ColorStream UserManual 11 2009

Océ
ColorStream
More Power When

Printing o
User Manual
Continuous Printing
System
Copyright
Copyright © Océ 2008–2009

All rights reserved. This documentation may not be reproduced, copied, changed or trans-
mitted in any form, either in whole or in part, without written authorization from Océ.
Océ does not assume any responsibility or offer any guarantee regarding the information
contained in this document and excludes in particular any implied warranty claims regarding
the market capability or usability for a certain purpose. Océ also reserves the right to revise
this documentation from time to time and amend the content without announcing these
changes.
The designations Océ ColorStream®, Océ VarioStream®, Océ JetStream®, Océ VarioPrint®,
Océ Web Buffer®, Océ PRISMA®production, Océ CustomTone®, Océ FlexiDark®, Océ
TonerSafe™ and Océ InkSafe™ are protected by trademark.
All hardware and software names used are trademarks of their respective owners.
We also offer courses in our Training Center for Océ ColorStream.
Information:
Phone +49 (0)8121 72 3940
Fax +49 (0)8121 72 3950
Océ Printing Systems GmbH

ITC
Postfach 1260
85581 Poing
Germany
Edition: A29246-X31-X-1-7680/2009-11
Contents
Contents
Chapter 1
Notes on the Printing System Documentation..............................................11
Notes on the Printing System Documentation — Overview................12
Guide through the Documentation.........................................................13
Notes on Help...........................................................................................15
Notes on the Help - Overview...........................................................15
Opening Help......................................................................................16
Navigating in Help..............................................................................18
Contents........................................................................................18
Index..............................................................................................19
Search............................................................................................20
Opening Direct Help...........................................................................21
Symbol Conventions................................................................................24
Symbols in the text............................................................................24
Symbols in figures.............................................................................25
Other Documents.....................................................................................27
Manufacturer of the printing system......................................................28
Statutory requirements............................................................................29
Chapter 2
Safety.................................................................................................................31
Safety — Overview...................................................................................32
Intended Purpose ....................................................................................33
Flagging of safety directives ..................................................................34
Warning and information signs..............................................................35
Accident and Damage Prevention..........................................................37
Accident and damage prevention - overview..................................37
Personal Representations..................................................................38
Operation............................................................................................39
Transportation, assembly and installation, repair...........................42
Fire, disposal.......................................................................................44
Safety Regulations and Standards.........................................................45
Safety regulations and standards — overview................................45
CE Mark...............................................................................................48
Accident prevention regulation for replacement carts (option).....49
Chapter 3
Description of the Printing System.................................................................51
Description of the Printing System — Overview...................................52
Main Modules...........................................................................................53
3
Contents
Doors and Covers.....................................................................................54

Internal View.............................................................................................56
Internal View — Overview.................................................................56
Photoconductor unit...........................................................................58
Transfer unit........................................................................................60
Filter module.......................................................................................61
Console................................................................................................62
Printing method........................................................................................64
Operating Elements.................................................................................67
Operating Elements - Overview........................................................67
On key..................................................................................................69
Additional Operator Panels...............................................................70
Operator Attention Light....................................................................72
Operator Attention Light (OPAL) — Overview...........................72
Operator Attention Light (OPAL)/Bundle 11 Version.................73
Operator Attention Light (OPAL)/Bundle 10 Version.................75
Operating elements in the printing system......................................77
Paper specifications.................................................................................78
Chapter 4
Description of the Operator Panel...................................................................81
Description of the Operator Panel — Overview.....................................82
A tool bar...................................................................................................83
Toolbar — Overview..........................................................................83
Buttons and Displays in the Left Area..............................................84
Buttons and Displays in the Center Area .........................................86
Frame toolbar.....................................................................................90
Menu Tree.................................................................................................91
Menu Tree — Overview.....................................................................91
'General' Menus.................................................................................93
'General' menus — overview......................................................93
'User management' menus.........................................................94
'User' menus.................................................................................95
'Security' menus...........................................................................96
'ColorStream' Menus.........................................................................97
'ColorStream' Menus — Overview..............................................97
'Displays' menus...........................................................................99
'Configuration' menus................................................................100
'Setup' menus.............................................................................101
'Replace consumables' menus..................................................102
Menu display..........................................................................................104
Chapter 5
Working with the Operator Panel.................................................................105
Working with the Operator Panel — Overview....................................106
4
Contents
Managing User Settings (Key Operator)..............................................107

Managing User Settings (Key Operator) — Overview..................107
Extended password protection (option).........................................109
'Add user' .........................................................................................110
'Delete user' .....................................................................................111
Set Password / 'General' Tab..........................................................112
Releasing and blocking menus and elements/'User rights' tab....113
Setting language/'User profile' tab.................................................114
Managing User Settings (Operator).....................................................115
Managing User Settings (Operator) — Overview..........................115
Log on as user and request an access ticket..................................116
Change Password / 'Password' Tab................................................118
Changing language/'User profile' tab.............................................119
Log off as user..................................................................................120
Selecting settings and entering values................................................121
Applying or resetting settings...............................................................122
Working with Setups..............................................................................123
Working with Setups — Overview..................................................123
Creating a new setup or changing a setup.....................................124
Importing a Setup.............................................................................125
Exporting a Setup.............................................................................127
Managing Resources.............................................................................129
Managing Resources — Overview..................................................129
Installing Resources.........................................................................130
Deleting Resources...........................................................................132
Editing 'Replace consumables' menus on the operator panel...........133
Chapter 6
Operating the Printing System......................................................................137
Operating the Printing System — Overview........................................138
Powering on the Printing System.........................................................139
After printing has stopped, switch the printing system back to 'Ready'
.................................................................................................................142
Inserting the paper web.........................................................................143
Inserting the Paper Web..................................................................143
Adjusting the Pressure Rollers........................................................148
Synchronizing the Paper Path.........................................................150
Affixing the paper web..........................................................................152
Removing the paper web .....................................................................155
Opening or Closing the Doors on the Printing System.......................156
Opening or Closing the Doors on the Printing System —
Overview...........................................................................................156
Opening Right Doors........................................................................157
Closing Right Doors.........................................................................159
Opening Left Doors..........................................................................161
5
Contents
Closing Left Doors............................................................................163

Replacing the Developer Station..........................................................165
Replacing the developer station — overview................................165
Preparing the replacement cart.......................................................169
Removing the Developer Station....................................................171
Removing the developer station...............................................171
Storing the Developer Station in the Developer Station Shelf.177
Putting the Developer Station on the Stacking Tray...............181
Installing the Developer Station......................................................183
Removing the Developer Station from the Developer Station
Shelf.............................................................................................183
Replacing the Developer Station from the Stacking Tray.......187
Installing the developer station.................................................189
Replacing the Light Protection Cover.............................................194
Removing the Light Protection Cover.......................................194
Installing the Light Protection Cover.........................................197
Completing developer station replacement...................................198
Checking the print image ......................................................................199
Printing Test Print Jobs.........................................................................200
Printing Test Print Jobs — Overview..............................................200
'5C_PrintQualityInspection.600' Test Print Job..............................202
Test Print Job "ColorProof.ipds".....................................................207
Test Print Job 'ColorProof.ipds' — Overview...........................207
Test Print Job 'ColorProof.ipds' — Page 1...............................208
Test Print Job 'ColorProof.ipds' — Page 6/7............................216
Test Print Job "ColorProof.ipds_pdf"..............................................218
Test Print Job 'ColorProof.ipds_pdf' — Overview...................218
Test Print Job 'ColorProof.ipds_pdf' — Page 8........................219
Test Print Job 'ColorProof.ipds_pdf' — Page 9........................222
Test Print Job 'ColorProof.ipds_pdf' — Page 10......................223
Test Print Job 'ColorProof.ipds_pdf' — Page 11/12.................225
Test Print Job "ColorProof.pcl"........................................................227
Test Print Job 'ColorProof.pcl' — Overview.............................227
Test Print Job 'ColorProof.pcl' — Page 1..................................228
Test Print Job 'ColorProof.pcl' — Pages 4-10...........................232
Test Print Job 'ColorProof.pcl' — Page 11................................234
Test Print Job 'ColorProof.pcl' — Page 12................................236
'SpotColorPalette.pcl' Test Print Job..............................................237
6
Contents
Optimizing the Color Printing................................................................239

Optimizing the Color Printing — Overview....................................239
Performing a Color Test...................................................................242
Calibrating the Colors of the Printing System...............................244
Calibrating the Colors of the Printing System — Overview....244
Printing Test Pages for Color Calibration.................................246
Scanning Test Pages for Color Calibration...............................249
Analyzing Test Pages for Color Calibration..............................253
Correcting Color Separation Shifts.......................................................255
Calibrating the Data Integrity Mark Sensor..........................................257
Converting the Printing System............................................................261
Emptying Condensation Water.............................................................263
Switching off the Printing System........................................................264
Chapter 7
Cleaning the Printing System........................................................................267
Cleaning the Printing System — Overview..........................................268
Cleaning Agents and Cleaning Intervals..............................................270
Cleaning the Surface of the Developer Stations..................................273
Cleaning the Surface of the Developer Stations — Overview......273
Swiveling off Developer Stations....................................................274
Cleaning Developer Station Surface...............................................275
Swiveling on developer stations.....................................................282
Cleaning the Paper Input.......................................................................283
Cleaning the Paper Output....................................................................286
Cleaning the Paper Path........................................................................289
Checking the Paper Path........................................................................296
Cleaning the Toner Suction System.....................................................301
Cleaning the Paper Brake Dust Filter....................................................305
Cleaning the Surface of the Printing System.......................................307
Cleaning the replacement cart for developer stations (option)..........308
Cleaning the Developer Station Shelf (Optional)................................309
Chapter 8
Replacing Consumables.................................................................................311
Replacing Consumables — Overview..................................................312
Order Numbers and Packing Units.......................................................313
Toner.......................................................................................................314
Toner Bottle Identification with Océ TonerSafe.............................314
Toner Supply with Additional Colors.............................................317
Refilling Toner (Standard: 6 kg / 13.2 lb Toner Bottle)..................318
Refilling Toner (Option: 1 kg / 2.2 lb Toner Bottle)........................324
Replace waste toner box..................................................................331
Filling a Toner Box...........................................................................335
Developer................................................................................................336
7
Contents
Replacing the Developer - Overview..............................................336

Draining the Developer Mixture......................................................337
Fill in Developer................................................................................340
Chapter 9
Replacing Expendables..................................................................................345
Replacing Expendables — Overview....................................................346
Order Numbers and Packaging Units for Expendables......................349
Replacing the Belt..................................................................................350
Replacing the Belt — Overview.......................................................350
Replacing the Photoconductor Belt in the Upper Print Unit.........352
Removing Photoconductor Belt in Upper Print Unit and Replacing
Photoconductor Blade................................................................352
Insert a photoconductor belt in the upper print unit...............358
Replacing the Photoconductor Belt in the Lower Print Unit.........364
Removing Photoconductor Belt in Lower Print Unit and Replacing
Photoconductor Blade. ..............................................................364
Inserting a Photoconductor Belt in the Lower Print Unit........370
Replacing the Transfer Belt in the Upper Print Unit......................376
Removing the Transfer Belt in the Upper Print Unit - Prepara-
tion...............................................................................................376
Removing Transfer Belt in the Upper Print Unit......................380
Insert the Transfer Belt in the Upper Print Unit.......................385
Insertion of a Transfer Belt in the Upper Print Unit (Comple-
tion)..............................................................................................392
Replacing the Transfer Belt in the Lower Print Unit......................395
Removing the Transfer Belt in the Lower Print Unit - Prepara-
tion...............................................................................................395
Removing the Transfer Belt in the Lower Print Unit ...............398
Inserting the Transfer Belt in the Lower Print Unit..................402
Inserting the Transfer Belt in the Lower Print Unit..................408
Running in a Belt..............................................................................411
Replacing Corotrons..............................................................................412
Replacing the corotron — overview...............................................412
Removing the cleaning corotron slide-in unit or charge corotron
slide-in unit of the photoconductor unit.........................................413
Installing the cleaning corotron slide-in unit or charge corotron slide-
in unit of the photoconductor unit .................................................416
Removing the cleaning corotron slide-in unit of the transfer unit.418
Installing the cleaning corotron slide-in unit of the transfer unit .420
Removing the reload corotron slide-in unit of the transfer unit....421
Installing the reload corotron slide-in unit of the transfer unit....423
Removing the recharge corotron slide-in unit of the transfer unit.425
Installing the recharge corotron slide-in unit of the transfer unit.427
Replacing corotron wire...................................................................428
8
Contents
Replacing the Cleaning Brush...............................................................433

Replacing the cleaning brush — overview.....................................433
Removing the cleaning brush of the photoconductor unit...........434
Installing the cleaning brush of the photoconductor unit.............437
Removing the cleaning brush of the transfer unit.........................439
Installing the cleaning brush of the transfer unit...........................441
Replacing fine filter................................................................................443
Replacing the cleaning felt....................................................................448
Replacing the Smoothing Rollers.........................................................454
Replacing the smoothing rollers — overview................................454
Removing the smoothing rollers....................................................455
Installing smoothing rollers.............................................................461
Replacing Expendables in Expert Mode...............................................469
Chapter 10
Correcting Errors.............................................................................................473
Correcting Errors — Overview .............................................................474
Processing messages on the operator panel ......................................475
Remote Diagnosis..................................................................................479
Allowing Remote Access — Overview...........................................479
Permitting or Blocking Remote Diagnosis.....................................480
Activating or Deactivating Remote Support..................................481
Correcting Fusing Problems..................................................................483
Correcting Print Image Errors...............................................................484
Appendix A
Technical Data.................................................................................................491
Technical Data — Overview..................................................................492
Technology and Print Speed.................................................................493
Paper........................................................................................................496
Electrical Values and Power Input........................................................498
Mechanical Conditions..........................................................................500
Environmental Conditions.....................................................................502
Replacement cart for developer stations (option)...............................503
Ruler for Checking Paper Path Synchronization..................................504
Appendix B
Comments.......................................................................................................507
Your comments on this User Manual...................................................508
9
Contents
10
Chapter 1
Notes on the Printing
System Documentation
Notes on the Printing System Documentation — Overview
Notes on the Printing System Documentation — Overview
Introduction
The purpose of this documentation is to ensure that all printing system-related work is
carried out safely and correctly. It contains safety directives that must be strictly observed.
Each section is divided into small, easy-to-understand subject areas. Overviews at the
beginning of the sections help you to find the precise information you are looking for
quickly.
Storage Tray for the User Guide

The user guide should always be kept near the console in the storage tray.
Overview
You will find information on the following topics:
■ ‘Guide through the Documentation’ on page 13
■ ‘Notes on the Help - Overview’ on page 15
■ ‘Symbols in the text’ on page 24
■ ‘Symbols in figures’ on page 25
■ ‘Other Documents’ on page 27
■ ‘Manufacturer of the printing system’ on page 28
■ ‘Statutory requirements’ on page 29
12 Chapter 1 - Notes on the Printing System Documentation

Guide through the Documentation
Introduction
Documentation available to you on the Océ ColorStream includes a printed user guide
and help on the operator panel. This help is updated with every new version of the oper-
ator panel software.
Security
This section gives you all necessary information on how to safely and efficiently operate
the printing system.
Description of the printing system

This section shows the structure of the printing system, describes the operating elements
and explains the printing principle. You will also find information on paper types and
how to handle the paper.
Description of the Operator Panel

This section describes the individual areas of the operator panel with the most important
menus, buttons and icons.
Working with the operator panel

This section explains how you manage all user settings, how you select or enter parameters
on the operator panel, how you collect special settings for frequently recurring print jobs
using setups, how you manage resources for printing operation and how you replace
consumables and expendables using the operator panel.
Operating the printing system

This section describes how to power the printing system on and off and the procedure
for inserting, affixing and removing the paper web, and also contains all other information
that you will need to operate the printing system.
Cleaning the printing system

This section shows you how often to clean the different components and how to carry
out this cleaning.
Chapter 1 - Notes on the Printing System Documentation 13

Replacing consumables
This section describes in detail all the steps required to replace consumables. It also provides
the order numbers and package units for all consumables.
Replacing expendables
This section describes in detail all the steps required to replace expendables. It also provides
the order numbers and package units for all expendables.
Correcting Errors
This section shows you how to locate and remedy errors using the messages displayed on
the operator panel. It also describes how you can enable remote access to allow remote
diagnosis by Service during print operation . You will also find information on how to
correct any fusing or print image errors.
Technical data
This section contains the most important technical data for the printing system.
You can use the ruler for controlling the paper path synchronization to assign the marks
on the paper input to certain form lengths.
Index
The fastest way to find particular topics is via the detailed index at the end of the user
guide.
Your comments on this user guide

We are interested in your opinion on this user guide for the Océ ColorStream. You can
help us improve this user guide by answering the questions in this section.

Notes on the Help - Overview
Notes on Help
Notes on the Help - Overview
Help target group

This Help is designed for the "Operator" and "Key Operator" user groups. This Help
should enable an "Operator" or "Key Operator" to use the printing system safely, appro-
priately and efficiently.
Menus that are available to the Service group only are not displayed in this Help. The
Océ service documentation is available for Service.
Contents of Help
This Help describes the printing system and operator panel with the following main
groups:
■ 'General'
■ 'VarioStream' or 'ColorStream' or 'JetStream'
■ 'Paperpath Manager'
■ With Océ VarioStream 9000 CustomTone or full-color printing systems and with
Océ ColorStream, also: 'Web Buffer'
Any connected pre- and post-processing devices are not covered in this Help. It is assumed
that the user is able to operate these devices properly and observes the safety instructions
in the relevant documentation sources for these pre- and post-processing devices.
Calling up Help
There are two ways you can access help topics:
■ Help button on the toolbar and subsequent navigation via contents, index or search:
‘Opening Help’ on page 16

‘Contents’ on page 18
‘Index’ on page 19
‘Search’ on page 20
■ Direct Help via the F1 key:
‘Opening Direct Help’ on page 21

Opening Help
Opening Help
To open Help
#
Proceed as follows:
1. Click on the following button in the frame toolbar:
The Help window opens. The navigation area is displayed initially:
The width of the navigation area can be changed with the mouse.

