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1 LICENSE AGREEMENT Static Control Components, Inc. (Static Control) grants this limited license to the person, firm or corporation (hereinafter "User) downloading electronically or by printing this file to use Static Control s copyrighted documents in accordance with the terms of this agreement. If you agree with the terms of the license then you may download this information. If you do not agree with the terms of the license, then you are not authorized to use this information, and any use of it may be in violation of Static Control s copyrights or trademarks. TRADEMARKS The Static Control material herein may make reference to its own trademarks, or trademarks of others. Static Control grants a limited license to the User to use Static Control s trademarks in its internal documents and for its internal purposes on the following terms and conditions. Any use of Static Control s trademark must be used in a context which makes it clear that the product reference is a Static Control Components, Inc. product, and not a product from any source. The materials provided to the User may include reference to trademarks of others. Any use of the User makes of these marks should reference the owner of those marks. Nothing in this agreement constitutes any authorization by Static Control to use any of these trademarks in any context. COPYRIGHTS Static Control grants a limited license to the User to use the attached copyrighted documents. The permitted use of these documents is limited to internal purposes and needs of the company. The company is prohibited from using these copyrighted documents, or any part of them, including graphic elements, in any materials that are used outside the physical business location of the User. The User is prohibited from using any materials in any documents whether printed or electronic, which are distributed to any third party. The use of these copyrighted documents, or parts of them, including graphic elements, from these documents in marketing material, either print, electronic or web is prohibited. The sale, transfer, copying of these documents or any parts of these documents to any other party is prohibited. Static Control Components, Inc. retains all rights to its copyrighted documents, and any use of these documents by User should reference Static Control s copyrights, with the notice "copyright Static Control Components, Inc." Static Control reserves the right to cancel this license on 30-days written notice. All of the User s material incorporating Static Control s copyrighted documents shall be destroyed upon receipt of its notice of termination. The User may not distribute, share, and otherwise convey the copyrighted documents to any other persons, corporations or individuals. The User, by use of these documents, acknowledges Static Control s copyright in these materials. STATIC CONTROL DOES NOT GUARANTEE OR WARRANT DOWNLOADED INFORMATION The information User is downloading is published by Static Control in "as is" condition "with all faults". Static Control makes no representations or warranties of any kind concerning the quality, safety, or suitability of the downloadable materials, either express or implied, including without limitation any implied warranties of merchantability, fitness for a particular purpose, or non-infringement. Further, Static Control makes no representations or warranties as to the truth, accuracy or completeness of any statements, information or materials concerning items available for download. In no event will Static Control be liable for any indirect, punitive, special, incidental, or consequential damages however they may arise even if Static Control has been previously advised of the possibility of such damages.

2 Hewlett Packard LaserJet 8500 (HP8500) Remanufacturing Instructions Cartridge Reference System Support Series 299 About the Printer Released in October 1998, the Hewlett- Packard Color LaserJet 8500 was positioned as a high-performance, high-volume printer targeted at the corporate department. The 8500 offered a number of additional features not found on the HP4500, which was released the same month. Additional features included faster print speeds, a hard disk drive support, 11" x 17" paper size capability, and more robust paper input and output capabilities. At the time of its introduction, the Canon engine in the 8500 was one of the fastest on the market with a color print speed of 6 ppm and a monochrome speed of 24 ppm. In April 2000, Hewlett-Packard introduced the 8550 as an upgrade model featuring a faster processor and a suggested list price reduction of approximately $2000. The 8550 product line is comprised of the base-level 8550 model, two enhanced versions, the 8550 DN and GN, and an 8550 MFD version featuring a scanner to provide digital copier functionality. The 8500 and 8550 feature chemically-manufactured color toners, an oil-less fuser design, and a rotating carousel color cartridge mechanism. Both the 8500/8550 use a conventionallymanufactured magnetic, monocomponent black toner. Although very similar in many ways to the HP4500, the 8500 and 8550 use a transfer drum rather than an intermediate transfer belt. The supplies set for the HP8500 and 8550 consists of seven consumables: four toner cartridges, an image drum, a transfer drum, and a fuser assembly. Engine Information Engine Name Canon EP-82 Date of U.S. Printer Introduction HP October Canon C May HP April 2000 Print Speed (pages per minute) ppm color, 24 ppm monochrome Duty Cycle ,000 pages per month Print Resolution (dpi) x 600 dpi Supplies Information Item OEM Part # Yield List Street HP Canon Black Toner* C4149A R K $ $94.00 Cyan Toner* C4150A R K $ $ Magenta Toner* C4152A R K $ $ Yellow Toner* C4151A R K $ $ Drum Unit* C4153A N/A 12.5K $ $ Fuser Assembly* C4155A (110V) N/A 100K $ $ Transfer Kit C4154A N/A 75K $ $ *Prices as of June 2001 Table of Contents Introduction Tools & Supplies You Will Need..2 Use of Compressed Air Drum Unit Black Toner Unit Color Toner Unit Disassembly Black Toner Hopper Section Reassembly of the Black Toner Hopper Section Disassembly Color Toner Hopper Section Reassembly of the Color Toner Hopper Section Disassembly of the Drum Section Reassembly of the Drum Section Get the latest information on the web at Static Control s Hewlett-Packard LaserJet 8500 Online Engine Center at System Support Series documents are available on our Web site in Adobe Acrobat format. If you need additional information or technical assistance, please contact your Regional Support Team (USA) (Int l) +44 (0) (UK) info@scc-inc.com (US ) info@scceurope.co.uk (UK ) Model Compatibility Hewlett Packard Color LaserJet 8500, 8500 N, 8500 DN Hewlett Packard Color LaserJet 8550, 8550 N, 8550 DN, 8550 GN, 8550 MFP Canon imageclass C2100, C2100 PD, C2100 CS

