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Xerox DocuPrint 4890 IPS Maintenance Manual

Guide to performing routine maintenance
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Xerox DocuPrint 4850/4890 IPS
Guide to Performing Routine Maintenance
Version 7.1
August 2000
721P89110

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  • Page 1 Xerox DocuPrint 4850/4890 IPS Guide to Performing Routine Maintenance Version 7.1 August 2000 721P89110...
  • Page 2 Printing Systems Documentation and Education 701 South Aviation Boulevard, ESM1-058 El Segundo, CA 90245 ©1997, 1998, 1999, 2000 by Xerox Corporation. All rights reserved. Copyright protection claimed includes all forms and matters of copyrightable material and information now allowed by statutory or...

  • Page 3: Laser Safety

    The laser danger labels on the system are for Xerox service representatives and are on or near panels or shields that must be removed with a tool. DO NOT REMOVE LABELED PANELS OR PANELS NEAR LABELS.

  • Page 4: Operation Safety

    Operation safety Your Xerox equipment and supplies have been designed and tested to meet strict safety requirements. They have been approved by safety agencies, and they comply with environmental standards. Please observe the following precautions to ensure your continued safety.

  • Page 5: Table Of Contents

    Storing the cart and CCU 6. Waste containers Checking and replacing the developer waste container Checking and replacing the dry ink waste container XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE Contents Conventions Guidelines for loading paper Loading the trays...
  • Page 6 Cleaning the 4mm cartridge tape drive 9. Maintenance and support services Xerox Customer Services Support Center Xerox Documentation and Software Services Xerox Font Center Operator Training Xerox Customer Education Reporting billing meters Index XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE INDEX-1...

  • Page 7: About This Guide

    Refer to the entire Xerox DocuPrint IPS Series documentation for information on other tasks required for printing with your DocuPrint printer.

  • Page 8: Index

    • Chapter 9, “Maintenance and support services,” provides information on how to call for service, order supplies, and report meter readings. An index is provided at the back of the guide. XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE...
  • Page 9 Conventions XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE This guide uses the following conventions: • Italics — Document and library names are shown in italics (for example, the Xerox DocuPrint 4850/4890 IPS Guide to Performing Routine Maintenance). •...

  • Page 10: Related Publications

    IBM documents This document is part of the Xerox DocuPrint IPS publication set. Following is a list of all Xerox DocuPrint IPS documents. For a complete list and description of available Xerox documentation, refer to the Xerox Customer Documentation Catalog (publication number 610P17517), or call your service representative.

  • Page 11: Feeder Trays

    Checking feeder trays XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE This chapter describes the processes for loading paper in the 4850/4890 IPS feeder trays, and explains what actions are necessary if a paper stock is changed. Check the amount of paper in each feeder tray by examining the green lights on the door of the tray.

  • Page 12: Guidelines For Loading Paper

    • Place any paper left in the bottom of the tray on top of the new paper stack. • When loading predrilled paper, fan the paper and remove loose paper plugs. XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE...

  • Page 13: Loading The Trays

    Loading the trays XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE Follow these steps to load a feeder tray: 1. If the Ready To Open indicator on the feeder tray door is not lit, press the Tray Unlock button and wait for the tray to descend and the Ready To Open indicator light before opening the tray.
  • Page 14 5. Squeeze the lever against the back of the length guide and slide the guide toward the back of the printer. 6. Remove any paper remaining in the tray and set it aside to be placed on top of the new paper. XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE...
  • Page 15 XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 7. Load paper, following the instructions at the front of the feeder tray and carefully positioning the paper in the right-front corner of the tray. 8. Pull the length guide forward to touch the back of the paper stack.
  • Page 16 Make changes on the window as appropriate, then save your changes. For detailed information on the Input Configuration window, refer to the Xerox DocuPrint 4850/4890 IPS Guide to Configuring and Managing the System. XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE...

