Xerox DocuPrint 4635 Manual

XEROX
Xerox 4635 Laser Printing System
Operator Guide
January 1996
721P83011

Xerox Corporation
701 S. Aviation Boulevard
El Segundo, CA 90245
© 1994, 1995, 1996 by Xerox Corporation. All rights reserved.
Copyright protection claimed includes all forms and matters of
copyrightable material and information now allowed by statutory
or judicial law or hereinafter granted, including without limitation,
material generated from the software programs which are
displayed on the screen, such as icons, screen displays, looks,
etc.
Printed in the United States of America
Publication number: 721P83011
Xerox® and all Xerox products mentioned in this publication are
trademarks of Xerox Corporation. Products and trademarks of
other companies are also acknowledged.
WARNING: This equipment has been tested and found to
comply with the limits for a Class A digital device, pursuant to
Part 15 of the FCC Rules.
Changes are periodically made to this document. Changes,
technical inaccuracies, and typographic errors will be corrected in
subsequent editions.
This document was created on the Xerox 6085 Professional
Computer System using VP software. The typeface is Optima.

Laser safety
WARNING: Use of controls or adjustments, or performances
other than specified herein, may result in hazardous laser light
exposure. Mirrors and/or optical devices should not be used to
view or deflect the laser beam.
The 4635 Laser Printing System is certified to comply with laser
performance standards set by the U.S. Department of Health,
Education, and Welfare and by IEC 825 for non-U.S. markets as a
Class 1 laser product. This is a class of laser products that does
not emit hazardous radiation. This is possible only because the
laser beam is totally enclosed during all modes of customer
operation.
Ozone information
Note: This product produces ozone during normal operation.
The ozone produced is dependent on print volume and is
heavier than air. Providing the proper environmental parameters
as specified in the Xerox installation instructions will ensure that
concentration levels meet safe limits. If additional information
concerning ozone is needed, request Xerox publication
600P83222, “OZONE,” by calling 1-800-828-6571.
Operation safety
Your Xerox equipment and supplies have been designed and
tested to meet strict safety requirements. These include safety
agency examination and approval, and compliance to established
environmental standards. Attention to the following notes will
ensure the continued safe operation of your equipment.
• Always connect equipment to a properly grounded power
source receptacle. If in doubt, have the receptacle checked
by a qualified electrician.
WARNING: Improper connection of the equipment
grounding conductor can result in risk of electrical shock.
XEROX 4635 LASER PRINTING SYSTEM OPERATOR GUIDE iii

• Always place equipment on a solid support surface with
adequate strength for the weight of the machine.
• Always use materials and supplies specifically designed for
your Xerox equipment. Use of unsuitable materials may
result in poor performance and can possibly create a
hazardous situation.
• Never move or relocate either the printer or the system
controller without first contacting Xerox for approval.
• Never use a ground adapter plug to connect equipment to a
power source receptacle that lacks a ground connection
terminal.
• Never attempt any maintenance function that is not
specifically described in this operator guide.
• Never remove any covers or guards that are fastened with
screws. There are no operator-serviceable areas within these
covers.
• Never override or “cheat“ electrical or mechanical interlock
devices.
• Never use supplies or cleaning materials for other than their
intended purposes. Keep all materials out of the reach of
children.
• Never operate the equipment if unusual noises or odors are
noticed. Disconnect the power cord from the power source
receptacle and call Xerox service to correct the problem.
• Always follow all warnings and instructions marked on or
supplied with the product.
• Never allow anything to rest on the power cord. Never
locate the equipment where persons will walk on the cord.
• Never use an extension cord between the printer power cord
and an electrical outlet.
• Never place containers of coffee or other liquids on the
equipment.
If you need any additional safety information concerning the
equipment or materials Xerox supplies, call Xerox Product Safety
at the following toll-free number:
1-800-828-6571
Notice
This publication may contain descriptions of concepts and
features not currently available for your Xerox Laser Printing
System. Consult your Xerox sales representative or your
operating system software program description for additional
information.
iv XEROX 4635 LASER PRINTING SYSTEM OPERATOR GUIDE

