Xerox 490/980 Color Continuous Feed Printing System Printer Operator Guide If Not Then
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21 October 2008
Xerox® 490/980TM Color
Continuous Feed Printing System
Printer Operator Guide
Table of Contents
1
Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
More Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
System Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Simplex Printing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Duplex Printing Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
L-shape Duplex configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
In-Line Duplex configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Component Names and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Front Side of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Outer covers and doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Indicator lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Feeder Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Printer Stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Fuser Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Back Side of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Operation Panels and Dials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Touch Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Power Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Feeder Station Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Printer Station Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Fuser Station Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Paper Tension Dials 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Paper Tension Dial 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Nip Release Sub-Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Paper Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Storing and Handling Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Printable Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
2
Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Powering On/Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Powering On the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Powering off the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Loading Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Before Loading Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Loading Paper (for Simplex Printing System) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Loading Paper (for Duplex Printing System) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Loading Pinfed paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Paper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Creating New Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Selecting and loading paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Splicing Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Before Splicing Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Splicing Paper of the Same Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
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Simplex Printing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Duplex printing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Splicing paper of different widths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Simplex printing system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Splicing after clearing paper jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Checking If Paper Is Running Correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Checking if paper is running correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
If the paper is away from the side guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
If the paper edge is bent, curved or folded . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Unloading or Ejecting Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Unloading paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Ejecting paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Eject Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
When to eject paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
Changing from Duplex to Simplex Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Changing from Simplex to Duplex Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Before Starting Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Basic Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Clearing Paper Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Before handling paper jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Handling the Fuser Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
If pieces of jammed paper remain in the Fuser Station . . . . . . . . . . . . . . 3-2
Steps to Clear Paper Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Adjusting Print Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Adjusting Print Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Setting value fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Horizontal/vertical adjust buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Unit (mm or inch) select buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Adjusting Print Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Adjusting Print Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Adjusting print density (color mode). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Color Mode Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Selecting the Color Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
[Setting] and [Cancel] buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Pausing a Print Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Pausing a Print Job with the [Stop] Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
[OK] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
[Cancel] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Changes to Pending Jobs in Print Queue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Canceling a Print Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
[OK] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Adjusting Print Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Scumming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Print Image Partially Missing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Uneven print density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Smudge (unclear print) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Uneven toner fixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Irregular printed image (enlarged, reduced, overlapped, or shifted) . . . . 3-18
Void . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Poor print quality shortly after power-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
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Poor quality in hot or damp environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Adjusting the Mark Reading Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Paper width measurement value < Paper width setting . . . . . . . . . . . . . . . . 3-21
Paper width measurement value > Paper width setting . . . . . . . . . . . . . . . . 3-22
Paper width measurement value = paper width setting . . . . . . . . . . . . . . . . 3-23
ROF mark measurement value < 0.97 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
ROF mark measurement value > 0.97 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
ROF mark measurement value = 0.97 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Reading Position Change Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
4
Replacing Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Before Replacing Consumables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
About Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Types of Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Functions of Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Procedure for Replacing Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Checking Status of Consumable Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Starting Consumable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Finishing Consumables Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Supplying Toner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
When to supply toner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Steps for Supplying Toner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Steps for Replacing Developer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
When to Replace Developer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Steps for Replacing Developer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Batch Replacement of Developers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Batch replacement of K, C, M, and Y developers . . . . . . . . . . . . . . . . . . . 4-23
Replacing Kit A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
When to replace Kit A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Steps for replacing Kit A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Replacing Kit B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
When to replace Kit B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Steps for replacing Kit B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Replacing Waste Toner Containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
When to replace waste toner containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Steps for Replacing waste toner containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Replacing Transfer Roller Cleaners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
When to replace Transfer Roller Cleaners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Steps for replacing Transfer Roller Cleaners . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Replacing Smoke Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
When to replace Smoke Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Steps for replacing Smoke Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
5
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Before Cleaning the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Reloading paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Cleaning Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Cleaning the Feeder Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Steps for cleaning the idle roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Cleaning the Aligning Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
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Table of Contents
Xerox 490/980 Color Continuous Feed Printing System
Cleaning the Brush near the feeder opening . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Cleaning Printer Stations 1 and 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Cleaning the Paper Transport Plates (2 for each color) . . . . . . . . . . . . . . . . . 5-10
Cleaning around Toner Refills and Waste Toner Containers . . . . . . . . . . . . 5-12
Cleaning the transfer guide roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Cleaning the Fuser Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Before cleaning the Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Procedure for cleaning the Fuser Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Steps for Cleaning the Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Cleaning around the Paper Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Cleaning the idle roller below the fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Cleaning the tension arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Cleaning the sub driver roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Cleaning the Turn Bar - All Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
6
Peripheral Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Built-in Peripheral Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compact Flash (CF) card reader/writer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Card slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Access lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cautions in Using the Pre- and Post-Processing Devices . . . . . . . . . . . . . . . . . . . . .
Power-on steps and cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Powering on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Caution in printing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cautions for setting paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cautions for failure on the pre-processing and post-processing units .
Notes on the duplex printing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A
6-1
6-2
6-2
6-2
6-3
6-3
6-3
6-3
6-3
6-3
6-4
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Optional Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Hardware Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
B
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Printed Registration Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Form Registration (ROF) mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Color Registration (ROC) mark. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sheet ID mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROF mark position (without pin fed holes) . . . . . . . . . . . . . . . . . . . . . . . . . .
ROF mark shape/dimensions (without pin fed holes) . . . . . . . . . . . . . . . .
ROF mark position (with pin fed holes). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mark shape/dimensions (with pin fed holes) . . . . . . . . . . . . . . . . . . . . . . . .
Color registration (ROC) mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROC mark print position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROC mark (with / without pin fed holes) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-printing Registration Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROF mark for paper without pin fed holes. . . . . . . . . . . . . . . . . . . . . . . . . . .
ROF mark for paper with pin fed holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-printed TOF mark (common with or without pin fed holes). . . . . . .
C
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Procedure for Creating / Importing /Setting a Mark . . . . . . . . . . . . . . . . . . . . . . . . .
Creating a Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Import TIFF file to the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting a Mark by Imposition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
vi
B-1
B-1
B-1
B-1
B-2
B-2
B-3
B-3
B-4
B-4
B-5
B-6
B-6
B-6
B-7
C-1
C-1
C-2
C-5
Printer Operator Guide
Product Overview
1
Features
This section provides general information about functions and features of Xerox 490/980 Color
Continuous Feed Printing System ("the machine"). The machine is a continuous feed printer
offering outstanding performance for fast, high-quality business color printing. The Xerox 490
Color Continuous Feed Printing System consists of one printer to perform simplex printing. The
Xerox 980 Color Continuous Feed Printing System consists of two printers to perform duplex
printing.
Note
The paper speeds given represent an 18-inch (457mm) paper width, with page count based
on cut-sheet paper.
The Xerox 490 Color Continuous Feed Printing System processes simplex printing at speeds of
up to 464 prints per minute on A4 paper, 2-up, simplex and 493 prints per minute using lettersized paper, 2-up simplex.
The Xerox 980 Color Continuous Feed Printing System delivers duplex printing at up to 900
prints per minute on A4 paper, 2-up, duplex and 986 prints per minute using letter-sized paper,
2-up, duplex.
More Features
•
High resolution:
High density printing with a 600 dpi resolution allows small letters, superscripts, and fine
lines to be printed clearly.
•
Duplex printing:
The duplex system consisting of two printers allows fast color printing in duplex mode. The
optional switching operation, which can be achieved to uncouple two printers, allows you to
use them as individual simplex printers.
•
Print resources for the Xerox EPS/LPS series are reusable:
Print resources for the Xerox PS/LPS series, such as forms and fonts, can be used on the
machine without any modification. These resources are imported from the CF drive, which
is a standard component included in the machine.
For more information on the EPS/LPS series, refer to documents supplied with the following
products:
DocuPrint 180 EPS, DocuPrint 155 EPS, DocuPrint 115 EPS, 4669 LPS, 4569 LPS, 4489 LPS,
4439 LPS, 4239 LPS.
Printer Operator Guide
1-1
Product Overview
•
Xerox 490/980 Color Continuous Feed Printing System
Multi-PDL printer:
The machine supports multiple PDLs including Adobe PostScript(R) 3TM. The machine helps
improve productivity with excellent output flexibility by offering support for any type of
host (mainframe, server/client, etc.), as well as support for legacy/open combined
environments. The machine also achieves smooth printing of various types of data by
offering a number of fonts (12 Japanese fonts/CID-Keyed and 136 European fonts) and by
supporting PDF.
To support a PDL, the corresponding optional software is required. Examples of possible
digital front end (DFE) products as IPDS clients are listed below:
• Emtex VIP
• GMC PrintNet
• InfoPrint Manager
• Solimar
Please refer to the documentation supplied with these products for installation instructions.
In addition, IPDS requires additional options: the IPDS print mechanism and the extended
print mechanisms 1 and 2.
•
Flash Fusing Technology:
The Flash Fusing Technology eliminates the need for warm-up time. As toner is fixed with
no paper contact, output is printed without being affected by the paper surface curvature
or thickness. Furthermore, this technology eliminates areas that are mechanically operated,
and thus minimizes machinery damage and toner scattering.
•
EAN 128 barcode printing:
With a high 600 dpi resolution, the machine is able to clearly print the international
standard EAN 128 barcode images.
•
Touch screen with excellent visibility and operability:
A color touch screen is included on the printer station. You can control all printer operations
from this screen.
The touch screen features an energy-saving design. The light is off when the machine is
inactivate and quickly illuminates when activated.
•
Various types of continuous paper supported:
The machine supports high-quality or recycled continuous paper in a range of highly
demanded widths and weights: 8.3" - 19.5" (211mm - 495mm) and 64 gsm - 160 gsm (35
kg - 135 kg).
To use special paper, verification is required for fixing, crimping, and other characteristics.
For more information, please contact your Xerox support representative.
•
Remote controlled PC-GUI:
When the PC-GUI is connected, you can manage and operate jobs from a remote
computer.
1-2
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Product Overview
System Configuration
This section describes configurations of the machine. Three machine configurations are
described as follows.
Simplex Printing System
The simplex printing system uses one printer to perform simplex printing.
Note
For instructions and precautions on using the pre and post-processing devices and the
paper handling mechanism for a duplex system, refer to the documents supplied with these
devices.
Component
Function
Printer
Prints data.
Remote PC
Provides functions to control the machine from a remote place.
Pre-Processing Device
Feeds paper to the printer.
Post-Processing Device
Collects output prints.
Printer Operator Guide
1-3
Product Overview
Xerox 490/980 Color Continuous Feed Printing System
Duplex Printing Systems
The duplex printing system uses two printers to perform duplex printing. The L-Shaped and InLine configurations are shown as follows.
L-shape Duplex configuration
In-Line Duplex configuration
1-4
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Product Overview
Component
Function
Printer 1 (Upstream printer)
In duplex mode, prints data on the front side of paper.
Printer 2 (Downstream printer)
In duplex mode, prints data on the back side of paper.
Remote PC
Provides functions to control the machine from a remote place.
Pre-Processing Device
Feeds paper to the printer.
Paper handling mechanism in
duplex system (Turn Bar)
Carries and inverts paper to allow Printer 2 to print on the back
side.
Post-Processing Device
Collects output prints.
For instructions and precautions on using the Pre- and Post-Processing Devices, refer to the
documents supplied with these devices.
Printer Operator Guide
1-5
Product Overview
Xerox 490/980 Color Continuous Feed Printing System
Component Names and Functions
This section describes names and functions of the printer components. The printer consists of
the following four stations.
Fuser Station
Printer Station 2
Printer Station 1
Feeder Station
Name
Function
Feeder Station
Carries and feeds paper.
Printer Station 1
Transfers toner onto paper. Contains black and cyan toner.
Printer Station 2
Transfers toner onto paper. Contains magenta and yellow toner.
Fuser Station
Makes toner adhere to paper with Flash Fusing Technology.
1-6
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Product Overview
Front Side of the Printer
This section describes names and functions of the components on the front side.
Outer covers and doors
Names and functions of the outer covers and doors on the front side are listed in the table
below.
(16)
(17)
(15)
(8)
(3)
(4)
(14)
(7)
(6)
(2)
Attention Light
Power Panel
(5)
Touch Screen
Fuser
Station
Panel
(1)
(13)
(12)
Emergency Stop
Feeder Station Panel
(11)
(10)
(9)
No.
Name
Function
(1)
Feeder Door*
(2)
Feeder Front Door*
Provides access for loading paper, clearing paper jams, or
cleaning the paper path.
(3)
Printer 1 Top Cover*
(4)
Printer 2 Top Cover*
(5)
Toner Refill Door (K)*
Provides access for supplying black toner or cleaning the toner
hopper.
(6)
Toner Refill Door (C)*
Provides access for supplying cyan toner or cleaning the toner
hopper.
(7)
Toner Refill Door (M)*
Provides access for supplying magenta toner or cleaning the
toner hopper.
(8)
Toner Refill Door (Y)*
Provides access for supplying yellow toner or cleaning the toner
hopper.
(9)
Printer (K) Front Door
Provides access for replacing consumables or cleaning the entry
port for black developer.
Printer Operator Guide
Provides access for loading paper, clearing paper jams, replacing
consumables, cleaning toner hoppers, or cleaning the paper
path.
1-7
Product Overview
Xerox 490/980 Color Continuous Feed Printing System
No.
Name
Function
(10)
Printer (C) Front Door
Provides access for replacing consumables or cleaning the entry
port for cyan developer.
(11)
Printer (M) Front Door
Provides access for replacing consumables or cleaning the entry
port for magenta developer.
(12)
Printer (Y) Front Door
Provides access for replacing consumables or cleaning the entry
port for yellow developer.
(13)
Smoke Filter Door
Provides access for replacing smoke filters.
(14)
Fuser Front Door*
(15)
Fuser Top Cover*
Provides access for loading paper, clearing paper jams, cleaning
the fuser station, or cleaning the paper path.
(16)
Fuser Door*
(17)
Exhaust Duct
Exhausts air from the fuser station.
Note
* When any cover or door is opened while the printer is in operation, the printer will stop. If
this happens, the print quality is not guaranteed. The only exception is toner refill doors (5)
to (8) which will only suspend the printer toner supplying operation (the printing operation
will not stop).
1-8
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Product Overview
Indicator lamps
Names and functions of the indicator lamps provided on the front side of the printer area listed
in the table below.
(9)
(4)
(3)
(2)
(1)
(10) (11)
(8)
(7)
(6)
(5)
No.
Name
Function
(1)
Life Indicator Lamp (K)
(2)
Life Indicator Lamp (C)
(3)
Life Indicator Lamp (M)
Off: Indicates the container has a sufficient amount
of toner.
Blink:Indicates the consumable is near end of life.
On:Indicates toner should be replaced now.
(4)
Life Indicator Lamp (Y)
(5)
Status Lamp (K)
(6)
Status Lamp (C)
(7)
Status Lamp (M)
(8)
Status Lamp (Y)
(9)
Fuser Front Door Lamp
Off: Indicates the Fuser Front Door cannot be opened.
On: Indicates the Fuser Front Door can be opened.
(10)
Smoke Filter Indicator Lamp 1
(11)
Smoke Filter Indicator Lamp 2
Off: Indicates the installed Smoke Filter is still
effective.
On: Indicates the Smoke Filter needs replacing.
Printer Operator Guide
Off:Indicates the container has a sufficient amount of
toner.
Blink:Indicates toner is being supplied.
On:Indicates the toner container is removed, or the
container is empty. The machine is ready for container
replacement.
1-9
Product Overview
Xerox 490/980 Color Continuous Feed Printing System
Feeder Station
This section lists components of the Feeder Station.
(1)
(9)
(2)
(8)
Power Panel
(7)
(6)
(5)
Printer front side
(4)
(3)
No.
Name
Function
(1)
Paper Retaining Magnet
Prevents loaded paper from dropping while loading.
(2)
Nip Release Lever
Releases the nip roller when paper is loaded.
(3)
Paper Tension Dial 1
Adjusts paper tension.
(4)
Nip Release Sub-Lever
Changes the setting to suit the paper width. Releases the
roller when paper is loaded.
