Xerox DocuColor 250 Service Manual and Parts List Manual (Edition 1, 05/2005)


Accurate, clear and concise text, combined with detailed illustrations, lists of error code, instruction and diagrams, guide you through procedure of repair, remediate, maintenance and adjustments your copier, printer or scanner.
Present manual Xerox DocuColor 250 contain clear instructions and procedures on how to fix the problems occurring in your equipment.
The information contained in this repair manual is necessary for the repair, but also prevention, resulting in a longer life of your equipment.
Format of the manual: PDF, makes it easy to navigate, instant download and print. English language.
To see what contain, please read table of contents:

INTRODUCTION
About this Manual
Organization
How to Use this Documentation
Symbology and Nomenclature
Translated Warnings

1. SERVICE CALL PROCEDURES
Service Call Procedures
Initial Actions
Call Flow
Detailed Maintenance Activities (HFSI)
Cleaning Procedures
Final Actions

2. STATUS INDICATOR RAPs

3. IMAGE QUALITY
3.1a IOT Image Quality Entry RAP
IQ1 IOT Image Quality Entry RAP
3.1b IIT Image Quality Entry RAP
IQ2 IIT Image Quality Entry RAP
3.1c Image Quality RAPs
IQ3 Low Image Density RAP
IQ4 Repeating Bands, Streaks, Spots, and Smears RAP
IQ5 Blank Page RAP
IQ6 Black Print RAP
IQ7 Skew/Misregistration RAP
IQ8 Process Direction Bands and Streaks RAP
IQ9 Residual Image (Ghosting) RAP
IQ10 Solid Color Print RAP
IQ11 Background RAP
IQ12 Spots RAP
IQ13 Unfused Copy/Toner Offset RAP
IQ14 Wrinkled Image/Paper RAP
IQ15 Partial Image Deletions RAP
IQ16 Cross Process Direction Faded Bands and Streaks RAP
IQ17 Cross Process Direction Bands and Streaks RAP
IQ18 Process Direction Faded Bands and Streaks RAP
IQ19 Mottle RAP
IQ20 2nd BTR Checkout RAP
IQ21 1st BTR Checkout RAP
IQ22 Developer Bias RAP
IQ23 BCR Checkout RAP
IQ24 Scorotron Checkout RAP
3.2 Image Quality Specification
Image Quality Specifications
3.3 Defect Samples
Image Defect Samples
Background
Color Misregistration
Debris-Centered Deletions
Deletions
High Frequency Bands
Irregular Process Direction Streak
Low Image Density
Moire
Mottle
Newton Rings
Regular (Repeating) Bands, Streaks, Spots, or Smears
Residual Image
Streak Deletion in Process Direction
Wrinkled Image
Cloud Defect
IBT Cleaner Streak