Opening Help
Function of the Buttons in the Help Window

#
Button Function
Hides or displays the navigation area with the following tabs:
■ ‘Contents’ on page 18
■ ‘Index’ on page 19
■ ‘Search’ on page 20
When the navigation area is hidden, more space is available to view

the help topics.
Switches between the last help topics (backwards or forwards).
Reloads the displayed help topic, in case not all the necessary content
was loaded (e.g. graphics).
Switches from any help topic directly to the Help start page.
Closes Help.

Contents
Navigating in Help
Contents
To call up Help topics via the contents

#
Proceed as follows:
1. Click on the 'Contents' tab.
2. Click the buttons of the individual help levels to fade them in and out.
Example:
[13]
3. Click on a help topic.

Index
Index
Introduction
Entries on the 'Index' tab are sorted alphabetically. Any number of secondary keywords
can be attached to a primary keyword.
To select information via the Index

#
Proceed as follows:
1. Click on the "Index" tab.
2. Scroll through the index entries
or
enter text (including partial words) into the 'Search' field and press Enter.
Example:
[14]
3. Click on a help topic

Search
Search
Introduction
You can access the full text search function via the "Search" tab. The full text search is
used to find one or more specific words in the entire Help. Uppercase or lowercase is not
relevant for the search. Partial words cannot be found.
To call up information via the full text search

#
Proceed as follows:
1. Click on the 'Search' tab.
2. Enter the text in the 'Search' input field.
3. Press Enter.
The search results are listed by the title of the corresponding help topic, and
are sorted by level of matches and the frequency in which the word appears in
the help topic. Example:
The circle in the first column indicates the level of matching. The more filled
the circle is, the better the result matches the text that was searched for.
The number in the second column of the search result indicates how often it
occurs in the Help topic.
4. Click on a help topic

Opening Direct Help
Opening Direct Help
Introduction
Context-sensitive Direct Help provides detailed information on all:
■ Menus
■ Operating elements in menus
■ Errors and warnings
Note
When calling up the Direct Help, ensure that you have selected the element
for which you wish to call up the Help text.
The selected element can be identified by the blue frame. In the following ex-
ample, the 'Edit user' menu in the first illustration is only highlighted, but has
not been selected for the use of Direct Help. In the second illustration it is
selected.
If the element is not selected correctly, pressing the F1 button will only display
the start page instead of the respective Help page.
Selected element without a blue frame:
Selected element with a blue frame:

Opening Direct Help
To call up the Direct Help

#
Proceed as follows:
1. Select menu
or
select operating element

or
select message
2. Press F1.
The Help window opens. The navigation area is initially hidden, e. g.:

Opening Direct Help
Function of the Buttons in the Help Window

#
Button Function
Hides or displays the navigation area with the following tabs:
■ ‘Contents’ on page 18
■ ‘Index’ on page 19
■ ‘Search’ on page 20
When the navigation area is hidden, more space is available to view

the help topics.
Switches between the last help topics (backwards or forwards).
Reloads the displayed help topic, in case not all the necessary content
was loaded (e.g. graphics).
Switches from any help topic directly to the Help start page.
Closes Help.

Symbols in the text
Symbol Conventions
Symbols in the text
Display of operating elements on the operator panel

The operating element description is shown in inverted commas on the operator panel,
e.g.
'Configuration' menu.
Notes
Note:
This symbol indicates notes - tips for operating the Océ ColorStream.
Safety directives
Symbols are used for the safety directives, as well as different alert words depending on
the degree of danger: see ‘Flagging of safety directives ’ on page 34.

Symbols in figures
Symbols in figures
Introduction
If not indicated otherwise, diagrams and illustrations of actions depict the starting position
of the respective component for the described step.
To ease understanding, the illustrations depict the components that are directly relevant
to the immediate context in a larger line thickness.
Note:
As a result of the continuous technical further development, it may be that some of the
details on the images in the documentation are not always completely up-to-date with
the delivered printing system.
Arrows
Arrows denote the positions where you should perform an action or observe something
in particular. The colors of the arrows denote the type of actions and the sequence in
which they are performed:
#
Arrow Meaning
Black arrow: Direction arrow
Perform this action first
Grey arrow: Direction arrow
Perform this action next
If further actions are depicted in an illustration, the numbers
on the arrows indicate the sequence of these further actions.
White arrow: Note arrow

An action should be performed in this area.
Overview Graphics
To provide a clear overview, the VarioStream 9000 and ColorStream printing systems
also indicate the side of the printing system where the action is to be performed.

Symbols in figures
Overview graphic Meaning

Paper input
Left-hand side of printing system
Right-hand side of printing system
Filter module
Paper output

Other Documents
Other Documents
In Addition to the User Guide

The following documents are also provided for every printing system, in addition to the
user guide:
#
Title Order number

Safety information A29246-X34-X-n-79 (multi-lingual)
Paper specification A29249-X5-X-n-mm59
'Océ Web Buffer' User Guide A29246-X27-X-n-mm80
Note:
The respective edition of the document is indicated in the order number by the digit
"n", for example: Edition 3: n = 3. The letters "mm" stand for the language code of the
document:
■ German: mm = --
■ English: mm = 76
■ French: mm = 77
■ Italian: mm = 72
■ Spanish: mm = 78
■ Dutch: mm = 54
■ Japanese: mm = 5Z
■ Chinese: mm = 5D

Manufacturer of the printing system
Manufacturer of the printing system
Océ ColorStream
The printing system Océ ColorStream was manufactured by:

Postfach 1260
85581 Poing
Germany

Statutory requirements
Technical changes
The information, data and instructions in this documentation were up-to-date at the
time of going to press. The right of technical modifications due to further development
of the printing system is reserved. For this reason, the information, illustrations and de-
scriptions in this documentation cannot give rise to any claims for modifications or addi-
tions to printing systems that have already been shipped and accepted.
Liability
No liability is accepted for damages resulting from:
■ Failure to comply with the documentation
■ Errors due to improper handling
■ Work performed incorrectly on the printing system
■ Use of non-original expendable parts, replacement parts and accessories
■ Use of non-original consumables
■ Unauthorized modification and retrofitting of the printing system by the agent or the
agent’s personnel.


Chapter 2
Safety
Safety — Overview
Safety — Overview
Security
This section gives you all necessary information on how to safely and efficiently operate
the printing system.
Safety Directives
In addition to the safety directives in section ‘Accident and damage prevention - overview’
on page 37, you must also observe the safety directives elsewhere in this documentation.
Please also observe the safety directives in the documentation for any pre-processing and
post-processing devices that may be connected.
Overview
■ ‘Intended Purpose ’ on page 33
■ ‘Flagging of safety directives ’ on page 34
■ ‘Warning and information signs’ on page 35
■ ‘Accident and damage prevention - overview’ on page 37
■ ‘Safety regulations and standards — overview’ on page 45
32 Chapter 2 - Safety
Intended Purpose
Intended Purpose
Océ ColorStream
The Océ ColorStream printing system shall only be considered as being used for its in-
tended purpose if the notices and instructions in this documentation are strictly observed:
■ The printing system is intended solely for printing materials that comply with the
paper specification requirements (see ‘Other Documents’ on page 27).

■ The printing system must only be operated with the recommended consumables (see
‘Order Numbers and Packaging Units for Expendables’ on page 349).

■ The printing system must only be operated under the prescribed operating conditions
(see ‘Technical Data — Overview’ on page 492).
Any other use of the printing system can cause damage to the printing system or property
as well as injury to persons.
Chapter 2 - Safety 33
Flagging of safety directives
Flagging of safety directives
Definition
The following notational conventions are used for the safety directives in the text of the
manual:
#
Symbol Alert word

Type or source of danger and consequences of failure to observe the
safety directives
Instructions on avoiding danger
Different alert words are used for the safety directives, depending on the degree of danger.
Two classes of safety directives
Caution:
Warns against dangers that could lead to injuries.
Attention:
Warns against situations that could lead to damage to the printing system or disruptions
to operation.
Example of a safety directive
Attention:
Fluid can get inside the printing system. This could cause irreparable damage to the
electrical and mechanical components.
Do not place cleaning fluids on top of or in the immediate vicinity of the printing system.
Take care to prevent fluids from seeping into the printing system.
Warning and information signs
Identification of Danger Points

The following signs are affixed inside the printing system at potential danger points:
#
Label Meaning
Warning: Live electric parts
There are live electric parts behind safety covers bearing this
sign. These safety covers may only be removed by authorized
Océ Service personnel.
Warning about rotating parts

In these areas, body parts (especially fingers), unprotected long
hair and loose hanging clothing (e.g. ties, jewelry, loose belts
etc.) can be pulled in by the rotating parts of the printing sys-
tem, trapped and crushed.
Warning about hot components
In order to prevent burns, you must observe the cooling periods
and other directives specified in the documentation for all work
in these areas.
Observe documentation
For all work in this area, you must observe the relevant instruc-
tions in the documentation.
Disposal
This symbol means that separate, proper disposal of the compo-
nents at the end of the product service life is obligatory in the
EU Member States. The black bar indicates that the regulation
became effective on August 13, 2005. Directive: 2002/96/EC.
The "Environmental Protection Use Period (EPUP)", applicable

in the People's Republic of China, amounts to 20 years for the
printing system.
This EPUP, which does not record consumables and expend-
ables according to regulations, does not affect the liability for
defects and no special guarantee is given for the printing system.
Additional warning and information signs on the Océ ColorStream

#
Sign Meaning
Warning regarding laser beams
Components that produce laser beams are located behind pro-
tective covers bearing this sign. These protective covers may
only be removed by authorized Océ Service personnel.
Accident and damage prevention - overview
Accident and Damage Prevention

Accident and damage prevention - overview
Overview
■ ‘Personal Representations’ on page 38
■ ‘Operation’ on page 39
■ ‘Transportation, assembly and installation, repair’ on page 42
■ ‘Fire, disposal’ on page 44
Personal Representations
Personal Representations
Agent
An agent is any individual or legal entity (corporate body) that uses or commissions the
use of the printing system.
Operator
The Operator
■ is trained directly on the printing system as to how to operate it and has been instructed
on the tasks assigned to them. They are familiar with the contents of the documenta-
tion.
■ is aware of the potential dangers of improper handling of the printing system.
■ has been informed about necessary safety installations, safety precautions and operating
conditions.
■ has been instructed or commissioned by the agent to operate the printing system.
■ can load defined setups.
Key Operator
The Key Operator
■ is an operator with a higher qualification assigned additional tasks by the agent (e.g.
assignment of user rights and passwords).

■ can also display or hide menus for the different operators and accordingly adapt the
menu structure to the respective requirements.

■ can compile defined printing system configurations to create setups.
Service
Service staff are specialized Océ personnel who carry out all work on and with the printing
system that operators may not (e.g., any work on the power circuits in the printing system).
Operation
Operation
Introduction
Observe the following instructions when operating the printing system:
Service personnel
Only operators, key operators and Service personnel may operate the printing system.
The printing system must not be operated by persons under the influence of alcohol or
drugs, or by persons taking certain types of medication, such as psychotropic drugs.
Before operating the printing system, carefully read through the documentation. Please
ask if you do not understand anything in the documentation (e. g. regarding Service).
In cases of emergency, power off the printing system off immediately with the main
switch. In the event of damage to the casing, power cable or operating elements, or pen-
etration of fluids or foreign bodies, call the appropriate Service representative.
Do not wear any loose hanging clothing (e. g. ties, sleeves, scarves), necklaces and bracelets,
loose belts, rings and unprotected long hair. These can catch in the drive mechanisms or
moving parts of the printing system and cause injury.
Safety covers
Do not attempt to remove safety covers yourself; do not manipulate safety equipment
such as the switches monitoring the safety covers, fuses etc., and do not perform any work
not intended to be performed by operators. Such action can cause accidents and may also
damage the printing system.
Safe operation of the printing system is guaranteed only when the outer paneling is fully
mounted. Only properly and fully affixed casing ensures:
■ Protection from electrical shocks
■ Protection against injury from mechanical parts, e.g. cuts, drawing in, crushing
■ Protection against the spread of fire
■ Sufficient cooling of the printing system.
Keep all doors, trims, flaps and covers closed while the printing system is in operation.
This ensures that limit values for electromagnetic compatibility are not exceeded. Noise
emission is also minimized.
Operation
Cleaning
Always use an industrial vacuum cleaner with a grounded suction tube, rubber nozzle
and filter set for fine dust. An explosion-proof industrial vacuum cleaner must be used
for large toner quantities because there can be a high build-up of static charge when
draining toner spill.
When cleaning the printing system, observe the instructions in the following sections:
■ ‘Cleaning the Printing System — Overview’ on page 268
■ ‘Cleaning Agents and Cleaning Intervals’ on page 270
Foreign bodies, noises

Make sure that no objects (e.g. jewelry chains, paper clips, coins etc.) or liquids get into
the interior of the printing system, since this may result in electric shocks or short circuits.
Do not place objects on the printing system, and especially do not place containers with
fluid, such as drinking bottles, glasses, cups or vases on top of or in the immediate vicin-
ity of the printing system.
Should the printing system emit any unusual or noticeable noises or smells, power off
the printing system and contact your Service engineer.
Cooling, Heat, Emissions

Do not obstruct the cooling ducts, since this may result in overheating or combustion
while the device is in operation.
Make sure there is an adequate supply of fresh air and cooling air to the room in which
the printing system is located (see ‘Cooling air, fresh air, and air purity’ on page 502).
Do not obstruct the operating and maintenance areas of the Océ ColorStream printing
system with other devices or objects.
During operation, the inner area of the fuser module in the printing system becomes very
hot (greater than 500°C/932°F). Before doing any work on or around the fuser module,
always allow it to cool down for the specified length of time. Failure to observe the direc-
tives in this documentation could result in burns.
The ozone produced when the photoconductor and transfer belts are loaded is suctioned
off within the printing system and then transformed into oxygen through a catalytic filter
Operation
system. The life cycle of the filter system is designed so that it does not have to be replaced
during the lifetime of the printing system.
During printing, the ozone concentration is below the maximum allowable work place
concentration (MAC) of 0.1 ppm (0.2 mg/m3). With proper ventilation, harmful con-
centrations do not occur even if the filter system fails entirely. For ventilation, see ‘Cooling
air, fresh air, and air purity’ on page 502.
Consumables and Expendables

Observe the safety directives given in the manual for:
■ Toner
■ Developer
■ Fine filter
■ Photoconductor belt
■ Transfer belt
■ Cleaning agent
Keep all consumables for the printing system out of the reach of children. Store consum-
ables away from containers used for food and drink.
Optical wave guide

If your printing system has an optical wave guide connection:
Never look directly down a glass fiber cable or glass fiber cable connection. The laser
beams in fiber optic devices can injure your eyes.
Laser
If the printing system includes a laser:
Never look directly into a laser beam or laser optics. Never move a tool into the area of
the laser beam so that you do not unintentionally diffract the laser beam. The laser beams
in fiber optic devices can injure your eyes.
Remote control via LAN

If you operate the printing system from a remote operator panel:
The access ticket ensures that only one user at a time can access the printing system.
Warning and Information Signs

Observe all warning and information signs on and in the printing system (see ‘Warning
and information signs’ on page 35).
Transportation, assembly and installation, repair
Transport
The printing system may only be transported by Service personnel or authorized transport
companies.
Assembly and installation

Observe the following instructions when assembling and installing the printing system:
■ The printing system may only be assembled and installed by Service personnel.
■ The printing system must have a dedicated electrical connection or type B plug con-
nection (complying with VDE directives, EN 60950).

■ Do not route the lines and cables in such a way that they can be trodden on or tripped
over.
■ A fume hood should be installed over the fuser module (without a security detector).
In very seldom cases, paper that has been caught in the fuser module will be damaged
by the infrared fusing and will begin to smoke. However, even in this case there is no
danger of fire because the affected component is immediately isolated from the remain-
ing printing system by sealed bulkheads. This bulkhead is part of a proven safety
concept and does not affect the availability of the printing system after the jammed
paper has been removed.
■ All printing system accessories and options must comply with statutory regulations
and directives for safety, electromagnetic compatibility, telecommunications terminal

devices as well as with the specifications published by Océ Printing Systems GmbH.
■ The installation of other accessories may constitute a violation of these requirements
and directives, and may also damage the printing system.

■ Consult Service personnel for details on which accessories and options are permitted
for the printing system.

