HP4600TECH

Technical Instructions
CORPORATE LOS ANGELES, USA
US 1 800 394.9900 Intl +1 818 837.8100 FAX 1 800 394.9910 Intl +1 818 838.7047

Printers

OEM Info
Part Number: C9720A Yield @ 5%: 9,000pgs Part Number: C9721A Yield @ 5%: 8,000pgs Part Number: C9722A Yield @ 5%: 8,000pgs Part Number: C9723A Yield @ 5%: 8,000pgs Black Cyan Yellow Magenta

Tools
#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

ATLANTA, USA
US 1 877 676.4223 Intl +1 770 516.9488 FAX 1 877 337.7976 Intl +1 770 516.7794

Canon ImageClass C2500 Canon LBP-2510 HP Color LaserJet 4600 HP Color LaserJet 4600 DN HP Color LaserJet 4600 DNT HP Color LaserJet 4600 HDN HP Color LaserJet 4650 HP Color LaserJet 4650 N HP Color LaserJet 4650 DN HP Color LaserJet 4650 DNT HP Color LaserJet 4650 HDN

DALLAS, USA
US 1 877 499.4989 Intl +1 972 840.4989 FAX 1 877 774.1750 Intl +1 972 840.1750

Photo 1

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

MIAMI, USA
US 1 800 595.429 Intl +1 305 594.3396 FAX 1 800 522.8640 Intl +1 305 594.3309

NEW YORK, USA

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

SANFORD,USA
US 1 800 786.9049 Intl +1 919 775.4584 FAX 1 800 786.9049 Intl +1 919 775.4584

Photo 2

Step 2
Locate the square holes located (shown in Photo 2 and Photo 3) on the top left and right sides of the waste hopper.

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

BUENOS AIRES, ARG

ARG 0810 444.2656 Intl +011 4583.5900 FAX +011 4584.3100

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

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

Photo 3

MONTEVIDEO,URY
URY 02 902.7206 Intl +5982 900.8358 FAX +5982 908.3816

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

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2
Photo 4

HP4600 Technical Instructions

Step 3
Using a 1/8 inch drill bit, drill a hole through the square holes on top of the waste hopper. The hole must be drilled at an angle so the drill bit hits the end of the cartridge pin, forcing the pin outward. (See Photo 4) NOTE: If the pins are not pushed out, insert a small flat blade screwdriver into the drilled holes and push the pin out the end of the cartridge. (See Photo #4b)

Photo 4b

Photo 5

Photo 6

Step 4
Flip the cartridge over so the toner hopper is facing up. Using diagonal cutters, remove the cartridge pins from each end of the cartridge. (See Photos 5 & 6)

Notes

Photo 7

Step 5
Using a spring hook, release the tension spring that holds the waste hopper to the toner hopper on the contact side of the cartridge. (See Photo 7)

Photo 8

Step 6
Lift the toner hopper away from the waste hopper. (See Photo 8) Set the toner hopper aside.

Photo 10

Photo 9

Step 7
Using a small Phillips screwdriver, remove the screw that holds the blue cartridge handles on each end of the waste hopper. (See Photos 9 & 10)

HP4600 Technical Instructions

Photo 11

3
Step 8
Remove the blue cartridge handle and the tension spring from the contact side of the waste hopper. (See Photo 11)

Notes

Photo 12

Step 9
Using a spring hook, pull the tines holding the lock washer to the drum axle. (See Photo 12) Pull on each tine one at a time until the washer is removed.

Photo 13

Step 10
Remove the washer from the drum axle. (See Photo 13)

Photo 14

Step 11
Grab the drum drive hub located on the drum axle and pull the axle out from the drum. (See Photo 14) NOTE: It maybe necessary to tap the drum axle out from the contact side of the cartridge. The drum axle bearing may come out when the drum axle is removed from the hopper. If not, remove the drum axle bearing from the contact side of the waste hopper. (See Photo 15)

Photo 15

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Photo 18

HP4600 Technical Instructions

Step 14

Step 12
Carefully lift the drum out from the waste hopper. (See Photo 16)

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

Photo 16

Photo 19

Step 15
Remove the drum shutter from the drum shutter arm. (See Photo 19)

Photo 20

Step 13
Pull the drum shutter bar out of its positioning hole on the contact side of the waste hopper. (See Photo 17)

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 the PCR.