4. REPAIRS/ADJUSTMENTS
Chain 4
ADJ 4.1 UI Touch Panel Origin Point Correction
Chain 5
ADJ 5.1 DADF Skew Adjustment
ADJ 5.2 DADF Side Edge Registration
ADJ 5.3 DADF Lead Edge Registration
ADJ 5.4 DADF Height Adjustment
ADJ 5.5 DADF Trail Edge Registration Adjustment
ADJ 5.6 DADF Slow Scan Direction Reduce/Enlarge Adjustment
ADJ 5.7 DADF Document Calibration
ADJ 5.8 Half Rate/Full Rate Carriage Position Adjustment
ADJ 5.9 IIT Lead Edge/Side Edge Registration Adjustment
ADJ 5.10 IIT Vertical/Horizontal Reduce/Enlarge
ADJ 5.11 IIT Calibration
ADJ 5.12 Optical Axis Alignment
Chain 7
ADJ 7.1 Tray 5/Bypass Guide Adjustment
Chain 9
ADJ 9.1 MAX Setup
ADJ 9.2 ATC Sensor Setup
ADJ 9.3 Toner Density Setup (Tone Up/Down)
ADJ 9.4 Manual TRC Adjust
ADJ 9.5 ProCon On/Off Print Check
ADJ 9.6 Copy Mode Color Balance
ADJ 9.7 IOT Lead Edge/Side Edge Registration
ADJ 9.8 Registration Control Setup cycle
ADJ 9.9 Registration Measurement Cycle
ADJ 9.10 Registration Control Sensor Check Cycle
ADJ 9.11 Inboard/Outboard Manual Density Setup
ADJ 9.12 Secondary Transfer Output Voltage
ADJ 9.13 Belt Edge Learn
Chain 12
ADJ 12.2 Finisher Leveling
ADJ 12.4 Booklet Fold Skew
ADJ 12.5 Booklet Fold Position
ADJ 12.6 Booklet Staple Position (Staple on Fold)
ADJ 12.7 Booklet Staple Alignment
ADJ 12.8 Finisher Booklet Wrinkle
ADJ 12.9 Booklet Fold Position (Fine Adjustment)
ADJ 12.10 Booklet Staple Position (Staple on Fold Fine Adjustment)
Chain 1
REP 1.1 Power Unit
Chain 3
REP 3.1 Chassis Assembly
REP 3.2 Control Unit
REP 3.3 Main Drive Assembly
REP 3.4 Network Controller
REP 3.5 ESS PWB
REP 3.6 VSEL PWB
Chain 4
REP 4.1 Tray Assembly and UI
REP 4.2 UI PWB
Chain 5
REP 5.1 DADF
REP 5.2 DADF Setting to the Vertical Service Position
REP 5.3 DADF Covers
REP 5.4 DADF Left Counter Balance
REP 5.5 DADF Right Counter Balance
REP 5.6 DADF PWB
REP 5.7 DADF Invert Drive Roll
REP 5.8 DADF Feed Clutch
REP 5.9 DADF Feed Motor Belt
REP 5.10 DADF Takeaway Roll
REP 5.11 DADF Lead Reg Sensor
REP 5.12 DADF Registration Roll
REP 5.13 DADF Exit Roll 1
REP 5.14 DADF Exit Roll 2
REP 5.15 DADF Feed Roll
REP 5.16 DADF Nudger Roll
REP 5.17 DADF Platen Exit Sensor
REP 5.18 DADF Invert Sensor
REP 5.19 DADF Exit Sensor 1
REP 5.20 DADF Exit Sensor 2
REP 5.21 DADF Reg Sensor
REP 5.22 DADF Retard Roll
REP 5.23 DADF Platen Exit Roll
REP 5.24 Opening / Closing the IIT Frame
REP 5.25 IIT Lens Cover
REP 5.26 IIT Registration Sensor
REP 5.27 Platen Angle Sensor
REP 5.28 CCD Flexible Print Cable
REP 5.29 IIT Lens Assembly
REP 5.30 IPS Fan
REP 5.31 Lamp Fan
REP 5.32 CCD Fan
REP 5.33 Carriage Motor
REP 5.34 Full Rate Carriage
REP 5.35 Rear Carriage Cable
REP 5.36 IIT/IPS, BDEC, Extension Memory, PSDC PWBs
REP 5.37 Exposure Lamp
REP 5.38 Lamp Ballast PWB
REP 5.39 Slide Cord
Chain 6
REP 6.1 ROS Assembly (C,K)
REP 6.2 ROS Assembly (Y, M)
Chain 7
REP 7.1 HCF Tray 6
REP 7.2 HCF Feeder
REP 7.3 HCF Undocking and redocking
REP 7.4 HCF Tray Cables
REP 7.5 HCF Retard/Feed/Nudger Rolls