  • Page 17: Output Trays

    Checking and unloading dual stacker trays XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE Your print jobs are sent to printer output trays, which you must unload. You can unload each of the output trays while the system is printing.
  • Page 18 Note: When both trays are full, you must empty at least one tray before you can resume printing. Note: Your service representative can set up your printer so that printing continues automatically after a dual stacker tray is unloaded and replaced. XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE...

  • Page 19: Checking And Unloading The Stitcher/Stacker Tray

    Checking and unloading the stitcher/stacker tray Unloading the stitcher/stacker tray XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE An electronic counter in the stitcher/stacker keeps track of the number of sheets printed and the number of stapled sets produced.

  • Page 20: Checking And Unloading The Sample Tray

    Note: The sample tray can receive purged sheets after a paper jam. Always clear the sample tray after clearing a jam to prevent purged sheets from being confused with good sheets. XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE...

  • Page 21: Stitcher Wire

    XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE The Wire Percentage indicator is located on the printer control console of IPS systems configured with a stitcher/stacker. The indicator displays approximate percentage of stitcher wire remaining on the spool. Your service representative can set the display to flash at a predetermined percentage as a warning that you are running low on stitcher wire.
  • Page 22 To continue printing without replacing the wire, press the Continue button. The document is then printed without being stapled. XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE...

  • Page 23: Adding Fuser Lubricant

    Adding fuser lubricant XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 4Fuser lubricant and pressure This chapter describes how to add fuser lubricant and how to replace the pressure roll wiper on your system. The fuser uses heat to fuse the print image to the paper. It is critical that the fuser be kept lubricated with fuser lubricant and that its reservoir be kept full.
  • Page 24 Caution: There is an orange float that indicates the lubricant level. It may stick to the reservoir wall. Be careful not to overfill the reservoir or an overflow of lubricant may occur. XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE Ä...
  • Page 25 XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE FUSER LUBRICANT AND PRESSURE ROLL WIPER 7. Open a tube of fuser lubricant and cut the pointed spout diagonally. Carefully squeeze the lubricant into the reservoir until the orange float reaches the top (C), or until you see the oil reach the top edge below the fuser cap.

  • Page 26: Replacing The Pressure Roll Wiper

    2. Open the printer doors and locate the fuser drawer. 3. Move the green lever (A) counter-clockwise, grasp the green handle on the fuser drawer, (B) and pull it out until it stops. XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE...
  • Page 27 XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE FUSER LUBRICANT AND PRESSURE ROLL WIPER 4. Determine if the fuser is cool. Place your hand approximately 1 inch (25mm) above the fuser area. If you feel heat, STOP, leave the fuser drawer out, and wait for the fuser to cool.
  • Page 28 7. Remove the lower rod from the springs and lift the wiper assembly away. 8. Place the used wiper in the plastic bag that came with the new wiper and dispose of the bag in a trash receptacle. XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE...
  • Page 29 XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE FUSER LUBRICANT AND PRESSURE ROLL WIPER 9. Rotate the pressure roll while wiping the dirt off with a clean cloth. Discard the cloth in the trash receptacle when you are finished.
  • Page 30 15. Close the fuser drawer by pressing down on the green latch (A), and push the fuser drawer in until it latches in place. 16. Close the printer doors and power on the printer. 17. Wash your hands to remove any fuser agent. XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE...

  • Page 31: Adding Dry Ink

    Note: Do not discard damaged, unused dry ink bottles. Return the bottles to Xerox for exchange (for credit in the USA). Caution: To prevent dry ink spillage, remove the cartridge only...
  • Page 32 3. Pull the empty dry ink bottle toward you until it stops. Caution: If there is still dry ink in the bottle, the ink may spill as you move the bottle back onto its lid. XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE...
  • Page 33 XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 4. Remove the empty bottle and discard it. 5. Shake the new ink bottle at least ten rotations, taking care to support the bottle cap. It is important that you mix the contents thoroughly by allowing the material inside the bottle to fall and settle toward the label side at each rotation.
  • Page 34 Heat sets the ink permanently. Inform dry cleaners that the spot is dry ink for a printer so they do not use a solvent that sets the stain. XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE...

