DC-240/250 Fuser Roller Replacement Guide

This technical support guide provides step-by-step instructions for replacing the fuser roller on the Xerox DocuColor 240 and Xerox DocuColor 250.

The complete replacement procedure consists of 27 illustrated steps covering removal of the fuser components, replacement of the fuser roller, and reassembly of the fuser unit.

Compatible Models

  • Xerox DocuColor 240
  • Xerox DocuColor 250

Before You Begin

This guide is intended for technicians and users familiar with servicing copier equipment. Follow the illustrated instructions carefully and ensure the machine is switched off and the fuser has cooled before servicing.

Fuser Roller Replacement Procedure

Steps 1–3: Remove the Covers

  1. Remove the four screws from the top cover and detach the top cover from the fuser unit.
  2. Remove two screws from each side cap and detach both side caps.
  3. Prepare the fuser unit for further disassembly.

Your original guide specifies tools including a small flat screwdriver, Phillips screwdriver, calliper and ratchet screwdriver.

Steps 4–6: Remove the Rear Components

  1. Remove the metal brush plate.
  2. Remove the back cover.
  3. Using a small flat screwdriver, unclip the plastic clip from one side of the metal plate and remove one screw from each end of the plate.

Steps 7–9: Disconnect the Fuser Components

  1. Detach the three plugs from each side of the fuser unit before removing both end plates.
  2. Remove the three heater lamps from inside the fuser roller.
  3. Remove the two large screws from the bottom of the fuser unit.

Steps 10–12: Open the Fuser Unit

  1. Remove two screws from each end of the fuser unit.
  2. Remove two screws from the back end of the fuser unit.
  3. Separate the fuser unit by lifting the upper portion. Lift the metal flap covering the fuser roller before removing the roller for replacement.

Steps 13–15: Replace the Fuser Roller

  1. Remove the bearings from both ends of the old fuser roller and reinstall them onto the new roller.
  2. Install the new fuser roller with the bearings attached.
  3. Attach the upper part of the fuser unit back onto the lower portion.

Steps 16–18: Begin Reassembly

  1. Drive the two screws into both ends of the unit.
  2. Attach the blue plug as shown in the illustrated guide.
  3. Attach the screws at both ends.

Steps 19–21: Reinstall the Heater Lamps and Brush Plate

  1. Insert all three heater lamps into the fuser roller.
  2. Attach the three plugs on each side of the fuser unit.
  3. Install the metal brush plate and secure the two screws at both ends.

Steps 22–24: Reinstall the Cover

  1. Install the two large screws at both ends.
  2. Install the cover as shown in the illustrated guide.
  3. Secure the cover with two screws.

Steps 25–27: Complete the Reassembly

  1. Attach the side plates at both ends and secure them with screws.
  2. Attach the side caps at both ends of the fuser unit.
  3. Attach the top cover with two screws. The completed fuser unit is now ready to be installed back into the machine.

Download the Illustrated Technical Guide

For detailed photographs accompanying each step, download the complete Xerox DocuColor 240/250 Fuser Roller Replacement Technical Guide (PDF).