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Xerox DocuPrint 4890 Manual

Guide to performing routine maintenance
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Xerox DocuPrint
4850/4890/92C
NPS/IPS
Guide to Performing Routine Maintenance
721P90050
Version 8.0
October 2002

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Summary of Contents for Xerox DocuPrint 4890

  • Page 1 Xerox DocuPrint 4850/4890/92C NPS/IPS Guide to Performing Routine Maintenance 721P90050 Version 8.0 October 2002...
  • Page 2 Printed in the United States of America. Publication number: 721P90050 Xerox® and all Xerox product names mentioned in this publication are trademarks of Xerox Corporation. Products and trademarks of other companies are also acknowledged. Changes are periodically made to this document. Changes, technical...

  • Page 3: Table Of Contents

    Table of contents Safety ..........v Laser safety .
  • Page 4 Operator training ......... . 9-2 Xerox Customer Education ........9-3 Reporting billing meters .

  • Page 5: 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.

  • Page 6: Ozone Information: U. S. Only

    1-800-828-6571 to request the Xerox publication 600P83222, OZONE. Operation safety: U. S. 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.

  • Page 7: Operation Safety: Europe

    Disconnect the power cord from the electrical outlet and call service to correct the problem. If you need any additional safety information concerning the equipment or materials Xerox supplies, call Xerox Product Safety at the following toll-free number in the United States: 1-800-828-6571 For customers outside the United States, contact your local Xerox representative or operating company.

  • Page 8: Electrical Supply

    This product should not be placed in a built-in installation unless proper ventilation is provided, please contact your Xerox representative for advice. Never push objects of any kind into the ventilation vents of the product.

  • Page 9: Maintenance

    A full declaration of conformity, defining the relevant directives and referenced standards, can be obtained from your Xerox representative. In order to allow this equipment to operate in proximity to...

  • Page 10: Radio And Telecommunications Equipment Directive (Europe Only)

    Radio and telecommunications equipment directive (Europe only) Certification to 1999/5/EC Radio Equipment and Telecommunications Terminal Equipment Directive: This Xerox product has been self-certified by Xerox for pan- European single terminal connection to the analog public switched telephone network (PSTN) in accordance with Directive 1999/5/EC.

  • Page 11: For Further Information

    Safety For further information For more information on Environment, Health and Safety in relation to this Xerox product and supplies, please contact the following customer help lines: Europe:+44 1707 353434 USA:1 800 8286571 Canada:1 800 8286571 Guide to Performing Routine Maintenance...
  • Page 12 Safety Guide to Performing Routine Maintenance...

  • Page 13: Introduction

    Introduction This guide provides information on how to perform basic maintenance tasks on the Xerox DocuPrint 4850/4890/92C NPS/ IPS. About this guide This guide is designed for operators whose job consists of operating each of the system components, running print jobs, solving simple system problems, and performing basic maintenance tasks, such as replenishing printer supplies.

  • Page 14: Conventions

    <ENTER> (for example, enter y). • Italics: Document and library names are shown in italics (for example, the Xerox DocuPrint NPS/IPS Guide to Managing Print Jobs). • Quotation marks: Keywords you can enter as arguments appear in quotes (for example, “USLetter”).

  • Page 15: Related Publications

    Warnings alert you to conditions that may affect the safety of people. Related publications The Xerox DocuPrint NPS/IPS documentation set includes the documents listed below. NOTE: For a list of IBM reference manuals for IPDS printing, refer to the Solutions Guide for IPDS Printing.
  • Page 16 Introduction • Submitting your Jobs from Windows NT 4.0 (QuickPrint) Quick Reference Card • Submitting your Jobs Using Windows NT 4.0 Drivers Quick Reference Card The documentation set also includes an electronic version, the DocuPrint NPS/IPS Interactive Customer Documentation CD. Guide to Performing Routine Maintenance...

  • Page 17: Feeder Trays

    Feeder trays This chapter shows the steps needed to load and check feeder trays on the DocuPrint printer, and explains what actions are necessary if paper stock is changed. Checking and loading feeder trays Check the amount of paper in each feeder tray by examining the green lights on the door of the tray.

