Xerox DocuPrint 96/4635/180 IPS
Guide to Performing Routine Maintenance
Version 7.1
August 2000
721P88160
Xerox Corporation
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
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: 721P88160
Xerox® and all Xerox products 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.
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.
Ozone information
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 1-800-8286571 to request the Xerox publication 600P83222, OZONE.
XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE iii
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.
• Always connect equipment to a properly grounded electrical
outlet. If in doubt, have the outlet checked by a qualified
electrician.
Warning: Improper connection of the equipment grounding
!
conductor may result in risk of electrical shock.
• 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.
• 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.
iv XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE
Table of contents
Laser safety iii
Ozone information iii
Operation safety iv
Introduction vii
About this guide vii
Contents vii
Conventions viii
Related publications ix
1. Feeder trays 1-1
Checking feeder trays 1-1
Loading feeder trays 1-2
Guidelines for loading paper 1-2
Loading trays 1 and 2 1-3
Loading trays 3, 4, 5, and 6 1-7
2. Output trays and bins 2-1
Checking and unloading sample trays 2-1
Checking and unloading purge trays 2-1
Checking and unloading high-capacity stacker (HCS) bins 2-2
3. Fuser lubricant 3-1
4. Adding dry ink 4-1
5. Replacing the dry ink waste container 5-1
6. Cleaning 6-1
Cleaning the keyboard, monitor, and the exterior of the Printer Controller 6-1
Cleaning the sensors and the reflective surfaces 6-1
Cleaning the Q850 sensor 6-2
Cleaning the Q1011 sensor and mirror 6-3
Cleaning additional sensors 6-4
Sensor Q1107 6-4
Q1106 and Q1166 6-5
Sensor Q1164 6-6
Cleaning the 4mm cartridge tape drive 6-7
XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE v
TABLE OF CONTENTS
7. Maintenance and support services 7-1
Xerox Customer Services Support Center 7-1
Xerox Documentation and Software Services 7-2
Xerox Font Center 7-2
Operator Training 7-2
Xerox Customer Education 7-3
Reporting billing meters 7-3
Index INDEX-1
vi XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE
About this guide
Introduction
The Xerox DocuPrint 96/4635/180 IPS Guide to Performing Routine
Maintenance describes how to perform basic maintenance on the
Xerox DocuPrint 96/4635/180 IPS.
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 Xerox DocuPrint IPS Series documentation for
information on other tasks required for printing with your DocuPrint
printer.
Users should have an understanding of Printer Controller operations.
Contents
Before using this guide, become familiar with its contents and
conventions.
This section lists the contents of this guide.
• Chapter 1, “Feeder trays,” provides information on how to load
feeder trays.
• Chapter 2, “Output trays and bins,” describes how to unload
output trays and bins for the DocuPrint printer.
• Chapter 3, “Fuser lubricant,” describes both how to refill the
fuser agent reservoir, and how to replace the pressure roll
wiper.
• Chapter 4, “Adding dry ink,” lists the steps for adding dry ink to
the printer.
• Chapter 5, “Replacing the dry ink waste container,” lists the
steps for replacing the dry ink waste container in the printer.
• Chapter 6, “Cleaning,” provides instructions on how to clean the
various printing system components.
• Chapter 7, “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 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE vii
INTRODUCTION
Conventions
This guide uses the following conventions:
• Italics — Document and library names are shown in italics (for
example, the Xerox DocuPrint 96/4635/180 IPS Guide to
Performing Routine Maintenance).
• Capitalization of graphical user interface (GUI) window titles
matches the titles as they appear on the screen. In cases where
a window does not have a title, it is referenced using all lower
case. For example:
— At the graphical user interface, use the Output
Configuration window to group the trays.
— The main window displays the current system status.
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 could affect the
!
safety of people.
viii XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE
Related publications
Xerox documents Following is a list of all Xerox DocuPrint IPS documents. For a
INTRODUCTION
This document is part of the Xerox DocuPrint IPS publication set.
complete list and description of available Xerox documentation, refer
to the Xerox Customer Documentation Catalog (publication number
610P17517), or call your service representative.
