Xerox 495 Continuous Feed Duplex Printer Operator Guide January 2007 708P88702
Prepared and translated by: Xerox, GKLS European Operations, WELWYN GARDEN CITY, AL7 1BU United Kingdom ©2007 by Xerox Corporation. All rights reserved. Xerox® and all the products mentioned in this publication are trademarks of Xerox Corporation and Xerox Limited. Products and trademarks of other companies are also acknowledged.
Table of Contents Table of Contents 1. About this manual End User License Agreement Audience Document organization Document conventions Notes, cautions, and warnings 2.
Table of Contents The Print Line Bus (PLB) Identifying the PLB boxes Cabling the PLB Characteristics Segmentation Licensing Renewing the license 3. Getting started Switching the printer on and off Local power on and off Remote powering on and off Emergency stop Using help Making general configurations Setting the time on the screen Setting print modes Changing user roles Setting locked components Changing the password Changing the user language 4.
Table of Contents Checking the existence of a job Defining a job Creating or amending a job Copying a job definition Exporting a job definition to the Production screen Importing a job definition from the Production screen Deleting a job definition Defining paper characteristics Creating or amending a paper definition Copying a paper definition Exporting a paper definition to the Production screen Importing a paper definition from the Production screen Deleting a paper definition Defining applications Crea
Table of Contents 9.
Table of Contents INDEX Xerox 495 Continuous Feed Duplex Printer Operator Guide Page -v
Table of Contents Page -vi Xerox 495 Continuous Feed Duplex Printer Operator Guide
1. About this manual Thank you for purchasing the Xerox 495 Continuous Feed Duplex Printer. The printer is designed for ease of use, but to use your machine to its fullest potential, take some time to read this Operator Guide. End User License Agreement In order to operate the Xerox 495 Continuous Feed Duplex Printer, it is mandatory for an end user representative to accept an XPe (XP embedded) End User License Agreement (EULA).
AUDIENCE ABOUT THIS MANUAL Audience This Operator Guide is intended to be used by Operators and Key Operators of the printer in order to run and define production jobs. Some functions only available to Maintenance and Support level users are also included. Where procedures are only relevant to specific user levels, these are clearly identified. It is assumed that all users understand the peripheral equipment that may be used in the print line.
ABOUT THIS MANUAL DOCUMENT ORGANIZATION Document organization The Operator Guide contains the following sections: • Chapter 2 - Product Overview which describes the main components. • Chapter 3 - Getting Started shows you how to switch the printer off and on, the use of the Help and how to change from one user role to another. • Chapter 4 - shows the procedures for Running Production Jobs. • Chapter 5 - deals with the procedures for loading paper and making Paper Path adjustments.
DOCUMENT CONVENTIONS ABOUT THIS MANUAL Document conventions A document convention is simply a way of presenting information. This section explains the conventions used in this Guide. Notes, cautions, and warnings This manual uses notes, cautions, and warnings to emphasize information the reader needs. Notes contain information that supplements the text. Cautions provide information where non conformance could cause damage to the machine.
2. Product overview The Xerox 495 Continuous Feed Duplex Printer is a non-impact continuous-feed printer combined from the LED recording and dry electrophotographic recording technologies for double-sided printing. The machine is controlled from a liquid crystal colour touch screen where you can view your operation and application settings.
PRODUCT OVERVIEW (Operator, Key Operator, Maintenance and Support) where all users other than the Operator are required to enter a password to access the functions. Front and back marking units In order to carry out duplex printing, the printer has two marking units A (Front) and B (Back). Using the default settings, the front side data will print on the A marking unit and the back side data will print on the B marking unit.
PRODUCT OVERVIEW GETTING TO KNOW THE PRINTER ENGINE Getting to know the printer engine Inside the printer you will find the printer engine and the controller. The Printer Engine contains the image processing, paper handling and fusing components. The Controller has two PCs which are used to control printer functions, communications and configurations. The following illustrations show the major areas of the printer, the location of the covers and doors and the different control panels and interfaces.
GETTING TO KNOW THE PRINTER ENGINE PRODUCT OVERVIEW Components inside the printer doors Opening the printer left and right doors provides access to the main printing units. Fuser Door Fuser Left Door Touch Screen Kit A[R3a] Display LED Kit B[R3b] Display LED Toner Supply Unit [Ka] Toner Display LED [Ka] Toner Supply Unit [Kb] Developer Display LED [R2a] Internal Door Toner Display LED [Kb] Developer Display LED [R2b] The Touch screen is used to run and configure production jobs.
PRODUCT OVERVIEW GETTING TO KNOW THE PRINTER ENGINE Components inside the internal door The internal door, when opened, provides further access to the maintenance task components.
GETTING TO KNOW THE PRINTER ENGINE PRODUCT OVERVIEW Components inside the Fuser Door The Fuser Door, when opened, provides access to the fusing components.
PRODUCT OVERVIEW GETTING TO KNOW THE PRINTER ENGINE Components inside the stacker door The stacker doors, when opened, provide access to the stacker components, the smoke filter and the controller PC.
GETTING TO KNOW THE PRINTER ENGINE PRODUCT OVERVIEW Rear covers and doors There are two doors at the rear of the printer which provide access to the waste toner and empty developer containers. Rear Right Door Patrol Lamp Empty Developer Container Rear Left Door Vent Waste Toner Container The location is referenced as looking from the rear. • The Rear Left Door provides access to the waste toner container.
PRODUCT OVERVIEW GETTING TO KNOW THE PRINTER ENGINE Paper loading components The paper loading section components are shown in the following illustration. Emergency Power-Off Switch Autoload Panel Sub-operator panel (inside door) Tractor Assembly Hopper Paper Guides • Sub-operator panel - See “Sub-operator panel” on page 2-28. • Autoload panel - See “Autoload panel” on page 2-30.
UNDERSTANDING THE TOUCH SCREEN PRODUCT OVERVIEW Understanding the touch screen The touch screen has been designed to make your work easier. The design is intuitive and user-friendly, using colour coding, icons, dialog boxes, pull-down menus, bubble menus, scroll boxes, buttons, toggle buttons, tabs and check boxes. The touch screen gives you fingertip control over the printer. Simply touch the screen with your finger to move the cursor and select the various commands.
PRODUCT OVERVIEW UNDERSTANDING THE TOUCH SCREEN Symbol Meaning Vertical scrollbar - press on the up or down arrow to scroll one line up or down. If you keep your finger on the up or down arrow, the screen will scroll continuously, one line at a time until you remove your finger from the screen. Press in the space to scroll to the position where you place your finger. You can also slide the scrollbar by pressing the gray box and dragging it up or down. Radio-button - used to select alternative items.
UNDERSTANDING THE TOUCH SCREEN PRODUCT OVERVIEW Functional areas The touch screen forms the main control panel of the Xerox 495 Continuous Feed Duplex Printer through which most of the functions and configurations can be selected. The language of this display can be in English, French (Français), Italian (Italiano), German (Deutsche), Spanish (Espanol) or Dutch (Nederlands) by changing the language through the Users tab. The following illustration shows the functional areas of the touch screen.
PRODUCT OVERVIEW UNDERSTANDING THE TOUCH SCREEN Title bar Product name, software package version and customer name Printer Name User Role The title bar gives the product name, software package version, customer name, the name given to the local printer and the current user role. In three places, there are links to other tabbed pages. These are: • If you press on the software revision, the Engine > Revisions tab is displayed (see "Checking software and hardware revisions" on page 9-12).
UNDERSTANDING THE TOUCH SCREEN PRODUCT OVERVIEW Tab view Press the button to switch to this view. The default tab view is the Production tab (see "Running jobs" on page 4-3) which is used to select, modify and run jobs. The following illustration shows the Production tab in the tab view. Each tab view contains the items that can be chosen or set for that function. There are five top level tabs some of which will lead to further tabbed pages. • Production. • Definitions. • Engine. • Tools.
PRODUCT OVERVIEW UNDERSTANDING THE TOUCH SCREEN These five tabs are used to access the different screens as well as several sub-screens. The following table shows the tab screen structure. Production Definitions Engine Tools Job Config Test Paper Print Mode Errors Rev. Resident Lic.
UNDERSTANDING THE TOUCH SCREEN PRODUCT OVERVIEW Run view The Run view logs and displays user actions and activities, error codes and their labels, resolution, page counters and print charge counters. It is shown in the following illustration. The condition is displayed in the Error Log. Press the button will flash if an error button to switch to this view.
PRODUCT OVERVIEW UNDERSTANDING THE TOUCH SCREEN • Error log - This displays all error codes and their labels, as they occur. By clicking on an error label, you will immediately access its accompanying Help. When you press the Reset button, all errors that have been remedied will be removed from the Error Log. • Print charge counters - Print charge counters are used to calculate how much has been printed for a job in order to apply the appropriate charges.
UNDERSTANDING THE TOUCH SCREEN PRODUCT OVERVIEW Consumables view Consumables view - will display one of two consumables screens. The first shows the usage of all of the consumables that you are able to replace and provides a means to access the procedures to change that consumable (see "Checking consumable use" on page 8-4). The second screen shows the usage of consumables that need to be replaced for maintenance purposes. This screen is for information only and the Change buttons are grayed out.
PRODUCT OVERVIEW UNDERSTANDING THE TOUCH SCREEN The percentage values shown in the windows have the following significance. Consumable Green Orange Red Toner [Ka] & [Kb] 100% - 18.9% 18.
UNDERSTANDING THE TOUCH SCREEN PRODUCT OVERVIEW Print line The print line shows a graphical representation of the print line selected and displayed in the Line field under the Production tab. The following print line shows a print line composed of a cutter, a printer and an unwinder. The Data Lamp indicates the device that receives the data. It will be green when there is data, red when data is being discarded and grey when no data is available.
PRODUCT OVERVIEW UNDERSTANDING THE TOUCH SCREEN Background colour The device background changes colour and pattern according to the device state and its alignment condition.” The device state determines the background colour. The following table shows the possibilities. Colour Meaning Red - The device is in error. To clear the error, you should refer to the relevant error clearing procedure in the error help. Light Gray - The device is in a Ready state.
UNDERSTANDING THE TOUCH SCREEN PRODUCT OVERVIEW alignment condition changes the background pattern as follows: Some Devices, such as an unwinder, have no alignment state. These devices are always considered as aligned. During a print position check (from start print position check till stop print position check), the printer device is considered as not aligned. Device name For printers, this shows the printer name entered in the Engine>Config. tab.
PRODUCT OVERVIEW UNDERSTANDING THE TOUCH SCREEN Bubble menu A bubble menu will be displayed on the screen whenever you press on a device icon in the print line. The contents of the bubble menu will vary according to the device selected and the status of that device. Press on a device representation to display a bubble menu of commands that can be carried out on that device. Bubble menu command buttons depend on the exact equipment in the print line (See "Bubble menus" on page 4-11).
UNDERSTANDING THE TOUCH SCREEN Window PRODUCT OVERVIEW Description Description window Describes the error or current status. The message shown in this window must be passed on to your service provider when placing a service call. Code window Gives the current error code (see "Clearing errors" on page 9-2). Option window Indicates the status of any installed options. The following can be displayed: Gray box- the option is not present, switched off or the license has expired.