■ With the exception of optical wave guide connections, all data, signaling, process,
measurement and control lines mapping the printing system with other devices must
be properly grounded.
■ Data transmission lines should neither be connected nor disconnected during electrical
storms.
Repairs
Repairs to the printing system must only be carried out by Service personnel. Access to
locked areas and areas which can only be opened with special tools is reserved for Service
personnel. Opening the device without authorization and improperly effected repairs
may put operators at considerable risk.
The access ticket used by the Service technician ensures that the printing system cannot
be used via an LAN from a remote operator panel during repair work.
Fire, disposal
Fire, disposal
Fire
Observe the following instructions:
■ Poisonous gases can occur in any fire. They can also result from the printing system
Océ ColorStream.
■ Self-contained breathing apparatus must be worn when fighting fire or smoke emission.
Instructions to this effect should be deposited at the fire alarm center and with the
local fire-fighting force.
Disposal
Océ operates a system by which expendables and consumables can be returned for envi-
ronmentally sound disposal.
Keep all used parts and consumables that are to be returned for disposal for collection by
Service or the contracted shipping company. These will be recycled or disposed of appro-
priately by Océ Printing Systems GmbH or a contracted disposal company.
Safety regulations and standards — overview
Safety Regulations and Standards

Introduction
The printing system Océ ColorStream complies with the relevant safety requirements for
information technology equipment. It meets the following national and international
safety regulations and standards:
Safety Standards
#
VDE 0160 Fitting of high-voltage systems with electrical equipment

VDE 0805 Safety of information technology systems including elec-
tronic office machines
2006/95/EC Low voltage directive
EC directive for harmonization of the legal requirements
of member states regarding electrical equipment for use
within certain voltage limits (modified by EC Directive
93/68/EWG)
IEC 60950 Safety of information technology equipment including
electrical business equipment
EN 60950-1 (Europe) Safety of information technology equipment, including
office devices, in connection with the CE mark
UL 60950-1 (USA) Safety of information technology equipment including
electrical business equipment
CAN-CSA Standard Standard for safety of information technology equipment
CSA 60950-1 (Canada) including electrical business equipment
Certified Safety
General device safety is verified by:

■ VDE/GS
■ TÜV/GS
■ Or similar
Electromagnetic Compatibility
#
89/336/EWG EMVDirective
EC Directive for harmonization of the legal requirements
of member states regarding Electromagnetic Compatibility
(modified by Directive 91/263/EEC, 92/31/EEC, and
Directive 93/68/EEC)
EN 55024 Europe
EN 55022 / Class A
FCC Part 15 Subpart B USA
Class A
C108.8-M1983 (Class Canada
A)
Environmental Standards
#
DIN / IEC 68 Environmental Conditions - Test

EN 60721 - Part 3 Environmental conditions for products
Permitted noise emissions from devices
2002/95/EG RoHSDirective
EC directive on the restriction of the use of certain haz-
ardous substances in electrical and electronic equipment =
RoHS Directive (binding since 06/30/2006)
2002/96/EG WEEDirective
EC directive on waste electrical and electronic equipment
= WEEE Directive (binding since 06/30/2006)
Recooler
The recooler complies with the following regulations and directives:
■ EMV-Directive 2004/108/EC
■ Low Voltage Directive 2006/95/EC
■ DIN EN 378 Refrigerating systems and heat pumps — safety and environmental re-
quirements
■ RoHS Directive
■ TÜV/GS
Overview
Here you will find additional information on the following topics:
■ ‘CE Mark’ on page 48
■ ‘Accident prevention regulation for replacement carts (option)’ on page 49
CE Mark
CE Mark
Océ ColorStream
The printing system Océ ColorStream fulfills the requirements of the EC directives
89/336/EWG, "Electromagnetic Compatibility" and 73/23/EWG "Low Voltage Direc-
tive".
The CE Mark indicates that the printing system complies with these EC directives.
The printing system is a Class A product (EN 55022). This product may cause radio in-
terference in a domestic environment. In this case, the agent may be required to take ap-
propriate measures to correct the interference at his or her own expense.
The printing system can cause the power supply to fluctuate if the power network is not
in order. According to EN 61000-3-11, the printing system should only be used on
premises that have a network with a continuous current-carrying capacity of 100 A per
phase or are supplied by a distribution network of 400/230 V.
The agent must ensure that the printing system is operated in a power supply network
that meets these requirements. If necessary, consult the power company to ensure that
the continuous current-carrying capacity of the power system at the connection point to
the public power grid is sufficient to connect the device.
Connected Devices
The optional "maintenance cart for developer stations" and "movable developer station
shelf" are also CE-certified.
All other devices that are connected to the printing system must also comply with the
requirements set forth in the relevant EC directives.
Accident prevention regulation for replacement carts (option)
Technical inspection
A technical inspection must be carried out annually by a technical expert as per BGV D8
"Winches, Lifting and Pulling Devices" or relevant country-specific regulations. The
technical inspection includes the following services:
■ Completeness, suitability and effectivity of the security mechanisms (e.g. rebound
guards, holdbacks, braking mechanisms, auxiliary brakes, winders, equipment for

locking the load shaft, overloading guards, emergency stopping equipment).
■ Condition of device, supports, castors, equipment and frame.
Records of the results of device inspections must be retained. The inspection can be
documented e.g. by entering the inspection results in an inspection log, by maintaining
a file or by affixing an inspection badge (with the date of inspection and the inspector in
each case).
Requirement for affixing the inspection badge: The device has no safety defects.
Chapter 3
Description of the Printing
System
Description of the Printing System — Overview
Description of the Printing System — Overview
Description of the printing system

This section shows the structure of the printing system, describes the operating elements
and explains the printing principle. You will also find information on paper types and
how to handle the paper.
Overview
■ ‘Main Modules’ on page 53
■ ‘Doors and Covers’ on page 54
■ ‘Internal View — Overview’ on page 56
■ ‘Printing method’ on page 64
■ ‘Operating Elements - Overview’ on page 67
■ ‘Paper specifications’ on page 78
52 Chapter 3 - Description of the Printing System

Main Modules
Main Modules
Modular Design
The printing system has a modular structure consisting of the following main modules:
3 2 1
5
Unit Designation
1 Paper Input Module
2 Print Unit
3 Fuser module
4 Filter module
5 Console
#
Paper path direction
Chapter 3 - Description of the Printing System 53

Doors and Covers
Doors and Covers
Introduction
Note:
Right-hand side means right in paper path direction.
Left-hand side means left in paper path direction.
Right-Hand Side of Printing System
Left-Hand Side of Printing System
Legend
#
Color Meaning
These doors may be opened during printing without causing
any adverse effects. There is no danger, even if a door is open

Doors and Covers
Color Meaning
These doors and covers must not be opened during printing.
To avoid any danger, the entire printing system shuts down if
they are opened.
Option With the optional toner supply using 1 kg (2.2 lb) toner bottles,
this door can be opened during printer operation without having
to disconnect the printer from the mains.
However, if highest levels of print quality are to be maintained,
we recommend that this door be left closed during printer op-
eration.
Paper path direction
Note:
Detailed information on opening and closing the doors is provided in the following
sections:
■ ‘Opening Right Doors’ on page 157
■ ‘Closing Right Doors’ on page 159
■ ‘Opening Left Doors’ on page 161
■ ‘Closing Left Doors’ on page 163

Internal View — Overview
Internal View
The Most Important Components
Note:
The figure shows the maximum configuration of the Océ ColorStream printing system
with five developer stations in the upper and lower print unit.
1 2 3 4 5 6 7 8
11 12 7 6 5 10 9
Component / Designation Function

1 Paper cooling In the paper cooling system, the printed paper web
is cooled down to such an extent that it can be
processed further without problems.
2 Smoothing module In the smoothing module, the toner is optimally
bonded to the hot paper web, using smoothing
rollers.
3 Filter module ‘Filter module’ on page 61


4 Fuser module/Infrared In the fuser module, the toner is fused on the front
lamp and rear sides of the paper by means of an infrared
lamp.
5 Print unit In the print unit, the front and rear sides of the
Upper print unit paper are printed at the same time via the upper
Lower print unit and lower print units.
6 Upper photoconductor ‘Photoconductor unit’ on page 58
unit
Lower photoconductor
unit
7 Upper transfer unit ‘Transfer unit’ on page 60
Lower transfer unit
8 Paper input The paper web is fed into the print module from
the external paper feed via the paper input.
9 Rocker The rocker is unlocked and opened to insert the
paper web.
10 Heat exchanger Together with an external recooler, the heat ex-
changer keeps the temperature of the developer
stations constant.
11 Paper output The paper web is fed into the vacuum unit of the
web buffer via the paper output.
#
12 Toner Feed Unit The developer stations are filled with toner using
toner bottles of 6 kg (13.2 lb) each (see ‘Console’ on
page 62) or bottles of 1 kg (2.2 lb) each (optional).
#
Paper web

Photoconductor unit
Photoconductor unit
Important Components of the Photoconductor Unit

The illustration shows a cross section of the photoconductor unit in the upper print unit
with five developer stations.
9 2
3
6
8

1 LED print head Exposes the negatively charged photoconductor
belt and neutralizes the charge in areas where toner
is afterwards to be applied.
2 Charge corotron Negatively charges the photoconductor belt.
3 Photoconductor blade Cleans away toner residue on the photoconductor
belt.
4 Cleaning brush Brushes away toner particles not transferred to the
transfer belt.
5 Cleaning corotron Removes any residual charge on the photoconduc-
tor belt.

Photoconductor unit

6 Toner box Maintains a constant level of toner for the toner
feed.
7 Toner mark sensor Measures the quantity of toner for each color.
8 Developer stations Applies toner to areas on the photoconductor belt
exposed by the LED print head.
9 Photoconductor belt (= Establishes an image pattern for each color, fol-
OPC belt = Organic lowed by a toner image.
Photo Conductor belt)

Transfer unit
Transfer unit
Important Components of the Transfer Unit

The illustration shows a cross section of the transfer unit in the upper print unit.

1 Transfer corotron Establishes the required potential difference on
(only in the upper print the transfer roller point between the transfer belt
unit) and paper by reversing the polarity of the toner
particles from negative to positive.
2 Transfer belt Collects the colored image patterns for individual
colors with register accuracy and then transfers
these together to the paper web.
3 Cleaning corotron Reverses the polarity of residual toner particles on
the paper after the transfer process back to negative
in preparation for cleaning.
4 Cleaning brush Brushes away toner particles not transferred onto
the paper.

Filter module
Filter module
Important components of the filter module
Component / Designation Description

1 Waste toner box The waste toner, which is drained from the print
unit, is collected in the waste toner box.
2 Fine filter The exhaust air is cleaned with a fine filter and
sent out of the top of the filter module.

Console
Console
Important Components of the Console
3 4 5
#
Component Description
1 Screen
2 Keyboard and mouse
3 Storage for the user guide
4 Toner supply
5 Toner hoses on the printing system
Color Allocation in the Console

The developer stations for all colors are supplied by a toner suction system consisting of
toner bottles weighing 6 kg (13.2 lb) each. For full-color printing systems, the developer
station slots for CMYK are predefined. In order to keep the toner suction hoses as short
as possible, the slots in the console are also predefined:

Console
Slot Color
1 Yellow
2 Magenta
3 Cyan
4 Black
5/6 CustomTone or additional black, cyan, magenta or yellow
toner bottles.
Note:
In the case of CustomTone printing systems, the color allocation in the console can be
changed by Service.

Printing method
Printing method
Introduction
The print image is created through an electrophotographic printing process with LED
print heads and two-component developers.
With a full color printing system, the colors are generated using the subtractive color
mixing technique, using the color separations cyan, magenta and yellow:
To reduce the coverage and achieve a greater depth with dark colors, black is also used
as the fourth color.
Printing Process
#
Level Description
1 The rastered controller pages are written to the photoconductor belt
with the LED print head.
■ During bilevel printing, each dot can be assigned either 100% color
or 100% white (= LED in LED print head on or off).

■ During multilevel printing, the light intensity of each LED can range
between 16 brightness levels. This dot modulation allows continuous

runs.
2 The developer station inks the image pattern.

3 The inked image pattern is transmitted from the photoconductor belt
to the transfer belt.

Printing method
Level Description
4 The photoconductor belt is cleaned.
5 Transfer is from the transfer belt to the paper web. In double-sided print
operation, the upper and the lower printed page are transferred at the
same time.
■ Single color printing: Black/White Printing System
For single color printing, the inked image pattern is transferred from
the transfer belt to the paper web. The transfer roller point remains
swiveled onto the paper web and paper transport is not stopped.
■ Color collection mode: Full-color or CustomTone printing system
The colored image patterns for the individual colors are first collected
on the transfer belt and then transferred together to the paper web.
During the collection process, the transfer roller point is swiveled off
from the paper web and paper transport is stopped (Start/Stop oper-
ation).
Example: Color collection mode in a full color printing system with

CustomTone as the fifth color
6 The transfer belt is cleaned.

7 The inked paper is fused to the paper via infrared radiation in the fuser
module (simultaneously for single and double-sided printing).

Printing method
Level Description
8 The paper is cooled in the paper cooling unit for further processing in
the paper post-processing unit.

Operating Elements - Overview
Operating Elements
The Most Important Operating Elements
1 2 1
1 2
3
#
Number Description
1 Additional operator panels
2 Operator attention light
3 On key
4 Main switch
5 Operator panel
Standard PC with screen, keyboard and mouse on external console
close to the printing system

Note:
Additional operator panels can be used optionally. They do not have to be set up in
close proximity to the printing system. The access ticket ensures that parameters are not
set by different users at parallel operator panels.
Overview
■ ‘On key’ on page 69
■ ‘Additional Operator Panels’ on page 70
■ ‘Operator Attention Light (OPAL) — Overview’ on page 72
■ ‘Operating elements in the printing system’ on page 77

On key
On key
Display
#
Key Function
The printing system is on.
(green)
Transitional states
(flashing yellow)
The printing system is in standby mode (main switch is on).
(yellow)
The printing system is off.
(off)

Additional Operator Panels
Three Key Operator Panels

Three additional identical key operator panels are located on the corners of the printing
system.
Function of the Keys
Note:
The function of the keys corresponds to the function of the buttons in the operator
panel toolbar (see ‘Buttons and Displays in the Left Area’ on page 84).
#
Key Function
READY Switches the printing system to ready for operation again from
the 'Stop' or 'Operator intervention necessary' statuses.
Requirements:
■ No errors present
■ Controller and system control are ready
Additional function: With the READY key, print operation

can also be interrupted to check the printed paper web (see
‘Checking the print image ’ on page 199).
ADVF Moves the paper slowly forwards without fusing while the but-
(= ADVanced ton is being pressed. The paper speed increases the longer you
Forward) press the button. However, synchronization is lost.
Requirement:
■ This function can only be executed in the 'Stop' status.

Key Function
ADVR Moves the paper slowly backwards without fusing while the
(= ADVanced button is being pressed. The paper speed increases the longer
Reverse) you press the button. However, synchronization is lost.
Requirement:
NPRO Moves the last printed pages out of the printing system with
(= Non Process the correct page alignment. Already printed pages will still be
Run Out) fused. If required, the NPRO transport can be cancelled using
the 'Stop' key.
Requirement:
EJECT Transports the paper web forward at print speed while the
button is pressed. The paper web is not printed. Already printed
pages will still be fused.
Requirement:
AUTOFEED Moves the autofeed clamp to paper input position

or
Starts feeding the paper web into the printing system
STOP Switches the printing system to 'Stop' status
or
Cancels a function that is running

Operator Attention Light (OPAL) — Overview
Operator Attention Light

Operator Attention Light (OPAL) — Overview
Note:
For the Operator Attention Light (OPAL), Service can switch the flash concept between
the standard versions for bundle 11 and bundle 10. The following variants are preset:
■ ColorStream and 'VarioStream 9400 / 9500 / 9600 / 9700': Bundle 11 version
■ 'VarioStream 9200': Bundle 10 version
Overview
■ ‘Operator Attention Light (OPAL)/Bundle 11 Version’ on page 73
■ ‘Operator Attention Light (OPAL)/Bundle 10 Version’ on page 75

Operator Attention Light (OPAL)/Bundle 11 Version
Displays
The most important displays are summarized in the following table:
#
Display Meaning
The printing system is in standby mode.
(Main switch is on).
(off)
Print data is available; the printing process has started.
(green)
The printing system is in the 'Stop' or '... getting Ready' status.
(slowly flash-
ing green)
The printing system is in 'Ready' or 'Energy saving mode ready'
status (if the fuser station has cooled down from the operating
temperature).
(flashing
green)
■ There is a warning in the 'Stop' status.
■ One of the 'Special functions' is being executed.
■ One of the 'NPRO', 'ADVF', 'ADVR', 'Eject' or 'Autofeed' keys
(yellow) has been pressed.
■ A software update is being executed.
■ The printing system is being powered off.
There is a warning in the 'Ready' status.
(flashing yel-
low)

Display Meaning
There is an error message.
(red)
The printing system has been stopped by the post print processing
unit (external stop). The printing system changes from the 'Ready'
status to the 'Stop' status after a preset amount of time.
(green/red)

Displays
The most important displays are summarized in the following table:
#
Display Meaning
The printing system is in standby mode.
(Main switch is on).
(off)
The printing system is in the status
■ 'Ready'
■ or 'Energy saving mode ready' (the operating temperature of the
(green) fuser station has cooled down)

■ or in a transitional status.
Print data is available; the printing process has started.
(flashing
green)
The 'Ready' status indicates a "Toner empty" warning.
(flashing
green/yellow)
The 'Stop' status indicates a "Toner empty" warning.
(flashing
red/yellow)
One of the 'Special functions' is being executed
or the printing system is cooling down
or a software update is being executed (until restart).
(yellow)

Display Meaning
The printing system is in the 'Operator intervention necessary' status.
(flashing red)
The printing system is not ready ('Stop' status)
or one of the 'NPRO', 'ADVF', 'ADVR', 'Eject' or 'Autofeed' keys
has been pressed
(red) or the printing system is in a transitional status.
The printing system has been stopped by the post print processing
unit (external stop). The printing system changes from the 'Ready'
status to the 'Stop' status after a preset amount of time.
(green/red)

Operating elements in the printing system
Operating elements in the printing system
Example
All operating elements for normal, incident-free printing operation are designed in blue-
green, e.g.:

Paper specifications
General information
To ensure maximum system availability, the paper for the Océ ColorStream printing
systemmust comply with the applicable paper specifications and be stored in an environ-
ment with suitable ambient conditions.
Non-compliance with the paper specifications can cause damage to the printing system
and may also result in the release of substances from the paper that can contaminate the
environment or have a detrimental effect on health. Océ Printing Systems GmbHaccepts
no liability for such damages.
The printing system is designed to process a wide range of paper types. However, the
operational properties of the printing system and the print quality also depend on factors
such as:
■ Paper quality
■ Grammage
■ Moisture content
■ Dimensional stability
■ Smoothness, etc.
Before using new media, ensure that they comply with the paper specifications. If in
doubt, please contact the paper laboratory at:

Papierlabor
Postfach 1260
85581 Poing
Germany
Paper types
All media that comply with the requirements of the electrophotographic printing method
can be used in all specified formats and paper weights.
Using other paper qualities may result in reduced operational results, lower availability
and possibly also higher usage of consumables and expendables.
Paper handling
The climate (temperature and relative humidity) of the storeroom and processing room
is of major importance in ensuring optimum paper processing. Unsuitable conditions

can, for example, give the paper an excessive curl, make it bumpy, or alter its electrical
resistance.
Observe the following guidelines to ensure that the original high quality of the paper is
not impaired in any way.
■ Store the paper in its packaging until it is used.
■ Do not store paper on the floor or next to walls, or in the vicinity of water pipes, radi-
ators, ventilators, windows (sunlight) etc.

■ Do not store paper in rooms in which the ambient conditions are subject to constant
change.
■ Before you use the paper, store it (in its packaging) near the printing system for a few
days if possible, or at least for 24 hours, to equalize temperature between paper and
room temperature.
■ Do not unpack more paper than you need.
■ Always use opened boxes of paper first. If you have to store open packs over a longer
period of time, cover the paper with protective film, so that no climate-related changes
occur.


