This document provides technical instructions for remanufacturing an HP5200 toner cartridge. It consists of 37 steps detailing how to disassemble and clean the cartridge components, replace supplies like the toner and doctor blade, and reassemble the cartridge to be ready for reuse. The instructions include photos corresponding to each step for visual guidance.

1. HP5200TECH
Technical Instructions Printers & OEM Info Tools & Supplies 1
CORPORATE Printers: Printers: Tools: Utility Knife
LOS ANGELES, USA HP5200 HP M5025 Drill Hot Glue Gun
US 1 800 394.9900 HP5200tn HP M5035P 3/32” Drill Bit
Int’l +1 818 837.8100 HP5200dtn HPM5035x Needle Nose Pliers Supplies:
FAX 1 800 394.9910 HPM5035xs Channel Locks Conductive Grease
Int’l +1 818 838.7047
Supplies: #2 Philips Screwdriver Padding Powder
Q7516A – 12,000 pages Supplies: Small Flat 540 Grams Toner
ATLANTA, USA
US 1 877 676.4223 @ 5% coverage Q7570A – 15,000 pages Blade Screwdriver
Int’l +1 678 919.1189 @ 5% coverage
FAX 1 877 337.7976
Int’l +1 770 516.7794
Photo 1
KANSAS CITY, USA Step 1
US 1 913 871.1700
FAX 1 913 888.0626 Using a 3/32” drill bit, drill 2 holes next to the
cartridge pin on each end of the cartridge.
MIAMI, USA (See Photos 1 & 2)
US 1 800 595.4297
Int’l +1 305 594.3396
FAX 1 800 522.8640
Int’l +1 305 594.3309
NEW YORK, USA
US 1 800 431.7884
Int’l +1 631 588.7300
FAX 1 800 431.8812
Int’l +1 631 588.7333 Photo 2
TORONTO, CAN
CAN 1 877 848.0818
Int’l +1 905 712.9501
FAX 1 877 772.6773
Int’l +1 905 712.9502
BUENOS AIRES, ARG
ARG 0810 444.2656
Int’l +011 4583.5900
FAX +011 4584.3100
MELBOURNE, AUS
Photo 3
AUS 1 800 003. 100
Int’l +62 03 9561.8102 Step 2
FAX 1 800 004.302
Int’l +62 03 9561-7751
Using needle nose pliers, pull the cartridge pins
out from each end of the cartridge.
SYDNEY, AUS
AUS 1 800 003.100 (See in Photo 3 and Photo 4)
Int’l +62 02 9648.2630
FAX 1800 004.302
Int’l +62 02 9548.2635
MONTEVIDEO, URY
URY 02 902.2001
Int’l +5982 902.2001
FAX +5982 900.0858 Photo 4
JOHANNESBURG, S.A.
S.A. +27 11 974.6155
FAX +27 11 974.3593
SÃO PAULO, BRAZIL
Int’l +55 11 5524.8000
RAANANA, ISRAEL
ISR 09 760.12.39
Int’l +972 9760.12.39
ISR 052.38.555.82
Int’l +972 5238.555.82
E-mail: info@futuregraphicsllc.com Website: www.futuregraphicsllc.com
REV. 5/16/07

2. 2 HP5200 Technical Instructions
Photo 8
Step 6
Carefully lift out the PCR. (See Photo 8) Clean
the PCR using a lint free cloth or if needed a
Step 3 mild soap and water can also be used.
Separate the two sections of the
cartridge. (See Photo 5) Set the
toner hopper aside.
Step 7
Using a #2 Philips screwdriver, remove the
Photo 9 2 screws that hold the wiper blade.
Photo 5 (See Photo 10)
Step 8
Clean the waste hopper using dry compressed
air or a vacuum. Clean the PCR saddles using
a cotton swab and alcohol. Apply new con-
ductive grease to the black conductive saddle.
Photo 10
Step 9
Apply padding powder to the new wiper blade.
Step 4 Place the wiper blade onto the waste hopper
Use channel locks to grab the drum and install the 2 screws that hold the blade.
axle pin, pull the drum axle pin from (See Photo 10)
the end of the waste hopper.
(See Photo 6)
Photo 11
Step 10
Place the clean PCR into the saddles.
Photo 6 (See Photo 11)
Photo 12
Step 11
Apply padding powder to the drum. Install the
drive gear into the bearing plate.
Step 5 (See Photo 12)
While lift the non-gear end of the
drum, pull the drive gear out from
the bearing end plate.
(See Photo 7)
Photo 7 Photo 13
Step 12
Install the drum axle pin into the end of the
waste hopper.
(See Photo 13)