  • Page 35: Exchanging Customer Changeable Units (Ccus)

    Exchanging Customer Changeable Units (CCUs) XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE You need to exchange the currently loaded CCU in either of the following situations: • A print job requires another colored dry ink to be loaded. When a document is in the color housing wait state, change the housing unless you decide to cancel the job.

  • Page 36: Removing The Ccu

    2. Open the printer doors and locate the color housing area on the left side of the printer. Gold recess used to align cart Gold backup roller handle Gold CCU handle XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE...
  • Page 37 XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 3. Open the top cover of an empty cart. Gold alignment knob Top cover Pedal Pallet 4. Push the cart up to the printer, lining up the gold knob on the cart with the gold recess on the printer inner cover.
  • Page 38 6. Push firmly on the cart pedal until you hear or feel the pedal catch. The pedal should stay locked down. The pallet within the cart is raised. 7. Turn the backup roller handle clockwise for a quarter turn to an upright position. XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE...
  • Page 39 XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 8. Turn the CCU latch handle clockwise for a quarter turn. 9. Using the CCU latch handle, pull the CCU out of the printer until it is completely in the cart.
  • Page 40 INKS 11. Close the cart top cover and store the cart. 5-10 XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE...

  • Page 41: Inserting A Ccu

    Inserting a CCU XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE To insert a CCU, follow these steps. 1. Open the top cover of the cart containing the new color CCU. Note: CCUs are not interchangeable between printer models.
  • Page 42 9. Remove the cart from the printer and close the cart top cover. 10. Close the printer doors. 11. Store the cart. XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE...

  • Page 43: Storing The Cart And Ccu

    Storing the cart and CCU XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE Note: If any dry ink gets on your hands, wash them with soap and cold water. Heat sets the ink permanently. If any dry ink gets on your clothes, brush them with a dry paper towel or a stiff-bristled brush.
  • Page 44 INKS 5-14 XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE...

  • Page 45: Waste Containers

    Checking and replacing the developer waste container XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 6Waste containers The waste container in the DocuPrint 4850/4890 IPS collects dry ink and developer after it has been used by the printer. When the container becomes full, it must be replaced, or the printer eventually stops printing.
  • Page 46 Let the tab-end of the container touch the floor, then grasp the container by the handle. Note that a full container weighs approximately 8 pounds/3.6 kg. XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE...

  • Page 47: Checking And Replacing The Dry Ink Waste Container

    Checking and replacing the dry ink waste container XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 4. Use the cap from the new container to recap the old container. 5. Discard the waste material and container according to the instructions on the label.

  • Page 48: Replacing The 4850 Dry Ink Waste Container

    A full dry ink waste container weighs about 15 pounds/6.8 kg. 3. Place the cap, which is tethered to the bottle, onto the mouth of the container. XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE...
  • Page 49 XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 4. Discard the dry ink waste container according to the instructions on the label. Once the waste container is removed, the message DRY INK WASTE CONTAINER NOT PRESENT displays on the printer control console, and the printer remains idle until a new container is inserted.

  • Page 50: Replacing The 4890 Dry Ink Waste Container

    Once the waste container is removed, the message DRY INK WASTE CONTAINER NOT PRESENT displays on the printer control console, and the printer remains idle until a new container is inserted. XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE...
  • Page 51 XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 5. Remove the cap from the new dry ink waste container. 6. Align the waste container with the support guides and slide the container into the storage compartment, gently lifting it up and over the ridge.
  • Page 52 WASTE CONTAINERS XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE...

  • Page 53: Bypass Transport

    XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 7Bypass transport The bypass transport is installed in tray 1 of the dual stacker on the DocuPrint 4890 IPS. This chapter describes how to remove and install the bypass transport. Figure 7-1.

  • Page 54: Removing The Bypass Transport

    3. Unplug the two cables from the rear of the bypass transport. 4. Open the front cover of the bypass transport and unlock the transport by turning the green handle counterclockwise one quarter turn. XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE...
  • Page 55 XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 5. Grasp the recessed handles on the front and rear of the bypass transport and slide the transport out of the tray toward the front of the printer. 6. Place the transport in its storage location.