Application Programmer/System Administrator Quick Reference
Card
Customer Information Quick Reference Card
Generic MICR Fundamentals Guide
Glossary
Guide to Configuring and Managing the System
Guide to Performing Routine Maintenance
Helpful Facts About Paper
Installation Planning Guide
Master Index
Messages Guide
Solutions Guide
System Overview Guide
Troubleshooting Guide
Xerox Standard Font Library Font User Guide
The documentation set also includes an electronic version, the
DocuPrint IPS Interactive Customer Documentation CD.
IBM documents Following are related IBM documents. Contact your local IBM
representative for ordering instructions for IBM AFP/PSF manuals
that might be useful for your specific installation.
IBM 3825 Page Printer Product Description
IBM Intelligent Printer Data Stream Reference
IBM Advanced Function Presentation Printer Summary
IBM ITSC Distributing AFP Printing from a Host System
IBM Advanced Function Printing Data Stream Reference
IBM Data Stream and Object Architectures: Mixed Object Document
Content Architecture Reference
Guide to Advanced Function Presentation
XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE ix
INTRODUCTION
x XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE
Checking feeder trays
1. 1Feeder trays
This chapter describes the processes for loading paper in the
96/4635/180 IPS feeder trays, and explains what actions are
necessary if a paper stock is changed.
Note: The number of feeder trays on your system depends on the
number of feeder/stacker modules installed.
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 (grams per
square meter) paper.
Figure 1-1. Feeder tray lights
• You do not have to interrupt a print job to load paper since 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.
• 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.
XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 1-1
FEEDER TRAYS
Loading feeder trays
Guidelines for loading paper
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 IPS printer’s operation.
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.
• For trays 3, 4, 5 and 6, load paper with curl side up. If you do
not detect paper curl, load paper with the wrapper seam side
down.
Additional guidelines for loading special stocks:
• When loading predrilled paper, fan the paper and remove
loose paper plugs.
• Load transparencies into trays 1 and 2 only.
• When loading tab stock, remove deformed, bent, or damaged
stock.
• Load preprinted paper in trays 3, 4, 5, and 6 only, in order not
to smudge the print. These trays are vacuum-type feeders,
unlike trays 1 and 2, which are friction-type.
1-2 XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE
Loading trays 1 and 2
FEEDER TRAYS
Trays 1 and 2 are the processor feeder trays.
Figure 1-2. Processor feeder trays (trays 1 and 2)
Follow these steps to load feeder trays 1 and 2.
1. Select the tray you want to load by pressing the Tray Unlock
button on the door of the paper tray or by touching the
appropriate unlock icon on the printer control console.
Note: If the printer has stopped due to a low paper condition,
you do not need to press the Tray Unlock button.
2. Wait until the Ready to Open indicator lights.
XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 1-3
FEEDER TRAYS
3. Pull the feeder tray out until it stops.
4. Pull out any partially fed paper from the feeder assembly and
discard it. There will be some resistance.
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. Load paper, following the instructions on the labels of the feeder
tray and carefully positioning the paper in the right front corner
of the tray.
1-4 XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE
FEEDER TRAYS
Caution: Do not load above the MAX line shown on the paper
guide.
8. Pull the length guide forward to touch the back of the paper
stack.
XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 1-5
FEEDER TRAYS
9. Latch the paper feeder assembly by pressing the green dot next
to the green release lever until the assembly clicks into position.
10. Push the tray in slowly but firmly until it latches. Do not slam the
tray closed. This can cause improper latching or machine
damage.
11. If the printer stopped due to a low paper condition, press the
Continue button on the printer control console to resume
printing.
1-6 XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE
Loading trays 3, 4, 5, and 6
FEEDER TRAYS
Follow these steps to load feeder trays 3, 4, 5, and 6:
1. Select the tray you want to load by pressing the Tray Unlock
button on the door of the paper tray or by touching the
appropriate unlock icon on the printer console.
Note: If the printer has stopped due to a low paper condition,
you do not need to press the Tray Unlock button.
