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Drawn from a series of Articles first published in ENX Magazine (www.enxmag.com)

DocuColor 250 (DC250 style) Technical Information Xerox Docucolor 240, 250, 242, 252, 260, WorkCentre 7655, 7665, 7675, 7755, 7765, 7775
Warning : 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. 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. Ive 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, lets get started with a brief introduction and then take a dip in the rather large pool of possible Fault Codes you might encounter. Well 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. Ok I am told these machines are easy to work on as far as physical mechanics are concerned. How easy? Well there are 3 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 weve seen so far, except that the method to enter the diagnostic mode changed early on in the WC-7655 group of models (v2 software). Well cover the two ways to get into diagnostics after the fault code list. The Fault Codes 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) (example: 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 reffered 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:
002-770 003-xxx codes 005-xxx codes 005-121 thru 005-158 005-194 thru 005-199 005-275/280 005-281 thru 005-283 005-284 005-285 005-286 005-303 005-304 005-305 005-306 The Hard Drive (HDD) is over capacity Generally: Communication Errors between boards in the machine Generally: Document Feeder problems Document Jams Document size mismatch problems Document Feeder communication errors Document Tray lift problems Document APS (Automatic Paper Sensors) failure (there are 3 sensors which detect various paper widths on the document feeder) Document Nudger up failure Document feed-out sensor failure Document Tray Interlock is open Document Platen Interlock opened during a job Document Top Cover Interlock opened during a job Document Tray Interlock opened during a job

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005-308/309 005-906 thru 005-918 010-xxx codes 010-311 010-319 * 010-320 ** Document Left Cover is open or opened during a job Document is still detected in feeder after power-on or after closing one of the document door interlocks Generally: Fuser faults Open fuser thermistor was detected (white connector) Fuser Heat Control problem *NOTE: This code must be cleared from Diagnostic Mode details below. 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. Fuser thermistor open circuit detected (NC Center Sensor or Rear Thermistor) Fuser NVM (Memory) failure *** NOTE: This code must be cleared from Diagnostic Mode details below. Fuser Heat Control problems Fuser Motor failure Fuser Module nearing end of life... NOTE: Read below for fuser count reset info. 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. Generally: Finisher problems Generally: Finisher / Booklet Maker problems Generally: Options or Software failures Scanner not detected ESS (Network Controller) problems Paper size Sensing problems (in one of the paper drawers) Face Up Tray interlock open Face Down Tray 1 full / Face Down Tray 2 full Toner Cartridge Empty Y / M / C OCT (Offset Catch Tray) full / Stacker Tray full Paper type mismatch errors Tray not in position (T1/2/3/4) No Paper in tray (T1/2/3/4/5/6/7)

010-322 thru 010-323 010-324*** 010-326 thru 010-327 010-330 010-420 010-421

012-xxx codes 013-xxx codes 016-xxx codes 016-311 024-340 thru 024-747 024-910 thru 024-917 024-919 024-920/922 024-923/924/ 925 024-927/930 024-934 thru 024-939 024-946/947/ 948/949 024-950/951/ 952/953/954/ 955/956 042-313 042-320/321/ 322/323 042-324 042-325 042-326 042-327 042-328 042-330 042-331 042-600/601/ 602 042-603 045-xxx codes 061-320/321 061-323 thru 061-607 062-357 062-360 062-371 071-101 thru 071-105 071-210 072-101 thru

Rear Fuser Cooling Fan failure Drum Motor failures 320=Y, 321=C, 322=M, 323=K (black) IBT Belt Drive Motor failure Main Motor failure IBT Belt Home position not detected in time **** IBT Belt Position failure IBT Belt Edge Sensor failure Fuser Exhaust Fan failure Blower Motor Fan failure Belt Edge timing failures Suction Filter end of life Printing communication failures ROS (Laser Unit) polygon motor failures ROS (Laser Unit) problems CCD (Scanner) Fan failure Exposure Carriage position failure. Exposure Lamp not lighting (or very dim) Paper Jams from Tray 1 at takeaway or registration Tray 1 Lift failure Paper jams from Tray 2 at takeaway or registration

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072-105 072-210 073-101 thru 073-105 073-210 074-101 thru 074-105 074-210 075-100 thru 075-135 075-210/211 077-103 thru 077-118 077-120 077-123 thru 077-130 077-300 077-301 077-302 077-303 077-909 078-100 thru 078-151 078-250 078-300 078-301 089-600 thru 089-617 091-311 091-312 091-313 091-320 091-400 091-401 091-403 091-404 091-411 091-421 091-431 091-910 091-911 091-913 091-914 thru 091-916 or 091-921 091-917/920/ 924/925/927 091-918/922/ 928 091-919/923/ 926/929 091-932 091-933 091-934 092-649/650 092-651/652 092-653 thru 092-660 093-300 093-313 thru 093-317 093-320 093-421 thru 093-425 093-600 thru 093-912 093-918 thru