Photo 17

Photo 21

Step 17
Carefully bend back the brown film on the wiper blade to access the screws holding the wiper blade. Remove the two screws using a Phillips screwdriver. (See Photo 21)

Photo 22

Step 18
Lift one end of the wiper blade and pull the blade away from the sealing foam. (See Photo 22)

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HP4600 Technical Instructions

Photo 23

5
Step 19
Dump the waste toner from the hopper. Using a vacuum or dry compressed air, clean out the waste hopper.

Notes

Step 20
Remove the OEM wiper blade sealing foam. (See Photo 23)

Photo 24

Step 21
Clean the waste hopper using a dry lint-free cloth. Apply the wiper blade sealing end foams onto the waste hopper at each end of the waste hopper. (See Photo 24)

Photo 25

Step 22
Apply the wiper blade sealing foam to the waste hopper. (See Photo 25)

Photo 26

Step 23
Apply padding powder to the new wiper blade. Install the blade and the two screws that hold the blade in place. (See Photo 26)

Photo 27

Step 24
Install the cleaned PCR into the hopper. (See Photo 27)

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Photo 30

HP4600 Technical Instructions

Step 27
Install the drum axle bearing, the washer and the lock washer to the drum axle on the contact side of the hopper. (See Photo 30) Rotate the drum 5-10 revolutions. Clean the padding powder off the PCR using a dry lintfree cloth.

Step 25
Apply padding powder to the OPC drum. Place the drum into the waste hopper so the drive hub is on the gear side of the hopper. (See Photo 28)

Photo 31

Step 28
Photo 28

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

Photo 32

Step 29
Install the blue cartridge handle on the contact end of the hopper and install the small screw that holds the handles on each side of the waste hopper. (See Photo 32)

Step 26
Slide the drum axle through the drum, starting on the gear side. (See Photo 29) NOTE: Make sure the bearing on the drive hub side of the drum axle is seated properly in the side of the waste hopper.

Photo 33

Step 30
Install the drum shutter post into the drum shutter arm. Install the drum shutter bar into the alignment holes on each side of the hopper. (See Photo 33)

Photo 29

Photo 34

Step 31
Set the waste hopper aside and cover.

Step 32
Remove the screw holding the contact end cap to the toner hopper. (See Photo 34)

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HP4600 Technical Instructions

Photo 35

7
Step 33
Using a small flat blade screwdriver, release the locking clip that holds the contact end cap to the toner hopper. (See Photo 34) Remove the contact end cap.

Step 37
Release the locking clip that holds toner hopper agitator drive gear to the agitator bar. (See Photo 40) Remove the gear.

Photo 36

Step 34
Remove the two screws that hold the developer roller end cap to the toner hopper. (See Photo 36) Remove the end cap.

Photo 40

Photo 37

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

Step 38
Remove the two screws holding the developer roller end cap to the toner hopper. (See Photo 41) Remove the end cap. NOTE: Do not lose the bearing that sits in the developer roller end cap. (See Photo 42)

Photo 38

Step 35
Rotate the cartridge 180. Remove the two screws holding the gear housing end cap to the toner hopper. (See Photo 38) Remove the gear housing end cap.

Photo 41

Photo 39

Step 36
Remove the five loose gears from the side of the hopper. (See Photo 39)

Photo 42

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Photo 45

HP4600 Technical Instructions

Step 41
Remove the white bushings from the ends of the developer roller. (See Photo 45) Clean the bushings with a dry lint-free cloth and alcohol.

Step 42 Step 39
Grab the toner charge roller by the ends and remove the roller from the hopper. (See Photo 43) Clean the roller using dry compressed air. NOTE: Some Newer cartridges from HP do not have a toner charge roller. If the TCR is not present skip this step.
Photo 46

Install the drive gear end of the developer roller axle into a drill and tighten the chuck. Clean the developer roller using a lint-free cloth and 99% Alcohol while the roller is rotating in the drill. Once the roller is clean, go over the roller again using distilled water and a lint-free cloth. Make several passes. Dry the roller using a dry lint-free cloth. (See Photo 46) NOTE: The surface of the developer roller may change and become wrinkled. If properly cleaned, the developer roller will go back to its original state when finished with the cleaning process.