  • Page 18: Loading Feeder Trays

    Feeder trays • The printer does not feed all the paper out of a tray. A stack of approximately 1/4 inch / 6 mm remains in the tray. Loading feeder trays It is important to load paper properly in the feeder trays to prevent jams and loss of production time.
  • Page 19 Feeder trays 1. Ready to Open Indicator 2. Tray Unlock button 2. Lift and pull on the bar along the top of the feeder tray. Slide the tray all the way out for best access and ease of loading. Guide to Performing Routine Maintenance...
  • Page 20 Feeder trays 3. Press the green lever down to unlatch the paper feeder assembly. CAUTION Attempting to move the lever in any other direction can break it. 4. Pull out any partially fed paper from the feeder assembly and discard it. There will be some resistance. Guide to Performing Routine Maintenance...
  • Page 21 Feeder trays 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. 7.
  • Page 22 Feeder trays 10. Slide the tray into the printer until it latches. The tray rises automatically into position. 11. Press the Continue button to resume printing. NOTE: If you change the paper stock, you must use the procedure to set trays at the printer controller: •...

  • Page 23: Output Trays

    Output trays Your print jobs are sent to printer output trays (bins) that you must unload. You can unload each of the output trays while the system is printing. This chapter discusses how to check and unload the various types of trays available. In all cases, if the printer has stopped due to a full output tray and does not resume automatically when the tray is emptied, press the Continue button on the printer control console.

  • Page 24: Checking And Unloading The Stitcher/Stacker Tray

    Output trays 1. Scuffer arm 2. Tray Full indicators 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 output tray is unloaded and replaced.
  • Page 25 Output trays NOTE: A false tray full condition may occur when you remove small stapled sets without pulling the tray out. The counter is not reset, causing the printer to stop before the tray is actually full. The stitcher/stacker tray holds 2000 sheets (unstapled) of 20- pound or 80 gsm paper.

  • Page 26: Checking And Unloading The Sample Tray

    Output trays NOTE: Your service representative can adjust your printer so that printing continues automatically when the stitcher/stacker tray is unloaded and replaced. Checking and unloading the sample tray The sample tray holds up to 100 sheets of paper from 8.5 by 11 inches / 216 by 279 mm to 8.5 by 14 inches / 216 by 356 mm.

  • Page 27: Stitcher Wire

    Stitcher wire The Wire Percentage indicator is located on the printer control console of 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 28 Stitcher wire – IF UNABLE TO FIX, PRESS CONTINUE TO RESUME WITHOUT STITCHING – STITCHER IS OUT OF WIRE PRESS ‘CONTINUE’ TO RESUME PRINTING. If you continue printing the job without replacing the wire, the documents print without being stapled. The printer status display shows the following message: OUT OF WIRE Contact your key operator or your service representative when...

  • Page 29: Fuser Lubricant And Pressure Roll Wiper

    Fuser lubricant and pressure roll wiper This chapter describes how to add fuser lubricant and how to replace the pressure roll wiper on your system. Adding fuser lubricant The fuser assembly uses heat and pressure 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 30 Fuser lubricant and pressure roll wiper 4. Hold the lever down while you grasp the green fuser drawer handle (B) and pull the drawer out until it stops. 5. Put on gloves. WARNING Fuser lubricant contains silicone, which can cause eye irritation upon contact.
  • Page 31 Fuser lubricant and pressure roll wiper CAUTION The orange float that indicates the lubricant level may stick to the reservoir wall. Be careful not to overfill the reservoir or an overflow of lubricant may occur. 7. Open a tube of fuser lubricant and cut the pointed spout diagonally.
  • Page 32 Fuser lubricant and pressure roll wiper 8. Replace the reservoir cap by turning it clockwise. 9. Close the fuser drawer by pressing down on the green latch (A) and pushing the fuser drawer in until it latches in place. Guide to Performing Routine Maintenance...