Tray 2 Lift failure Paper jam from Tray 3 at takeaway or registration Tray 3 Lift failure Paper jam from Tray 4 at takeaway or registration Tray 4 Lift failure Paper jam from Tray 5 at takeaway or registration Tray 5 Lift failure / Lift down failure Fuser Exit Sensor jam or final Exit Sensor jam. Post 2nd BTR Roll Sensor jam Inverter jams Front Cover interlock open Left Door interlock open Right Cover interlock open Transfer Module 2 interlock open Paper detected in paper path at power-on Paper jam from Tray 6 / High Capacity Feeder (HCF) at takeaway or registration Tray 6 (HCF) Lift failure HCF (Hi Capacity Feeder) Top Cover interlock open HCF Docking Interlock open Image Registration Control problems BCR and Black Charge Corotron Cleaner control problem Black Charge / Preclean HVPS (Hi Volt Power Supply) failure Drum Cartridge CRUM (chip) communication failure Black Charge Corona Wire is broken Waste Toner Bottle replacement needed soon Black Drum Cartridge near end of life Black Charge Corotron Assembly near end of life Black Charge Corotron Assembly has reached end of life Yellow Drum Cartridge near end of life Magenta Drum Cartridge near end of life Cyan Drum Cartridge near end of life Waste Toner Bottle not detected Waste Toner Bottle full Black Drum Cartridge at end of life Black Drum Cartridge CRUM communication problems

Yellow Drum Cartridge CRUM communication problems Magenta Drum Cartridge CRUM communication problems Cyan Drum Cartridge CRUM communication problems Yellow Drum Cartridge end of life Magenta Drum Cartridge end of life Cyan Drum Cartridge end of life ADC Sensor Shutter failures IBT Belt ADC Sensor (MOB ADC) failures ATC (from Developer Unit) problems 653/657=yellow, 654/658=magenta, 655/659=cyan, 656/660=black Marking Drawer Interlock open Toner Dispense problems 314=Y, 315=M, 316=C, 317=K (black) Developer Motor failure Toner Cartridges low 421/422=K(black), 423=Y, 424=M, 425=C Toner Dispense problems (600=Y, 601=M, 602=C, 603/912=K(Black), Toner CRUM failures (918/924/925/926/936/940=K(black),

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093-940 094-320/321 094-322/323 102-xxx codes 112-700 116-xxx codes 123-xxx codes 124-xxx codes 127-xxx codes 927/933/937=Y, 928/934/938=M, 929/935/939=C 1st BTR (Transfer Roll) retract or contact problems 2nd BTR (Transfer Roll) retract or contact problems Generally: Network Controller (ESS) problems Finisher Punch Dust Box full (hole punch bin) Generally: Network Controller (ESS) problems Generally: UI (control panel) faults Generally: Configuration errors (example: serial number disagreement between various boards or machine speed errors, etc) Printing failures

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 744-350 back to 0. ***Fuser NVM (memory) failure (010-324) Read below about how to reset NVM value 744-352 back to 0. ****IBT Belt Home Position Sensor Failure (043-326) Read below about how to reset NVM value 741-105 to 0 Warning : 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 (the CE Access Number). Use the default password 6789, and press Confirm. For most WC-7655/7665/7675s (some of them with earlier software work like the DC250 above): Hold down together *, #, & Stop until the CE Access Number screen prompts you for a password. Then use the default password: 6789 followed by Confirm. 2. Press the Log-in / Log-out button then on the touchscreen, touch System Settings, followed by Common Settings, and finally Maintenance / Diagnostics. 3. Choose Adjustments from the menu which appears, then look for: Dc131 NVM Read / Write. 4. Touch the first empty block to enter the chain 744. The 1st three digits in an NVM code are called the chain and the second set of 3 digits are called the Function. Enter the appropriate Function code (351 for Fault Code 010-319, 156 for Fault Code 010-320, or 352 for Fault Code 010-324). Touch the Read button. The current setting will show up. Press Val to then change the value back to 0 and press Save. 5. Finally when you exit diagnostics be sure to reboot the machine so the changes stick. Use the Call Close button.

The Machine Status Button:

The Machine Status button near the lower left of the control panel gives folks access to the following stuff: Machine Information (includes serial number, machine configuration, a paper tray status chart, & software versions) Billing Meters Print Report / List (basic reports like job status, copy mode settings, print mode settings, or scan mode settings) Consumables (a list of customer replaceable consumables and their status) While the current fault code or message is normally displayed on the upper left corner of the screen, you may want to also view a Fault History Report to see what faults have been going on lately. This can be done by pressing the Machine Status button. Then touch the Faults tab. A button will show up which will allow you to print out the Fault History Report

System Administrator Mode:

This password protected mode allows the key operator or administrator more access to things like default settings. To get into System Administrator Mode: For DC240/242/250/252/260: Press Log-in/out and enter the password (the default is 11111 (five 1s)). For WC-7655/7665/7675: Press Log-in/out and enter a user name admin followed by the password (the default is 1111 (four 1s)). If the default password does not work, youll need to ask the customer for the new password. Once youre in the System Administrator mode, youll see a menu with 4 choices: System Settings (This choices submenu is covered below) Setup Menu (Paper Tray Attributes settings) System Administrator Settings (Login ID, Administrator Password, & Maximum Login Attempts) Login Setup / Auditron Administration

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System Settings brings you to a submenu: Common Settings, Copy Mode Settings, Scan Mode Settings, & Network Controller Settings. If you choose Common Settings youll see a nice long list of choices: Machine Clock / Timers Audio Tones Screen Defaults Paper Tray Settings Image Quality Adjustments Reports Maintenance / Diagnostics (in System Admin Mode, two choices appear: Initialize Hard Drive, or Delete All
Data, youll see later that this submenu has a much wider range of choices from CE mode / UI Diagnostic Mode.)