Chapter 4
Description of the Opera-
tor Panel
Description of the Operator Panel — Overview
Description of the Operator Panel — Overview
Description of the Operator Panel

This section describes the individual areas of the operator panel with the most important
menus, buttons and icons.
Overview
The operator panel is divided into the following areas:
Description
#
Area Description
1 ‘Toolbar — Overview’ on page 83
2 ‘Menu Tree — Overview’ on page 91
3 ‘Menu display’ on page 104
82 Chapter 4 - Description of the Operator Panel

Toolbar — Overview
A tool bar
Toolbar — Overview
Overview
The toolbar can be used to quickly access the important functions of the printing system
and to switch directly to frequently used menus.
Description
#
Area Description
1 ‘Buttons and Displays in the Left Area’ on page 84
2 ‘Buttons and Displays in the Center Area ’ on page 86
3 ‘Frame toolbar’ on page 90
Chapter 4 - Description of the Operator Panel 83

Buttons and Displays in the Left Area
Function of the Buttons
Note:
The function of the buttons corresponds to the function of the keys on the printing
system's additional operator panels.
#
Button Function
'Ready' Switches the printing system to ready for operation
again from the 'Stop' or 'Operator intervention neces-
sary' statuses.
Requirements:
■ No errors present
■ Controller and system control are ready
'ADVF' Moves the paper slowly forwards without fusing while

= ADVanced the button is being pressed. The paper speed increases
Forward the longer you press the button. However, synchroniza-
tion is lost.
Requirement:
■ This function can only be executed in the 'Stop'
status.
'ADVR' Moves the paper slowly backwards without fusing while

= ADVanced the button is being pressed. The paper speed increases
Reverse the longer you press the button. However, synchroniza-
tion is lost.
Requirement:
status.
'NPRO' Moves the last printed pages out of the printing system
= Non Process with the correct page alignment. Already printed pages
Run Out will still be fused. If required, the NPRO transport can
be canceled using the 'Stop' key.
Requirement:
status.

Button Function
'Eject' Transports the paper web forward at print speed while
the button is pressed. The paper web is not printed.
Already printed pages will still be fused.
Requirement:
status.
'Autofeed' Moves the autofeed clamp to paper input position

or
Starts feeding the paper web into the printing system
'Stop' Switches the printing system to 'Stop' status

or
Cancels a function that is running
Display
#
Display Function
'Data ready' Gray background:
Indicates that currently no print data has been transferred from the
host.
Green background:
Indicates that print data has been transferred from the host.
'System' Gray background:
'Restart' Standard display (no controller restart).
Red background:
Indicates that the controller is performing a restart.
If this display appears, the print data transmission from the host
must be repeated, as proper printing or fusing of the last pages is
no longer guaranteed against errors.

Buttons and Displays in the Center Area
Buttons
#
Button Function
'Job control' Switches to the buttons under 'Job control' in the 'Emula-
tions' menu.
'Channel control' Switches to the 'Channels' menu.
The following buttons are available here:
Activates the channel, the printing system is online. The

connecting icon is closed.
Deactivates the channel, the printing system is offline. The

connecting icon is opened.
During the time required to activate or deactivate a channel,
the connecting icon is displayed in yellow.
If a message was also transmitted by the data stream, this
icon is displayed.
Click here to switch directly to the 'Job preparation' tab in
the 'Job setup' menu. The complete message will be dis-
played there.
If there is a new message from another user, this icon is
displayed.
Click here to switch directly to the 'Notes' menu. All notes
or messages are displayed here.
Flashes when there is an error message.
Flashes when there is a warning.
Flashes when there is information.

When there is no error message, warning or information,
this button is hidden.
Clicking this button switches to the 'Errors and warnings'
menu.

Button Function
Indicates that remote access is activated. The Service center
can use this to perform remote diagnostics during print
operation.
Clicking the button deactivates remote access directly
without having to go through the menu.
Also indicates that remote Service diagnosis is activated. If

remote Service support was also activated, the remaining
time is displayed. One minute prior to automatic deactiva-
tion, the yellow display flashes to indicate that remote
support will shortly be deactivated.
Indicates that remote access is not activated.
Clicking the button activates remote access directly without
having to go through the menu.
Switches to the 'Consumable counter' menu.
In this menu, the current counter values and their respective
limit values are displayed for all consumables and expend-
ables of the printing system.
'Service ticket' Switches to the 'Service ticket' menu.
This menu displays all the data required to notify the rele-
vant Service center.
Status displays
The current printer status is displayed on the centre of the toolbar. The individual status
displays have different background colors:
■ Green: The printing system is printing or is ready to print. If the printing of data in-
tegrity marks is turned off for the current configuration, an additional message to this
effect will appear.
■ Red: The printing system is stopped, operator intervention is necessary.
■ Gray: all other printer states
Status displays with green background

#
Display Meaning
'Ready' The printing system is ready to print; there are no error
messages.

Display Meaning
'Printing' [%] Normal print operation.
The set speed level appears in the menu 'Print speed' in
brackets.
'Process optimization' If necessary, process optimization is started by the device
control during print operation.
'... getting Ready' The printing system switches from the 'Stop' status to the
'Ready' status.
Status displays with red background

#
Display Meaning
'Operator intervention An error message is displayed. The error must be corrected,
necessary' otherwise printing cannot continue.
All current messages are also displayed in the 'Errors and
warnings' menu.
Status displays with gray background

#
Display Meaning
'Cool down' The fuser station is cooling down.
'Warm-up' The fuser station is heating up.
'Autofeed: Insert paper' The autofeed clamp is in insert position. The paper web
can be inserted.
'Autofeed: Remove pa- The autofeed clamp has reached the paper output. The
per' paper web can be removed.
'Autofeed: Started' Paper web insertion has been started via the 'Autofeed' key.
The autofeed clamp is moved to the insert position.
'Autofeed: Paper infeed' The autofeed clamp together with the paper web is trans-
ported to the paper output.
'Energy saving mode The operating temperature of the fuser station has cooled
ready' down.
'Printing system stop- The printing system switches to the 'Stop' status.
ping'
'Initialization' The printing system is being initialized and is not yet ready
for printing.

Display Meaning
'Job advance' The 'NPRO' key has been pressed. The last printed pages
are being moved out of the printing system. Pages that are
already printed will also be fused.
'Adjusting paper width' The paper width sensor has detected that a paper web of a
different width has been inserted. Paper web stop plates are
being adjusted.
'Paper measurement' The paper measurement routine has been started.
'Advance paper reverse' The 'ADVR' key was pressed; the paper web is being moved
backwards.
'Advance paper for- The 'ADVF' key was pressed; the paper web is being moved
ward' forwards.
'Powering off' The printing system is being prepared to power off. A shut-
down setup is being written; all components are being exit-
ed.
'Page advance' The 'Eject' key was pressed; the paper web is being moved
forward at print speed.
'Setup' A setup is being loaded or saved.
'Special functions' Consumables are being replaced or the printing system is
being cleaned.
'Starting' The printing system is being prepared for printing.
'Stop' The printing system has stopped.
'Energy saving mode The operating temperature of the fuser station has cooled
stop' down.
'Preparation' The printing system is powered on; device control is being
prepared.
'Pre-/post-processing Printing is interrupted because the pre/post-processing unit
not ready' has stopped. The printing process will continue when the
pre/post-processing unit is ready again.
Display of error messages

As soon as an error occurs on the printing system, it is displayed within the status display
with black text on a white background. The same applies for warnings.

Frame toolbar
Frame toolbar
Buttons
The buttons in the frame toolbar can be used to quickly access superordinate functions
for the complete printing stream and to switch directly to frequently used menus.
#
Button Function
Switches to the 'User profile' menu.
The language of the operator panel can be changed in this menu.
Indicates that the presently logged-on user possesses the access

ticket.
Clicking releases the access ticket directly without going through
the menu.
Indicates that the access ticket is released for other users.
Clicking requests the access ticket directly without going through
the menu.
Opens the Help window.
Switches to the 'Change user' menu.

Users can be registered or canceled in this menu.
Displays the user currently logged on.
Powers down the entire printing system if the 'Do you really want
to power off the printing system?' query is confirmed.
Changes from each sub-menu directly to the main menu of the

printing system or the Paper Path Manager.

Menu Tree — Overview
Menu Tree
Note:
The menus displayed in the menu tree depend on the different rights for the individual
user categories.
This documentation describes all menu options normally set up for the user categories
"Operator" and "Key operator".
Information on the Paper Path Manager can be found in Help in the printing system
operator panel. Information on the Web Buffer can be found in Help in the printing
system operator panel and in the Océ Web Buffer user guide.
Main Groups
You can call all the menus through the menu tree. The menus are arranged into main
groups, e.g.:
■ [00] 'General'
You can define user settings valid for the entire print processing unit in these menus.
■ [02] 'ColorStream'
You can set the relevant parameters for the Océ ColorStream printing system in these
menus.
■ [BU] 'Web Buffer'
You can set the relevant parameters for the paper web buffer in these menus.
■ [FF] 'Paperpath Manager'
In these menus, you can gain an overview of all UP3I-capable devices of the print
processing unit.
■ [xx] Any additional device for paper pre-print processing and/or post-print processing.
The numbers before the main groups (= 'Paper sequence ID') are required to identify the
devices in the print processing unit.
Navigation
Clicking the switches in the menu tree lets you show or hide other menu levels, e. g.:

You can switch directly to the main menu from any menu. Click the following button
in the toolbar for this purpose:
Overview
■ ‘'General' menus — overview’ on page 93
■ ‘'ColorStream' Menus — Overview’ on page 97

'General' menus — overview
'General' Menus
'General' menus — overview
Overview
You can define the user settings valid for the entire printing system in the 'General' menus.
Note:
Menus that can only be opened by the "Key Operator" user by default are shown in
bold in the table.
#
Menu Description
'User manage- The sub-menus contain the user settings relating to the Key
ment' Operator.
'User' The sub-menus contain the user settings relating to the Opera-
tor.
'Security' The sub-menus contain security-related settings and displays.

'User management' menus
'User management' menus
Overview
Note:
The menus listed in the table can only be accessed by the"Key Operator" user.
The menus under 'User management' contain the user settings relating to the Key Oper-
ator.
#
Menu Description
'Add user' Add new users or user templates
'Delete user' Delete users or user templates
'Edit user' Settings for:
■ Password
■ User rights for menus and elements
■ Language

'User' menus
'User' menus
Overview
The menus under 'User' contain the user settings relating to the Operator.
#
Menu Description
'Change user' Log a user on or off
'User profile' Select the operator panel language and change the password
'Tools' Two different functions are combined into this menu:
■ Facilitate screen cleaning during printing
■ Also write an error log when the 'Operator trace' menu can
no longer be started.
'Emergency display Display of current error and warning messages and information
for error' in the event that the printing system-specific menus and conse-
quently the 'Errors and warnings' menu cannot be opened.

'Security' menus
'Security' menus
Overview
The menus under 'Security' contain security-related settings and displays.
#
Menu Description
'Access ticket' Requesting or releasing the access ticket for a specific operator
panel in the printing system.
'Network manage- Overview of the computer connected to the printing system.
ment LAN A/LAN
B'
'Safety violations' Display of any security violations.

'ColorStream' Menus — Overview
'ColorStream' Menus
Display of Basic Information

The following basic information on the printing system is displayed in the 'ColorStream'
menu:
#
Display Description
'User counter (to- Number of all 12" pages previously printed in user operation
tal)' Further counters are displayed in the 'General counters' menu.
'Print job:' Current print job
The job name will be displayed at the same time as data transfer
to the printing system occurs. As a maximum of 256 pages can
be saved in the page buffer, the job name will no longer be dis-
played some time before printing the last page.
'Job setup:' Currently loaded job setup
'Color setup:' Currently loaded color setup
The Color Setup Verification ID (CSVID) is displayed in addi-
tion to the name.
'Printing system:' Description of the printing system
'Serial No.:' Serial number of the printing system
'Emulation:' Currently selected mode
'ColorStream' Menus
The sub-menus contain all settings and displays relating to the Océ ColorStream printing
system.
'Displays' menus
The sub-menus contain displays on current error and warning messages and the various
counters on the printing system.
'Configuration' menus
The sub-menus contain the parameters relevant for setting the printing system.

'Setup' menus
In setups, special settings for frequently recurring print requests can be grouped together
and saved. By loading a setup, the printing system can be configured quickly with the
right parameters for a print request.
If the printing system is powered up and it is not possible to load a setup, then the settings
from before the printing system was powered down continue to apply.
'Changing consumables' menus

The sub-menus contain the procedures for replacing consumables and expendables and
for cleaning the printing system. A menu for identifying the toner used is also available.

'Displays' menus
'Displays' menus
'Displays' menus
The sub-menus contain displays on current error and warning messages and the various
counters on the printing system.
'Errors and warnings' menu

Displays the current error and warning messages and information.
'General counter' menu

Displays page counters, warm-up time and user counters.
'Consumable counter' menu

Displays the current counter values and the relevant limit values for all consumables and
expendables for the printing system.
'Consumable history' menu

Displays replacement procedures for all replaced consumables and expendables, each with
time and counter reading.
'Notes' menu
Display and input of notes. The notes are stored for three months.

The sub-menus contain the parameters relevant for setting the printing system.
'Paper'
The sub-menus contain the parameters for the paper webs to be printed.
'Print parameters' menu

The sub-menus contain specific parameters for the printing system.
'Color' Menu
The sub-menus contain all parameters relevant for full-color, CustomTone or black-and-
white printing.
'Emulations' menu
Displays the emulations, and buttons for job control, restarting, and the PCL settings.
'Channels' menu
Display and setting of parameters for coupling the printing system to the network.
'Post-processing' Menu
The sub-menus contain the parameters for the post print processing marks.
Note:
The 'Mark extensions' menu is only displayed if a UP3I device is connected.
'Special functions' menu

The sub-menus contain the settings and displays for superordinate parameters and proce-
dures for configuring and converting the printing system.

'Setup' menus
'Setup' menus
'Setup' menus
'Overview of loaded setups'

Display of all currently loaded setups. If the current settings have been changed since the
time when the setup was loaded, this is also displayed.
On the 'Color setup', the Color Setup Verification ID ('CSVID') is displayed in addition
to the name. Whether or not the 'CSVID' is displayed decimally or hexadecimally depends
on the setting in the 'Emulations' menu -> 'General' -> 'Display of CSVID'.
If the relevant channel is available, information on the channel setup is also displayed.
'Job setup' Menu

Displays generally valid print job parameters.
A job setup can also be linked to a color setup.
'Color setup' menu

Display of parameters for the colors currently used in the printing system (including
black).
In color setups, parameters for the colors currently used in the printing system can also
be loaded and saved. The color setups are independent of the job setups.
Menu 'Setup channel A' / 'Setup channel B' / 'Setup channel C'
Display of setups for 'Channel A', 'Channel B' or 'Channel C'.
Channel-specific settings for frequently recurring print jobs can be combined into a
channel setup and saved under a name. By loading a setup of this type, the printing system
is automatically set up with the corresponding parameters for the print job.

'Replace consumables' menus
'Changing consumables' menus

The sub-menus contain the procedures for replacing consumables and expendables and
for cleaning the printing system. A menu for identifying the toner used is also available.
'Expert mode' menu

Procedure for replacing several expendables. As the necessary preparation and completion
phases for replacing expendables are only executed once in expert mode, the time required
is significantly reduced.
'Replace belt' menu

Procedure for:
■ Replacing the photoconductor belt and the photoconductor blade in the upper or
lower print unit

■ Replacing the transfer belt in the upper or lower print unit
■ Running in a photoconductor belt or transfer belt.
'Replace brush' menu

Procedure for replacing the cleaning brush of the photoconductor or transfer unit in the
upper or lower print unit.
'Replace corotrons' menu

Procedure for replacing the cleaning, charge and reload, and recharge corotrons of the
photoconductor or transfer unit in the upper or lower print unit.
'Replace fine filter' menu

Procedure for replacing the fine filter.
'Replace developer' menu

Procedure for refilling or draining the developer in a developer station of the upper or
lower print unit.

'Cleaning the printing system' menu

Procedure for cleaning or inspecting the paper input module, paper path and paper output.
'Swivel developer stations' menu

Procedure for swiveling the developer stations in the upper or lower print unit on or off.
'Toner bottle identification' Menu

Displays information on the toners used.
'Fill toner box' Menu

Procedure for manually filling the toner box of a developer station that is supplied by the
toner suction system.
'Replace smoothing roller' menu

Procedure for replacing the smoothing rollers in the smoothing module.
'Replace cleaning felt' menu

Procedure for replacing the cleaning felt in the smoothing module.

Menu display
Menu display
Introduction
This area shows the menu selected in the menu tree.
Direct help via the F1 key

Detailed information on all menus and operating controls is available directly in the op-
erator panel via the context-sensitive direct help. The context-sensitive help system can
be called up by selecting the relevant menu or operating element and then pressing the
F1 key.
If necessary, all the requirements for setting the respective parameters are also listed in
the context-sensitive direct help. Specified standard settings and values are denoted in
bold.

Chapter 5
Working with the Operator
Panel
Working with the Operator Panel — Overview
Working with the Operator Panel — Overview
Working with the operator panel

This section explains how you manage all user settings, how you select or enter parameters
on the operator panel, how you collect special settings for frequently recurring print jobs
using setups, how you manage resources for printing operation and how you replace
consumables and expendables using the operator panel.
Overview
This section contains information on the following topics:
■ ‘Managing User Settings (Key Operator) — Overview’ on page 107
■ ‘Managing User Settings (Operator) — Overview’ on page 115
■ ‘Selecting settings and entering values’ on page 121
■ ‘Applying or resetting settings’ on page 122
■ ‘Working with Setups — Overview’ on page 123
■ ‘Managing Resources — Overview’ on page 129
■ ‘Editing 'Replace consumables' menus on the operator panel’ on page 133
106 Chapter 5 - Working with the Operator Panel

Managing User Settings (Key Operator) — Overview
Managing User Settings (Key Operator)

Introduction
By default, 3 user groups are pre-defined: Operator, Key Operator and Service. Any
changes made to their associated user profiles will be reset when a new operator panel
version is installed.
However, changes to profiles of self-created users will be unaffected by the installation
of a new operator panel version.
Predefined users for VarioStream 9000 and ColorStream

For the VarioStream 9000 and ColorStream printing systems, a number of users are already
predefined within the "Operator" user group:
■ Sample operator 1-1
(for single color bilevel printing)

■ Sample operator 1-1 ML
(for single color GraphicArts printing/multilevel)

■ Sample operator color
(for multi-color bilevel printing)

■ Sample operator color ML
(for multi-color GraphicArts printing/multilevel)
The following table indicates which color menus are displayed for each user:
#
Menu Sample op- Sample op- Sample op- Sample op-

erator erator erator erator
1-1 1-1 ML color color ML
'Contrast' yes yes yes yes
'Default values' yes yes yes yes
'Raster' no yes no yes
'Tone transfer curve' no yes no yes
'Color properties' no no yes yes
'Color station selection' no no yes yes
'Color order' no no yes yes
'PCL simple color' no no yes yes
Chapter 5 - Working with the Operator Panel 107

Overview
As Key Operator, you can normally determine the following user settings:
■ ‘'Add user' ’ on page 110
■ ‘'Delete user' ’ on page 111
■ ‘Set Password / 'General' Tab’ on page 112
■ ‘Releasing and blocking menus and elements/'User rights' tab’ on page 113
■ ‘Setting language/'User profile' tab’ on page 114
Note:
Once logged on, users can only add, delete or edit other users that belong to a lower
user group. Users in the same or higher user groups are not included in the selection
lists.