(5)
Emergency Power-off Button
Powers off the machine in emergency situations.
(6)
Feeder Station Panel
Allows paper to move forward or backward.
(7)
Touch Screen
Allows various print settings and operations.
(8)
Paper Tension Dial 2
Adjusts paper tension.
(9)
Attention Light
Illuminates when operator interaction is needed.
1-10
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Product Overview
Printer Stations
Components inside the Printer Stations 1 and 2.
(13)
(3)
(4)
(11)
(12)
Cleaner brush
(8)
(14)
(10)
(7)
(1)
(2)
(9)
(5)
(6)
(15)
(16)
(19)
(Y)
(19)
(M)
(19)
(C)
Cleaner blade
(19)(K)
(18)
No.
Name
Function
(1)
Black Toner
(2)
Cyan Toner
Emptied toner containers are used as waste toner
containers.
(3)
Magenta Toner
(4)
Yellow Toner
(5)
Toner Hopper (K)
Keeps hold of black toner, and then supplies it to the
developing module.
(6)
Toner Hopper (C)
Keeps hold of cyan toner, and then supplies it to the
developing module.
(7)
Toner Hopper (M)
Keeps hold of magenta toner, and then supplies it to the
developing module.
(8)
Toner Hopper (Y)
Keeps hold of Yellow Toner, and then supplies it to the
developing module.
(9)
Transfer Station (K)
Transfers Black Toner onto paper.
(10)
Transfer Station (C)
Transfers Cyan Toner onto paper.
(11)
Transfer Station (M)
Transfers Magenta Toner onto paper.
(12)
Transfer Station (Y)
Transfers Yellow Toner onto paper.
(13)
Transfer Roller Cleaner
Cleans transfer rollers. Equipped on each Transfer Station (K,
C, M, Y).
(14)
Kit B
Cleans the photoconductive drum.
Cleaner brush
Cleaner blade
Printer Operator Guide
1-11
Product Overview
Xerox 490/980 Color Continuous Feed Printing System
No.
Name
Function
(15)
Developer Entry Port
Developer is poured from this port with a funnel.
(16)
Developer Discharge Lever
Opens to discharge developer.
(17)
Printer Station Panel
Shows steps to replace developer containers.
(18)
Waste Developer Container
Emptied developer containers are used to collect waste
developer.
(19)
Funnel (K)
Helps pour Black Developer.
Funnel (C)
Helps pour Cyan Developer.
Funnel (M)
Helps pour Magenta Developer.
Funnel (Y)
Helps pour Yellow Developer.
1-12
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Product Overview
Fuser Station
This section describes components of the Fuser Station.
(1)
(3)
(2)
(11)
(4)
(5)
(7)
(10)
(8)
Printer front side
(9)
No.
Name
Function
(1)
Tension Arm
Applies tension on paper.
(2)
Fuser Station
Makes toner adhere to paper.
(3)
Fuser Facing Area
(4)
Paper Tension Dial 3
Adjusts paper tension.
(5)
Smoke Filter Door 1
Provides access for replacing Smoke Filters.
(6)
Smoke Filter Door 2
(7)
Nip Release Lever
Releases the nip roller when paper is loaded.
(8)
Fuser Station Panel
Allows paper to be ejected.
(8)
Sub Driver Roller
Auxiliary roller used to move paper.
(10)
Paper Exit
Ejects paper.
(11)
Fuser Door
Provides access for loading paper, clearing paper jams, or
cleaning the paper path.
Printer Operator Guide
1-13
Product Overview
Xerox 490/980 Color Continuous Feed Printing System
Back Side of the Printer
This section describes components on the back side of the printer.
(5)
(6)
(7)
(8)
(9)
(11)
(1)
(2)
(3)
(4)
(10)
Kit A
Bag filter
Line filter
No.
Name
Function
(1)
Printer (K) Rear Door
(2)
Printer (C) Rear Door
Provides access for replacing consumables
or cleaning around the waste toner
container.
(3)
Printer (M) Rear Door
(4)
Printer (Y) Rear Door
(5)
Waste Toner Container Indicator Lamp (K)
(6)
Waste Toner Container Indicator Lamp (C)
(7)
Waste Toner Container Indicator Lamp (M)
(8)
Waste Toner Container Indicator Lamp (Y)
(9)
Bag Filter Box
Holds Kit A.
(10)
Waste Toner Container
Contains waste toner.
(11)
Kit A
Filters exhaust air from the Printer
Stations.
Bag filter
Line filter
1-14
Off: Indicates the installed waste toner
container is serving.
On: Indicates the waste toner container
needs replacing.
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Product Overview
Operation Panels and Dials
This section describes functions of operation panels and how to use dials. Operation panels
include:
•
•
•
•
•
Touch screen
Power panel
Feeder station panel
Printer station panel
Fuser station panel
Dials include Paper Tension Dials 1, 2 and 3
Touch Screen
The touch screen has menu buttons with icons, scroll bars, pull-down menus, etc. for intuitive
and user-friendly operation.
The touch screen provides controls for operating and configuring the machine. The Menu
screen is shown below.
Printer Operator Guide
1-15
Product Overview
Xerox 490/980 Color Continuous Feed Printing System
Power Panel
The power panel is located on top of the right side of the printer. Component names and
functions are listed below.
Button name
Function
switch
Powers on the machine.
switch
Powers off the machine.
Clears the Alarm indicator.
switch
Switches between enabling and disabling connection with the power
supply.
Multi: Enables connection with the power supply. When this setting is
selected, selecting the switch on a printer also turns on the
power for all of the printers that are set for Multi.
Single: Disables connection with the power supply. When this setting is
selected, selecting the switch on a printer turns on only
that printer.
switch
Powers off the heater unit equipped in the photoconductive drum.
switch
Captures information on controller failures.
Black billing counter
Counts the amount of printed output in Black/White mode.
Color billing counter
Counts the amount of printed output in Color (CMYK) mode.
•
With the duplex printing system whose / switch on the power panel is set
to , it can be switched on from any other device connected. Before accessing the
printer for servicing, for example, be sure to turn off the power distribution board breaker
located in the printer installation space as a precaution of safety assurance.
•
Check the setting of the / switch on the power panel when changing from
the duplex to the simplex printing system or vice versa.
Lamp name
Color
Function
Power lamp
Green
Indicates the machine is powered on.
Heater lamp
Green
Indicates the heater unit in the photoconductive drum is
being controlled.
Alarm 7-segment lamp
-
Displays an Alarm code.
1-16
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Product Overview
Feeder Station Panel
The feeder station panel is located on the front side of the feeder station. Component names
and functions are listed below.
Button name
Function
While this button is held, paper is advanced toward the exit.
The paper in the printer for the duplex printing system is slowly sent
forward (at 1/6 the speed for normal printing). Select once to continuously
send paper. To stop sending paper, select this button again or select the
button. If no stopping operation is performed, paper feed is
stopped when paper feeding for the duplex path length is completed.
Advances paper toward the exit. Selecting and holding this button
advances paper continuously.
Measures paper width and adjusts paper tension.
Cleans all chargers automatically.
Advances paper in Printer 1 toward the exit.
Lamp name
Color
Function
Setting SW lamp
Green
Indicates paper is being set.
Cleaning SW lamp
Green
Indicates chargers are being cleaned automatically.
Printer Operator Guide
1-17
Product Overview
Xerox 490/980 Color Continuous Feed Printing System
Printer Station Panel
The printer station panel is located on the printer station. Component names and functions are
listed below.
Button name
Function
button
Select to proceed to the next step.
button
Select to return to the previous step, cancelling the current operation.
button
Select to automatically clean chargers in paneled stations.
Lamp name
Color
Function
<1> lamp
Green
Indicates the operation is currently in Step 1 (start) of developer
replacement.
<2> lamp
Green
Indicates the operation is currently in Step 2 of developer replacement.
<3> lamp
Green
Indicates the operation is currently in Step 3 of developer replacement.
<4> lamp
Green
Indicates the operation is currently in Step 4 of developer replacement.
<5> lamp
Green
Indicates the operation is currently in Step 5 of developer replacement.
<6> lamp
Green
Indicates the operation is currently in Step 6 of developer replacement.
<7> lamp
Green
Indicates the operation is currently in Step 7 of developer replacement.
lamp
Red
Indicates an error occurred during developer replacement.
SW
lamp
Green
Indicates chargers are being cleaned automatically.
1-18
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Product Overview
Fuser Station Panel
The Fuser station panel is located on the fuser station. Component names and functions are
listed below:
Button/lamp name
Function
Printer
button
Starts the print operation. This button is available when no error
occurs in the machine and the printer status is [Paused].
button
Suspends the print operation. This button is available when the
printer status is [Idle], [Printing], or [Ejecting].
Selecting this button changes the printer status to [Paused].
button
Select this button if an error occurs that requires the reset operation
to clear the error.
button
Sends paper out to the exit. This button is available when the printer
is stopped.
button
The paper in the printer for the duplex printing system is slowly sent
forward (at 1/6 the speed for normal printing). Select once to
continuously send paper. To stop sending paper, select this button
again or select the button. If no stopping operation is
performed, paper feed is stopped when paper feeding for the duplex
path length is completed.
button
Moves paper backward to the feeder area in 1/6 inch steps.
button
Advances paper toward the exit. Selecting and holding this button
advances paper continuously.
button
Use this button for special paper. Selecting this button applies or
releases paper tension.
Manual Feed
Paper tension
Lamp name
Color
Function
SW lamp
Green
Indicates the printer can start printing.
Printer Operator Guide
1-19
Product Overview
Xerox 490/980 Color Continuous Feed Printing System
Lamp name
Color
Function
SW lamp
Green
On: Indicates paper tension is applied.
Blink: Indicates the paper tension mechanism is activated.
Off: Indicates paper tension is released.
Paper Tension Dials 1 and 2
Paper Tension Dials 1and 2 are located on the feeder station. Use the dials to adjust paper skew.
The term "Paper skew" is defined as the positional deviation (toward the front or back side of
the machine) of paper from its ideal running course. Begin with 0 and adjust accordingly using
the Paper Tension Dial 1.
To release the nip roller, set the dial to the position marked with symbols.
Paper Tension Dial 3
Paper Tension Dial 3 is located on the Fuser Station. This dial is used to adjust the paper tension.
If the paper is 130 gsm to 160 gsm in weight and less than 15.0 inches (381 mm) in width:
1.
Set Paper Tension Dial 2 to [5].
2.
Set Paper Tension Dial 3 to [3].
If the paper is not applicable to the above weight or width:
1.
Set Paper Tension Dial 2 to [3].
2.
Set Paper Tension Dial 3 to [3].
Note
A lower tension level causes the paper to sag, and a higher level causes the paper to stretch.
For the locations of the Paper Tension Dials 2 and 3, refer to the diagrams above.
1-20
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Product Overview
Nip Release Sub-Lever
The nip release sub-lever located on the feeder station is used to set the paper pulling force.
1.
Adjust the lever to position #1 when the paper width is between 8.3 and 12 inches.
2.
Adjust the lever to position #2 when the paper width is between 12 and 16 inches.
3.
Adjust the lever to position #3 when the paper width is in the range between 16 inches and
19.5 inches.
4.
To release the roller, adjust the lever to the nip release (open) position.
Printer Operator Guide
1-21
Product Overview
Xerox 490/980 Color Continuous Feed Printing System
Paper Path
This section describes the paper path in the machine.
Note
Knowledge of the paper path will be helpful when you clear paper jams.
Paper is loaded in the pre-processing device, and carried through the feeder station. Next, toner
is transferred onto the paper in the printer station, then the toner adheres to the paper in the
fuser station. Finally, paper is sent to the post-processing device.
The loaded paper in the paper path area (shaded portion in the enlarged view) is not viewable
due to the covers in the feeder station. To load paper smoothly, be sure to observe all of the
precautions listed.
For instructions and precautions on using the Pre- and Post- Processing Devices and the Turn
Bar, refer to the documents supplied with these devices.
Paper Type
Note
The printed image may fade due to water, rain, vapor, or moisture. For more information,
please contact your local Xerox service representative.
This machine supports the following paper types:
1.
High grade, recycled paper; weight 64-160 gsm.
2.
Continuous roll paper (with/without pin fed holes).
3.
Pre-printed paper, on condition that registration marks are pre-printed.
1-22
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Product Overview
Storing and Handling Paper
Ensure that appropriate precautions are considered when storing and handling paper.
Printable Area
Only jobs that are run within the following specifications have guaranteed print quality:
1.
Maximum print width: 19.5 inches (495.3 mm)
2.
Paper without feed holes:
a.
b.
3.
0.25 inch (6.35 mm) width from both edges of paper in the horizontal direction.
0.04 inch (1.0 mm) length from the page's bottom edge in the feed direction.
Paper with pin fed holes:
a.
b.
0.50 inch (12.7) mm width from both edges of paper in the horizontal direction.
1.0 mm length from the page's bottom edge in the feed direction (length can only be
in whole inch or half inch settings).
4.
If a high density image is printed on an edge of the print area, the edge of the paper could
be warped, resulting in a device error. Verify print performance fully beforehand.
5.
Supported paper sizes are as follows:
Width/Length
Size
Variability
Width
8.3 in. (210.0 mm) - 19.5 in. (495.3 mm)
Continuously variable
Length
(FCB length)
3.0 in (76.2 mm) - 28 in. (711.2 mm)
Variable in 1/6 inch (4.23
mm) steps
Pin fed: Only whole inch
and 1/2 inch (12.7 mm)
steps
6.
To print on a page wider than 18 inches, the optional extended print mechanisms 1 and 2
are required.
7.
Rotating an image larger than 19.5 inches in length may be accomplished only in pre press
prior to bringing it to the printer.
8.
FCB length of non pre-printed paper does not depend on paper. This means the length can
be changed on the printer.
9.
Supported paper weight is 64 gsm - 160 gsm (35 kg - 135 kg).
10. When running a duplex system, detection of pin fed paper is as follows:
a.
b.
Printer 1 (Upstream) paper is read using pin fed.
Printer 2 (Downstream) is read using ROF (Registration of Feed) mark.
11. When using pin-fed paper, the printer will allow setting of less than whole or 1/2 inch
increments; but an error will occur.
Printer Operator Guide
1-23
Product Overview
1-24
Xerox 490/980 Color Continuous Feed Printing System
Printer Operator Guide
Basic Operation
2
Powering On/Off
Powering On the Machine
When the machine is powered on, the controller software starts, and the machine becomes
ready for printing.
1.
Open the small door on the side of the feeder station to expose the power panel. On a
duplex configuration, set both printers to [Multi] and press the [ON] button of either
printer.
Printer Operator Guide
2-1
Basic Operation
Xerox 490/980 Color Continuous Feed Printing System
2.
In approximately 3 seconds, the lamp will illuminate in green and the touch screen will be
activated.
3.
The Printer Status screen with the message "Initializing..." will appear on the touch screen.
4.
The initial Printer Status screen appears on the touch screen.
5.
It will take about 5 to 10 minutes for the machine to start after powered on.
2-2
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Basic Operation
Powering off the machine
To power off the machine, perform the procedure described below.
1.
Select the [Power Off] button on the touch screen.
2.
Select [OK]. For a duplex printing system, turning off one of the printers causes both the
printers to be tuned off.
3.
In case of abnormal conditions (e.g., the touch screen does not start, or a system
communications error occurred), power off the machine by selecting the [Off] button in the
[Power] area of the panel on the right side of the machine
4.
About 60 seconds later, the touch screen is deactivated. About 30 seconds after that, the
machine is powered off.
5.
When the machine is powered off, the lamp will turn off.
6.
If the system power will not power off, please contact your local Xerox service
representative.
Printer Operator Guide
2-3
Basic Operation
Xerox 490/980 Color Continuous Feed Printing System
Loading Paper
This section describes how to load printing paper into the machine.
Before Loading Paper
Before loading paper, be sure to perform the appropriate steps listed below:
1.
If you are going to load paper after clearing paper jams, clean along the entire paper path.
2.
If you are going to load paper of different width, clean the machine.
3.
Check conditions of the paper to be loaded.
4.
If you have some difficulty in feeding the paper, fold the paper edge as illustrated below.
