CHOE RESIDENCE - PLANT LIST
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1. Blank Fuser Connector Pin 12 Bias Static Eliminator Brushes brown wire Testing the N4525 Circuits e Hi Watt Lamp amp Thermostats Circuit Pins 9 amp 3 should be between 4 and 12 Ohms Q e Lo Watt Lamp amp Thermostats Circuit Pins 7 amp 3 should be between 4 and 12 Ohms Q e Front Thermistor Circuit Pins 4 amp 5 e Rear Thermistor Circuit Pins 1 amp 2 Both Thermistor circuits should measure a high but not infinite resistance on the 1000 Ohms Q scale and should drop as the face of the thermistor is warmed up You ll also want a quick run down of how to approach each possible fuser related Status Code Sometimes these machines are reluctant to display a Status Code at all Pressing the Machine Status button DC220 and DC332 styles only will usually give you an opportunity to view the Fault History the top code is the most current Status Code Some of the codes need to be reset from the diagnostics before the machine will attempt to warm up again U4 1 Status Code means Fuser Under temperature you ll be looking for a bad heat lamp or blown thermostat The U4 1 does not require a reset from diagnostics U4 2 Status Code means Fuser Over temperature This code you ll want to approach with extra caution You need to figure out why the fuser got too hot otherwise you ll pop a new fuser in and have it ruined by the same initial problem which caused the overheat It coul2. Fixing the Fusers Xerox DC220 style DC332 style amp N24 style Document Centre DC220 DC230 DC420 DC426 also DC332 DC340 DC425 DC432 DC440 Docuuprint N24 N32 N40 N3225 N4025 amp N4525 If you ve been following recent ENX articles you ve seen we ve repeatedly turned the floodlight of our attention to the fuser modules and how to fix them Here is a series of machines which is definitely plentiful enough to be worth learning about The Xerox Document Centre 220 230 420 426 and also the DC 332 340 425 432 440 are copiers which are basically Printers with a separate scanning section suspended above the printer engine The straight printers in this series include the N24 32 40 N3225 4025 and the N4525 These machines are plentiful and the fusers are moving rather well out there They are not terribly difficult to disassemble and just about all of the parts are available so unless you are super busy and don t have time to do this sort of work it pays to take home the used fuser and fix it in the comfort of your own workbench for the next customer who calls needing one First we ll do a quick rundown of the 3 basic versions of the Fusers in this group including the part numbers which apply to them Then we will dissect one of these things and see how they come apart Afterward we ll look at how to reset the Fuser Overheat Status Codes and the Maintenance Cycle The fusers are offered in the OEM Parts Lists as Fuse
3. acing Cover AC Connector removed 6 Next remove the bar which is adjacent to the Pressure Roll it has static eliminator brushes attached to it Take note of how the 3 tined fork like contact at the front end is seated against the bar The bar can be released by simply backing out the screws a tiny bit one from either end of the bar Don t take those screws off all of the way because the white plastic bushings which are on either end will fall off easily into several pieces This step doesn t apply to the DC220 version which is missing this bar 7 Remove the Heat Roll Stripper Assembly 2 screws 10mm self tapping Clean off the magnets which are opposite of each finger these serve to catch any toner flakes which the fingers scrape off of the heat roller There are no such magnets on the DC220 version To get the individual 5 fingers off of the assembly bracket you must first remove a tiny screw at one end to take a metal plate off of the assembly 8 Check the height of the pressure screws at both front and rear and write down the measurements so that you can return the screws to the same height There is a Fuser Nip Adjustment available for the DC220 which we ll look at later on Back out both of the Fuser Pressure Screws and place the screws springs and collets or washers aside n a safe place where they won t disappear on you 9 Now if you lift the pressure arms the Pressure Roll with its bearings can be remov
4. d be that the Fuser Cooling Fan is not doing its job properly make sure it turns freely in operation and that any filter which may be present isn t clogged also make sure the machine has adequate space around it to breathe Its also possible that a short in the wiring or on the Driver Board is causing one or both heat lamps to stay on continuously so once you reset the U4 2 code from diagnostics you ll want to watch the fuser to see if the lamps come on and more importantly you ll want to make sure that once they ve reached the ready state they cycle on and off like they re supposed to Once you re ready to watch the lamps carefully and you ve repaired the problem which caused the U4 2 code you can reset it from the Diagnostics as follows Enter Diagnostic Mode press Access on the panel then enter the default password 1 1 followed by Enter Then touch dC Routines and then dC131 Scroll through the list to 50 20 Fuser Over temp Reset Press Read and then change the value from 1 to 0 and press confirm to lock n your selection When you turn the power off and back on the machine will attempt to warm up again watch those lamps to make sure they cycle out when the fuser s fully heated U4 3 Status Code means Fuser Thermistor Failure This code comes up if the machine detects an Open Circuit across the Thermistor Circuit Make sure the fuser s f