Extended password protection (option)
Extended password protection (option)
Introduction
The "Extended password protection" function can be activated by Service as an option.
Rules
In this case, all users must use a password according to the following rules:
■ It contains at least 8 characters.
■ It contains at least 1 letter and 1 special character, and 1 number.
■ A maximum of 2 identical characters may follow each other.
■ It is case sensitive.
■ The last 3 passwords may not be the same.
■ The new password is valid for 3 months.
Note:
The password can contain any number of characters if the "Extended password protec-
tion" function was not activated by Service. The password will in this case be valid in-
definitely.

'Add user'
'Add user'
To add a user
#
Proceed as follows:
1. Click on the 'General' -> 'User management' -> 'Add user' menu.
2. Select user template.
The settings for this user template will be adopted for the new user. These set-
tings can then be adjusted in the 'User management' -> 'Edit user' menu if
necessary.
3. Enter a name for the new user. The following characters are permitted:
■ A-Z
■ a-z
■ 0-9
■ Underscore, hyphen, space
4. Click on the 'Create' button.

5. Enter a new password, confirm password and then click on 'OK'.
The password can contain any number of characters if the "Extended password
protection" function was not activated by Service.
Extended rules will apply to the password if Service has activated the "Extended
password protection" function. see ‘Extended password protection (option)’ on
page 109.

'Delete user'
'Delete user'
Introduction
All user-defined users and possible pre-defined users "Sample operator" can be deleted,
with the exception of the pre-defined user groups Operator and Key Operator.
To delete a user
#
Proceed as follows:
1. Click on the 'General' -> 'User management' -> 'Delete user' menu.
2. Select the names of the user.
3. Click on the 'Delete' button and confirm.

Set Password / 'General' Tab
Set Password / 'General' Tab
Note:
A password will remain valid indefinitely if the "Extended password protection" function
has not been activated by Service.
A password will remain valid for 3 months if the "Extended password protection"
function has been activated by Service. When the password has expired, you can enter
a new password in the 'Edit user' menu or the 'User profile' menu.
To set a password
#
Proceed as follows:
1. Click on the 'General' -> 'User management' -> 'Edit user' menu.
2. Select the user.
3. Click on the 'General' tab.
4. Click on the 'Change password' button.
5. Enter a new password, enter it again in 'Password confirmation' and then click
on 'OK'.
page 109.
6. Click on the 'Apply' button.

Releasing and blocking menus and elements/'User rights' tab
Releasing and blocking menus and elements/'User rights'

tab
Note:
You can activate or block menus and elements for self-created users. Menus and elements
cannot be activated or blocked for the predefined user groups.
For security reasons, the 'Change user', 'User profile' and 'Network management LAN
A/LAN B' menus cannot be hidden.
To release or block menus and elements

#
Proceed as follows:
2. Select the User.
3. Click on the 'User rights' tab.
All menus and elements in the operator panel will be displayed. The icons in
the check boxes mean for the user group or the users currently selected:
This menu or element is activated. It cannot be blocked.
This menu or element is blocked. It cannot be activated.
This menu or element is blocked for predefined user groups. It can be acti-
vated for self-created users by clicking on it.
This menu or element is currently activated. It can be blocked by clicking
on it.
This menu or element is currently blocked. It can be activated by clicking
on it.
4. Under 'Menus', activate the checkboxes in front of the menus that are to be
displayed for the user in the menu tree.
If a menu is not supposed to be displayed, deactivate the respective checkbox.
This also prevents the user from accessing all subordinate menus.
In principle, only those menus or elements can be activated that are also activated
for the editing user himself.
5. Under 'Elements', click on the checkboxes in front of the operator elements
for a specific menu that are to be editable for this user.
If an element should be read-only (not editable), deactivate the respective
checkbox.

Setting language/'User profile' tab
Setting language/'User profile' tab
Introduction
The operator panel language can be selected in the 'User profile' tab. The appearance of
the operator panel cannot be changed for the user groups "Operator" and "Key Operator."
To set a language
#
Proceed as follows:
2. Select the User.
3. Click on the 'User profile' tab.
4. Select the desired language from the 'Language' list.
5. Click the 'Apply' button.

Managing User Settings (Operator) — Overview
Managing User Settings (Operator)

Managing User Settings (Operator) — Overview
Overview
As an Operator, you can normally make the following user settings:
■ ‘Log on as user and request an access ticket’ on page 116
■ ‘Change Password / 'Password' Tab’ on page 118
■ ‘Changing language/'User profile' tab’ on page 119
■ ‘Log off as user’ on page 120

Log on as user and request an access ticket
Introduction
To be able to set parameters on the operator panel, you must first log on as a user and
then request the access ticket.
The access ticket ensures that parameters are not set by different users at parallel operator
panels.
Note:
A message will be displayed if a user on a higher authorization level has already requested
the access ticket. The access ticket can be requested directly from users with the same
authorization level.
Note:
In certain circumstances, the user groups "Service" and above may need to log in using
a USB dongle with an appropriate license. These user groups can access the Océ service
documentation for more information.
The "Operator" and "Key Operator" user groups do not need to log in using a USB
dongle.
To log in as a user and request the access ticket

#
Proceed as follows:
1. Click on the 'General' -> 'User' -> 'Change user' menu.
2. Select the desired user from the selection list.
3. Enter password.
4. Click on the 'Log on' button.
Only if several operator panels are connected to the printing system:
5. Click on the 'General' -> 'Security' -> 'Access ticket' menu.

Proceed as follows:
6. Click on the 'Request access ticket' button.
If the access ticket has already been requested, the button is deactivated.
Note
The access ticket can also be requested and released directly via the buttons in
the frame toolbar without going through the menu:

Change Password / 'Password' Tab
Change Password / 'Password' Tab
Note:
A password will remain valid indefinitely if the "Extended password protection" function
has not been activated by Service.
A password will remain valid for 3 months if the "Extended password protection"
function has been activated by Service. When the password has expired, you can enter
a new password in the 'Edit user' menu or the 'User profile' menu.
To change a password
#
Proceed as follows:
1. Click on the 'General' -> 'User' -> 'User profile' menu.
2. Click on the 'Password' tab.
3. Click on the 'Change password' button.
4. Enter the old password.
5. Enter a new password, enter it again in 'Password confirmation' and then click
on 'OK'.
page 109.

Changing language/'User profile' tab
Changing language/'User profile' tab
Introduction
The operator panel language can be selected in the 'User profile' tab. The appearance of
the operator panel cannot be changed for the user groups "Operator" and "Key Operator."
To change the language

#
Proceed as follows:
1. Click on the 'General' -> 'User' -> 'User profile' menu.
2. Click on the 'User profile' tab.
3. Select the desired language from the 'Language' list.

Log off as user
Log off as user
To log off as a user

#
Proceed as follows:
1. Click on the 'General' -> 'User' -> 'Change user' menu.
2. Select the desired user from the selection list.
3. Click on the 'Log off' button.

Selecting settings and entering values
Selecting settings and entering values
Introduction
All parameters of the printing system can be set at the operator panel. The following
prerequisites have to be satisfied:
■ The necessary rights are available. These rights are assigned by the respective "Key
Operator" in the 'Edit user' menu.

■ The access ticket for this operator panel is requested.
■ The printing system is in the 'Stop' or 'Operator intervention necessary' status. While
the printing system is running, you can check the parameters but not reset them.
You can select predefined settings and values through various operating elements, such
as selection lists, option fields, checkboxes, slide controls.
You can also enter new values in the input fields using the keyboard.
Example: Entering the Paper Length

#
Proceed as follows:
1. Select unit for paper length.
The first click opens the selec-
tion list, the second click selects
the unit.
2. Select the number via the slide

control, or enter it into the input
field using the keyboard.
3. ‘Applying or resetting settings’ on page 122

Applying or resetting settings
Applying or resetting settings
'Apply' / 'Reset'
If you change parameters in a menu, you have to save these changes before switching to
another menu.
#
Button Function
'Apply' The current settings in the displayed menu are saved.
'Reset' The current settings in the displayed menu are not saved, the settings
before the changes were made are restored.
Query
If you switch to another menu without applying the changed parameters, the 'Save current
changes?' query is displayed:
#
Button Function
'Yes' The parameters are saved.
The new menu is opened.
'No' The parameters are not saved; the parameters in place before the
change are restored.
The new menu then opens.
'Cancel' The parameters are not saved.
The menu remains open.

Working with Setups — Overview
Working with Setups

Working with Setups — Overview
'Setup' menus
Overview
■ ‘Creating a new setup or changing a setup’ on page 124
■ ‘Importing a Setup’ on page 125
■ ‘Exporting a Setup’ on page 127

Creating a new setup or changing a setup
Creating a new setup or changing a setup
Requirements
Requirements for saving setups:
■ The Key Operator or an operator authorized by the Key Operator must be logged on.
■ There can be no error message.
To create a new setup or change a setup

#
Proceed as follows:
1. If the printing system has not yet stopped, click the 'Stop' button.
2. On the operator panel, select:
■ For generally valid print job setups:
'Setup' -> 'Job setup' menu

■ For color setups:
'Setup' -> 'Color setup' menu

■ For channel-specific setups:
'Setup' -> 'Setup channel A' / 'Setup channel B' / 'Setup channel C' menu
3. Select the setup in the 'Setup list' tab.

4. If this setup is not yet loaded, click the 'Load' button.
5. Click on the 'Setup contents' tab and check the settings.
6. Adjust settings as required in the menus under 'Configuration'.
Note
An existing link between a job setup and a color setup can be saved at the same
time using the 'Save' button. Using the 'Save as' button, on the other hand,
the link will not be saved.
In both cases, the color setup is not saved at the same time.
7. Overwrite the setup using the same name (not for "default" setup). Click the
'Save' button.
Or save setup under a new name. To do this:
■ Click the 'Save as' button.
■ Enter the new name in the dialog window.
■ For a color setup, a new Color Setup Verification ID must also be entered.
Whether or not this CSVID has to be entered decimally or hexadecimally

depends on the setting in the 'Emulations' -> 'General' menu under 'Display
of CSVID'.
■ Click the 'Execute' button.

Importing a Setup
Importing a Setup
Introduction
You can apply all setups that were created on another printing system Océ ColorStrea-
musing the same software version.
To Import a Setup
#
Proceed as follows:
■ For print job setups:


Note
When importing setups, existing links between job and color setups will be
taken into account.
3. Click the 'Import' button.
4. Select where the setup is to be imported from:
■ USB memory stick
■ Transfer area (a directory on the drive of the controller hard disk; used for
remote data transfer of setups)
Caution
Follow virus protection instructions
When importing from a USB memory stick, ensure that there are no viruses
on the USB memory stick.

Importing a Setup
Proceed as follows:
5. If importing from a USB memory stick:
Insert the USB memory stick with the setups into the USB port. The USB
port is located below the operator panel near the paper input.
6. In the dialog window,

■ open the \transfer\ directory and
■ select one or more setups.
7. Click the 'Import' button.
Note:
If a setup is imported containing values that have changed since the last import, detailed
information on the setup is displayed on the 'Import message' tab. If all values have re-
mained unchanged, the tab is not displayed.

Exporting a Setup
Exporting a Setup
Introduction
Self-created setups can also be used for other printing systems Océ ColorStream.
Prerequisites:
■ The Key Operator or an operator authorized by the Key Operator must be logged on.
■ The same software version must be installed for the printing systems involved, or a
later version must be installed on the printing system for which a setup is to be export-
ed.
■ A loaded setup cannot be exported.
■ When exporting a setup, an existing link will be taken into account.
■ Default setups cannot be exported, as these are already installed on every printing
system.
To Export a Setup
#
Proceed as follows:
■ For print job setups:


3. Select the setup in the 'Setup list' tab.

Note
When exporting setups, existing links between job and color setups will be
taken into account.
4. Select the form in which the setup is to be exported:
■ For use on other printing systems:
Click the 'Export' button.

■ To display a text file with the settings stored in setup:
Click the 'Export as text' button.

Exporting a Setup
Proceed as follows:
5. Select where the setup is to be exported:
■ Transfer area (a directory on the drive of the controller hard disk; used for
remote data transfer of setups)
6. When exporting to a USB memory stick:

Insert the USB memory stick into the USB port. The USB port is located below
the operator panel near the paper input.
7. Click the 'OK' button.

The setup is exported to the \transfer\ directory.

Managing Resources — Overview
Managing Resources
Managing Resources — Overview
Resources in I Mode
The following can be installed or deleted in I mode
■ Font tables (".CDP" file format)
■ Fonts (".CHS" file format)
■ Fonts for PDF (optional; within PDF containers)
■ Color mapping tables (= Color Mapping Tables; ".CMT" file format)
Resources in PCL mode

The following can be installed or deleted in the PCL mode:
■ Character sets
■ Macros
Color Resources
The following color resources can be installed or deleted in the designated folders:
■ Color profile files with the ".ICM" file format
■ Color profile files with the ".ICC" file format
Note:
Color profile files with an ICC version of 4.0 or more recent must be used.
Overview
■ ‘Installing Resources’ on page 130
■ ‘Deleting Resources’ on page 132

Installing Resources
Requirement
The Key Operator or an operator authorized by the Key Operator must be logged on.
To Install a Resource
#
Proceed as follows:
2. Deactivate all channel links to the host. Also click the following button for
the respective channel in the 'Channels' menu:
Caution
Follow virus protection instructions
When installing resources from a USB memory stick, ensure that there are no
viruses on the USB memory stick.

Proceed as follows:
3. Insert the USB memory stick with the new resources into the USB port. The
USB port is located below the operator panel near the paper input.

■ For I mode:
'Configuration' -> 'Emulations' -> 'I mode' -> 'Resource management'

menu
■ For PCL mode:
'Configuration' -> 'Emulations' -> 'PCL mode' -> 'Resource management'

menu
■ For colors:
'Configuration' -> 'Color' -> 'Resource management' menu
5. Under 'New', select one of the displayed resources and click the 'Install' button.
The file will be tested and converted. Once the installation is complete, the
file will be displayed under 'Current'.

Deleting Resources
Deleting Resources
Requirement
The Key Operator or an operator authorized by the Key Operator must be logged on.
To Delete a Resource
#
Proceed as follows:
■ For I mode:
'Configuration' -> 'Emulations' -> 'I mode' -> 'Resource management' menu
■ For PCL mode:
Menu path 'Configuration' -> 'Emulations' -> 'PCL mode' -> 'Resource
management'
■ For colors:
'Configuration' -> 'Color' -> 'Resource management' menu
3. Under 'Current', select one or all resources of one type and click on the 'Delete'
or 'Delete all' button.

Editing 'Replace consumables' menus on the operator panel
Introduction
The operator panel informs you about the current status of the printing system. Warnings
or error messages indicate when consumables or expendables have to be refilled or replaced.
You can also check the current counter status at any time in the 'Consumable counter'
menu, e.g:
In 'Counter mode', you can select whether the previous runtime or the remaining runtime
is displayed for the 'Counter value', the 'Warning value' and the 'Accumulated value'.
All page counters are shown in 12" pages; all time counters in hours.
#
Column Description
'Status' The service life of the consumable or expendable is below the
warning value.
No action required.
The warning value has been exceeded. This consumable or ex-
pendable must be replaced soon.
The end value has been exceeded. This consumable or expend-
able must be replaced.
'Counters' Brief description of each consumable or expendable.
'Counter value' Number of pages printed since the last replacement.
'Unit' The values relate to hours or to 12" pages.
'Warning value' A warning appears when this value is reached.
'End value' An error message appears when this value is reached.

Prerequisites
Every time a consumable or expendable part is replaced, individual working steps must
be carried out on the operator panel. Requirements for this:
■ The user rights are available for this menu
■ The access ticket for this operator panel is requested
■ The printing system is in the 'Stop' or 'Operator intervention necessary' status, and
is therefore not printing

■ No other replacement function is executed.
Explanation of icons
#
Icon Function
The icons on the left-hand side show the type of the respective step:
Answer a query at the operator panel.
The progress display is automatically moved forward.
Carry out a mechanical adjustment of the printing system.
The progress display is not automatically moved further for this
type. To display the details of the next work step, you must switch
to the next work step by clicking on the 'Next' button.
This step is carried out by the printing system without the operator's
involvement. The progress display is automatically moved forward.
The icons on the right-hand side indicate the progress:
This step is currently in progress.
This step was not yet performed and must still be carried out.
This step was successfully completed.
This step was not completed successfully.
Procedure Example
#
Proceed as follows:
1. Select menu, e.g. 'Replace consumables' -> 'Replace cleaning brush'.

Proceed as follows:
2. Select a print unit and an assembly, e.g.
In the printer view, the selected consumable or expendable is highlighted in

color.
The printer view can also be completely hidden or shown by clicking the arrow
icons.

Proceed as follows:
3. Click the 'Next' button.
A new menu window opens, in which all necessary work steps are displayed
in the correct sequence, e.g.
If necessary, you can return to the selection page via the 'Back' button.
4. Perform all the displayed steps in the given order.
The work steps are described in more detail under 'Details'.
Note
You can find additional help on each replacement procedure:
■ in the user guide
■ or directly on the operator panel; via the context-sensitive direct help. You
can call up the context-sensitive direct help by selecting the corresponding

menu and then pressing the F1 key.
5. Complete the replacement procedure. As a result, the following will occur au-
tomatically:
■ The message on the operator panel is deleted
■ The consumable/expendable replacement is logged in the 'Consumable
history' menu
■ The counter in the 'Consumable counter' menu is reset.