Paper direction
Note
If you want to use non-standard paper, consult your Xerox service representative before
doing so.
2-4
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Basic Operation
Loading Paper (for Simplex Printing System)
Warning
To carry paper stock of 44 lbs/20 kg or more, use two people or appropriate equipment.
To load paper in the simplex system comprised of a single printer, follow the process below.
1.
Open the Feeder Door.
Feeder Door
2.
Lift the Nip Release Lever to release the roller.
Nip Release Lever
3.
Adjust the nip release sub-lever to the nip release position to release the roller.
Nip Release Sub-Lever
Printer Operator Guide
2-5
Basic Operation
4.
Xerox 490/980 Color Continuous Feed Printing System
Turn the Paper Tension Dial 1 to release the roller.
Paper Tension Dial 1
Roller
Paper Tension Dial 1
5.
Insert paper below the roller (1). Lead the paper over the guide (2), insert it below the roller
(3), and then pull the paper upward.
(3)
(2)
(1)
6.
Ensure the paper is going through the slit in the skew sensor.
Slit
2-6
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
7.
Basic Operation
Insert the paper below the guide, and feed the paper forward.
Note
Feed an extra amount of paper to allow the paper to sag.
Guide
8.
Hold the paper with the paper Retaining Magnet.
Paper Retaining
Magnet
9.
Open the Feeder Front Door.
Feeder Front Door
Printer Operator Guide
2-7
Basic Operation
Xerox 490/980 Color Continuous Feed Printing System
10. Guide the paper into the Print Station 1.
Print Station 1
11. Open both of the Printer 1 and Printer 2 Top Covers.
Printer 2 Top Cover
Printer 1 Top Cover
12. Bring the paper in front of the Transfer Station (K).
Feeder
Station
Paper
Transfer Station (K)
2-8
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Basic Operation
13. Holding the handle, open the Transfer Stations (K), (C), (M) and (Y).
Handle
Y
M
C
K
14. Lead the paper below the Transfer Stations.
Paper
15. Insert the paper below the guide to bring it into the Fuser Station.
Note
Before advancing the paper into the Fuser Station, pull an extra length of paper that will be
fed into the Fuser Station, and hold this length of paper on the sheet guide in the print
station.
Fuser Station
Guide
Printer Operator Guide
2-9
Basic Operation
Xerox 490/980 Color Continuous Feed Printing System
16. Open the Fuser Front Door.
Fuser
Front Door
17. Lead the paper below the guide roller.
Guide roller
18. Let the paper pass between the Fuser Station and the Fuser Facing Area.
Fuser Station Facing Area
2-10
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Basic Operation
19. Open the Fuser Top Cover
Fuser Top Cover
20. Pull up the paper beyond the top.
21. Guide the paper over the guide, and then below the roller.
Guide
Printer Operator Guide
Roller
Guide
2-11
Basic Operation
Xerox 490/980 Color Continuous Feed Printing System
22. Open the Fuser Door.
Fuser Door
23. Pull down the paper.
Fuser Door
24. Lift the Nip Release Lever to release the roller.
Nip Release Lever
Roller
2-12
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Basic Operation
25. Lead the paper below the roller.
Roller
26. Align the paper edge with the paper edge position mark.
Paper edge position mark
Ensure the paper edge is aligned with the line.
Edge position
Printer Operator Guide
mark Line
2-13
Basic Operation
Xerox 490/980 Color Continuous Feed Printing System
27. Lower the Nip Release Lever to lock the roller.
Nip Release Lever
Roller
28. Holding the handle, close the Transfer Stations (K), (C), (M), and (Y).
Handle
Y
M
C
K
29. Remove the paper Retaining Magnet.
Paper Retaining
Magnet
2-14
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Basic Operation
30. On the Feeder Station, align the paper edge with the paper edge position mark.
Paper edge position mark
Note
Ensure the paper edge is aligned with the line. If the paper edge cannot be aligned, check
the feeding device to ensure the paper alignment is correct.
Edge position
mark Line
31. Remove the slack from the paper.
Printer Operator Guide
2-15
Basic Operation
Xerox 490/980 Color Continuous Feed Printing System
32. Lower the Nip Release Lever to lock the roller.
Nip Release Lever
33. Remove the slack from the paper.
34. Align the paper width and set the nip release sub-lever.
Nip Release Sub-Lever
3
Roller
2-16
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Basic Operation
35. Set the Paper Tension Dial 1 to a level suitable for the paper type.
Paper Tension Dial 1
36. Specify the paper width.
Printer Operator Guide
2-17
Basic Operation
Xerox 490/980 Color Continuous Feed Printing System
Loading Paper (for Duplex Printing System)
This section describes the steps to load paper in the duplex system comprised of two printers.
1.
Refer to Loading Paper (for Simplex Printing System) steps 3 through 33, load paper into
the upstream printer (Printer 1).
2.
Select the [Pre-Printer Load] button on the Feeder Station Panel or the downstream printer
(Printer 2). Paper is fed from Printer 1.
Feeder Station Panel
3.
Load the paper referring to the instruction manual supplied with the paper handling
mechanism for duplex system.
4.
Referring to “Loading paper (for simplex printing system), Steps 3 through 33, load paper
into Printer 2.
2-18
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Basic Operation
Loading Pinfed paper
When using pinfed paper, use the following instructions to load and use this particular paper
type.
1.
Load the pinfed paper using the previous instructions on loading paper.
2.
On the GUI screen, select [Paper Settings] and select [Pin Feed Hole] and select [Enable].
3.
Enter the width of the paper.
4.
Enter the paper Length. Pinhole paper length must be in whole or half-inch units. Ex: 11 0/6
inch, 11 3/6 inch, 12 0/6 inch.
5.
Select [Paper Setting] at the top right of the screen.
6.
Select [Settings] on the Feeder unit panel to enable the new paper.
7.
If the pinfed paper has no pre-printed marks, ensure that all selected options match those
in the Pre-printed Info tab. The Pre-printed Enable/Disable should be set to Disable.
Printer Operator Guide
2-19
Basic Operation
8.
Xerox 490/980 Color Continuous Feed Printing System
If the previous setting is not selected appropriately, you will receive the “12-03” fault code.
If you receive this code, perform the following:
a.
Open the Feeder Front Door and "cheat" the interlock.
Note
Ask your local Xerox service representative for the desired interlock cheater to use.
b.
c.
2-20
Check if the ROF LED in front of the machine is aligned in the middle of the pinhole.
If the error persists, refer to the procedure on Adjusting the Mark Reader Sensor
described in Chapter 3.
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
9.
Basic Operation
If the LED is not aligned, adjust the position of the ROF LED by changing the values of the
SENSOR position as shown in the graphic from step 7. Each increment of the slider moves
the ROF LED 0.02 inch (0.5 mm). To get the screen to refresh after moving the slider, go to
the MARK screen and then back to the Sensor screen.
10. Select [Settings] on the Feeder unit panel to enable the new position.
11. Check the ROF LED once again to insure it is in the middle of the pin hole.
Caution
In the following step, ensure that the Feeder Front Door is closed before starting the job.
12. To ensure proper operation, run test jobs. If intermittent fault codes involving the ROF
sensor occur, recheck the position of the ROF sensor and ensure the paper is the correct
type and the pinholes are punched out.
13. If error code B2-C5 occurs, refer to Chapter 3 on how to adjust the mark reading position.
14. If the error code B2-C6 occurs, notify your local Xerox service representative.
Printer Operator Guide
2-21
Basic Operation
Xerox 490/980 Color Continuous Feed Printing System
Paper Settings
This section describes defining the paper to be used.
2-22
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Basic Operation
Creating New Paper
Perform the steps below to define the new paper.
1.
On the Menu screen, select [Resource Management].
2.
Select the [Paper Resource] tab (1), then select [New] (2).
3.
Set the options on the screen.
Printer Operator Guide
2-23
Basic Operation
4.
Xerox 490/980 Color Continuous Feed Printing System
Select [OK]. The newly-created paper is added to the Stock List.
Selecting and loading paper
Follow the steps below to select and load paper.
1.
If the printer status is [Idle], select the [Stop] button. If the printer status is [Paused], go to
Step 3.
2.
Select [OK]. The printer status changes to [Paused].
3.
Select the [Paper setting] button. The [Paper Setting] screen is displayed below.
4.
In the Stock List, select the paper you want to use.
2-24
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
5.
Basic Operation
Confirm or load the selected paper.
The [Load] button
The information on the selected paper is sent to the printer, and the paper is loaded.
The [Paper Setting] button
The information on the selected paper is sent to the printer, but the paper is not loaded.
Printer Operator Guide
2-25
Basic Operation
Xerox 490/980 Color Continuous Feed Printing System
Splicing Paper
This section describes paper splicing. If the loaded paper runs out or is cut during a print job,
you can splice two pieces of paper of the same type with masking tape or other suitable
adhesive tape.
Before Splicing Paper
Follow the precautions as illustrated below.
Note
Ensure there is no waved or wrinkled paper on both of the simplex (Upstream) and duplex
(Downstream) sides.
•
After opening the Feeder Door, align the left edges of paper pieces.
•
Splice the pieces of paper within the following allowances:
L = 1.18 to 2.36 inch (30 to 60 mm) X1 = 0-0.08 inch (0 to 2 mm) X1 <= X2 <= 0.16 inch
(4 mm)
Paper feed direction
Downstream paper
Upstream paper
X1
X2
L
2-26
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Basic Operation
Splicing Paper of the Same Width
When the loaded paper runs out during a print job, you can splice paper of the same or
different width. This section describes the procedure for splicing paper of the same width and
weight. Follow the precautions as illustrated below.
1.
Place the upstream (Printer 1) paper on top of the downstream (Printer 2) paper.
2.
In parallel with the paper direction, put pieces of splicing tape at three positions (center
and both edges).
3.
Place a strip of splicing tape all across the paper width.
a.
b.
c.
Xerox recommended splicing tape is Permacel P781-19mm-55mm.
It is acceptable to use a few short pieces of splicing tape joined together.
Paper weight should be 64 gsm or above.
Paper feed direction
Splicing tape
Downstream
(masking tape, etc.)
paper
Upstream
paper
Simplex Printing System
1.
Splice the paper at a place suitable for the operation (typically at the Pre-Processing
Device).
2.
If the printer status is [READY], select the [Stop] button. If the printer status is [NOT
READY], go to step 4.
3.
Select [OK]. The printer status changes to [NOT READY].
Printer Operator Guide
2-27
Basic Operation
Xerox 490/980 Color Continuous Feed Printing System
4.
Select the [Paper Setting] Button. The [Paper Setting] screen is displayed.
5.
Select the [Load] button. Before the splice reaches the Feeder Station, select the [Stop]
button to stop feeding the paper.
6.
Lift the Nip Release Lever at the Feeder Station to release the roller.
Nip Release Lever
7.
Pull the Nip Release Sub-Lever toward you, and then turn the Paper Tension Dial 1 to
release them.
Paper Tension Dial 1
Nip Release Sub-Lever
2-28
Roller
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
8.
Basic Operation
Open both of the Printer 1 and Printer 2 Top Covers. Then, holding the handle, lift the
Transfer Stations (K, C, M, and Y).
Printer 2 Top Cover
Printer 1 Top Cover
Handle
Y
9.
M
C
K
Lift the Nip Release Lever at the Fuser Station to release the roller.
Nip Release Lever
Roller
10. Feed the paper manually until the splice passes the main driver roller.
Main Driver Roller
Printer Operator Guide
2-29
Basic Operation
Xerox 490/980 Color Continuous Feed Printing System
11. Feed the sagging paper from the sheet guide in the print station into the Fuser Station. Pull
the paper at the paper exit to remove slack from the paper.
Fuser Station
12. Align the paper edges in accordance with the instructions on loading paper, then lock the
following pinches:
a.
b.
Feeder Station: Nip Release Lever, Nip Release Sub-Lever, Paper Tension Dial 1.
Fuser Station: Nip Release Lever.
13. Select the [Load] button and feed the paper slowly until the splice reaches the postprocessing device.
a.
b.
c.
d.
e.
2-30
At some midpoint in feeding the paper, select the [Stop] button and check the paper
condition near the side guide. You can check the paper condition near the side guide by
seeing through the window on the Feeder Door.
When paper feed is in progress, check the status of paper at the side guide section. You
can check it through the window of the feeder cover.
Manually adjust the position of the paper if paper comes off the side guide section or
if the edge of the paper is bent or folded.
When touching the paper being sent at low speed, be careful not to touch its edges.
If you observe any of the following paper conditions, adjust the Paper Tension Dial 1:
The paper is away from the side guide; The paper edge is bent or curved on the side
guide; or the paper edge is folded.
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Basic Operation
Duplex printing system
1.
Splice the paper at a place suitable for the operation (typically at the Pre-Processing
Device).
2.
If the printer status is READY, select the [Stop] button. If the printer status is NOT READY,
go to Step 4.
3.
Select [OK] to change the printer status to NOT READY.
4.
Select [Set/Release] on the Fuser Station panel on both the upstream (Printer 1) and
downstream (Printer 2) printers to release paper pulling force.
5.
Select [Sync.Forward] on the Feeder Station panel on the upstream (Printer 1) printer to
feed paper.
Printer Operator Guide
2-31
Basic Operation
6.
Xerox 490/980 Color Continuous Feed Printing System
Stop paper feed before the splice reaches the Feeder Station of the upstream (Printer 1)
printer. Paper feed can be stopped in one of two ways:
a.
b.
By selecting the [Sync.Forward] button.
By selecting the [Stop] button on the operation panel.
Feeder station panel
Operation panel
7.
Open the feeder cover on the upstream printer, and then lift the Nip Release Lever to
release it.
Nip Release Lever
Feeder cover
8.
Pull the Sub Nip Release Lever toward you, and then turn the paper Tension Dial to 0 to
release it.
Paper Tension Dial 1
Nip Release Sub-Lever
2-32
Roller
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
9.
Basic Operation
Open both of the Printer 1 and Printer 2 Top Covers. Then, holding the handle, lift the
transfer units (K, C, M, and Y)
Printer 1 Top Cover
Printer 2 Top Cover
Handle
Y
M
C
K
10. Open the Fuser cover at the upstream printer, and then lift the Nip Release Lever to release
it.
Nip Release Lever
Roller
Fuser cover
11. Feed the paper manually until the splice passes the Main Driver Roller.
Main Driver Roller
Printer Operator Guide
2-33
Basic Operation
Xerox 490/980 Color Continuous Feed Printing System
12. Feed the sagging paper from the sheet guide in the print station into the Fuser station. Pull
the paper at the paper exit to remove slack from the paper.
Fuser Station
13. Align the paper edges in accordance with the instructions on loading paper, then lock the
following pinches:
a.
b.
Feeder Station: Nip Release Lever, Nip Release Sub-Lever, Paper Tension Dial 1.
Fuser Station: Nip Release Lever.
14. Holding the handle, close the transfer units (K, C, M, and Y) and then close both of the
Printer 1 and Printer 2 Top Covers, the Fuser Cover and the Feeder Cover.
Printer 1 Top Cover
Printer 2 Top Cover
Handle
Y
M
C
K
15. By selecting [Forward] on the Feeder Station Panel at the downstream printer, feed the
paper slowly. This procedure removes any slack in the paper between the upstream and
downstream printers.
2-34
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Basic Operation
16. Release [Forward] with the buffer unit between the upstream and downstream printers set
at an appropriate position (A, S or B in the figure below) to stop the paper transfer and
remove slack in the paper transferred between the upstream and downstream printers.
Upstream
Fuser station
Buffer unit
Turn bar
17. Select [Sync.Forward] on the duplex printer Feeder Panel or Fuser Panel to feed the paper
slowly until the splice passes the Turn Bar.
Feeder Station
Operation
Fuser
Stationpanel
18. After the paper has passed the Turn Bar, select [Stop] on the Fuser Station Panel to stop
paper feed.
19. At some midpoint in feeding the paper, select [Stop] and check the paper condition near
the side guide. You can check the paper condition near the side guide by seeing through the
screen on the Feeder Door.
20. If you observe any of the following paper conditions, adjust the Paper Tension Dial 1 to
make adjustments: The paper is away from the side guide; The paper edge is bent or curved
on the side guide; or the paper edge is folded.
