Step 7Using the provided .136 (#29) drill bit, drilla hole through the contact end cap.(See Photo 10)
Step 8Remove the Drill Guide.
Step 6Place the Side Plate Drill Guide onto thebottom of the toner hopper. The SidePlate Drill Guide has three alignment pins.(See Photo 8) The large alignment pin fitsinto the square notch on the bottom of thecontact end cap, the smaller alignmentpin located next to the large pin fits justover the first supporting rib next to theend cap. The last alignment pin will fit overthe fourth supporting rib. (See Photo 9)
Step 9Remove the 2 screws holding the cartridge contact end cap to the cartridge.
(See Photo 11)
Photo 12Step 10Place a small flat blade screwdriver at thebase of the three plastic welds that holdthe end cap to the toner hopper. Pry up onthe screwdriver to break the welds.
(See Photo 12)
Step 4Open the drum shutter, expos-ing the drum. The drum shutterbar is keyed on the non-contactside of the cartridge. Slide theshutter bar back until the barcan be removed from the car-tridge end cap. (See Photo 6)
Step 5Pull the drum shutter bar fromthe cartridge contact end cap.(See Photo 7) Set the drum shutter aside.
Step 15Remove the screw holding the drum axle. (See Photo 17) Remove the axle.
Photo 17
Photo 18Photo 14
Photo 15
Step 14While holding the opposite end of the car-tridge, remove the gear assembly end capfrom the cartridge. (See Photo 16)Separate the two sections and set thetoner hopper aside.
Step 12Using diagonal cutters cut the 3 plasticwelds flush with the contact end cap. (See Photo 14)
Step 13Rotate the cartridge 180°. Remove the 4screws holding the gear housing end cap.(See Photo 15)
HP4200 Technical Instructions 3
Step 11Insert a flat blade screwdriver between thetoner hopper and the contact end cap,next to the plastic welds that hold the endcap to the toner hopper. Carefully pry theend cap away from the toner hopper. (See Photo 13) Remove the end cap.
Photo 13
Step 16Lift the drum by the small gearand pull the drum from thebearing hub. (See Photo 18)
Step 17Remove the PCR from the PCR saddles.(See Photo 19)NOTE: If you are going to reuse the PCRclean the roller using a lint free cloth andDI water.
Step 18In order to remove the wiper blade, pullthe OEM sealing foam material away fromthe wiper blade. (See Photo 20)NOTE: The OEM sealing foam material issticky and is not easily removed.
Step 19NOTE: This step is only for the HP4300.Using a Dremel with a cutting bit cut awaythe retaining wall that prevents the wiperblade from being removed. (See Photo 21)
Step 20Remove the 2 screws holding the wiperblade. (See Photo 22) Remove the blade.
Step 21Dump the waste toner from the hopper.Clean the hopper using dry compressedair or a vacuum.
Step 22Apply padding powder to the new wiperblade and place the blade onto the wastehopper. Install the 2 screws that hold theblade in place. (See Photo 23)
Step 27Install the contact end plate. (See Photo 28) NOTE: Make sure the contact plate sitsflush with the end of the waste hopper.
Photo 28
Photo 24Step 23To seal the area around the wiper blade usean expanding foam with an adjustablebead. Apply the foam along the edge of theblade and in the square holes on the ends.(See Photo 24)
Photo 25Step 24Clean the PCR saddles using a swab andalcohol. (See Photo 25)
Step 25Apply new conductive grease to the blackcontact saddle. Install the cleaned PCR.(See Photo 26)
Step 26Apply high temperature grease to thebearing hub before installing the drum.Apply padding powder to the drum. Slide the drive gear into the bearing hub. (See Photo 27)
Photo 34Step 34Pull the mag roller end plate from the tonerhopper. (See Photo 34)
NOTE: Do not lose the bearing that sitsinside the mag roller end plate. (See Photo 35)
Photo 35
Step 35Lift the free end of the mag roller, slide theroller out of the mag roller end plate on theopposite side of the toner hopper. (SeePhoto 36)
NOTE: Do not lose the bearing that sitsinside the mag roller end plate. (See Photo 37)
Step 36Remove the mag roller bearings from theeach end of the roller. (See Photo 38)Clean the mag roller using dry com-pressed air or a vacuum, then using a lintfree cloth and a mag roller cleaner. Cleanthe mag roller bearings using alcohol anda lint free cloth.
Step 38 Lift the plastic scrapers and mylar shimsoff each end of the doctor blade. (See Photo 40)
Step 37Remove the 2 screws holding the doc-tor blade. (See Photo 39)
Step 39Lift the doctor blade from the tonerhopper. (See Photo 41) If you plan onusing the doctor blade again, clean thedoctor blade using dry compressed airor a vacuum, then using a lint free clothand alcohol.
Step 40Dump the old toner out of the tonerhopper. Using dry compressed air or avacuum, clean out the hopper.
Step 41Fill the toner hopper with the correctamount of toner depending on the car-tridge type you are building.
