HP3600_3800TECH

Technical Instructions Printers OEM Info Tools 1

CORPORATE HP Color LaserJet 3000n (Q7534A) Q6470A – Black (HP CLJ3600/3800) Tools required:
HP Color LaserJet 3000dn (Q7535A) Q7581A – Cyan (HP CLJ3800) #1 Phillips Screwdriver,
LOS ANGELES, USA Small Flat Blade Screwdriver,
US 1 800 394.9900 HP Color LaserJet 3600n (Q5987A) Q7582A – Yellow (HP CLJ3800)
X-acto knife,
Int’l +1 818 837.8100 HP Color LaserJet 3600dn (Q5988A) Q7583A – Magenta (HP CLJ3800) DRPINTOOL, Hammer,
FAX 1 800 394.9910 HP Color LaserJet 3800 (Q5981A) Q6471A – Cyan (HP CLJ3600) Diagonal cutters, Spring Hook,
Int’l +1 818 838.7047 HP Color LaserJet 3800n (Q5982A) Q6472A – Yellow (HP CLJ3600) Needle-nose Pliers
HP Color LaserJet 3800dn (Q5983A) Q6473A – Magenta (HP CLJ3600)
HP Color LaserJet 3800dtn (Q5984A) Q7560A – Black (HP CLJ3000) Supplies Required:
ATLANTA, USA Padding Powder
US 1 877 676.4223 Q7561A – Cyan (HP CLJ3000)
Soft Lint-Free Cloth
Int’l +1 678 919.1189 Q7562A – Yellow (HP CLJ3000) Cotton Swabs
FAX 1 877 337.7976 Q7563A – Magenta (HP CLJ3000) Conductive Grease
Int’l +1 770 516.7794 Anhydrous Isopropyl Alcohol
Vacuum or Compressed Air
Sealing Foam
KANSAS CITY, USA
US 1 913 871.1700
FAX 1 913 888.0626
Photo 1
MIAMI, USA Step 1
US 1 800 595.4297
Int’l +1 305 594.3396 Hold the cartridge with the gear side facing you.
FAX 1 800 522.8640 Use an X-acto knife to remove the plastic cover-
Int’l +1 305 594.3309
ing the cartridge pin.
NEW YORK, USA (See Photos 1 & 2)
US 1 800 431.7884
Int’l +1 631 588.7300
FAX 1 800 431.8812
Int’l +1 631 588.7333

TORONTO, CAN Photo 2

CAN 1 877 848.0818
Int’l +1 905 712.9501
Step 2
FAX 1 877 772.6773 Using the diagonal cutters, remove the car-
Int’l +1 905 712.9502
tridge pin.
BUENOS AIRES, ARG NOTE: If needed, use the X-acto knife to cut
ARG 0810 444.2656 slots for improved access to the pin using the
Int’l +011 4583.5900
FAX +011 4584.3100
diagonal cutters.
(See Photo 3)
MELBOURNE, AUS
AUS 1 800 003. 100
Int’l +62 03 9561.8102
FAX 1 800 004.302 Photo 3
Int’l +62 03 9561-7751 Step 3
SYDNEY, AUS Rotate the cartridge to the contact side. Repeat
AUS 1 800 003.100 Steps 1 and 2 to remove the cartridge pin.
Int’l +62 02 9648.2630
FAX 1800 004.302 (See Photos 4 & 5)
Int’l +62 02 9548.2635
Photo 5
MONTEVIDEO, URY
URY 02 902.2001
Int’l +5982 902.2001
FAX +5982 900.0858

JOHANNESBURG, S.A. Photo 4

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

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REV. 8/01/06
 2 HP3000/3600/3800 Technical Instructions

Photo 9
Step 7
Position the waste hopper with the drum fac-
ing up and the blue handles towards you.
Step 4 (See Photo 9)
Release the cartridge tension spring
on the contact side attached to the
toner hopper using a spring hook.
(See Photo 6)
Photo 10
Step 8
Photo 6 Remove the drum shutter axle from the con-
tact side of the cartridge.
(See Photo 10)

