3501i - Fuser problem

[BillyCarpenter]

This is a little involved so bear with me. On Friday I responded to a call on a 3501i for a dark streak. I pulled the fuser and immediately saw that the teflon was worn off in the same area that corresponded with the smudge on the paper.

I didn't have a fuser with me so I reinstalled the original fuser and got a C6610 error code. I ran U906 w/no success. I reseated both fuser connectors and checked for any bent pins. Everything looks great there. I ran U030 to check the fuser release motor. I could hear the motor but it sounded funky and quickly stopped. Not sure what it's supposed to sound like. I could never clear the C6610 error code.

My next step was to put a new fuser on order...which arrived today. The instructions in the box said to update the firmware before installing this fuser. I did that.

I then turned the machine on and noticed a smell. I wasn't too concerned because a new fuser will produce a smell. I ran a test page and there was a double image. I ran another test page with blank paper. After about 5-sheets it coded out., This time it was a C6000 error. I removed the fuser and inspected and that's when I saw that a chuck of the orange roller had stuck to the upper roller.

I'm at a loss. I don't want to install another new fuser and ruin it, too.


Any help would be appreciated.


PS - I did a forum search and saw where blackcat talked about a U163 simulation to reset a fuser error but it isn't there on this machine nor do I see it in the manual. ?????

[kleankopy]

Re: 3501i - Fuser problem

I believe we had 1 do that and it was the power supply. Not switching lamps off and melted fuser.

[Ropariva]

[BillyCarpenter]

Re: 3501i - Fuser problem


U167 clears the counter...which I did. But it's does not reset an error code.

[blackcat4866]

Re: 3501i - Fuser problem

The U163 applies only to the Alphard Mercury & AlphardII Mercury (color), (not sure about AlphardIII Mercury & AlphardIV Mercury).

It's possible that you've got a hot spot in the IH coil.
It's possible that you've got a bad IH board.
It's possible that you've got a bad main board.

And you'll need another fuser. Preferably you'll try an old used fuser first, to determine if it's going to melt down, before you install the new good fuser.

I'd also confirm that the U161 fuser settings are at default, before doing anything else.

You probably glanced at the recent post about Alphard fusing, in which I discovered the machine plugged into a 375W UPS battery backup, causing very strange, inconsistent fusing. I got some very bizarre power quality analysis readings in this situation. =^..^=

[BillyCarpenter]

Re: 3501i - Fuser problem

The U163 applies only to the Alphard Mercury & AlphardII Mercury (color), (not sure about AlphardIII Mercury & AlphardIV Mercury).

It's possible that you've got a hot spot in the IH coil.
It's possible that you've got a bad IH board.
It's possible that you've got a bad main board.

And you'll need another fuser. Preferably you'll try an old used fuser first, to determine if it's going to melt down, before you install the new good fuser.

I'd also confirm that the U161 fuser settings are at default, before doing anything else.

You probably glanced at the recent post about Alphard fusing, in which I discovered the machine plugged into a 375W UPS battery backup, causing very strange, inconsistent fusing. I got some very bizarre power quality analysis readings in this situation. =^..^=

I just want to express my appreciation for all the help that you've provided me over the past couple of years or how ever long its been. I'm sure that I speak for many people on here as you've provided a ton of help to people.

[BillyCarpenter]

Re: 3501i - Fuser problem

I'm gonna take a used fuser out to the problem machine today but first I wanted to do my homework. Just looking at all the different error codes that pertain to the fuser, it all goes back to the following components as possible problem areas:

1. Engine PWB
2. Power Source Board
3. Fuser Unit

I'm assuming that the Engine PWB is responsible for the all the signal voltages that control the on/off state of the fuser heater. The Power Source Board is, of course, responsible for the high voltage to the fuser heater., And then we have the fuser itself with its different components.

The thing that troubles me a bit is that there was no problem with the original fuser unit until I pulled it and reinstalled. The only problem was the teflon was worn in one spot. Only after reinstalling did I get C6610. I check the wiring. I didn't see any bent pins.

As a young tech, I was was told that if you hear hoof sounds, don't go looking for an elephant. In other words, if the old fuser wasn't coding out when I got there, it's likely that I did something to cause it. But for the life of me, I can't find anything that I did wrong.

Is it possible that it was a coincidence that the fuser release motor just happened to go bad when I was there? I suppose its possible. But then what about the new fuser that I installed that melted down? Is it possible that I received a bad fuser unit? That's a lot of coincidents.


Just thinking this out logically...all i did was disconnect and reconnect 2 wiring harnesses to the fuser unit itself. I see no bent pins or shorted wires but someething tells me to look again. I just don't want to melt down another fuser. Keeping my fingers crossed.

[copykat93]

Re: 3501i - Fuser problem

Good morning... I have been following this post and I am just curious if at the time you pulled their original fuser to inspect it, did you turn off the machine & pull the power cord? I have seen some funky stuff happen when the machine is on, you open the door to access the fuser, remove it & reinstall while power is still on (even though it isn't actually powering up to start) it causes a surge in the engine board & then the issues start. Kind of like disconnecting a doc feeder while the machine is plugged in and when you connect the doc feed harness, it pops the main board in the doc feeder. Just a thought... nothing more.

[BillyCarpenter]

Re: 3501i - Fuser problem

Good morning... I have been following this post and I am just curious if at the time you pulled their original fuser to inspect it, did you turn off the machine & pull the power cord? I have seen some funky stuff happen when the machine is on, you open the door to access the fuser, remove it & reinstall while power is still on (even though it isn't actually powering up to start) it causes a surge in the engine board & then the issues start. Kind of like disconnecting a doc feeder while the machine is plugged in and when you connect the doc feed harness, it pops the main board in the doc feeder. Just a thought... nothing more.

You may be on to something. I did turn the power off before removing the fuser but I didn't unplug. I always unplug if I'm working with boards, drums, dv's, ect., but I've always just turned the power off if its just a fuser.


Anyway, the problem was a bad Engine PWB. I replaced and it worked like a champ. I promise you this, I'll unplug the machine the next time. This was a pain in the ass.


Edit - I misread you post. No, I didn't open the door and leave the power on when removing the fuser. I turned the power switch off.

[blackcat4866]

Re: 3501i - Fuser problem

That's unusual. Thanks for sharing. =^..^=

[BillyCarpenter]

Re: 3501i - Fuser problem

That's unusual. Thanks for sharing. =^..^=

I was just going thru my checklist this morning. I took with me the following:


1. Wiring harness. The one with the flat connector that runs back to the engine PWB.
2. Used Fuser Unit.
3. Engine PWB.

I replaced the wiring harness w/no success.

I replaced the Fuser Unit w/no success.

Finally I replaced the Engine PWB and that did the trick.

I was praying that it wasn't the Power Source Board.

I still feel like I did something wrong that started this domino effect. But time to move on to the next one. Thanks for your help.