2. Wait until the Ready to Open indicator lights.
3. Pull the feeder tray out until it stops.
4. Slide both length guides away from the paper. For the rear
guide, squeeze the lever against the back of the length guide
and slide the guide toward the back of the printer.
XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 1-7
FEEDER TRAYS
5. Remove any paper remaining in the tray and set it aside to be
placed on top of the new paper.
6. Load paper, following the instructions on the label at the front of
the feeder tray and carefully positioning the paper in the rightfront corner of the tray.
Note: The way you load the paper depends on the paper size
required by the job. For paper longer than 14 inches, load the
long edge against the back guide.
7. Slide both length guides back against the paper.
1-8 XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE
FEEDER TRAYS
8. Push the tray in slowly but firmly until it latches. Do not slam the
tray closed. This can cause improper latching or machine
damage.
9. If the printer stopped due to a low paper condition, press the
Continue button on the printer console to resume printing.
Note: When you change the paper size in one of the feeder trays,
a message displays asking you to make sure the printer is warmed
up, ready, and loaded with the proper media. The message displays
the media defined for the tray, as well as the paper currently loaded
in the tray.
Currently, there is no method of restoring the Input Configuration to
its original state. Once you select Modify, the Input Configuration
window appears. Make changes on the window as appropriate, then
save your changes. For detailed information on the Input
Configuration window, refer to your Xerox DocuPrint 96/4635/180
IPS Guide to Configuring and Managing the System.
XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 1-9
FEEDER TRAYS
1-10 XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE
2. 2Output trays and bins
Your print jobs are sent to output trays or bins which you must
unload. You can unload each of the output trays or bins while the
system is printing. How you do so, however, depends on the type of
tray. This chapter discusses how to check and unload the output
trays and bins.
If the printer has stopped due to a full output tray and does not
resume automatically when the bin is emptied, press the Continue
button on the printer control console.
Note: The number of output trays on your system depends on the
number of feeder/stacker modules installed.
Checking and unloading sample trays
The sample tray holds up to 100 sheets of paper from 7 by 10 inches
/ 178 by 254 mm to 14.33 by 17 inches / 364 by 432 mm. No message
appears when the sample tray is full. Since a paper jam can occur if
the tray is allowed to overfill, empty the sample tray regularly, if it is
in use.
To empty the sample tray, simply remove the printed pages.
Note: Since the sample tray can receive waste sheets purged after
a paper jam, always clear the sample tray after clearing a jam. This
prevents waste sheets from being confused with good sheets.
Checking and unloading purge trays
Aborted sheets (that is, sheets damaged during printing or cleared
before or after a paper jam) are sent to the purge tray. Sheets may
be purged before, during, or after print jobs. Sheets are also sent to
the purge tray following a fuser area jam. The sheets purged at that
time clean the fuser area, ensuring good print quality for your
subsequent jobs.
The purge tray holds up to 100 sheets of paper 7 by 10 inches / 178
by 254 mm to 14.33 by 17 inches / 364 by 432 mm. No message
appears when the purge tray is full. Since a paper jam can occur if
the tray is allowed to overfill, empty the purge tray at least once a day.
To empty the purge tray, simply remove the printed pages.
XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 2-1
OUTPUT TRAYS AND BINS
Checking and unloading high-capacity stacker (HCS) bins
The 4635 and 180 IPS printers can have up to four high-capacity
stacker (HCS) bins; the 96 IPS can have up to two. Each highcapacity tray holds 2500 sheets of 20lb or 80 gsm paper. (Refer to
your Xerox DocuPrint 96/4635/180 System Overview Guide for
additional information on the high-capacity stacker bins.)
Note: If you use large paper sizes such as A3 or 11 x 17 inch, the
stacker may hold less than 2500 sheets. This is to ensure that the
stack is at a safe weight for lifting and unloading by the operator.
• You can lower, pull out, and unload any bin not currently in use,
without interrupting printing, as long as another HCS is ready to
receive paper.
• If you select a bin that is in use, the printer begins stacking in
the next defined high-capacity stacker bin if it is available. If no
stacker bin is available, printing stops.