PRODUCT OVERVIEW UNDERSTANDING THE TOUCH SCREEN Action bar buttons The buttons at the bottom of the screen are used to control your printer. Button Description Power button - used for powering the printer engine on and off. When the engine is powered on, the button shows this state and the green LED is lit. When powered off the LED is red. There are two power states: Power on/off - where the engine and the controller are on or off. This is carried out at the Sub-Operator Panel.
UNDERSTANDING THE TOUCH SCREEN PRODUCT OVERVIEW Button Description START button - used to set the printer ready. STOP button - used to set the printer to not ready. Reset button - used for indicating that an error condition has been cleared. This button replaces the START/STOP button. Printer diagram The Printer diagram is an animated representation of the printer. The patrol lamp in the representation will indicate the status of the machine.
PRODUCT OVERVIEW UNDERSTANDING THE TOUCH SCREEN Under the printer diagram, you will find the following icons: • - This icon means that the buzzer is activated. When it is crossed , it means that the buzzer is not activated. See “Making general configurations” on page 3-6. • - This icon means that a high print coverage ratio is selected. When it is crossed , it means that a high print coverage ratio is not selected. See “Running jobs” on page 4-3.
OPERATOR PANELS PRODUCT OVERVIEW Operator panels There are a number of additional operator panels. These are: • Sub-operator panel • Autoload panel • Stacker panel • Paper forward and reverse switch panel Sub-operator panel The sub-operator panel is behind the small door at the upper part on the right side of the printer. Open the small door to use the panel.
PRODUCT OVERVIEW OPERATOR PANELS Name Function Counter This mechanical counter is incremented every 26" of printing. In duplex printing, front and back side prints are counted separately and the combined totals are displayed. The mechanical counter will count every 26" of print length and the Xerox billing system will list total meter "clicks" and show the charger per 26" click. The customer must multiply by 2.17 to get the actual linear feet used.
OPERATOR PANELS PRODUCT OVERVIEW Autoload panel The autoload panel is used to load paper automatically and can be found at the right side of the printer. The components are shown in the following table: Name Emergency switch Page 2-30 Function Effectiveness Hit this switch to stop the printer engine and paper handling devices in the event of an emergency. It requires a key to reset. The emergency switch is for emergency use only. Using this switch may destroy data in the system. Effective always.
PRODUCT OVERVIEW OPERATOR PANELS Name Forms Load Function Load Feeds paper automatically to the stacker table when pressed with paper set on the tractor. This function is called autoload. The main operator panel displays “Autoloading” If paper is set up to the stacker, the paper width is measured. Then the main operator panel displays “Measuring paper width”. Effectiveness Effective when the printer is not operating. While the paper is automatically being loaded, the LED of this switch remains lit.
OPERATOR PANELS PRODUCT OVERVIEW Stacker panel The stacker panel is at the top of the stacker. Open the right stacker door on the front of the printer to use the stacker panel. Paper output selector lever Stacker Panel Paper tension lever The components are shown in the following table: Name Function Printer Start switch This has the same function as the Start button on the touch screen (see page 26).
PRODUCT OVERVIEW OPERATOR PANELS Name Function Paper tension lever Select the position of the lever according to requirements as follows: Lever position Use Standard Ordinary printing (Weak) Using special paper Release Removing a paper jam The lever is set to the weak position when using special paper. Paper forward and reverse switch panel The Paper Forward/Reverse switch is at the upper part on the front of the printer. Name Function Effectiveness Forward Feeds paper 1/6” (4.
PRE- AND POST-PROCESSING EQUIPMENT PRODUCT OVERVIEW Pre- and post-processing equipment Paper input to the printer may come from a pre-processing device such as an unwinder or from a paper box at the hopper. Paper that has been processed can be delivered to an external postprocessing device such as a cutter, folder or rewinder.
PRODUCT OVERVIEW THE PRINT LINE BUS (PLB) The Print Line Bus (PLB) The Print Line Bus (PLB) connects all devices in a defined print line. It is made up of PLB boxes connected to each other. Each PLB box is also connected to a single device. The PLB box is unique to the device to which it is attached. This can be pre- and post-processing devices as well as printers. The defined print line or print line segment will comprise a number of devices, all connected through the PLB.
THE PRINT LINE BUS (PLB) PRODUCT OVERVIEW It doesn’t matter which PLB box in the print line segment provides the power for the PLB, however, each print line segment must have only one source of power. The RS232 connection is used by support personnel to maintain the PLB box. It is also used by the printers to carry communications data. Characteristics The maximum length of PLB cable between the first PLB box and the last is of 100 metres (330 feet). Up to 10 PLB boxes can be networked on the PLB.
PRODUCT OVERVIEW LICENSING Licensing There are two licenses associated with the Xerox 495 Continuous Feed Duplex Printer: • XRX_XE495CF - Without this license the printer is prevented from operating. The license enables you to put an attachment online, to start a job and to make a software upgrade. • XRX_BasicDiagCF - Without this license access to engine diagnostics will not be available to Maintenance or Support users.
LICENSING PRODUCT OVERVIEW The table is divided in three columns. • Feature - If there is a feature name in the current license.dat, the name will appear in this column. • Expiry Date - This column displays the expiry date of the license for each feature recognized. • Status - The licenses can either be: • Active: the license is operational. These licenses are denoted by a green background. • Expiring: the license for this feature is still operational for maximum of 30 days.
3. Getting started This chapter tells you: • How to switch the printer on and off including emergency stop procedures. • How to use the on-line help provided at the touch screen. • Making general configurations • Setting Print Modes • How to change your user role. WARNING Operator tasks identified in this chapter should only be completed if the required training has been given to enable the tasks to be completed without risk or injury.
SWITCHING THE PRINTER ON AND OFF GETTING STARTED Switching the printer on and off Power to the printer can be switched on at the sub-operator panel (Local) or remotely (Remote) from an external device. Local power on and off To switch on the printer: 1. Check that the main power switch is set to ON. The main circuit breaker is situated to the rear of the machine, close to the power cable in the bottom left-hand corner. 2. Open the small door on the right panel to access the sub-operator panel.
GETTING STARTED SWITCHING THE PRINTER ON AND OFF This procedure switches off the printer engine and the controller. To switch off the engine only, press the Power button on the Production screen. Notes: When turning the power off, check that the green lamp of the fuser is lit. It takes up to four and a half minutes until the green lamp at the fuser lights. If the power is turned off immediately after printing, paper may be scorched at the fuser.
SWITCHING THE PRINTER ON AND OFF GETTING STARTED Emergency stop The emergency stop is a strike button mounted above the autoload panel on the right end door of the printer engine. This will force the engine to turn off immediately and execute a controlled shutdown for the controllers. After being activated, a key is needed to reset it. If a pre- or post-processor is attached to the printers emergency power off loop, operating the emergency power of switch on the device will also cause a shutdown.
GETTING STARTED USING HELP Using help Your printer has built-in help, which can be accessed in a number of ways: 1. In the form of a book with a table of contents leading you to the procedure you want to carry out. This is accessed by pressing the button. The links to the procedures are shown in green and underlined. Navigate to the required procedure by pressing the appropriate link. Press the Table of Contents link to start the navigation through the help.
MAKING GENERAL CONFIGURATIONS GETTING STARTED Making general configurations For each printer engine, the Key Operator can give the printer a name and switch the warning buzzer on or off. In addition, the Support user can enter a Customer name to be displayed in the title bar. To make general configuration changes: 1. Press the to make the printer engine Not Ready. 2. Select the Engine tab, then the Config. tab. The Configuration screen is displayed. 3. Select the Printer Name field.
GETTING STARTED MAKING GENERAL CONFIGURATIONS Setting the time on the screen The time displayed on the screen can be changed. This will change the time in the controller and on the screen. To change the time: 1. Press on the time section of the display. A time adjust dialog will be displayed. 2. Press the + button to increment the time by 1 minute or the - button to decrement the time by 1 minute. 3. Continue until you have the desired time displayed. 4.
SETTING PRINT MODES GETTING STARTED Setting print modes Note: The counters referred to in this section are located in the Run view (touch screen) and not the mechanical counter on the sub-operator panel. The mechanical counter counts drum rotations and not pages. The Print Mode tab is provided to enable or disable the following print mode features: • The Both Side Printing Enabled box – when checked, this enables duplex printing.
GETTING STARTED SETTING PRINT MODES indicated number. The printer will then stop, cutting the second engine. After approximately. one minute, the printer will restart in simplex mode and 1 page will be added each time to the counter. • When a duplex job is received after a simplex job, the printer will stop and then initialize the second engine. This can take up to 6 minutes. Once printing, 2 pages will be added each time to the counter. • If the value is zero, then simplex mode is disabled.
CHANGING USER ROLES GETTING STARTED Changing user roles There are four user roles defined: Operator, Key Operator, Maintenance and Support. When the machine is first switched on or after a timeout period specified for all other users, touch screen access reverts to the Operator User. All users other than Operator have a password controlled access to the facilities available. Note: The current user role is shown on the top right of the screen.
GETTING STARTED CHANGING USER ROLES Setting locked components The notebook can be locked or unlocked by Key Operators in order to prevent Operator access to any or all features available in the Notebook. When the machine starts up for the first time, the Notebook will be closed with the cover displayed. To change Operator access: 1. Select the Users tab. The Users screen is displayed. 2. Press the Key Operator button and enter your password. 3. Press the button.
CHANGING USER ROLES GETTING STARTED 4. Check each box where you want to allow operator access to the Notebook. 5. Press . Changing the password To change your password: 1. Change to your user role and enter your existing password. 2. Press the password button corresponding to your role. 3. Enter and confirm your new password. The next time that you change to your role, you will need to use the new password.
GETTING STARTED CHANGING USER ROLES The Users screen is displayed. 2. Press the Language button. 3. Choose the language. 4. Press Xerox 495 Continuous Feed Duplex Printer Operator Guide .
CHANGING USER ROLES Page 3-14 GETTING STARTED Xerox 495 Continuous Feed Duplex Printer Operator Guide
4. Running production jobs This chapter describes the procedures used for running production jobs. The contents are: • Quick start - a checklist for experienced Operators. • Running jobs - step-by-step instructions. • Cancelling jobs WARNING Operator tasks identified in this chapter should only be completed if the required training has been given to enable the tasks to be completed without risk or injury.
QUICK START RUNNING PRODUCTION JOBS Quick start The following is a simplified method for starting a new job. Note: You should follow the full procedures if you are new to the printer or unsure of what to do. 1. Eject the paper and remove the completed job from the output device if you want to use a paper different from the one currently being used. If the paper has been output to a pre- or post-processing device see the appropriate user manual.
RUNNING PRODUCTION JOBS RUNNING JOBS Running jobs 1. Select the Production tab. The Production screen is displayed. This is the normal screen when printing and will be the opening screen. The facilities on this tab are available to all users. Note: The Notebook area in the illustration shown below has been unlocked by the Key Operator enabling Operator level users to adjust a number of items relating to the job to be run. See “Changing the notebook settings” on page 4-6..
RUNNING JOBS RUNNING PRODUCTION JOBS Application definitions with respect to their original configuration. Note: Before you can switch between Job and Application, you must first select OFFLINE for Attachment. • Paper pull-down list - this is used to choose the name of the paper previously defined under the Definitions>Paper tab. An asterisk (*) is displayed to the right of the name for any modification made to Paper Thickness value through the Notebook or through the Definitions tab.