Related publications
The Xerox 4635 Laser Printing System Operator Guide is part of
the ten-manual reference set for your laser printing system. The
entire reference set is listed in the table below. Several other
related documents are also listed for your convenience. For a
complete list and description of available Xerox documentation,
refer to the Xerox Documentation Catalog (Publication number
610P17417) or call the Xerox Documentation and Software
Services (XDSS) at 1-800-445-5554.
Publication Number
Xerox Dynamic Document Interface
Operator Guide 720P13670
Xerox Dynamic Document Interface
Command Summary 720P13680
Xerox 4635 Laser Printing System
Operator Guide 721P83011
Xerox 4635 Laser Printing System
Operations Reference 721P83021
Xerox 4635 Laser Printing System
Sysgen Guide 721P83030
Xerox 4635 Laser Printing System
Message Guide 721P83040
Xerox 4635 Laser Printing System
PDL/DJDE Reference 721P83050
Xerox 4635 Laser Printing System
Forms Creation Guide 721P83060
Xerox 4635 Laser Printing System
Product Reference 721P83071
Xerox 4635 Laser Printing System
Installation Planning Guide 721P83081
Xerox 4635 Laser Printing System
Operator Command Summary Card 721P83090
Xerox 4635 Laser Printing System
PC UI Reference 721P83101
Xerox Laser Printing Systems
Tape Formats Manual 600P86175
Xerox Laser Printing Systems
Standard Font Library Font User Guide 600P86174
Helpful Facts About Paper 721P82490
XEROX 4635 LASER PRINTING SYSTEM OPERATOR GUIDE v

Table of contents
Laser safety iii
Ozone information iii
Operation safety iii
Notice iv
Related publications v
Introduction xvii
About the reference set xvii
4635 Laser Printing System documentation set xvii
About this manual xx
Document conventions xxi
1. System overview of the 4635 LPS 1-1
Base components 1-1
System controller components 1-2
System user interface 1-2
Operator control panel 1-3
1/4 inch cartridge tape drive 1-4
Printer components 1-4
Feeder trays 1-5
High-capacity stacker bins 1-7
Inverter 1-8
Sample tray 1-8
Purge tray 1-8
Printer control console 1-8
Attention light 1-11
Registration transport levers 1-11
Optional components 1-12
Optional system controller components 1-12
Peripheral cabinet 1-12
Open-reel tape drive 1-12
1/2 inch cartridge tape drive 1-13
Floppy disk drive 1-14
Optional printer components 1-14
Feeder/stacker 1-14
Bypass Transport Module 1-14
XEROX 4635 LASER PRINTING SYSTEM OPERATOR GUIDE vii

TABLE OF CONTENTS
Input enablement device 1-15
7 x 10 enablement kit 1-15
Bar code device 1-15
Magnetic Ink Character Recognition (MICR) 1-16
Printer configurations 1-17
2. Using the PC UI 2-1
PC UI 2-1
Powering on the PC UI 2-2
Adjusting the PC UI monitor 2-3
Components of the PC UI 2-4
PC UI keyboard 2-4
Special function keys 2-5
Cursor 2-5
Types of cursors 2-5
Moving the cursor 2-5
PC UI mouse 2-6
Selecting options with the mouse 2-6
PC UI desktop 2-7
Desktop icons 2-8
Windows 2-10
Working with windows 2-15
Moving and resizing windows 2-16
Using the scroll bars 2-18
Activating an open window 2-19
Performing operator tasks through the PC UI 2-19
Performing tasks through windows 2-19
Entering commands through the Messages window 2-20
Key-in conventions 2-20
Guide command conventions 2-21
Terminal emulation mode (TEM) 2-21
3. Paper facts 3-1
Important facts about paper 3-1
Paper storage 3-1
Paper specifications 3-1
Paper performance guides 3-3
Paper sizing and print jobs 3-8
Feeder trays 3-8
Feeder tray features 3-8
Loading a feeder tray 3-9
viii XEROX 4635 LASER PRINTING SYSTEM OPERATOR GUIDE

TABLE OF CONTENTS
Stacker bins 3-15
Unloading a stacker bin 3-17
Sample tray and purge tray 3-20
Sample tray 3-20
Purge tray 3-20
4. System control tasks 4-1
System control tasks through windows of PC UI 4-2
System control tasks through command line 4-2
System control tasks 4-3
Power on the LPS 4-3
Power off the LPS 4-4
Boot the LPS 4-5
System rollover 4-7
System version 4-10
Attention light/alarm 4-10
Turn off Attention light or alarm 4-12
Energy saver 4-12
Set date/time 4-13
Console log 4-15
Displaying a console log 4-16
Printing a console log 4-19
Stopping the printing of a console log 4-20
Saving the current console log 4-20
Emptying the current console log 4-21
Deleting a saved console log 4-21
Requesting log debug information 4-21
Converting a console log 4-22
Problem 4-23
Audit log 4-25
Selecting a header option 4-26
Selecting a device 4-26
Selecting an Audit option 4-26
Sorting reports and jobs 4-26
Listing logs 4-26
Exit to DOS 4-27
5. Job control tasks 5-1
Job control tasks through windows of PC UI 5-2
Job control tasks through command line 5-2
Job control tasks 5-3
XEROX 4635 LASER PRINTING SYSTEM OPERATOR GUIDE ix

