Technical Tip

Xerox^® 7525 Family Fuser Modules

Part 2 – Repairing and Rebuilding the Fusers for the WorkCentre^®7525, 7530, 7535, 7830, 7835; WC-7545, 7556, 7845, 7855; and Phaser^® 7800

Last month we started cracking open one of the fusers for the Xerox WC-75xx and WC-78xx copiers. It was a good long procedure—too long to fit into one article, so this month we’ll finish the story and cover the second half of taking one of these apart. 

10. Remove two shoulder screws from the front end (red screws as shown in Photo #10).

11. Now you can remove the rear metal bracket assembly (five screws as shown in Photo #11). One of the screws (#4) is partly hidden behind part of the bracket. Since you can’t get at it straight on, the 5.5mm nut driver won’t get it loose easily. You’ll need a Phillips head driver at an angle for that one. Be careful not to let any of the gears fall off, as several will be loose on their shafts at this point.

12. Next remove one more screw to take off a small metal plate that retains the largest black gear. Also remove one e-clip, which holds the smaller black press roll idler gear (see Photo #12).

13. Remove the e-clips from the front & rear pressure pivot point shafts (see Photo #13 which shows the rear one).

14. Remove the rear inner frame (two red shoulder screws). See Photo #14 that shows the fully disassembled rear end.

15. Now you will remove the pressure roll assembly. Gently lift the rear end of the pressure roll assembly and then shift the assembly toward the rear end till it slides off of the front pivot point shaft. See Photo #15, which shows the pressure roll assembly removed.

16. Moving on to the final stretch, remove the heat belt stripper plate (black plastic). You will want to first find something you can use as a gauge for spacing the stripper plate from the heat belt when you go to reassemble the fuser. A pair of flat credit cards serves well for this purpose (see Photo #16).

17. Remove the heat belt assembly from its frame (four screws, two from either end). Note that these four screws are short dome-headed Phillips head screws. Be sure to re-use these same short screws in their right places during reassembly.

18. Finally, carefully slide the heat belt off of the thermal control assembly, which is at its core (see Photo #17). Be gentle with the thermistor heads when you go to slide the new heat belt back into place. You’ll need to tuck those thermistor heads back in.

19. Reassemble everything. Take your time. There are a lot of parts and a lot of screws, but with the photos in this write-up, and showing off your good mechanic skills, it’ll all go back together nicely.

Well done, you’ve rebuilt a costly fuser and kept it from the landfills. I hope you are all having a wonderful autumn. Hope to catch up with you next month.