iGen4/150 MMR Developer Housing Rebuild

The following parts will be replaced during this procedure:

Auger gears 604k83980 Mag roll gears 604k73240

Trimmer bar 25e07390 Auger 94k05002
Mag roll A 59k83350 Auger mix 94k05370
Mag roll B 59k63300 Mag roll C 59k84281
Mag roll D 59k76811 Mag roll gears 604k73240
Mag motor gears 604k73441 Coupling disk 5e29291
Center baffle 55k44170 Donor rolls 604k84030
Donor bias brush (4) 113k3230 Donor roll idler 7k20000
IB Block Assembly 14k10495 Roll A block (K only) 14k10441
OB Block Assembly 14k11043 Roll A block (C only) 14k10421

Other parts that are good to have just in case:

13K4460 bearing end plate(rare seized bearing--not necessarily known until removal of augers)
25E7390 trim bar(this part is reversible)
93K20351 trickle port pos 3(inspect for clog or lever failure)
93K20361 trickle port pos 4(inspect for clog or lever failure)
5K12881 dispense interface(check foam seal deterioration)
52K9471 NOHAD coupling(cold air duct, also foam seal)

Tools Required:
5.5mm nutdriver Small flat blade screwdriver
7mm nutdriver 7mm wrench
10mm nut driver Needle nose pliers
T10 Torx T20 Torx
Vacuum Trimmer bar tools (600T02387, order from MAP’s)
600t41512 Shim stock (needed to adjust gap of the guide blade on lower manifold area)
TC Calibration Spreadsheet Fresh Material Method Tool found in GSN library 4254
Procedure

1) Remove all developer material from the housing before removing the unit from
the machine.

2) Remove the housing from the rail and place on a work surface.

3) Remove the two screws on the lint screen cover

4) Remove the one screw securing the lint screen. Thoroughly clean the lint
screen making sure there is no material caked on the edges. There should be a
1mm gap between the transducer and the screen. Reinstall the lint screen and the
cover.

5) Attach vacuum cleaner hose to both the upper and lower manifolds and vacuum
all residual toner from the manifolds. A 14 inch tywrap works well for scraping
toner out.
6) Turn the housing upside down and remove the two screws that secure the lower
vacuum manifold to the donor roll frame.

7) Loosen the one screw at the rear pivot point of the lower vacuum manifold so it
clears the pivot point. Remove the lower manifold.

8) Remove the 2 screws that secure the TC sensor. Remove the sensor. Place a
small piece of tape over the hole to prevent any leakage of material.
9) Turn the housing right side up. Remove the donor rolls. Inspect the contacts for
any signs of arcing or wear. Clean the contacts with emery cloth.

10) Remove the center baffle.

11) Disconnect P651 from the donor roll drive motor. Remove the 2 screws that
secure the motor cover then remove the 3 screws that secure the motor and place
motor aside.
12) Loosen the 2 screws from the back side of the auger gear cover and remove
the one screw from the front. Place the cover aside.

13) Use a 7mm wrench to hold the shaft stationary and a 10mm socket to remove
the auger gears. You will install new gears later in this procedure.

14) Remove the 3 screws from the side plate and remove the plate. Use caution so
you don’t pinch the wires that are secured to the plate.
15) Remove the e-rings from the auger shafts

16) Remove the 2 screws that hold the mag motor cover on and place cover aside.

17) Remove the two 5.5mm screws and one 7mm nut that secure the mag motor
and set motor aside. Be careful not to drop the coupling.

18) Remove the spring and idler assembly from the side plate by removing 2 nuts.
19) Remove the remaining long screw to remove the entire plate. Be very careful
not to damage the trickle port linkage.

20) Remove the auger drive belt pulleys by removing the 7mm screws. Remove
the gear/pulley by removing the T20 screw.

21) Remove the three T20 screws and remove the side plate using caution not to
damage the wires fastened to the plate.
22) Remove the four 7mm screws (two for each strap) that secure the housing
straps and set straps aside. Remove the 2 T20 screws that secure the upper vacuum
manifold and remove the manifold.

23) Remove the five T20 screws that secure the housing top cover. Do not
remove the cover at this time.

24) Remove the eight T20 screws (4 on each side) that secure mag rolls. Remove
the bias wire. Do not remove the mag rolls yet.
(Picture shows assembly already removed.)
25) Loosen the three 7mm nuts on the bottom plate and remove the plate. Now,
pull the mag roll assembly off.

26) Move the top cover to the side to access the trimmer bar. Remove the trimmer
bar. There is a bias wire attached to the outboard end of the bar.

27) Remove the 4 screws that secure the auger plate. Remove any remaining e-
clips from either side of the augers and remove both augers.
28) Disassemble the mag rolls. Remove the four T10 screws that secure the block
assembly to roll A and slide the block off.

29) Remove all the clips from the ends rolls B, C and D and remove the gears.

30) On the other side of the assembly, remove the T10 screws that secure the rolls
to the block.

THIS COMPLETES THE DISASSEMBLY PROCESS.

 Reassembly

1) Assemble the new mag rolls with new blocks. Make sure you have the right
mag roll A block for the cyan or black housing. Do not install assembly in housing
yet.

2) Install new mag roll drive gears

3) Install the new augers and plate. Attach all four e-clips removed earlier.

4) Install the mag roll assembly.

5) Install the trimmer bar and adjust with trimmer bar gap tool.

6) Install the lower plate removed in step 25

7) Install the top cover removed in step 23.

8) Install the upper vacuum manifold and housing straps removed in step 23.

9) Install the side plate removed in step 21.

10) Install new auger drive belt pulleys, gears and belt. 604k73440 and
23e32130.

11) Install the plate removed in step 19.

12) Install the auger drive belt idler, spring and tension the belt.

13) Install the mag roll drive motor removed in step 17. Be sure to align the
coupling. Failure to do so will cause loss of drive to the rolls.

14) Install the mag motor cover and plug in P-652.

15) Install new donor roll idler on side plate removed in step 14 and then install
the side plate.

16) Install new auger gears removed in step 13, then install the auger gear cover.

17) Install the donor roll motor and motor cover.

18) Install the center baffle, new bias brushes (113k3230) and install the donor
rolls.
19) Install the TC sensor and lower vacuum manifold.

THIS COMPLETES THE REASSEMBLY

1) Install the housing back in the machine. Install fresh developer.

2) Calibrate the packer sensor using the TC Calibration Spreadsheet Fresh Material
Method Tool found in GSN library 4254.

Kindly direct any questions to John.Fiocca@xerox.com or call 708-514-4030