Printer Operator Guide
2-35
Basic Operation
Xerox 490/980 Color Continuous Feed Printing System
21. Adjust the Turn Bar position so that it is aligned with the upstream paper.
90 Turn Bar
Downstream
paper
Upstream
paper
22. Select [Forward] on the upstream printer Fuser Station Panel to feed the paper for about 20
seconds to produce a slack in the paper on the buffer unit between upstream and
downstream printer.
Upstream
Fuser station
Buffer unit
Turn bar
23. After the splice passes the Turn Bar, cut the paper at the splice area. Then put the upstream
paper on top of the downstream paper to splice the paper ends again.
Buffer unit
Turn bar
2-36
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Basic Operation
24. Open the downstream printer Feeder Cover and lift the Nip Release Lever to release the
roller.
Nip Release Lever
Feeder cover
25. Pull the sub Nip Release Lever, and then set the paper Tension Dial 1 to “0” to release.
Paper Tension Dial 1
Roller
Nip Release Sub-Lever
26. Open both of the upstream Printer 1 and downstream Printer 2 Top Covers. Then, holding
the handle, lift the transfer units (K, C, M, and Y).
Printer 1 Top Cover
Printer 2 Top Cover
Handle
Y
M
Printer Operator Guide
C
K
2-37
Basic Operation
Xerox 490/980 Color Continuous Feed Printing System
27. Open the Fuser Cover at the duplex printer, and then lift the Nip Release Lever to release it.
Nip Release Lever
Roller
Fuser cover
28. Feed the paper manually until the splice passes the main Driver Roller. Check the paper
positioned between the upstream and duplex printers for slack.
Main Driver Roller
29. Align the paper edges in accordance with the instructions on loading paper, then lock the
following pinches:
a.
b.
Feeder station: Nip Release Lever, Sub Nip Release Lever, Paper Tension Dial.
Fuser Station: Nip Release Lever.
30. Holding the handle, close the transfer units (K, C, M, and Y) and then close both of the
Printer 1 and Printer 2 Top Covers, the Fuser Cover and Feeder Cover.
Printer 1 Top Cover
Printer 2 Top Cover
Handle
Y
2-38
M
C
K
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Basic Operation
31. Select the [Sync.Forward] button on the downstream printer Feeder Panel or Fuser Panel to
feed the paper.
Feeder Station
Fuser
Station
Operation
panel
30. When the splice has been fed into the Post-Processing Device, select the [Stop] button on
the Feeder Station Panel to stop feeding the paper.
31. When the paper has been successfully loaded, select the [Paper Setting] button on the
upstream printer touch screen.
32. By selecting the [Load] button, feed the paper slowly until the load completes.
33. At some midpoint in feeding the paper, select the [Stop] button and check the paper
condition near the side guide. You can check the paper condition near the side guide by
seeing through the screen on the Feeder Door.
34. If you observe any of the following paper conditions, adjust the Paper Tension Dial 1 to
make adjustments:
a.
b.
c.
The paper is away from the side guide.
The paper edge is bent or curved on the side guide.
The paper edge is folded.
Printer Operator Guide
2-39
Basic Operation
Xerox 490/980 Color Continuous Feed Printing System
Splicing paper of different widths
When the loaded paper runs out, you can splice paper of different widths.
1.
If the upstream paper width is narrower, put the splicing tape all across the upstream paper
width.
2.
If the upstream paper width is larger, fold the corner of the downstream paper as in valley
fold as illustrated below.
Simplex printing system
1.
Splice the paper at a place suitable for he operation (typically at the Pre-Processing Device).
2.
If the printer status is Ready, select the [Stop] button. If the printer status is NOT READY,
go to Step 4.
3.
Select [OK]. The printer status changes to NOT READY.
4.
Select the Paper Setting button. The Paper Setting screen is displayed.
5.
Select the [Load] button. Before the splice reaches the Feeder Station, select the [Stop]
button to stop feeding the paper.
2-40
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
6.
Basic Operation
Lift the Nip Release Lever at the Feeder Station to release he roller.
Nip Release Lever
7.
Pull the Nip Release Sub-Lever toward you, and then turn the paper tension Dial 1 to release
the Roller.
Paper Tension Dial 1
Roller
Nip Release Sub-Lever
8.
Open both of the Printer 1and Printer 2 Top Covers. Then, holding the handle, lift the
Transfer stations (K, C, M, and Y).
Printer 2 Top Cover
Printer 1 Top Cover
Handle
Y
M
Printer Operator Guide
C
K
2-41
Basic Operation
9.
Xerox 490/980 Color Continuous Feed Printing System
Lift the Nip Release Lever at the Fuser Station to release the Roller.
Nip Release Lever
Roller
10. Feed the paper manually until the splice passes the main Driver Roller.
Main Driver Roller
11. Feed the sagging paper from the sheet guide in the print station into the Fuser Station. Pull
the paper at the paper exit to remove slack from the paper.
Fuser Station
Note
Set the nip release sub-lever according to the paper width chosen on the simplex system.
12. Align the paper edges in accordance with the instructions on loading paper, then lock the
following pinches.
a.
b.
2-42
Feeder Station: Nip Release Lever, Nip Release Sub-Lever, Paper Tension Dial 1.
Fuser Station: Nip Release Lever.
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Basic Operation
13. By selecting the [Load] button, feed the paper slowly until the splice reaches the postprocessing device.
a.
b.
c.
d.
At some midpoint in feeding the paper, select the [Stop] button and check the paper
condition near the side guide. You can check the paper condition near the side guide by
seeing through the window on the Feeder Door.
When paper feed is in progress, check the status of paper at the side guide section. You
can check it through the window of the feeder cover.
Manually adjust the position of the paper if paper comes off the side guide section or
if the edge of the paper is bent or folded.
When touching the paper being sent at low speed, be careful not to touch its edges.
14. If you observe any of the paper conditions below, adjust Paper Tension Dial 1:
a.
b.
c.
The paper is away from the side guide.
The paper edge is bent or curved on the side guide.
The paper edge is folded.
15. After the splice passes through the Turn Bar, cut the splice area.
16. Adjust the Turn Bar position so that it is aligned with the upstream paper.
90 Turn Bar
Downstream
paper
Upstream
paper
17. Align the opposite edges and splice the paper pieces again.
Printer Operator Guide
2-43
Basic Operation
Xerox 490/980 Color Continuous Feed Printing System
18. Feed the paper at a lower speed until the splice reaches the Post-Processing Device, as in
the steps for Printer 1 (Step 2 and the subsequent steps).
2-44
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Basic Operation
Splicing after clearing paper jams
This section describes the procedure for splicing after paper james are cleared.
1.
Load paper from the Feeder Station.
2.
Splice the paper at the Fuser Station.
Note
Be sure to avoid causing skewed or misaligned paper when splicing.
Paper edge position mark
3.
Ensure the paper edge is inside the paper edge position mark.
Note
Ensure the paper edge is aligned with the line.
Edge position
Printer Operator Guide
mark Line
2-45
Basic Operation
4.
2-46
Xerox 490/980 Color Continuous Feed Printing System
Load the paper referring to the section on “Selecting and loading paper”.
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Basic Operation
Checking If Paper Is Running Correctly
After loading or splicing paper, make sure that paper is running correctly in the machine. If any
problem persists after the procedure below has been performed, please contact the customer
support center.
Checking if paper is running correctly
This section describes the procedure for checking if the paper is running correctly.
1.
Select the [Eject] button on the touch screen to advance the paper in the machine.
2.
After 3 to 10 seconds, select the [Stop] button to stop feeding the paper.
Warning
In the following step, do not touch the moving paper. Serious injury can result.
3.
Through the window on the Feeder Door, observe how the paper is running along the side
guide.
Window
Printer Operator Guide
2-47
Basic Operation
4.
Xerox 490/980 Color Continuous Feed Printing System
If the paper is away from the side guide, refer to the next section. If the paper is to close to
the side guide and the paper edge is bend, curved or folded on the guide, refer to the
section devoted to this on the next page.
Side guide
5.
2-48
The paper is correctly running if the paper edge is just along the side guide.
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Basic Operation
If the paper is away from the side guide
If the paper is away form the side guide, perform the steps listed below.
1.
Load the paper again in the Feeder Station, making sure the paper is placed in he correct
position.
2.
Turn the left paper tension Dial 1 to he next higher level. If the left dial is already set to [9],
turn the right dial to the next higher level.
3.
Close the Feeder Door, and then select the [Eject] button on the touch screen to advance
the paper in the machine.
4.
After 3 to 20 seconds, select the [Stop] button to stop feeding the paper.
Warning
In the following step, do not touch the moving paper. Serious injury can result.
5.
Through the window on the Feeder Door, observe how the paper is running along the side
guide.
Window
Printer Operator Guide
2-49
Basic Operation
6.
Xerox 490/980 Color Continuous Feed Printing System
If the paper is still away from the side guide, repeat Steps 1 to 4 until the paper runs just
along the guide.
Note
If both the left and right Paper Tension Dial 1 are set to [9] and the paper is still away from
the side guide, turn the Paper Tension Dial 2 to the next higher level.
2-50
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Basic Operation
If the paper edge is bent, curved or folded
If the paper edges bent, curved, or folded on the side guide, follow the steps below.
1.
Load the paper again in the Feeder Station, and make sure the paper is placed in the
correct position.
2.
Turn the right Paper Tension Dial 1 to the next lower level. If the right dial is already set to
[0], turn the left dial to the next lower level.
3.
Close the Feeder Door and then select the [Eject] button on the touch screen to advance
the paper in the machine.
4.
After 3 to 10 seconds, select the [Stop] button to stop feeding the paper.
Warning
In the following step, do not touch the moving paper. Serious injury can result.
5.
Though the window on the Feeder Door, observe how the paper is running along the side
guide.
Window
Printer Operator Guide
2-51
Basic Operation
6.
Xerox 490/980 Color Continuous Feed Printing System
If the paper edge is still bent, curved, or folded, repeat Steps 1 through 4 until it is smooth.
Note
If both the left and right Paper Tension Dial 1 are set to [0] and the paper edges are bent or
curved, turn the Paper Tension Dial 2 to the next lower level.
2-52
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Basic Operation
Unloading or Ejecting Paper
Unloading paper
To unload or take out paper from the Post-Processing Device, refer to the instruction manual
supplied with the device.
Ejecting paper
To eject paper from the machine, select the [Eject] button on the touch screen.
1.
If the printer status is Idle, select the [Stop] button. If the printer status is Paused, go to
Step 3.
2.
Select [OK]. The Printer status changes to Paused.
3.
Select [Eject]. A confirmation message appears.
4.
Select [OK].
5.
The printer status changes to EJECTING. The paper ejection method differs depending on
the current eject setting. For information on changing the setting, refer to the next section
on Eject Setting.
Printer Operator Guide
2-53
Basic Operation
Xerox 490/980 Color Continuous Feed Printing System
Eject Setting
You can change the paper ejection method that is used when the [Eject] button is selected.
Select the [Eject] button for approximately 3-5 seconds to display the screen shown below.
1.
[Close] button - Select to close the screen with no action.
2.
[Setting] button - Select to apply your changes and close the screen.
3.
Mode - Select the paper ejection mode.
a.
b.
4.
[Normal] - Every sheet of paper will be ejected.
[Page Specification] - Only the selected pages will be ejected.
Specify the number of pages using the virtual keypad, in the range of 1 to 1,023 pages.
While the Page Specification mode is selected, the specified page number appears on the
[Eject] button. For example, specifying "88" changes the appearance of the [Eject] button
as shown below.
Note
The Number of Pages field is enabled only when the [Page Specification] button is
selected. At the start and end of paper feeding, the actual amount of ejected paper may be
different from the specified number of pages.
2-54
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Basic Operation
When to eject paper
Caution
Always eject paper whenever a hard stop is experienced. If an eject is not performed, the
internal components of the machine will require cleaning. See the following for what is
classified as a hard stop.
Paper must be ejected from the machine whenever there is a hard stop.
A hard stop is classified as any sudden stopping of a print job, either as a result of a manual
stop operation or an internal error of the machine. A hard stop will cause streaks of each color
(Y/M/C/K) to appear on the paper inside the machine.
Warning
In the following procedure, do not touch the moving paper as you uncover the Paper Entrance
Sensor. Serious injury can result.
In addition, if a Hunkeler post-processing cutter/stacker is used, these streaks of color will be
misinterpreted by the paper entrance sensor as a cut mark. Using the picture below as a guide
(see yellow highlighting), cover the Paper Entrance Sensor with a folded piece of white paper
until the color streaks pass through the post-processor. The folded piece of white paper can
then be removed and normal operation of the post-processor cutter device will resume.
Printer Operator Guide
2-55
Basic Operation
Xerox 490/980 Color Continuous Feed Printing System
Changing from Duplex to Simplex
Configuration
Note
If the pre/post equipment needs to communicate differently in simplex than in duplex,
please notify your local Xerox service representative.
This following procedure outlines steps to switch the printers from a duplex to a simplex
configuration.
1.
Both of the print engines work independently in the simplex mode. Power-off both the
upstream and downstream printers.
Warning
Ensure that the upstream and downstream printers have completely powered off before
disconnecting cables in Step 2.
2.
2-56
Move the Rocker Switch shown below from to on the Feeder Power Panel
on both the upstream and downstream printers.
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
3.
Basic Operation
Disconnect the following cables from either the upstream or downstream printer:
a.
b.
c.
d.
LAN cable
IEEE 1394 cable
Power Synchronization Cable
RPC plug
4.
Power-on both printers.
5.
After completing the start-up sequences, each printer will automatically recognize that the
duplex cables have been disconnected and will display a pop-up window on the IOT-UI
asking how to proceed. Select [Single].
6.
Ensure the Printer Status screen shows only one machine.
7.
Load the paper through or under the paper path to the finishing equipment as described in
the section on loading paper.
Printer Operator Guide
2-57
Basic Operation
Xerox 490/980 Color Continuous Feed Printing System
Changing from Simplex to Duplex
Configuration
Note
If the pre/post equipment needs to communicate differently in simplex than in duplex,
please notify your local Xerox service representative.
This following procedure outlines steps to revert the printers (initially used in a duplex
configuration but then changed to a simplex configuration) back to a simplex configuration.
1.
Ensure that both printers are powered off.
2.
On the Feeder Power Panel, move the Rocker Switch shown below from to
on both the upstream and downstream printers.
2-58
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
3.
Re-connect the duplex cables shown in the following table and diagram that were
previously removed:
a.
b.
c.
d.
Re-connect LAN cable
Re-connect IEEE 1394 cable
Re-connect Power Synchronization Cable
Re-connect RPC plug
Upstream
Downstream
LAN cable
LAN3
LAN2 (a)
IEEE1394 cable
UP3I2
UP3I1 (b)
Power Sync cable
RPC-in
RPC-out (c)
RPC plug
RPC-out
RPC-in (d)
4.
Basic Operation
Power on both printers.
Printer Operator Guide
2-59
Basic Operation
Xerox 490/980 Color Continuous Feed Printing System
Note
Steps 5-11 can be performed on either the upstream or downstream printer.
5.
Select [Menu], [Permission], [System Administrator].
6.
Type in the password xerox and select [OK].
7.
Select [Menu], [Printer Management], and the [Printer Config] tab.
8.
Double-select a printer in the Device List, drag the printer icon displayed in the device
display area (to the right of the device list) and drop it either before or after the other
printer icon as shown in the following diagram.
2-60
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
9.
Basic Operation
Select [Setting] to save changes and [OK] at the prompt that appears. The other printer
will power-off. Next, select [Configuration Change End]. The printer that is currently being
used will power-off.
Caution
Wait at least 30 seconds after the upstream printer has shut down before performing the
following steps. Failure to do so may result in damage to internal components of the printers.
10. Power on either the upstream or downstream printer.
11. Check that the printer status screen on the upstream and downstream printers appears in
the duplex configuration mode.
12. Pause both printers by selecting [Stop] and [OK] at the prompt that appears.
13. Select [Paper Setting] and the [Basic Info] tab. Set information based upon the paper roll
loaded in the pre-processing device.