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6. ed It is a Sleeved roller The Heat Roll is now also available to lift out of the assembly You ll want to release the green ground strap from the rear pressure arm to give you more room to open that rear arm wide 10 With the Heat Roll Assembly out you can access the Thermistor and the two Thermostats Note that the DC220 version has only one Thermostat The N4525 has as second Thermistor located close to the front end of the fuser 11 Reassemble Folks often ask which way the Thermistor and Thermostats flanges on the heat rolls are supposed to be positioned The bearing flanges need to be positioned towards the end of the roller and must sit outside of the metal frame on both ends when you go to place it back in the fuser The newer versions of the fusers have a rather clever way of releasing the tension on the pressure roller during storage and shipping This is important because it doesn t take terribly long for the pressure roll to develop a flat spot which will cause all kinds of clunking noises before it rounds out and recovers They come with a metal cap which is twisted down over the Pressure screw to cam up the pressure arm When someone goes to install the new fuser it comes with instructions to turn each of these caps 1 2 turn counterclockwise to remove them before using the fuser if you were to forget and leave the caps in place the fuser would have no pressure and the copies would come out unfused Keep any o
7. essure Roll Cover Assembly It is relatively fragile so removing it early in the process is a good idea It is held on by 3 screws self tapping 2 Remove the Front Outer Facing Cover which has the green jam removal gear attached to it 2 screws 6mm machine thread You can now lift out the front yellow plastic finger pull not present on the DC220 version 3 Release the two front Heat Lamp Contacts they are screwed to the Front End Cover Once the lamp contacts are freed up it is safe to remove the Front End Cover 2 screws from the front 10mm machine thread Be gentle with the lamp return contact which is now exposed and vulnerable You can see how trying to yank the Front End Cover off before you release the lamps would be a mistake which would result in broken glass Front End Exposing the two Lamp Contacts 4 Now for the rear end Start with the Rear Outer Facing Cover with its front yellow plastic finger pull 2 screws from the outer face short machine thread This reveals a sphagetti of wires see Photo Then you can release the Rear End Cover and pivot it out of your way 2 screws from the rear end 10mm machine thread 5 You ll need to release the two wire leads for the fuser lamps in order to then slide them out through the opposite front end I found it most convenient to put the lamp terminal screws right back n place re securing the red and blue wires which go on to the Rear End With the Outer F
8. f these caps you run across for future use They are handy indeed Pressure Relief Cap for storage Removed during installation of fuser When you respond to a Fuser Related call you ll want to bring a new fuser or one you rebuilt earlier and little bit of information First thing to do is to check out the fuser s fuser lamp circuits and the thermistor circuit as well It Il be handy to know which pins are which on the fuser module so that you can diagnose the problem without needing to take the fuser apart You ll notice that the pin numbering is not consistent This is because the pin out in the Service Manual is not consistent The DC220 numbers the pins top to bottom and the others number the pins from right to left Lets pin these things out one style at a time DC220 style Fuser Connector PJ12 Pin out Pin 1 Thermistor thin black wire Pin 2 Blank Pin 3 Hi Watt Heat Lamp red wire Pin 4 Lo Watt Heat Lamp blue wire Pin 5 Thermistor thin black wire Pin 6 Ground green wire Pin 7 Blank Pin 8 Return from Heat Lamp amp Thermostat Circuit white wire Testing the DC220 style Circuits e Hi Watt Lamp amp Thermostat Circuit DC220 style Pins 3 amp 8 should be between 4 amp 12 Ohms Q Fuser Connector e Lo Watt Lamp amp Thermostat Circuit Pins 4 amp 8 should be between 4 amp 12 Ohms Q e Thermistor Circuit Pins 1 amp 5 should measure around 300K Oh
