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Introduction: The Xerox DC12 style machines.
All accounts of the Xerox Docucolor 12 which I’ve heard so far, seem to consider this a superb piece of equipment. It’s a full color copier and printer capable of producing color prints and copies which are truly impressive. There are quite a few of these machines out there… we’ll start with a quick overview and then plunge into the rather deep pool of Status Codes (actually, we’ll just wade a little… the complete listing would take up way too many pages).
The DC12 and the DCCS50 are covered together in one service manual so they are very closely related. These machines are said to run well so long as regular maintenance is observed… one of the most sensitive parts of the machine lies in the Fuser’s Oil application system. Problems in copy quality which may at first appear to be caused by other things can wind up being in the fuser oiler section. Its important to understand the way the machine works a little bit… there is a Copy Cartridge (Drum Cartridge) and an “IBT” belt which is a transfer belt… the Drum gets written on by a laser and then developed by one of the 4 colors, that image is then transfered onto the Transfer Belt by the "First BTR Roller" which is located inside the IBT Belt Unit. Then the next color of developer unit rotates into position (the 4 color developer unints are on a rotary module which allows each to in turn interface with the Drum Cartridge). The same drum then gets written on with the next color to then be overlaid over the earlier image on the IBT Belt. Once all 4 colors have been placed on the IBT Belt the image is then transfered onto the paper by the 2nd BTR Roller Assembly (2nd Bias Transfer Roller) and then on to the Fuser Module. With all the layering, it is understandable how crucial a roll the fuser plays in this system. It must have the right temperature, lubrication and pressure to do its job. The Fuser is different from many of the black and white copiers / printers which I know in that it has three Fuser Rollers (the Heat Roll, the Pressure Roll, and the External Roll). It has heater lamps in all three of these rollers as well as thermal fuses. It also has thermistors for heat control and overheat on all 3 rollers (for a grand total of 6 thermistors and 3 thermal fuses / thermostats if you’re keeping count).Read more in the Fuser Reconditioning Notes.
There is a way to enter into the Diagnostic Mode from the Control Console or User Interface (UI) although access is somewhat limited. Ideally, you’d be equipped with a PWS (Portable Work Station) which is a laptop computer loaded with software to interface with the machine. From a PWS you’d have a menu driven way of accessing the diagnostics. From the Control Console, you’ll need to get a listing of the codes… there’s no approaching this one blind. You’ll also have to pay extremely close attention to make sure you enter the code you really intend to since the display will give you little to go on.
While there are plenty of regular maintenance work and mechanical repair work which any competent tech can handle, it’ll be important to recognize when you’re in over your head…. Take on the problems which make sense to you and know when to run. If you run into logic problems, you’ll need to get in an expert for sure… let the customer know that you can repair some of the basic and more common problems which occur (such as replacing fuser parts, feed components, and other consumable items... etc.) but that you have limited access to information and in some cases, it may b e necessary to find someone who is trained on the machine (someone who owns a PWS would be best). If you make friends with someone who knows these machines, keep their number handy.
Like many of the more complex Xerox machines, this one is a bit logic-heavy… so there are more codes than we’ll actually list here, but at least this will give you a good idea which way to look when you get a status code.
Below are the basic layout of the meanings behind the Status Codes:
1-300 Front Door Interlock is open.
1-304 Left Cover Interlock is open.
2-310 User Interface (UI) Panel failure.
2-340 UI RAM failure.
3-xxx Codes are all Communication and memory failures
4-001 Main Motor problem.
4-002 Drum Motor problem.
5-xxx Codes are all Document Feeder (DADF) problems… below are a few you’ll want to know:
5-110 to 5-113 DADF Registration jams.
5-115 to 5-116 DADF Exit jams.
5-196 Document sensed at Document Sensor at power on or when the DADF Top Cover was closed.
5-197 Document sensed at Registration Sensor at power on or when the DADF Top Cover was closed.
5-198 Document sensed at Exit Sensor at power on or when the DADF Top Cover was closed.
5-199 Document duplex sensor jam.
5-301 DADF Top Cover is open.
6-xxx Codes relate to the optics… below are a few select ones:
6-360 Carriage Position Failure.
6-371 Exposure Lamp failure.
6-389 Carriage overrun at scan end.
6-390 Carriage overrun at home end.
7-xxx Codes relate to the Paper Supply…some of the simpler ones are below:
7-281 Tray 1 Lift Motor failure.
7-282 Tray 2 Lift Motor failure.
7-283 Tray 3 Lift Motor failure.
7-284 Tray 4 Lift Motor failure.
7-286/287 Tray 5 Lift Motor problems.
8-xxx Codes are Paper Feed and Registration problems
9-xxx Codes are all Xerographic problems such as toner problems, developer problems, Drum Cartridge problems, ADC (Auto Density Control) problems too. Some examples:
9-271 Yellow Toner empty.
9-272 Magenta Toner empty.
9-273 Cyan Toner empty
9-274 Black Toner empty.
9-311 Wrong Drum Cartridge.
9-372 No Drum Cartridge sensed.
9-374 No Waste Bottle sensed.
9-376 Waste Bottle full.
9-378 Drum Cartridge count expired (40K).
10-xxx Codes are Fuser problems and Paper Exit problems.
10-102 to 10-117 Fuser area paper jams.
10-127 to 10-163 Duplex jams.
10-300 Inverter Cover is open.
10-341 Fuser Oil bottle is empty (30-40K expected yield if the oiler system including the metering blade, donor roll, etc are in good working order). This code should reset automatically when a new Oil Bottle is installed.
10-342 Fuser Web Cartridge needs changing (this code should reset automatically when a new Web Cartridge is installed).
10-359 Open Heat Roll Control Thermistor (the one closer to the middle of the roll).
10-360 Open Heat Roll Overheat Thermistor.
10-361 to 10-365 : Heat Roll not hot enough.
10-366* to 10-367*: Heat Roll Over-temperature.
10-368 Open Press Roll Control Thermistor (the one closer to the middle of the roll).
10-369 Open Press Roll Overheat Thermistor.
10-370 to 10-374: Press Roll not hot enough.
10-375* to 10-376*: Press Roll Over-temperature10-377 to 10-378: Open External thermistor failures.
10-379 to 10-385 External Heat Roll not hot enough.
10-386* to 10-387*: External Heat Roll Over-temperature
* Overheat codes must be reset from Diagnostics (NVM adjustments) by entering code 777-160 and changing the value to a ‘0’ after repairs are complete. To get to the NVM adjustments, you’ll need to turn on the power, then while holding down the ‘0’ button, press ‘Start’. The screen will prompt you for an “Access Number”… use the keypad to enter ‘6789’.
11-xxx Codes are all Sorter related stuff…
14-xxx Codes are ROS (Raster Output Scanner or Laser Module) failures.
15-xxx Codes have to do Image Processing System (IPS) failures in the logic / communications.
16-xxx Codes generally point to network faults.
21-504 Code indicates a problem with an Accessory device such as a Coin Kit.
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