REP 7.6 HCF Feed Shaft
REP 7.7 HCF Retard Lever Spring
REP 7.8 HCF Nudger Bracket/Nudger Lever/Torsion Spring
REP 7.9 HCF Casters
REP 7.10 HCF Takeaway Roll
REP 7.11 HCF PWB
REP 7.12 HCF Feed Motor
REP 7.13 HCF Nudger Solenoid
REP 7.14 Tray 5 / Bypass Feeder
REP 7.15 Tray 5 / Bypass Retard, Feed, and Nudger Rolls
REP 7.16 Tray 5 / Bypass Nudger Bracket, Nudger Lever, Torsion Spring
REP 7.17 Tray 5 / Bypass Feed/Nudger Shaft
REP 7.18 Tray 1 Feed Assembly
REP 7.19 Tray 2 Feed Assembly
REP 7.20 Tray 3 Assembly
REP 7.21 Tray 4 Assembly
REP 7.22 Tray 3 Feed Assembly
REP 7.23 Tray 4 Feed Assembly
REP 7.24 Feed/Nudger/Retard Roll (Trays 1 and 2)
REP 7.25 Feed/Nudger/Retard Roll (Tray 3)
REP 7.26 Feed/Nudger/Retard Roll (Tray 4)
REP 7.27 Tray 3 Rear Cable
REP 7.28 Tray 3 Front Left and Right Cables
REP 7.29 Tray 4 Front Cable
REP 7.30 Tray 4 Rear Cable
REP 7.31 Tray 5 / Bypass Chute Assembly
Chain 8
REP 8.1 Registration Transport Assembly
REP 8.2 Duplex Motor Assembly
REP 8.3 Inverter 1 and 2 Transport
Chain 9
REP 9.1 Transfer Belt Unit
REP 9.2 IBT Cleaner Assembly
REP 9.3 Transfer Belt
REP 9.4 2nd BTR Roll Assembly
REP 9.5 2nd BTR Roll
REP 9.6 2nd BTR Blade Assembly
REP 9.7 1st BTR HVPS
REP 9.8 Drum Cartridges (Y, M, C & K)
REP 9.9 Dispenser Assembly (Y, M, C & K)
REP 9.10 Drum Motor Assembly (K)
REP 9.11 Developer Drive Assembly (K) and Belts
REP 9.12 Developer Drive Assembly (Y, M, C)
REP 9.13 MOB ADC Assembly
REP 9.14 Developer Housing (Y, M, C & K)
REP 9.15 Developer Replacement (Y, M, C & K)
REP 9.16 Dispenser (K)
REP 9.17 Dispenser (C)
REP 9.18 Dispenser (M)
REP 9.19 Dispenser (Y)
REP 9.20 Low Toner Sensor PWB
REP 9.21 Low Toner Sensor (K)
REP 9.22 Low Toner Sensor (C)
REP 9.23 Low Toner Sensor (M)
REP 9.24 Low Toner Sensor (Y)
Chain 10
REP 10.1 Fuser
REP 10.2 Vacuum Transport Assembly
REP 10.3 Transport Belt
REP 10.4 Fuser Drive Assembly
Chain 12
REP 12.1 I/F Module Rear Cover
REP 12.2 I/F Module Top Cover
REP 12.3 I/F Module
REP 12.40 A/P Finisher Front Door
REP 12.41 A/P Finisher Rear Upper Cover
REP 12.42 A/P Finisher Rear Lower Cover
REP 12.43 A/P Finisher Top Cover
REP 12.44 A/P Finisher Front Top Cover
REP 12.45 A/P Finisher Top Tray
REP 12.46 A/P Finisher Eject Cover
REP 12.47 A/P Finisher Tray Spring Guide
REP 12.48 A/P Finisher Inner Cover
REP 12.50 A/P Finisher
REP 12.52 A/P Finisher Punch Frame Assembly
REP 12.53 A/P Finisher Stapler Assembly
REP 12.54 A/P Finisher Stapler Rail
REP 12.55 P Finisher Booklet Maker Unit
REP 12.56 P Finisher Booklet Stapler
REP 12.57 A/P Finisher Compiler Tray
REP 12.58 A/P Finisher Stacker Tray Position
REP 12.59 A/P Finisher Paddle Shaft
REP 12.60 A/P Finisher Stacker Drive Belt
REP 12.61 A/P Finisher Buffer Path Sensor
REP 12.62 A/P Finisher Gate Sensor
REP 12.63 A/P Finisher Top Tray Full Sensor
REP 12.64 A/P Finisher Buffer Roll
REP 12.65 A/P Finisher Bottom Buffer Chute Assembly
REP 12.67 A/P Finisher Eject Chute Assembly
REP 12.68 A/P Finisher PWB

