Xerox 645 Repair Manual

REPAIR THE FUSERS !
Xerox Workcentre Pro645 style & Pro665 style...
Pro635, 645, 657 & Pro665, 685, 765, 785
So, the heat lamp blew... or the gear broke, or the
thing overheated... It used to be that a technician would
replace the fuser part which actually failed and get paid for the
labor as well as little bit for the part. Nowadays though, its all
about "just replace the fuser module"... The tech makes a 15
minute service call, replaces the fuser, makes a few bucks on the fuser and throws the broken
fuser out... or sends it to the manufacturer for a small credit perhaps. Not much labor there,
so you'd better replace a lot of fusers! Lots of independent technicians are hurting partly
because of this trend... especially now that more and more of the fusers are considered to be
customer replaceable.
Stay in the game... Repair the fusers and save your customer money while working in
the comfort of your own workbench. The whole idea of replacing entire fusers was hatched
by the OEM manufacturers. Xerox and other makers like it this way... they get to have
things done in a warehouse assembly line. A very efficient way to handle equipment repairs,
indeed. To push things in this direction, they've chosen not to spare many of the important
parts in the fusers. Fortunately, many of these "not spared" parts are beginning to surface in
the aftermarket... and if you are in the business of repairing the fusers, you will gather used
cores which have many of the parts in perfectly useable condition. All you really need to
repair a majority of cases, is to find a source for the fuser lamps and heat rolls.
In a recent article, we got the ball rolling on the issue of repairing fuser modules. We
covered the C35 style (C35, C45, C55, Pro35, Pro45, Pro55, M35, M45, M55, DC535,
DC545, DC555). That one is going to be good and popular it appears... in the next year or so
they should start hitting your work bench. Another group of machines which could use all of
our attention are the Xerox WorkCentre Pro645 style (Pro635, Pro645, Pro657) and the
Pro665 style (Pro665, Pro685, Pro765, & Pro785). These machines had a predecessor in the
7042 style (4010, 4011, 7041, 7042). The 7042 had a very similar fuser (126K3210) although
there were some substantial differences as well. The parts which are common to all three
"styles" include the Fuser Heat Roller, Fuser Pressure Roller, Bearings (both heat and press),
the Fuser Drive Gear, and the 3 fuser idler gears. The items which do not cross to the 7042
fuser include the Fuser Lamp, Thermistor, Thermostat, Exit Switch, Exit Roller and Picker
Fingers.
The only apparent difference between the Pro645 style fuser (126K9420 for the
110volt version) and the Pro665 style (126E1920 for 110 volt) is the Thermistor... the wiring
for the two versions have a different Connector on them.
FUSER REMOVAL PROCEDURE:
Removal procedures for getting the fusers out of the machines vary only in the way
you access the connectors to unplug them. For the Pro645 style:
• Open the clamshell
• Remove the Drum Cartridge / DV Unit Assemblies
• Disconnect a connector at the rear of the fuser and a second one at the front end...
• Remove two screws (one near the front end and one near the rear end), both are down
near the base on the feed-in side of the fuser.
Pro645 style - Fuser Assembly