The purpose of this document is to provide a start to finish igen developer

housing rebuild procedure that yields consistent and successful results.

(Please review the developer housing rebuild/repair training video located in GSN Library 4272)

The following parts will be replaced during this procedure.

Dev Housing Gears 600K88871 Center Baffle 55K34512

Trimmer Bar 604K40991 Bias Brush 113k3230-2
Donor Roll Idler 7K20000 Bias Brush 19k6141
Mag Roll Bearing 14K9501 Donor Rolls 604k41641
Bearing Plate Seals 35E60861-2
Mag Roll* M- 59K30185
Y- 59K30194
C- 59K30204
K- 59K30214

The following parts will be inspected and possibly replaced.

Left Side Bearing Plate 13K3994 Right Side Bearing Plate 13K2643
Housing Top Cover 606k15640 (Kit contains covers for all 4 housings)
iGen4 Augers** 94K4143 (Mix/Black) & 94K4591 (Pickup/White)
iGen3 Augers** 94K4143 (Mix/Black) & 94K4602 (Pickup/White)

Replace the augers if you see many “Level 1 TC Recovery” log only faults or if the shafts are
scored.

Replace the bearing plates if developer/toner is leaking from the bearings or auger shafts are
scored.

NOTE: *Each developer station has a unique mag roll and top cover. ** The pickup augers are
not interchangeable between igen3 and igen4.

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 (600T02294 order from MAP’s)
TC Calibration Spreadsheet Fresh Material Method Tool found in GSN library 4254

1 Rev. October, 2011

Procedure

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

2) Disconnect the lower vacuum manifold hose and remove the four 10mm bolts that secure the
housing to the rail.

3) Remove the housing from the rail and place on a work surface. Remove the two screws on
the lint screen cover.

2 Rev. October, 2011

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. Note that the screw in the cable clamp has 2 washers attached.

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.

3 Rev. October, 2011

8) Remove the two T10 screws that secure the packer sensor. Remove the sensor. Place a
small piece of tape over the hole to prevent any leakage of material. (iGen3 pictured here)

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.

4 Rev. October, 2011

11) Remove the connector P652 from the mag roll motor. Remove the motor cover. Remove
the four long screws that secure the motor and motor and housing. Remove the motor and
housing. For iGen4 be careful not to damage the trickle port linkage.

12) Using a 7mm wrench, locate the flat spots on the auger and mag roll shafts. The flat is
located behind the gears. Secure the shaft with your wrench and remove the 10mm nuts that
secure the gears to the shafts. Remove all 3 gears.

13) Remove the 2 e-clips that secure the auger shafts

5 Rev. October, 2011

14) Remove the 5 screws that secure the bearing plate. Remove the plate. If the plate is difficult
to remove use an emery cloth to clean the shafts.

15) For iGen3, remove the vacuum hose from the trickle port.

16) Remove the bias wire from the mag roll bias brush.

6 Rev. October, 2011

17) Remove the 2 screws for the mag roll bearing and remove the bearing assembly. Do not
discard the bearing yet.

18) Disconnect P651 from the donor roll motor. Remove the 3 screws that secure the donor roll
motor and frame to the housing. Remove the assembly.

19) Remove the e-clips for the augers on the left bearing plate.

7 Rev. October, 2011

20) Remove the two 7mm screws that secure the ESV bar. Slide the bar out of the way to the
left using caution not to damage any wires.

8 Rev. October, 2011

21) Remove the upper manifold by removing the 2 screws that secure the handle clamps and
then removing the 2 screws that secure the vacuum port to the developer housing frame.

22) Remove the e-clip from the donor roll idler and remove the gear.

9 Rev. October, 2011

23) Remove the donor roll bias brushes. Leave the wires connected to them for now.

24) Remove the 4 screws securing the donor roll frame and remove the frame.

10 Rev. October, 2011

25) Remove the 4 screws securing the top cover and gently lift cover and move to the rear of the
housing. It is not necessary to remove and hoses or wires.

26) Remove the 2 screws securing the trimmer bar and remove the bar. Careful, a worn bar has
a very sharp edge!

11 Rev. October, 2011

27) On the left side of the housing, remove the 2 screws securing the mag roll and the mag roll
keeper. Note that the screw for the mag roll is longer. Using a pocket screwdriver, gently pry
the keeper off the mag roll shaft while moving the mag roll inboard to outboard. Once the
keeper is removed, the mag roll can be removed from the housing.