Chapter 6
Operating the Printing
System
Operating the Printing System — Overview
Operating the Printing System — Overview
Operating the printing system

This section describes how to power the printing system on and off and the procedure
for inserting, affixing and removing the paper web, and also contains all other information
that you will need to operate the printing system.
Overview
■ ‘Powering on the Printing System’ on page 139
■ ‘After printing has stopped, switch the printing system back to 'Ready' ’ on page 142
■ ‘Inserting the Paper Web’ on page 143
■ ‘Affixing the paper web’ on page 152
■ ‘Removing the paper web ’ on page 155
■ ‘Opening or Closing the Doors on the Printing System — Overview’ on page 156
■ ‘Replacing the developer station — overview’ on page 165
■ ‘Checking the print image ’ on page 199
■ ‘Printing Test Print Jobs — Overview’ on page 200
■ ‘Optimizing the Color Printing — Overview’ on page 239
■ ‘Correcting Color Separation Shifts’ on page 255
■ ‘Calibrating the Data Integrity Mark Sensor’ on page 257
■ ‘Converting the Printing System’ on page 261
■ ‘Emptying Condensation Water’ on page 263
■ ‘Switching off the Printing System’ on page 264
138 Chapter 6 - Operating the Printing System

Powering on the Printing System
Attention:
Ensuring the cooling of the developer stations.
The external recooler must always be activated during the printing operation.
To Power on the Printing System

#
Proceed as follows:
1. If the external recooler is
switched off, set the main circuit
breaker of the recooler to 'ON'.
2. Power main switch on.
Chapter 6 - Operating the Printing System 139

Proceed as follows:
3. Press the On key.
4. If necessary, power on the photo-

conductor operator panel.
The printing system is initialized
(duration approx. 7 minutes).
The printing system's current
status information is displayed
on the operator panel
5. Log on as a user and request an access ticket.

Proceed as follows:
6. Activate the required channel on the operator panel. Click the 'Channel control'
button.
The 'Channels' menu is displayed.
Click on the following button to activate the channel:
During the time needed for activation, the connecting icon is shown in yellow.
An activated channel is represented by the following icon:
Proceed as follows:
7. Insert paper web (see ‘Inserting the Paper Web’ on page 143).
Proceed as follows:
8. Configure the settings required for the print job on the operator panel.
9. Click the 'Ready' button.
The printing system is in the 'Ready' status.
If the printing system is ready for operation, the Operator Attention Light lights
up green.
Note:
The 'Printsystem Manager' can be used to enter whether the operator panel is to be
started manually or automatically when the printing system is switched on. For more
information, please contact your Service center.

After printing has stopped, switch the printing system back to 'Ready'
After printing has stopped, switch the printing system back

to 'Ready'
Introduction
A print stop may be caused by the following:
■ The 'Stop' button was pressed on the operator panel or on an additional operator
panel.
■ The printing system was stopped by an error message.
■ The controller has run out of data.
If the 'Stop' button has been pressed

#
Proceed as follows:
The print operation is continued without any impairment to print or fusing
quality. The temperature of the fuser station decreases in stages in the case of
longer standby times. For this reason, the fuser station may first have to be re-
heated to its operating temperature. Depending on the type of paper, this may
take up to 30 seconds.
If the Printing System was Stopped by an Error Message

#
Proceed as follows:
1. Correct the cause of the print stop as specified in the error message (see also
‘Processing messages on the operator panel ’ on page 475).
Printing operation is restarted.
If the Controller Has Run Out of Print Data

#
Note
If the printing system controller no longer has any print data, the printing
system stays in 'Ready' status and continues printing automatically any print
data that arrives.

Inserting the Paper Web
Inserting the paper web

Attention:
When inserting a paper web, make sure that there is no paper between the paper input
and the paper output.
A continuous paper supply from the high stack or unroller must be guaranteed during
the entire insertion process.
Note
The printing system automatically switches to paper insert mode after detecting
that the system has run out of paper.
To Insert the Paper Web

#
Proceed as follows:
Caution
The paper input rocker opens automatically.
Do not stand directly in front of the rocker.
1. Press the 'Autofeed' key.
The autofeed clamp moves to
the paper insert position at the
paper input in approx. 20 sec-
onds. The rocker then opens au-
tomatically.

Proceed as follows:
2. Press the clamp opener.
This will retract the clamp
rollers.
3. Ensure that the paper edge is

straight and at right angles. Do
this by bending a section of the
paper web upwards and folding
it so that the side edges are
aligned.
Only for heavy paper (that can-
not be held by the clamp with a
fold): Cut off the additional pa-
per web along the fold edge so
that the crease on the fold is
completely removed.
4. Move the start of the paper web
under the rocker.

Proceed as follows:
5. Align the paper web on the left
side to the "0" mark of the ruler
on the clamp opener.
6. Close the rocker. Hold on to the

paper web while doing this to
prevent it sliding sideways.
7. Press the clamp opener and push

the paper web into the autofeed
clamp to the stop point.
8. Lightly pull back on the paper web to ensure that it is securely held by all five
clamp modules (visual check). If not, press the clamp opener and push the
paper web back to the stop point again.

Proceed as follows:
Caution
The flap of the paper output opens automatically.
Do not stand directly in front of the flap.
9. Press the 'Autofeed' key on the

additional operator panel.
The autofeed clamp moves to
the park position at the paper
output together with the paper
web in approx. 20 seconds. The
flap then opens automatically.
10. Press the clamp opener into the

autofeed clamp; remove the pa-
per web and place outside ma-
chine.

11. Insert the paper web below the

data integrity sensor:
■ Open the angle bracket.
■ Insert the paper web below
the data integrity sensor. Ob-

serve the mark.
■ Close the angle bracket.
12. If a paper web with a different width has been inserted, check the position of
the pressure rollers in the paper output (see ‘Adjusting the Pressure Rollers’ on
page 148).
13. Close the paper output flap.
14. To move the paper web forward, press the 'ADVF' button.
15. If necessary, synchronize the paper path (see ‘Synchronizing the Paper Path’ on
page 150).
16. If necessary, paste the paper web to the post print processing unit or insert it
into the post print processing unit and make operational.
17. Press the 'Ready' key.

Adjusting the Pressure Rollers
Introduction
If a paper web with a different width was inserted, the position of the pressure rollers in
the paper output must be checked.
To avoid damage, the paper edge must not run directly along a pressure roller. To this
end, the two pressure rollers on the right-hand side in the paper path direction (1 and 2)
can each be moved to 3 positions (A), (B, (C). These positions are marked on the pressure
roller holder.
■ If a pressure roller runs outside of the paper web: This pressure roller must be moved
so that the distance between the paper web and the pressure roller is at least 10 mm
(0.39").
■ If a pressure roller runs on the paper web: This pressure roller must be moved so that
the distance to the edge of the paper web is at least 15 mm (0.59").
Note:
The position of the pressure rollers must be the same for both pressure roller holders.
If, for instance, pressure roller 1 is set to position B in the upper row, pressure roller 1
must also be set to position B in the lower row.
To Adjust the Pressure Rollers

#
Proceed as follows:
1. Select the following menu on the operator panel:
'Configuration' -> 'Special functions' -> 'Setting the pressure rollers'.

Proceed as follows:
2. Click the 'OK' button to start adjusting the pressure rollers:
For information on the icons displayed on the operator panel under 'Steps',
see ‘Explanation of icons’ on page 134.
3. Bring pressure roller 1 to the position shown on the operator panel, then click
the 'Next' button.
4. Bring pressure roller 2 to the position shown on the operator panel, then click
the 'Next' button.
6. To complete pressure roller adjustment, click the 'OK' button.

Synchronizing the Paper Path
Introduction
With a synchronized paper path, the print image is set e.g. to a preprinted mark.
To Synchronize the Paper Path

#
Proceed as follows:
1. In the 'Configuration' -> 'Paper' -> 'Preprinted marks' menu on the operator
panel, select the desired synchronization.
2. Using the 'ADVF' and 'ADVR'
buttons, position the preprint
mark or horizontal perforation
to exactly ±1 mm under the
swiveled ruler of the paper input.

Proceed as follows:
3. Press the 'Ready' button to start printing.
4. Check the synchronization:

If the synchronization is correct,
the tractor hole or the preprint
mark is positioned exactly at the
marker on the lateral ruler for
the respective form length after
a stop.
Assignment of the markers to
specific form lengths can be
copied from the graphic in the
annex (see ‘Ruler for Checking
Paper Path Synchronization’ on
page 504).
5. If the synchronization needs to be corrected:

■ Press the 'Stop' key.
■ Correcting the position:
- If preprint marks are used for synchronization: In the 'Preprinted marks'

menu adjust the position of the preprint mark to the print image.
- If tractor holes are used for synchronization: Correct the position of the
tractor hole using the 'ADVF' and 'ADVR' keys.
■ Press the 'Ready' key.

Affixing the paper web
Introduction
Instead of inserting a new paper web using the autofeed function, you can affix the new
paper web to an already inserted paper web. In this case, the assemblies remain swiveled
on, and the paper web does not have to be rethreaded into the paper post-processing unit.
You can also affix a paper web with a different width. If the affixed paper is wider, the
projecting edge should be cut diagonally, e.g.
Attention:
Paper webs that are affixed offset or at an angle result in paper path problems.
Make sure that the edges of the paper webs are flush.
Preventing soiling of paper post-processing unit
Make sure that all the printed pages from the last print job are fused before the end of
the paper web.

To affix the paper web

#
Proceed as follows:
1. Cut off the end of the paper web
at the unroller or paper input at
a clean right angle.
2. Cut off the beginning of the new paper web at a clean right angle.
3. Affix the paper web with any
popular adhesive (e. g. Scotch
ATG 700). Make sure that the
shift of the reference edge is
minimal (<1 mm), and that the
edge is as flush as possible.
Depending on the utilized paper,
either:
■ affix to the stack (1),
■ or affix overlapping (2). Al-
ways fold back the projecting

edge of an overlap so that it
cannot cause a jam.
Caution
If the adhesive joint is moved too quickly, the paper web may be damaged or
torn.
Only move the affixed paper web with the 'ADVF' button and monitor the
paper transport. If you use the 'Eject' button to move the paper, you might
overlook damage to the paper web and not be able to prevent it in time.

Proceed as follows:
4. Move the affixed paper web with the 'ADVF' button through the printing
system until the adhesive strip has completely passed through the paper post-
processing unit.
Watch the paper web at the paper input, and correct the path of the paper
web as needed by running your hand sideways across the web.

Removing the paper web
Removing the paper web
Attention:
To be able to remove the paper web, the printing system must be in the 'Stop' status.
To remove the paper web

#
Proceed as follows:
1. If the printing system is not yet in the 'Stop' status:
Press the 'Stop' button.
2. If required:
Switch the paper post-processing unit to 'Stop'.
3. Press the 'NPRO' button.
The paper is moved forwards by around 3.5m.
4. Separate the paper at right angles to the transport device around 1m before
the paper input.
5. Press the 'NPRO' button.
The paper is moved in the paper path direction. After a brief stop, the paper is
moved forward until it exits the printing system.

Opening or Closing the Doors on the Printing System — Overview
Opening or Closing the Doors on the

Printing System
Opening or Closing the Doors on the Printing System —
Overview
Introduction
Note:
Right-hand side means right in paper path direction.
Left-hand side means left in paper path direction.
Overview
■ ‘Opening Right Doors’ on page 157
■ ‘Opening Left Doors’ on page 161

Opening Right Doors
Opening Right Doors
To Open the Doors on the Right-Hand Side

#
Proceed as follows:
1. On the right-hand side of the
printing system, open the doors
as shown.
2. Press the button at the bottom

right on the center cover.
3. Pull center cover forward by the

lower side and then lift upwards
to remove.

Opening Right Doors
Proceed as follows:
4. Hang center cover on the desig-
nated bracket on the left door.
5. Open the inner door. Do this by

lifting up the handle slightly and
releasing the latch.

Closing Right Doors
Closing Right Doors
To Close the Doors on the Right-Hand Side

#
Proceed as follows:
printing system, close the inner
door.
Bring the latch to a horizontal
position, lift up the inner door
slightly using the handle and in-
sert into lock.
Caution
The center cover is connected to a printing system switch via a pin.
Ensure that the pin is exactly in front of the switch when you attach the center
cover.

Closing Right Doors
Proceed as follows:
2. ■ First attach the center cover
above.
■ Push the bottom of the cen-
ter cover against the printing
system until it latches into
place. The pin must be exact-
ly in front of the switch .
3. Close doors.

Opening Left Doors
Opening Left Doors
To Open the Doors on the Left-Hand Side

#
Proceed as follows:
1. On the left-hand side of the
printing system, open the doors
as shown.
2. Press the button at the bottom

right on the center cover.
3. Pull the center cover forward on

the lower side and then lift up-
wards to remove.

Opening Left Doors
Proceed as follows:
4. Hang the center cover on the
bracket provided on the left-
hand door.
5. Open the inner door. Do this by

lifting up the handle slightly and
releasing the latch.

Closing Left Doors
Closing Left Doors
To Close the Doors on the Left-Hand Side

#
Proceed as follows:
printing system, close the inner
door.
Bring the latch to a horizontal
position, lift up the inner door
slightly using the handle and in-
sert into lock.
Caution
The center cover is connected to a printing system switch via a pin.
Ensure that the pin is exactly in front of the switch when you attach the center
cover.

Closing Left Doors
Proceed as follows:
2. ■ First attach the center cover
above.
■ Push the bottom of the cen-
ter cover against the printing
system until it latches into
place. The pin must be exact-
ly in front of the switch.
3. Close doors.

Replacing the developer station — overview
Replacing the Developer Station

Introduction
A replacement cart is required to replace a developer station.
Caution:
■ Heavy weight
Note the heavy weight of the developer station (approx. 70 kg/145.35 lb) and the
correct functioning of the locks on the replacement cart.
■ Danger of tilting
Lower the developer station to the lowest position of the hoisting lift before transporting
it, otherwise there is an increased danger of tilting on uneven floors.
■ Danger of crushing
There is a danger of injury due to crushing when lowering or raising the hoisting lift.
Keep hands, feet and objects out of the hoisting area.
■ Hot surfaces
After a longer period of printing, the motor of the developer station may be hot. Do
not touch the motor.
Caution:
■ Check operational readiness
Before each use, check the developer station shelf for operational readiness. In the case
of defects that could cause health hazards or material damage, the device must not be
used.
■ Heavy weight
Secure the movable developer station shelf to prevent it from rolling away. Take care
on steep slopes and ramps.
■ Keep a safe distance
The developer stations protrude over the developer station shelf by approx. 14 cm
(5.5") on the steering caster side.

Attention:
Avoid incidence of light
All 10 slots must be occupied either with developer stations or light protection covers. If
a developer station is removed and stored without being replaced by another developer
station, a light protection cover must be fitted in this slot. If you wish to re-install a de-
veloper station, you must first remove the light protection cover.
Attention:
Avoid damage
Bear in mind the width and height of the replacement cart when moving it.
Note:
An additional adapter to hold developer stations allows developer stations to be stored
complete with adapter. Rearranging the individual developer stations within the adapter
is thus no longer necessary.
The procedure for changing a developer station is the same for all colors and both print
units.
Maintenance Cart
The maintenance cart consists of the following components:

1 Sliding bracket
2 Hoisting lift
3 Brake bracket
4 Developer station adapter
5 Locking mechanism
Developer Station Shelf (Optional)
A movable developer station shelf is recommended to store the developer station, which
can be used for the safe storage of up to four developer stations. This simplifies the process
of converting the printing system for different color configurations.

Overview
‘Preparing the replacement cart’ on page 169
■ ‘Removing the developer station’ on page 171

■ ‘Storing the Developer Station in the Developer Station Shelf’ on page 177
■ ‘Putting the Developer Station on the Stacking Tray’ on page 181
■ ‘Removing the Developer Station from the Developer Station Shelf’ on page 183
■ ‘Replacing the Developer Station from the Stacking Tray’ on page 187
■ ‘Installing the developer station’ on page 189
■ ‘Removing the Light Protection Cover’ on page 194

■ ‘Installing the Light Protection Cover’ on page 197
‘Completing developer station replacement’ on page 198

Preparing the replacement cart
Caution:
Before each use, check the replacement cart for operational readiness. If you find serious
defects that could cause health hazards or material damage, the device must not be used.
Attention:
The replacement cart batteries should be recharged every night, or occasionally if the re-
placement cart is not in use for a longer period of time. The batteries cannot be overloaded.
Strictly observe the following safety directives when charging the batteries:
■ Never connect the battery charger to the hoisting lift only, as this results in the batteries
being discharged.
■ Do not heat batteries or put them into or close to a fire.
■ Keep batteries away from children.
■ Do not use special batteries with other devices.
■ Do not open or break batteries.
■ Always charge the battery packs through the charging socket in the housing.
■ Always use the original battery charger to recharge the batteries. It is equipped with
charge characteristic monitoring to ensure optimal recharging and a long battery life.
Use of a different battery charger may result in damage to the battery through power
surges, heat buildup or stray voltage.
■ Always dispose of batteries through the recycling system; do not dispose of them in
normal garbage.
To charge the batteries

#
Proceed as follows:
1. Connect the battery charger to the hoisting lift connection (18 V, 6.5 Ah).
2. Connect the charger to the power socket.
The red and yellow LEDs light up.
3. When the batteries are charged (the green and red LEDs light up):
■ Disconnect the battery charger from the power socket.
■ Disconnect the battery charger from the charging connection of the hoisting
lift.

To adjust the height of the sliding bracket

#
Proceed as follows:
1. Undo the black rotating handles
by turning them counterclock-
wise.
2. Adjust the height of the sliding bracket and lock it by turning the black turning
knobs clockwise.

Removing the developer station
Removing the Developer Station

Caution:
■ Heavy weight
■ Hot surfaces
Attention:
Avoid damage
To Remove the Developer Station

#
Proceed as follows:
1. If the printing system has not yet stopped, click the 'Stop' button:
2. If not all developer stations have been swiveled off in the relevant print unit,
select the following menus and elements on the operator panel:
■ 'Replace consumables' -> 'Swivel developer stations' menu
■ 'Select task': 'All - upper print unit' or 'All - lower print unit'
■ 'Select action to be executed': 'Swivel off'
■ Click the 'Next' button.
■ Click the 'OK' button to start the swiveling process.
The developer stations are swiveled off.