RUNNING PRODUCTION JOBS RUNNING JOBS is solely done by the printer and not recognized by the host computer. Therefore, if a paper jam occurs, a duplicate page may be printed as the recovery page. • Line pull-down list - this is used to choose the name of the Line system previously created under the Definitions > Line tab. The print line will change to reflect the components of the chosen line and the status of each of the components. Note: You must deselect the attachment before you choose a new line.
RUNNING JOBS RUNNING PRODUCTION JOBS 7. Check that the correct paper is loaded in the printer (see "Paper Loading" on page 5-3). 8. Set the Check Output value. 9. Press the button to set the printer to a ready state. The job will be printed once the host has sent it. Changing the notebook settings Notebook settings are provided to change certain parameters set in a job definition. Note: You can only change settings here if you are the Key Operator, or if the Key Operator has provided you with access.
RUNNING PRODUCTION JOBS RUNNING JOBS Notebook paper settings The paper settings page of the notebook deals with the settings for the different grades of paper and is shown in the following illustration. Paper Size button Paper Thickness circular list Paper Size button - displays the paper size defined for the job. Paper Thickness circular list - is used to choose the paper thickness (thin or thick).
RUNNING JOBS RUNNING PRODUCTION JOBS down list for any modification to the margins with respect to the original configuration. The settings can be entered in millimeters or inches by pressing the corresponding buttons. The 0 button resets the offset to 0. The settings made will be displayed in the Offset display to the right of the arrows. Notebook density settings This page displays a density cursor for both sides of the paper and is used to set the image density for both sides.
RUNNING PRODUCTION JOBS RUNNING JOBS Offset buttons allow you to precisely position on the sheet where the logical pages (data) will be printed. This is especially useful when using pre-printed paper. The left offset button is used to position the logical page on the left side of the sheet. The right offset button is used to position the logical page on the right side of the sheet.
RUNNING JOBS RUNNING PRODUCTION JOBS step 7. 3. If the number of pages to print for preview needs to be modified, press the counter button. This opens a touch screen keyboard. 4. Enter the number of pages to be printed (between 1 and 999). 5. Press the button. 6. Alternatively, press the Cancel button to keep the value of the previous number of pages. You will return to the Production tab, the number of pages to be printed will be displayed inside the counter, and the feature is enabled. 7.
RUNNING PRODUCTION JOBS RUNNING JOBS printed. The counter is reset to its original setting. 11. Press the button to return to the state where the feature is enabled and accessible but not active. The printer goes back to NOT READY. Bubble menus A bubble menu will be displayed when you press on a component in the print line diagram. The menu contents will vary according to the equipment chosen. The menu contains action buttons and status indicators.
RUNNING JOBS RUNNING PRODUCTION JOBS Bubble menu possibilities Bubble menu command buttons depend on the exact equipment in the print line. The following bubble menu command buttons are available for the printer. • Toggle button Start Print Position Check / Stop Print Position Check: • Start Print Position Check - When you press this button, paper is forwarded to the stacker and the stacker automatically lowers. This allows you to check the printing status on the stacker table.
RUNNING PRODUCTION JOBS RUNNING JOBS if you go to the bubble menu and press Release when the Unwinder is powered off, the paper will start moving and finally provoke a jam, because it breaks or tears. • Load or Load & Align - This action is usually performed when installing new paper, after changing paper, or after clearing a paper jam/break. The Load button will appear for devices that do not need to be aligned, (folders, for example).
CANCELLING JOBS RUNNING PRODUCTION JOBS Cancelling jobs The Cancel button is used to interrupt print jobs from the host system or to cancel a Print Position Check. Cancelling a print job When the Cancel button is pressed during a print job, the following dialog box will be displayed: • Press the Discard Buffers button to stop the current print job and discard all pending print buffers from the printer leaving the job in the host job queue.
5. Paper path This chapter describes how to load paper into the printer and how to make adjustments to the paper path components. WARNING Operator tasks identified in this chapter should only be completed if the required training has been given to enable the tasks to be completed without risk or injury. WARNING When completing any of the tasks in this chapter, observe all applicable warnings as indicated in the user precautions.
EJECTING PAPER FROM THE PRINTER PAPER PATH Ejecting paper from the printer Ejection can take place using either of the Eject buttons on the action bar at the bottom of the touch screen. In addition, you can eject paper using a selection from the bubble menu associated with a device. The Eject button only works for the device from which the eject is requested and affects the whole print line. The possibilities are: The Eject one page button moves the paper on by one sheet for each press.
PAPER PATH PAPER LOADING Paper Loading Paper loading is a two-stage procedure. 1. The paper is loaded on the hopper. 2. The paper is autoloaded. Loading on the hopper To load paper in the hopper: 1. Remove the paper from the printer (see "Removing Paper" on page 5-12). 2. Check that the stacker components are in the following state: • There is no paper left on the stacker table and the Table Auto switch is set. • The paper tension lever is set at a suitable position for the new paper.
PAPER LOADING PAPER PATH • Press the right-side guide against the right side of the paper box. • Turn the knob to secure the right-side guide. 4. For paper coming from a pre-processing device, feed the paper to the hopper. Paper autoloading Autoloading moves the paper from the hopper and positions it ready for printing. To autoload the paper: 1. Prepare the leading edge of the paper as shown in the following diagram.
PAPER PATH PAPER LOADING 2. Thread the paper through the decurler and brush.
PAPER LOADING PAPER PATH 3. Open the tractor covers. Tractor Covers Tractor Adjuster Rear Tractor Pins Tractor Cover (open) Front Tractor Pins PAPER EDGE LINE 4. Align the paper end with the paper edge line (white line located underneath the paper) on the tractor and insert the sprocket holes of the paper onto the front tractor pins. 5. Adjust the rear tractor pins to the paper width (rear sprocket holes) by turning the tractor adjuster.
PAPER PATH PAPER LOADING 6. Check that the sprocket holes of the paper are correctly inserted onto the front tractor pins, then close the tractor covers. 7. Check that the brush is down. Brush Paper Decurler 8. Check that the decurler is released (on the Standard label side). 9. Check that the supplementary table lever is towards the Printing side and the table is down. Note: The decurler is provided for the following special situations: a.
PAPER LOADING PAPER PATH The display shows the folding length in inches and the perforation number will be recalculated and displayed. 11. Press the Load switch on the autoload panel. The paper is automatically fed to the stacker through the transfer unit and fuser to complete the initial setup. If the paper jams during loading, press the Cancel switch on the autoload panel to stop autoloading, clear the paper jam then try again (see "Clearing paper jams" on page 9-3.
PAPER PATH SETTING THE PERFORATION POSITION Setting the perforation position After a paper jam has been removed or if the paper position is changed with the Forward or Reverse switch, you will need to set the perforation position. Note: This operation is not necessary at ordinary autoloading or during automatic switching mode (e.g. changing from simplex to duplex). The paper moves automatically to the correct position before starting to print. To set the paper position: 1.
SETTING THE PERFORATION POSITION PAPER PATH 4. Set the supplementary table lever to the Align Perforation side. Supplementary table Supplementary table lever 5. Move the perforation position according to the scale on the supplementary table. Scale 6. Press the Fold-out/in Select switch and set the lever to the Print side to lower the supplementary table.
PAPER PATH CUTTING PAPER Cutting paper If it is necessary to cut the paper, cut it outside the decurler.
REMOVING PAPER PAPER PATH Removing Paper 1. To completely remove the paper, cut it at the hopper (see "Cutting paper" on page 5-11). 2. Press the Eject button located on the touch screen action bar. 3. Press the Stacker Down button on the stacker control panel. The table stops at the paper removal position. 4. Pull down and fold the paper. 5. Pull the stacker table out using the handles. 6.
PAPER PATH REMOVING PAPER When the stacker table goes up (1), the paper may move to the right or left (2) and hit the guides (3). This is not good and the printer will fall into the error “Form length guide held up.” To correct the error, the paper on the stacker table must be readjusted. 9. Press the Stacker Down button on the stacker control panel. 10. Adjust the paper by pressing it against the right side of the stacker. 11. Set the table switch to Auto. 12. Cloose the right stacker door. 13.
CHECKING PRINTING PAPER PATH Checking printing The printer is capable of checking both the front-side and back-side print quality and position (see "Front and back marking units" on page 2-2). These can be monitored by: • Checking the printed paper • Checking at the printing check position • Using the printing position check function Checking printed paper 1. Stop printing after several pages and press the Eject button on the touch screen to eject the prints in the stacker. 2.
PAPER PATH CHECKING PRINTING Check by the printing position check function Feed prints from the printer into the stacker table and check the printing status. After checking, return the paper to the original printing position and restart printing from the page after the last confirmed print. 1. Print a necessary number of sheets for checking. 2. Open the bubble menu for the printer device and press the Start Print Position Check command.
LOADING PAPER TO A POST-PROCESSING DEVICE PAPER PATH Loading paper to a post-processing device To load paper to a post-processing device: 1. Turn the paper output selector lever in the stacker to the External position. Paper output selector lever 2. Press Load in the bubble menu to release enough paper for the postprocessing device. Note: If insufficient paper is ejected, then the distance between devices has not been properly set during the definition of the print line.
6. Adjusting print quality These settings should be made during the definition of a job and recalled when the job is run (see "Defining applications" on page 7-12). The setting for the individual marking units can be made locally using the Notebook settings, if they are made available to you. These changes are made by selecting one of the five possible settings defined for the job (see "Notebook offsets" on page 4-7). Print density affects toner consumption and fusing.
ADJUSTING PRINT QUALITY Page 6-2 Xerox 495 Continuous Feed Duplex Printer Operator Guide
7. Defining production jobs This chapter contains the procedures for creating jobs. All of the screens are accessed under the Definitions tab, the facilities of which are available to the Key Operator level User and above. To create a new job, the paper to be used must be defined and must be available. The printing application must have been created at a system level in order to be able to carry out tests.
QUICK START DEFINING PRODUCTION JOBS Quick start There are seven steps for creating a job: Step Checking the existence of a job Actions 1. Select the Job tab and press the press to use the search facility. Defining a new job 1. Select the Job tab, create a new job and choose the name of the paper and application that you have just created (or others since several jobs can use the same paper, for example). 2. Press the diskette icon, then select the Write As field. 3.
DEFINING PRODUCTION JOBS CHECKING THE EXISTENCE OF A JOB Checking the existence of a job 1. Select the Definitions tab, then the Job tab. 2. Press the icon on the top left of the Job pull-down list to display the search facility. The scroll down list on the right shows all of the entries from which you can choose a Job selection. 3. Use the keyboard to enter all or part of the Job name. The Job name will be highlighted as soon as sufficient information is entered. 4.
DEFINING A JOB DEFINING PRODUCTION JOBS Defining a job Before you can create a job, you will need to define: • The paper See “Defining paper characteristics” on page 7.. • The application See “Defining applications” on page 12.. Note: To define a job you must have the User status of Key Operator or higher. A job definition determines the previously defined characteristics for the paper and application that will be used to run a job.
DEFINING PRODUCTION JOBS DEFINING A JOB 2. Press the button to create a new job or choose an existing job from the pull-down list. 3. Choose the required Paper from the pull-down list. This list has the names of each paper definition previously created in the Paper screen. 4. Choose the required Application from the pull-down list. This list has the names of each application definition previously created in the Application screen. 5. Press the button to save the current job.
DEFINING A JOB DEFINING PRODUCTION JOBS Importing a job definition from the Production screen The job definitions can all be amended from the Production screen. You may want to create or amend the job definition from the settings there. To create or amend a job from a production job: 1. Select the Definitions tab, then the Job tab. 2. Press the button to import the job parameters from the current Production screen. The parameters set in the Production screen are then applied to the Job screen.