3 Use of Compressed Air As of April 28, 1971, the Occupational Safety & Health Administration (OSHA) Standard, 29 CFR paragraphs a & b for general industry requires effective chip guarding and personal protective equipment (PPE) when using compressed air. When cleaning residual toner particles from cartridges using a compressed air system, you must use air nozzles meeting OSHA requirements. Air nozzles that regulate air pressure to a maximum of 30 psi comply with this standard. Refer to the OSHA publication for any updates or changes that have occurred since the date noted above. Use of Isopropyl Alcohol For best results, we recommend using ONLY 91-99% isopropyl alcohol for cleaning as directed in these instructions. 91% Isopropyl alcohol is available at most major drug stores; 99% Isopropyl alcohol is available through distributors of chemical products. Follow the alcohol manufacturer's safety instructions. Tools and Supplies You Will Need For Basic Remanufacturing: Small-Tipped Flat-blade Screwdriver Needlenose Pliers Snap Ring Pliers (removal tool) Phillips Screwdriver Funnel for Toner Bottle Compressed Air for Cleaning (See above) 91-99% Isopropyl Alcohol (See above) Lint-Free Foam Tip Swab LFSWAB Lint-Free Cleaning Cloth LFCCLOTH Cotton Swab QTIP Conductive Cartridge Lubricant CONCLUBE Kynar Lubricating Powder KPOW Shallow Trough for Dipping the Wiper Blade SCC Hook Tool HTOOL Industrial Adhesive CSS-47 page 2

4 HEWLETT-PACKARD COLOR LASERJET 8500 DRUM UNIT Drum Protector Cover Hub Axle Bushing PCR Static Discharge Brush PCR Cover Assembly OPC Drum Endplate Brush Actuator Arm Brush Support Compression Spring Drum Wiper Felt End Foam PCR Wiper Blade Waste Bin Section Endplate Tension Spring Auger Drive Wheels Drive Gear Train Recovery Blade Assembly Recovery Blade Sealing Foam Drum Toner Remover Roller page 3

5 HEWLETT PACKARD LASERJET 8500 BLACK TONER CARTRIDGE Bearing Bearing Air Gap Bushing Mag Roller Air Gap Bushing End Plate Support Housing Toner Hopper Actuator Arm Doctor Blade Mag Roller Sealing Blade Mag Roller End Felt Mag Roller Assembly Doctor Blade End Foam Doctor Blade Sealing Foam page 4

6 HEWLETT-PACKARD COLOR LASERJET 8500 COLOR TONER UNIT HP8500, Remanufacturing Instructions Electrical Contact Snap Ring Drive Gear Bearing Bushing Developer Roller Bushing Bearing End Plate Developer Roller Sealing Blade End Support Plate End Plate Cover Toner Adder Roller Actuator Spring Support Arm Hopper Cap Roller Assembly Contact Spring End Foam Main Drive Train Top Plate Doctor Blade Base Plate Developer Roller End Felt Doctor Blade Sealing Foam (Forward) Doctor Blade Sealing Foam (Rear) page 5

