Xerox DocuColor 250 (DC250 style) Technical Information - Part I (Fault Code Meanings) Xerox Docucolor 240, 250, 242, 252, 260, WorkCentre 7655, 7665, 7675, 7755, 7765, 7775 When we dove into the fuser modules for this same series a while back, I had noted that "few Xerox models have earned as much praise as the DocuColor 250 series". I've not changed my mind on that. A good sign that this series is here to stay for a while is that there are new models just coming out that use the same engine (the WC 7755/7765/7775 are 2010 releases). These are all sturdy, full color machines with very few inherent problems to report. The machine is well laid out and extremely technician friendly. This month, let's get started with a brief introduction and then take a dip in the rather large pool of possible Fault Codes you might encounter. We'll also cover how to get into the Diagnostic Mode so you can clear a few of the Faults which you might run into in your adventures. I am told these machines are easy to work on as far as physical mechanics are concerned. How easy? Well, there are three maintenance drawers. One with the Drum Cartridges and Developer units, a second one with the Transfer Belt Assembly and Belt Cleaner Assembly, and a third drawer with the 2nd BTR (Transfer Roll Assembly) and Fuser Module. A novice can take the DV Unit out if it came down to it. This is unusual and extremely refreshing, an engineering marvel by all means. The two groups of machines within this "DC250 style" have many similarities, but naturally there are differences as well. They share the same fuser modules, toner cartridges and drum cartridges, so internally they are virtually identical. The diagnostics appear to be very similar from what we've seen so far, except that the method to enter the diagnostic mode changed early on in the WC-7655 group of models (v2 software). We'll cover the two ways to get into diagnostics after the fault code list. The Fault Code and their RAPs (Repair Analysis Procedures) in the Service Manual take up a whopping 900 + pages, so this list will have to be severely abbreviated. The plan is to stick to the codes which are more important to field techs. The codes are all laid out as 3 digits (the "Chain") followed by a dash and then 3 more digits (the "Function") (e.g.,: for '010-330', the chain would be '010'). The first three digits do give some hint as to which part of the machine is being referred to (chain '010' for example refers to fuser problems) so it makes sense to generalize in the list as to what part of the machine the various "Chains" point to. Here goes: FAULT CODE LIST: Fault Code: Description / Notes: 075-100 thru 075-135 Paper jam from Tray 5 at takeaway or registration 075-210/211 Tray 5 Lift failure / Lift down failure 077-103 thru 077-118 Fuser Exit Sensor jam or Fault Code: Clearing some fault codes (from Diagnostics): *Fuser Heat Control problems (010-319)… Read below about how to reset NVM value 744-351 back to '0'. **Fuser Overheat problems (010-320)… Read below about how to reset NVM value 744-156 back to '0'. ***Fuser NVM (memory) failure (010-324)… Read below about how to reset NVM value 744-352 back to '0'. Warning (disclaimer): The diagnostics on these machines are designed to be used by experienced copier technicians only. These are very sensitive machines and changing the wrong NVM setting can potentially cause serious problems. Only use the information which follows if you are willing to take 100% responsibility for your actions. 1. Diagnostic Entry: For DC240/242/250/252/260: Hold down the '0' button for 5 full seconds and then while still holding the '0', press 'Start'. A prompt for a password will show up. Use the default password '6789'. For most WC-7655/7665/7675's (some early ones work like the DC250 above): Hold down together '*', '#', & 'Stop' until the password prompt shows up. Then use the '6789' default password. 2. Press "Log-in/Log-out" button, then on the touch screen, touch "System Settings", followed by "Common Settings", then "Maintenance / Diagnostics". 3. From the menu which appears, scroll down to "NVM Read / Write". 