• Once a sheet is delivered to a stacker bin, each subsequent
sheet must be within 25 mm (approximately 1 inch) of length
and width of the first sheet.
Unloading a stacker bin To unload a stacker bin:
1. Select a bin for unloading by pressing the Bin Unload button on
the bin control panel. (You can also select the bin for unloading
through the printer mimic of the printer control console.)
Once a bin is selected, the bin elevator lowers and the bin
cannot be used until it is emptied completely. When the bin
elevator stops in the down position, the Ready to Unload
indicator lights.
2-2 XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE
OUTPUT TRAYS AND BINS
2. Open the bin doors, pull the platform out until it stops, and lift
the paper stack off the platform to a nearby table or paper cart.
Caution: Always use both hands to lift the paper stack out of
the bin.
3. Firmly push the platform back to its original position and close
the bin doors. The bin elevator rises, and the bin is again ready
for use.
Note: If the bin is not empty, the elevator remains down, and a
message appears on the printer control console and Printer
Controller display telling you to empty the bin.
XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 2-3
OUTPUT TRAYS AND BINS
2-4 XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE
3. 3Fuser lubricant
The fuser on the 96, 4635, and 180 IPS is responsible for fusing the
print image to the paper with heat. It is critical that the fuser be kept
lubricated with fuser agent and that its reservoir be kept full. This
chapter describes the procedure for adding fuser lubricant in the
printer.
To add fuser lubricant:
1. Open the right and left doors of the printer and locate the fuser
area.
2. Place a dropcloth on the floor under the fuser area.
XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 3-1
FUSER LUBRICANT
3. Grasp the green handle on the fuser drawer and pull it out until
it stops.
4. Put on gloves.
Warning: Fuser agent contains silicone, which can cause
!
irritation upon contact with the eyes. Be sure to wash your hands
with soap and water after you finish this procedure.
3-2 XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE
FUSER LUBRICANT
5. Locate the fuser agent reservoir, pull it out until it stops, and
remove the reservoir cap by turning it counterclockwise.
6. Remove the cap from a new bottle of fuser agent and carefully
pour the fuser agent into the reservoir, until the level reaches
the MAX line.
XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 3-3
FUSER LUBRICANT
Warning: If any fuser agent spills on the floor, remove it
!
immediately. Fuser agent spills make the floor slippery. Use of
Xerox Film Remover (isopropyl alcohol) is recommended to
clean up spills.
Caution: The fuser reservoir has an anti-splash seal. Do not
push the fuser agent bottle into the reservoir with excessive
force, as this can damage the seal.
7. Replace the reservoir cap by turning it clockwise and push the
fuser agent reservoir in until it stops.
8. Push the fuser drawer in until it latches in place.
9. Dispose of the dropcloth and any empty agent bottles in a trash
receptacle. If there is any agent left in the bottle, cap the bottle
and store it for future use.
10. Remove and dispose of the gloves in a trash receptacle, being
careful not to let any residue come in contact with your skin.
11. Close the printer doors.
Note: The fuser agent message disappears after the printer
prints between 32 and 40 sheets. Since the sheets must be
processed continuously, you may want to run 45 test pages in
order to clear the message from the system (unless the current
print job contains at least 40 pages).
12. Wash your hands to remove any fuser agent.
3-4 XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE
4. 4Adding dry ink
Dry ink is the black powder that forms the image on the printed page.
This chapter describes the procedure for adding dry ink to the printer.
When the printer is low on dry ink, the Attention light turns on, and the
message ADD DRY INK displays on the printer console. Add dry ink
at your earliest convenience.
If you do not add dry ink, the printer eventually stops printing. It does
not resume printing until you replace the dry ink bottle.
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
when directed to do so by a message on the printer control
console.
To add dry ink:
1. Open the printer doors and locate the dry ink area on the left
side of the printer.
2. Place a dropcloth on the floor under the dry ink area.
XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 4-1
ADDING DRY INK
3. Pull the empty dry ink cartridge out until it stops.
4. Move the green handle to the right (the unlatched position) to
release the cartridge and lid.