  • Page 56: Installing The Bypass Transport

    3. Lift the bypass transport assembly by the front and rear recessed handles and slide it into stacker tray 1 as far as it will XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE...
  • Page 57 XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 4. Open the front cover of the bypass transport and lock the transport by turning the green handle clockwise one quarter turn. (You will feel some resistance.) 5. From the rear of the dual stacker module, plug the two cables into the rear of the bypass transport.
  • Page 58 BYPASS TRANSPORT XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE...

  • Page 59: Cleaning

    Cleaning the keyboard, monitor, and the exterior of the Printer Controller XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE This chapter describes the cleaning tasks you need to perform regularly on the DocuPrint 4850/4890 IPS. Clean the exterior surfaces of your Printer Controller, including monitor and keyboard, as required.

  • Page 60: Cleaning The 4Mm Cartridge Tape Drive

    Press the Unload button to eject the cleaning cartridge and discard it. 3. Remove the cleaning cartridge after it is automatically ejected following the cleaning cycle. You can use the cartridge tape drive immediately after cleaning. XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE...

  • Page 61: Maintenance And Support Services

    XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 9Maintenance and support This chapter provides information on the services Xerox provides to help you keep your DocuPrint printer running efficiently. It describes the services available to you and how to take advantage of these services.

  • Page 62: Xerox Documentation And Software Services

    You can also order on the web: www.xdss.com The Xerox Font Center (or your local Xerox operating company) can send you samples and catalogs of the fonts available for your printer. To receive font samples, obtain price information, obtain technical support, or order licensed or custom fonts, call: 1-800-445-FONT (3668) between 6:00 a.m.

  • Page 63: Xerox Customer Education

    To do this, you need the serial number for your system. The serial number is located behind the narrow door to the far left, on the front of the printer. If you are reporting meters for other Xerox printers during the same call, make sure you have the serial number available for each one before calling.
  • Page 64 Meter H counts all good duplex sheets delivered to the intended output destination. It is a user meter and can be cleared by the controller. • Meter J is not used. XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE...
  • Page 65 6-1–6-3 documentation other, x dry ink adding, 5-1–5-4 stains, 5-4, 5-13 XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE dry ink waste container replacing for 4850, 6-3–6-5 replacing for 4890, 6-6–6-7 dual stacker trays, unloading, 2-1 education, customer, 9-3 electronic counter, 2-3 feeder trays, 1-1–1-5...
  • Page 66 Wire Percentage indicator, 3-1 Xerox Customer Education, 9-3 Xerox Customer Service Support Center, 9-1 Xerox Documentation and Software Services (XDSS), 9-2 Xerox Font Center, 9-2 XEROX DOCUPRINT 4850/4890 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE...
  • Page 67 ../../../IPS & LPS Graphics/dpc0010a.cgm iii ../../../IPS & LPS Graphics/DPC0017A.CGM 1-1 ../../../IPS & LPS Graphics/DPC0018A.CGM 1-3 ../../../IPS & LPS Graphics/DPC0019A.CGM 1-3 ../../../IPS & LPS Graphics/DPC0020A.CGM 1-4 ../../../IPS & LPS Graphics/DPC0021A.CGM 1-4 ../../../IPS & LPS Graphics/DPC0022A.CGM 1-5 ../../../IPS & LPS Graphics/DPC0089A.CGM 1-5 ../../../IPS &...
  • Page 68 ../../../IPS & LPS Graphics/dpc0073a.cgm 7-4 ../../../IPS & LPS Graphics/dpc0074a.cgm 7-4 ../../../IPS & LPS Graphics/dpc0075a.cgm 7-5 ../../../IPS & LPS Graphics/dpc0076a.cgm 7-5 ../../../IPS & LPS Graphics/bill180.wmf 9-4 DOUBLE-CLICK ON THIS TEXT FROM ANY MASTER PAGE AND EDIT THE DEFINITION...

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