The most frequently replaced part in the fuser would be the Fuser Cleaning Cartridge (fuser module). There are several valid part numbers including 008R13042 / 008R13085 / 008R13000. These web cartridges retail for around $200.-. A less expensive alternative is to replace the web only with a good aftermarket product (example 4110FW – Fuser Web). See photo #1 where you can see how the web material is routed in the web cartridge. The Cleaning Cartridge is removable by one centrally located screw near the front end, and then by releasing a single thumb screw near the rear end of the top of the Cleaning Cartridge.
Now let’s get into how to remove the fuser from the machine: FUSER REMOVAL:
CAUTION: These things get super hot, so shut down the machine and then allow plenty of time for the fuser to cool off before you handle it.
Photo #2: Fuser Front Cover – detach the Front Fuser Fan Connector & remove 2 screws marked 1 & 2 above
Photo #2: Fuser Front Cover – detach the Front Fuser Fan Connector & remove 2 screws marked 1 & 2 above
1. Remove the Duplex Drawer by opening the front door and sliding the Duplex Drawer out. Release the stoppers found near the center of each rail, which when pushed in will allow the drawer to slide further till you can gently lift the Duplex Module off its rails.
2. Push in and turn the green handle marked with a “2” to release the Marking Drawer. The Marking Drawer is the one in which the fuser sits. Slide it out and then release the stoppers found near the center of each rail. Releasing those will allow you to slide the Maintenance Drawer further out to the “Maintenance Position.”
3. Remove the Fuser Cleaning Cartridge from the top of the fuser (1 screw + 1 thumbscrew).
4. Take off the Front Cover of the Fuser (2 screws and release the front fuser cooling fan connector) (see Photo #2).
5. Remove the Transfer Belt front cover (2 screws from the front).
6. Remove the Pin Support (2 screws). This piece is located just to the right of the Marking Drawer Release Handle (a green lever-like handle with the “2” on it) below the fuser.
7. Now open the “2d” Fuser Upper Chute and swing it up to the left out of the way.
8. Be sure the fuser is cool first, then grab the fuser from the top center and lift it out of the Marking Drawer carefully.
NOTE that when reinstalling the fuser, the fuser module has two holes in the bottom which line up with a pair of pins sticking up out of the Marking Drawer. To re-secure the Pin Support, wait till everything is back together and the Marking Drawer is slid all the way back into the machine with the green “2” lever back to its latched position, and THEN secure the Pin Support.
Now that you have the fuser out of the machine, you can disassemble it. I think you’ll like this. It’s pretty easy once you know the ropes.
Photo #3: Lower Input Chute (2 screws)
Photo #3: Lower Input Chute (2 screws)
FUSER DISASSEMBLY PROCEDURE:
1. First take off the Lower Input Chute (2 screws) from the left side of the fuser (see Photo #3).
2. Remove the Lower Exit Chute (2 screws) from the right side of the fuser (see Photos #4 & 5).
3. Take off the Press Roll Picker Finger Assembly (2 screws fasten a pair of metal plates to a metal bar) (see Photo #6).
4. Remove the 3 Fuser Heat Lamps by disconnecting their connectors at either end. At the rear end there is a Connector Cover which is snapped in place. Pay attention at this point to which ones go where to help make reassembly easier for you later. The two white connectors at the front end can be interchanged without a problem but at the rear end you have to have 1 white, 1 blue and 1 red connector.
Photo #4: Lower input chute (2 screws)
Photo #4: Lower input chute (2 screws)
Photo #5: Lower Input Chute (2 screws)
Photo #5: Lower Input Chute (2 screws)
5. Next, you will be preparing to open up the Clam Shell to expose the Heat and Press Rolls. You must first raise the Upper Exit Chute (a green lever marked “2a” can be found at the front end of this chute which includes the Fuser Exit Sensor and the Heat Roll Picker Finger Assembly). Then you also need to remove one screw from the front end (see Photo #7) and one from the rear end (see Photo #8).
6.Now open the Clam Shell up by pivoting the heat roll half of the fuser up and to your left (if you’re facing the front end of the fuser) till the fuser is fully opened up (see Photo #9 for a fully opened fuser).
Photo #6: Press Roll finger Assembly removal.
Photo #6: Press Roll finger Assembly removal.
Photo #7: Front Clam Release Screw
Photo #7: Front Clam Release Screw
Photo # 8: Rear Clam Release Screws
Photo # 8: Rear Clam Release Screws
7. Now you can remove the Pressure Roll Assembly out of its cradle. Note at this time how the Press Roll Shaft sits securely in the lever grooves, so you can return it to the same position at reinstallation
8. Next comes the Fuser Heat Roll Assembly. Loosen the scr