5. Remove the empty cartridge and discard it.
6. Turn a new, full cartridge of dry ink upside down and shake it
well to loosen the contents thoroughly.
7. Insert the new cartridge into the printer until it stops.
4-2 XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE
ADDING DRY INK
8. Move the green handle to the left (the latched position) to
secure the lid of the cartridge.
9. Hold the cartridge in place and pull off the paper seal.
10. Discard the seal along with the dropcloth.
11. Close the printer doors.
Caution: If any dry ink gets on your hands, wash them with soap
and cold water. If any dry ink gets on your clothes, brush them with a
dry paper towel or a stiff-bristled brush. If this does not remove the
ink, immediately launder with detergent and cold water. 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 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 4-3
ADDING DRY INK
4-4 XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE
5. 5Replacing the dry ink waste
container
The dry ink waste container receives the dry ink inside the printer that
does not fuse to paper during printing. This container must be
replaced when full.
To replace the dry ink waster container:
1. Open the right and left printer doors and locate the dry ink
waste container.
2. Place a dropcloth on the floor under the dry ink waste container
area.
Caution: To prevent dry ink spills, do not tip or tilt the waste
container.
XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 5-1
REPLACING THE DRY INK WASTE CONTAINER
3. Pull the full waste container out of the printer.
4. Remove the cap from the top of the full container and screw the
cap onto the mouth of the container.
5. Discard the waste material and container according to the
instructions on the label.
5-2 XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE
REPLACING THE DRY INK WASTE CONTAINER
6. Slide a new, empty dry ink waste container into the printer until
it stops.
Note: Do not remove the cap from the container.
7. Close the printer doors.
8. Dispose of the dropcloth.
Caution: 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. If this does not remove the ink, launder with detergent and
cold water. Tell dry cleaners that the spot is dry ink for a printer so
they do not use a solvent that sets the stain.
XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 5-3
REPLACING THE DRY INK WASTE CONTAINER
5-4 XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE
6. 6Cleaning
This chapter describes the cleaning tasks you need to perform
regularly on the 96/4635/180 IPS printer.
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:
• Monitor: Use a soft, lint-free cloth dampened with a glass
cleaner. Do not spray the liquid directly onto the monitor, it may
cause damage.
• Keyboard: Use a mild household detergent that has been
poured or sprayed onto a cloth lightly dampened with water. Do
not saturate the cloth; just dampen it.
• Exterior: Use a mild household detergent that has been poured
or sprayed onto a cloth lightly dampened with water. Do not
saturate the cloth; just dampen it.
Caution: Do not allow liquids to drip onto anything electrical or
mechanical. For the same reason, never spray or pour the cleaner
directly onto the keyboard or the exterior surfaces of the system.
Cleaning the sensors and the reflective surfaces
Sensors at various points along the paper path indicate where sheets
of paper are passing. After a sheet has passed a sensor, if too much
time elapses before another sheet arrives, the system determines a
jam has occurred, and printing stops. If a sensor becomes dirty, it
may not accurately detect sheets passing and may give incorrect jam
information. Therefore, it is important to clean sensors regularly.
Sensors are usually cleaned by your Xerox service representative as
part of regular maintenance. However, under certain conditions you
may be directed to clean them yourself by the Xerox Customer
Support Center or by your local operating company.
1. Brush or wipe the sensor window lightly with a lint-free cloth,
cleaning pad, or cotton swab.
Note: If the sensor is very dirty, use a small amount of alcohol
on the swab.
2. Remove any paper dust present in the area.
Caution: Do not use any abrasives or strong solvents on the
sensors.
XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 6-1
CLEANING
Cleaning the Q850 sensor
To clean the Q850 sensor:
1. Open the printer right and left doors and locate area 4.
2. Raise the area 4 green handle until it locks into place.
3. Locate the Q850 sensor and gently wipe the sensor with a dry
cleaning pad.
4. Lower the area 4 green handle.
5. Close the printer doors.
6-2 XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE
Cleaning the Q1011 sensor and mirror
To clean the Q1011 sensor and mirror:
1. Open the right and left doors of the printer and locate the
CLEANING
Q1011 sensor.