■ When swiveling off is finished, click the 'OK' button again.

Proceed as follows:
3. If the doors are not yet open, open them now:
To remove a developer station in the upper print unit; open all doors on the
left-hand side of the printing system.
To remove a developer station in the lower print unit; open all doors on the
right-hand side of the printing system.
4. Detach the toner feed hose from

the developer station, take it out
of the two mountings and attach
it to the parking tube.
If the developer station is cooled
via a cooling air tube, disconnect
the tube from the developer sta-
tion and set it aside.

Proceed as follows:
5. Push the maintenance cart in
front of the developer station.
■ To move a developer station
over a shorter section, move

the brake bracket to the cen-
ter position.
This means all four wheels
are free and the lift can be
freely moved.
over a longer section, move

the brake bracket to the top
position.
This locks the rear left wheel
and the lift can only be
moved straight (forwards or
backwards).
6. Align the maintenance cart at a

right angle to the print module
and move the hoisting lift of the
maintenance cart to the height
of the developer station.

Proceed as follows:
7. Push the brake bracket down-
wards.
Caution
Observe height and alignment of the hoisting lift
The hoisting lift mandrel must be carefully inserted up to the stop point.
8. Unlock the hoisting lift and push
the hoisting lift mandrel careful-
ly into the notch below the devel-
oper station to the stop point.
If the hoisting lift mandrel does
not slide easily into the notch,
correct the height and/or align-
ment of the hoisting lift.
9. Lock the hoisting lift.

Pull the maintenance cart to
check that it is properly secured,
and correct if necessary.

Proceed as follows:
10. Pull the developer station on to
the hoisting lift up to the stop
point. The developer station au-
dibly snaps into place.
11. Detach the brake bracket, unlock

the hoisting lift and move the
maintenance cart as far from the
print module as is necessary to
prevent any collision between
the developer station and print
module during operation.
Caution
Make sure there is sufficient distance between the maintenance cart and print
module.
12. Lower the developer station.

Proceed as follows:
13. Move the maintenance cart with
the developer station to the devel-
oper station shelf or to a stacking
tray:

ter position.
freely moved.

position.
backwards).
14. ■ If the developer station is to be stored on the developer station shelf: ‘Storing
the Developer Station in the Developer Station Shelf’ on page 177.
■ If the developer station is to be stored on a stacking tray: ‘Putting the Devel-
oper Station on the Stacking Tray’ on page 181.

Storing the Developer Station in the Developer Station Shelf
Caution:
■ Heavy weight
■ Hot surfaces
Caution:
used.
■ Heavy weight
Attention:
Avoid damage

To Store the Developer Station in the Developer Station Shelf

#
Proceed as follows:
1. Push both brake brackets of the
developer station shelf down-
wards.

right angle to the developer sta-
tion shelf and move the hoisting
lift of the maintenance cart to
the required height.
Caution

Proceed as follows:
3. Carefully slide the hoisting lift
mandrel as far as it will go into
the notch below the developer
station.
4. Lock the hoisting lift and check

that it is properly secured by
pulling the replacement cart.
Caution
Insert the developer station carefully to avoid damage.
5. Pull the locking bolt and push
the developer station carefully
and evenly into the developer
station shelf up to the stop point.

Proceed as follows:
6. Unlock the hoisting lift and
carefully detach the maintenance
cart from the developer station
module.
7. ‘Removing the Developer Station from the Developer Station Shelf’ on page 183.

Putting the Developer Station on the Stacking Tray
Caution:
■ Heavy weight
■ Hot surfaces
Attention:
Avoid damage
To Put the Developer Station on a Stacking Tray

#
Proceed as follows:
1. Carefully lower the developer
station onto the stacking tray.

Proceed as follows:
2. Release locking mechanism and
move the hoisting lift away from
the developer station.
3. ■ If a developer station is to be re-installed:

‘Replacing the Developer Station from the Stacking Tray’ on page 187.
■ If no developer station is to be installed, a light protection cover must be
fitted instead: ‘Installing the Light Protection Cover’ on page 197.

Removing the Developer Station from the Developer Station Shelf
Installing the Developer Station

Removing the Developer Station from the Developer Station
Shelf
Caution:
■ Heavy weight
■ Hot surfaces
Caution:
used.
■ Heavy weight
Attention:
Avoid damage

To Remove the Developer Station from the Developer Station Shelf

#
Proceed as follows:
1. Push both brake brackets of the
developer station shelf down-
wards.

right angle to the developer sta-
tion shelf and move the hoisting
lift of the maintenance cart to
the height of the developer sta-
tion.
Caution

Proceed as follows:
3. Carefully slide the hoisting lift
mandrel as far as it will go into
the notch below the developer
station.
4. Lock the hoisting lift.

Pull the maintenance cart to
check that it is properly secured,
and correct if necessary.
5. Pull the developer station on to

the hoisting lift up to the stop
point. The developer station au-
dibly snaps into place.

Proceed as follows:
6. Detach the brake bracket of the
maintenance cart, unlock the
hoisting lift and move the main-
tenance cart as far from the devel-
oper station shelf as is necessary
to prevent any collision between
the developer station and the
developer station shelf during
operation.
7. ‘Installing the developer station’ on page 189.

Replacing the Developer Station from the Stacking Tray
Caution:
■ Heavy weight
■ Hot surfaces
Attention:
Avoid damage
To Replace the Developer Station from the Stacking Tray

#
Proceed as follows:
1. Move the maintenance cart to the developer station shelf or the stacking tray
with the new developer station.
2. Position the hoisting lift of the
replacement cart at the height of
the developer station adapter.

Proceed as follows:
3. Insert the rolls of the replace-
ment cart halfway into the
guides of the developer station
adapter.
Pull the locking mechanism in
the direction of the arrow and
push the replacement cart in
completely until it snaps in.
The two green arrows on the
right and left of the replacement
cart are then aligned above each
other.
4. ‘Installing the developer station’ on page 189.

Installing the developer station
Caution:
■ Heavy weight
■ Hot surfaces
Attention:
Avoid damage

To Install the Developer Station

#
Proceed as follows:
1. Push the maintenance cart in
front of the print module.

ter position.
freely moved.

position.
backwards).

right angle to the print module
and move the hoisting lift of the
maintenance cart to the height
of the developer station.
Caution

Proceed as follows:
3. Unlock the hoisting lift and push
the hoisting lift mandrel careful-
ly into the notch below the devel-
oper station to the stop point.
4. Lock the hoisting lift and check

that it is properly secured by
pulling the replacement cart.
Caution
Insert the developer station carefully
To prevent damage, slide the developer station carefully and evenly into the
print module up to the stop point.
5. Pull the locking bolt and push
the developer station carefully
and evenly into the print module
up to the stop point.

Proceed as follows:
6. Unlock the hoisting lift and
carefully detach the replacement
cart from the print module.
Caution
Make sure there is sufficient distance between the replacement cart and devel-
oper station.
7. Detach the brake bracket and
move the replacement cart as far
from the developer station as is
necessary to prevent any collision
between the developer station
and replacement cart during op-
eration.
Lower the hoisting lift all the
way and park the maintenance
cart in a suitable place.

Proceed as follows:
8. Remove the toner feed hose from
the parking tube, insert it into
the two mountings and attach it
to the developer station.
If the developer station is cooled
via a cooling air tube, reconnect
the tube to the developer station.
9. ■ If an additional developer station is to be replaced: ‘Removing the developer

station’ on page 171.
■ If all necessary developer stations have been replaced: ‘Completing developer
station replacement’ on page 198.

Removing the Light Protection Cover
Replacing the Light Protection Cover

Caution:
Hot surfaces on developer stations
After a longer period of printing, the motor of the developer station may be hot. Do not
touch the motor.
Attention:
Avoid damage
To remove a light protection cover, all developer stations in the relevant print unit must
be swiveled off.
Attention:
To Remove the Light Protection Cover

#
Proceed as follows:
2. If not all developer stations have been swiveled off in the relevant print unit,
select the following menus and elements on the operator panel:
■ 'Select task': 'All - upper print unit' or 'All - lower print unit'
■ Click the 'OK' button to start the swiveling process.
The developer stations are swiveled off.

■ When swiveling off is finished, click the 'OK' button again.

Proceed as follows:
3. If the doors are not yet open, open them now:
To remove a light protection cover in the upper print unit; open all doors on
the left-hand side of the printing system.
To remove a light protection cover in the lower print unit; open all doors on
the right-hand side of the printing system.
Caution
If a developer station is pulled out too quickly and suddenly, it may be pulled
out over the stop points and fall down.
Always pull a developer station out slowly and evenly to the stop point of the
guide rails. Take care not to stretch the toner hoses.
4. For all developer stations that are
below the light protection cover
to be removed:
■ Press the lock button.
■ Pull the developer station out
slowly and evenly as far as the

stop.
The developer stations must not
be removed.

Proceed as follows:
5. Pull the lock downwards and
then pull the light protection
cover out of the guides by the
handle.
6. Remove further light protection covers as necessary. To do so, repeat the process
from step 4.
7. If a developer station is to be installed instead of the light protection cover:
‘Installing the developer station’ on page 189.
If a light protection cover is to be re-installed: ‘Installing the Light Protection
Cover’ on page 197.

Installing the Light Protection Cover
Installing the Light Protection Cover
Attention:
To Install the Light Protection Cover

#
Proceed as follows:
1. Insert the light protection cover:
■ Insert the light protection
cover straight into the guides

and push it in until about 5
cm (2") before the stop.
■ Press the lock downwards
and then push the light pro-

tection cover all the way to
the stop.
2. Ensure that the lock is correctly engaged.

3. Install further light protection covers as necessary. To do so, repeat the process
from step 1.
4. If all necessary light protection covers have been installed: ‘Completing developer
station replacement’ on page 198.

Completing developer station replacement
Completing developer station replacement
To Complete the Replacement of the Developer Stations

#
Proceed as follows:
Caution
Observe the position of the cooling air tubes
Make sure that the cooling air tubes are positioned in such a way that they do
not obstruct the developer stations when swiveling on.
1. Close all doors.
2. To swivel on the developer stations again and complete the replacement, click
the 'Stop' button.

Checking the print image
Checking the print image
Introduction
To check the printed paper web at the paper output, printing can be interrupted with a
Web Inspection Stop.
To Check the Print Image

#
Proceed as follows:
1. Press the 'Ready' button on an
additional operator panel during
printing.
The print operation is interrupt-
ed.
2. Check the printed paper web.

After the preset length of time, the printing system continues printing without
a new initialization phase.
Note:
If the 'Print speed' menu has been activated by Service for the "Key Operator" and
"Operator" user groups, the preset length of time of 50 seconds for the Web Inspection
Stop is changed.
To Change the Preset Length of Time for the Web Inspection Stop
#
Proceed as follows:
1. Call up the 'Configuration' -> 'Print parameters' -> 'Print speed' menu.
2. Set the length of time using the control slider under 'Web inspection'.

Printing Test Print Jobs — Overview
Printing Test Print Jobs

Introduction
Preinstalled test print jobs can be started via the 'Test print' menu. These print jobs,
which are grouped in test sequences, can be used to optimize the print quality for a certain
application. These optimized settings can then be saved in a setup.
Prerequisites:
■ The printing system must be in the 'Stop' status.
■ The channel must be deactivated ('Channels' menu).
Some elements of the current printing system configuration are shown under 'Display':
■ Type of printing system and currently used color stations
■ 'Print image' -> 'Print mode' menu: 'Simplex' or 'Duplex'
■ 'Print image' -> 'Paper output' menu: 'Face up' or 'Face down'
Note:
The test print is always printed using the current printing system configuration. Ensure
that the activated raster and the activated output profile match up correctly (see 'Raster'
and 'Parameter' menus).
To Activate a Test Print:

#
Proceed as follows:
2. If the channel is still not deactivated, deactivate the channel in question in the
'Channels' menu.
'Configuration' -> 'Emulations' -> 'Test print'.
4. Under 'Test job selection', select a test print for the relevant configuration.
5. Click the 'Start test print' button.
The display changes from red to green. The test job is only printed until the
test print is canceled.

Note:
You will find detailed information about the individual test print jobs in the following
sections:
■ Print quality test for full-color printing
‘'5C_PrintQualityInspection.600' Test Print Job’ on page 202

■ Test of the color functionality of the controller in 'I mode'
‘Test Print Job 'ColorProof.ipds' — Overview’ on page 207

‘Test Print Job 'ColorProof.ipds_pdf' — Overview’ on page 218
■ Test of the color functionality of the controller in 'PCL mode'
‘Test Print Job 'ColorProof.pcl' — Overview’ on page 227

‘'SpotColorPalette.pcl' Test Print Job’ on page 237
Note:
The depicted test pages in each case serve to describe the test print job and should not
be used as reference to make optical comparisons.
To cancel a test print:

#
Proceed as follows:
1. Click the 'Cancel test print' button.
The display changes from green to red. Terminating a test job simultaneously
deletes all data that has not yet been printed.

'5C_PrintQualityInspection.600' Test Print Job
Test Sequences
The individual test sequences can be assessed to judge the print quality.



Description
#
Test sequence Description Settings on operator panel

1 Optical density: Designation of 'Configuration' -> 'Color' ->
full tone coloration on the full 'Contrast' menu
tone bar at right angles to the
print orientation.
2 Determination of detail accuracy 'Configuration' -> 'Color' ->
or character thickness by means 'Contrast' -> 'Fine adjustment'
of lines and text in different menu
sizes.
3 Designation of tone transfer 'Configuration' -> 'Color' ->
curve on 8-bit halftone wedge 'Raster' menu
presentation (100% to 0%). 'Configuration' -> 'Color' ->
'Tone transfer curve' menu
3a Test blocks with coded test strips 'Configuration' -> 'Color' ->
for each color. These test strips 'Calibrate color' menu
can be scanned and evaluated for
the color calibration.
3b A unique three-digit 'Identifica-
tion number' is printed for each
'5C_PrintQualityInspec-
tion.600' test print job.

Test sequence Description Settings on operator panel

4 Designation of passage behavior 'Configuration' -> 'Print param-
at places printed on both sides. eters' -> 'Transfer optimization'
menu
5 Designation of print image posi- 'Configuration' -> 'Paper' ->
tioning on front and back pages. 'Shift' menu
6 Determination of fusing level in 'Configuration' -> 'Print param-
continuous print operation on eters' -> 'Print image' -> 'Fusing
the full tone bars at right angles temperature' menu
to and in line with print orienta- 'Configuration' -> 'Print param-
tion. eters' -> 'Print image' ->
'Smoothing' menu
7 Determination of color separa- 'Configuration' -> 'Color' ->
tion setting in longitudinal direc- 'Color plane shift' menu
tion (register).
Visualization of certain settings:

#
Test sequence Description

8a The graphics show the achievable color spectrum/the curve of the
four colors.
8b The graphics show peaked light (reflection) and depth drawing
(structure in dark tone).
8c The text field shows information on printer-specific settings.
8d The graphics in CMYK show the tone transfer curve (contouring).

Test Print Job 'ColorProof.ipds' — Overview
Test Print Job "ColorProof.ipds"

Test Print Job 'ColorProof.ipds' — Overview
Introduction
The ColorProof test print jobs can be used to test the color functionality of the controller:
■ The 'ColorProof.ipds' test print job is designed for 'I mode' without 'Abobe PDF
Print Engine'.
■ The 'ColorProof.ipds_pdf' test print job also tests the 'Abobe PDF Print Engine'
component. Pages 1 to 7 of this test print job are identical to the 'ColorProof.ipds'
test print job.
Each test page contains information on the current configuration of the printing system
in the left-hand margin.
Note:
PTOCA: Presentation Text Object Content Architecture
MO:DCA: Mixed Object Document Content Architecture, device-independent data
stream
Overview
■ ‘Test Print Job 'ColorProof.ipds' — Page 1’ on page 208
■ ‘Test Print Job 'ColorProof.ipds' — Page 6/7’ on page 216

Test Print Job 'ColorProof.ipds' — Page 1
Color Spaces
The page shows an extract from the individual printer color spaces.
PTOCA Color Spaces

The different PTOCA color spaces are addressed in the upper area. For PTOCA, 'Satu-
ration' is used as the default 'Rendering Intent' in color management.

Color space Description

OCA color space The OCA color space including all OCA names is addressed in
(Named Colors) the first row. This color space contains a small number of pre-
defined colors.
■ The primary colors are always printed with 100% application
and without a raster.

■ The (R, G, B) secondary colors are each printed using 100%
mixtures of primary colors.

■ The right part of the color row is printed with a predefined
raster.
■ The 'Gray' field is not created using "composite black", but
with 50% K coloration (black only).

■ A fixed coloration of 0% (no toner application) is used for
the 'White' field.

■ The selection of color profiles and 'Rendering Intent' on the
operator panel has no effect on the OCA colors. As a result,

color row 1 is not always identical to color rows 2 to 4.
RGB color space A unique RGB value is assigned to each OCA name in
(sRGB) MO:DCA. This RGB value is used for the RGB color space in
the second row.
CieL*a*b* space The RGB values are converted into the CieL*a*b* space and
with the recom- printed.
mended D50 white
point
Indexed Color The L*a*b* values are printed as an Indexed Color in a Color-
ManagementResource (Color Palette CIELAB Tag with the
recommended D50 white point).
Color rows 2 to 4 must correspond color-wise in a vertical direction.
Object Container Space

Here, the same RGB values are used as for the PTOCA color spaces.
For Object Container Space, 'Perceptual' is used as the default 'Rendering Intent' in
color management.
#

TIFF (LZW) The RGB values are printed as TIFF (LZW).
JPEG The RGB values are printed as JPEG.


GIF The RGB values are printed as GIF. The RGB values are inte-
grated into the Image as indexed colors.
All three color rows must conform color-wise in a vertical direction.
Device Color Spaces

The individual RGB values are converted into CMYK values.
Color management is not applied in the CMYK color space, thus the colors are printed
directly as device colors without any adjustment.
#

PTOCA The PTOCA-Images are printed in the CMYK color space.
TIFF The TIFF-Images are printed in the CMYK color space.
IOCA FS45 The IOCA FS45-Images are printed in the CMYK color space.
The three color rows must correspond color-wise in a vertical direction.

