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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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Xerox®  Pro645 & Pro665 style TECH INFO
Pro635, Pro645, Pro657 & Pro665, Pro685, Pro765, Pro785
Pro645 style Fax Machine illustration

Intravia’s Guides covers these models as well as many other makes and models in the Guide to Fax Machines, 1st Edition.

FULL TECHNICAL INFORMATION is in the works...
    In the mean time, here's an article which we produced which was published in ENX Magazine. You'll find most of what you need to get your feet wet with this series of machines... including Status Messages, Diagnostic procedures, adjustments, etc. Also, below, you'll find information on how to Reset the Drum Count if the cartridge fails to do it automatically the way it's supposed to.


Xerox®  Workcentre Pro645 style & Pro665 style    -     The Fax side of things.
Courtesy of ENX Magazine.

    Until recently I've been sticking mostly to copiers, however it has become abundantly clear that with the disappearance of analog copiers, there is no longer any clear distinction between copiers, printers and fax machines.  Anything you lay your hand to these days is really a multifunction machine… sure they still market various versions of new releases as "copiers" or "faxes"  or "printers" but the differences are now mostly superficial.  Today's article deals with a set of machines which are primarily marketed as fax machines.

    Xerox has been rather loose with the designation "Workcentre Pro".  There is a wide range of models which start off with that description, many of which have little or nothing to do with one another, other than perhaps to serve small office multifunctional needs.  There were the Pro215's and Pro16's which fit nicely into the XD100 style.  Then there's the Pro412 style which is another completely different series.  Today's article will take a good look at a group of models which have nothing to do with those others but which are drawn from the same basic engine as one another.  First there is the Pro645 style as we're calling it (Pro635, 645, 657), then the Pro665 style (Pro665, 685, 765, 785).  Beware because there are a whole bunch of other models which sound very similar but are actually completely different machines including the Pro535/555, and another group the Pro735/745 (which by the way, aside from being quite different physically uses many similar diagnostic procedures including the drum count reset).  You can see how it may get confusing to know which model is related to what. Let's first take a look at the various Error Codes and Error Messages… then we'll hit on the diagnostic functions available to you.

    There are a number of "Error Codes" as well as "Error Messages". We'll cover the Error Codes first... the Error Messages will follow later.  The Error Codes are numeric codes which will sometimes appear on the display and are also shown on Failure Reports which the machine will automatically print out whenever a send, receive or other action fails.  The "Error Code" on the report will show up on a line labeled "Status"…   then there will be shown an "NG" followed by the Error Code.
Here is a listing for you:

ERROR CODES:
(Note: If the code is accompanies with a message which says "Printer Problem, Notify the Serviceman", find it in "Error Messages" below...)

10 = Out of Paper       
11 = Paper Jam
12 = Document Jam
13 = Clamshell opened during operation
20 = Power Failed during an operation
22 = File Error… perform "Memory Clear"
30 = Communication aborted by 'stop' button
32 = Mismatched # of Document pages
33 = Polling Error
42 = Memory exceeded in trasmission or receiving (use 'direct send tranmission' if document is too large for memory)
50 = Busy signal at remote machine
53 = Security block on incoming fax
87 = Remote machine's memory exceeded
B0-B5, C0-C4, D0-D2, E0-E6… all of these are related to communication failures between the local and remote fax units… too much detail to cover here. 

   There are also "Error Messages"  which will come up on the display from time to time…  most of them are rather self-explanatory but a few could use a little bit of elaboration (I've listed only the ones which need explanation below).

ERROR MESSAGES:

"Broken Registration"  NVM Battery failure, backup data is lost.

"Check Process Unit"  Machine is not sensing either the Drum Unit or Developer Unit.  The wrong type of drum cartridge would also cause this message (for example, a 7041 drum cartridge would physically fit in these models but the pair of contacts on top are in a different position so they don't line up properly with the contacts on the laser unit above… so the machine can tell the difference.

"Drum Life Warning"  The drum count has reached the 9,000 copy mark. 

"Replace Drum"  Time to replace the Drum Unit… 1,000 copies after warning or toner empty was detected during the warning period.

"Entry Memory Full"  Maximum number of phone book entries has been reached.

"Printer Problem, Notify the Serviceman"  This message is generally accompanied by a numeric code as follows

            21 = Developer Unit problem

            22 = Fuser not at correct temperature

            41 = Laser Motor problem

            42 = Laser malfunction

            61 = Printer Drive Motor (Main Motor)

            71 = Fan problem

            72 = Optional paper supply problem

NOTE:  some of these "Printer Problem" codes have the same number as the "Error Codes" above… there is no relation however, so try not to confuse the two… these only appear along with the message "Printer Problem…".