2. Apply a small amount of lens and mirror cleaner to a cleaning
pad.
3. Gently wipe the sensor and mirror with the cleaning pad.
4. Close the printer doors.
XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 6-3
CLEANING
Cleaning additional sensors
Sensor Q1107
Open the top cover of the high-capacity stacker. Locate and clean
the following sensors with a cleaning pad.
Sensor Q1107 is at the right front corner of the stacker, shown below.
Note: For systems with more than one stacker, clean each Q1107
location.
6-4 XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE
Q1106 and Q1166
CLEANING
Raise the platform by lifting the green handle. Sensors Q1106 and
Q1166 are shown below. Clean the sensors gently with a cleaning
pad.
XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 6-5
CLEANING
Sensor Q1164
Sensor Q1164 is on the last feeder/stacker module (the one
containing the purge tray), as shown below. Clean the sensors gently
with a cleaning pad.
6-6 XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE
Cleaning the 4mm cartridge tape drive
Clean the 4mm cartridge tape drive every 25 hours of actual tape
operation. Use only a cleaning cartridge designed for the 4mm
cartridge tape drive. No fluids or other preparations are necessary
with the use of these cartridges.
Caution: Do not use cleaning cartridges or any types of fluids
designed for use in audio devices as these can damage your tape
drive.
To clean the tape drive:
1. Insert the cleaning cartridge into the tape drive as you would a
regular 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 blinks rapidly.
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.
CLEANING
You can use the cartridge tape drive immediately after cleaning.
XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 6-7
CLEANING
6-8 XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE
7. 7Maintenance 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.
Note: The support services described in this chapter apply to the
United States only. For information on the support services available
internationally, consult your Xerox representative.
Xerox Customer Services Support Center
Before calling your Customer Service Support Center, make sure
you have tried the corrective actions described in the Xerox
DocuPrint 96/4635/180 Troubleshooting Guide. If a problem persists,
gather the necessary information and call your customer service
support center (or contact your local Xerox operating company).
services
Refer to the Xerox DocuPrint 96/4635/180 Troubleshooting Guide
chapter “Calling for service” for the information you should have
ready when you call.
In the United States, call the following number to report DocuPrint
hardware or software problems:
1-800-822-2979
Note: This phone number is attached to your printer at installation
time.
XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 7-1
MAINTENANCE AND SUPPORT SERVICES
Xerox Documentation and Software Services
XDSS distributes the documents you need to install and use the
DocuPrint printer, other Xerox printers, and associated software. If
you register for site subscription service, XDSS will automatically
send you updates and revisions as they become available.
To order this documentation, call Xerox Documentation and Software
services:
1-800-327-9753 (U.S. only), between the hours of 6:00 a.m. and
4:00 p.m., Pacific time.
XDSS representatives will explain the services available, answer
your questions, and take orders for documentation.
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.
Operator Training
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. and 5:00 p.m.,
Pacific time.
You can get font information on the web:
www.font.net
Operator training is conducted at your location shortly after your
DocuPrint printer is installed. Training takes approximately two to
four hours, depending on the system configuration. It includes handson practice running basic jobs, performing routine maintenance, and
solving problems. Determine the number of operators you want to
attend the initial training, schedule training dates and times through
your Xerox sales representative.
Additional training classes, such as Advanced Customer Training
(ACT) for operators, teach advanced service and maintenance skills.
A variety of classes and workshops are available through Xerox
Customer Education.
7-2 XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE
Xerox Customer Education
Reporting billing meters
MAINTENANCE AND SUPPORT SERVICES
Xerox offers classes and tutorial documents on various topics
relating to printing systems and document production. For
information about Xerox training courses, or to receive a catalog, call
Xerox Customer Education at:
1-800-445-5554 (U. S. only)
You can also obtain information on the web:
http://www.xerox.com/services/training/customer-ed
On a regular basis, usually every month, you need to report your
printer billing meter readings to Xerox.
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.
If you know how to read the billing meters for your system, you can
have that information ready when you call. Otherwise, the service
representative will provide you with instructions when you call.