5. PARTS LIST
Overview
Introduction
Subsystem Information
Symbology
Parts Lists
Drives
PL 1.1 Drive Unit (1 of 2)
PL 1.2 Drive Unit (2 of 2)
PL 1.3 Fuser Drive Assembly
PL 1.4 Main Drive Assembly
PL 1.5 Developer Drive Assembly (K)
PL 1.6 Developer Drive Assembly (Y, M, C)
Trays
PL 2.1 Tray 1/2
PL 2.2 Tray 3/4 (1 of 2)
PL 2.3 Tray 3/4 (2 of 2)
PL 2.4 Tray 1 Assembly
PL 2.5 Tray 2 Assembly
PL 2.6 Tray 1 Feed Assembly (1 of 2)
PL 2.7 Tray 1 Feed Assembly (2 of 2)
PL 2.8 Tray 2 Feed Assembly (1 of 2)
PL 2.9 Tray 2 Feed Assembly (2 of 2)
PL 2.10 Tray 3 Feed Assembly (1 of 2)
PL 2.11 Tray 3 Feed Assembly (2 of 2)
PL 2.12 Tray 4 Feed Assembly (1 of 2)
PL 2.13 Tray 4 Feed Assembly (2 of 2)
PL 2.14 Tray 3 Assembly
PL 2.15 Tray 4 Assembly
PL 2.16 Tray 5 / Bypass Chute Assembly
PL 2.17 Pre Registration Motor Assembly
PL 2.18 Takeaway Roll
PL 2.19 Left Chute Cover
PL 2.20 T/A Drive
PL 2.21 Tray 3/4 Gear Assembly
Bypass
PL 3.1 Tray 5 / Bypass Accessory
PL 3.2 Tray 5 / Bypass Cover
PL 3.3 Tray 5 / Bypass Component (1 of 2)
PL 3.5 Tray 5 / Bypass Tray Component
PL 3.6 Tray 5 / Bypass Feeder Component
PL 3.7 Tray 5 / Bypass Upper Feeder Component
PL 3.8 Tray 5 / Bypass Lower Feeder Component
PL 3.9 Retard/Feed/Nudger Roll Component
PL 3.10 Feed/Nudger Shaft Component
Drawer Unit
PL 4.1 Transfer Module Assembly (1 of 2)
PL 4.2 Transfer Module Assembly (2 of 2)
PL 4.3 Duplex Transport
PL 4.4 Registration Transport Assembly
PL 4.5 Pre Registration Slide Assembly
PL 4.6 V-Transport Assembly
ROS
PL 5.1 ROS
Developer
PL 6.1 Drum/Toner Cartridge
PL 6.2 Dispense Unit
PL 6.3 Dispense Assembly (Y, M, C, K)
PL 6.4 Dispense Assembly
PL 6.5 Dispense Unit (1 of 3)
PL 6.6 Dispense Unit (2 of 3)
PL 6.7 Dispense Unit (3 of 3)
PL 6.8 Rear Frame (1 of 2)
PL 6.9 Rear Frame (2 of 2)
PL 6.10 Direct Pipe Assembly
PL 6.11 Joint/Leveler Box Assembly
IBT
PL 7.1 IBT Unit (1 of 2)
PL 7.2 IBT Unit (2 of 2)
PL 7.3 Transfer Belt Unit
PL 7.4 IBT Frame Assembly (1 of 4)
PL 7.5 IBT Frame Assembly (2 of 4)
PL 7.6 IBT Frame Assembly (3 of 4)
PL 7.7 IBT Frame Assembly (4 of 4)
PL 7.8 2nd BTR Roll Assembly (1 of 2)
PL 7.9 2nd BTR Roll Assembly (2 of 2)
PL 7.10 IBT Drawer
Fuser
PL 8.1 Fuser Unit
Air System
PL 9.1 Air System (1 of 3)
PL 9.2 Air System (2 of 3)
PL 9.3 Air System (3 of 3)
Inverter
PL 10.1 Inverter
PL 10.2 Inverter 1 Transport (1 of 2)
PL 10.3 Inverter 1 Transport (2 of 2)
PL 10.4 Inverter 2 Transport (1 of 2)
05/16/05
5-2 DocuColor 250
Parts List Launch
PL 10.5 Inverter 2 Transport (2 of 2)
Electrical
PL 11.1 Electrical (1 of 3)
PL 11.2 Electrical (2 of 3)
PL 11.3 Electrical (3 of 3)
PL 11.4 Wire Harness
PL 11.5 Control Unit (1 of 2)
PL 11.6 Control Unit (2 of 2)
Cover
PL 12.1 Cover (1 of 2)
PL 12.2 Cover (2 of 2)
IIT
PL 13.1 IIT Cover – Front/Top
PL 13.2 IIT Cover – Rear/Right, Power Chassis (DADF-250)
PL 13.3 IIT Bottom Bracket
PL 13.4 IIT Component
PL 13.6 IIT Housing – Electrical
PL 13.7 IIT Housing – Carriage
PL 13.8 IIT/IPS Unit
PL 13.9 Full Rate Carriage Component
PL 13.10 Half Rate Carriage Component
DADF
PL 14.1 DADF
PL 14.2 DADF Cover
PL 14.3 DADF PWB, Counter Balance
PL 14.4 DADF Document Tray, Tray Motor
PL 14.5 Feeder Upper Chute, DADF Left Upper Cover
PL 14.6 Feed Motor, Feed Clutch, Invert Drive Roll
PL 14.7 Pre Registration Motor, Pre Registration Roll Chute, Take Away Roll, Baffle Solenoid
PL 14.8 Registration Motor, Registration Roll
PL 14.9 Platen Motor, Platen Roll, Out Roll
PL 14.10 Exit Motor, Exit Roll
PL 14.11 Exit Gate Solenoid, Simp/Dup Gate Solenoid, Nip Solenoid, Inverter Exit Chute, Guide Chute
PL 14.12 Exit Upper/Lower Chute, Registration Out Chute, Feeder Lower Chute
PL 14.14 DADF Document Tray Component
PL 14.15 DADF Document Bottom Tray Component
PL 14.16 DADF Document Upper Tray Component
PL 14.17 Feeder Upper Chute Component
PL 14.18 Feeder/Nudger Roll Component
PL 14.19 DADF Left Upper Cover Component
PL 14.20 Pre Registration Roll Chute Component
PL 14.21 Inverter Exit Chute Component
PL 14.22 Guide Chute Component
PL 14.23 Exit Upper Chute Component
PL 14.24 Exit Lower Chute Component
PL 14.25 Registration Out Chute Component
PL 14.26 Feeder Lower Chute Component
SCT/OCT
PL 16.1 SCT
PL 16.2 OCT (1 of 2)
PL 16.3 OCT (2 of 2)
UI
PL 17.2 UI (Left)
PL 17.3 UI
PL 17.4 LCD Touch Panel
HCF
PL 18.1 HCF Unit
PL 18.2 HCF Tray 6 (1 of 2)
PL 18.3 HCF Tray 6 (2 of 2)
PL 18.4 HCF Feeder (1 of 3)
PL 18.5 HCF Feeder (2 of 3)
PL 18.6 HCF Feeder (3 of 3)
PL 18.7 HCF Top Cover Unit
PL 18.8 HCF Electrical and Rail
A/P Finisher
PL 21.1 A/P Finisher
Finisher
PL 21.2 Finisher Cover: 1 of 2
PL 21.3 Finisher Cover: 2 of 2
PL 21.4 Finisher Stack
PL 21.5 Finisher Punch
PL 21.6 Finisher Stapler
PL 21.7 Finisher Eject: 1 of 3
PL 21.8 Finisher Eject: 2 of 3
PL 21.9 Finisher Eject: 3 of 3
PL 21.10 Finisher Transport: 1 of 2
PL 21.11 Finisher Transport: 2 of 2
PL 21.12 Finisher Electrical
PL 21.13 Finisher Harness
PL 21.15 Booklet Accessory
PL 21.16 Booklet Component – 1
PL 21.17 Booklet Component -2 (End Guide)
PL 21.18 Booklet Component -3
PL 21.19 Booklet Component -4
PL 21.20 Booklet Component -5
PL 21.21 Booklet Component -6 (Chute)
PL 21.22 Booklet Component -7
PL 21.23 Booklet Tray Component
PL 21.25 I/F Module Component (Drive)
PL 21.27 I/F Module Component (Chute)
PL 21.28 Finisher OCT
Common Hardware
Common Hardware
Part Number Index