Photo 11
Step 9
Remove the drum shutter tension spring
assemble and the drum shutter axle from the
gear side of the cartridge.
Step 5 NOTE: Be careful not to lose the coil spring
inside the tension spring assemble.
Rotate the cartridge to the gear side. (See Photos 11 & 12)
Release the cartridge tension spring
attached to the waste and toner hop-
per using a spring hook.
(See Photo 7)
Photo 12

Photo 7

Photo 13
Step 10
Locate the spring pin that locks the drum’s
drive hub in place. Rotate the drum until the
Step 6 square opening on the drive hub faces up.
Separate toner hopper from the (See Photo 13)
waste hopper. Set toner hopper
aside. (See Photo 8)

Step 11
Photo 8 Photo 14
Use the DRPINTOOL to push the spring pin
through the round opening of the drum hub
and shaft. Use the alignment pin to ensure the
feed through hole of the tool is correctly
aligned. Turn the tool handle clock wise and
align the point of the tool shaft into the spring
pin hole. Turn the handle with consistent effort
until the pin exits from the feed through hole.
(See Photo 14)
 HP3000/3600/3800 Technical Instruction 3
Photo 15
Step 12
Remove the drum axle and drum. Set aside
and cover the drum to protect the drum from
light exposure. Step 17
(See Photo 15) Apply padding powder to the new
wiper blade using a dry, soft, lint-
free cloth. Place the new blade onto
the waste hopper. Install the two
screws that hold the wiper blade in
Photo 16 place. (See Photo 21)
Step 13
Release the white PCR retaining clips and care-
fully remove the PCR. (See Photo 16)
NOTE: If needed, water can be used to clean Photo 21
the PCR.

Photo 17
Step 14
Clean PCR saddle blocks with cotton swab
and Anhydrous Isopropyl Alcohol.
(See Photo 17)
Step 18
Apply sealing foam along the edge
of the wiper blade and waste car-
tridge. (See Photo 22)

Photo 18
Step 15 Photo 22
Use the X-acto knife to cut the seal holding the
wiper blade. (See Photo 18)

Using a #1 Phillips screwdriver, remove the two

Photo 19
mounting screws from the wiper blade. Lift one
end of the wiper blade with the needle-nose pli-
ers and pull the blade away from the waste
hopper. (See Photos 19 & 20)

Photo 20 Step 16
Clean the waste hopper with a vacuum or dry,
compressed air.
Remove any remaining toner using a dry, soft,
lint-free cloth.
Remove the OEM wiper blade sealing foam
from the waste hopper.
 4 HP3000/3600/3800 Technical Instruction
Step 19
Apply conductive grease to the
black PCR saddle block.
(See Photo 23)
Place the white PCR retaining arms
on each side of the PCR and install
the PCR. NOTE: Retaining arm
differences – gear side and contact
side. (See Photo 24)
Photo 23
Photo 24
Step 20
Clean drum axial bearings and drum
axial contact with cotton swab and
Anhydrous Isopropyl Alcohol.
(See Photos 25 & 26)
Photo 25
Photo 26
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Photo 27
Step 21
Apply conductive grease to the contact side
axle bearing. (See Photo 27) Apply padding
powder to the OPC drum using a dry, soft, lint-
free cloth.
Photo 28
Step 22
Place the OPC drum onto the waste hopper so
that the drive hub sits next to the contact. Install
the drum axle through the OPC drum.
(See Photo 28)
Photo 29
Step 23
Align the square on the drum drive hub with the
hole in the drum axle. Install the drum spring
pin. Use the alignment pin to ensure the feed
through hole of the tool is correctly aligned
with the drum drive hub hole. Turn the tool
handle with consistent effort until approxi-
mately 1/8” of pin is exposed through both
sides of the drum drive hub. (See Photo 29)
Photo 30
Step 24
Apply conductive grease to the drum axle con-
tact. (See Photo 30) Rotate the drum five to 10
revolutions to ensure drum is not binding on
the wiper blade. Using a dry, soft, lint-free
cloth, clean the padding powder from the drum
and PCR while rotating the drum.
Photo 31
Step 25
Install the drum shutter axle into the contact
side mounting hole of the waste unit.
(See Photo 31)
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 HP3000/3600/3800 Technical Instruction 5

