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Xerox Phaser 8200 Heater Repair - Replacement - TechnologyInstructions.com

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Xerox Tektronix Phaser 840/850/860/8200 Drum Heater Replacement Instructions

These Xerox Phaser printers have heaters in them that warm up the printer and aid in melting the ink sticks for the printer to work. They call them thermal heaters or some sort of technical name like that but the fact of the matter is they are simply Halogen flood light bulbs that you find at any full supply hardware store like Home Depot, Lowe's, etc. I'm not sure if all the bulbs are of the same wattage but the ones in the 8200 model are 150 watt. It takes two of them and they cost about $6 each.

The instructions below are written by me so I think you will find them to be in plain English. I have no college degree and have not been to any extensive tech geek school so most people will understand my instructions. When I first ran into this problem with my printer I did some research, took my machine apart about 5 times, broke a thing or two so I think I can help you avoid repeating my struggles. I guess I should say that I am not a Xerox technician and do not warrant these instructions to be full proof so USE THESE INSTRUCTIONS AT YOUR OWN RISK! There you go, have fun. I'm a little slow so the entire process took me 2-1/2 hours the first time and 1-3/4 hour each time after that.

WHAT YOU WILL NEED:

  1. Two double ended 150 watt halogen bulbs.
  2. One T-15 star tip screwdriver (or the bit).
  3. One T-20 star tip screwdriver (or the bit).
  4. One strong paperclip.
  5. Optional: One pair of rubber gloves to avoid touching the light bulbs.
  6. You can also use the actual repair manual pages for these procedures, click here.

INSTRUCTIONS:

  1. Power the machine down properly. Make sure it turned itself totally off before you start. If you fail to do this the inside may not be parked properly and you will have problems getting stuff out of the inside.
  2. Unplug the machine. An electrical jolt may not have the same affect as a cup of coffee.
  3. Remove the paper tray.
  4. Flip down the front panel that allows you access to the waste tray/maintenance kit.
  5. Remove the maintenance kit by pulling it out. Set it somewhere on a level surface and keep it level.
  6. At the top corners of the opening you will see one screw on each side, remove them.
  7. Reach around to the rear of the printer and remove the two screws you find for the side covers near the top of the printer.
  8. Once you have those 4 screws removed you can remove the covers by lifting them off. It helps to lift open the top panel kind of pry up on the clip at the top of the printer then push out at the top. Once the top is loose the lower edge lifts off, almost falls off.
  9. Disconnect the head tilt spring on the left side.
  10. Take the feed drive belt loose from the lower gear on the left side.
  11. Remove the clip from the upper feed roller clutch and slide it off the shaft (photo above). I just let it hang by it's wires while I did the rest. Remember it has that slot in the end of it that has to fit over that metal bracket when it goes back on.
  12. Slide the gear off the shaft. It has a slot in the otter edge of it that needs to slide over the bracket.
  13. With the front panel open, remove the two screws that hold the chrome duplex guide, and remove the guide.
  14. Remove the left side maintenance drawer guide. Remove the one screw at the front, then pull guide away from the metal frame about 1/4" then push it back a little.

    This action will cause it to fall in so you can pull it all the way out of the machine.
  15. The right side is a little tricky. If you look way back under the machine you will see a large roller at the right side that is actually in the way of the right guide coming out. On the outer right side of the machine you will see a gear behind a metal guard, turn that gear counter clockwise several times to get that roller to move to the left, out of the way of the guide.

    Once you have that roller moved to the left, remove the screw that holds the right guide and remove the right maintenance tray guide. Remember to pull the front edge of it away from the side before you push back on it a little to free it for removal.
    WARNING: The next step should be done with extreme care. There is a small paper feed sensor that can be broken if you do not watch it.
  16. Remove the upper feed roller assembly. This is done by removing the screw on the right.

    Then unplug the electrical connector on the left, remove the shaft clip from the left edge of the shaft. It is a little hard to reach so I used a bent standard paperclip (the paper clip was a medium size one, not the very small one).
    NOTE: When you remove the clip you will notice a brass bushing on the left side that needs to go back the way it is when you put the printer back together.
    You can now remove the unit by carefully holding the bottom of this assembly with both hands, slide it to the left about a 1/4 of an inch then slide the right end out, and then slide the left end out of the hole.
    NOTE: Set this assembly down carefully. There is no need to take it apart. It does have that fragile paper feed sensor in it so try not to break it.
  17. From the right side of the printer, unplug the heater assembly. If you look into the machine you will see it at the right, it is a brown connector with about 7 wires going into the plug.
  18. From inside the printer, remove the two larger screws that hold the heater assembly in place.

    They have larger screw heads like the exterior side panels. Do not remove the smaller inner screws. Once you have the two screws removed take the heater assembly out.
  19. NOTE: Figure out a way to replace the bulbs without touching the glass parts with your fingers (you can use surgical or rubber gloves). The oil from your hands will effect the life and performance of the bulbs (have fun doing that, I had a hard time just getting them out of the package without touching them).
    Replace the bulbs and put the printer back together.

ASSEMBLY TIPS:

  1. Step 16: While replacing the upper feed roller assembly you will notice that there are actually two shaft brass bushing, one on each side that will need to be aligned and seated properly for the assembly to be properly installed.
  2. Step 15: When you put the printer back together, do not worry about turning the gear back to the far right. The printer will re-set that itself when the power is turned on.
  3. Step 14: Whey you install the left maintenance guide, you may have to turn the gear on the right side of the printer clockwise a little to get the guide to fit back in it's slots.

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This page was last modified on 07/30/2010

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