Watermark Other Settings

DIAGNOSTICS UI (User Interface) Diagnostic Mode (also called CE Mode):

CAUTION: I think it is very important to caution anyone who might read this, that the UI Diagnostic Mode is for experienced technicians changing settings or running internal tests on these machines without an in-depth understanding of what you are doing can cause serious problems or even damage to the machine, and can also be dangerous for the person running the tests. Do not use the information presented here unless you are willing to take 100% responsibility for your actions. The process for getting into the UI Diagnostic Mode depends on exactly which model youre working on. 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 (the CE Access Number screen). Use the default password 6789 followed by Confirm. Next press the Log-in / Log-out button. For most WC-7655/7665/7675s (some early ones work like the DC250 above also probably true for the 7755/7765/7775): Hold down together *, #, & Stop until the password prompt shows up. Then use the 6789 default password followed by Confirm. Next press the Log-in / Log-out button. Once youre in UI Diagnostic Mode, choose System Settings, then choose Common Settings, followed by Maintenance / Diagnostics. Here youll find the most important menu Well talk briefly about each of the menu items afterwards. Here are the things youll see: Software Options (Allows an OEM rep to install upgrades for the machine using passwords provided by the OEM using the
machines serial number to generate the password. If a machine has options installed, make sure to keep a backup of all any passwords for that machines options. )

Print Test Patterns MAX Setup (for color registration setup, etc.) Initialize Hard Disk (Warning Dont use this without a full understanding of what the procedure will do youll need to have
the full Service Manual on-hand. This will reformat partition 1 eliminating all fonts & Job Templates)

NVM Intialization (Warning Dont use this one either without a full understanding of what the procedure will do you should
only use this stuff if you have the full Service Manual with you.) IO Check (Component Control allows you to test Input & Output Components you will need a list of what each Components Control Code is to use this) Sub System (has a sub menu choice: Belt Edge Learn necessary for whenever the IBT Belt is replaced)

Delete All Data NVM Read/Write (allows you to change NVM [Non Volatile Memory] settings you will need a list of what each NVM Setting
Code is before you can make use of this.) Registration (Registration of the image on the paper read more below)

Adjustment / Others (has a sub menu with two choices: Machine ID / Billing Data Settings & Initialize HFSI Counter)

This is a fair range of access. Dont get me wrong the authorized dealers who have the PWS Laptops (the Portable work Station) do maintain some significant advantages. The main limitation you face without a PWS (Portable Work Station), is that in Component Control and also in NVM / Read Write (memory settings), you

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Drawn from a series of Articles first published in ENX Magazine (www.enxmag.com) cant browse through a list of codes to choose from. For these two functions, youll need to know which code you are going to enter, so youll be needing lists of these codes. These lists are only viewable from the PWSs screen. Now lets have a more in-depth look at each of the menu choices from the list above: Software Options: If you press Software Options followed by Keyboard, you can then punch in the password for the optional service you are installing or re-installing then select Save followed by Reboot. Print Test Patterns: There are many available test patterns which are useful for troubleshooting copy quality problems and for isolating which board may be responsible for the symptom you are troubleshooting. There are a wide range of patterns to choose fromEach has its own 3 digit code. It appears that the list will not show up onscreen so, you will need a list of the patterns 3 digit codes or else youd be choosing blindly.
Pattern # 001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 018 019 110 112 113 115 117 119 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 137 138 139 140 141 142 Test Pattern Name Registration Grid Grid 45 Degree Color Registration Color Registration -Visual Banding Ted/starvation Automatic Tone Correction -Adjustment Automatic Tone Correction -Check ProCon 16 tone Halftone In/out Adjustment (Primary Colors) In/out Adjustment (Secondary Colors) In/out Adjustment (Single Color) Highlight Adjustment Color Patch 182 Gradation Adjustment in SS direction_YC Adjustment in SS direction_MK IIT Analog Gradation RGB IIT Analog Gradation BW Pre-IPS_FS Increment RGB Pre-IPS_FS Increment BW Pre-IPS_SS Increment RGB Pre-IPS_SS Increment BW Pre-IPS_Grid BW Pre-IPS_Shading Data Color Pre-IPS_Shading Data BW Pre-IPS_Vertical Stripes Pre-IPS_8 Tone Patch Pre-IPS_Solid Post-IPS 4C Post-IPS_BW Post-IPS_FSRE Grid Post-IPS_FSRE Diagonal Grid Post-IPS_Bit Pattern 2 Level BW Post-IPS_Bit Pattern 2 Level 4C Post-IPS_Bit Pattern Multi-level BW Post-IPS_Bit Pattern Multi-level 4C TAG Fixed Copy 1 Pre-IPS_FS Increment (Ext Bypss) Pre-IPS_SS increment (Ext bypass) Pre-IPS_Vertical Stripes (Ext Bypass) Pre-IPS_FS increment (via Ext Mem. PWB) Pre-IPS_SS increment (via Ext Mem. PWB) Pre-IPS_Vertical Stripes (via Ext. Mem. PWB) Source MCU PWB MCU PWB MCU PWB MCU PWB MCU PWB MCU PWB MCU PWB MCU PWB MCU PWB MCU PWB MCU PWB MCU PWB MCU PWB MCU PWB MCU PWB MCU PWB MCU PWB MCU PWB MCU PWB IIT/IPS PWB IIT/IPS PWB IIT/IPS PWB IIT/IPS PWB IIT/IPS PWB IIT/IPS PWB IIT/IPS PWB IIT/IPS PWB IIT/IPS PWB IIT/IPS PWB IIT/IPS PWB IIT/IPS PWB IIT/IPS PWB IIT/IPS PWB IIT/IPS PWB IIT/IPS PWB IIT/IPS PWB IIT/IPS PWB IIT/IPS PWB IIT/IPS PWB IIT/IPS PWB IIT/IPS PWB IIT/IPS PWB IIT/IPS PWB IIT/IPS PWB IIT/IPS PWB IIT/IPS PWB