Photo 32
Step 26
Install drum shutter tension axle into the gear
side mounting hole and the drum shutter
spring assemble on to the gear side mounting
Step 29
post of the waste unit. Remove the large drive gear and
Set the waste unit aside. Cover waste unit to the developer roller gear.
protect OPC drum unit from light. (See Photo 37)
(See Photos 32 & 33)

Photo 33 Photo 37

Step 30
Photo 34 Remove the gear retaining plate
Step 27 from the five posts using the small
Rotate the toner hopper so that the contact flat blade screw driver.
end cap is facing you. Remove the two Phillips (See Photo 38)
screws holding the contact end cap to the
toner hopper using the #1 Phillips screwdriver.
Remove contact side end cap. Photo 38
(See Photo 34)

Photo 35
Step 28
Rotate the toner hopper so that the gear
assembly is facing you.
Using the small flat blade screw driver, careful-
ly depress the three plastic clips holding the
gear end cap. Remove gear end cap. Step 31
(See Photos 35 & 36) Remove the three gears from the
end of the developer roller end cap.
(See Photo 39)

Photo 36 Photo 39
 HP3000/3600/3800 Technical Instruction 6

Photo 40
Step 32
Using the #1 Phillips screwdriver, remove the
two screws that hold the developer roller end
cap to the toner hopper. Remove developer Step 37
roller end cap. (See Photo 40) Clean the toner hopper with a vac-
uum or dry, compressed air.
Remove any remaining toner using
a dry, soft, lint-free cloth. Remove
the OEM doctor blade sealing foam
Photo 41 from the toner hopper.
Step 33
Lift the developer roller from the toner cartridge. Step 38
Remove the white bushings from the ends of the
Fill the toner unit with the required
developer roller. (See Photo 41)
toner through the adder roller and
doctor blade opening.
(See Photo 46)
Step 34
Install the drive gear end on the developer
Photo 42 roller axle into a drill motor and tighten in the
Photo 46
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
soft lint-free cloth. Make several passes. Dry
the roller using a dry soft lint-free cloth.
NOTE: The surface of the developer roller may
change and become wrinkled. If properly
cleaned, the developer roller will return to its
original state when the cleaning process is fin-
ished. (See Photo 42)
Photo 43
Step 39
Step 35 Place the doctor blade onto a flat
Remove the two phillips screws holding the surface or a cleaning fixture. Clean
doctor blade to the toner hopper. Remove the doctor blade using a lint free
doctor blade. (See Photo 43) cloth and Anhydrous Isopropyl
Alcohol. (See Photo 47)
NOTE: Do not use pressure to
clean the surface of the doctor
blade. Wipe the surface of the
blade until all the toner build up is
Photo 44 removed from the blade. Do not
Step 36 bend the doctor blade. Visually
Remove the two toner adder roller felt wash- inspect the doctor blade before
ers. (See Photo 44) reinstalling the blade onto the car-
Remove adder roller by pulling the roller from tridge.
the gear side shaft compressing the foam until
the contact side shaft can clear the toner unit
frame. Remove adder roller.
(See Photo 45) Photo 47

