Xerox DocuPrint 4890 User manual

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

Xerox Corporation
701 S. Aviation Boulevard
El Segundo, CA 90245
©2001, 2002 by Xerox Corporation. All rights reserved.
Copyright protection claimed includes all forms of matters of copyrightable
material and information now allowed by statuory 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, and so on.
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
inaccuracies and typographic errors will be corrected in subsequent editions.

Guide to Performing Routine Maintenance iii
Table of contents
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Laser safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Ozone information: U. S. only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vi
Operation safety: U. S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vi
Operation safety: Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Warning markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
Operator accessible areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ix
Before cleaning your product . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ix
CE mark: Europe only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ix
Radio and telecommunications equipment directive (Europe only) . . . . . x
For further information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xi
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
About this guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv
Related publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
1. Feeder trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Checking and loading feeder trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Loading feeder trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Guidelines for loading paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Loading the trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
2. Output trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Checking and unloading dual stacker trays . . . . . . . . . . . . . . . . . . . . . . 2-1
Checking and unloading the stitcher/stacker tray . . . . . . . . . . . . . . . . . 2-2
Checking and unloading the sample tray . . . . . . . . . . . . . . . . . . . . . . . 2-4
3. Stitcher wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
4. Fuser lubricant and pressure roll wiper . . . . . . . . . . . . . . . . . . . . 4-1
Adding fuser lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Replacing the pressure roll wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Table of contents
iv Guide to Performing Routine Maintenance
5. Inks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Adding dry ink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Exchanging Customer Changeable Units (CCUs) . . . . . . . . . . . . . . . . 5-5
Removing the CCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Inserting a CCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Storing the cart and CCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
6. Waste containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Checking and replacing the developer waste container . . . . . . . . . . . . 6-1
Checking and replacing the dry ink waste container . . . . . . . . . . . . . . . 6-4
Replacing the 4850 dry ink waste container . . . . . . . . . . . . . . . . 6-4
Replacing the 4850/4890/92C dry ink waste container . . . . . . . 6-6
7. Bypass transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Removing the bypass transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Installing the bypass transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
8. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Cleaning the keyboard, monitor, and the exterior of the printer controller .
8-1
Cleaning the 4mm cartridge tape drive . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
9. Maintenance and support services . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Xerox Customer Service Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Xerox Documentation and Software Services . . . . . . . . . . . . . . . . . . . . 9-1
Xerox Font Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Operator training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Xerox Customer Education . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Reporting billing meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

Guide to Performing Routine Maintenance v
Safety
Laser safety
WARNING
Adjustments, use of controls, or performance of procedures
other than those specified herein may result in hazardous
light exposure.
The Xerox DocuPrint printers are certified to comply with the
performance standards of the U.S. Department of Health,
Education, and Welfare for Class 1 laser products. Class 1 laser
products do not emit hazardous radiation. The DocuPrint printers
do not emit hazardous radiation because the laser beam is
completely enclosed during all modes of customer operation.
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. ONLY XEROX SERVICE REPRESENTATIVES HAVE
ACCESS TO THESE PANELS.

Safety
vi Guide to Performing Routine Maintenance
Ozone information: U. S. only
This product produces ozone during normal operation. The
amount of ozone produced depends on copy volume. Ozone is
heavier than air. The environmental parameters specified in the
Xerox installation instructions ensure that concentration levels
are within safe limits. If you need additional information
concerning ozone, call 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. Please observe the following
precautions to ensure your continued safety.
WARNING
Improper connection of the equipment grounding conductor
may result in risk of electrical shock.
• Always connect equipment to a properly grounded electrical
outlet. If in doubt, have the outlet checked by a qualified
electrician.
• Never use a ground adapter plug to connect equipment to an
electrical outlet that lacks a ground connection terminal.
• Always place equipment on a solid support surface with
adequate strength for its weight.
• Always use materials and supplies specifically designed for
your Xerox equipment. Use of unsuitable materials may result
in poor performance and may create a hazardous situation.
• Never move either the printer or the printer controller without
first contacting Xerox for approval.
• Never attempt any maintenance that is not specifically
described in this documentation.
• Never remove any covers or guards that are fastened with
screws. There are no operator-serviceable areas within these
covers.
• Never override electrical or mechanical interlocks.