  • Page 33: Replacing The Pressure Roll Wiper

    Fuser lubricant and pressure roll wiper 10. Dispose of the drop cloth and any empty lubricant tubes in a trash receptacle. If there is any lubricant left in the tube, cap the tube and store it for future use. 11. Remove and dispose of the gloves in a trash receptacle, being careful not to let any residue come in contact with your skin.
  • Page 34 Fuser lubricant and pressure roll wiper 4. Determine if the fuser is cool. Place your hand approximately 1 inch / 25 mm above the fuser area. Guide to Performing Routine Maintenance...
  • Page 35 Fuser lubricant and pressure roll wiper If you feel heat, STOP , leave the fuser drawer out, and wait for the fuser to cool. DO NOT touch the fuser while it is hot. If you DO NOT feel heat, continue with the procedure. WARNING Perform this task only when the fuser is cool.
  • Page 36 Fuser lubricant and pressure roll wiper 8. Place the used wiper and its drip pad in the plastic bag that came with the new wiper and dispose of the bag in a trash receptacle. 9. Rotate the pressure roll while wiping the dirt off with a clean cloth.
  • Page 37 Fuser lubricant and pressure roll wiper 11. Insert the short rod in the upper loop of the new wiper. 12. Insert the long rod through the drip pan and the lower loop of the new wiper. 13. Insert the lower rod into the springs on both ends of the pressure roll.
  • Page 38 Fuser lubricant and pressure roll wiper CAUTION Make sure the smooth side of the wiper is facing the pressure roll. 14. Center the wiper on the pressure roll. Pull up the wiper and place the upper rod onto the brackets on both ends of the pressure roll, as shown.
  • Page 39 Fuser lubricant and pressure roll wiper 17. Close the printer doors and power on the printer. 18. Wash your hands to remove any fuser lubricant. 4-11 Guide to Performing Routine Maintenance...
  • Page 40 Fuser lubricant and pressure roll wiper 4-12 Guide to Performing Routine Maintenance...

  • Page 41: Inks

    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 bottle only when directed to do so by a message on the printer control console.
  • Page 42 Inks 1 Color dry ink bottle 2 Black dry ink bottle 2. Spread a dropcloth on the floor under the dry ink area. 3. Pull the empty dry ink bottle toward you until it stops. Guide to Performing Routine Maintenance...
  • Page 43 Inks CAUTION If there is still dry ink in the bottle, the ink may spill as you move the bottle back onto its lid. 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.
  • Page 44 Inks CAUTION Each bottle is uniquely coded to the color of the housing; do not attempt to insert the wrong color bottle into the color housing. You risk damaging the bottle and the housing by using excessive force. 7. Hold the cartridge in place and pull the paper seal off the mouth of the bottle.

  • Page 45: Exchanging Customer Changeable Units (Ccus)

    Inks Exchanging Customer Changeable Units (CCUs) 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 46 Inks 1. Gold recess used to align cart 2. Gold backup roller handle 3. Gold CCU handle 3. Open the top cover of an empty cart. 1. Gold alignment knob Guide to Performing Routine Maintenance...
  • Page 47 Inks 2. Top cover 3. Pedal 4. 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. 5. Push the cart firmly against the printer until you can feel the two latch together.
  • Page 48 Inks 7. Turn the backup roller handle clockwise for a quarter turn to an upright position. 8. Turn the CCU handle clockwise for a quarter turn. Guide to Performing Routine Maintenance...
  • Page 49 Inks 9. Using the CCU handle, pull the CCU out of the printer until it is completely in the cart. 10. Push down firmly on the cart pedal until you hear or feel a click. The pallet, which now contains the CCU, is lowered into the cart.
  • Page 50 Inks 11. Close the cart top cover and store it. 5-10 Guide to Performing Routine Maintenance...

  • Page 51: Inserting A Ccu

    Inks Inserting a CCU 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. Make sure you order and use the one designed for your printer.

  • Page 52: Storing The Cart And Ccu

    Inks 8. Push down firmly on the cart pedal until you hear or feel a click. If the pallet does not drop, check that the CCU is all the way in the printer and the pallet is released, then push down on the pedal again.
  • Page 53 Inks NOTE: Always keep the top cover of the cart closed when storing a CCU in the cart. The cover prevents dust and dirt from contaminating the developer material. Such contaminants can cause white spots and deletion defects in the printed output. 5-13 Guide to Performing Routine Maintenance...
  • Page 54 Inks 5-14 Guide to Performing Routine Maintenance...

  • Page 55: Waste Containers

    Waste containers The waste containers in the 4850/4890/92C NPS/IPS collect dry ink and developer after it has been used by the printer. When a container becomes full, it must be replaced, or the printer eventually stops printing. This chapter contains the procedures for replacing the dry ink and developer waste containers.
  • Page 56 Waste containers To replace the waste container: 1. Open the printer doors and locate the dry ink cartridge at the left side of the printer. The developer waste container is located under the color dry ink bottle. 2. Spread a dropcloth on the floor under the developer waste container area.
  • Page 57 Waste containers 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. 6. Grasp the new, empty container with both hands, one hand on the handle and one on the container tab.