DEFINING PRODUCTION JOBS DEFINING PAPER CHARACTERISTICS Defining paper characteristics To define paper characteristics you must have the User status of Key Operator or higher. A paper definition determines the printer characteristics that will be applied to the paper.
DEFINING PAPER CHARACTERISTICS DEFINING PRODUCTION JOBS The Paper Dimensions screen is displayed. 5. Select the Length field, type in the length, then press the inch or mm button according to whether you have entered the length in inches or millimeters. However, you should be aware of the following restrictions: When printing to an internal stacker, the GUI range is from 7 to 14 inches (177.8 to 355.
DEFINING PRODUCTION JOBS DEFINING PAPER CHARACTERISTICS GUI width that is equal to or within the range of the width measured by the IOT ± a tolerance of 1/6 inch. In this case, the IOT value is used. If you do not place a tick in the Paper Width Checked box, take the following into consideration: • You must enter a GUI width that is equal to or within the range of the width measured by the IOT ± the tolerance. In this case, the IOT value is used.
DEFINING PAPER CHARACTERISTICS DEFINING PRODUCTION JOBS 10. Press the button to save the current paper definition. The Save screen containing the list of existing paper definitions is displayed. 11. For a new paper definition, select the Write As field, enter a name for the paper definition using the alphanumeric keyboard and press the Enter button. 12. Press on the Save screen.
DEFINING PRODUCTION JOBS DEFINING PAPER CHARACTERISTICS 2. Press the button to import the paper definition from the current Production screen. The parameters set in the Production screen are then applied to the Paper screen. Importing is impossible if the paper definition is in the process of modification or if it has the same name as that on the Paper screen. 3. Press the button to save the current paper definition. The Save screen containing the list of existing paper definitions is displayed. 4.
DEFINING APPLICATIONS DEFINING PRODUCTION JOBS Defining applications Note: To define an application you must have the User status of Key Operator or higher. An application definition determines the way that the printed data appears on the page. The Default Application configuration is as follows: • Emulation pull-down list - IPDS • Resolution cursor - 240 • Paper width checked box - Checked. • Offset arrows - 0, 0. • Density - level 1 is 8, 2 is 9, 3 is 10, 4 is 11 and 5 is 12. • 2-up -None.
DEFINING PRODUCTION JOBS DEFINING APPLICATIONS 2. Press the Main tab. 3. Press the button to create a new application or choose an existing Application from the pull-down list. 4. Select the required Emulation from the pull-down list. The current available emulation is IPDS. 5. Select the required Resolution from the pull-down list. The choices of resolution are 240, 300 or 600.
DEFINING APPLICATIONS DEFINING PRODUCTION JOBS 7. Press the Offset tab. 8. For each marking unit, press the Offset arrows to position the print on the page. You can choose to define your margins in inches or in millimeters by pressing the appropriate buttons. The 0 button sets the margins to 0. Offsets can also be directly defined or changed in the Notebook of each printer used in the print line.
DEFINING PRODUCTION JOBS DEFINING APPLICATIONS 9. Press the Density tab. Each marking unit has 5 density levels, which can be set from the Density tab. Each of these 5 density levels has 15 contrast levels, which can also be set from the Density tab. A contrast level of 1 is the lightest, while a contrast level of 15 is the darkest. In the Notebook, each density level can be preset to a particular contrast level. To set each density level, first press the left or right arrows on the density level cursor.
DEFINING APPLICATIONS DEFINING PRODUCTION JOBS setting. When you select a contrast between 1 and 7, or between 13 and 15, a warning icon will display to the right of the density level cursor. This is because you have moved outside the default values, between 8 and 12. Press the Default button to restore 1 to 8, 2 to 9, 3 to 10, 4 to 11 and 5 to 12. 10. Press the 2-up tab. Note: The illustration above shows the 2-up selection for the front side with the back side tab grayed out.
DEFINING PRODUCTION JOBS DEFINING APPLICATIONS between -0.5” and +0.5” (-12.7mm and +12.7mm). Offset buttons allow you to precisely position on the sheet where the logical pages (data) will be printed. This is especially useful when using pre-printed paper. The left offset button is used to position the logical page on the left side of the sheet. The right offset button is used to position the logical page on the right side of the sheet.
DEFINING APPLICATIONS DEFINING PRODUCTION JOBS This allows you to request the position of the command sheet when it reaches the stacker. Normal Front - When a stack is removed from the stacker, the command sheet is facing down. The stack must be turned 180 degrees for the command sheet to face up. Reverse Back - When a stack is removed from the stacker, the command sheet is facing up. 17. Press the Line Mode tab. The Line Mode screen is displayed.
DEFINING PRODUCTION JOBS DEFINING APPLICATIONS place on each printed page. Flash overlays can be imported from floppy disc or CD (see "Importing flash overlays" on page 7-34). The settings can be entered in millimeters or inches by pressing the corresponding buttons. The 0 button resets the margins to 0. Settings made will be displayed in the Offset display to the right of the arrows. 22. Press the button to save the current application.
DEFINING APPLICATIONS DEFINING PRODUCTION JOBS Importing an application definition from the Production screen The application definitions can all be amended from the Production screen. You may want to create or amend the application definition from the settings there. To create or amend an application from a production application: 1. Select the Definitions tab, then the Application tab. 2. Press the button to import the application parameters from the current Production screen.
DEFINING PRODUCTION JOBS DEFINING A PAPER PATH Defining a paper path Note: To define a paper path you must have the User status of Key Operator or higher. A line definition determines the print line to be used. The print line is the printer and the pre- and post-processing equipment used. A line is created by dragging and dropping a representation of the device from the selection on a pull-down list to a representation of the whole print line.
DEFINING A PAPER PATH DEFINING PRODUCTION JOBS 4. Press on the device icon and, keeping your finger on the screen, drag it to the line representation being created. The added device interlocks with the existing devices in the position chosen. Note: You can only add the device to the appropriate end of the printer. To delete an item from the line, drag the item from the line. The representation changes to a waste bin. Drag the item to the waste bin to remove it from the line. 5.
DEFINING PRODUCTION JOBS DEFINING A PAPER PATH 8. Press the button to save the current line. The Save screen containing the list of existing lines is displayed. 9. For a new line, select the Write Line As field, enter a name for the line using the alphanumeric keyboard and press the Enter button. 10. Press on the Save screen. Note: When you press , you will be prompted to confirm whether you want to replace an existing definition if it already exists.
DEFINING A PAPER PATH DEFINING PRODUCTION JOBS Reviewing installed devices You can review the settings for any device from the Device tab. 1. Select the Definitions tab, the Line tab, then the Device tab. 2. Choose a Device from the pull-down list. Details of the device are shown on the screen. Note: Only devices defined for your configuration are listed. Once you have selected a device, the image changes and details of that device are displayed.
DEFINING PRODUCTION JOBS DEFINING A PAPER PATH an existing Marks definition from the pull-down list. A table showing details of the marks is shown on the screen. • The X position is the distance from the edge of the paper nearest the front of the machine. • The Y position is the distance from the leading edge of the paper. • The W is the width of the mark measured from front to back of the machine. The maximum value is 18 inches (457.2mm).
DEFINING A PAPER PATH DEFINING PRODUCTION JOBS The marks entry screen is displayed. 4. Press the side icon, front or back(see "Front and back marking units" on page 2-2) on the lower left side of the tab window until the appropriate side is displayed (back is shown in the illustration above). 5. For each dimension, press the appropriate button and enter the value using the keypad. 6. Press the Inch or the mm buttons to choose the measurement units to be used (1 inch = 25.4mm). 7.
DEFINING PRODUCTION JOBS DEFINING A PAPER PATH Enter button. 12. Press on the Save screen. Note: When you press , you will be prompted to confirm whether you want to replace an existing definition if it already exists. Deleting a marks definition To delete a marks definition: 1. Select the Definitions tab, the Line tab, then the Marks tab. 2. Choose a Marks definition from the pull-down list. 3. Press the button to delete the marks definition.
DEFINING THE ATTACHMENT DEFINING PRODUCTION JOBS Defining the attachment There are two types of attachment, IBM Channel and TCP/IP. Note: To define a Channel or TCP/IP attachment you must have the User status of Key Operator or higher. To define a File attachment, you must be a Maintenance or Support user. An attachment definition determines the way in which the attached host system is connected.
DEFINING PRODUCTION JOBS DEFINING THE ATTACHMENT 3. Press the Physical Port radio button corresponding to the system to which your printer is attached. This is Channel A or Channel B. 4. Select the required Emulation from the pull-down list. The current emulation is IPDS. 5. Press the Channel Address field. A dialog box opens up. 6. Enter the physical address of the channel to which your printer is connected (from 00 to FF in hexadecimal) on the keyboard. 7. Press . 8.
DEFINING THE ATTACHMENT DEFINING PRODUCTION JOBS attachment using the alphanumeric keyboard and press the button. 11. Press on the Save screen. Note: When you press , you will be prompted to confirm whether you want to replace an existing definition if it already exists. For immediate use the new definition will need to be exported to the Production screen where it will be selected (see "Exporting an attachment definition to the Production screen" on page 7-33).
DEFINING PRODUCTION JOBS DEFINING THE ATTACHMENT 3. Select the required Emulation from the pull-down list. The current available emulation is IPDS. 4. Press the TCP Port field to insert a new port or leave the default one as it is. 5. Use the window keyboard to enter your selection then press .
DEFINING THE ATTACHMENT DEFINING PRODUCTION JOBS Default Gateway fields will open up a dialog box upon selection. 6. Press the IP Address field to insert a new address or leave as default. 7. Press the Subnet Mask field to insert a new mask or leave as default. 8. Press the Default Gateway field to insert a gateway or leave as default. 9. In the Link box, select the appropriate link. Select only the link that is currently indicated as “Present”. 10. Press the button to save the current line attachment.
DEFINING PRODUCTION JOBS DEFINING THE ATTACHMENT Copying an attachment definition If you want a copy of the attachment definition, select an attachment definition on the Attachment tab and use the Write As feature to rename it. The name of the selected definition will be displayed and highlighted. To enter a new name, use the alphanumeric keyboard or press << to clear the field and enter the name.
IMPORTING FLASH OVERLAYS DEFINING PRODUCTION JOBS Importing flash overlays A flash overlay is a bitmap image that will be placed in the same place on each printed page. Flash overlays can be imported from a CD. Once imported, they can be renamed or deleted from the system. Flash overlays can only be used in Line Mode (option) emulations. 1. Open the left stacker door of the printer. A black blanking panel is located in front of the Stampa PC.
DEFINING PRODUCTION JOBS IMPORTING FLASH OVERLAYS 4. Select the Tools tab, then the Resident tab. 5. Press . 6. Navigate to where the overlays are located. 7. Choose the overlays to import. Note: You can select multiple files as long as they are consecutive. To do this, touch the screen to the right of the first file, keep your finger on the screen and drag it left across that file name. With your finger still on the screen, drag it down the list until all of the names are highlighted. 2.
IMPORTING FLASH OVERLAYS DEFINING PRODUCTION JOBS 9. Remove the CD from the CD-ROM drive of the Stampa PC. 10. Move the sliding door back into place and fix the top left screw. 11. Close the left stacker door. To delete a flash overlay: 1. Select the Tools tab, then the Resident tab. 2. Select the file that you want to delete. 3. Press . 4. Confirm the deletion. To rename a flash overlay: 1. Select the Tools tab, then the Resident tab. 2. Select the file that you to rename. 3. Press the Rename button.