 

Now for some diagnostic stuff…

ENTERING SERVICE MODE … hold down the '1', and '3' keys while powering up… then for most of the functions you'll press 'menu', '9', followed by whichever code you want to run.  There are 3 basic menus which are numbered 1,2, & 3 which you'll select from next, followed by a 2 digit code…so for example to run a test pattern from diagnostics, you would hold down '1' and '3' while powering up, then press :  'menu', '9', '1', '0', '2'… a choice between two test patterns will appear, select '1' for the standard pattern or '2' for a black pattern and press 'Enter'… the machine will produce a Test pattern from memory.

Diagnostic Codes: (remember, start with 'menu', '9', then one of the codes below)

'1' Menu: (input and output component testing)
1, 0, 1 Control Panel Test
1, 0, 2 Print Test Pattern
1, 0, 3 Modem Test
1, 0, 4 Dial Test
1, 0, 5 Pix Memory test … tests DRAM memory (reports "ok" or errors found)
1, 0, 6 Sensor Tests
1, 0, 7 Output tests… allows you to test from the following list of components:
Main Motor, Developer Motor, Fan, Charge Hi Voltage, TCV1, TCV2
1, 0, 8 MF Rx Test
1, 0, 9 Speaker Volume Test
1, 1, 0 ADF Test

'2' Menu: (Memory adjustments)

2, 0, 1 = Memory Clear (menu of various sections of memory you can clear)  Note: to clear the drum count, you'll need a different procedure detailed later in this article.

2, 0, 2 = Set Functions (Soft Switches)

2, 0, 3 = Memory Write (used to set SysFUNC Soft Switches)

2, 0, 4 = Sets scanning contrast level… Choose "Normal Mode" (binary, or "Gray Mode (halftone)… range is from 1 to 5)

2, 0, 5 = Shifts Error counters from "actual" to "history" part of memory

2, 0, 6 = Registration adjustments… Run a test pattern first for you to refer to… then go into this adjustment… display will show "Lead Edge +0.0mm" … use the up and down arrows to select the setting you'd like and press 'Enter', then the display will show "Side Edge +0.0mm", use the up and down arrows again and once again hit 'Enter'. 

2, 0, 8 = Fuser Setting (range is from 0-6) use up and down arrows and press 'Enter' to lock in your selection

'3' Menu:  (Reports)

3, 0, 1 = Protocol Trace List (prints a report of results of last job)

3, 0, 2 = Error Count List (prints a list of the communication Error occurences by code)

3, 0, 3 = Function List (prints current Soft Switch Settings.. you'd need the manual for that to be of help to you)

3, 0, 4 = Drum History (prints a drum replacement history including current drum count)

3, 0, 5 = Memory Dump List (again, you'd need a manual for this to be of any use to you)

   Another report which you can run is the "Settings Report" which is done by holding down the '1' and '3' buttons while turning on the power and then pressing 'menu', '2', '1'. 

DRUM COUNT RESET:

   The final bit of info was, to my dismay, not published in the OEM Service Manual (or at least I could not find any reference to it at all)… this would be how to reset the Drum Count.  I have already had tech customers of mine run into situations where they needed to reset the drum count without actually needing to replace the drum cartridge.  One customer had replaced the drum cartridge approximately 2,000 copies early to solve a copy quality issue.  Apparently the count didn't reset and the message "Drum Life Warning" came up shortly thereafter.  It may well be that the new cartridge won't reset the count unless the machine is in the "Drum Life Warning" or "Replace Drum" condition (this is something which I've not been able to verify myself as of yet).  I would like to preface this by saying that if you simply reset the count and walk away without checking out the drum and blade, you'll likely get a recall back to fix it when it fails.  These drum cartridges are built to run the 10K copies and not a whole lot beyond that.  This procedure will help also in a pinch if you want to keep a good customer running for a few days while you wait for the new drum cartridge to arrive.

   To reset the Drum Count, Press and hold down the '1', '3', and '0' buttons together while turning on the power.  The display will say "F/T  NMB = " prompting you to enter a code.  Enter '80' using the numeric keys… the display will briefly show "DRUM MNG DATA CLEAR".  Turn the power off and back on to exit this special diagnostic mode and restore the machine to use.  I recommend you be very careful not to enter any other codes as there is no listing to show what other codes are available or what they may do (could change something you wouldn't want to change and create difficulties for you).  The code is activated by itself, so you don't get an opportunity to press 'enter' to confirm the code… so don't be sloppy about pressing the '80' and never try to guess the code if you don't remember it for sure. 

   Well, that should do it…   Will also have to compare some other models to see what else fits in this grouping in the future. 

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