28) Remove the augers by sliding them out from the right side of the housing. Note the location
of the magnet. Be careful not to damage it. The white augers ore NOT interchangeable
between iGen3 and iGen4. Inspect the auger shaft for any signs of wear. If scoring is present,
replace the bearing plates. If you have been experiencing Level 1 TC Recovery Log Only Faults
replace the augers.

29) Inspect the bearings on the left side bearing plate. It is not necessary to remove it unless
you see signs of wear.

12 Rev. October, 2011

30) Thoroughly clean and inspect the inside of the housing. Look for metal shavings or other
contaminates.

This concludes disassembly and inspection. To reassemble, we will follow a slightly different
sequence.

31) Reinstall the left side bearing plate, if removed, with a new seal 35K15640. Reinstall the
augers removed in step 28.
32) Reinstall the e-clips on the left side of the augers removed in step 19.
33) Install a new mag roll. Remember, each mag roll is unique to the developer station so make
sure you order the correct roll for the color housing you are repairing. Use a channel locks to
make the magnet stay in place while you line up the d-shaft on the end of the mag roll to the flat
on the keeper.

13 Rev. October, 2011

The magnet will tend to spin when you align the keeper to the shaft. The channel locks will
help hold the magnet in the correct orientation when aligning the keeper to the shaft.

The keeper will pin in place once the shaft is aligned to it. Insert the longer screw removed in
step 27 into the mag roll shaft. The shorter screw is used to secure the keeper in place. This
alignment is critical to mag roll performance.

34) Install a new mag roll bearing, 14k9501, to secure the shaft on the right side of the housing.
Reinstall the 2 screws removed in step 17.

35) Install a new bias brush, 19k6141, in the mag roll bearing. Use the contact from the old
bearing being careful not to damage it.

36) Install a new trimmer bar, 604k40991, making sure to connect the wire removed in step 26.
Do not tighten the hardware (2 screws) yet.

37) Adjust the trimmer bar gap using the spacers supplied in kit 600T2294, Insert the spacer
between the trimmer bar and the mag roll. The spacer should fit flat on the top of the trimmer
bar. The black spacers are used to adjust Magenta, Cyan and Black. The yellow spacers should
only be used in a yellow housing. Move the trimmer bar so that the spacer fits snugly between
the trimmer bar and the mag roll. Tighten the trimmer bar hardware.

38) Inspect the top cover for any signs of wear. A worn trimmer bar or a sagging top cover can
cause wear. Replace or reinstall the top cover using the four screws removed in step 25. Note:
Each developer housing has a unique top cover. 600K15640 contains all 4 covers.

39) Reinstall the donor roll frame using the 4 screws removed in step 24.

40) Install a new donor roll idler, 7k20000, reference step 22.

14 Rev. October, 2011

41) Reinstall the donor roll motor and frame assembly using the 3 screws removed in step 18.
Connect P651

42) Inspect the right side bearing plate. If material leaks from the bearings or the outer race of
the bearing spins in the frame, replace the bearing plate. Replace or reinstall the right side
bearing plate (five screws) using caution not to pinch any of the wires or hoses removed in step
14 with a new seal 35K60861.

43) Reinstall the e-clips on the auger shafts removed in step13.

44) Reconnect the mag roll bias lead removed in step 16.

45) Install new drive gears from kit 600k88871 using the 10mm nuts removed in step 12.
Lubricate the gears with the grease supplied in the kit.

46) Reinstall the mag motor (4 long screws) and cover removed in step 11. Connect P652 to the
motor.

47) Remove the wires from the old donor roll bias brushes and install new bias brushes Part
number 113k3230. Reference step 23. Use caution routing the wires. Note there is a detent in
the donor roll frame where the brushes fit.

48) Reinstall the upper vacuum manifold removed in step 21.

49) Reinstall the ESV bar removed in step 20.

50) Install new center baffle part number 55k34512, reference step 10.

51) Install new donor rolls part number 604k41641, reference step 9. Make sure you have good
contact with the donor roll brushes (113k32300)

52) Turn the housing upside down and reinstall the lower vacuum manifold removed in step 6.
Note the screw with the 2 washer secures the cable clamp.

53) Reconnect the trickle port vacuum hose (iGen3 only)

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

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

15 Rev. October, 2011

Please direct any suggestions or comments to john.fiocca@xerox.com

16 Rev. October, 2011