DEFINING PRODUCTION JOBS VALID PRINT AREA (VPA) Valid print area (VPA) The data will be printed centrally on the page with a margin of 0.5 inches (12.7mm) either side. This is called the Valid Print Area (VPA). If the page is offset in the Notebook or on the Application > Offset tab so that the data moves into the margin, the image will be clipped. Processing marks can be placed outside the VPA with the following limitations Non-print area Processing marks can be printed in this area 0.5” (12.7mm) 0.
VALID PRINT AREA (VPA) Page 7-38 DEFINING PRODUCTION JOBS Xerox 495 Continuous Feed Duplex Printer Operator Guide
8. Performing routine maintenance This chapter contains the routine maintenance procedures for the printer. The Operator tasks are listed on the next page with a cross reference to where the procedures for those tasks can be found. WARNING Operator tasks identified in this chapter should only be completed if the required training has been given to enable the tasks to be completed without risk or injury.
OPERATOR TASKS PERFORMING ROUTINE MAINTENANCE Operator tasks Operator tasks are as follows with the frequencies. Items Frequency As required for normal operation Loading and removing the paper (see "Paper Loading" on page 5-3). As required or with Error Code 01-01 or 02-01 Adjusting the print contrast (see "Adjusting print quality" on page 6-1). At each operation Consumable replacement Replacing the toner (see "Replacing the toner" on page 8-6).
PERFORMING ROUTINE MAINTENANCE ORDERING SUPPLIES Ordering Supplies Various supplies are available for the printer. To obtain supplies, contact your local Xerox office, giving your company name, the product number and its serial number. Use the spaces below to keep a record of the telephone number and machine serial number. Supplies Telephone Number: ............................................................. Serial Number: .............................................................
CHECKING CONSUMABLE USE PERFORMING ROUTINE MAINTENANCE Checking consumable use The Consumables view provides details of the use of the printer's consumable items. Refer to the procedure in this Operator Guide to determine whether you are permitted to replace the item. If no procedure exists in this Guide, then it is not operator replaceable.
PERFORMING ROUTINE MAINTENANCE CHECKING CONSUMABLE USE there is sufficient life remaining. • Orange - means that the consumable is nearing its end of life. • Red - means that the life of the consumable has expired. An error message will be displayed and, to continue, you will have to replace the consumable. When several consumables need to be changed simultaneously, there is no particular order for their replacement. 2.
REPLACING THE TONER PERFORMING ROUTINE MAINTENANCE Replacing the toner An error Code 04-01 or 04-02 is displayed and the patrol lamp flashes green and yellow when a toner reservoir is low. The code is displayed for both front and back toner reservoirs Note: Do not add toner if the printer does not require it. CAUTION Keep toner away from your eyes or mouth. If the toner gets on your skin during replacement, immediately wash it off.
PERFORMING ROUTINE MAINTENANCE REPLACING THE TONER receptacle and push it in fully. Toner Cassette 5. Lift the toner cassette lock lever to secure the toner cassette. Toner Cassette Lock Lever Seal Entry Port Lid 6. Pull out the entry port lid. 7. Slowly pull forward the seal at the lower part of the toner cassette to remove it from the cassette. Seal 8. Check that the toner has totally dropped and that the seal did not break.
REPLACING THE TONER PERFORMING ROUTINE MAINTENANCE 9. Push in the entry port lid fully. Entry Port Lid 10. Lower the toner cassette lock lever. Toner Cassette Lock Lever 11. Remove the empty toner cassette by sliding it back out of the toner cassette holder. Note: Keep the empty toner cassette and use it at a later stage as a toner collector. 12. Close the left and right printer doors. 13. Press the button on right of the touch screen to confirm the change and to return to the consumables view.
PERFORMING ROUTINE MAINTENANCE REPLACING THE TONER Replacing Toner [Kb] To replace the toner for the back marking unit, proceed as follows: 1. Press the button to switch to the consumables view which shows the usage of all consumables and press the Change button beside Toner [Kb] in the Back box. The consumables replacement screen for Toner [Kb] will be displayed. 2. Open the right and left printer doors. 3. Check that the Toner [Kb] LED is flashing. Toner Entry Port [Kb] Toner Cassette Receptacle 4.
REPLACING THE TONER PERFORMING ROUTINE MAINTENANCE 5. Lift the toner cassette lock lever to secure the toner cassette. Toner Cassette Lock Lever Seal Entry Port Lid 6. Pull out the entry port lid. 7. Slowly pull forward the seal at the lower part of the toner cassette to remove it from the cassette. Seal 8. Check that the toner has totally dropped and that the seal did not break. 9. Push in the entry port lid fully.
PERFORMING ROUTINE MAINTENANCE REPLACING THE TONER 10. Lower the toner cassette lock lever. Toner Cassette Lock Lever 11. Remove the empty toner cassette by sliding it back out of the toner cassette holder. Note: Keep the empty toner cassette and use it at a later stage as a toner collector. 12. Close the right front door of the printer. 13. Press the button on the right of the touch screen to confirm the change and to return to the consumables view.
REPLACING THE DEVELOPER PERFORMING ROUTINE MAINTENANCE Replacing the developer There is a counter linked to developer life. An Error Code 06-01 or 06-02 is automatically displayed when the counter reaches its theoretical replacement value. As a rule, you should only change the developer when the Error Code is displayed. However, if a particular application requires better print quality, you can change the developer before its normal end of life by following the same procedure.
PERFORMING ROUTINE MAINTENANCE REPLACING THE ROLLER UNIT Replacing the roller unit There is a counter linked to the life of both roller A and roller B. An Error Code 03-01 or 03-03 is automatically displayed when either roller reaches its theoretical replacement value. Do not damage the guide roller surface of the roller unit. The roller unit is a guide roller with a cleaner. The guide roller surface has a special coating. Damaging the surface may result in dirty printing.
REPLACING THE ROLLER UNIT PERFORMING ROUTINE MAINTENANCE 4. Loosen the thumbscrew on the left of Roller unit A[R1a]. Roller unit A[R1a] Thumbscrew 5. Grasp the handle of Roller unit A[R1a] and pull the unit out fully. Waste Toner Cap Guide Roller CAUTION Do not touch the waste toner cap of the roller unit, as it may open and cause the toner to scatter. 6. Line up the guides of the new roller unit with those of the transfer unit and insert the roller unit fully.
PERFORMING ROUTINE MAINTENANCE REPLACING THE ROLLER UNIT CAUTION Do not damage the guide roller of the new roller unit. 7. Tighten the thumbscrew to secure the unit. 8. Turn the lever of transfer unit A in a clockwise direction to close the transfer unit, and then push the handle in. 9. Close the internal door and the right and left printer doors. 10. Press the button on the right of the touch screen to confirm the change and to return to the consumables view.
REPLACING THE ROLLER UNIT PERFORMING ROUTINE MAINTENANCE clockwise direction, to open the Roller Unit B[R1b] fully. Thumbscrew Retraction Lever Roller Unit B[R1b] Drum Unit A 4. Loosen the green thumbscrew on the right of roller unit B[R1b]. 5. Grasp the handle of roller unit B[R1b] and pull the unit out fully. Waste Toner Cap Guide Roller CAUTION Do not touch the waste toner cap of the roller unit, as it may open and cause the toner to scatter. 6. Insert the roller unit fully.
PERFORMING ROUTINE MAINTENANCE REPLACING THE ROLLER UNIT CAUTION Do not to damage the guide roller of the new roller unit. 7. Tighten the thumbscrew to secure the unit. 8. Turn the retraction lever of roller unit B[R1b] in a 90 degrees counterclockwise direction, to return the unit to the set position. 9. Close the internal door and the right and left printer doors. 10. Press the button on right of the touch screen to confirm the change and to return to the consumables view.
REPLACING THE CLEANER BRUSH AND BLADE PERFORMING ROUTINE MAINTENANCE Replacing the cleaner brush and blade There is a counter linked to the cleaning brush and blade life. An Error Code 0A-03 or 0A-04 is automatically displayed when the counter reaches its theoretical replacement value. CAUTION Keep toner away from your eyes or mouth. If the toner gets on your skin during replacement, immediately wash it off. Prolonged inhalation of excessive amounts of toner particles may cause lung damage.
PERFORMING ROUTINE MAINTENANCE REPLACING THE CLEANER BRUSH AND BLADE 6. Remove the cover and store it temporarily in a safe place. Cleaner Brush cover A[R3a] 7. Place the disposal bag (attached to kit A[R3a]) at the entry of the cleaner brush slot. Disposal Bag 8. Hold the collection bar bonded inside the bag and push it into the cleaner brush core rod. Disposal Bag Cleaner Brush Core Rod Collection Bar 9.
REPLACING THE CLEANER BRUSH AND BLADE PERFORMING ROUTINE MAINTENANCE gather the toner into the disposal bag. Cleaner Brush 10. Remove the mouth of the disposal bag from the brush slot. 11. Hold the handle of the new cleaner brush and insert the brush fully into the brush slot. 12. Hold the knob of cleaner blade A and pull it towards you. Cleaner Blade A 13. Insert the new cleaner blade A, making sure that is positioned correctly in the guides.
PERFORMING ROUTINE MAINTENANCE REPLACING THE CLEANER BRUSH AND BLADE 15. Close the internal door, then the left and right printer doors. 16. Press the button on the right of the touch screen to confirm the change and to return to the consumables view. Replacing kit B[R3b] To replace cleaner brush and blade kit B[R3b], proceed as follows: 1. Press the button to switch to the consumables view which shows the usage of all consumables and press the Change button beside Kit B[R3b] in the Back box.
REPLACING THE CLEANER BRUSH AND BLADE PERFORMING ROUTINE MAINTENANCE cleaner brush slot. Disposal Bag 8. Hold the collection bar bonded inside the bag and push it into the cleaner brush core rod. Disposal Bag Cleaner Brush Core Rod Collection Bar 9. Extract the collection bar gradually, along with the cleaner brush, to gather the toner into the disposal bag. Cleaner Brush 10. Remove the mouth of the disposal bag from the brush slot. 11.
PERFORMING ROUTINE MAINTENANCE REPLACING THE CLEANER BRUSH AND BLADE 12. Hold the knob of cleaner blade B and pull it towards you. Cleaner Blade B 13. Insert the new cleaner blade B, keeping it making sure that is positioned correctly in the guides. New Cleaner Blade B CAUTION Do not wipe the white powder from the cleaner blade. 14. Attach cleaner brush cover B[R3b] and tighten the thumbscrews to secure. 15. Close the internal door, then the left and right printer doors. 16.
REPLACING THE TONER COLLECTOR PERFORMING ROUTINE MAINTENANCE Replacing the toner collector The toner collector must be replaced when Error Code 05-01 is displayed. CAUTION Keep toner away from your eyes or mouth. If the toner gets on your skin during replacement, immediately wash it off. Prolonged inhalation of excessive amounts of toner particles may cause lung damage. If this occurs, consult a doctor immediately.