To report billing meter readings, call 1-800-891-8405 (all U.S.
locations) or contact your local Xerox operating company.
Your printer maintains the page count in the Billing window. You can
read the meters any time the printer is not running. To display the
Billing Information window: From the Administration menu, select
Billing Information.
XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE 7-3
MAINTENANCE AND SUPPORT SERVICES
Figure 7-1. Billing Information window
Note: The information in the IOT Engine Type field varies,
depending on your IPS model.
• Meter A gives the total impressions successfully delivered by
the printer. This meter keeps a permanent cumulative record of
how many sheets are delivered to an output destination. It
cannot be cleared or reset. This recording is reported by the
customer.
• Meter C counts all sheets fed into the paper path from trays 1,
2, 3, or 4. It is a user meter and can be cleared by the controller.
• Meter E counts all good sheets sent to the intended output
destination. It is a user meter and can be cleared by the
controller.
• Meter F performs the same function as Meter A (total
impressions successfully delivered), except it can be cleared by
the controller.
• 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.
7-4 XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE
Index
Numerics
4mm cartridge tape drive, cleaning, 6-7
A
Advanced Customer Training (ACT), 7-2
B
Bin Unload button, 2-2
bins, 2-1–2-3
C
checking
feeder trays, 1-1
high-capacity stacker (HCS) bins, 2-2
purge trays, 2-1
sample trays, 2-1
cleaning
4mm cartridge tape drive, 6-7
keyboard, 6-1
mirror, 6-3
monitor, 6-1
Printer Controller exterior, 6-1
reflective surfaces, 6-1
sensors
Q1011, 6-3
Q1106, 6-5
Q1107, 6-4
Q1164, 6-6
Q1166, 6-5
Q850, 6-2
customer education, 7-3
D
F
feeder trays, 1-1–1-9
friction-type feeders, 1-2
fuser agent
adding, 3-1–3-4
G
guidelines, loading paper, 1-2
H
high-capacity stacker (HCS) bins, 2-2
hotlines
ozone information, iii
safety, iv
I
input trays, loading, 1-1–1-9
K
keyboard, cleaning, 6-1
L
labels, danger, iii
laser safety, iii
length guide, 1-5
lights, feeder trays, 1-1
loading
paper, 1-2
trays 1 and 2, 1-3–1-6
trays 3,4,5, and 6, 1-7–1-9
loading, feeder trays, 1-1–1-9
danger labels, iii
documentation
other, ix
dry ink
adding, 4-1–4-3
stains, 4-3
E
education, customer, 7-3
XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE INDEX-1
M
maintenance services, 7-1–7-4
monitor, cleaning, 6-1
O
operation safety, iv
operator training, 7-2
output trays, 2-1–2-3
ozone, iii
INDEX
P
paper
loading, 1-2
predrilled, 1-2
preprinted, 1-2
trays, see trays
paper feeder assembly, 1-6
predrilled paper, 1-2
preprinted paper, 1-2
Printer Controller exterior, cleaning, 6-1
procedures
4mm cartridge tape drive, cleaning, 6-1
dry ink
waste container, replacing, 5-1–5-3
dry ink, adding, 4-1–4-3
fuser agent, adding, 3-1–3-4
sensors, cleaning
Q1011, 6-3
Q850, 6-2
stacker bins, unloading, 2-2–2-3
trays 1 and 2, loading, 1-3–1-6