6. GENERAL PROCEDURES AND INFORMATION
UI Diagnostic Mode
Entering and exiting CE mode
Functions enabled in CE mode
Accessing UI Diagnostics
Software Options
Print Test Patterns
MAX Setup
NVM Initialization
Initialize Hard Disk
Delete All Data
NVM Read/Write
Machine ID/Billing Data Settings
Initialize HFSI Counter
Component Control
Printing CSE Reports
PWS Diagnostics
Entering PWS Diagnostic mode
DC Quick
dC118 Jam Counter
dC120 Fault Counter
dC122 Shutdown History
dC128 Finisher Setup
dC129 System Registration Setup
dC131 NVM Read/Write
dC135 HFSI Counters
dC140 Analog Monitor
dC301 NVM Initialization
dC330 Component Control
dC351 NVM Background Processing
dC355 Hard Disk Diagnostics/Setup
dC527 DADF Document Calibration
dC612 Test Pattern Print
dC671 RegiCon Measurement Cycle Control
dC673 RegiCon Sensor Check Cycle Control
dC675 RegiCon Setup Cycle Control
dC710 No Paper Run
dC726 Paper Path Timing
dC740 Tray 5 Guide Adjustment
dC919 Color Balance
dC924 TRC Adjustment
dC937 ProCon On/Off Print
dC945 IIT Calibration
dC950 ATC Sensor Setup
dC991 Tone Up/Tone Down
General Procedures
GP 1 Special Boot Modes
GP 2 Software Download
GP 3 Jam Bypass Mode
GP 4 Serial Number Synchronization Procedure
GP 5 Hard Stop Procedure
GP 6 Printing Reports
GP 7 Network Printing Simulation
GP 8 Auto Gradation Procedure
GP 10 Billing Meter PWBs
General Information
Space Requirements
Product Specifications
Common Tools
Product Tools and Test Patterns
Cleaning Materials
Machine Consumables
Glossary of Terms
Change Tags

Xerox DC250 DC 250