This document provides technical instructions for remanufacturing toner cartridges for several HP printer models, including the HP5500, HP5550, and related models. It outlines 49 detailed steps for disassembling and cleaning the cartridge components, replacing consumables, and reassembling the cartridge. The instructions include photos to illustrate each step in the remanufacturing process.

1. HP5500TECH
Technical Instructions Machine Compatibility OEM Info Tools 1
CORPORATE HP5500 Part Number: C9730A – Black Small Phillips Screwdriver
LOS ANGELES, USA HP5500dn Yield @ 5%: 13,000pgs #2 Phillips Screwdriver
US 1 800 394.9900 Part Number: C9731A – Cyan X-acto Knige
Int’l +1 818 837.8100 HP5500dtn
Yield @ 5%: 12,000pgs 1/8 inch drill bit
FAX 1 800 394.9910 HP5500n Drill
Int’l +1 818 838.7047 Part Number: C9732A – Yellow
HP5550 Yield @ 5%: 12,000pgs Spring hook
HP5550dn Part Number: C9733A – Magenta Needle-nose Pliers
ATLANTA, USA
US 1 877 676.4223 HP5550dtn Yield @ 5%: 12,000pgs
Int’l +1 678 919.1189 HP5550hdn Supplies Required:
FAX 1 877 337.7976 HP5550n 99% Alcohol
Int’l +1 770 516.7794 Cotton Swabs
Toner
KANSAS CITY, USA Drum
US 1 913 871.1700 Silcone or other sealant
FAX 1 913 888.0626
MIAMI, USA
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 Photo 1
US 1 800 431.7884 Step 1
Int’l +1 631 588.7300
FAX 1 800 431.8812 Using an X-acto knife with a flat blade cut
Int’l +1 631 588.7333
off the plastic caps that cover the car-
TORONTO, CAN tridge pins on each end of the cartridge.
CAN 1 877 848.0818 (See Photos 1 & 2)
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
Photo 2
Step 2
MELBOURNE, AUS Using a 1/8 inch drill bit, drill out the exist-
AUS 1 800 003. 100
Int’l +62 03 9561.8102 ing rectangular slots located on the top of
FAX 1 800 004.302 the waste hopper next to the ends of the
Int’l +62 03 9561-7751
metal plate. (See Photos 3 & 4)
SYDNEY, AUS
AUS 1 800 003.100 This will force the pins out from the ends
Int’l +62 02 9648.2630
FAX 1800 004.302 of the cartridge.
Int’l +62 02 9548.2635
MONTEVIDEO, URY
URY 02 902.2001
Int’l +5982 902.2001 Photo 3 Photo 4
FAX +5982 900.0858
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. 5/10/05

2. 2 HP5500 Technical Instructions
Photo 8
Step 5
Lift the waste hopper away from the toner
hopper. (See Photo 8)
Step 3
With a spring hook release the Set the toner hopper aside.
tension spring from the contact
end of the toner hopper.
(See Photo 5)
Photo 5 Photo 9
Step 6
Rotate the waste hopper so the drums
drive element is toward you. Remove the
2 small Philip screws that hold the blue
cartridge handle to the waste hopper.
(See Photo 9)
Photo 10
Step 4 Step 7
Remove the cartridge pins Rotate the cartridge so the other cartridge
using needle nose pliers. handle is towards you. Remove the 2
screws that hold the blue cartridge handle
(See Photos 6 & 7) to the waste hopper. (See Photo 10)
Photo 6 Photo 11 Remove the cartridge handle and the ten-
sion spring from the end of the waste hop-
per. (See Photo 11)
Photo 7 Photo 12
Step 8
Use a spring hook to remove the locking
washer from the end of the drum axle.
(See Photo 12)

