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Important:.. the information presented here is for the use of a qualified, experienced technician. Without the background knowledge which comes with training, you risk doing more damage than good to the copier & also risk your own safety.
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DC265 style TECH INFO
Document Centre (DC) 240, 255, 265, 460, 470, 480, 490
Workcentre Pro65, Pro75, Pro90, Docuprint DP65, DP75, DP90
Docutech DT65, DT75, DT90, C65, C75, C90
Xerox DC265 style Machine

NEWS ARTICLE:
First Published in ENX Magazine... go check out all the new articles and information at www.ENXmagazine.com

Know when to run & when to stick to your guns.

     The Xerox Document Centre (DC) 265 style machines are heavy hitters compared to what we usually deal with.  They are relatively high volume (40-65 pages per minute).   Just about every tech I’ve spoken with who have knowledge of, or have worked on these, has had virtually nothing but compliments for it.  This is what a Xerox copier is all about.  On the upside, they are the ultimate in modular…  that is to say that even a non technical person can replace the Fuser Module, or Xerographic Module or any of the Feed Heads for that matter.   The downside… (and this is a pretty major down side) is that a vast majority of the diagnostic functions and adjustments on this series can only be accessed from a separate laptop computer known as a “PWS” (Portable Workstation).   The good news is that the machine is incredibly reliable...  so you may go many service calls before a PWS adjustment is actually necessary.   There is money to be made supporting these, but you need to know what your capabilities are, and what your limitations are as well.  We’ll start with a quick overview of what the PWS is all about and then give some background info on what makes these machines tick and what the modules are all about.   Then it’s time for a list of Status Codes.  We’ll wrap up with a discussion about what functions are available to a tech who is not equipped with a PWS.

     A PWS (Portable Workstation) is a Laptop computer equipped with licensed Xerox software to interface with the logic of the machine.   The licensing, I am told, is available on a per machine basis for around $3,500.00 and then annual renewal for the licensing of the software costs around $800.00 per year.   I must say though, calling Xerox directly to ask about purchasing the licensed software does meet with some resistance…  they want to be the repair guys for this machine and aren't very forthcoming.  I was unable to get a clear answer to verify the costs mentioned earlier.   A User ID and Password are part of the security.  It’s important to let your customer know that while you can help with many of the service needs of the machine, there are limitations to what can be done and that, it may be necessary in some cases to call in the cavalry…  fill them in on the PWS and the costs which are involved in setting up such a system.

     The DC240 runs 40 copies per minute, the DC265 does 65 copies per minute.   The DocuTech 65 also fits into this series although the manual only mentions it in a few instances.   The newer DC480/490 are extremely similar but they are covered in a seperate Service Manual.   It may be helpful at this point to know what the postscript after the model numbers mean: LP = Laser Printer, ST = Networked System, and DC = Digital Copier.  

These machines are as you’d probably guess digital machines.   They use a laser to discharge the black areas of the image. These use a hybrid development system which has developer material on a mag roll which deposits toner onto a donor roll which then finally deposits toner on the photoreceptor belt (wherever the laser discharges it that is).   This developer is continuously replenished with a trickle flow of fresh material because each new toner cartridge has a small amount of developer mixed into the toner and then the old stuff is walked off into a developer waste bin.   The toner Ctg. contains 2.4 liters of toner and developer mixed and is expected to run around 20,000 copies at 6% coverage.   The Toner Cartridges are offered under two reorder numbers: 6R849 (2 pack) 6R821 (6 pack).

     There are two main “Modules” in these machines.   The first is the Xerographic Module, and then there is the Fuser Module.   Each is equipped with a “CRUM” (Customer Replaceable Unit Monitor) or connector with an EEPROM on it which keeps track of the count for the module.   The CRUM also tells the machine which version of the module it is. They have a “Metered” version (for machines under Full Service Maintenance Agreements (FSMA)) and “Sold” versions of each module.   Machines which are set up by the OEM for “Metered” status are able to take either version, but a machine which has been set up for “Sold” will only accept the Sold version.   Like many of the Copy Cartridge connectors for previous models, I have no doubt these “Connectors” will be repairable sometime in the near future, although I have yet to have seen any in the market.   At that point, it’ll be necessary to find aftermarket parts as none of the individual parts are spared in the Parts List, except as complete modules.   Replacing either of the Modules with a new one automatically resets the counter for that module, as the CRUM Connector is what keeps track of the count.   If you try to replace a module with one which has wrong version of the CRUM on it, a status Code will result…  for the Xerographic Module the code would be an 09-352 or 09-353.   For the Fuser Module, a wrong CRUM code show up as Status Code 10-352 or 10-353.