Safety
Guide to Performing Routine Maintenance vii
• 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 you notice unusual noises or
odors. 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.
Operation safety: Europe
This Xerox product and supplies are manufactured, tested and
certified to strict safety regulations, electromagnetic regulations
and established environmental standards.
Any unauthorised alteration, which may include the addition of
new functions or connection of external devices, may impact the
product certification.
Please contact your Xerox representative for more information.
Warning markings
All warning instructions marked on or supplied with the product
should be followed.
This WARNING alerts users to areas of the product where there
is the possibility of personal damage.
This WARNING alerts users to areas of the product where there
are heated surfaces, which should not be touched.

Safety
viii Guide to Performing Routine Maintenance
Electrical supply
This product shall be operated from the type of electrical supply
indicated on the product’s data plate label. If you are not sure
that your electrical supply meets the requirements, please
consult your local power company for advice.
This product must be connected to a protective earth circuit. This
product is supplied with a plug that has a protective earth pin.
This plug will fit only into an earthed electrical outlet. This is a
safety feature. Always connect equipment to a properly grounded
electrical outlet. If in doubt, have the outlet checked by a qualified
electrician.
To disconnect all electrical power to the product, the disconnect
device is the power cord. Remove the plug from the electrical
outlet.
Ventilation
Slots and opening in the enclosure of the product are provided
for ventilation. Do not block or cover the ventilation vents, as this
could result in the product overheating.
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.
Operator accessible areas
This product has been designed to restrict operator access to
safe areas only. Operator access to hazardous areas is restricted
with covers or guards, which would require a tool to remove.
Never remove these covers or guards.
WARNING

Safety
Guide to Performing Routine Maintenance ix
Maintenance
Any operator product maintenance procedures will be described
in the user documentation supplied with the product. Do not
carry out any maintenance on the product, which is not
described in the customer documentation.
Before cleaning your product
Before cleaning this product, unplug the product from the
electrical outlet. Always use materials specifically designated for
this product, the use of other materials may result in poor
performance and may create a hazardous situation. Do not use
aerosol cleaners, they may be flammable under certain
circumstances.
CE mark: Europe only
January 1, 1995: Council Directive 73/23/EEC, amended by
Council Directive 93/68/EEC, approximation of the laws of the
member states related to low voltage equipment.
January 1, 1996: Council Directive 89/336/EEC, approximation
of the laws of the member states related to electromagnetic
compatibility.
March 9, 1999: Council Directive 99/5/EC, on radio equipment
and telecommunications terminal equipment and the mutual
recognition of their conformity.
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
Industrial, Scientific and Medical (ISM) equipment, the external
radiation for the ISM equipment may have to be limited or special
mitigation measures taken.
This is a Class A product. In a domestic environment this product
may cause radio frequency interference, in which case the user
may be required to take adequate measures.
Shielded interface cables must be used with this product to
maintain compliance with Council Directive 89/36/EEC.

Safety
x Guide to Performing Routine Maintenance
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.
The product has been designed to work with the national PSTNs
and compatible PBXs of the following countries:
In the event of problems, contact your local Xerox representative
in the first instance.
This product has been tested to, and is compliant with, TBR21, a
specification for terminal equipment for use on analog switched
telephone networks in the European Economic area.
The product may be configured to be compatible with other
country networks. Please contact your Xerox representative if
your product needs to be reconnected to a network in another
country. This product has no user-adjustable settings.
NOTE: Although this product can use either loop disconnect
(pulse) or DTMF (tone) signaling, it should be set to use DTMF
signaling. DTMF signaling provides reliable and faster call setup.
Modification or connection to external control software, or to
external control apparatus not authorized by Xerox, invalidates
its certification.
Austria Germany Luxembourg Sweden
Belgium Greece Netherlands Switzerland
Denmark Iceland Norway United Kingdom
Finland Ireland Portugal
France Italy Spain

Safety
Guide to Performing Routine Maintenance xi
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:[phone]
USA:1 800 8286571
Canada:1 800 8286571