TABLE OF CONTENTS
Abort 5-3
Reset 5-4
Align 5-5
Print Darkness 5-8
Lead edge screen 5-9
MICR control 5-11
Bar code reader control 5-11
Fonts/forms/graphics 5-11
Sample files 5-13
Stop input/output 5-16
Continue input/output 5-17
Sample 5-18
6. Online printing tasks 6-1
Online printing tasks through windows of PC UI 6-2
Online printing tasks through command line 6-3
Place the LPS online to the host computer 6-3
Online printing tasks 6-3
Start an online print job 6-3
Space 6-5
Endjob 6-6
Drain 6-6
Disk saturation 6-7
7. Offline printing tasks 7-1
Open-reel tape drive procedures 7-2
Power on the open-reel tape drive 7-2
Load an open-reel tape 7-3
Load an open-reel tape by hand 7-4
Unload an open-reel tape 7-8
Unload an open-reel tape during a power failure 7-9
Power off the open-reel tape drive 7-12
Handle open-reel tapes 7-13
1/2 inch cartridge tape drive procedures 7-14
Power on the 1/2 inch cartridge tape drive 7-14
Load a 1/2 inch cartridge tape 7-15
Unload a 1/2 inch cartridge tape 7-17
Power off the 1/2 inch cartridge tape drive 7-18
Handle cartridge tapes 7-19
1/4 inch cartridge tape drive procedures 7-21
Load a 1/4 inch cartridge tape 7-22
x XEROX 4635 LASER PRINTING SYSTEM OPERATOR GUIDE

TABLE OF CONTENTS
Unload a 1/4 inch cartridge tape 7-22
Handle 1/4 inch cartridge tapes 7-23
Floppy disk drive procedures 7-23
Load a floppy disk 7-24
Unload a floppy disk 7-24
Handle floppy disks 7-25
Offline printing tasks through windows of PC UI 7-26
Offline printing tasks through command line 7-27
Offline printing tasks 7-27
Start an offline print job 7-27
Rewind/unload tape 7-29
Space 7-30
Move 7-31
8. HIP printing tasks 8-1
HIP printing tasks through windows of PC UI 8-2
HIP printing tasks through command line 8-3
HIP printing tasks 8-3
Enter HIP communication mode 8-3
Select a communication mode 8-5
Place HIP online 8-5
Take HIP offline 8-6
Start a HIP print job 8-6
Stop HIP print jobs 8-8
Abort a HIP print job 8-8
HIP jobs status 8-10
End HIP 8-15
9. Status and print tasks 9-1
Status and print tasks through windows of PC UI 9-3
Status and print tasks through command line 9-3
Understanding clusters 9-3
Status and print tasks 9-4
Printer status 9-4
Select feeder trays 9-8
Select stacker bins 9-10
Tray loading 9-12
Clusters 9-13
Ordered stock 9-17
Transparencies 9-18
Select units 9-19
XEROX 4635 LASER PRINTING SYSTEM OPERATOR GUIDE xi

TABLE OF CONTENTS
Purge Feed 9-20
Lower trays and bins 9-21
Set tray size 9-21
Set container size 9-22
Bin full criteria and setting bin limits 9-24
Separate 9-28
Jobs status 9-28
Configure feeding or finishing device 9-30
Notepad 9-32
10. File control tasks 10-1
File control tasks through windows of PC UI 10-2
File control tasks through command line 10-2
File control tasks 10-2
Display/Print 10-3
Type 10-4
Copy 10-4
Copy labeled tapes 10-5
Copy unlabeled tapes 10-10
Copy to/from floppy 10-12
Delete 10-14
Review 10-14
Rename 10-15
Fix 10-15
Scale 10-16
11. Maintenance tasks 11-1
Precautions you should take 11-1
Cleaning supplies 11-1
Maintaining the printer 11-1
Replacing the dry ink cartridge 11-2
Replacing the dry ink waste container 11-5
Adding fuser agent 11-7
Cleaning the sensors and the reflecting surfaces 11-10
Cleaning the Q850 sensor 11-10
Cleaning the Q1011 sensor and mirror 11-11
Cleaning additional sensors 11-12
Cleaning the terminal and the exterior surfaces
of the system 11-14
Cleaning the open-reel tape drive 11-15
Tape drive cleaning schedule 11-15
Cleaning precautions—READ BEFORE CLEANING 11-17
xii XEROX 4635 LASER PRINTING SYSTEM OPERATOR GUIDE