MAX Setup: The MAX setup menu contains the following stuff:
Procon ON/OFF Print IIT Calibration In/Out Manual Setup ATC Sensor Setup TRC Adjust Tone Up/Down Color Balance

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Component Control: Here is where youll go to test Input Components such as Sensors and Switches and also Output Components such as motors, solenoids, lamps, & clutches. You will be needing the list of codes and their corresponding components to use this at all since it does not appear in a menu on the Control Panel. Well cover the list in an abbreviated fashion in the next article. It is a very lengthy list. Delete All Data: To quote the Service Manual: This procedure deletes user-defined/registered information and information recorded automatically by the system from the hard disk, the ESS NVM PWB and Buffer RAM. NVM Read / Write: This will need to be covered in a future article because the lists of NVM codes are not browse-able from the Control Panel. The list is very long. Until the list is available, you wont be able to change any NVM Settings (youd be working totally blind). Machine ID / Billing Data Settings There are 3 boards in the machine which all have the Serial Number, Product Number and Billing Counters: the MCU NVM PWB (the IOT or Main machine logic board), the SEEP ROM (on the ESS or Network Controller, known as Sys1), and the ESS NVM PWB (sys2 on the ESS or Network Controller). These 3 must agree with each other (otherwise a Fault Code will be called 124-310, 124-311, 124-312, 124-313, 124-324, or 124-325). This process is designed to synchronize the three boards when one of them gets corrupted or needs to be replaced. From Machine ID / Billing Data Settings, choose a Board which has the correct data on it and select Start Enter the correct Serial Number and then select Confirm. In Part II of this series, we got into the Diagnostic Mode (CE Mode). Lots of good stuff in there, but to use the Component Codes to test motors, sensor, etc, you need to know what each code is. In this months article, well begin to list em starting with the Input Component Codes. It makes for rather bland reading, but it is one of the keys to being able to troubleshoot & solve problems on these machines so here goes. Component Control Once youre in UI Diagnostic Mode, choose System Settings, then choose Common Settings, followed by Maintenance / Diagnostics. Scroll down and choose IO Check & finally select: Component Control. From the Component Control screen, youll enter the Chain (the first 3 digits of the code) followed by the Function (the second 3 digits of the code). Press Start to activate the test. For these Input Component Tests, you will be able to see on-screen the status of the component (H for high or L for low) you can toggle the actuator or otherwise activate the switch or sensor youre trying out and see if the status of the component changes on-screen. Press Stop button to stop the current test. When youre done, press Close to leave the Component Control screen. Below is an abbreviated list of the component codes. There were simply too many codes to include in a magazine article. The ones which are missing were either relating to peripherals such as the finishers, or the description for the comoponent was too ambiguous to be of use. The list is followed by a quick run-down of what some of the acronyms stand for.

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014-100 Xport entrance sensor Buffer path sensor Gate sensor Registration clutch on IOT exit sensor Top exit tray sensor Compile exit sensor Compile tray no paper sensor Decurler-in sensor Decurler-out sensor Side registration sensor_1 Side registration sensor_2 Polygon motor 1 ready Polygon motor 2 ready IIT (scan) registration sensor DADF present APS sensor 1 APS sensor 2 Scan start Platen interlock switch Angle sensor Tray 1 pre feed sensor Feed out sensor 1 Tray 1 stack height sensor Tray 1 no paper sensor Tray 1 size select Tray 2 pre feed sensor Feed out sensor 2 Tray 2 stack height sensor Tray 2 no paper sensor Tray 2 size select Tray 3 pre feed sensor Feed out sensor 3 Tray 3 stack height sensor Tray 3 no paper sensor Tray 4 pre feed sensor Feed out sensor 4 Tray 4 stack height sensor Tray 4 no paper sensor MSI (bypass) pre feed sensor

Input Component Codes:

Code
005-102 005-110 005-115 005-119 005-150 005-151 005-202 005-203 005-204 005-205 005-206 005-207 005-208 005-209 005-210 005-211 005-212 005-213 005-214 005-215 005-216 005-217 005-218 005-219 005-220 005-221 005-222 005-223 005-224 005-225 005-226 005-300 005-301 010-200 010-201 010-202 010-203

014-101 014-102 014-110 014-111 014-115 014-150 014-151 014-190 014-191 014-200 014-201 061-200 061-201 062-212 062-240 062-251 062-253 062-272 062-300 062-301 071-100 071-101 071-200 071-201 071-202 072-100 072-101 072-200 072-201 072-202 073-100 073-101 073-200 073-201 074-100 074-101 074-200 074-201 075-100