4. Scroll down until you get to "chain 744". Find the appropriate code (744-351 for Fault Code 010-319, 744-156 for Fault Code 010-320, or 744-352 for Fault Code 010-324). Select the code you want to change and click on "read / write" or "change" (the manual is vague about this final part). You will need to confirm or lock-in your change. 5. Finally when you exit diagnostics, be sure to reboot the machine so the changes stick. Since we hit on the diagnostic entry, you might as well learn how to get into the User Tools mode. USER TOOLS MODE: For DC240/242/250/252/260: Press "Log-in/Log-out" and enter the password '11111' (five 1's). For WC-7655/7665/7675: Press "Log-in/Log-out" and enter the username "admin" followed by the password '1111' (four 1's) Fault Code: Description / Notes: 002-770 The Hard Drive (HDD) is over capacity 003-xxx codes Generally: Communication Errors between boards in the machine 005-xxx codes Generally: Document Feeder problems 005-121 thru 005-158 Document Jams 005-194 thru 005-199 Document size mismatch problems 005-275/280 Document Feeder communication errors 005-281 thru 005-283 Document Tray lift problems 005-284 Document APS (Automatic Paper Sensors) failure (there are 3 sensors which detect various paper widths on the Document Feeder) 005-285 Document Nudger up failure 005-286 Document feed-out sensor failure 005-303 Document Tray Interlock is open 005-304 Document Platen Interlock opened during a job 005-305 Document Top Cover Interlock opened during a job 005-306 Document Tray Interlock opened during a job 005-308/309 Document Left Cover is open or opened during a job 005-906 thru 005-918 Document is still detected in feeder after power-on or after closing one of the document door interlocks 010-xxx codes Generally: Fuser faults 010-311 Open Fuser Thermistor was detected (white connector) 010-319 * Fuser Heat Control problem *NOTE: This code must be cleared from Diagnostic Mode… details below. 010-320 ** Fuser Overheat problem… (can be reported by any of the 3 thermistors in the fuser) ** NOTE: This code must be cleared from Diagnostic Mode… details below. 010-322 thru 010-323 Fuser Thermistor open circuit detected (NCCenter Sensor or Rear Thermistor) 010-324*** Fuser NVM (Memory) failure *** NOTE: This code must be cleared from Diagnostic Mode… details below. 010-326 thru 010-327 Fuser Heat Control problems 010-330 Fuser Motor failure 010-420 Fuser Module nearing end of life... NOTE: Read below for fuser count reset info. 010-421 Fuser Module "End of Life"… NOTE: If the fuser is still good, you can replace the Fuser Reset Fuse (on top of the fuser) and possibly the Fuser Heat Roll to keep it running. 012-xxx codes Generally: Finisher problems 013-xxx codes Generally: Finisher / Booklet Maker problems 016-xxx codes Generally: Options or Software failures 016-311 Scanner not detected 024-340 thru 024-747 ESS (Network Controller) problems 024-910 thru 024-917 Paper size Sensing problems (in one of the paper drawers) 024-919 Face Up Tray interlock open 024-920/922 Face Down Tray 1 full / Face Down Tray 2 full 024-923/924/ 925 Toner Cartridge Empty - Y / M / C 024-927/930 OCT (Offset Catch Tray) full / Stacker Tray full 024-934 thru 024-939 Paper type mismatch errors 024-946/947/ 948/949 Tray not in position (T1/2/3/4) 024-950/951/ 952/953/954/ 955/956 No Paper in tray (T1/2/3/4/5/6/7) 042-313 Rear Fuser Cooling Fan failure 042-320/321/ 322/323 Drum Motor failures - 320=Y, 321=C, 322=M, 323=K (black) 042-324 IBT Belt Drive Motor failure 042-325 Main Motor failure 042-326 IBT Belt Home position not detected in time 042-327 IBT Belt Position failure 042-328 IBT Belt Edge Sensor failure 042-330 Fuser Exhaust Fan failure 042-331 Blower Motor Fan failure 042-600/601/ 602 Belt Edge timing failures 042-603 Suction Filter end of life 045-xxx codes Printing communication failures 061-320/321 ROS (Laser Unit) polygon motor failures 061-323 thru 061-607 ROS (Laser Unit) problems 062-357 CCD (Scanner) Fan failure 062-360 Exposure Carriage position failure. 