100 are found onthe waste hopper of each toner cartridge.The chips store color type and manufac-

turing information as well as job, pageand other counts. The printer tracksseparately both drum and developerroller rotations, storing these counts inthe cartridge memory chips.

These counts are tracked separatelybecause all of the OPC drums rotatewhenever the ETB is moving but the

developer rollers may not be turninthey are disengaged. Dependingprinting mode these counts can devsignificantly.

Even the toner sensing mechanisthe HP4600 is much more compThe percentage toner remaidisplayed on the Supplies Status Pfor each cartridge comes from possible sources (without any indica

to the user of which).For the first 75% of a toner cartrid

life the value is based on pixel countWhen the level remaining reaches 2the printer switches the source tooptical sensing system. Light is deteafter passing through each toner hop

The two other sources of the perlife remaining value are the OPC dand developer roller cycle costored in the cartridge memory ch

A cartridge may be removed from sebefore the useful amount of toneconsumed because either the drumdeveloper count exceeds preset valu

This is explained in the HP SerManual to prevent waste secoverflow (drum count) or print quproblems due to degradation of the titself or developer roller wear (develocount).

The HP4600 also uses a new all-in-cartridge design. The cartridges are idtical so the remanufacturing procesthe same for all four cartridges, the

difference being the black cartryields 1,000 pages more than the ccartridges.

The black cartridge (C9720A) p9,000 pages at 5% coverage whilecolor cartridges cyan (C9721A), mag(C9723A), and yellow (C9722A) p8,000 pages at 5% coverage.

Future Graphics (FG) is a distributor of compatible replacement parts and products for imagining equipment.

None of FG's products are genuine OEM replacement parts and no affiliation or sponsorship is to be implied between FG and any OEM.

HP Color LaserJet 4600

Documents

HP4600 Toner Dis Assembly