Photo 43

Photo 47

Step 43
Remove the two screws holding the doctor bar. (See Photo 47)

Step 40
Carefully lift out the developer roller. (See Photo 44)

Photo 48

NOTE: On some of the old HP4600 cartridges the doctor blades are adhered to the developer roller end felts. If so, insert an angled knife behind the ends of the doctor blade and carefully cut the doctor blade free. (See Photo 48)

Photo 44

Photo 49

Step 44
Remove the doctor blade from the toner hopper. (See Photo 49) Clean the doctor blade using dry compressed air.

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HP4600 Technical Instructions

Photo 50

9
Step 45
Place the doctor blade onto flat surface or a cleaning fixture. (See Photo 50) Clean the doctor blade using a lint free cloth and 99% Alcohol. NOTE: Do not use pressure to clean the surface of the doctor blade. Wipe the surface of the blade till all the toner build up is removed from the blade. NOTE: Do not bend the doctor blade. Visually inspect the doctor blade before reinstalling the blade onto the cartridge.

Step 52
Place the developer roller bearings onto the ends of the roller. Place the developer roller onto the toner hopper. (See Photo 55)

Photo 51

Step 46
Remove the sealing felt washers from the axle of the toner supply roller. (See Photo 51)

Photo 55

Step 47
Remove the toner hopper fill plug.

Photo 52

Step 48
Using dry compressed air clean out the hopper. NOTE: Do not damage the toner supply Visually inspect the roller for flat spots. spots are found the feed roller will have replaced. toner roller. If flat to be

Step 53
Slide the developer roller end cap onto the gear side of the toner hopper. Install the two screws that hold the end cap in place. (See Photo 56)

Step 49
Place the sealing felt washers onto the end of the supply roller axle. (See Photo 52)

Photo 53

Photo 56

Step 50
Place the cleaned doctor bar onto the hopper. Install the two screws that hold the blade in place. (See Photo 53)

Photo 54

Step 51
Apply a small amount of toner to a lint-free cloth. Wipe toner onto the developer roller to help prevent dry start. (See Photo 54)

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Photo 59

HP4600 Technical Instructions

Step 56

Step 54
If present in the cartridge, install the toner charge roller into the white bearing in the developer roller end cap. (See Photo 57) NOTE: Insert the end of the toner charge roller that is marked on the axle into the gear end of the hopper.

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

Photo 60

Step 57
Place the gear assembly end cap onto the end of the hopper. Install the two screws that hold the end cap in place. (See Photo 60) Rotate the developer roller 5-10 revolutions.

Photo 57

Photo 61

Step 58
Fill the toner hopper with toner. Install the fill plug. Once the toner hopper is filled, rotate the developer again. Check for toner build up between the developer roller and doctor blade. If present, a problem occurred during the cleaning process. Recheck the developer roller and doctor blade.

Step 55
Slide the developer roller end cap on the contact side of the hopper. Make sure the axle of the toner charge roller fits into the white bearing in the end cap. Install the two silver screws that hold the end cap on. (See Photo 58)

Step 59
Photo 62

Place the contact end cap onto the hopper. Install the screw that holds the end cap in place. (See Photo 61)

Step 60
Place the waste hopper on the work bench so the drum is facing up. Place the toner hopper so it is under the blade on the drum shutter. (See Photo 62)

Photo 58

Photo 63

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

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HP4600 Technical Instructions

11

Photo 64

Step 61
Install the cartridge pins in each side of the cartridge. NOTE: The large pin goes on the gear end of the cartridge. (See Photos 64 & 65)

Notes

Photo 65

Photo 66

Step 62
Attach the tension spring to the contact side of the toner hopper. (See Photo 66)

Photo 67

Step 63
Replace the cartridge chip. (See Photo 67)

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HP4600 Technical Instructions