062-371 Exposure Lamp not lighting (or very dim) 071-101 thru 071-105 Paper Jams from Tray 1 at takeaway or registration 071-210 Tray 1 Lift failure 072-101 thru 072-105 Paper jams from Tray 2 at takeaway or registration 072-210 Tray 2 Lift failure 073-101 thru 073-105 Paper jam from Tray 3 at takeaway or registration 073-210 Tray 3 Lift failure 074-101 thru 074-105 Paper jam from Tray 4 at takeaway or registration 074-210 Tray 4 Lift failure 075-100 thru 075-135 Paper jam from Tray 5 at takeaway or registration 075-210/211 Tray 5 Lift failure / Lift down failure 077-103 thru 077-118 Fuser Exit Sensor jam or final Exit Sensor jam. 077-120 Post 2nd BTR Roll Sensor jam 077-123 thru 077-130 Inverter jams 077-300 Front Cover interlock open 077-301 Left Door interlock open 077-302 Right Cover interlock open 077-303 Transfer Module 2 interlock open 077-909 Paper detected in paper path at power-on 078-100 thru 078-151 Paper jam from Tray 6 / High Capacity Feeder (HCF) at takeaway or registration 078-250 Tray 6 (HCF) Lift failure 078-300 HCF (Hi Capacity Feeder) Top Cover interlock open 078-301 HCF Docking Interlock open 089-600 thru 089-617 Image Registration Control problems 091-311 BCR and Black Charge Corotron Cleaner control problem 091-312   Black Charge / Preclean HVPS (Hi Volt Power Supply) failure 091-313 Drum Cartridge CRUM (chip) communication failure 091-320 Black Charge Corona Wire is broken 091-400 Waste Toner Bottle replacement needed soon 091-401 Black Drum Cartridge near end of life 091-403 Black Charge Corotron Assembly near end of life 091-404 Black Charge Corotron Assembly has reached end of life 091-411 Yellow Drum Cartridge near end of life 091-421 Magenta Drum Cartridge near end of life 091-431 Cyan Drum Cartridge near end of life 091-910 Waste Toner Bottle not detected 091-911 Waste Toner Bottle full 091-913 Black Drum Cartridge at end of life 091-914 thru 091-916 or 091-921 Black Drum Cartridge CRUM communication problems 091-917/920/924/925/927 Yellow Drum Cartridge CRUM communication problems 091-918/922/ 928   Magenta Drum Cartridge CRUM communication problems 091-919/923/ 926/929   Cyan Drum Cartridge CRUM communication problems 091-932 Yellow Drum Cartridge end of life 091-933 Magenta Drum Cartridge end of life 091-934 Cyan Drum Cartridge end of life 092-649/650 ADC Sensor Shutter failures 092-651/652 IBT Belt ADC Sensor (MOB ADC) failures 092-653 thru 092-660 ATC (from Developer Unit) problems…653/657=yellow, 654/658=magenta, 655/659=cyan, 656/660=black 093-300 Marking Drawer Interlock open 093-313 thru 093-317 Toner Dispense problems… 314=Y, 315=M, 316=C, 317=K (black) 093-320 Developer Motor failure 093-421 thru 093-425 Toner Cartridges low 421/422=K(black), 423=Y, 424=M, 425=C 093-600 thru 093-912 Toner Dispense problems (600=Y, 601=M, 602=C, 603/912=K(Black), 093-918 thru 093-940 Toner CRUM failures (918/924 /925/926/936/ 940=K(black),927/933/937 =Y, 928/934/938 = M , 929/935/939=C 094-320/321 1st BTR (Transfer Roll) retract or contact problems 094-322/323 2nd BTR (Transfer Roll) retract or contact problems 102-xxx codes Generally: Network Controller (ESS) problems 112-700 Finisher Punch Dust Box full (hole punch bin) 116-xxx codes Generally: Network Controller (ESS) problems 123-xxx codes Generally: UI (control panel) faults 124-xxx codes Generally: Configuration errors (e.g., serial number disagreement between various boards or machine speed errors, etc) 127-xxx codes Printing failures   That's it for this month. We'll just have to get a machine in-house to learn a bit more before we tackle a more in-depth exploration of the diagnostics. Eventually, it'd be good to also get into some of the disassembly procedures. This machine is relatively quick and easy to get parts in and out of it, once you know what you're doing. See you all next month! 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, including many of Britt's past ENX articles on their website, ( www.partsdrop.com ) If you'd like to read more about Xerox brand office equipment, there's also a complete listing of past articles under contributing writers on the ENX website ( www.ENXMAG.com )  C