3. HP5200 Technical Instructions 3
Photo 14
Step 13
Rotate the drum 5-10 revolutions to ensure the
drum and wiper blade are properly lubricated.
Using a lint free cloth, wipe the padding pow- Step 18
der from the PCR. (See Photo 14) Using the small flat blade screw-
driver break the sonic weld posts
Step 14 on the contact end cap.
(See Photo 20)
Set the waste hopper aside and cover.
Photo 15
Step 15 Photo 20
Using a small flat head screwdriver release the
plastic locking clip the locks the drum shutter
arm to the toner hopper. (See Photo 15)
NOTE: The drum shutter arm must be in
the closed position for it to be removed. Do not
lose the tension spring that fit in the drum
shutter arm.
Photo 16
Step 16
Remove the drum shutter bar from both ends Step 19
of the toner hopper. Insert a utility knife between the
toner hopper and the end cap to
(See Photos 16 & 17) break the sonic weld that holds the
end cap to the hopper.
(See Photo 21)
Photo 17
Photo 21
Photo 18
Step 17
Using a 3/32” drill bit, drill a screw hole through
both sonic welds that hold the contact end cap
to the toner hopper.
(See Photos 18 & 19)
Photo 19

4. 4 HP5200 Technical Instructions
Photo 25
Step 22
Remove the 2 screws that hold the doctor
blade. Lift off the mag roller scrapers from both
Step 20 ends of the blade. (See Photo 25)
Using a small flat head screwdriver
pry the contact end cap away from
the toner hopper breaking the sonic
weld on the top of the end cap.
(See Photo 22)
Photo 26
Step 23
NOTE: Clean the contact plate in
the end cap using a cotton swab Remove the doctor blade from the toner hop-
and alcohol. (See Photo 23) per. (See Photo 26) Clean the doctor blade
Apply new conductive grease to the using dry compressed air.
contact plate.
Step 24
Photo 22
Clean the toner hopper using dry, ionized com-
Photo 27 pressed air or a vacuum. NOTE: When clean-
ing to toner hopper, make sure you are blowing
the toner away from the gear housing end cap.
Step 25
Fill the toner hopper through the mag roller
opening. (See Photo 27)
Photo 23
Photo 28
Step 26
Place the cleaned doctor blade onto the toner
hopper. Place the mag roller scrapers on each
end of the doctor blade and install the
2 screws that hold the blade.
(See Photo 28)
Step 21
Carefully lift the contact end of the
mag roller and slide the rollers gear Photo 29
hub from the stabilizer arm on the Step 27
gear side of the toner hopper. Carefully slide the drive gear hub of the mag
(See Photo 24) roller through the mag roller stabilizer arm.
(See Photo 29) Rotate the mag roller drive gear
NOTE: Blow off the mag roller using till the gear fits onto the end of the mag roller.
dry, ionized compressed air. Clean
the roller using a lint free cloth and
mag roller cleaner.
Photo 30
Photo 24 Step 28
Rotate the magnet inside the mag roller till the
keyed end of the magnet fits into the gear
housing end cap.
(See Photo 30)
E-mail: info@futuregraphicsllc.com Website: www.futuregraphicsllc.com

5. HP5200 Technical Instructions 5
Photo 31
Step 29
Place the contact end cap on the end of the
toner hopper. Install 2 cartridge screws to hold Step 34
the end cap in place. (See Photo 31) Install the cartridge pins into each
NOTE: To insure you don’t strip the screw end of the cartridge.
holes you may want to use a manual screw- (See Photo 37)
driver to install these screws.
Photo 32 Photo 37
Step 30
Install the drum shutter bar into the saddles on
both sides of the toner hopper.
(See Photo 32)
Step 35
Using a knife carefully cut the top,
Photo 33 melted area of the waste hopper
Step 31 that houses the cartridge chip.
Place the drum shutter arm tension spring into (See Photo 38) Make sure you do
the arm. (See Photo 33) Slide the drum shutter not damage the guides that hold
arm onto the alignment post on the end of the the cartridge chip.
toner hopper.
(See Photo 34)
Photo 38
Photo 34
Step 36
Remove the spent OEM chip and
install a new aftermarket chip.
(See Photo 39)
Photo 35
Step 32
Photo 38
Slide the drum shutter arm away from the mag
roller to engage the drum shutter arm tension
spring.
(See Photo 35)
Step 37
Place a small amount of hot glue at
the top of the chip where the plas-
Photo 36 tic was cut to remove the chip.
Step 33 (See Photo 40)
Align the toner hopper and the waste hopper,
join the 2 sections together.
Photo 40
(See Photo 36)