14. Select the [Pre-printed Info] tab. Set information based upon the paper roll loaded in the
pre-processing device.
15. Select [Paper Setting] and [Load] at the prompt that appears.
16. Wait for paper to load through the pre-processing devices, upstream printer, turn bar(s),
downstream printer, and post-processing devices.
17. If the pre/post devices must be moved to accommodate the change in the paper path
length between the machines, please contact your Xerox customer service representative.
Printer Operator Guide
2-61
Basic Operation
2-62
Xerox 490/980 Color Continuous Feed Printing System
Printer Operator Guide
Maintenance
3
Before Starting Maintenance
This section shows general maintenance steps for your information before starting machine
maintenance.
Basic Steps
Before performing machine maintenance in the steps below:
1.
Check the message appearing on the touch screen.
2.
Find the corresponding message and perform the appropriate maintenance work.
Clearing Paper Jams
This section describes how to clear paper jams that may occur in the machine. When a paper
jam occurs, the following message appears in the Printer Status area on the touch screen.
Printer Operator Guide
3-1
Maintenance
Xerox 490/980 Color Continuous Feed Printing System
Before handling paper jams
When handling paper jams, always follow the precautions below.
Caution
In case a paper jam occurs causing smoke, select the [Power Off] button, power off the
machine, and notify service immediately.
In this case, do not open any doors or covers on the front side of the machine.
Handling the Fuser Station
While the lamp is off, do not take out or pull paper from the Fuser Station. Once the lamp
illuminates, open the Fuser Station and pull out the paper.
Immediately after the machine has stopped, the paper left inside the Fuser Station is heated to
an extremely high temperature. Do not pull out the heated paper because it may cause fire.
Even if the paper looks questionable, do not pull out or move the paper in any way until the
green lamp on the Fuser Station illuminates.
If pieces of jammed paper remain in the Fuser Station
Any bit or piece of jammed paper remaining may cause the paper to burn. When clearing paper
jams, carefully make sure that no bits or pieces of jammed paper are left inside or around the
Fuser Station.
Do not print with a piece of paper left inside the Fuser Station or on the nearby print path. Toner
may not adhere to the paper or the paper may get burned. After clearing paper jams, make sure
no bits or pieces of paper are left inside the Fuser Station.
Areas with warning labels indicating high temperature may cause you to get burned.
Warning
•
Do not touch these areas until they are cooled down.
•
Carefully close the Fuser Station and Transfer Station to avoid injury to your fingers.
•
Do not touch loose toner particles.
Toner is not fused on the paper when it is between the Transfer Station and the Fuser Station.
Print defects may occur if torn paper is trapped inside the Transfer Station.
3-2
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Maintenance
Steps to Clear Paper Jams
This section describes the steps to clear paper jams assuming that toner is fused on the paper.
Caution
If the paper has unfused toner, do not use the Autoload panel to load the paper.
•
•
Do not allow unfused toner to pass through the Fuser Station. If this should occur, clean
the glass surface in the Fuser Station.
1.
Open the Fuser Door.
Fuser Door
2.
Lift the Nip Release Lever to release the Roller.
Nip Release Lever
Roller
3.
Open both of the Printer 1 and Printer 2 Top Covers.
Printer 2 Top Cover
Printer Operator Guide
Printer 1 Top Cover
3-3
Maintenance
4.
Xerox 490/980 Color Continuous Feed Printing System
Holding the handle, open the Transfer Stations (K), (C), (M), and (Y).
Handle
Y
5.
M
C
K
Open the Feeder Door.
Feeder Door
6.
Pull the Nip Release Sub-Lever toward you to release the lower Roller.
Roller
Nip Release Sub-Lever
3-4
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
7.
Maintenance
Lift the Nip Release Lever to release the Roller.
Nip Release Lever
8.
Turn the Paper Tension Dial 1 to release the Roller.
Paper Tension Dial 1
Roller
9.
Cut the paper at the Feeder Station.
Cut paper
Printer Operator Guide
3-5
Maintenance
Xerox 490/980 Color Continuous Feed Printing System
10. Cut the paper at the Fuser Station.
Cut paper
11. Pull the paper forward from the middle of the Print Station.
12. Clean the fusing area in the Fuser Station as outlined in Chapter 5.
3-6
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Maintenance
13. Clean the sheet guide in the Print Station as outlined in Chapter 5.
14. Load the paper referring to the steps in Chapter 2.
15. Select [Reset] on the touch screen to clear errors, and then select [Start].
16. On the Paper Setting screen, select [Load] to make sure the paper is correctly fed.
Printer Operator Guide
3-7
Maintenance
Xerox 490/980 Color Continuous Feed Printing System
Adjusting Print Position
This section describes how to adjust print positions. To display the screen for adjusting print
density, select [Printer Management] in he Menu screen, and then select the [Dens/Pos
Adjust] tab.
Positions of pre-printed forms and process marks cannot be adjusted here; these are defined in
imposition files.
Note
To adjust print positions, the printer has to be in the Paused status. If the status is Idle,
change it to Pause.
3-8
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Maintenance
Adjusting Print Position
Setting value fields
Select the setting value field for Horizontal Position or Vertical Position to display a virtual
numerical keypad which allows you to enter values.
Horizontal/vertical adjust buttons
Select and hold the horizontal or vertical adjusting button to increase or decrease the value
continuously.
Decreases a negative value.
Increases value.
Decreases a negative value.
Increases value.
Resets horizontal/vertical offset values to 0.
Unit (mm or inch) select buttons
Use these buttons to select the unit of setting values, [mm] or [inch].
Printer Operator Guide
3-9
Maintenance
Xerox 490/980 Color Continuous Feed Printing System
Adjusting Print Density
To display the screen for adjusting print density, select Printer management in the Menu screen,
and then select the [Dens/Pos Adjust] tab.
The factory default is 4. To adjust print density, the printer has to be in the Paused status. If the
status is Idle, change it to Paused.
Adjusting Print Density
You can change the print density by selecting one of seven density levels. In black and white mode,
use the [B/W] tab. In full color mode, make the setting for each of the tabs (colors); [K] (black),
[C](cyan), [M] (magenta), and [Y] (yellow).
Select one from predefined seven density levels by selecting the
[(-)] or
[(+)] button.
Density adjustment
tabs
3-10
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Maintenance
Adjusting print density (color mode)
In color mode, make setting for each of the tabs (colors).
[K] black
[Y] yellow
[C] cyan
[M] magenta
You should see improvement in the color balance when you change the density level in the color
mode.
Printer Operator Guide
3-11
Maintenance
Xerox 490/980 Color Continuous Feed Printing System
Color Mode Setting
You can select either Color or Black/White mode. To display the screen for selecting the color
mode, select [Printer Management] in the Menu screen, and then select the [Color Mode] tab.
"Monochrome" indicates the mode where data is printed with black toner only.
If the print mode is set to Monochrome, but the mode was already set to Color in the Color tab
on the Queue Management screen, a message will appear before a print job asking you to
confirm your desire to continue the job.
If the print mode is set to Color, but the mode was already set to Monochrome in the Color tab
on the Queue Management screen, no message appears before a print job.
Note
You cannot change the color mode when there is any active print job and the job is being
processed. To select the color mode, the printer has to be in the Paused status. If the status
is Idle, change it to Paused.
Selecting the Color Mode
To select the color mode, select either the [Monochrome] or [Color] button.
[Setting] and [Cancel] buttons
Select [Setting] to confirm the changes, or select [Cancel] to cancel the changes.
3-12
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Maintenance
Pausing a Print Job
This section describes how to pause a print job. A print job can be paused by selecting the
[Stop] button on the touch screen.
Pausing a Print Job with the [Stop] Button
When you select [Stop] on the touch screen, the following confirmation message appears.
[OK]
When you select [OK], any print job being processed is paused and the printer status changes to
[NOT READY].
Printer Operator Guide
3-13
Maintenance
Xerox 490/980 Color Continuous Feed Printing System
[Cancel]
If you select [Cancel], the machine will proceed with processing print jobs.
Changes to Pending Jobs in Print Queue
All changes to pending jobs in the print queue will cause the current print job to stop and give
the message, “I became an intermittent print state in job ID #____”.
1.
Select [OK] and make all necessary changes to the pending jobs (Cancel, Hold, Delete, etc.)
2.
Select [Start] to resume printing.
Canceling a Print Job
You can cancel the print job when the printer status is [READY]. When you select [Cancel], the
following message appears.
[OK]
When you select [OK], the {Fault Job Handling] window is displayed. The printer status then
changes to [Error].
3-14
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Maintenance
Note
This window does not appear for IPDS or other streaming jobs.
The [Fault Job Handling] window has the options and functions listed below.
Option name
Function
Restart Printing
Resumes printing the job. When this option is selected, two
options ([Print Continuously] and [Physical Page Specification])
become available. The [Physical Page Specification] option
allows you to specify the physical page number from which
printing is resumed.
Interrupt Printing (Hold)
Stops and holds the print job.
Cancel Printing (Delete)
Cancels the print job. When this option is selected, the print job
is removed from the queue. The job data is also deleted from
the spool.
Restart Printing
When [Restart Printing] is selected, the following options
become available:
Print Continuously
Resumes printing the job.
Physical Page Specification
Allows to specify the physical page number from which printing
is resumed. [Printing Start Page Range] is displayed.
Printing Start Page Range
Allows to specify the physical page number from which printing
is resumed.
Close
Closes the [Fault Job Handling] window without applying the
changes on this window. The [Error] printer status is unchanged.
When [Reset] is selected, the printer status changes to
[Paused].
OK
•
Applies the changes made on this window.
Select [No] to close the confirmation window.
Printer Operator Guide
3-15
Maintenance
Xerox 490/980 Color Continuous Feed Printing System
•
Use the [Reset] button to clear errors from the machine. To resume printing with the
[Restart Printing] button on the [Fault Job Handling] window, errors must be cleared from
the machine in advance.
•
If you select [No] to close the confirmation window or select [Close] to close the [Fault Job
Handling] window, the job still remains active with the Fault status. You have to hold,
delete, or resume the job as appropriate.
•
If recovery page print is specified in the imposition file, the recovery page is printed on one
sheet when you select [Restart Printing] to resume printing.
•
If job mark print is specified in the imposition file, the job mark is printed following the
recovery page when you start printing from the beginning.
•
In Duplex mode, even numbers are displayed both as the Printing Start Page on the pop-up
dialog and as the physical page numbers appearing on printed pages.
•
In Duplex mode, printing is resumed from the front of a page even though an even page
number is specified as the print resuming page.
•
Continuous printing (as with printing from the specified page number of printed page)
restarts from the last completed page number plus one. "Completed page" means the page
that is already stacked.
3-16
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Maintenance
Adjusting Print Quality
This section describes print quality problems and how to solve them. If the print quality is not
good, follow the steps described below.
If the problem persists after the steps are performed, please contact the customer support
center.
For information about calibration in the Color mode, refer to the Color Management Guide.
Scumming
Scumming is the phenomenon in which toner dust remains entirely or partially on the printed
surface. If scumming occurs in black and white mode, perform the procedure below to solve the
problem.
1.
Make sure all doors and covers on the machine are closed.
2.
Select [Printer Management] on the touch screen, then select the [Dens/Pos Adjust] tab.
3.
Select the [B/W] tab.
4.
Select the [(-)] button to lower the print density level.
5.
Print about 30 or 40 test pages.
6.
Lower the density level until there occurs no scumming.
a.
b.
For more information on covers and doors on the machine, refer to Chapter 1.
For more information on changing the density level, refer to the section on Adjusting
Print Density.
Print Image Partially Missing
If the print image is partially missing (curved or straight white stripes appear), perform the
procedure below to solve the problem.
1.
Make sure the paper is correctly loaded.
2.
If the paper is damp, replace with new paper.
Uneven print density
If print density is uneven in black and white mode, perform the procedure below to solve the
problem.
1.
Make sure the paper is correctly loaded.
2.
Select [Printer Management] on the touch screen, then select the [Dens/Pos Adjust] tab.
3.
Select the [B/W] tab.
4.
Select the [(+)] button to raise the print density level.
5.
Print about 30 or 40 test pages.
6.
Raise the density level until the print quality is improved.
a.
b.
For more information on loading paper, refer to Chapter 2.
For more information on changing the density level, refer to the section on adjusting
print density in this chapter.
Printer Operator Guide
3-17
Maintenance
Xerox 490/980 Color Continuous Feed Printing System
Smudge (unclear print)
Smudge is the phenomenon in which the outline of print image is unclear.
If smudge occurs, and it occurs immediately after powering on the machine, wait 10 minutes
then try printing again.
Uneven toner fixing
If toner fixing is uneven in the black and white mode, perform the procedure below to solve the
problem.
1.
Make sure the glass surface in the Fuser Station is clean.
2.
Select [Printer Management] on the touch screen, then select the [Dens/Pos Adjust] tab.
3.
Select the [B/W] tab.
4.
Select the [(-)] button to lower the print density level.
5.
Print about 30 or 40 test pages.
6.
Lower the density level until toner is evenly fixed.
For information on checking the glass surface in the Fuser Station, refer to the section on
cleaning the fuser station.
For more information on changing the density level, refer to the section on Adjusting Print
Density.
Irregular printed image (enlarged, reduced, overlapped, or
shifted)
If the printed image is irregular, make sure the paper is correctly loaded.
For more information on loading paper, refer to the section on Loading Paper.
Void
Void is the phenomenon in which some white spots appear in a black print image. If void occurs
in black and white mode, follow the steps below to solve the problem.
1.
Select [Printer Management] on the touch screen, then select the [Dens/Pos Adjust] tab.
2.
Select the [B/W] tab.
3.
Select the [(-)] button to lower the print density level.
4.
Print about 30 or 40 test pages.
5.
Lower the density level until there occurs no void.
For more information on changing the density level refer to the section on Adjusting Print
Density.
3-18
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Maintenance
Poor print quality shortly after power-on
If the machine is powered on after a long period since its last power-off, the images may be
printed in poor quality probably because the machine is in a damp operating environment.
In this case, keep the machine powered on all night. The machine should then consistently
provide good print quality.
Poor quality in hot or damp environments
If the machine is in a hot or damp environment, lower the print density level.
For more information on changing the density level, refer to the section on Adjusting Print
Density.
Others
When the room temperature suddenly drops in a damp environment, condensation may
develop in the machine to cause unclear print or paper jams.
Poor print quality may also be caused by some machine maintenance practices, such as the
need for corotron cleaning, or paper conditions.
Printer Operator Guide
3-19
Maintenance
Xerox 490/980 Color Continuous Feed Printing System
Adjusting the Mark Reading Position
This section describes how to adjust the mark reading position.
Adjust the mark read sensor when the following errors have occurred:
Note
If a mark read error occurs on the upstream printer in a duplex printing system, measure
the paper width.
1.
B2-C4: Registration mark read error (face).
2.
B2-C5: Registration mark read error (back).
3.
12-03: Mark detection time-out error. This error may also require a mark read sensor
adjustment. First make the following two checks:
a.
b.
Check that the paper is set at the correct position.
Check the paper settings for the presence or absence of pin fed holes and also check
that preprinted information has been correctly set.
If a mark read sensor adjustment is required, enter the Sensor Pos. Adjust screen. Select the
[Printer Management] button on the menu screen and select the [Sensor] tab to display the
setup screen.
If the Mark Reading Position error occurs, the reading position needs to be adjusted. Based on
the paper width measurement value and paper width setting value, use one of the following
procedures that best describes the current situation:
•
Paper width measurement value < Paper width setting on page 21 of this chapter
•
Paper width measurement value > Paper width setting on page 22 of this chapter
•
Paper width measurement value = paper width setting on page 23 of this chapter
•
ROF mark measurement value < 0.97 mm on page 24 of this chapter
•
ROF mark measurement value > 0.97 mm on page 25 of this chapter
•
ROF mark measurement value = 0.97 mm on page 25 of this chapter
3-20
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Maintenance
Paper width measurement value < Paper width setting
Note
Adjustment value = (Paper width setting (in or mm) - Paper width measurement value/0.05
mm (fractions rounded off to a whole number).
1.
Select the [+] button at Reading Position to set an adjustment value.
2.
Select the [Setting] button.