3. HP5500 Technical Instructions 3
Photo 13
Step 9
Grab a hold of the drive gear element and
pull the drum axle out from the end of the
Step 12
waste hopper, it maybe necessary to tap
on the other end of the drum axle in order Remove the drum shutter from
to get it through the waste hopper. the drum shutter arm.
(See Photo 13) (See Photo 18)
Photo 18
Photo 14 Remove the drum axle bearing from the
end of the waste hopper. (See Photo 14)
Step 13
Photo 15 Remove the PCR.
Step 10
(See Photo 19) Clean the PCR
Carefully lift the drum out from the waste using a lint free soft cloth. Water
hopper. can also be used to clean the
(See Photo 15) PCR if needed.
Photo 19
Photo 16
Step 11
Pull the drum shutter bar out of its posi-
tioning holes on each side of the waste
hopper.
Step 14
(See Photos 16 & 17) Remove the two Philip screws
holding the wiper blade.
(See Photo 20)
Photo 20
Photo 17

4. 4 HP5500 Technical Instructions
Photo 24
Step 18
Seal the area around the wiper blade
Step 15 using foam or silicone.
(See Photo 24)
Using needle nose pliers pull
the wiper blade away from the
sealing foam. (See Photo 21)
Remove the OEM sealing foam.
Photo 21
Photo 25
Step 19
Install the cleaned PCR into the hopper.
(See Photo 25)
Step 16
Dump the waste toner from the
hopper, using dry compressed
air or a vacuum clean out the
Photo 26
waste hopper. Remove the Step 20
OEM wiper blade sealing foam.
Apply padding powder to the OPC drum.
(See Photo 22)
Carefully place the drum into the waste
hopper so the drive hub is on the correct
side of the hopper. (See Photo 26)
Photo 22
Photo 27
Step 21
Slide the drum axle through the drum.
(See Photo 27)
Step 17 NOTE: Make sure the drive pin is seated
into the drive hub and the bearing is resting
Apply padding powder to the
properly in the side of the cartridge.
wiper blade. Place the wiper
blade onto the waste hopper.
Install the 2 screw that hold the
blade in place.(See Photo 23)
Photo 28
Step 22
Install the drum axle bearing, the washer
Photo 23 and the locking washer onto the drum
axle on the contact side of the cartridge.
(See Photo 28) Rotate the drum 5-10
revolutions to ensure proper lubrication.
Clean the padding powder off the PCR
using a lint free cloth.

5. HP5500 Technical Instructions 5
Photo 29
Step 23
Place the tension spring onto its position-
ing post. (See Photo 29)
Step 28
Remove the 2 screws that hold
the developer roller end cap to
the toner hopper.
(See Photo 34)
Photo 34
Photo 30
Step 24
Install the blue cartridge handle onto the
end of the waste hopper. Install the
screws that hold the handles to each side
of the waste hopper.
(See Photo 30)
Step 29
Rotate the cartridge 180°.
Photo 31 Remove the white spacer on the
Step 25 end of the metal gear housing
Install the drum shutter post into the drum end plate. (See Photo 35)
shutter arm. Install the drum shutter bar Remove the 2 screws that hold
into the alignment holes on each side of the metal gear housing end
the waste hopper. (See Photo 31) Set the plate to the toner hopper.
waste hopper aside and cover. (See Photo 36)
NOTE: The 2 screws that hold
the end plate are longer than
the standard cartridge screws.
Make sure the correct screws
Photo 32
Step 26 are used are used during the
Using a Philips screwdriver remove the 2 reassembly process. Remove
screws holding the contact end cap to the end plate.
the toner hopper.
(See Photo 32)
Photo 35
Photo 33
Step 27
Remove the contact end cap from the Photo 36
toner hopper. Clean the contacts using a
cotton swab and alcohol. (See Photo 33)
Apply new conductive grease to the
contacts.

6. HP5500 Technical Instructions 6
Photo 37
Step 30
Remove the 5 drive gears from the end of
the toner hopper. (See Photo 37)
Step 36
Remove the 2 screws that hold
the doctor blade in place.
(See Photo 43)
Photo 38
Carefully blow off the doctor
Step 31 blade using dry compressed air.
Place the doctor blade on a flat
Release the locking clip that holds the
surface so the blade sits flush.
toner hopper agitator drive gear to the
(See Photo 44)
agitator. (See Photo 38) Remove the gear.
Carefully clean the surface of
the doctor blade using a lint free
Step 32 cloth and alcohol.
Photo 39 Remove the 2 screws that hold the devel-
oper roller end cap to the toner hopper.
(See Photo 39) Photo 43
NOTE: The 2 screws that hold the devel-
oper roller end cap are longer than the
standard cartridge screws. Make sure the
correct screws are used in the reassembly
process.
Photo 40
Step 33
Remove the developer roller end caps
from each end of the toner hopper.
(See Photo 40)
Photo 44
Photo 41
Step 34
Remove the white developer roller bush-
ings from the ends of the developer roller.
(See Photo 41) Clean the bushing using a
lint free cloth and alcohol.
Step 37
Photo 42
Step 35 Dump out the unused toner
from the toner hopper. Using
Install the drive gear end of the develop- dry compressed air or a vacuum
er roller into a drill and tighten the chuck. clean the toner hopper.
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. (See Photo 42)

