Xerox Digital Color Press DCP-700/700i/770, Color Press C75/J75 and Versant V80, V180, V2100, V3100
While it hasn’t been an option in the past, it’s finally becoming possible to rebuild or repair decurler transport assemblies. Foam decurler rollers are spared in the J75 parts book, where they were missing from the DCP700 list.
So let’s begin by checking out how to protect the gears on the front end of the unit; these four little white gears are known for getting chewed up for reasons we’ll discuss. Then we’ll take one of these units apart far enough to replace these four gears.
DCP700 decurler transport
There are three versions of the decurler transport assemblies, and each version has its own OEM part numbers. While they are similar, there are some differences between them. The large foam rollers are the same for all three versions.
- DCP700/700i/770 version (059K62633)
o OEM Refurbished= 641S00720 - J75 / C75 version (059k79264)
o OEM Refurbished= 641S01011 - V80/V180/V2100 version (059K81491)
o OEM Refurbished= 641S01072
In many cases, the limiting factor for these units ends up being four small white gears at the front end. There are two idler gears—one with 11 teeth, and one with 13 teeth—and there are two drive gears which fit onto D shafts (one fits on the upper drive roll and one fits the lower drive roll).
These gears are in harm’s way of toner and developer falling from the developer unit above. The grit gets into the teeth of the gears and wears them down rather quickly. One look at the ramp-like black front-end cover makes it clear why so much grit lands on the gears, but installing a Mylar sheet on this cover will protect these gears. (See photos #1 and 2)
Photos #1 & 2: lower front cover and a solution to protect the gears
Now let’s open one up and see how to get to the four important gears.
Tools required
- #1 Phillips head screwdriver or 5.5mm hex driver
- Small flathead screwdriver
Parts you may need
- Decurler transport gear kit, four gears (DC700DTGK or V80DTGK)
- Decurler foam roll (DC700DTFR or V80DTFR: 059K56451)
Procedure
1. Lay the unit on its right side and remove the hinge-limit bracket (1 screw, see photo #4). While holding both upper and lower halves steady, carefully lift the green latch to release the two halves and open the unit up all the way.
Photo #4 & 5: hinge retainer bracket and upper assembly shown hinged all the way open
Caution: the hinge’s spring is strong, so take care not to let go of either half until the unit is fully open (see photo #5).
2. Remove the two idler gears (11-toothed and 13-toothed) from their shafts on the inside of the front-end frame (one e-clip each, see photo #3). Important: Take care not to lose the tiny white plastic spacer ring which shares the same shaft as the 11-toothed idler gear.
Photo #3: lower assembly parts
3. Remove the upper drive-roll gear (one e-clip, see photo #6)
Photo #6: upper drive-roll gear
4. Next up is the lower drive-roll gear. Start by removing the lower drive-roll coupling from the rear end of the unit (one e-clip) and the inner e-clip and bearing (see photo #7).
Photo #7: lower drive coupling
5. Take off the black plastic cover from the lower left corner of the front end (one screw, see photo #8).
Photos #8 & 9: lower left cover and motor bracket assembly
6. From the front end of the lower half, take off the motor mounting bracket (three screws and two wiring harness clips to release, see photo #9).
7. Remove the e-clip and bearing from the front end of the lower drive roller.
8. Shift the lower drive roller toward the rear of the unit until you can slide the gear off the front end of the roller. That’s the fourth of the group of small white gears which usually fail.
Photo #10: lower drive shaft removal
OK, time to take a breather. You’ve taken it apart enough to replace the four gears. Next month, we’ll take things a bit further by replacing the upper and lower foam rollers, as well as the four small white back-up rollers hiding behind the two drive rollers. The back-up rollers have the smallest-imaginable ball bearings.
Happy repairs, everyone—see you next month for Part 2!