3.
Reprint the job to make sure that no mark read error occurs.
4.
If the mark read error persists, perform the Reading Position Change Procedure on page 26 of
this chapter.
Printer Operator Guide
3-21
Maintenance
Xerox 490/980 Color Continuous Feed Printing System
Paper width measurement value > Paper width setting
1.
Select the [-] button at [Reading Position] to set an adjustment value.
Note
Adjustment value = (ROF mark measurement value - 0.97 mm)/0.5 mm (fractions rounded
off to a whole number).
2.
Select the [Setting] button.
3.
Reprint the job to make sure that no mark read error occurs.
4.
If the mark read error persists, perform the Reading Position Change Procedure on page 26 of
this chapter.
3-22
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Maintenance
Paper width measurement value = paper width setting
Note
This procedure is also for when the calculated value = 0.
1.
If a mark read error occurs on duplex print in a duplex printing system, measure the
distance of the ROF mark from the edge of paper.
Paper edge
Measurement position
ROF mark
2.
If the mark read error persists, perform the Reading Position Change Procedure on page 26 of
this chapter.
Printer Operator Guide
3-23
Maintenance
Xerox 490/980 Color Continuous Feed Printing System
ROF mark measurement value < 0.97 mm
1.
Select the [+] button are Reading Position to set an adjustment.
Note
Adjustment value = (0.97 mm - ROF mark measurement value)/0.5 mm (fractions rounded
off to a whole number).
2.
Select the [Setting] button.
3.
If the mark read error persists, perform the Reading Position Change Procedure on page 26 of
this chapter.
3-24
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Maintenance
ROF mark measurement value > 0.97 mm
Note
Adjustment value = (ROF mark measurement value - 0.97 mm)/0.5 mm (fractions rounded
off to a whole number).
1.
Select the [-] button at Reading Position to set an adjustment.
2.
Select the [Setting] button.
3.
Reprint the job to make sure that no mark read error occurs.
4.
If the mark read error persists, perform the Reading Position Change Procedure on page 26 of
this chapter.
ROF mark measurement value = 0.97 mm
Note
This procedure is also for when the calculated value = 0.
Perform the Reading Position Change Procedure on page 26 of this chapter.
Printer Operator Guide
3-25
Maintenance
Xerox 490/980 Color Continuous Feed Printing System
Reading Position Change Procedure
1.
Change Reading Position by repeating steps 1 through 4 in the following graphic by
changing the settings in the order of (1) to (4), until read errors no longer exist.
Current
value-n
X-n
Current Current Current
value -1 value value+1
X-1
X
X+1
Current
value+n
X+n
(1)
(2)
(3)
(4)
2.
3-26
Reprint the job to make sure that no mark read error occurs.
Printer Operator Guide
Replacing
Consumables
4
Before Replacing Consumables
This chapter provides information about types of consumables and replacement procedures.
Carefully read the descriptions before replacing consumables.
For efficient operation of the machine, it is recommended to replace the appropriate
consumable item immediately after the prompting message appears. It is also recommended
to always have extra consumables in stock
Warning
•
Keep toner away from your eyes and mouth. If toner gets on your skin, immediately wash
it off.
•
When toner has spilled onto the floor, use a broom or a non-woven cloth moistened with a
neutral detergent. To avoid sparks and possible explosion, never use a household vacuum
cleaner to clean spilled toner.
•
When replacing toner cartridges or waste toner containers, toner may spill on to the floor.
To avoid soiling the floor, lay cloth or paper (such as packing paper for paper stock) on the
floor in advance of replacing consumables.
•
While a print job is in progress, you can supply toner, replace waste toner containers, and/
or replace smoke filters. To replace other types of consumables, wait until the print job is
finished.
•
If a message with the mark
appears on the touch screen indicating replacement of
particular consumables, print jobs cannot begin until the replacement is finished.
Caution
Printer Operator Guide
4-1
Replacing Consumables
Xerox 490/980 Color Continuous Feed Printing System
About Consumables
The use of consumables not recommend by Xerox may impair quality and performance of the
machine. Use only the consumables recommended by Xerox for the machine.
Types of Consumables
Caution
Before using consumables, carefully read the instructions and precautions written on the
packages and/or containers.
The machine uses the following consumable items that need to be replaced periodically. They
are made according to specifications suitable for the machine.
Note
The print capacity varies depending on print settings and the complexity of the image. Use
the listed print capacity values in the table below only as estimates.
Part
Replacement
quantity
Weight
Number
Stock
quantity
Print
capacity
Black Toner
006R01321
2 items
1 item
4 kg
36K
Cyan Toner
006R01322
2 items
1 item
4 kg
36K
Magenta Toner
006R01323
2 items
1 item
4 kg
36K
Yellow Toner
006R01324
2 items
1 item
4 kg
36K
Black Developer
005R00726
1 container
1 container
4 kg
305K
Cyan Developer
005R00727
1 container
1 container
3.5 kg
229K
Magenta Developer
005R00728
1 container
1 container
3.5 kg
229K
Yellow Developer
005R00729
1 container
1 container
3.5 kg
229K
*Kit A
053K92781
1 set
1 set/color
--
212K
**Kit B
042K93361
1 set
1 set/color
--
327K
***Waste Toner Container
With Toner
1 item
1 container/
color
--
73K
Transfer Roller Cleaner
022K73150
1 set
1 set/color
--
529K
****Smoke Filter
053K92930/
or 053K92931
1 item
1 item
--
26K
Name of consumable
Note
* Kit A consists of a bag filter and a line filter.
** Kit B consists of a cleaner brush and a cleaner blade.
*** Waste Toner Container is an emptied toner container.
**** Smoke Filter consists of two filters allowing alternate replacement.
4-2
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Replacing Consumables
Functions of Consumables
The following table contains functions of the consumables.
Consumable
Function
Toner Cartridge/
Waste Toner Container
The Yellow, Magenta, Cyan, and Black Toner Containers contain toner
of that color respectively. An empty container is reused as the waster
toner container.
Empty Toner and Waste Toner Containers are safe and approved for
local recycling with common commercially used plastics. This is the
preferred method of disposal.
Developer
The Yellow, Magenta, Cyan, and Black Developer containers contain
developer of that color respectively. An empty container is used to
collect waste developer.
For used toner and developer, landfill is the recommended method of
disposal. This material is not a hazardous waste according to Federal
Regulation 40 CFR 261 and European Waste Code 08 03 18. State or
Local requirements may, however, be more restrictive.
Consult with the appropriate State or Local waste disposal authorities
for additional information. If incineration is to be carried out care
must be taken to prevent dust clouds forming. Incinerate using a
closed container which retains the waste material.
Kit A
Kit A serves as a filter to contain waste toner in the machine. It is
made up of a bag filter and a line filter.
The used Kit A is collected and disposed of by Xerox. Please notify your
local Xerox service representative when these items are ready to be
collected.
Kit B
Kit B serves as a wiper to clean out toner remaining on the drum. It is
made up of a cleaner brush and a cleaner blade.
The used Kit B is collected and disposed of by Xerox. Please notify your
local Xerox service representative when these items are ready to be
collected.
Transfer Roller Cleaner
This is a guide roller to assist toner transfer and stable paper transport.
The used Transfer Roller Cleaner is collected and disposed of by Xerox.
Please notify your local Xerox service representative when these items
are ready to be collected.
Printer Operator Guide
4-3
Replacing Consumables
Xerox 490/980 Color Continuous Feed Printing System
Consumable
Function
Smoke Filter
The Smoke Filter absorbs vaporized toner generated in the Fuser
Station.
The used Smoke Filter is collected and disposed of by Xerox. Please
notify your local Xerox service representative when these items are
ready to be collected.
4-4
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Replacing Consumables
Procedure for Replacing Consumables
This section describes the steps for replacing consumables. When it is time to replace a
consumable item, a prompting message appears on the touch screen. Replace the consumable
when a message similar to the one shown below displays.
Printer Operator Guide
4-5
Replacing Consumables
Xerox 490/980 Color Continuous Feed Printing System
Checking Status of Consumable Items
To check the status of consumable items, display the Printer Status on the touch screen.
1.
On the touch screen, select the [Menu] button to display the Menu screen.
2.
Select [Printer Status] to display the Printer Status screen.
Consumable items are listed with status on the screen. The consumables management counter
appears when the printer is paused.
The consumables management counter
The icons below represent the following meanings.
•
Indicates the consumable item should be replaced now.
•
Indicates the consumable item should be replaced soon.
Note
Consumables replaced by the operator are listed on the User (left) side of the screen.
Consumables listed under the CE (right) side of the screen must be replaced by your
customer service representative.
4-6
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Replacing Consumables
Starting Consumable Replacement
To start replacing consumables, display the Printer Management screen on the touch screen. To
use the Printer Management screen for consumables replacement, you have to log on with the
rights of System Administrator or Operator.
1.
On the touch screen, select the [Menu] button to display the Menu screen.
2.
Select the [Printer Management] button
3.
Select the [Consumables] tab.
4.
From the consumables list, select the consumable item that needs to be replaced, and then
select Start. The example below illustrates refilling the Yellow Toner cartridge.
Printer Operator Guide
to display the screen displayed.
4-7
Replacing Consumables
Xerox 490/980 Color Continuous Feed Printing System
Note
For the remainder of this procedure, step-by-step instructions to replace consumables are
displayed on the screen.
5.
Follow the instructions and select [Next].
6.
The [End] button appears at the end of the steps.
To finish replacing consumables, follow the steps described in the next section.
4-8
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Replacing Consumables
Finishing Consumables Replacement
When you have reached the end of the steps to replace consumables, select the [End] button
on the touch screen.
The following example shows the steps for completing the replacement of consumables.
1.
Select the [End] button, which appears at the end of the steps to replace consumables.
When the consumables replacement is completed, the screen will return to the list of
consumable items.
2.
Ensure the consumable item replaced is now shown as [Good] in the Status column.
Consumables replacement is complete.
Printer Operator Guide
4-9
Replacing Consumables
Xerox 490/980 Color Continuous Feed Printing System
Supplying Toner
This section describes the steps for supplying toner. The machine contains one toner cartridge
for each of the four colors (CMYK). The same steps are used for supplying each toner cartridge.
Note
Toner can be supplied during a print job.
When to supply toner
When a toner cartridge of any color needs refilling, the following message appears on the touch
screen. Supply the applicable toner when this message appears.
Warning
Keep toner away from your eyes and mouth. If the toner gets on your skin, immediately wash
it off.
Toner particles may damage your lungs if ingested for an extended period of time. If this
occurs, consult a doctor immediately.
Caution
The use of toner cartridges not recommended by Xerox may impair quality and performance
of the machine. Use only the toner cartridges recommended by Xerox for the machine.
You can refill only one cartridge at a time. If you refill more than one cartridge at a time, toner
may be spilled and cause poor print quality or damage the toner box.
4-10
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Replacing Consumables
Steps for Supplying Toner
To supply toner, perform the steps described below when both the Life Indicator Light and the
Status Light are illuminated.
Note
Do not open the toner refill door if the status indicator light is blinking. Ensure that the
toner life indicator light (green) is illuminated before opening the toner refill door. Also
ensure that the labels for the toner cartridge, toner refill door, and toner hopper are the
same. Replace only with the toner color indicated.
Life indicator light
Status Light
1.
Pull on the handle and open the toner refill door.
Toner refill
door
2.
Holding the handle, pull the toner cartridge drawer forward.
Handle
Toner drawer
Printer Operator Guide
4-11
Replacing Consumables
3.
Xerox 490/980 Color Continuous Feed Printing System
Grasp the handles, lift and remove the empty toner cartridge. After removing the toner
cartridge, clean residual toner from the toner refill area.
Note
The empty toner cartridge will be reused as a waste toner container.
Handles
4.
Gently shake the new toner cartridge from side-to-side several times.
5.
Place the toner cartridge on the toner entry port. Ensure to insert the cartridge along the
guide.
Guide
4-12
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
6.
Replacing Consumables
Holding the handle, push in the toner cartridge drawer.
Handle
Toner drawer
7.
Close the toner refill door.
Empty toner containers and waste containers are safe and approved for local recycling with
common commercially used plastics. This is the preferred method of disposal
Printer Operator Guide
4-13
Replacing Consumables
Xerox 490/980 Color Continuous Feed Printing System
Steps for Replacing Developer
This section describes the procedure for replacing developer. The machine contains one
developer container for each of the four colors. The same procedure is used for replacing each
color developer container.
For used developer, landfill is the recommended method of disposal. This material is not a
hazardous waste according to Federal Regulation 40 CFR 261 and European Waste Code 08 03
18. State or Local requirements may, however, be more restrictive. Consult with the appropriate
State or Local waste disposal authorities for additional information. If incineration is to be
carried out care must be taken to prevent dust clouds from forming. Incinerate using a closed
container which retains the waste material.
To replace developer, perform the steps described below.
When to Replace Developer
When developer of any color needs replacing, the following message appears on the touch
screen. Replace the developer when this message appears.
Warning
•
Keep developer away from your eyes and mouth. If the developer gets on your skin during
replacement, immediately wash it off. If developer gets into your eyes or mouth, consult a
doctor immediately.
•
Do not open the door until the machine operation has stopped.
Caution
The use of the developer not specified by Xerox may impair quality and performance of the
machine. Use only the developer recommended by Xerox for the machine.
4-14
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Replacing Consumables
Steps for Replacing Developer
Please notify your local Xerox service representative when your used developer needs to be
collected.
To allow easy access for developer replacement:
1.
Raise the Printer 1 or Printer 2 Top Cover corresponding to the developer to be replaced. An
error message (6A-05 XU Top Cover Open -CMYK) will appear on the touch screen.
2.
Insert a cheater clamp on the interlock switch of the print station.
3.
Clear the fault code on the screen to proceed.
4.
Display the [Consumables] tab. From the list of consumables, select the developer to be
replaced, then select [Start].
5.
Open the printer front door corresponding to the developer color.
Printer Operator Guide
4-15
Replacing Consumables
Xerox 490/980 Color Continuous Feed Printing System
6.
Ensure the lamp [1] is illuminated on the print station panel.
7.
Ensure an empty developer container is available.
8.
Select the [Next/Yes] button, then ensure the lamp [2] is on.
4-16
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
9.
Replacing Consumables
Holding up the unlocking lever, turn the developer discharge lever counterclockwise.
10. Select the [Next/Yes] button. The lamp [3] will illuminate, and the developer will be
discharged. It takes abut 3 minutes until all the developer is drained.
Caution
Once the developer replacement is started, the procedure cannot be canceled. Please be
careful when performing this step.
Note
For disposal of waste developer, please notify your local Xerox service representative.
11. When the lamp [3] illuminates and all the developer is discharged, turn the developer
discharge lever clockwise.
Printer Operator Guide
4-17
Replacing Consumables
Xerox 490/980 Color Continuous Feed Printing System
12. Remove the waste developer container, and shake it several times. Ensure the discharged
developer is above the indicated level. If the discharged developer is above the level, select
the [Next/Yes] button ensuring the lamp [4] illuminates.
Note
If the discharged developer is below the level, follow the four steps in the order listed below.
If not, continue on to Step 13 on page 19.
1.
Reinstall the waste developer container.
2.
Holding up the unlocking lever, turn the developer discharge lever counterclockwise.
4-18
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Replacing Consumables
3.
Select the [Next/Yes] button.
4.
The developer will discharge. Go back to Step 11 and check if the discharged developer is
now over the specified level.
Note
The remainder of the developer replacement procedure continues below.
13. Ensure the developer discharge lever is in the closed position.
14. Select the [Next/Yes] button. The lamp [5] will illuminate.
Printer Operator Guide
4-19
Replacing Consumables
Xerox 490/980 Color Continuous Feed Printing System
15. Open the developer entry port, and install the funnel. Check the label on the funnel to
ensure the installed funnel is of the same color as the developer to be replaced. If the
funnel is of a different color, print jobs may not be successful.
Funnel
Entry port
16. Select the [Next/Yes] button. The lamp [6] will blink.
Note
Gently shaking the funnel will help pour the developer. Be careful not to move the funnel
away from the port.Pour new developer from the funnel.
a.
b.