7. HP5500 Technical Instructions 7
Photo 45
Step 38
Place the clean doctor blade onto the
toner hopper and install the 2 screws
that hold the blade in place. Step 44
(See Photo 45) Place the metal gear housing
end plate over the drive gears.
Install the 2 large screws that
hold the end plate in place.
Photo 46 Place the white spacer onto the
Step 39 end of the end plate.
Apply a small amount of toner to a lint (See Photo 51)
free cloth. Wipe the toner onto the devel-
oper roller to help prevent dry start. (See
Photo 46)
Photo 51
Photo 47
Step 40
Place the developer roller bushings onto
the ends of the developer roller. Place the
developer roller onto the toner hopper.
(See Photo 47)
Step 45
Fill the toner hopper with toner.
Photo 48 Rotate the developer roller to
Step 41 ensure the toner is charging
Slide the developer roller end cap onto the correctly and its adhering to the
gear side of the toner hopper. Install the 2 developer roller. If you see toner
large screws that hold the end cap in building up between the devel-
place. (See Photo 48) oper roller and the doctor blade,
the toner hopper must be disas-
sembled.
Photo 49
Step 42
Step 46
Slide the developer roller end cap on the
Place the contact end cap onto
other side of the toner hopper. Install the 2
the end of the toner hopper.
screws that hold the end cap in place.
Install the 2 screws that hold the
(See Photo 49)
end cap in place.
(See Photo 52)
Photo 50 Photo 52
Step 43
Place the 5 drive gears onto the gear end
of the toner hopper. (See Photo 50)

8. 8 H5500 Technical Instructions
Photo 55
Step 48
Install the cartridge pins in each side of
the cartridge. The long pin goes on the
Step 47 gear side and the short pin goes on the
Place the waste hopper on the contact side.
workbench so the drum is facing (See Photos 55 & 56)
up. Place the toner hopper so it
is under the mylar blade on the
drum shutter. (See Photo 53) Photo 56
NOTE: Check the tension spring
on the back of the cartridge- it
must sit flat against the toner
hopper. (See Photo 54)
Photo 53
Photo 57
Step 49
Attach the tension spring to the contact
side of the toner hopper.
(See Photo 57)
Photo 54 Photo 58
Step 55
Replace the cartridge chip. (See Photo 58)
Test the cartridge.
Remanufacturing the HP Color LaserJet 5500/ 5550
The HP Color LaserJet 5500 was released in color. When HP released the HP5550 they
back in November 2002, as the replacement increased the overall print speed to 27ppm for
for the HP Color LaserJet 8500 and 8550. The both monochrome and color.
Color LaserJet 5500 is based on a similar
engine as the Color LaserJet 4600 only wider The toner cartridges for the HP Color
to accommodate the A3 paper this tabloid LaserJet 5500 are similar in design as the HP
printer handles. 4600 and the remanufacturing procedures are
similar as well. The black cartridge (C9730A)
While the HP Color LaserJet 8550 printer yields 13,000 pages at 5% and sells for
series was based around a multipass engine $225.99 while the cyan cartridge (C9731A),
that could print 24ppm in monochrome and yellow cartridge (C9731A), and the magenta
only 6ppm color. The Color LaserJet 5500 cartridge (C9733A) yield 12,000 pages and
was a little slower when printing mono- sells for $315.99.
chrome, 21ppm but it could also print 21ppm
E-mail: info@futuregraphicsllc.com Website: www.futuregraphicsllc.com