7 Disassembly of the Black Toner Unit 1. Use a small screwdriver to depress the locking clip (FIG 1) and then slide out the mag roller shutter support bracket (FIG 2). Be careful not to break the locking clip. 3. Rotate the drum shutter down (FIG 4) and pull the shutter free from the drum shutter actuator arm (FIG 5). Depress Locking Clip FIG 1 FIG 4 Support Bracket Drum Actuator Arm FIG 2 FIG 5 2. On the opposite end of the shutter pull the shutter support bar loose from the cartridge (FIG 3). 4. Remove the four screws that secure the mag roller end plate (FIG 6). Remove the end plate. Pull Support Bar Loose End Plate FIG 3 FIG 6 page 6. SSS 299.

8 5. Remove the mag roller and mag roller bearings (FIG 7). 7. Dump the remaining toner and clean the cartridge with dry, filtered, compressed air (FIG 9). Mag Roller Bearings FIG 7 6. Remove the two screws that secure the doctor blade (FIG 8). Remove the doctor blade. 8. Inspect the end felts and sealing blade and replace as needed (FIG 10). FIG 9 Sealing Blade Doctor Blade End Felts FIG 8 FIG 10 Reassembly of the Black Toner Unit 1. Install a new doctor blade and secure with the two screws (FIG 11). 2. Fill the hopper with toner through the toner port (FIG 12). Toner Port Doctor Blade FIG 12 FIG 11 For further sealing instructions, refer to System Support Series SSS 300 HP8500 Sealing Instructions. page 7. SSS 299.

9 3. Replace the mag roller, making sure the slots on the end of the mag roller line up with the slots inside the mag roller drive gear (FIG 13). 5. Secure the mag roller end plate with the four screws (FIG 16). Mag Roller Drive Gear End Plate FIG 13 Slots FIG Holding the mag roller shutter in the position shown, slide the shutter into the shutter actuator arm (FIG 17). 4. Replace the mag roller end cap, making sure the key on the end of the magnet (FIG 14) lines up with the slot inside the end plate (FIG 15). Key Actuator Arm Mag Roller FIG 17 FIG Rotate the shutter over the mag roller (FIG 18) and place the left end of the shutter support bar in corresponding hole on the end of the cartridge (FIG 19). Key FIG 15 FIG 18 page 8. SSS 299.

10 8. Replace the shutter support housing, making sure the right end of the shutter support bar fits in the corresponding hole in the support housing (FIG 20). Support Bar FIG 19 Support Housing FIG 20 Disassembly of the Color Toner Unit 1. Remove the two screws on each endplate and carefully remove both of the endplates (FIG 21 & 22). 2. Remove the two large gears in the main drive train from the right side of the cartridge (FIG 23). Large Gears Light Posts FIG 23 Right Side FIG 21 NOTE: Make sure not to break or damage the light posts, if broken the cartridge will not work. 3. Use a hook tool (HTOOL) to pull the spring arm back in order to release the spring (FIG 24 & 25). Left Side FIG 22 Spring Arm FIG 24 page 9. SSS 299.

11 Hook Tool 6. Using a flat-blade screwdriver, pry the electrical contact from the gear (FIG 28). Electrical Contact FIG 25 FIG Remove the shutter support arm (FIG 26). 7. Using snap ring pliers, remove the snap ring from the gear (FIG 29). Support Arm Snap Ring FIG 26 FIG Pull shutter arms free from each side of the cartridge (FIG 27). 8. Remove the two gears from the cartridge (FIG 30). Arm Gears FIG 27 FIG 30 page 10. SSS 299.

12 9. Using a Phillips screwdriver, remove the two screws from the cartridge and remove the inner endplate (FIG 31). Make sure when removing the endplate not to lose or damage the contact spring on the roller assembly (FIG 32). FIG 31 Spring Arm Tension Spring FIG 35 NOTE: When removing the endplate make sure not to lose or damage the spring, the arm, or the tension spring underneath the arm. 13. When removing the support plate take care not to damage the electrical contact which is attached to the plate (FIG 36). Contact Spring FIG Remove the developer roller from the cartridge (FIG 33). Electical Contact FIG 36 Developer Roller 11. Remove the developer roller bushings and bearings (FIG 34). Bearings FIG Using a Phillips screwdriver, remove the three (black) screws from the roller assembly and remove the assembly. Then, remove the two (silver) screws from the top plate and remove the top plate (FIG 37). Notice the difference in the left and right silver screws with washer (FIG 38). Bushings FIG Using a Phillips screwdriver, remove the two screws from the cartridge and remove the support plate (FIG 35). Left Side Right Side FIG 37 Washer FIG 38 page 11. SSS 299.