To pour new developer, lower the container opening with its handle facing the left side.
Be sure to use the new developer of the same color as the discharged one. Pouring
developer of a different color will result in failure in print jobs requiring you to replace
the units. If this occurs, please notify your local Xerox support representative.
New developer
Handle
4-20
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Replacing Consumables
17. When all the developer is poured, select the [Next/Yes] button. Lamp[6] will illuminate.
18. Remove the funnel, and close the developer entry port.
Funnel
Entry port
19. Select the [Next/Yes] button. The lamp [7] will illuminate.
Printer Operator Guide
4-21
Replacing Consumables
Xerox 490/980 Color Continuous Feed Printing System
20. Remove the container of the discharged developer, and install an empty developer
container. After replacing developer, clean the remaining dust or spilled developer around
the outlet and entry port of the developer.
21. Select the [Next/Yes] button. The lamps [1] through [7] will turn off.
22. Close the printer front door.
23. Select the [End] button on the touch screen.
4-22
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Replacing Consumables
Batch Replacement of Developers
All of the developers may be replaced at the same time. The Batch replacement operation is
performed when the current color mode setting is Color, and the printer status is NOT READY,
ERROR, or the printer color mode is being changed.
When the current color mode setting is B/W, the following popup message appears and the
operation cannot be performed.
Batch replacement of K, C, M, and Y developers
To allow easy access for batch developer replacement:
1.
Raise the both Printer 1 and Printer 2 Top Covers. An error message (6A-05 XU Top Cover
Open -CMYK) will appear on the touch screen.
2.
Insert a cheater clamp on the interlock switches on each of the print stations.
3.
Clear the fault code on the screen to proceed.
After enabling easy access to all of the developers, use the following steps to replace the K, C, M,
and Y developers at the same time.
1.
Select the [Change all developer] button on the operation panel.
Printer Operator Guide
4-23
Replacing Consumables
2.
Xerox 490/980 Color Continuous Feed Printing System
Select the [Next] button. A popup message will appear.
Note
After selecting the [Yes] button, you cannot cancel the operation.
3.
Select the [Yes] button.
4.
Repeat steps 2 through 20 in the steps for replacing developer (from earlier in this chapter)
to replace the K, C, M, and Y developers.
5.
Select the [End] button on the operation panel.
This process is not completed until the K, C, M, and Y developers have all been replaced.
4-24
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Replacing Consumables
Replacing Kit A
This section describes the steps for replacing kit A.
Kit A includes a bag filter and a line filter, and serves as a filter to contain toner in the machine.
The same Kit A unit is used for each color toner. Dispose of the used Kit A as industrial waste.
When to replace Kit A
When Kit A for any color needs replacing, the following message appears on the touch screen.
Warning
•
Keep toner away from your eyes and mouth. If the toner gets on your skin, immediately
wash it off. Toner may also damage clothing.
•
Toner particles may damage your lungs if ingested for long periods time. If this occurs,
consult a doctor immediately.
•
If you reuse Kit A or do not replace it on time, the waste toner container will overflow with
toner. Spilled toner needs to be cleaned with a non-woven cloth moistened with a neutral
detergent. Spilled toner may damage the machine components.
•
Machine must be operating in Color mode to replace Kit A.
Caution
Printer Operator Guide
4-25
Replacing Consumables
Xerox 490/980 Color Continuous Feed Printing System
Steps for replacing Kit A
To replace Kit A, perform the steps described below.
1.
Display the [Consumables] tab. From the consumables list, select Kit A to be replaced, and
then select [Start].
2.
Open the printer rear door.
3.
Open the bag filter door.
1
Door
Open
4.
4-26
Pull the handle forward and move the guide in the arrow direction.
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Replacing Consumables
2
Guide
Handle
5.
Grasp the bag filter on both sides, and remove.
3
Bag filter
Note
Clean dust and spilled toner with a non-woven cloth.
6.
Lift the filter retainer and remove the line filter in the arrow direction.
Filter
retainer
Line filter
Printer Operator Guide
4-27
Replacing Consumables
Xerox 490/980 Color Continuous Feed Printing System
Note
Be sure to insert the line filter in the arrow direction.
7.
Insert the new line filter in the machine and lower the filter retainer.
Filter
retainer
New line
filter
8.
Insert the bag filter along the guide.
3
Guide
4-28
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
9.
Replacing Consumables
Replace the guide in the arrow direction. Push the handle to secure the bag filter.
Guide
Handle
10. Close the bag filter door.
11. Close the printer rear door.
12. Select the [End] button on the touch screen.
Printer Operator Guide
4-29
Replacing Consumables
Xerox 490/980 Color Continuous Feed Printing System
Replacing Kit B
This section describes the steps for replacing Kit B.
Kit B includes a cleaner brush and a cleaner blade for wiping out toner remaining on the drum.
The same Kit B unit is used for each color toner. The used Kit B is collected and disposed of by
Xerox. Please notify your local Xerox service representative when these items are ready to be
collected.
When to replace Kit B
When Kit B for any color needs replacing, the following message appears on the touch screen.
4-30
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Replacing Consumables
Steps for replacing Kit B
To replace Kit B, perform the steps provided below.
Note
When the cleaner brush is removed or inserted, it must be attached to the cleaner blade to
avoid toner from scattering inside the machine.
1.
Display the [Consumables] tab referring to “Starting Consumables replacement”. From the
consumables list, select the appropriate Kit B to be replaced, and then select [Start].
2.
Open the appropriate printer front door depending on the Kit B color being replaced.
(Y)
(M)
(C)
(K)
Printer front door
3.
Loosen the thumb nut holding the cleaner brush.
Cleaner brush
Printer Operator Guide
Thumb nut
4-31
Replacing Consumables
4.
Xerox 490/980 Color Continuous Feed Printing System
Pull the knob forward to remove from the brush.
Knob
The graphic below shows the structure of a cleaner brush.
Brush
Knob
5.
Attach the collector bag to the opening of the cleaner brush. Holding the collector bar
inside of the bag, firmly push the bar into the cleaner brush.
Collector bag
4-32
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
6.
Replacing Consumables
Ensure the collector bar is correctly aligned with the opening of the cleaner brush.
Opening
Collector Cleaner
brush
bag
Collector bar
7.
Slowly pull out the collector bar along with the cleaner brush. Contain the cleaner brush
inside of the bag, and remove the bag from the brush opening.
Cleaner brush
Collector bag
Note
Clean dust and toner with a non-woven cloth.
8.
Loosen the thumb nut holding the cleaner blade.
cleaner blade
Printer Operator Guide
Thumb nut
4-33
Replacing Consumables
9.
Xerox 490/980 Color Continuous Feed Printing System
Pull the cleaner blade knob slightly forward and remove.
Knob
10. Insert the cleaner blade into the collector bag. Pull out the bag removing the cleaner blade.
Caution
Do not touch the cleaner blade. The lubricant powder on the cleaner blade may become
displaced. This causes an increase of friction which shortens the usable life of the cleaner
blade.
11. Attach the knob to the cleaner blade by inserting along the guide, and tighten the thumb
nut.
4-34
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Replacing Consumables
12. Insert the new cleaner brush.
13. Tighten the cleaner brush thumb nut to secure the brush.
14. Close the printer front door.
15. Select the [End] button on the touch screen.
Printer Operator Guide
4-35
Replacing Consumables
Xerox 490/980 Color Continuous Feed Printing System
Replacing Waste Toner Containers
This section describes the steps for replacing waste toner containers. The same steps are used
for replacement of each color toner container. Waste toner containers are safe and approved for
local recycling with common commercially used plastics. This is the preferred method of
disposal.
When to replace waste toner containers
The waste toner container does not have a sensor. The machine will indicate the bottle is full
following replacement of two toner cartridges, and also at times when it is empty. The waste
toner container should be checked at regular intervals.
When a waste toner container needs replacing, the following message will appear on the touch
screen.
Warning
Keep toner away from your eyes and mouth. If the toner gets on your skin, immediately wash
it off. Do not operate the lock lever except when you replace waste toner containers. Toner
may overflow the container due to irregular replacement cycles.
Lock lever
4-36
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Replacing Consumables
Steps for Replacing waste toner containers
To replace waste toner containers, follow the steps described below.
1.
Display the [Consumables] tab to begin consumables replacement. From the consumables
list, select the waste toner container to be replaced and then select [Start].
2.
On the back of the printer station, ensure the waste toner container indicator lamp is
illuminated.
Waste toner container indicator lamp
3.
Open the printer rear door corresponding with the illuminated indicator lamp.
Printer rear door
Printer Operator Guide
4-37
Replacing Consumables
4.
Xerox 490/980 Color Continuous Feed Printing System
Release the lock lever. When replacing the container during print operations, install the new
container within 3 minutes.
Lock lever
5.
Hold and pull the drawer handle forward until the drawer stops.
Handle
6.
Hold and lift the toner container handles upward to remove the container. Install an empty
toner container.
Handles
4-38
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
7.
Replacing Consumables
Holding the drawer handle, slide the toner container into the machine.
Handle
8.
Move the lever to the lock position.
Lock lever
9.
Close the printer rear door.
10. Select [End] on the touch screen.
Printer Operator Guide
4-39
Replacing Consumables
Xerox 490/980 Color Continuous Feed Printing System
Replacing Transfer Roller Cleaners
This section describes the procedure for replacing Transfer Roller Cleaners. The same procedure
is used for each color Transfer Roller Cleaner.
The used Transfer Roller Cleaner is collected and disposed of by Xerox. Please notify your local
Xerox service representative when these items are ready to be collected.
When to replace Transfer Roller Cleaners
When the Transfer Roller Cleaner needs replacing, regardless of color, the following message
appears on the touch screen.
Warning
Keep toner away from your eyes and mouth. If the toner gets on your skin, immediately wash
it off.
4-40
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Replacing Consumables
Steps for replacing Transfer Roller Cleaners
1.
Display the [Consumables] tab. From the consumables list, select the Transfer Roller Cleaner
to be replaced and then select [Start].
2.
Open the printer 1 or printer 2 top cover.
3.
Remove the two thumb nuts.
Thumb nuts
Printer Operator Guide
4-41
Replacing Consumables
4.
Xerox 490/980 Color Continuous Feed Printing System
Holding the handles, slightly move the Transfer Roller Cleaner forward (1),and then lift
upward (2).
(2)
Handles
(1)
5.
Place the removed Transfer Roller Cleaner into a box.
6.
Holding the handles on the new Transfer Roller Cleaner, install it on the machine (1) and (2)
carefully, without touching or damaging the guide roller on the new Transfer Roller Cleaner.
(2)
Handles
(1)
4-42
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
7.
Replacing Consumables
Tighten the two thumb nuts.
Thumb nuts
8.
Close the printer 1 or printer 2 top cover.
9.
Select the [End] button on the touch screen.
Printer Operator Guide
4-43
Replacing Consumables
Xerox 490/980 Color Continuous Feed Printing System
Replacing Smoke Filters
To replace Smoke filters, follow the step listed below. Dispose of the used Smoke Filter as
industrial waste.
When to replace Smoke Filters
When the Smoke Filter needs replacing, the following message will appear on the touch screen.
Warning
Keep toner away from your eyes and mouth. If the toner gets on your skin, immediately wash
it off.
4-44
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Replacing Consumables
Steps for replacing Smoke Filters
Before starting the steps for replacing the smoke filter, unpack a new smoke filter and place it in
an accessible location.
Note
Steps 3 to 10 need to be completed within 30 seconds.
To replace Smoke Filters, follow the steps listed.
1.
Display the [Consumables] tab. From the consumables list, select the Smoke Filter and then
select [Start].
2.
Open the smoke filter door.
Smoke filter door
Printer Operator Guide
4-45
Replacing Consumables
Xerox 490/980 Color Continuous Feed Printing System
Note
The Smoke Filter can be replaced during printing. Either the right or the left indicator lamp
will be illuminated.
3.
Release the lock lever indicated by the illuminating lamp. Pull the smoke filter door forward
and open it.
Smoke filter indicator lamp
Open
Lock lever
4.
Pull the handle forward.
Handle
5.
Pull the Smoke Filter forward.
Smoke Filter
4-46
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
6.
Replacing Consumables
Insert the new smoke removing filter into the box, ensuring the black packing is faced
upward. Check the label to ensure the filter is not upside down.
Black packing
Smoke Filter
7.
Push the smoke filter inside the machine, while pushing the handle inward.
Handle
8.
Close the smoke filter door and move the lever to the lock position.
Close
Lock lever
9.
Close the smoke filter door.
10. Select [End] on the touch screen.
Printer Operator Guide
4-47
Replacing Consumables
4-48
Xerox 490/980 Color Continuous Feed Printing System
Printer Operator Guide
Cleaning
5
Before Cleaning the Machine
This chapter provides information needed before cleaning the machine. When cleaning the
machine, always follow the precautions listed below.
Warning
•
Keep toner away from your eyes and mouth. If toner gets on your skin, immediately wash
it off.
•
When closing the Fuser Station, take care not to pinch your fingers.
•
Be sure to switch off and unplug the machine before accessing the interior for cleaning,
maintenance or fault clearance to avoid possible electrical shock.
•
When the machine is stopped, the paper inside the Fuser Station is heated to a very high
temperature. Do not open the Fuser Station until its green lamp is illuminated.
•
When toner has spilled onto the floor, use a broom or a non-woven cloth moistened with a
neutral detergent. To avoid sparks and possible explosion, never use a household vacuum
cleaner to clean spilled toner.
•
To clean the Fuser Station, open its door before powering off the machine. The Fuser
Station door will lock when the machine is powered off.
•
Check the machine conditions each time before starting the machine or loading paper
stock not recommended by Xerox, regardless of suggested maintenance intervals.
Recycled paper in particular tends to generate paper dust affecting normal machine
conditions.
Caution
Reloading paper
Reload paper after the cleaning of every area is complete.
Printer Operator Guide
5-1
Cleaning
Xerox 490/980 Color Continuous Feed Printing System
Cleaning Procedure
This section describes when and where to clean the machine. To keep the machine in good
condition, prevent paper jams and poor print quality, the machine needs to be cleaned on a
daily basis. Toner particles collect in numerous areas of the machine. A non-woven cloth
moistened with neutral detergent should be used to clean toner build up.
The following table indicates which parts require routine cleaning on the machine.
Where
When
Station Name
Parts Name
Single / Duplex
Printing System
(Printer 1)
Duplex Printing
System (Printer 2)
Feeder Station
Idle roller
Daily
Daily
Aligning roller
Daily
Daily
Brush near the feeder opening
Daily
Daily
Paper Transport Plates
Daily
Daily
Around toner supply areas and
waste toner containers
Daily
Daily
Transfer guide roller
Daily
Daily
Charge Assembly Cleaning Button
Daily
Daily
Fuser Station Window
Daily
Daily
Manifold
As needed
As needed
Paper Guide
Daily
Daily
Around paper exit
Daily
Daily
Idle roller below the fuser
Daily
Daily
Tension arm
Daily
Daily
Sub driver roller
Daily
Daily
Turn Bar(s)
Cutter/Separator/Stacker
Urge Unit
Daily
Daily
Printer Stations
1&2
Fuser Station
Pre & Post Finishing
Devices
5-2
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Cleaning
Cleaning Items
The items used for cleaning the machine are listed below.
•
Work gloves - Keep your hands free from toner, paper dust and protect your hands from
heated parts.
•
Non-woven cloth - Used to wipe out various areas of the machine.
•
Scraper (shown in the following diagram) is supplied with the machine and is used for
cleaning the glass window and the manifold located in the Fuser Station.
Scraper
Warning
•
Keep toner away from your eyes and mouth. If toner gets on your skin, immediately wash
it off.
•
When toner has spilled onto the floor, use a broom or a non-woven cloth moistened with a
neutral detergent. To avoid sparks and possible explosion, never use a household vacuum
cleaner to clean spilled toner. Use a non-woven cloth moistened with neutral detergent to
clean spilled toner.
Printer Operator Guide
5-3
Cleaning
Xerox 490/980 Color Continuous Feed Printing System
Cleaning the Feeder Station
Steps for cleaning the idle roller
1.
Open the Feeder Door.
Feeder Door
2.
