Xerox 645 Repair Manual

REPAIR THE FUSERS ! 

Pro645 style - Fuser Assembly 

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.