TABLE OF CONTENTS
Cleaning procedures 11-17
Access to the tape path 11-17
Cleaning the tape path 11-18
Cleaning the exterior of the tape path 11-18
Cleaning the 1/2 inch cartridge tape drive 11-19
When to clean the tape drive 11-19
Cleaning procedures 11-19
Cleaning the tape path 11-19
Cleaning a cartridge 11-19
Cleaning the 1/4 inch cartridge tape drive 11-20
Cleaning the floppy disk drive 11-20
How to clean the floppy disk drive 11-20
Using the custom transfer assist blade 11-22
When not to use the custom transfer assist blade 11-22
Installing the custom transfer assist blade 11-23
Setting tray size with the custom transfer assist blades 11-23
12. Problem solving tasks 12-1
LPS problems 12-1
Fault masking and the printer control console 12-1
Printing problems 12-3
Prints are skewed or damaged 12-3
Paper jams 12-5
Paper curl and paper jams 12-6
Aids to paper jam clearance 12-8
Clearing area paper jams 12-8
Checking job integrity following a paper jam 12-9
Printer areas 12-10
Clearing a misfeed (feeder tray fault) 12-21
Frequent misfeeds (processor feeder trays) 12-23
Faults are cleared but the Attention light is still on 12-25
Printing does not continue when the Continue button
is pressed 12-25
Incorrect paper size message 12-26
Stacker bin problems 12-26
Papers are being thrown around the stacker 12-26
Paper stack is falling over or sliding around the bin 12-26
System controller problems 12-26
LPS does not boot (system controller terminal) 12-26
Printer does not respond to system controller 12-27
Blank display (system controller terminal) 12-28
XEROX 4635 LASER PRINTING SYSTEM OPERATOR GUIDE xiii

TABLE OF CONTENTS
Rasterization messages 12-28
Power failure 12-28
Status file nearly full message 12-29
Open-reel tape drive problems 12-30
Tape drive does not perform self-load routine 12-30
“OK“ appears on the tape drive message display, but
the loading door is closed 12-31
“LID OPEN“ appears on the tape drive message display 12-31
1/2 inch cartridge tape drive problems 12-32
Basic recovery procedure 12-32
Initial program load (IPL) procedure fails 12-32
You cannot insert a cartridge 12-33
Tape does not unload 12-33
Unloading a cartridge after a power failure 12-34
Tape winds completely out of cartridge 12-34
Message display is blank 12-34
Tape drive does not become ready 12-35
Calling for service 12-35
13. MICR operating procedures 13-1
Overview 13-1
Features of the 4635MX system 13-1
MICR materials 13-2
Turning MICR mode on or off 13-2
MICR mode echo 13-3
Should MICR be turned off or on? 13-3
Points regarding MICR mode and the system UI 13-3
MICR mode following a sysgen 13-3
MICR output 13-4
Tools to check MICR output 13-5
MICR position and dimension gauge 13-5
8 power (X) comparator with MICR grid 13-6
Adding dry ink 13-6
14. Bar code operating procedures 14-1
Introduction 14-1
Laser safety 14-1
Turning bar code on or off 14-1
Bar code mode echo 14-3
Adjusting the bar code reader 14-4
xiv XEROX 4635 LASER PRINTING SYSTEM OPERATOR GUIDE

TABLE OF CONTENTS
Appendices A. Meter reading and reporting A-1
Meter reading and billing report A-1
Billing report through the command line A-1
Billing report through windows of the PC UI A-2
Reporting meter reads A-4
Touchtone Telephone Direct Meter Read Entry System A-5
Understanding the system A-7
Entering meter read information A-8
Reviewing and changing data A-10
B. Supplies B-1
How to order supplies (in U.S.A.) B-1
Consumable supplies table B-1
Glossary GLOSSARY-1
Index INDEX-1
XEROX 4635 LASER PRINTING SYSTEM OPERATOR GUIDE xv