PERFORMING ROUTINE MAINTENANCE REPLACING THE TONER COLLECTOR 4. Slide the lid of the toner collector to close. Lid 5. Discard the toner collector using the attached vinyl bag. 6. Slide the lid of the new toner collector to open. Lid 7. Bend the ledge of the lid at the notch. 8. Attach the new toner collector by sliding it slowly into place. Note: Whenever you replenish the toner, keep the empty toner cassette to use as a toner collector. 9. Close the waste toner collector door. 10.
REPLACING THE SMOKE FILTER PERFORMING ROUTINE MAINTENANCE Replacing the smoke filter The smoke filter must be replaced when Error Code 0B-01 is displayed. To replace the smoke filter, proceed as follows: 1. Press the button to switch to the consumables view which shows the usage of all consumables and press the Change button beside Smoke Filter. The consumables replacement screen for the smoke filter will be displayed. 2. Open the left stacker door. 3. Open the smoke filter door.
PERFORMING ROUTINE MAINTENANCE CLEANING THE MACHINE Cleaning the machine Three areas of the machine should be cleaned on a regular basis. These are: • The fuser glass (front and back). • The Toner supply and collector areas. • The touch screen. The fuser glass (front and back) The fuser glass should be cleaned periodically because poor fusing or dirty background may occur if the glass is dirty. In addition toner particles may adhere to the glass during printing.
CLEANING THE MACHINE PERFORMING ROUTINE MAINTENANCE necessary, remove toner from the glass with the resin scraper provided. If the glass is too dirty to clean, call for service. 6. Push the lamp unit in completely. 7. Close the Fuser Door, then the right and left printer doors. The Toner supply and collector areas If the toner has scattered during toner replenishment or collection, wipe the toner off with a non-woven cloth or use a vacuum cleaner. CAUTION Keep toner away from your eyes or mouth.
PERFORMING ROUTINE MAINTENANCE CLEANING THE MACHINE Cleaning the touch screen From time to time you may want to clean the touch screen. In order to do this the screen needs to be deactivated to prevent unwanted selections. The screen will remain deactivated for 10 seconds after the last contact you make with it. To clean the touch screen: 1. Press the Tools tab, then the Screen tab. 2. Press the Clean button. The screen goes blank and is deactivated.
CALIBRATING THE TOUCH SCREEN PERFORMING ROUTINE MAINTENANCE Calibrating the touch screen Screen calibration is provided to align the screen cursor with the position that you press. This needs to be carried out whenever the cursor does not line up with your finger when you touch the screen. To calibrate the touch screen: 1. Press the Tools tab, then the Screen tab. 2. Press the Calibrate button.
9. Problem solving This chapter provides useful information when trying to resolve problems. The contents are: • Clearing paper jams • Checking software revisions • Using the system tools • Status codes • Error codes WARNING Operator tasks identified in this chapter should only be completed if the required training has been given to enable the tasks to be completed without risk or injury.
CLEARING ERRORS PROBLEM SOLVING Clearing errors When an error occurs, the message and code will be displayed and the button will flash. To access help in order to clear the error: 1. Press the button to display the Run view. All error codes and their labels are shown in the Error Log window, as they occur. 2. Press on the error label, you will immediately access its associated Help. Alternatively, you can press the message on the status bar to access the help. 3.
PROBLEM SOLVING CLEARING PAPER JAMS Clearing paper jams CAUTION Remove paper jammed during autoload or printing completely so as not to leave any piece of paper left on the transport path. If printing is resumed with paper left in the transport path, the paper may be scorched, emit smoke at the fuser or cause poor fusing. When removing jammed paper, do not pass a non-fused sheet through the fuser. If a non-fused sheet is put through the fuser by mistake, clean the fuser glass.
CLEARING PAPER JAMS PROBLEM SOLVING 4. Raise the R guide lever completely. R Guide Lever After checking for jammed paper, hold the lever and carefully close the R guide. 5. Raise transfer unit B lever and open the transfer unit completely. After checking for jammed paper, close transfer unit B completely. Transfer Unit B Lever 6. Raise transfer unit A lever and open the transfer unit completely. After checking for jammed paper, close transfer unit A completely. Transfer Unit A Lever 7.
PROBLEM SOLVING CLEARING PAPER JAMS 8. Hold the lamp unit lever of fuser B and pull this slightly towards you. Autoloader B Autoloader B Lever Lamp Unit Reflector Unit Reflector Unit Lever Lamp Unit Lever 9. While pulling the reflector unit lever towards you, open the unit downward. 10. Raise the autoloader B lever to open it. After checking for jammed paper, hold the reflector unit lever and close it completely. Carefully close autoloader B and push the lamp unit lever in completely. 11.
CLEARING PAPER JAMS PROBLEM SOLVING 14. Hold the fuser exit guide lever and open the guide completely. Fuser Exit Guide Lever After checking for jammed paper, carefully close the guide. 15. Close the Fuser Left door and open the Right Stacker door. 16. While holding the pinch roller unit lever, pull the lock bracket to open the unit completely. Pinch Roller Unit Lever After checking for jammed paper, close the unit carefully until it is locked. 17. Close the right stacker door.
PROBLEM SOLVING CLEARING PAPER JAMS • Open the reflector unit for fuser B and autoloader B. Autoloader B Fuser A Fuser B Reflector unit • Cut the paper before the tractors and before fuser A. Autoloader B Fuser A Paper Cutting Position Extract in this direction Reflector Unit Fuser B Drum Unit A Paper Cutting Position Drum Unit B Do not extract in this direction • If the paper is at fuser A, extract it from the entry of fuser A by hand.
CLEARING PAPER JAMS PROBLEM SOLVING be sure to extract the paper in the direction shown. Autoloader B Fuser A Paper Cutting Position Extract in this direction Reflector Unit Fuser B Drum Unit A Paper Cutting Position Drum Unit B Do not extract in this direction Remove the paper from the tractors as follows: Second Tractor Cover Back Tension Cover Paper Removal Lever Tractor Cover • Open the tractor cover and detach the paper from the tractor pins.
PROBLEM SOLVING CLEARING PAPER JAMS Clearing a paper jam at autoload If an autoloading error causes a paper jam, execute autoload again after removing the jammed paper completely from the printer as explained below. 1. Locate the paper jam (See “Locating the paper jam” on page 3.). 2. Put your hand into the opening of transfer unit A (or B) and extract the paper in the direction shown (downward). After extracting all the jammed paper, cut and remove the paper through the opening.
CLEARING PAPER JAMS PROBLEM SOLVING Clearing a paper jam outside the drum unit 1. Cut off the jammed paper and remove it through the nearest opening (See “Locating the paper jam” on page 3.). 2. Cut the paper before the tractors. 3. Open the tractor and back tension covers and detach the paper from the tractor pins. Second Tractor Cover Back Tension Cover Tractor Pins Tractor Cover 4. Remove the paper from the tractors, stacker, or other accessible section where the paper can be removed easily.
PROBLEM SOLVING CLEARING A POST-PROCESSOR JAM Clearing a post-processor jam Jams in post-processing equipment fall into two categories: • Jam in post-processors that report jams • Jam in post-processors that do not report jams These are handled as follows: Jam in post-processors that report jams • The print line remains aligned • A jam is reported to the host • After jam is cleared, line is set to ready again and printing resumes Jam in post-processors that do not report jams There are two possi
CHECKING SOFTWARE AND HARDWARE REVISIONS PROBLEM SOLVING Checking software and hardware revisions To check the software and hardware revisions, select the Engine tab, then the Revisions tab.
PROBLEM SOLVING USING THE TOOLS SCREEN Using the tools screen A number of tools are available for monitoring and testing the activities of the printer. The system maintains a log of errors listed in order of severity. This can be consulted to check for error patterns. All users, except for those with the status of Operator, can delete the log file. A number of on-line test patterns are available to check the quality of the print.
USING THE TOOLS SCREEN PROBLEM SOLVING 2. Select the Source to trace. 3. Select one of the error filter radio buttons according to how you want to filter the errors. These are: Page 9-14 • only the Intervention Errors are displayed. These are errors without a need to reprint or reconstruct pages. These errors are displayed on the panel and you need to press the Reset button. • only the Recovery Errors are displayed.
PROBLEM SOLVING USING THE TOOLS SCREEN • only the Fatal Errors are displayed. These are errors that generally occur at Initial Program Load (IPL) from which there is no recovery. These errors are displayed on the panel and you need to press the Reset button, configure the printer and host and restart the job. • All errors are displayed including successful and informational messages. 4. Press the arrows of the scroll bar to scroll upwards or downwards a line at a time.
PRINTING TEST OVERLAYS PROBLEM SOLVING Printing test overlays Note: Test patterns do not print when forced two-up has been set by software. To print a test overlay: 1. Stop the current job. 2. At the Production tab, press the Online button to switch the system to the offline state (Online is not illuminated). 3. Select the Test attachment and press the Online button to enable it. 4. Make sure that the line is in a Not Ready State. 5. Select the Tools tab, then the Test tab.
PROBLEM SOLVING STATUS CODES Status codes Status codes are displayed along with some engine state messages. These codes are shown in the following table.
ERROR CODES PROBLEM SOLVING Error codes Error codes fall into two categories, those reporting problems in the printer engine and those reporting problems with the software. For all errors: 1. Record the displayed error code and message. 2. If the code is listed in the tables, carry out the suggested action(s). 3. Press the RESET button to clear the error code. 4. If the problem persists, power the printer off then on. See "Switching the printer on and off" on page 3-2. 5.
PROBLEM SOLVING Code ERROR CODES Display Message Procedure 05-01 Toner collector full If you would like to change this consumable now then go to the Consumables view and press the Change button to replace the toner collector. 05-02 No toner collector The toner collector has either shifted or has not been installed (see "Replacing the toner collector" on page 8-24). 05-04 Toner shutter A open 1. 2. 3. 4. Open the right printer door. Close the lid to toner supply port A.
ERROR CODES Code PROBLEM SOLVING Display Message Procedure 08-05 Paper tension lever released (during printing or emergency stop) 1. Open the right stacker door. 2. Set the paper tension lever to match the paper in use. 'Standard' is for ordinary printing. 'Weak' is for when printing with special paper. 3. Close the right stacker door. 4. Press RESET on the touch screen. 5. Press FORWARD/REVERSE on the autoload panel to match the correct perforation number. 6.
PROBLEM SOLVING Code ERROR CODES Display Message Procedure 09-02 Stacker table not set The stacker table is not in the correct position. It may have been pulled out. 1. Push in the stacker table fully. 2. Press AUTO on the stacker panel to raise the table to the correct position. 3. Close the right stacker door. 4. Press RESET on the touch screen and then set the printer to ready. 09-03 Stacker table safety switch check The stacker table safety switch has tripped.
ERROR CODES Code PROBLEM SOLVING Display Message Procedure 0A-01 Cleaner blade A missing 1. Cleaner blade A has not been installed (see "Replacing the cleaner brush and blade" on page 8-18). 2. Press RESET on the touch screen. 0A-02 Cleaner blade B missing 1. Cleaner blade B has not been installed (see "Replacing the cleaner brush and blade" on page 8-18). 2. Press RESET on the touch screen.
PROBLEM SOLVING Code ERROR CODES Display Message Procedure 0D-08 Incomplete paper width measurement The paper width was set manually but LOAD was not pressed on the autoload panel. 1. Press LOAD on the autoload panel. 2. Press RESET on the touch screen and then set the printer to ready. 0D-10 Back tension cover open 1. Close the back tension cover of the printer. 2. Press RESET on the touch screen and then set the printer to ready. 0D-11 Hopper bar not set/Seam detected (during autoloading) 1.