Step 42Place the new or cleaned doctor bladeonto the toner hopper. Place the mylarshims and the plastic scrapers on eachend of the doctor blade. Install the 2 screws holding the blade in place. (See Photo 42)
Step 43Slide the black mag roller bearing ontothe contact end and the white bearingonto the drive gear end of the magroller. Slide the mag roller contact hubinto the mag roller bearing plate on thetoner hopper. (See Photo 43)
Photo 44Step 44Align the mag roller bearing end plate tothe toner hopper and slide the end plateonto the toner hopper. (See Photo 44)
Photo 45Step 45Install the mag roller tension spring andthe screw into the mag roller bearing endplate. (See Photo 45)
Step 46Install the hinge pin into the mag rollerbearing end plate. (See Photo 46)
Step 47Slide the mag roller drive gear onto themag roller. (See Photo 47) NOTE: Makesure the two injection molding points onthe mag roller drive gear face outward.(See Photo 48)
HP4200 Technical Instructions 9
Step 48Place the mag roller drive gearhousing onto the end of themag roller, making sure thekeyed end of the magnet fitsinto the gear housing. (See Photo 49)
Step 49 Using a 3/32-drill bit, drill a holenext to the toner sensing con-tact on the cartridge contactend cap as shown in photo 50.
Step 52Insert the HP4200PIN into the drilled holein the bottom of the contact end cap. (SeePhoto 53)
Photo 51
Photo 52
Photo 53
Step 50Join the toner hopper and wastehopper together. Place the car-tridge gear housing end caponto the side of the cartridge.Install the 4 screws that hold theend cap in place. (See Photo 51)
Step 51Place the contact end cap ontothe end of the cartridge. Installthe 2 screws that hold the endcap in place. (See Photo 52)
Photo 55
Photo 56
Photo 54Step 53Install the keyed end of the drum shutterbar into the gear housing end cap. (See Photo 54)
Step 54Install the non-keyed end of the drumshutter bar into the contact end cap. (See Photo 55)
Step 55Slide the drum shutter arm onto the positioning post. Push the drum shutterarm into the drum shutter. (See Photo 56) Slide open the drum shutter to engage thetension spring.
Photo 57
Step 56Place one probe of an Ohmmeter on thetoner sensor contact and place the otherprobe into the hole that was drilled next tothe contact. (See Photo 57) Locate thesensor bar that comes out from the tonerhopper through the hole drilled in the endcap, making sure you have a low resist-ance connection. (See Photo 58)
NOTE: If contact is not made between thesensor bar and the contact on the endplate this will result in an error “54.1Remove Sealing Tape” or if contact is lostduring usage a premature toner low canoccur.
Hewlett Packard’s LaserJet 4200and the LaserJet 4300 series of print-ers were first released in November2002. They were designed to replacethe now discontinued HP4100 printer.Based on a new print engine, the4200 and 4300 have increased printspeeds of 35 ppm for the 4200 and45 ppm for the 4300 with animproved first page out time of lessthan 9 seconds. At a starting cost ofabout $1,000 for the base model4200 and $1,399 for the base model4300, these new printers are priced atthe same cost as the HP4100.
Differences in the molding of car-tridges prevent them from beinginterchangeable. One notable differ-ence is in the design of the toner hop-per. The toner hopper on the HP4300is larger and holds 1050 grams oftoner for an estimated yield of 18,000pages @ 5% coverage. The smallertoner hopper on the HP4200 holdsonly 690 grams of toner and yields12,000 pages @ 5% coverage.Another notable difference is in the
waste section. The waste hopper ofthe HP4300 is larger to hold the extrawaste produced by the higher fillweight. The HP4200 waste hopperalso has a fin sticking up on the leftside of the hopper that prevents thecartridge from fitting into the HP4300printer.
Because the 4200 and the 4300 usethe same engine, the componentsthat make up the cartridges are thesame. The cartridge chips located onthe top right side of the waste hopperhowever, are in fact different. A slightdifference in programming preventsone chip from being used on bothcartridges, so it's important to usethe correct chip when remanufactur-ing the cartridge. Though the chip isphysically different than that of theHP4100, the information the chipstores is almost the same. A fewadditional items like First InstalledDate and Last Date Used are nowstored in the chips. This informationis displayed at the bottom of the
Supplies Status Page. Like theHP4100, the 4200 and 4300 can berun with a spent chip or with no chipinstalled at all.
Our testing shows that the chip canbe run again in the printer it was usedin originally. Running the used chipcauses a “Replace Cartridge” mes-sage and the loss of the toner lowwarning. Usage of the chip in amachine other than the one it waspreviously run in will result in a “NonHP Cartridge Detected” message andthe loss of all the information on theSupplies Status Page.
Running the cartridge without thechip will result in a “10.10.00 SuppliesMemory Error” when the cartridge isfirst installed. After pressing theSelect button a “Non HP CartridgeDetected” message will appearbefore the machine goes to ready. Allthe information stored in the chip willnot be available and a “Warning”message is all you will find on theSupplies Status Page.
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