Repetitve defect troubleshooting

First occurence of print defect 14 mm 33 mm 38 mm

39 mm

63 mm 75 mm 94 mm 107 mm

Roller
A toner charging roller B developing cylinder C primary charging roller D toner feed roller E media attaching roller F fuser pressure roller G photosensitive drum or transfer rollers (center-to-center distance)

Distance
14 mm 33 mm 38 mm 39 mm 38 mm 63 mm 75 mm

Type of Defect
defect on front of paper blank spots defect on front of paper poor fusing

Replacement Part
print cartridge print cartridge print cartridge print cartridge ETB fuser Replace any print cartridges that have a damaged photosensitive drum. Replace the ETB. print cartridge fuser

H photosensitive drum J fuser sleeve

94 mm 107 mm

defect on front of paper blank spots poor spots

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HP Color LaserJet 4600

In June 2002, HP released the Color LaserJet 4600 series of printers designed to replace the outdated HP4500 and HP4550 series printers. Capable of printing 17 pages per minute in both full color and monochrome at a resolution of 600 dpi (HP ImageREt 2400) and a first page out speed of 17.5 seconds, the HP4600 out performs the HP4500 in every way. At a starting price of $2,600, the HP4600 is priced $400 less than the starting price of the HP4500 when it was released back in October 1998. In order to reach the print performance found using the HP4600, Hewlett Packard used technology that we have not seen from them. A completely new development system using contact type developer rollers and toner charge rollers is found in the 4600 cartridges. This development system resembles more the non-magnetic contact systems found in Lexmark toner cartridges than the classic Canon/HP jumping development used in all of their previous printer models. Four-color registration is done directly on the print media eliminating the intermediate transfer belt found in earlier color printers. In preparation for toner transfer, the paper is attached to an electrostatic transport belt (ETB) that controls the paper movement sufficiently to allow for direct to paper 4-color registration. For lower power consumption and faster heat-up times, Canon/Hp has introduced an induction coil type fuser assembly in this printer. The toner cartridges are hinged so that a cam mechanism in the printer can disengage the developer rollers from the OPC drums. This allows for a developer rollers may not be turning if they are disengaged. Depending on printing mode these counts can deviate significantly. Even the toner sensing mechanism in the HP4600 is much more complex. The percentage toner remaining displayed on the Supplies Status Page for each cartridge comes from four possible sources (without any indication to the user of which). For the first 75% of a toner cartridges life the value is based on pixel counting. When the level remaining reaches 25% the printer switches the source to the optical sensing system. Light is detected after passing through each toner hopper. The two other sources of the percent life remaining value are the OPC drum and developer roller cycle counts stored in the cartridge memory chips. A cartridge may be removed from service before the useful amount of toner is consumed because either the drum or developer count exceeds preset values. This is explained in the HP Service Manual to prevent waste section overflow (drum count) or print quality problems due to degradation of the toner itself or developer roller wear (developer count). The HP4600 also uses a new all-in-one cartridge design. The cartridges are identical so the remanufacturing process is the same for all four cartridges, the only difference being the black cartridge yields 1,000 pages more than the color cartridges. The black cartridge (C9720A) prints 9,000 pages at 5% coverage while the color cartridges cyan (C9721A), magenta (C9723A), and yellow (C9722A) print 8,000 pages at 5% coverage.

monochrome-printing mode where only the black cartridge developer roller is engaged. All four developers are disengaged during ETB cleaning as well as primary and toner charge roller cleaning operations. The printer automatically initiates cleaning operations at intervals of 51, 90 and 140 pages (after the print job is completed). The HP4600 uses two active calibration sensors that (left and right) read reflected light from density patches developed directly on the ETB for adjusting print density and halftone quality. Calibration routines occur at various automatic intervals. The HP4500 printer used only one calibration sensor. A wireless rfid type memory chip, like the chips on the HP4100 are found on the waste hopper of each toner cartridge. The chips store color type and manufacturing information as well as job, page and other counts. The printer tracks separately both drum and developer roller rotations, storing these counts in the cartridge memory chips. These counts are tracked separately because all of the OPC drums rotate whenever the ETB is moving but the

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