Description
Document Sensor Document Regi Sensor _ Belt DADF and CVT Document Exit Sensor Document Duplex Sensor Document Size Sensor #1 Document Size Sensor #2 Document Feeder Bottom Sensor Document Feeder Level Sensor Document Feeder Feed Sensor Document Feed-out Sensor Document Pre-registration Sensor Document Lead Registration Sensor Document out Sensor Document Exit Sensor #1 Document Exit Sensor #2 Document Invert Sensor Feeder Cover Interlock Switch Document Feeder Platen Interlock Switch Document Tray Interlock Sensor DADF #1 tray APS sensor DADF #2 tray APS sensor DADF #3 tray APS sensor DADF #1 APS sensor DADF #2 APS sensor DADF#3 APS sensor DADF tray size sensor #1 DADF tray size sensor #2 DADF Left hand cover interlock switch DADF Scan start Sensor DADF Nudger position sensor DADF #2 invert sensor DADF Platen interlock switch DADF Top cover interlock switch Fuser entrance sensor Fuser exit sensor Detection of a new fuser CRU Fuser nip sensor

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075-200 075-201 075-202 075-203 077-100 077-101 077-102 077-103 077-104 077-105 077-106 077-107 077-108 077-203 077-300 077-301 077-302 077-303 077-304 078-100 078-101 078-200 078-201 078-202 078-203 078-204 078-300 078-301 091-200 091-201 091-202 093-200 093-201 093-202 093-203 093-205 093-206 094-200 094-201 094-202 MSI (bypass) stack height sensor MSI (bypass) lift down sensor MSI (bypass) no paper sensor MSI (bypass) paper set sensor Pre registration sensor Registration sensor OHP (transparency) sensor Invert in sensor Duplex in sensor Duplex path sensor Duplex out sensor IOT exit sensor MSI pre regi sensor Invert End sensor Left hand cover interlock Right hand cover interlock Transfer module 2 interlock Front cover interlock MSI (bypass) cover interlock HCF (Hi Capacity Feeder) 1 pre feed sensor HCF 1 feed out sensor HCF 1 no paper sensor HCF 1 stack height sensor HCF 1 size sensor A HCF 1 size sensor B HCF 1 tray in sensor HCF 1 transport interlock HCF 1 side out switch Waste toner bottle present sensor Waste toner bottle near full sensor Charge Scorotron fuse current signal Low toner sensor Y Low toner sensor M Low toner sensor C Low toner sensor K Dispense cover sensor Marking drawer interlock 1st BTR retract sensor 2nd BTR retract sensor Post 2nd BTR sensor Acronym interpretations: BCR = Bias Charge Roll (from color drum ctg) BTR = Bias Transfer Roll CC = charge Corona (on black drum cartridge) CCD = Charge Coupled Device (turns image into CVT = Constant Velocity Transport DADF = Duplexing Automatic Document Feeder HCF = High Capacity Feeder IBT = Image Belt Transfer IIT = Image Input Terminal (scanning section of machine) IOT = Image Output Termimal (printing section of machine) IPS = Image Processing J- tra = J Transport MOB = Marks On Belt MSI = Multiple Size Input (Bypass Tray) OCT = Oscillating Catch Tray V-tra = Vertical Transport

Output Component Codes:

Code
005-001 Thru 005-010 005-011 005-012 005-014 005-015 Thru 005-025 005-026 thru 005-035 005-036 005-037 038/039 005-040 005-041 Thru 005-047 005-048 Thru 005-054 005-055 005-057 Thru 005-061 005-062 005-063 005-065 005-067 005-068 005-069

Description
CVT - DADF feed motor _ speed 1 thru 10 Document Set gate solenoid open Document Set gate solenoid close CVT - DADF feed motor _ reverse CVT - DADF pre reg motor _ speed 1 thru 11

CVT - DADF reg motor _ speed 1 thru 10 CVT - DADF reg motor _ reverse CVT - DADF platen motor _ speed 1/2/3 DADF feed motor CVT - DADF platen motor _ speed 4 thru 10

CVT - DADF exit motor _ speed 1 thru 7 Document Belt motor non CVT mode_CW CVT - DADF exit motor _ speed 8 thru 12 CVT - DADF feed clutch Document Nudger solenoid down Document Baffle solenoid close Simplex/duplex gate solenoid duplex open Simplex/duplex gate solenoid simplex open Document Exit gate solenoid