ERROR CODES Code PROBLEM SOLVING Display Message Procedure 16-11 Guide roller motor rotation alarm A rotation error has been detected in the guide roller motor. 1. Check that Roller Unit A[R1a] is correctly installed and the thumbscrew is securely tightened (see "Replacing Roller unit A[R1a]" on page 8-13). 2. Press RESET on the touch screen and then set the printer to ready. 16-12 Fold-back motor rotation alarm A rotation error has been detected in the fold-back motor. 1.
PROBLEM SOLVING Code ERROR CODES Display Message Procedure 1B-0C Paper width measurement alarm A paper width of 18 inches or more has been detected. 1. Press RESET on the touch screen. 2. Remove the paper jam (see "Clearing paper jams" on page 93). 3. Restart the autoload procedure (see "Paper autoloading" on page 5-4). 4. Press LOAD on the autoload panel. 1C-0D Shutter motor time-out A shutter motor error has been detected in the heater unit. 1. Check the printing status and the paper position. 2.
ERROR CODES Code PROBLEM SOLVING Display Message Procedure 22-62 Fuser 2 temperature too high 1. 2. 3. 4. 5. Record the displayed error code and message. Press the RESET button to clear the error code. Set the printer to ready. If the problem persists, power the printer off then on. If the problem persists, call for service or advice quoting the error code number and message. 24-28 Flash 1 error 1 1. 2. 3. 4. 5. Record the displayed error code and message.
PROBLEM SOLVING Code ERROR CODES Display Message Procedure 26-5C Flash 2 cycle alarm 1. 2. 3. 4. 5. Record the displayed error code and message. Press the RESET button to clear the error code. Set the printer to ready. If the problem persists, power the printer off then on. If the problem persists, call for service or advice quoting the error code number and message. 27-2B Flash 1 runaway 1. 2. 3. 4. 5. Record the displayed error code and message. Press the RESET button to clear the error code.
ERROR CODES Code PROBLEM SOLVING Display Message Procedure 60-31 Developing unit 1 motor rotation alarm 1. 2. 3. 4. 5. Record the displayed error code and message. Press the RESET button to clear the error code. Set the printer to ready. If the problem persists, power the printer off then on. If the problem persists, call for service or advice quoting the error code number and message. 60-41 Developing unit 1 stirring axis rotation alarm 1. 2. 3. 4. 5.
PROBLEM SOLVING Code ERROR CODES Display Message Procedure 60-56 Developer 2 temperature alarm 1. 2. 3. 4. 5. 60-57 Developer discharge lever [R2b] closed (emergency stop) At this point during the replacement of Developer [R2b], the discharge lever should be open. 1. Lift the lock lever of Developer [R2b] to unlock the discharge lever. 2. Pull the discharge lever out to open it. 3. Press RESET on the touch screen.
ERROR CODES Code PROBLEM SOLVING Display Message Procedure 62-25 Toner 1 density too low 1. 2. 3. 4. 5. Record the displayed error code and message. Press the RESET button to clear the error code. Set the printer to ready. If the problem persists, power the printer off then on. If the problem persists, call for service or advice quoting the error code number and message. 62-54 Toner 2 density too high 1. 2. 3. 4. 5. Record the displayed error code and message.
PROBLEM SOLVING Code ERROR CODES Display Message Procedure 66-36 After-cleaner 1 discharging LED alarm 1. 2. 3. 4. 5. Record the displayed error code and message. Press the RESET button to clear the error code. Set the printer to ready. If the problem persists, power the printer off then on. If the problem persists, call for service or advice quoting the error code number and message. 66-65 Pre-transfer 2 discharging LED alarm 1. 2. 3. 4. 5. Record the displayed error code and message.
ERROR CODES Code PROBLEM SOLVING Display Message Procedure 6C-43 Toner 1 supply axis rotation alarm 1. 2. 3. 4. 5. Record the displayed error code and message. Press the RESET button to clear the error code. Set the printer to ready. If the problem persists, power the printer off then on. If the problem persists, call for service or advice quoting the error code number and message. 6C-44 Toner 1 stirring axis rotation alarm 1. 2. 3. 4. 5. Record the displayed error code and message.
PROBLEM SOLVING Code ERROR CODES Display Message Procedure 6F-E0 Heater temperature too high 1. 2. 3. 4. 5. Record the displayed error code and message. Press the RESET button to clear the error code. Set the printer to ready. If the problem persists, power the printer off then on. If the problem persists, call for service or advice quoting the error code number and message. 6F-E1 Heater temperature too low 1. 2. 3. 4. 5. Record the displayed error code and message.
ERROR CODES Code PROBLEM SOLVING Display Message Procedure 7D-4F Process board 1 alarm 1. 2. 3. 4. 5. Record the displayed error code and message. Press the RESET button to clear the error code. Set the printer to ready. If the problem persists, power the printer off then on. If the problem persists, call for service or advice quoting the error code number and message. 7D-7F Process board 2 alarm 1. 2. 3. 4. 5. Record the displayed error code and message.
PROBLEM SOLVING Code ERROR CODES Display Message Procedure 8D-B0 Video data parity error 1 1. 2. 3. 4. 5. Record the displayed error code and message. Press the RESET button to clear the error code. Set the printer to ready. If the problem persists, power the printer off then on. If the problem persists, call for service or advice quoting the error code number and message. 8D-B1 Video data empty 1 1. 2. 3. 4. 5. Record the displayed error code and message.
ERROR CODES Code PROBLEM SOLVING Display Message Procedure 8D-BA Video data overrun 2 1. 2. 3. 4. 5. Record the displayed error code and message. Press the RESET button to clear the error code. Set the printer to ready. If the problem persists, power the printer off then on. If the problem persists, call for service or advice quoting the error code number and message. 8D-BB Video buffer data remnant 1. 2. 3. 4. 5. Record the displayed error code and message.
PROBLEM SOLVING Code ERROR CODES Display Message Procedure 90-52 Grid 2 voltage too low 1. 2. 3. 4. 5. Record the displayed error code and message. Press the RESET button to clear the error code. Set the printer to ready. If the problem persists, power the printer off then on. If the problem persists, call for service or advice quoting the error code number and message. 90-68 Pre-charger 2 alarm 1. 2. 3. 4. 5. Record the displayed error code and message.
ERROR CODES Code PROBLEM SOLVING Display Message Procedure 95-20 Surface potential 1 alarm 1. 2. 3. 4. 5. Record the displayed error code and message. Press the RESET button to clear the error code. Set the printer to ready. If the problem persists, power the printer off then on. If the problem persists, call for service or advice quoting the error code number and message. 95-50 Surface potential 2 alarm 1. 2. 3. 4. 5. Record the displayed error code and message.
PROBLEM SOLVING Code ERROR CODES Display Message Procedure A2-91 Fuser cooling fan 1 circuit breaker alarm 1. 2. 3. 4. 5. Record the displayed error code and message. Press the RESET button to clear the error code. Set the printer to ready. If the problem persists, power the printer off then on. If the problem persists, call for service or advice quoting the error code number and message. A2-92 Fuser cooling fan 2 circuit breaker alarm 1. 2. 3. 4. 5. Record the displayed error code and message.
ERROR CODES Code PROBLEM SOLVING Display Message Procedure AF-83 Pre-charger ozone fan 1 alarm 1. 2. 3. 4. 5. Record the displayed error code and message. Press the RESET button to clear the error code. Set the printer to ready. If the problem persists, power the printer off then on. If the problem persists, call for service or advice quoting the error code number and message. AF-84 Choke coil cooling fan alarm 1. 2. 3. 4. 5. Record the displayed error code and message.
PROBLEM SOLVING Code ERROR CODES Display Message Procedure B0-03 Parameter not allowed 1. 2. 3. 4. 5. Record the displayed error code and message. Press the RESET button to clear the error code. Set the printer to ready. If the problem persists, power the printer off then on. If the problem persists, call for service or advice quoting the error code number and message. B0-04 Command sequence error 1. 2. 3. 4. 5. Record the displayed error code and message.
ERROR CODES Code PROBLEM SOLVING Display Message Procedure C0-05 NPLi temperature alarm 1. 2. 3. 4. 5. Record the displayed error code and message. Press the RESET button to clear the error code. Set the printer to ready. If the problem persists, power the printer off then on. If the problem persists, call for service or advice quoting the error code number and message. C0-06 PCU temperature alarm 1. 2. 3. 4. 5. Record the displayed error code and message.
PROBLEM SOLVING Code ERROR CODES Display Message Procedure C0-0D CME time-out 1. 2. 3. 4. 5. Record the displayed error code and message. Press the RESET button to clear the error code. Set the printer to ready. If the problem persists, power the printer off then on. If the problem persists, call for service or advice quoting the error code number and message. C0-0E IOT read command time-out 1. 2. 3. 4. 5. Record the displayed error code and message. Press the RESET button to clear the error code.
ERROR CODES Code PROBLEM SOLVING Display Message Procedure C0-26 Hardware error (IOT power) 1. 2. 3. 4. 5. Record the displayed error code and message. Press the RESET button to clear the error code. Set the printer to ready. If the problem persists, power the printer off then on. If the problem persists, call for service or advice quoting the error code number and message. C0-27 Hardware error (diagnostic) 1. 2. 3. 4. 5. Record the displayed error code and message.
PROBLEM SOLVING Code ERROR CODES Display Message Procedure C2-23 Illegal transaction code 1. 2. 3. 4. 5. Record the displayed error code and message. Press the RESET button to clear the error code. Set the printer to ready. If the problem persists, power the printer off then on. If the problem persists, call for service or advice quoting the error code number and message. C2-24 Illegal transaction parameter 1. 2. 3. 4. 5. Record the displayed error code and message.
ERROR CODES Code PROBLEM SOLVING Display Message Procedure F0-61 Undefined device type 1. Select the Definitions tab, the Line tab, then the Device tab on the touch screen. 2. Choose a device from the Device pull-down list. 3. Choose a device type from the Device Type pull-down list. 4. Press the Save button to save the current line definition. 5. Press the OK button on the Save screen. 6. Press RESET on the touch screen and then set the printer to ready. F0-62 Undefined device 1.
PROBLEM SOLVING Code ERROR CODES Display Message Procedure F0-A7 Invalid subnet mask 1. Select the Definitions tab, the Attachment tab, then the TCP/IP tab on the touch screen. 2. Press the Subnet Mask field to insert a new mask. 3. Use the window keyboard to enter your selection, then press the OK button. 4. Press the Save button to save the current line attachment definition. 5. Press the OK button on the Save screen. 6. Press RESET on the touch screen and then set the printer to ready. 7.
ERROR CODES Code PROBLEM SOLVING Display Message Procedure F0-AB Link not available 1. Select the Definitions tab, the Attachment tab, then the TCP/IP tab on the touch screen. 2. In the Link box, select the appropriate link. Select only the link that is currently indicated as “Present”. 3. Press the Save button to save the current line attachment definition. 4. Press the OK button on the Save screen. 5. Press RESET on the touch screen and then set the printer to ready. F1-11 Paper size error 1.
PROBLEM SOLVING Code ERROR CODES Display Message Procedure F4-12 Invalid channel transfer mode 1. 2. 3. 4. 5. F4-13 Invalid TCP/IP link 1. Select the Definitions tab, the Attachment tab, then the TCP/IP tab on the touch screen. 2. In the Link box, select the appropriate link. Select only the link that is currently indicated as “Present”. 3. Press the Save button to save the current line attachment definition. 4. Press the OK button on the Save screen. 5.