Pull the Nip Release Sub-Lever forward to release the roller.
Paper Tension Dial 1
Nip Release Sub-Lever
3.
Roller
Lift the Nip Release Lever to release the roller.
Nip Release Lever
5-4
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
4.
Cleaning
Turn Paper Tension Dial 1 to release the roller.
Paper Tension Dial 1
Roller
Paper Tension Dial 1
5.
Open the Fuser Door.
Fuser Door
Printer Operator Guide
5-5
Cleaning
6.
Xerox 490/980 Color Continuous Feed Printing System
Lift the Nip Release Lever to release the roller.
Nip Release Lever
Roller
7.
Loosen the paper to create enough slack so that cleaning can be performed properly.
8.
Using a non-woven cloth, clean the side of the idle roller that comes in contact with the
paper.
Idle roller
9.
5-6
Using a non-woven cloth, wipe all dirt and dust that is attached to the paper.
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Cleaning
Cleaning the Aligning Roller
Follow the steps described below.
1.
Open the Feeder Door.
Feeder Door
2.
Turn the Paper Tension Dial 1 to release the roller.
Paper Tension Dial 1
Roller
Paper Tension Dial 1
Printer Operator Guide
5-7
Cleaning
3.
Xerox 490/980 Color Continuous Feed Printing System
Pass a non-woven cloth through the gap between the roller and the guide moving it up and
down to clean dust from the face of the roller.
Non-woven cloth
5-8
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Cleaning
Cleaning the Brush near the feeder opening
1.
Open the Feeder Door.
Feeder Door
Warning
•
Keep toner away from your eyes and mouth. If toner gets on your skin, immediately wash
it off.
•
Use a non-woven cloth moistened with a neutral detergent to clean the brush at the paper
opening. To avoid sparks and possible explosion, never use a household vacuum cleaner to
clean spilled toner.
2.
Lift the paper and use a non-woven cloth moistened with a neutral detergent to clean the
brush at the paper opening.
Printer Operator Guide
5-9
Cleaning
Xerox 490/980 Color Continuous Feed Printing System
Cleaning Printer Stations 1 and 2
Cleaning the Paper Transport Plates (2 for each color)
1.
Open the covers located on top of Printer Stations 1 and 2.
Printer 2 Top Cover
2.
Printer 1 Top Cover
Holding the handle, lift the Transfer Stations and inspect the paper transport plates located
near the drum.
Handle
Y
M
C
K
Caution
Do not touch the drums while cleaning the paper transport plates. The drums can be
scratched and damaged if care is not taken while cleaning the paper transport plates.
3.
5-10
Clean out all toner on the paper transport plates with a non-woven cloth using caution not
to touch or damage the drums.
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Cleaning
Paper Transport Plates
Drum
Printer Operator Guide
5-11
Cleaning
Xerox 490/980 Color Continuous Feed Printing System
Cleaning around Toner Refills and Waste Toner Containers
Use a non-woven cloth to clean around the toner supply areas and waste toner containers.
Warning
•
Keep toner away from your eyes and mouth. If the toner gets on your skin, immediately
wash it off.
•
Do not operate the lock lever except when you replace waste toner containers. Toner may
overflow the container due to irregular replacement cycles.
The following graphic illustrates cleaning around toner supply areas.
The following graphic illustrates cleaning around waste toner containers.
5-12
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Cleaning
Cleaning the transfer guide roller
1.
Open the covers located on top of Printer Stations 1 and 2.
Printer 1 Top Cover
Printer 2 Top Cover
2.
Holding the handle, lift the Transfer Stations and check the paper transport plates on the
drum.
Handle
Y
M
C
Printer Operator Guide
K
5-13
Cleaning
Xerox 490/980 Color Continuous Feed Printing System
Caution
Do not touch the drums while cleaning the transfer guide roller. The drums can be
scratched and damaged if care is not taken while cleaning the transfer guide roller.
3.
Spin the transfer guide roller in the direction of the arrow and use a non-woven cloth to
clean the surface; being careful not to touch or damage the drum.
Transfer guide roller
Paper Transport Plates
Drum
5-14
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Cleaning
Cleaning the Fuser Station
Before cleaning the Fuser
1.
To avoid hazards, do no start cleaning until the green lamp on the Fuser Station front door
is illuminated.
2.
Pull out the Fuser before powering off the machine.
3.
Use caution not to damage or break the glass surface.
Procedure for cleaning the Fuser Station
Do not leave the glass surface in the Fuser soiled. Toner may not adhere to the paper and
scumming may occur if the surface is not clean.
Toner particles may adhere to the glass surface during a print job. Check and clean the Fuser on
a daily basis.
Warning
Ensure your fingers are clear when closing the Fuser to avoid injury.
Caution
Do not open the Fuser Station front door until the green light illuminates.
Ensure that no pieces of paper or paper dust are left in the Fuser after cleaning. Paper may
catch fire and emit smoke if left inside of the Fuser Station.
Printer Operator Guide
5-15
Cleaning
Xerox 490/980 Color Continuous Feed Printing System
Steps for Cleaning the Fuser
1.
Open the Fuser Station front door.
Fuser
front door
2.
While selecting and holding the button, grip the handle and pull out the Fuser.
Fuser Handle
Button
5-16
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Cleaning
Warning
•
Keep toner away from your eyes and mouth. If toner gets on your skin, immediately wash
it off.
•
Use a non-woven cloth moistened with a neutral detergent to clean loose toner particles.
To avoid sparks and possible explosion, never use a household vacuum cleaner to collect
loose toner particles.
3.
Use the scraper to remove the toner particles that are attached to the smoke filter slit on
the top of the fuser station. As toner particles are loosened, use a non-woven cloth
moistened with a neutral detergent to clean them from the smoke filter slit.
Smoke Filter Slit
4.
Clean the glass surface with a non-woven cloth.
Glass surface
Printer Operator Guide
5-17
Cleaning
5.
Slide the Fuser into position.
6.
Push the Fuser in until it stops.
5-18
Xerox 490/980 Color Continuous Feed Printing System
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Cleaning
Cleaning around the Paper Exit
1.
Open the Fuser Door.
Fuser Door
2.
Using a non-woven cloth, clean the roller surface and the eraser brush that are located near
the paper exit.
Roller
Eraser brush
Printer Operator Guide
5-19
Cleaning
Xerox 490/980 Color Continuous Feed Printing System
Cleaning the idle roller below the fuser
1.
Open the Fuser Door.
Fuser Door
2.
Spin the idle roller below the fuser and use a non-woven cloth to clean the surface.
Transfer guide roller
5-20
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Cleaning
Cleaning the tension arm
1.
Open the Fuser Station Top Cover.
Fuser Top Cover
2.
Use work gloves and a non-woven cloth to clean the side of the tension arm that comes
into contact with the paper.
Fuser Top Cover
The surface of the roller may become very hot. Use work gloves when working on the roller.
Printer Operator Guide
5-21
Cleaning
Xerox 490/980 Color Continuous Feed Printing System
Cleaning the sub driver roller
1.
Open the Fuser Door.
Fuser Door
Warning
Use work gloves when cleaning the surface of the sub drive roller. The surface of the sub
drive roller may become very hot.
2.
Use work gloves and a non-woven cloth to clean the surface of the sub driver roller.
Sub driver roller
3.
After cleaning all of the visible areas, close the fuser cover.
Fuser Door
5-22
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Cleaning
Note
For a duplex system, select [Forward] on the upstream printer to allow the paper adequate
slack. Then select and hold [Forward] on the downstream printer for about one second.
4.
Select and hold Forward on the fuser unit panel for about 1 second. The sub driver roller will
start to rotate.
5.
Repeat steps 1 to 4 until the entire surface of the sub driver roller is cleaned.
Printer Operator Guide
5-23
Cleaning
Xerox 490/980 Color Continuous Feed Printing System
Cleaning the Turn Bar - All Models
All rollers on the turn bar (located between Printer 1 and Printer 2) need to be cleaned of toner
dust on a daily basis prior to powering on the machine. This procedure is necessary for all
models and manufacturers of turn bar equipment.
1.
5-24
Clean the top (input) roller with a dry, non-woven cloth to remove all toner dust.
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Cleaning
Note
The rollers may require additional cleaning if excessive toner dust is accumulated during a
large print job. Ensure the machine is idle prior to cleaning the turn bar rollers.
2.
All toner dust must be removed from the bottom (output) roller using a dry, non-woven
cloth.
Printer Operator Guide
5-25
Cleaning
5-26
Xerox 490/980 Color Continuous Feed Printing System
Printer Operator Guide
Peripheral Devices
6
Built-in Peripheral Devices
CF card reader/writer
Printer Operator Guide
6-1
Peripheral Devices
Xerox 490/980 Color Continuous Feed Printing System
Compact Flash (CF) card reader/writer
Note
NTFS-formatted CF cards cannot be used. Use a CF card in FAT or FAT32 format.
The CF card drive is located on the Feeder Station right side. This CF card reader/writer is used
when importing resources or servicing the machine. This peripheral device provides storage for
fault information and legacy system data.
CF Card slot
Access lamp
Card slot
The CF card is inserted in this slot.
Access lamp
Illuminates when the CF card is correctly inserted and remains blinking while data in the CF
card is accessed.
6-2
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Peripheral Devices
Cautions in Using the Pre- and PostProcessing Devices
This section describes power-on steps and cautions taken after the machine is connected to the
Pre- and Post-Processing Devices.
Power-on steps and cautions
Follow the steps and cautions below after the machine is connected to the pre- and postprocessing devices.
Powering on
1.
Power on the Pre- and Post-Processing Devices prior to powering on the machine.
2.
Power on the machine
Caution in printing
Caution
Before starting a print job, power on the Pre- and Post-Processing Devices and ensure they are
in the ready state.
Cautions for setting paper
Caution
•
Before setting paper, check that the processing unit is in the ready status.
•
When sending printer paper while the post-processing unit is not in the ready status, select
the [Reset] button on the printer’s operation panel to clear the error indication, then select
the [Forward] button.
Cautions for failure on the pre-processing and post-processing units
Caution
When a failure occurs on the pre-processing unit, the message displayed on the printer's
operation panel may show an error message regarding the post-processing unit. This can
happen depending on the way that the pre-processing and post-processing units are
connected. If this problem occurs, check the status of the post-processing and pre-processing
units.
Printer Operator Guide
6-3
Peripheral Devices
Xerox 490/980 Color Continuous Feed Printing System
Notes on the duplex printing system
Note
3.
With the duplex printing system, the not-ready status may not appear on the operation
panel depending upon the status of its connection with the pre-processing or postprocessing device.
4.
Before feeding paper with the [Forward/Sync] or [Forward/Feed] button, check that the
pre-processing and post-processing devices are ready.
5.
In a duplex printing system, both print engines must be in the not-ready status before
changing to a color mode.
6.
Before feeding paper on the duplex printer, check also that the simplex printer is ready.
6-4
Printer Operator Guide
A
Appendix
Optional Items
This section describes optional hardware items available for the machine.
Note
Product types are subject to change. For the latest information, please contact your Xerox
service representative.
Hardware Options
Type
Description
Paper handling mechanism for duplex
system
Cable
400 volts supporting mechanism
Transformer (two for each printer)
Transformer cable
Printer Operator Guide
A-1
Appendix
A-2
Xerox 490/980 Color Continuous Feed Printing System
Printer Operator Guide
Appendix
B
Printed Registration Marks
This section is provided to assist with planning for pre-printed paper and customer workflow.
The machine uses the following marks for controlling the print position:
Form Registration (ROF) mark
A mark used to align the print position on the back of a form with print on the face of the form.
The ROF mark is also used to correct the feeding speed for a second machine installed.
Color Registration (ROC) mark
A mark used to correct the color registration of CMY with reference to K.
Sheet ID mark
A mark used by the printer to align printing surfaces with each other.
Printer Operator Guide
B-1
Appendix
Xerox 490/980 Color Continuous Feed Printing System
ROF mark position (without pin fed holes)
Edge of form
Edge of form
6.05mm
Page
boundary
10.16mm
Transport direction
6.4mm
Printing surface
5.08mm
ROF mark
6.35mm
6.35mm
Page
boundary
Top/back surface preprint prohibited area (excluding ROF and TOF marks at the left edge)
Top/back surface print prohibited area
ROF mark shape/dimensions (without pin fed holes)
B-2
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Appendix
ROF mark position (with pin fed holes)
Mark shape/dimensions (with pin fed holes)
Printer Operator Guide
B-3
Appendix
Xerox 490/980 Color Continuous Feed Printing System
Color registration (ROC) mark
ROC mark print position
Because ROF marks on the back surface and ROC marks on the top surface overlap, paper with
high transparency may present ROC mark read failure and/or deteriorate the print quality.
Before performing printing operation, check the type of paper to be used.
B-4
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Appendix
ROC mark (with / without pin fed holes)
Printer Operator Guide
B-5
Appendix
Xerox 490/980 Color Continuous Feed Printing System
Pre-printing Registration Marks
This section describes the pre-printing registration marks.
The ROF mark is a standard for the printer and a unique page registration mark that allows the
printed pages to be aligned in the main drive direction and secondary drive direction.
The TOF mark is a page registration mark generally used by other manufacturers' printers and
postprocessing units. The page printing start position can only be aligned in the vertical printing
direction.
ROF mark for paper without pin fed holes
ROF mark for paper with pin fed holes
B-6
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Appendix
Pre-printed TOF mark (common with or without pin fed holes)
Printer Operator Guide
B-7
Appendix
B-8
Xerox 490/980 Color Continuous Feed Printing System
Printer Operator Guide
Appendix
C
Procedure for Creating / Importing /
Setting a Mark
Creating a Mark
A mark is created with a TIFF file. TIFF files must conform to the following limitations:
1.
Resolution must be 600dpi.
2.
Height and Width must both be between 0.1 inch and 2 inches.
3.
Compression format must be one of the following:
•
•
•
•
•
•
•
4.
Uncompressed
G31d(MH)
G32d(MR)
G4(MMR)
JPEG
PackBits
LZW
Color space must be one of the following.
•
•
•
Gray(1bit)
MINISWHITE
MINISBLACK body text
Printer Operator Guide
C-1
Appendix
Xerox 490/980 Color Continuous Feed Printing System
Import TIFF file to the Printer
Import a TIFF file using the following procedure:
1.
Insert a Compact Flash (CF) card into the CF slot located next to the Feeder power panel.
2.
From the Main Menu, select [Resource Management] and select the [System Resource
Tab].
3.
Select [Removable Disk] from the Save To Options.
C-2
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Appendix
4.
Select the appropriate TIFF file.
5.
Select [Import].
6.
In the Import dialog that appears, select the folder that contains the mark to be imported
and select [OK].
Printer Operator Guide
C-3
Appendix
Xerox 490/980 Color Continuous Feed Printing System
7.
In the select Resource Type Dialog that appears, select [Print Mark] and select [OK].
8.
The imported TIFF file will appear at the bottom of the list of file names in the System
Resource Tab.
C-4
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
Appendix
Setting a Mark by Imposition
1.
Select the appropriate imposition file and select [Edit].
2.
Double-select the blank gray area above the front side to set the mark specifications for the
front side, or double-select the blank gray area above the back side to set the mark
specifications for the back side.
Printer Operator Guide
C-5
Appendix
3.
Xerox 490/980 Color Continuous Feed Printing System
Select the appropriate TIFF file.
Note
Up to 4 mark specifications can be selected at one time. When setting Offset parameters,
ensure that the X-direction is large enough so there is no interference with ROF marks.
Check post-processing equipment specifications for further details on their TOF mark
height and width requirements.
4.
C-6
Set the Offset for the appropriate mark specification and select [OK].
Printer Operator Guide
Xerox 490/980 Color Continuous Feed Printing System
5.
Appendix
The mark specification will now be shown in the appropriate page diagram on the
Imposition Information Edit Screen.
Printer Operator Guide
C-7
Appendix
C-8
Xerox 490/980 Color Continuous Feed Printing System
Printer Operator Guide
©2008 by Xerox Corporation. All rights reserved. Xerox® and the sphere of connectivity design and
490/980TM are trademarks of Xerox Corporation in the United States and/or other countries.
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