     The Xerographic Module includes the Transfer Corotron as well as the Charge Corotron.   It also contains the Photoreceptor belt and cleaning blade as well as a discharge lamp (red LED’s).   The CRUM connector counts up to _____ pages before timing out and forcing a replacement (or a connector repair some day hopefully).   Because of the enormous size of this module, you’d want to order it well in advance…  as overnight shipping charges would kill you.   The reorder numbers for these for the DC255/265/460/470 in the US are as follows: 113R00132 = “Metered”, 113R00131 / 113R00176 = “Sold”.   The other models in the series use different reorder numbers and are likely to use different CRUM's.  Different reorder numbers (and likely, different versions) are also used outside of the US.

     One precaution tidbit which I picked up by going through the Manual is that when removing the Xerographic Module, be very careful as some machines were equipped with a long plastic clip (more like a pin from the illustration in the Service Manual) on the Xerographic Drive Module which can catch the photoreceptor belt and cause damage to it…  To correct this, Xerox came out with a replacement clip which is shorter (kit part number = 606k06950) Tag 047 should be marked off on the Changed Tag Matrix on the machine when that kit is installed.

     Fuser Modules include heat and press rolls, fuser lamp, etc… also a cleaning web. The machine counts to 250,000 copies on the Fuser’s CRUM (fuser module connector)… the web however can run out as early as 80,000 copies if very long prints are made. The fuser for the DC240 is different from the DC255/265, DT65) as are the DC480/490… they have different fuser nips, a different lamp and different CRUMs of course.   The DC240 Fuser Modules are offered under the reorder numbers 109R00328 for the “Metered” version, and 109R00327 / 109R00346 for the “Sold” version.   The DC255/265 and DT65 machines use reorder numbers 109R00330 for the “Metered” version, and 109R00329 / 109R00347 for the “Sold” version.   Again, these reorder numbers are for USO (United States Operations) market only… overseas machines use different reorder numbers and probably are not interchangeable because of the CRUMs.

STATUS CODES:
This is far from a complete listing… but it should give you a clue where to look for most of the codes… Codes marked with an asterisk are codes which will involve checking a few connections and then, if the problem doesn’t resolve itself, it’s time to run and call a trained tech with the PWS laptop.
01-xxx codes : Interlock Problems
01-301: Front Door Interlock Open
01-305: HCF or Bypass Top Cover Open
01-310: VDC Interlock Open
01-705: IOT Overheat Fault
02-xxx codes:* UI (User Interface) Communication & Self Test Problems
03-xxx codes:* Communication Faults… These can involve quite a few different boards and accessories… below are a few which it might be helpful to know which component or accessory is involved. This way you can at least check for loose connectors in the appropriate places before calling in an expert.
03-311: ROS (Raster Output Scanner or Laser Unit) Communication Fault
312/313/314: Finisher Communication Faults
03-331/332: ESS Communication Faults
03-335: Finisher PWB Unexpected Reset
03-337: ROS Control Module Reset Detected
03-346/347: Control Panel or User Interface Communication Faults
03-349: SCSI PWB Communication Fault
03-354: Scanner Communication Fault
03-800 – 829: IIOC Module Controller Test Fault
03-831 – 834: HCF (High Capacity Feeder) or Bypass Tray Controller Test Fault
04-xxx codes: Drive Problems
04-201/202: Developer Drive Motor Faults
04-205/206: Photoreceptor Drive Motor Faults
04-210/211: Fuser Drive Motor Faults
05-xxx codes: DADF (Duplexing Automatic Document Feeder) problems
05-100 – 110: Doc Feeder Jams
05-310: DADF Raised During Document Feed
05-325: DADF Cover Opened During Document Feed
05-340: DADF Nudger Solenoid Failure
05-345: DADF Feed Clutch Failure
05-350: DADF Registration Gate Solenoid Failure
05-355: DADF Exit Clutch Failure
05-360: DADF Inverter Clutch Failure
05-365/375: DADF Feed Motor Fault
06-xxx codes: ROS (Raster Output Scanner … Laser Unit) problems
07-202.01 - 202.04 Tray 1 through 4 Elevator Faults
07-202.06: HCF (High Capacity Feeder, Tray 6) Elevator Fault
08-xxx codes: Paper Misfeeds & Jams
08-101.01 – 101.04: Tray 1 through 4 Misfeeds
08-101.05: Bypass Tray (Tray 5) Misfeed
08-101.06: HCF (Tray 6) Misfeed
08-105.01 – 105.04: Tray 1 through 4 Jams
08-105.05: Bypass Tray (Tray 5) Jam
08-105.06: HCF (Tray 6) Jam
08-110 – 120: Registration Transport Jams
08-701: Misfeed from any Tray
08-710: Vertical Transport Entrance Jam from any tray
09-xxx codes: Xerographic Control Faults (photoreceptor, toner problems, high voltage problems, etc.)
09-210: PR Belt Seam not detected
09-215: Multiple PR Belt Seams detected
09-310 – 320: ADC Patch faults
09-324: Too much Background detected
09-330: Toner Concentration Low
09-332: Toner Concentration High
09-334: Toner Control Patch Low
09-336: Toner Control Patch High
09-350: Xerographic Module Open
09-351: Invalid Xerographic Module Count
09-352/353: Wrong Xerographic Module
09-354: Xerographic Module CRUM not detected
09-355: Can’t Communicate with Xerographic Module CRUM
09-358: Developer Collector Full
09-370: Transfer Power Fault
09-372: Detack Power Fault
09-374: Charge Power Fault
09-376: Developer Bias Fault
09-380: Transfer Arc Fault
09-382: Detack Arc Fault
09-384: Charge Arc Fault
09-386: Developer Bias Arc Fault
09-870/880: Toner Bottle Empty
10-xxx codes: Transport and Fuser Problems
10-100: Prefuser Transport Jam
10-101: Fuser Exit Jam
10-105 – 130: Inverter Exit Jams
10-300: Fuser Thermistor Circuit Open
10-301: Fuser Failed to Warm Up
10-302: Fuser Undertemperature
10-303: Fuser Overtemperature
10-350: Fuser Module Connector Open
10-351: Invalid Fuser Module Count
10-352/353: Wrong Fuser Module
10-354/355: No Fuser Module CRUM detected
12-xxx codes: OCT (Offsetting Catch Tray) Faults
12-101 codes: Jam at OCT
12-213 codes: OCT Offset Motor Fault
13-xxx codes: Finisher Faults
14-xxx codes: Scanner Faults
14-300 – 320: Scanner Calibration Failed
14-325 – 335: Scan motion problems
14-700: Exposure Lamp output too low
16-xxx codes: ESS Faults
19-xxx codes:* Video and System Control Problems
21-xxx codes:* Modem Problems
22-xxx codes:* System Faults (software or configuration conflicts)