  • Page 58: Checking And Replacing The Dry Ink Waste Container

    Waste containers 8. Close the printer doors. 9. Dispose of the dropcloth. Checking and replacing the dry ink waste container Waste dry ink is transported into the sealed waste container located in a compartment in the lower left corner at the rear of the printer.
  • Page 59 Waste containers 2. Grasp the container handle and pull the container up and out over the ridge at the base of the storage compartment. 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.

  • Page 60: Replacing The 4850/4890/92C Dry Ink Waste Container

    Waste containers 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 console, and the printer remains idle until a new container is inserted.
  • Page 61 Waste containers 3. Place the cap, which is tethered to the bottle, onto the mouth of the container. 4. Discard the dry ink waste container according to the instructions on the label. After the waste container is removed, the message DRY INK WASTE CONTAINER NOT PRESENT displays on the printer console, and the printer remains idle until a new container is inserted.
  • Page 62 Waste containers 7. Close the rear door. A beep signals that the replacement is complete. Guide to Performing Routine Maintenance...

  • Page 63: Bypass Transport

    Bypass transport The bypass transport is installed in a dual stacker configuration only. It is installed in tray 1 on the DocuPrint 4890/92C printer. This chapter describes how to remove and install the bypass transport. Figure 7-1. DocuPrint 92C printer with bypass transport installed 1.
  • Page 64 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. 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.

  • Page 65: Installing The Bypass Transport

    Bypass transport 6. Place the transport in its storage location. 7. Press downward on the scuffer arm in stacker tray 1 until it rests in the tray. NOTE: The bypass transport support remains in place. It is permanently attached to your printer. 8.
  • Page 66 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 go. 4. Open the front cover of the bypass transport and lock the transport by turning the green handle clockwise one quarter turn.
  • Page 67 Bypass transport 5. From the rear of the dual stacker module, plug the two cables into the rear of the bypass transport. 6. Connect your finishing device following the instructions provided with the device. 7. Power on the printer. Guide to Performing Routine Maintenance...
  • Page 68 Bypass transport Guide to Performing Routine Maintenance...

  • Page 69: Cleaning

    Cleaning This chapter describes the cleaning tasks you need to perform regularly on your printing system. Cleaning the keyboard, monitor, and the exterior of the printer controller Clean the exterior surfaces of your printer controller including monitor and keyboard, as required. Clean daily, if possible. Use the following supplies to clean the exterior surfaces: •...
  • Page 70 Cleaning To clean the tape drive: 1. Insert the cleaning cartridge into the tape drive as you would a data tape cartridge. 2. Observe the green LED blinking slowly to indicate that the tape drive is automatically performing a cleaning cycle. NOTE: If the cleaning cartridge has been used for more than approximately 30 cleaning cycles, the amber LED will blink rapidly.

  • Page 71: Maintenance And Support Services

    Maintenance and support services This chapter provides information on the services Xerox provides to help you keep your printer running efficiently. It describes the services available to you and how to take advantage of these services. NOTE: The support services described in this chapter apply to the United States only.

  • Page 72: Xerox Font Center

    You can also order on the web: www.xdss.com Xerox Font Center 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 73: Xerox Customer Education

    To do this, you need the serial number for your system. The serial number is located behind the middle door to the far left, at 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 74 Maintenance and support services Guide to Performing Routine Maintenance...
  • Page 75 Index Numerics dual stacker trays, unloading 2-1 4850 dry ink waste container, replacing 6-4– 4mm cartridge tape drive, cleaning 8-2 electronic counter 2-2 Advanced Customer Training (ACT) 9-2 feeder trays 1-1 Attention light 2-1–2-2, 5-1 fuser agent, adding 4-1–4-5 bypass transport input trays, loading 1-1 installing 7-3–7-5 installing bypass transport 7-3–7-5...
  • Page 76 INDEX installing 7-3–7-5 removing 7-1–7-3 Xerox Customer Education 9-3 CCUs Xerox Customer Service Center 9-1 loading 5-11–5-12 Xerox Documentation and Software removing 5-5–5-10 Services (XDSS) 9-1 developer waste container, replacing Xerox Font Center 9-2 6-1–6-4 dry ink, adding 5-1–5-4 feeder trays, loading 1-2–1-6 fuser agent, adding 4-1–4-5...

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