ERROR CODES Code PROBLEM SOLVING Display Message Procedure F4-16 Invalid subnet mask 1. Select the Definitions tab, the Attachment tab, then the TCP/IP tab on the touch screen. 2. Press the Subnet Mask field to insert a new mask. 3. Use the window keyboard to enter your selection, then press the OK button. 4. Press the Save button to save the current line attachment definition. 5. Press the OK button on the Save screen. 6. Press RESET on the touch screen and then set the printer to ready. 7.
PROBLEM SOLVING Code ERROR CODES Display Message Procedure F4-1A Link not available 1. Select the Definitions tab, the Attachment tab, then the TCP/IP tab on the touch screen. 2. In the Link box, select the appropriate link. Select only the link that is currently indicated as “Present”. 3. Press the Save button to save the current line attachment definition. 4. Press the OK button on the Save screen. 5. Press RESET on the touch screen and then set the printer to ready.
ERROR CODES Code PROBLEM SOLVING Display Message Procedure F8-0A Invalid width 1. Select the Definitions tab, then the Paper tab on the touch screen. 2. Choose the existing paper definition from the Paper pull-down list. 3. Select the Paper Format field. 4. Select the Width field, type in the correct width, then select the inch or mm button. 5. Press the OK button to validate. 6. Press the Save button to save the current paper definition. 7. Press the OK button on the Save screen. 8.
A. Safety notes To ensure you operate the equipment safely please read these safety notes carefully before using this product Your Xerox product and recommended supplies have been designed and tested to meet strict safety requirements. These include safety agency approval, and compliance to established environmental standards. Please read the following instructions carefully before operating the product and refer to them as needed to ensure the continued safe operation of your product.
Electrical supply This product should be operated from the type of electrical supply indicted on the data plate label located on the rear cover of the power supply/transformer provided with the equipment. If you are not sure that your electrical supply meets the requirements, please consult your local power company for advice. The transformer provides 200V ac, 50 Hz, 3 phase as specified on the data plate of your Xerox 495 equipment. WARNING: This product must be connected to a protective earth circuit.
WARNING - ELECTRICAL SAFETY INFORMATION WARNING - Electrical safety information • Use only power cord supplied with this equipment. • Improper connection of the equipment-grounding conductor can result in electrical shock. • Do not place this equipment where people might step on or trip on the power cord. • Do not place objects on the power cord. • Do not override or disable electrical or mechanical interlocks. • Do not obstruct ventilation openings.
OPERATIONAL SAFETY INFORMATION Operational safety information To ensure the continued safe operation of your Xerox equipment, follow these safety guidelines at all times. Do these: • Always connect equipment to a correctly grounded supply. If in doubt, have the supply checked by a qualified electrician. • This equipment must be connected to a protective earth circuit. • Always follow all warnings and instructions that are marked on or supplied with the equipment.
MAINTENANCE INFORMATION Maintenance information Do not attempt any maintenance procedure that is not specifically described in the documentation that is supplied with your copier/printer. • Do not use aerosol cleaners. The use of cleaners that are not approved may cause poor performance of the equipment, and could create a dangerous condition. • Use supplies and cleaning materials only as directed in this manual. Keep all of these materials out of the reach of children.
REGULATORY INFORMATION Regulatory Information CE Mark The CE mark applied to this product symbolizes Xerox's declaration of conformity with the following applicable Directives of the European Union as of the dates indicated: January 1, 1995: Council Directive 72/23/EEC amended by Council directive 93/68/EEC, approximation of the laws of the member states related to low voltage equipment.
ENVIRONMENTAL COMPLIANCE Environmental Compliance Product Recycling and Disposal If you are managing the disposal of your Xerox product, please note that the product contains lead, mercury and other materials whose disposal may be regulated due to environmental considerations in certain countries or states. The presence of lead and mercury is fully consistent with global regulations applicable at the time that the product was placed on the market.
ENVIRONMENTAL COMPLIANCE Page A-8 Xerox 495 Continuous Feed Duplex Printer Operator Guide
B. Specifications This section contains the functional, physical and paper specifications for the Xerox 495 Continuous Feed Duplex Printer.
BASIC SPECIFICATIONS Basic specifications The following table lists the basic specifications of this printer. Item Printing method Printing type Printing speed Form Type Size Paper weight Paper feed Paper ejection Printing width Non-printing area Connection Page B-2 Specifications Dry electrophotographic printing by LED recording Double-sided simultaneous printing Linear speed 500 ipm at Letter, portrait/2-up, duplex 16,500 ipm at 6 lpi (duplex) Process speed = 22.
FUNCTIONAL SPECIFICATIONS Functional specifications The following table lists the functional specifications of this printer.
PAPER SPECIFICATIONS Paper Specifications The following table shows the physical properties required in forms paper used in the Xerox 495 Continuous Feed Duplex Printer; Item Paper quality Paper type Available paper size Basis weight (ream weight) (*1) Moisture Surface specific resistance Paper carton size Package conditions Storage conditions Page B-4 Specifications NIP, high-grade, and recycled paper Fanfold continuous forms with sprocket holes (unless feeding from a pre-processing device).
C. Principles of Operation This section describes the operation, the printing functions and the machine configuration of the Xerox 495 Continuous Feed Duplex Printer.
OPERATION OUTLINE Operation Outline This section gives an outline of printing by this printer. The printing operation consists of four cycles for every sheet. These are: 1. Information transfer cycle - the transfer of data from the Host computer to the Page buffer. 2. Recording cycle - the transfer of data from the page buffer to the Photoconductor drum. This cycle places toner on the electrostatic image in preparation for the transfer cycle. 3.
OPERATION OUTLINE command. Control characters are interpreted and graphic character codes are converted into internal codes and stored in the intermediate buffer. When one sheet of data for the front and back sides is stored in the intermediate buffer, the data is extended and one page of printing data is stored in the bit map memory. This information transfer cycle ends here and the next information transfer cycle starts.
CONFIGURATION Configuration The following illustration shows the unit arrangement of this printer looking from the front.
CONFIGURATION Outline of printing process The following illustration shows the printing processes of this printer. Toner Collection System Brush Blade Photoconductive drum surface 6. Cleaning 5. Fusing Printing Data Conductive 1. Precharging Paper Exposure 4. Transfer Toner Forms 2. Exposure 3. Development 1. The precharger uniformly charges the entire surface of the photoconductor drum at the center in the recording unit. 2.
CONFIGURATION Paper transport section The paper transport section consists of a hopper, a tractor assembly, transfer units, a fuser, and a stacker. 1. Hopper - consists of paper box guides for mounting a paper box (if a pre-processing unit is not in place), hopper guides for guiding paper, and a paper-end detector. 2. Tractor assembly - consists of the first and second tractors and a back tension unit. 3. Transfer unit - consists of a transfer charger and a peripheral for driving the charger.
INDEX INDEX Numerics 2-up tab 7-16 A A marking unit 2-2 access control 2-1 action bar buttons 2-25 action log 2-16 active marking unit icon 2-27 adjusting print quality 1-3 ADP indicator 2-29 aligned button 4-13 aligned/unjammed button 4-13 all errors 9-15 amending a job 7-4 amending a line 7-21 amending a paper definition 7-7 amending a TCP/IP attachment configuration 7-30 amending an application 7-12 amending an IBM Channel attachment configuration 728 amending from a production job 7-6 amp unit lever
INDEX Check Output button 4-9 check output button 4-4 check output enable 4-4 checking printed paper 5-14 choose print line 4-3 choosing an attachment 4-3 circular list 2-10 cleaner blade 8-18 cleaner blade A 2-5, 8-20 cleaner blade B 2-5 cleaner brush 8-18 cleaner brush cover A-R3a 2-5 cleaner brush cover B-R3b 2-5 cleaner brush replacement 8-2 cleaning 8-2 cleaning fuser glass 8-27 cleaning machine 8-27 cleaning toner collector area 8-28 cleaning toner supply area 8-28 cleaning touch screen 8-29 clearing
INDEX dialog boxes 2-10 discard buffers button 4-14 display button 2-11 disposal bag 8-19, 8-21 document conventions 1-4 drum unit A 2-5 drum unit B 2-5 E edit mark button 7-25 eject button 4-12, 5-2 eject buttons 2-25 eject one page button 2-25 eject pages button 2-25 eject states 2-25 ejecting 2-24 ejecting paper 4-2 ejection length 7-21 ejection lever A 2-5 ejection lever B 2-5 emergency stop 3-1, 3-4 emergency switch 2-30 empty developer container 2-8 empty toner cassette 8-8, 8-11 emulation list 7-12
INDEX internal door 2-4 intervention errors 9-14 IP address 7-31, 7-32 IPDS emulation 7-13, 7-31 IPDS tab 7-17 J job configuration 4-3 job definition 7-4 job list 4-3, 7-5 job pull-down list 7-3 job tab 7-3, 7-4 K key 2-17 key operator user 3-10 keyboard 2-10 kit A-R3a 8-18 Kit A-R3a LED 8-18 kit B-R3b 8-21 Kit B-R3b LED 8-21 kit display LED A-R3a 2-4 kit display LED B-R3b 2-4 L lamp unit lever B 9-5 left offset button 4-9, 7-17 left printer door 2-3 left stacker door 2-3 length field 7-8 license expiry
INDEX P page counter 4-5 page counters 2-16 pages lamp 2-20, 4-4 paper autoload 5-4 paper box guides 5-3 paper definition 7-4, 7-7 paper definition from paper screen 7-5, 7-10 paper definition from production screen 7-10 paper dimensions screen 7-8 paper format field 7-7 paper forward/reverse switch 2-5, 2-33 paper guides 2-9 paper handling 2-3 paper hopper 5-3 paper jam at autoload 9-9 paper jam clearance 9-3 paper jam location 9-3 paper jam outside the drum unit 9-10 paper list 4-4, 7-4, 7-5 paper master
INDEX removing paper 5-12, 8-2 renaming a flash overlay 7-36 replace roller unit A-R1a 8-13 replace toner collector 8-24 replace toner-Ka 8-6 replacing kit A-R3a 8-18 replacing kit B-R3b 8-21 replacing roller unit B-R1b 8-15 replacing smoke filter 8-26 replacing toner 8-6 replacing toner-Kb 8-9 reserve switch 2-31 reset button 2-26 resolution cursor 7-12 resolution icon 2-27 resolution list 7-13 reverse duplex printing box 4-4, 7-22 reverse switch 2-31, 2-33 reviewing device settings 7-24 revisions tab 9-1
INDEX toner collector replacement 8-2, 8-24 toner consumption 6-1 toner display LED -Kb 2-4 toner display LED-Ka 2-4 toner replacement 8-2 toner reservoir empty 8-6 toner supply area cleaning 8-28 toner supply unit-Ka 2-4 toner supply unit-Kb 2-4 toner-Ka LED 8-6 toner-Kb LED 8-9 tools 9-13 tools tab 2-14, 8-29, 8-30, 9-13, 9-16 touch screen 2-1, 2-4, 2-10, 2-12 touch screen calibration 8-30 touch screen cleaning 8-29 tractor assembly 2-9 tractor covers 5-6 transfer mode list 7-28, 7-29 transfer unit A 2-5
INDEX Index-8 Xerox 495 Continuous Feed Duplex Printer Operator Guide