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005-070 005-073 005-074 005-075 005-081 005-083 005-084 005-086 005-090 010-001 010-007 010-008 010-009 042-001 042-005 042-009 042-012 042-016 042-018 042-020 042-021 042-023 042-026 042-028 042-029 042-030 042-034 042-035 061-001 061-004 061-005 061-007 062-002 062-005 062-006 062-014 062-015 062-017 062-086 071-001 Document Nip release solenoid_PF1 CVT-DADF stamp solenoid CVT-DADF feed motor Regi gate solenoid Exit motor non CVT mode Document ready Document set LED Document Tray lift up Document Nudger initialize Fuser motor _ 320 mm/s Heat roll main lamp 1 Heat roll main lamp 2 Heat roll sub lamp Main motor_320 mm/s Drum motor K_320 mm/s Drum motor YMC_220 mm/s IBT drive motor_320 mm/s IBT steering motor (CW) High current IBT steering motor (CW) Low current Fuser exhaust fan_high speed Blower motor_high speed CC intake fan_high speed V_tra fan_high speed Invert front fan and dup fan Exit roll fans IBT Belt check_320 mm/s Rear cooling fan IBT steering motor reset Polygon motor 1_high speed Polygon motor 2_low speed LASER 1_high speed LASER 2_high speed IIT exposure lamp IIT scan motor_scan direction IIT scan motor_return direction IPS cooling fan_high speed_PF1 Lamp cooling fan_PF1 Ccd cooling fan IIT image area Tray 1 pre feed 071-002 071-004 072-001 072-002 073-001 073-002 074-001 074-002 075-001 075-002 075-003 075-004 075-005 075-006 077-001 077-002 077-003 077-004 077-006 077-007 077-010 077-011 077-012 077-013 077-014 077-015 077-016 077-018 077-019 078-001 078-002 078-003 078-004 078-005 089-001 089-002 091-001 091-002 091-007 091-008 Tray 1 feed Tray 1 lift up Tray 2 feed Tray 2 lift up Tray 3 feed Tray 3 lift up Tray 4 feed Tray 4 lift up MSI (bypass) feed motor_300 mm/s MSI (bypass) feed motor_220 mm/s MSI nudger solenoid_high current MSI nudger solenoid_low current MSI lift motor up (CW) sensor stop MSI lift motor down (CCW) sensor stop Take away motor Take away clutch 1 Take away clutch 2 Pre regi motor_640 mm/sec Pre regi motor_220 mm/sec Regi motor_430 mm/sec Exit motor Invert solenoid_gate in Invert solenoid_gate exit Invert motor_450 mm/s_invert direction Invert motor_350 mm/s_exit direction Invert motor_640 mm/s_dup path direction Invert solenoid Duplex motor Invert gate In and invert gate exit cycle HCF 1 nudger solenoid_low power HCF 1 nudger solenoid_high power HCF 1 feed motor_feed direction HCF 1 feed motor_lift up direction HCF 1 Takeaway motor_242 mm/sec MOB LED: High power MOB LED: Low power Erase lamp YMC Erase lamp K Scorotron Pre Charge Corotron (PCC)

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BCR Scorotron cleaner mot_1400PPS (CW) hi current ADC specular ADC Diffuse ADC shutter open ADC shutter close Toner cartridge motor_Y Toner cartridge motor_M Toner cartridge motor_C Toner cartridge motor_K1 Toner cartridge motor_K2 Dispense motor_Y Dispense motor_M Dispense motor_C Dispense motor_K Developer bias DC_Y Developer bias AC_Y, M, C Developer bias DC_M Developer bias DC_C Developer bias DC_K Developer bias AC_K Developer motor_220 mm/s Developer clutch Developer K rotation at 220 mm/s process speed Developer YMC rotation at 220 mm/s process speed 1st BTR contact 1st BTR retract 2nd BTR contact 2nd BTR retract 2nd BTR retract clutch

091-009 092-001 092-002 092-004 092-005 093-001 093-002 093-003 093-004 093-005 093-006 093-007 093-008 093-009 093-010 093-011 093-012 093-014 093-016 093-017 093-019 093-022 093-023 093-024 094-001 094-002 094-003 094-004 094-005

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These are friendly to technicians in nearly every way possible. The exception as mentioned earlier is that you actually need to know which 6 digit code you want to run. Even the Service Manual fails to provide lists. Fortunately if you pick through the RAPs (repair analysis procedures), the manual does give you suggestions as to which codes to use to test sensors, motors, etc. They will also usually (not always) tell you if a particular NVM setting needs to be changed back to 0 to clear the Fault Condition. As you look through the list, you will find that while some of the codes are useful in very specific circumstances, the most important ones revolve around resetting specific Fault Code conditions. These Fault Conditions will not reset automatically the machine will not even attempt to get going till a related Memory code is reset. Some are flags which are either 0 or 1 depending on if the fault condition exits or not, and others count up to 3 at which point the machine shuts down and needs that memory setting to be reset back to 0. Extremely important: Part of the reason the machines lock up until certain fault codes are cleared is because a tech needs to come and repair the cause of the fault. It is very unwise to allow a customer to keep running a machine calling one of these faults, by constantly resetting the codes. That would have the potential to cause more trouble and possibly damage to the machine. Do not ignore the cause of the fault codes Always get the problem solved before you get into resetting things If youre the owner of a machine, dont reset the code wait for the technician. Let them fix the problem and then let them reset the fault code. Heres how to get into Diagnostic Mode, and how to use NVM Read / Write. 6. 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 (the CE Access Number). Use the default password 6789, and press Confirm. For most WC-7655/7665/7675s (some of them with earlier software work like the DC250 above) & also for WC-7755/7765/7775: Hold down together *, #, & Stop until the CE Access Number screen prompts you for a password. Then use the default password: 6789 followed by Confirm. 7. Press the Log-in / Log-out button then on the touchscreen, touch System Settings, followed by Common Settings, and finally Maintenance / Diagnostics. 8. Choose Adjustments from the menu which appears, then look for: Dc131 NVM Read / Write. 9. Touch the first empty block to enter the chain. The 1st three digits in an NVM code are called the chain and the second set of 3 digits are called the Function. For example if the NVM code is 744-351 you will enter the Chain as 744 and the Function as 351 . Touch the Read button. The current setting will show up. Press Val to then change the value back to 0 and press Save. 10. Finally when you exit diagnostics be sure to reboot the machine so the changes stick. Use the Call Close button. Well be leaving a huge number of NVM codes off of the list to follow. Many of the codes you may have thought you wanted such as registration adjustments are far more effectively managed by using the Registration or Max Setup (color registration) choices in the diagnostic menu. Note that where Fault Codes are mentioned, the first digit will be a 0 if the machine is in the DC family (example 042-326) or it will be a 3 if the machine is a WorkCentre 76xx (Example: Fault Code 042-326 in a DC250 will appear instead as 342-326 in a WC-7655). Ok.. now to it! Heres the list