Introduction
About the reference set
This document is part of a reference set designed to help you
receive maximum benefit from your 4635 laser printing system.
To help you select the appropriate document for your needs, the
following section identifies the documents in the set and
describes the information contained in each.
4635 Laser Printing System document set
• Product overview
• Hardware and software
• LPS connections
• User considerations
• LPS comparisons
4635 LPS
Product
Reference
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• System overview
• PC UI procedures
• Paper facts and procedures
• Operating procedures
• Maintenance
• Problem solving
• Supplies
• Meter reading and reporting
4635 LPS
Operator
Guide
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• Print Description Language components and processes
• Input processing functions
• Output processing functions
• PDL/DJDE command summary
• Page formatting guidelines
• Character code assignment tables
• PDL/DJDE programming information with step-by-step
instructions
4635 LPS
PDL/DJDE
Reference
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XEROX 4635 LASER PRINTING SYSTEM OPERATOR GUIDE xvii

INTRODUCTION
• Configuration options
• Commands
• OSS software installation, upgrade, and modification
procedures
4635 LPS
System
Generation
Guide
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• Command syntax for operator and system administrator
procedures
• LPS defaults
• LPS resources
• Command summaries
• Communication and graphics on the LPS
• Command files
4635 LPS
Operations
Reference
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• Basic concepts for creating forms
• Coding and compiling for LPS Forms Description Language
• Sample form setup command sets
• Tips for successful forms creation
4635 LPS
Forms
Creation
Guide
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• PC UI procedures
• Hierarchy of PC UI windows
4635 LPS
PC UI
Reference
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• Provides a quick reference of commonly-used operator
commands.
4635 LPS
Operator
Command
Summary
Card
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• OSS and other messages
• Meaning and recovery procedures
4635 LPS
Message
Guide
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xviii XEROX 4635 LASER PRINTING SYSTEM OPERATOR GUIDE

INTRODUCTION
• Pre-installation site preparation
• Supplies and font ordering
• Documentation and training
• Post-installation requirements
4635 LPS
Installation
Planning
Guide
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• Characteristics of different formats
• File organization
• Data formats
• Carriage control conventions
Tape Formats
Manual
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• Font naming conventions
• Listing of standard fonts
• Data sheets
• Glossary of typography terminology
LPS Standard
Font Library
Font User
Guide
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• Selection and guidelines
• Storage and handling
• Specifications for different printers
Helpful Facts
About Paper
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XEROX 4635 LASER PRINTING SYSTEM OPERATOR GUIDE xix

INTRODUCTION
About this manual
The Xerox 4635 Laser Printing System Operator Guide provides
step-by-step instructions on operating and maintaining your
Xerox 4635 Laser Printing System. The guide is designed to help
you perform all standard operator tasks and should be kept near
the printer at all times.
This guide is intended for operators who perform the routine
operation and maintenance of the printer. If your job involves
other tasks, such as system administration or job creation, refer
to other documents in the Xerox 4635 LPS Reference.
The 4635 Laser Printing System Operator Guide is divided into
the following chapters and appendices:
Chapter 1. System overview of the 4635 LPS: Overview of the
base components and the optional components available for the
4635 system.
Chapter 2. Using the PC UI: Overview of the PC UI
components and explanation of how to perform operator tasks
through the PC UI vs. using windows.
Chapter 3. Paper facts: List of facts about paper, an overview
of the feeder trays, stacker bins, and the sample tray and purge
tray.
Chapter 4. System control tasks: System control tasks through
windows of PC UI and through the command line.
Chapter 5. Job control tasks: Job control tasks through
windows of PC UI and through the command line.
Chapter 6. Online Printing tasks: Online printing tasks
through windows of PC UI and through the command line.
Chapter 7. Offline printing tasks: Open-reel, 1/2 inch
cartridge, and 1/4 inch cartridge tape drive procedures, offline
printing tasks through windows of PC UI and through the
command line.
Chapter 8. HIP printing tasks: HIP printing tasks through
windows of PC UI and through the command line.
Chapter 9. Status and print tasks: Status and print tasks
through windows of PC UI and through the command line, and
explanation of clusters.
Chapter 10. File control tasks: File control tasks through
windows of PC UI and through the command line.
Chapter 11. Maintenance tasks: Maintenance and cleaning of
the system, and using the custom transfer assist blade.
Chapter 12. Problem solving tasks: Description and solution
of problems relating to the entire system, to the open-reel tape
drive, to the 1/2 inch cartridge tape drive, and instructions on
how to call for service.
Chapter 13. MICR operating procedures: Overview of the
MICR option on 4635MX systems.
Chapter 14. Bar code operating procedures: Overview of the
bar code option.
Appendix A. Meter reading and reporting
xx XEROX 4635 LASER PRINTING SYSTEM OPERATOR GUIDE