trays 3, 4, 5, and 6, loading, 1-7–1-9
publications, related, ix
purge trays, 2-1
Q
Q1011 sensor and mirror, cleaning, 6-3
Q1106 sensor, cleaning, 6-5
Q1107 sensor, cleaning, 6-4
Q1164 sensor, cleaning, 6-6
Q1166 sensor, cleaning, 6-5
Q850 sensor, cleaning, 6-2
R
Ready to Open indicator, 1-3
Ready to Unload indicator, 2-2
reflective surfaces, cleaning, 6-1
Reporting billing meters, 7-3
silicone, 3-2
stacker, unloading bins, 2-2–2-3
support services, 7-1–7-4
T
tab stock, 1-2
training, operators, 7-2
transparencies, loading, 1-2
Tray Unlock button, 1-3
trays
loading
1 and 2, 1-3–1-6
3,4,5, and 6, 1-7–1-9
loading feeder, 1-1–1-9
output, 2-1–2-3
purge, 2-1
sample, 2-1
U
unloading
high-capacity stacker (HCS) bins, 2-2
purge trays, 2-1
sample trays, 2-1
stacker bins, 2-2–2-3
V
vacuum-type feeders, 1-2
X
Xerox Customer Education, 7-3
Xerox Customer Service Support Center, 7-1
Xerox Documentation and Software Services
(XDSS), 7-2
Xerox Font Center, 7-2
S
safety
hotline, iv
precautions, iv
standards, iii
sample trays, 2-1
sensors, cleaning
methods, 6-1
Q1011, 6-3
Q1106, 6-5
Q1107, 6-4
Q1166, 6-5
Q850, 6-2
service telephone number, 7-1
INDEX-2 XEROX DOCUPRINT 96/4635/180 IPS GUIDE TO PERFORMING ROUTINE MAINTENANCE
../../../IPS & LPS Graphics/dpc0010a.cgm iii
../../../IPS & LPS Graphics/dpc0579.cgm 1-1
../../../IPS & LPS Graphics/dpc0734.cgm 1-3
../../../IPS & LPS Graphics/dpc0702.cgm 1-3
../../../IPS & LPS Graphics/dpc0703.cgm 1-3
../../../IPS & LPS Graphics/qtc0259-clr.cgm 1-4
../../../IPS & LPS Graphics/qtc0261-clr.cgm 1-4
../../../IPS & LPS Graphics/qtc0262-clr.cgm 1-5
../../../IPS & LPS Graphics/qtc0266-clr.cgm 1-5
../../../IPS & LPS Graphics/qtc0267-clr.cgm 1-6
../../../IPS & LPS Graphics/qtc0225.cgm 1-7
../../../IPS & LPS Graphics/qtc0269.cgm 1-7
../../../IPS & LPS Graphics/DPC0244A.CGM 1-7
../../../IPS & LPS Graphics/qtc0264-clr.cgm 1-8
../../../IPS & LPS Graphics/qtc0263-clr.cgm 1-8
../../../IPS & LPS Graphics/dpc0706.eps 2-2
../../../IPS & LPS Graphics/dpc0708.eps 2-2
../../../IPS & LPS Graphics/qtc0244-clr.cgm 3-1
../../../IPS & LPS Graphics/qtc0245-clr.cgm 3-2
../../../IPS & LPS Graphics/qtc0246-clr.cgm 3-3
../../../IPS & LPS Graphics/qtc0247-clr.cgm 3-3
../../../IPS & LPS Graphics/qtc0248-clr.cgm 3-4
../../../IPS & LPS Graphics/qtc0236-clr.cgm 4-1
../../../IPS & LPS Graphics/qtc0237-clr.cgm 4-2
../../../IPS & LPS Graphics/qtc0239-clr.cgm 4-3
../../../IPS & LPS Graphics/qtc0240.cgm 5-1
../../../IPS & LPS Graphics/qtc0241.cgm 5-2
../../../IPS & LPS Graphics/qtc0242.cgm 5-2
../../../IPS & LPS Graphics/qtc0243.cgm 5-3
../../../IPS & LPS Graphics/qtc0249-clr.cgm 6-2
../../../IPS & LPS Graphics/qtc0250-clr.cgm 6-2
../../../IPS & LPS Graphics/qtc0251-clr.cgm 6-3
../../../IPS & LPS Graphics/qtc0252.cgm 6-3
../../../IPS & LPS Graphics/qtc0270-clr.cgm 6-4
../../../IPS & LPS Graphics/qtc0253.cgm 6-5
../../../IPS & LPS Graphics/qtc0254-clr.cgm 6-6
../../../IPS & LPS Graphics/bill180.wmf 7-4
DOUBLE-CLICK ON THIS TEXT FROM ANY MASTER PAGE AND EDIT THE DEFINITION -1
Loading...