NVM (Non Volatile Memory) Codes:

Code 700-071 700-078 700-081 700-084 700-085 Description USB User Buffer Size Form Buffer Size Parallel (IEEE 1284) Buffer Size NetWare Buffer Size Apple Talk Buffer Size Min 64 128 64 64 64 Max 1024 2048 1024 1024 1024 Default 64 128 64 256 64 Details 1 step = 1 Kb, 32 Kb increments 1 step = 1 Kb, 32 Kb increments 1 step = 1 Kb, 32 Kb increments 1 step = 1 Kb, 32 Kb increments 1 step = 1 Kb, 32 Kb increments

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Drawn from a series of Articles first published in ENX Magazine (www.enxmag.com) 700-088 700-124 700-125 700-128 700-129 700-142 700-143 700-144 700-145 700-146 700-153 700-165 Saturation Buffer Size Auto clear and auto resume timer Job cancel timer Scanning Timer Low Power Mode Timer Low Power Mode Enable Job Memory Entry Tone Auto Log Print Flag Report Duplex Print Mail Box Receive Report Out of Paper Alarm Country Code SEEPROM 64 0 0 1 1 0 0 0 0 0 0 0 1024 240 5940 20 240 1 3 1 1 1 1 65535 256 60 600 1 15 0 2 0 0 1 1 840 0=disabled, 1=enabled 0=off, 3=loudest 0=off, 1=on 0=off, 1=on 0=off, 1=on 0=off, 1=on 840=USA, 124-Canada, 76=Brazil, 826=UK, 276=Germany, 380=Italy, 250=France, 724=Spain, 528=Netherlands 1=FX , 2=XC (U.S.), 3=XE, 4=AP 4-12 digits, ASCII 90 0 0 1 0 0 0 3000 1 255 3 1 1 3 600 1 0 1 0 1 0 0=Not Permitted, 1=Permitted 5=A4 (XE default), 44=Letter (XC default) 1=mm (XE default), 3=inch (XC default) 0=Permit, 1=Inhibit 0=disabled, 1=enabled 0=off, 1=Internal Auditron, 2=Network Accounting, 3=Remote/External 0=NVRAM, 1=HDD 0=Do not bypass Communication Faults, 1=Bypass (ignore) communication Faults 0=Do not bypass Scanner Faults, 1=Bypass (ignore) Scanner Faults 0=Fault Clear 1 step = 1 Kb, 32 Kb increments

700-166 700-171 700-197 700-198 700-397 700-399 700-420 700-446 700-540

Territory / Region Service Engineer Tools Password Max Number of Jobs Job Passing (permitted or not) Default Print Paper Size Millimeters vs. Inches Software Download Inhibit / Permit HDD Security Overwrite Enable Auditron Mode

700-543 711-297

User Information Memory Location Communication Fault Bypass

0 0

1 1

0 0

715-017 741-105* 741-181 741-192 741-195

IIT (scanner) Fault Bypass Transfer Belt Home Position Fault (Clear fault 042-326 or 342-326) Fuser Exhaust Fan Fault Bypass Blower Motor Fault Bypass Suction Filter End of Life Message on / off

0 0 0 0 0

1 3 1 1 1

0 0 0 0 0

0=End of Life Warning enabled, 1=End of Life not shown

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Drawn from a series of Articles first published in ENX Magazine (www.enxmag.com) 741-204 742-228 744-350* 744-351* 744-352* 744-354 744-355 749-291 749-292 749-293 749-294 749-295 751-105 751-449 752-084** 752-086 752-088 752-089 752-090 752-091 752-092 752-093 752-094 752-095 752-319** 752-320** 752-321** 752-322** 752-323** Rear Cooling Fan Fault Bypass Decurler present Fuser Overtemp Fault History (Clear fault 010-320 or 310-320) Differential Gain Fault History (Clear fault 010-319 or 310-319) Fuser Fault History (Clear fault 010-324 or 310-324) Fuser End of Life Warning Count Fuser End of Life Count Lead Edge Erase for Color Lead Edge Erase for Black / White Trail Edge Erase for Color Trail Edge Erase for Black / White Side Edge Erase Drum End of Life Count Charge Corotron Life Counter ADC Shutter Close Fault (Related to Faults 092-650 or 392-650) ADC Sensor Fault ADC Patch Fault for Yellow ADC Patch Fault for Magenta ADC Patch Fault for Cyan ADC Patch Fault for Black ADC Patch Fault Count for Yellow ADC Patch Fault Count for Magenta ADC Patch Fault Count for Cyan ADC Patch Fault Count for Black ATC Failure - Yellow (Related to Faults 092-653 or 392-653) ATC Failure - Magenta (Related to Fault 092-654 or 392-654) ATC Failure - Cyan (Related to Faults 092-655 or 392-655) ATC Failure - Black (Related to Faults 092-656 or 392-656) ATC Output Fault Count for Yellow (Related to Faults 092-653 or 392-653) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 7 2 1 500 500 100 100 100 100 100 255 429496 7295 1 1 1 1 1 1 65535 65535 65535 65535 1 1 1 1 65535 0 1 0 0 0 200 210 40 40 40 40 30 60 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0=reset 0=reset 0=reset 0=reset 0=reset 0=No Decurler, 1=With Decurler 0=Fault Clear 0=Fault Clear 0=Fault Clear 200=200K pages 210=210K pages 1 step=0.1mm 1 step=0.1mm 1 step=0.1mm 1 step=0.1mm 1 step=0.1mm 1 step=1000 pages

