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ENX Mexico &

Britt Horvat
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:
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
005-308/309
005-906 thru 005-918
010-xxx codes
010-311

Description / Notes:
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
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)

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)
Fuser NVM (Memory) failure *** NOTE: This code must be
cleared from Diagnostic Mode details below.

010-324***
010-326 thru 010-327
010-330

Fuser Heat Control problems


Fuser Motor failure

010-420
010-421

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.

012-xxx codes
013-xxx codes
016-xxx codes
016-311
024-340 thru 024-747
024-910 thru 024-917

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)

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

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)

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 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

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
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

077-103 thru 077-118


077-120

Fuser Exit Sensor jam or final Exit Sensor jam.


Post 2nd BTR Roll Sensor jam

Rear Fuser Cooling Fan failure


Drum Motor failures - 320=Y, 321=C, 322=M, 323=K (black)

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 091921
091-917/920/924/925/927
091-918/922/ 928

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

091-919/923/ 926/929

Cyan Drum Cartridge CRUM communication problems

091-932
091-933
091-934
092-649/650
092-651/652
092-653 thru 092-660

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) problems653/657=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),

093-300
093-313 thru 093-317
093-320
093-421 thru 093-425
093-600 thru 093-912

093-918 thru
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

Toner CRUM failures (918/924 /925/926/936/


940=K(black),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 (e.g., serial number
disagreement between various boards or machine speed
errors, etc)
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
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