9. ifferent shape to the metal contact at one end see photo of the ends of the two lamp types Most of the parts for the N4525 appear to be identical to the N24 DC332 version although obviously the AC Connector differences make it impossible to interchange the entire fuser module Another difference is that the newer N4525 has an extra wire which goes to a static eliminator brush on the heat roll The DC220 version of the fuser does not share common parts with the other fusers in spite of the design being very similar The Heat and Pressure Rollers of the DC220 fuser are considerably smaller in diameter compared to the others Even the Heat Roll Stripper Fingers will not interchange the DC220 has a taller profile so it won t fit into the holder bracket of the other versions Roller differences left DC332 N24 right DC220 First lets get oriented see the Orientation photo Ill be referring to the Rear and Front ends The Heat Roll Drive Gear 1s at the rear end Then there is the top and Bottom as the fuser would sit in the machine The Outer face is the part which 1s visible when you open the left door of the machine to access the fuser We will use the DC332 N24 version as the Guinea Pig and model Outer face for the disassembly part of this article Where Bottom appropriate I ll include a note about how the DC220 Orientation or N4525 procedure might differ Procedure 1 Remove the Pr
10. ms Q when the fuser is cold and resistance should drop if the thermistor s face is warmed up drops to around 1 5K Ohms when at operating temperature DC332 style amp N24 style Fuser Connector PJ12 Pin out Pin 1 Thermistor yellow wire Pin 2 Thermistor yellow wire Pin 3 Blank Pin 4 Bias Static Eliminator Brushes brown wire Pin 5 Lo Watt Heat Lamp blue wire Pin 6 Hi Watt Heat Lamp red wire Pin 7 Return from Heat Lamp amp Thermostat Circuit white wire Pin 8 Ground green wire Testing the DC332 amp N24 style Circuits e Hi Watt Lamp amp Thermostats Circuit DC332 style Pins 6 amp 7 should be between 4 amp 12 Ohms Q amp N24 style SR Fuser Connector e Lo Watt Lamp amp Thermostats Circuit Pins 5 amp 7 should be between 4 amp 12 Ohms Q e Thermistor Circuit Pins 1 amp 2 should measure around 300K Ohms Q when the fuser is cold and resistance should drop if the thermistor s face is warmed up drops to around 1 5K Ohms Q when at operating temperature N4525 Fuser Connector PJ12 Pin out Pin 1 Rear Thermistor yellow wire P n 2 Rear Thermistor yellow wire Pin 3 Return from Heat Lamp amp Thermostat Circuit white wire Pin 4 Front Thermistor black wire P n 5 Front Thermistor black wire Pin 6 Blank Pin 7 Lo Watt Heat Lamp blue wire Pin 8 Blank Pin 9 Hi Watt Heat Lamp red wire Pin 10 Ground green wire Pin 11
11. r Modules and they are also offered for some of the machines as part of the OEM Maintenance Kits The OEM kits include an OEM reworked Fuser Module 12 Feed Rolls enough to do 4 trays and a Bias Transfer Roller BTR Assembly Here are some of the part numbers which pertain to the fusers which are covered n this article DC220 230 420 426 Fuser Module 126K6050 DC332 340 425 432 440 Fuser Module 600K73193 N24 32 40 N3225 4025 Fuser Module 126K10011 Maintenance Kit 109R486 N4525 Maintenance Kit 109R48 The 4 types of fusers above are different in some ways from one another although the procedure for disassembling them remains virtually the same for all of them The easiest way to tell these apart 1s to look at the main AC Connector which interfaces with the one in the machine The DC220 version is substantially different from all of the other versions It has a white connector with 8 female contacts The N24 version has a very different AC Connector black with places for 8 pins The N24 version is proving to be interchangeable with the DC332 machines The newer N4525 model has a different AC Connector which is black and has places for 12 pins Take a look at the photos below which show all 3 versions DC22 Each of these fusers have two Fuser Lamps a H Watt Main Heat Lamp and a Low Watt Sub Heat Lamp They are different for each of the 3 versions shown above differences in wattages and also the DC220 version has a d
12. ully seated and that the fuser connector s making good contact with the connector n the machine Check the thermistor circuit using the 1000 Ohms scale as detailed earlier This code does not require resetting from diagnostics Maintenance Light N24 style and N4525 only The N24 style and the N4525 will call for a Maintenance Kit after 300K prints You will need to reset the Maintenance Counter from the Diagnostics before the machine will operate again Resetting the Maintenance Kit Counter Hold down the 2 lt Item Up gt And the 5 lt Item Down gt buttons at the same time while turning on the Printer Continue holding those two keys until the message IOT shows up Then within 5 seconds after the IOT message appears hold down the 0 lt On Line gt and 5 lt Menu Down gt keys at the same time until it says Reset Complete Please Reboot Then turn the power off and back on That should give you all you need to approach these fusers with confidence Nothing like a little bit of familiarity with a fuser before you begin ey Happy Repairs Britt works for The Parts Drop a company whose primary business is providing parts supplies and information for Xerox brand copiers printers and fax machines You can find more information on their website www partsdrop com There s a complete listing of past articles under contributing writers on the ENX website www ENXMAG com if you d like to read more about Xerox bran
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