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Drawn from a series of Articles first published in ENX Magazine (www.enxmag.com) 752-324** 752-325** 752-326** 752-327** 752-328** ATC Output Fault Count for Magenta (Related to Faults 092-654 or 392-654) ATC Output Fault Count for Cyan (Related to Faults 092-655 or 392-655) ATC Output Fault Count for Black (Related to Faults 092-656 or 392-656) ATC Amplitude Output Fault for Yellow (Related to Faults 092-657 or 392-657) ATC Amplitude Output Fault for Magenta (Related to Faults 092-658 or 392-658) ATC Amplitude Output Fault for Cyan (Related to Faults 092-659 or 392-659) ATC Amplitude Output Fault for Black (Related to Faults 092-660 or 392-660) ATC Amplitude Output Fault Count for Yellow (Related to Faults 092-657 or 392-657) ATC Amplitude Output Fault Count for Magenta (Related to Faults 092-658 or 392-658) ATC Amplitude Output Fault Count for Cyan (Related to Faults 092-659 or 392-659) ATC Amplitude Output Fault Count for Black (Related to Faults 092-660 or 392-660) IOT Temperature Sensor Fault (not in fuser in the machine's body) (Related to Faults 092-661 or 392-661) Humidity Sensor Fault (Related to Faults 092-662 or 392-662) Humidity Sensor Fault Count (Related to Faults 092-662 or 392-662) ADC Shutter Open Fault (Related to Faults 092-649 or 392-649) Toner Status (Black - K2) Toner Status (Black - K1) Toner Status (Yellow) Toner Status (Magenta) Toner Status (Cyan) 0 0 0 0 0 65535 65535 65535 1 1 0 0 0 0 0 0=reset 0=reset 0=reset 0=reset 0=reset

752-329** 752-330** 752-331**

0 0 0

1 1 65535

0 0 0

0=reset 0=reset 0=reset

752-332**

65535

0=reset

752-333**

65535

0=reset

752-334**

65535

0=reset

752-345**

0=reset

752-357** 752-358** 752-950** 762-274 762-275 762-276 762-277 762-278

0 0 0 0 0 0 0 0

1 65535 1 3 3 3 3 3

0 0 0 0 0 0 0 0

0=reset 0=reset 0=reset 0=reset 0=reset 0=reset 0=reset 0=reset

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Drawn from a series of Articles first published in ENX Magazine (www.enxmag.com) 762-312* 762-313* 762-314* 762-315* 763-001 Dispense Status (Yellow) (Clear Fault 093-314 or 393-314) Dispense Status (Magenta) (Clear Fault 093-315 or 393-315) Dispense Status (Cyan) (Clear Fault 093-316 or 393-316) Dispense Status (Black) (Clear Fault 093-317 or 393-317) Output Configuration 0 0 0 0 0 3 3 3 3 5 0 0 0 0 0 0=Fault Clear, 1 or 2 = normal, 3=Dispenser Broken 0=Fault Clear, 1 or 2 = normal, 3=Dispenser Broken 0=Fault Clear, 1 or 2 = normal, 3=Dispenser Broken 0=Fault Clear, 1 or 2 = normal, 3=Dispenser Broken 0=OCT, 1=HHCSS Base Finisher, 2= HHCSS w/ Booklet Maker, 3=HCSS Base Finisher, 4=HCSS w/ Booklet Maker, 5=HCSS Mail Box Finisher

* Codes listed above with 1 asterisk these codes are confirmed necessary to reset specific fault codes (read below for a list of faults which definitely require resetting from the NVM. ** Codes listed with 2 asterisks it is unclear in the manual if these actually require resetting from the NVM Read / Write or not. Some of them will likely reset by turning the power off and back on. If a machine seems locked up because of one of the related faults, its worth looking at the NVM codes to see if any of them are no longer showing a value of 0 as they should. Fault Codes which require resetting from NVM Read / Write: Remember to always solve the cause of the fault before resetting them in memory. 010-319 (310-319) Fuser Heat Control Problem - resets with 744-351 010-320 (310-320) Fuser Overheat - resets with 744-350 010-324 (310-324) Fuser Failure - resets with 744-352 042-326 (342-326) Belt Hole Sensing Problem - resets with 741-105 093-314 (393-314) Toner Dispense Problem (Yellow) - resets with 762-312 093-315 (393-315) Toner Dispense Problem (Magenta) resets with 762-313 093-316 (393-316) Toner Dispense Problem (Cyan) resets with 762-314 093-317 (393-317) Toner Dispense Problem (Black) resets with 762-315

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