13 15. Remove the doctor blade and the base plate (FIG 39). NOTE: Use caution removing the OEM hopper cap so as not to damage the vent material. 17. Clean the cartridge with dry, filtered, compressed air (FIG 41). Doctor Blade Base Plate FIG Remove the hopper cap and dump the remaining toner (FIG 40). FIG 41 Hopper Cap FIG 40 Reassembly of the Color Toner Unit For further sealing instructions, refer to System Support Series SSS 430 HP8500 Adhesive ProSeal Sealing Instructions. 1. Fill the cartridge with toner. Replace the hopper cap (FIG 42). 2. Install the base plate and the doctor blade (FIG 43). Make sure to they are centered on the cartridge. Hopper Cap Doctor Blade Base Plate FIG 43 FIG 42 page 12. SSS 299.

14 3. Install the top plate. Using a Phillips screwdriver, secure with the two (silver) screws on the top plate (FIG 44). Notice the difference in the left and right silver screws with washer (FIG 45). Install the assembly. Secure the three (black) screws on the top plate (FIG 44). 6. Replace the developer roller bushings and bearings (FIG 48). Bearings Bushings 7. Replace the developer roller (FIG 49). FIG 48 Left Side Right Side FIG 44 Washer FIG Replace the support plate and secure with the two screws (FIG 46). Developer Roller FIG Replace the inner endplate and secure with the two screws (FIG 50). Make sure when replacing the endplate to replace the contact spring on the roller assembly as shown (FIG 51). Spring Arm Tension Spring 5. Make sure the electrical contacts are in the correct position. The contact should slide under the two clips as shown (FIG 47). FIG 46 NOTE: When replacing the endplate make sure not to lose or damage the spring, the arm, or the tension spring underneath the arm. Contact Spring FIG 51 Gears NOTE: If the shutter gears are not replaced correctly (as shown above), the shutter will not close properly and can cause printer problems. FIG Replace the two gears as shown (FIG 52). Two Clips Electical Contact Gears FIG 47 NOTE: Make sure the end of the contact does not get positioned behind the DRS blade. FIG 52 page 13. SSS 299.

15 10. Using snap ring pliers, replace the snap ring to the gear (FIG 53). 13. Replace the shutter support arm (FIG 56). Snap Ring Support Arm FIG 53 FIG 56 NOTE: Gear must be put in correctly in order for the snap ring to be replaced. 11. Replace the electrical contact (FIG 54). 14. Replace the spring arm using a hook tool (HTOOL) as shown (FIG 57 & 58). Hook Tool Electrical Contact FIG 57 FIG Place the shutter arms back into the sides of the cartridge (FIG 55). Spring Arm Arm FIG 58 NOTE: Check the shutter gears (FIG 50) are working properly. FIG 55 page 14. SSS 299.

16 15. Replace the large gears in the main drive train (FIG 59). 16. Replace the endplates on each side of the cartridge and secure with two screws (FIG 60 & 61). Large Gears Light Posts FIG 59 NOTE: Make sure not to break or damage the light posts, if broken the cartridge will not work. Light Posts FIG 60 Disassembly of the Drum Unit FIG Remove the four screws on the endplate and remove the endplate (FIG 62). 2. Remove the three Auger drive gears (FIG 63). FIG 62 Auger Drive Wheels FIG 63 page 15. SSS 299.

17 3. Remove the four screws from the other endplate and remove the endplate (FIG 64). 6. Remove the gears of the drive gear train. Remove the brush actuator arm (FIG 67). Brush Actuator Arm Drive Gear Train FIG 64 FIG Remove the hub axle bushing (FIG 65). 7. Remove the PCR (FIG 68). Hub Axle Bushing PCR FIG 68 FIG Remove the OPC drum (FIG 66). 8. Using a Phillips screwdriver, remove the two screws from the PCR cover assembly and remove the assembly (FIG 69). OPC Drum FIG 66 PCR Cover Assembly FIG 69 page 16. SSS 299.