Safety
xii Guide to Performing Routine Maintenance

Guide to Performing Routine Maintenance xiii
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.
Refer to the entire list of documentation in the “Related
publications” section for information on other tasks required for
printing with your NPS/IPS printer.
Users should have an understanding of printer controller
operations.
Before using this guide, become familiar with its contents and
conventions.
Contents
This section lists the contents of this guide.
• Chapter 1, “Feeder trays,” provides information on how to
load feeder trays for your DocuPrint printer.
• Chapter 2, “Output trays,” describes how to unload output
trays for the DocuPrint printer.
• Chapter 3, “Stitcher wire,” provides information on how to
replace the stitcher wire spool, and on how to continue
printing when the spool is out of wire.
• Chapter 4, “Fuser lubricant and pressure roll wiper,”
describes how to refill the fuser agent reservoir, and how to
replace the pressure roll wiper.

Introduction
xiv Guide to Performing Routine Maintenance
• Chapter 5, “Inks,” describes how to add both black and color
dry ink, and how to replace the Customer Changeable Unit
(CCU) for the color dry ink.
• Chapter 6, “Waste containers,” provides information on how
to replace the developer and the dry ink waste containers.
• Chapter 7, “Bypass transport,” describes how to install and
remove the bypass transport.
• Chapter 8, “Cleaning,” provides instructions on how to clean
the various printing system components.
• Chapter 9, “Maintenance and support services,” provides
information on how to call for service, order documentation,
and report meter readings.
Conventions
This guide uses the following conventions:
•All caps and angle brackets: Within procedures, the names
of keys are shown in all caps within angle brackets (for
example, press <ENTER>).
•Angle brackets: Variable information, or the position of a
specified argument in the command syntax, appears in angle
brackets (for example, List Fonts <Pattern>).
•Bold: Within procedures, text and numbers that you enter are
shown in bold (for example, enter privilege operator).
•The word “enter” within procedures: The two-step process
of keying in data and pressing <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”).
•Vertical bars: Alternatives to specified arguments are
separated by vertical bars (for example, Set Time <Time |
Remote Host Name | IP Address>).

Introduction
Guide to Performing Routine Maintenance xv
NOTE: Notes are hints that help you perform a task or
understand the text.
CAUTION
Cautions alert you to an action that could damage hardware or
software.
WARNING
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.
•Guide to Configuring and Managing the System
•Guide to Managing Print Jobs
•Guide to Performing Routine Maintenance
•Guide to Submitting Jobs from the Client
•Guide to Using Page Description Languages
•Installation Planning Guide
•System Overview Guide
•Troubleshooting Guide
•Solutions Guide for IPDS Printing
•Decomposition Service and Tools Guide
•Glossary
•Master Index
•Customer Information Quick Reference Card
•Printer Controller Commands Quick Reference Card
•Operator Quick Reference Card
•Submitting your Jobs from Macintosh Quick Reference Card
•Submitting your Jobs from UNIX & DOS Quick Reference
Card

Introduction
xvi Guide to Performing Routine Maintenance
•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 1-1
1. 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. Each light represents 25
percent of a ream, or about 125 sheets of 20 pound or 80 gsm
paper.
• You do not have to interrupt a print job to load paper because
you can refill one tray while the printer is feeding from another
tray.
• If you try to load a tray that is currently in use, the feeding
switches to a backup tray if one is available. If a backup tray is
not available, the printer stops.

Feeder trays
1-2 Guide to Performing Routine Maintenance
• 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. The following
guidelines will help ensure maximum efficiency of your printer
operation.
Guidelines for loading paper
When you are loading the paper, follow these guidelines to
prevent paper jams:
• Remove damaged sheets.
• Load the paper with the package wrapper seam side up.
• Make sure that the direction of the curl is consistent.
• Avoid fanning the paper unless the stock is predrilled.
• Do not load the paper above the MAX line on the length
guide.
• 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.
Loading the trays
Follow these steps to load a feeder tray:
1. If the Ready To Open indicator light 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 to lit before
opening the tray.

Feeder trays
1-3 Guide to Performing Routine Maintenance
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.
1
2

Feeder trays
1-4 Guide to Performing Routine Maintenance
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.