Photo 45
 7 HP3000/3600/3800 Technical Instruction

Photo 51
Step 43
Install doctor blade using the two mounting
screws.
Step 40 (See Photo 51)
Clean excess toner from the adder
roller doctor blade area using a dry, Apply sealing foam along the top section of the
soft, lint-free cloth. doctor bar.
(See Photo 52)
Step 41 Photo 52
Install the adder roller by inserting
the gear side shaft into the toner
unit then compressing the adder
roller foam until the contact side
shaft can be inserted into the toner
unit. (See Photos 48 & 49)

Photo 48 Photo 53
Step 44
Install the two white developer roller bushing
onto the shaft of the developer roller. Position
the developer roller with the long shaft on the
gear side of the hopper.
(See Photo 53)

Photo 54
Step 45
Using a cotton swab and Anhydrous Isopropyl
Photo 49
Alcohol, clean the contacts on the contact side
end cap.
(See Photo 54)

Photo 55
Step 46
Clean and apply contact grease to the adder
roller and developer roller contact shaft ends.
Step 42 (See Photos 55 & 56)
Using the sealing foam, apply foam
around the mounting screw area of
the doctor blade. (See Photo 50) Step 47
Install contact end cap using two #1 Phillips
screws. (See Photo 57)
Photo 56 Photo 57
Photo 50

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 HP3000/3600/3800 Technical Instruction 8

Photo 58
Step 48
Install developer roller end cap using two #1
Phillips screws.
Step 54
(See Photo 58) Install the cartridge pins in each
end of the cartridge.
(See Photo 65)

Photo 59 NOTE: The large pin goes on the

Step 49 gear side of the cartridge.
Install the three gears onto the developer roller (See Photo 66)
end cap.

(See Photo 59)

Photo 65

Photo 60
Step 50
Install the gear retaining plate onto the devel-
oper roller end cap.

(See Photo 60)

Photo 61
Step 51
Install the developer roller gear and the large
Photo 66
drive gear onto the developer roller end cap.

(See Photo 61)

Photo 62
Step 52
Snap into position the gear end cap.

(See Photo 62)

Photo 63
Step 53 Step 55
Place the waste hopper on the work bench Connect the tension spring on the
with the drum up and the blue handles facing contact side of the cartridge.
away from you. Align the waste hopper with (See Photo 67)
the toner hopper. Ensure the tabs on the toner
hopper are positioned under the waste hop-
per’s drum shield. Check tension spring on
contact side of the waste hopper. Ensure the Photo 67
spring is positioned for installation.
Photo 64
(See Photos 63 & 64)
 9 HP3000/3600/3800 Technical Instruction

Photo 68
Step 56
Install the tension spring on the gear side of
the cartridge. Connecting hooks are on the
toner and waste units.

(See Photo 68)

Photo 69
Step 57
Replace the cartridge chip.

(See Photo 69)

HP CLJ 3000/3600/3800
In October of 2005, Hewlett-Packard (HP) released three color laser
printers into the North American market. The HP Color LaserJet 3000,
3600, and 3800 are based on a new Canon engine similar to the HP
Color LaserJet 2600. The single pass engine design enables the new
printers to print from 15ppm to 30ppm with only one model (HP CLJ
3000) slowing down to print color.

The HP Color LaserJet 3600 and 3800 share the same black car-
tridge, the rest of the cartridges are unique to each model. The HP CLJ
3600/3800 black cartridge, Q6470A, has a 6K page yield at 5% cov-
erage. The color cartridges for the HP CLJ 3800, Q7581A (cyan),
Q7582A (yellow), Q7583 (magenta), have a 6K page yield at 5% cov-
erage. The color cartridges for the HP CLJ 3600, Q6471A (cyan),
Q6472A (yellow), Q6473 (magenta), have a 4K page yield at 5% cov-
erage. The HP CLJ 3000 black cartridge, Q7560A, has a 6.5K page
yield at 5% coverage. The color cartridges for the HP CLJ 3000,
Q7561A (cyan), Q7562A (yellow), Q7563 (magenta), have a 3.5K page
yield at 5% coverage.

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