18 9. Remove the brush actuator arm, PCR static discharge brush, compression spring and brush support bearing (FIG 70). 12. Dump out residual toner and clean with dry, filtered, compressed air (FIG 73). Brush Actuator Arm PCR Static Discharge Brush Compression Spring and Brush Support Bearing FIG Using a Phillips screwdriver, remove the two machine screws on the wiper blade and then remove the wiper blade (FIG 71). Mark the cartridge around the wiper blade to ensure proper replacement. FIG Using a flat-blade screwdriver, loosen the top starting at one corner of the cartridge and running the screwdriver around the seam of the cartridge top (FIG 74). FIG Remove the plastic shims on both sides of the cartridge (FIG 72). FIG Using a Phillips screwdriver, remove the two screws and remove the inner grid of the drum section (FIG 75). Make sure not to misplace the toner level wiper. Toner Level Wiper Plastic Shim FIG 75 FIG Clean with dry, filtered, compressed air (FIG 76). NOTE SCC recommends removing the top of the cartridge to fully clean. An optional method is to shake and blow out the cartridge through the auger drive wheels side. However, toner dusting on the drum and cartridge may occur during shipment. In addition, the agitators inside of the drum section may come loose and would not be able to be fixed without removing the top. If top is not removed 25-35g of toner may remain in the cartridge. FIG 76 page 17. SSS 299.

19 16. Replace the inner grid and secure with two screws using a Phillips screwdriver (FIG 77). Replace the toner level wiper as shown. 18. Apply a thin, even bead of industrial adhesive (CSS-47) around the entire seam of the cartridge (FIG 79). Toner Level Wiper FIG 77 FIG Replace all gears on each side of the cartridge. Make sure that agitator gears are connected to the agitators. The agitators can come loose in the remanufacturing process (FIG 78). 19. Press firmly around the seam. Allow the adhesive to set for 2 hours before handling (FIG 80). FIG 80 FIG 78 Reassembly of the Drum Unit NOTE After removing the top, make sure to remove excess adhesive. This takes an additional 10 minutes. 1. Replace the plastic shims on both sides of the cartridge (FIG 81). 2. Replace the wiper blade, lining up the blade to the markings for accurate placement and secure with the two machine screws (FIG 82). Plastic Shim FIG 82 FIG 81 page 18. SSS 299.

20 3. Replace the brush actuator arm, PCR static discharge brush, compression spring and brush support bearing (FIG 83). 8. Replace the hub axle bushing. Make sure that slot in the bushing aligns with the notch on the cartridge (FIG 87). Brush Actuator Arm PCR Static Discharge Brush Compression Spring and Brush Support Bearing Hub Axle Bushing Notch FIG 87 FIG Replace the PCR cover assembly and secure with the two screws (FIG 84). 9. Replace the endplate and secure with the four screws (FIG 88). PCR Cover Assembly 6. Replace the PCR (FIG 85). FIG Replace the other endplate and secure with the three screws (FIG 89). FIG 88 PCR FIG Replace the OPC drum (FIG 86). FIG 89 NOTE: Make sure the brush support has been properly aligned when replacing the endcap. OPC Drum FIG 86 page 19. SSS 299.

21 Technology and Support You Can Rely On! We realize that the success of your business directly affects the success of Static Control. It s no longer a matter of keeping up with your competition, but surpassing them. That is why we invest so much time and effort in the technology necessary for your business to address new market opportunities quickly, and with confidence. Where monochrome once ruled the industry color is now emerging and taking a foothold. It is our pledge to you, our customer, to do all we can to help you move into this new opportunity and others, as quickly and effortlessly as possible. We will continue to support monochrome markets, while building a comprehensive color technology library for your reference, along with products to support your growing business. Together we can build a partnership for a successful future. STATIC CONTROL Static Control Components, Inc Lee Avenue PO Box 152 Sanford, NC US/Can US/Can Fax Int l Int l Fax Static Control Components (Europe) Limited Unit 30, Worton Drive Reading Berkshire RG2 0TG United Kingdom Tel +44 (0) Fax +44 (0) Static Control Components, Inc. All rights reserved worldwide. The stylized S is a registered trademark, and Static Control, SSS, ProSeal and System Support Series are trademarks of Static Control Components Inc. All other brand and product names are trademarks or registered trademarks of their respective companies. Adobe, Acrobat and the Acrobat logo are registered trademarks of Adobe Systems Incorporated.