That should head you roughly in the right direction when a status code comes up.

     So, what can you do without the aid of a PWS laptop computer thingy?  You can go and reset the life counters for the Feed Roll Cartridges for one thing:
Press ‘Access’…   enter the Password (‘1111’ is the default) followed by ‘Enter’… Select ‘Go to Tools’.   On the Touchscreen, select “More”, “Supplies Management”, and “Feed Roll Cartridge Replacement”… then with the “Feed Roll Cartridge Replacement” screen up, go and replace whichever Feed Roll Cartridge you need to replace… the machine will then prompt you to confirm replacement of the appropriate Feed Roll Cartridge… select “Confirm”.   Select “Close” and then select “Exit Tools”.

      The Feed Roll Cartridges are identical for all cassettes including the HCF (High Capacity Feeder) and the Bypass … these are sold under the reorder number 108R148.   The Document Feed Roll Cartridge is similar but a little bit different… it sells under the reorder number 108R149.

     If the Copy Quality is out of wack, there is a function available from the console called the “Xerographic Routine”… I did not find mention of this routine in the Service Manual and have not had the pleasure of running the routine myself as of yet, so the procedure is a bit fuzzy to me at this time.   I was told that you get to it from ‘Access’, ‘1111’, ‘Enter’, then select “Copy Quality”, followed by “Xerographic Routine”.   I’ve also been told that the machine is known for getting impacted toner on the donor roll in the DV Unit after between 300k and 500k prints.   Use pumice to remove the toner coating.   Also clean the sensor which detects the toner density (it’s described as black with a round hole and a corresponding square eye.   That along with some general cleaning of the optics and such will solve a majority of copy quality issues.

     It’s also helpful to know that you can run a report known as the “Call for Service Report” from “Customer Tools” which will give you the Machine’s Serial Number, Current system software version, total images billing meter, and Last 20 Faults.

If you are trying to work on a machine which is protected by an Auditron… you can try the default Access Code (‘1111’).   If it works, you can go in and change the machine’s “Mode” to disable the Auditron.  If it has been changed and is not known, you’ll need someone with a PWS to return the Access Code to the default.

     That’s the ins and outs of this series …  much to learn, but at least now you have a rough idea when you can help and when you can’t.


Written by Britt Horvat of The Parts Drop.
First Published in ENX Magazine.


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