Embedded Color Profiles
Color Profiles
#
Color profile Description

Images with embed- In the first section, the TIFF (LZW) and JPEG-Images from
ded sRGB IEC page 1 are used, whereby a sRGB profile is added for every
61966-2.1 source color field (embedded profile):
Color Profile The two TIFF and JPEG color rows must correspond to the
images on page 1 (without profile).
Images with embed- TIFF and JPEG-Images with embedded Wide Gamut Profile
ded wide Gamut are used in the second section. The two TIFF and JPEG Image
RGB source Color rows within this section must correspond. However, they differ
Profile from the first two rows. This is most clearly visible with cyan,
magenta and brown.

Color profile Description

Color management TIFF and JPEG-Images without embedded profile are used in
resource with wide the third section. However, a wide Gamut Audit Profile is as-
Gamut RGB Audit signed here.
Color Profile The two TIFF and JPEG Image rows within this section must
correspond. They must also correspond with the images from
the second section, as the same profile is applied in both cases
(once embedded, once external).
Gray Bar with LAB In the fourth section, two gray value ranges can be seen, which
or RGB colors are composed of a mixture of colors, creating a composite gray.
The first row uses the CieL*a*b* color space, and the second
row uses the RGB (sRGB) color space with the values R=G=B.
Using these gray value ranges, color deviations can be seen very
clearly, because the eye's neutral perception of gray is very
quickly disturbed if the values of the color areas shift in a certain
color direction.

Full Tone Coloration

Full tone bars with the primary colors (CMYK) are printed across the width of the page.
This means that full tone coloration can be tested across the entire print area.
Tone Transfer Path

The sRGB tone transfer curve can be used to check the composite gray structure. The
colorfulness can be reduced by calibrating the printing system. In addition, tone transfer
curves with the primary and secondary colors are printed. The calibration can be checked
here both optically and by measurement.
The first pixels should be visible with the naked eye from 3% onwards. The optical den-
sity of the color fields should then increase constantly. At 97%, a few white spots in the
raster can still be recognized using a magnifying glass.

Highlight Color
Raster Angle and Raster Width

All color stations are addressed using the 'I mode' color number via the Highlight Color.
The printed gauges can be used to read out the raster angle and raster width for every
color station. A moiré circle is created for every color station. The radial line in the center
of the moiré indicates the width of the raster in Ipi. The angle axis in the center of the
moiré indicates the raster angle.
Note:
The moiré circles display all raster angles correctly when printing in bilevel mode. If
GraphicArts (multilevel/dot matrix) is used, the raster angle is only correctly displayed
for black. Line halftones are used for cyan, magenta and yellow. Therefore, in this case,
90° must be added in a clockwise direction to each displayed angle.
Highlight Color Tone Transfer Curve

The tone transfer curve is activated via Highlight Color and tested. In calibrated printers,
the tone transfer curve is optically equidistant. The first pixels should be visible from 3%
onwards. The optical density of the fields should then increase constantly. At 97%, a few
white spots in the raster can still be recognized using a magnifying glass.

Color Mapping Table
In the first row, each OCA color is activated for foreground and background without
mapping (overlapping squares).
The second row shows the OCA colors with the Color MappingTable (CMT) currently
selected in the printing system.
The remaining rows each correspond to a pre-installed CMTs in the printing system.
To determine which Color MappingTable is currently loaded in the operator panel,
search for the Color MappingTable for the second row in the lower rows.

Test Print Job 'ColorProof.ipds' — Page 6/7
Reference Images
This test page uses reference images from ECI (© by European Color Initiative
www.eci.org). JPEG compression is used on page 6 of the test job, and TIFF (LZW)
format on page 7.
Extract from the description of these images from ECI:

#
Illustration Description
1 This image serves to visually check the reproduction quality of
detailed drawings and the color precision of highly saturated
colors.
2 Minor incorrect settings in the ratio of individual colors result
in clearly visible color shifts in the reproduction of images. This
image is also used to check the accuracy of the tonal reproduc-
tion in the highlights.
3 This image is printed exclusively with the primary color black.
4 Even slight color shifts are plainly visible in images with skin
tones. This image is therefore ideal for visual assessment of the
test print quality.

5 This image is used to assess the correct tonal reproduction in
dark areas. Also, brown tones are extremely sensitive to even
the smallest incorrect setting of print colors in relation to one
another.
6 Neutral colors are difficult to achieve without a color cast. As
is the case with skin tones, neutral colors display color deviations
at the slightest error in color management. In addition, the
quality of tonal reproduction in the critical areas of highlighting
('high key', white carpet) and lowlighting ('low key', belt) is
checked.

Test Print Job 'ColorProof.ipds_pdf' — Overview
Test Print Job "ColorProof.ipds_pdf"

Test Print Job 'ColorProof.ipds_pdf' — Overview
Introduction
The ColorProof test print jobs can be used to test the color functionality of the controller:
■ The 'ColorProof.ipds' test print job is designed for 'I mode' without 'Abobe PDF
Print Engine'.
■ The 'ColorProof.ipds_pdf' test print job also tests the 'Abobe PDF Print Engine'
component. Pages 1 to 7 of this test print job are identical to the 'ColorProof.ipds'
test print job.
Note:
PTOCA: Presentation Text Object Content Architecture
MO:DCA: Mixed Object Document Content Architecture, device-independent data
stream
Overview
■ ‘Test Print Job 'ColorProof.ipds' — Page 6/7’ on page 216
■ ‘Test Print Job 'ColorProof.ipds_pdf' — Page 8’ on page 219
■ ‘Test Print Job 'ColorProof.ipds_pdf' — Page 11/12’ on page 225

Test Print Job 'ColorProof.ipds_pdf' — Page 8
PDF Color Spaces
The page shows an extract from the individual printer color spaces controlled under PDF.
The entire PDF page is integrated as a IPDS object container. The color fields correspond
to the IPDS-OCA colors.
PDF does not know any color names that correspond to the OCA colors. Therefore, the
color values corresponding to the OCA colors are converted into PDF for the color spaces.
The OCA color names (Black, Red, Green, Blue, …, Dark Blue, White) appear as
headings above the color fields so that, in the event of an error, the user can see which
color should be displayed here.
The settings selected on the operator panel are used as 'Rendering Intent'.
Upper Area
CIE color spaces that are administered by color management are used in the upper area.

Color rows Description

sRGB color space The RGB values corresponding to the PTOCA colors are dis-
according to IEC played in sRGB (range from 0 to 1, where "0" equals no satura-
61965 standard tion and "1" (= 255 with RGB) represents maximum satura-
tion). The print output should correspond to theOCA colors.
CIE 1976 L*a*b* The RGB values for the OCA colors were converted to the
space with the CieL*a*b* space and printed. Value scale:
CCIR XA/11 rec- ■ L*: 0 (minimum brightness or black) to 100 (maximum
ommended D65 brightness or white)

white point ■ a*: -127 (green area) to +128 (red area)
■ b*: -127 (yellow area) to +128 (blue area)
The printed colors should correspond to the sRGB colors or

the OCA colors.
CIE 1931 XYZ Value scale:
space with the ■ X: 0 to 0.9505 (blue -> red)
CCIR XA/11 rec- ■ Y: 0 to 1.0 (blue -> green)
ommended D65 ■ Z: 0 to 1.089 (dark -> light)
white point
The printouts should correspond to the outputs of sRGB or
CIE L*a*b* and the OCA colors.
Gray value range A gray value range from white to black is printed. The gray
with sRGB color fields are made up of sRGB color values, where these values are
space according to identical (R = G = B = composite gray). A color shift can be
IEC 61965 stan- easily recognized as the eye reacts to this in a sensitive manner.
dard Ideally, no hue (reddish, yellowish etc.) should be visible.
Gray value range This corresponds to the fourth color row, in this case using the
with CIE 1976 color space CIE L*a*b* (whereby a*=b*=0 and only L varies
L*a*b* space with from 100 to 0). The result must be identical to the fourth row.
the CCIR XA/11 Ideally, no hue should be visible here either.
recommended D65
white point
Lower Area
Device color spaces are used in the lower area. Color management is not active. The colors
are similar, but not identical, to those in color rows 1 to 3.

Color rows Description

DeviceRGB The corresponding RGB values of the OCA colors were con-
verted to sRGB. These are the same color values as those in the
first color row with the scale of 0 to 1.
DeviceCMYK Here the four color stations are accessed directly. They are sent
color values on a scale of 0 to 1. In contrast to RGB, a "1" indi-
cates maximum coloration ("black" for all color stations), while
"0" represents maximum brightness. The gray field is not repre-
sented as "composite gray", but rather using only K values
(black).
DeviceGray This color row represents its color fields in black/white or
grayscale, where "S" indicates the saturation (corresponds to
the K value).
The values for "S" are derived from a formula that converts
colors to gray values: S = 0.299 * R + 0.587 * G + 0.114 * B.
If the printing system is switched to back/white mode, the same
result as in the other color rows should be achieved in this row,
in as far as possible.

PDF Tone Transfer Curves
In the upper area, full tone bars with the primary colors (CMYK) are printed across the
width of the page. Full tone coloration can be tested across the entire print area.
In the lower area, tone transfer curves with primary and secondary colors are printed.
The calibration is checked here both optically and by measurement.
The first pixels should be visible from 3% onwards. The optical density of the fields
should then increase constantly. At 97%, a few white spots in the raster can still be recog-
nized using a magnifying glass.

PDF Highlight Color
Raster Angle and Raster Width

The printed gauges can be used to read the PDF raster angle and raster width for each
print station. A moiré circle is created for every color station. The radial line in the center
of the moiré indicates the width of the raster in Ipi. The angle axis in the center of the
moiré indicates the raster angle.
Note:
The moiré circles display all raster angles correctly when printing in bilevel mode. If
GraphicArts (multilevel/dot matrix) is used, the raster angle is only correctly displayed
for black. Line halftones are used for cyan, magenta and yellow. Therefore, in this case,
90° must be added in a clockwise direction to each displayed angle.
Tone Transfer Path

The first four tone transfer curves are automatically set to the primary colors K, C, M,
Y.

Note:
In the case of the fifth tone transfer curve, the relevant color is only displayed if the fifth
color station is installed and "HLC5" is entered as the 'Alias' for this color station.
Otherwise, the color gradient appears in gray.
The first pixels should be visible from 3% onwards. The optical density of the fields
should then increase constantly. At 97%, a few white spots in the raster can still be recog-
nized using a magnifying glass.

Test Print Job 'ColorProof.ipds_pdf' — Page 11/12
Referenzbilder
This test page uses reference images from ECI (© by European Color Initiative
www.eci.org). The reference images are embedded in the PDF, which is itself integrated
as the IPDS Object Container.
JPEG compression is used on page 11 of the test job, and TIFF (LZW) format on page
12.

#
1 This image serves to visually check the reproduction quality of
detailed drawings and the color precision of highly saturated
colors.
2 Minor incorrect settings in the ratio of individual colors result
in clearly visible color shifts in the reproduction of images. This
image is also used to check the accuracy of the tonal reproduc-
tion in the highlights.
4 Even slight color shifts are plainly visible in images with skin
tones. This image is therefore ideal for visual assessment of the
test print quality.

5 This image is used to assess the correct tonal reproduction in
dark areas. Also, brown tones are extremely sensitive to even
the smallest incorrect setting of print colors in relation to one
another.
6 Neutral colors are difficult to achieve without a color cast. As
is the case with skin tones, neutral colors display color deviations
at the slightest error in color management. In addition, the
quality of tonal reproduction in the critical areas of highlighting
('high key', white carpet) and lowlighting ('low key', belt) is
checked.

Test Print Job 'ColorProof.pcl' — Overview
Test Print Job "ColorProof.pcl"

Test Print Job 'ColorProof.pcl' — Overview
Introduction
The ColorProof test print jobs can be used to test the color functionality of the controller.
The 'ColorProof.pcl' test print job is designed for 'PCL mode'.
Note:
The first 11 test pages are a minimum of 12 x 17 inches in size. If the paper size is set
smaller than this minimum size, the test printout will be cut off at the bottom and right-
hand margins. If necessary, the font test from page 12 is continued on the following
page.
Overview
■ ‘Test Print Job 'ColorProof.pcl' — Page 1’ on page 228
■ ‘Test Print Job 'ColorProof.pcl' — Pages 4-10’ on page 232

Test Print Job 'ColorProof.pcl' — Page 1
Color Spaces
The page shows an extract from the individual printer color spaces.
Description
#
Item Description
Color palettes The rectangles in the upper area are composed of polygons filled
with palette colors. The color palettes are defined in the RGB,
CMY and CIE L*a*b* color space.
Half tone images The rectangles in the middle area are halftone images in various
color spaces. The third line with the CIE L*a*b* color space is
missing, as the halftone image is not supported by the CIE
L*a*b* color space.
All five color rows must correspond color-wise in a vertical di-
rection.

Item Description
Full tone bars In the lower area, full tone bars with the primary colors are
printed across the width of the page. Full tone coloration can
be tested across the entire print area.

Palette Management
Description
#
Item Description
Upper Area Three different color palettes have been defined and saved:
■ Marked red: RGB
■ Marked cyan: CMY
■ Marked violet: CIE L*a*b*
Middle area Then the active palette was deleted and the four-color rectangle
was printed. No palette was activated for the first rectangle.
This is printed with the Default-RGB palette. The previously
saved palettes should appear for the other three rectangles.
Full tone bars In the lower area, full tone bars with the primary colors are
printed across the width of the page. Full tone coloration can
be tested across the entire print area.

Embedded Color Profiles
Description
#
Item Description
Upper Area Here, JPEG images are used, where a profile is added for every
color field (embedded profile).
In the first row, the halftone images are printed as a reference
in the RGB color space. The color profiles selected on the oper-
ator panel are used for the RGB halftone images.
Full tone bars The full tone bars for the primary colors (CMYK) are supple-
mented with three other mixed-color bars (red, green and blue)
here.

Test Print Job 'ColorProof.pcl' — Pages 4-10
Reference Images
These test page use reference images from ECI (© by European Color Initiative
www.eci.org).
Description of Images
#
2 Neutral colors are difficult to achieve without a color cast. As is the
case with skin tones, neutral colors display color deviations at the
slightest error in color management. In addition, the quality of tonal
reproduction in the critical areas of highlighting ('high key', white
carpet) and lowlighting ('low key', belt) is checked.
3 This image serves to visually check the reproduction quality of de-
tailed drawings and the color precision of highly saturated colors.

4 Even slight color shifts are plainly visible in images with skin tones.
This image is therefore ideal for visual assessment of the test print
quality.
5 Minor incorrect settings in the ratio of individual colors result in
clearly visible color shifts in the reproduction of images. This image
is also used to check the accuracy of the tonal reproduction in the
highlights.
6 This image is used to assess the correct tonal reproduction in dark
areas. Also, brown tones are extremely sensitive to even the smallest
incorrect setting of print colors in relation to one another.
Description of the Pages:

Description of the individual pages:
#
Page Description
4 The images are printed in the original format (JPEG).
5 The images are printed in monochrome print mode in JPEG format.
All images should appear in black and white, "composite black"
discoloration is not permitted.
6 The images are printed in 8-bit LZW format (multilevel,
monochrome). All images should appear in black and white, "com-
posite black" discoloration is not permitted.
7 The images are printed in HP-PCL image format and are "adaptive
compressed". The color space for the page is device RGB. The images
should correspond color-wise to the images on page 4.
8 The images are printed in HP-PCL image format and are "adaptive
compressed". The color space for the page is standard RGB. The
images should correspond color-wise to the images on page 4.
9 The images are printed in HP-PCL halftone image format and are
"adaptive compressed". The color space for the page is CMY. The
images should correspond color-wise to the images on page 4.
10 The images are printed as HP-PCL palette images and are "adaptive
compressed". The palette only contains gray, so that the images ap-
pear monochrome. "Composite black" discoloration can appear on
this page.

HPGL/2
All graphical elements on this page are described in HPGL/2. If this page is reproduced
correctly then the HPGL/2 function of the controller is largely free of errors.

Description
#
Item Description
Raster Angle and All color stations are addressed via the 'Color index'. You can
Raster Width adjust the 'Color index' on the operator panel in the 'PCL
simple color' menu.
The printed gauges can be used to read out the raster angle and
raster width for every print station. A moiré circle is created for
every print station. The radial line in the center of the moiré
indicates the width of the raster in Ipi. The angle axis in the
center of the moiré indicates the raster angle.
Note:
The moiré circles display all raster angles correctly when
printing in bilevel mode. If GraphicArts (multilevel/dot
matrix) is used, then the raster angle will also be correct-
ly displayed for black. Line halftones are used for cyan,
magenta and yellow. Therefore, in this case, 90° must
be added in a clockwise direction to each displayed an-
gle.
Highlight Color The tone transfer curve is activated via Highlight Color and
tone transfer curve tested. In calibrated printers, the tone transfer curve is optically
equidistant. The first pixels should be visible from 3% onwards.
The optical density of the fields should then increase constantly.
At 97%, a few white spots in the raster can still be recognized
using a magnifying glass.
HPGL/2 default The default RGB color palette is printed in the lower area. The
palette palette only contains eight colors. From Pen #8, the colors are
repeated cyclically, except for Pen #0.

Font Test
Description
A test line is printed using all of the available internal fonts.

'SpotColorPalette.pcl' Test Print Job
Introduction
This test print job can be used to test the color palette in the HLC color space.
PCL Basic Colors

A color component can be assigned to each color. All color spaces supported in the PCL
mode are created with three components. Each of these components is a byte that shows
the semi-tone value of the color components.
A color component may only be allocated once in a print unit. The color component can
however be allocated differently between the upper and lower print units. On the operator
panel, the PCL basic colors can be set via the 'Configuration' -> 'Color' -> 'Color station
selection' menu path.
These PCL basic colors are used to define a color palette for the test print job. At least
two pages are printed, each containing 25 color bars — one page for the upper print unit
and one for the lower. If the PCL primary colors for the upper and lower print unit differ,
different colors are printed on the front and back pages.
Required Paper Width and Length

To accommodate the 25 color bars, the paper width must be at least 10 inches. If the set
paper width is less than 10 inches, the test printout will be truncated at the right edge.
The total paper length required is 22 inches. If the set paper length is less than 22 inches,
the color bars will be distributed across multiple pages.

Example: Basic color 1 cyan, basic color 2 magenta, basic color 3 yellow
Example: Basic color 1 yellow, basic color 2 magenta, basic color 3 cyan

Optimizing the Color Printing — Overview
Optimizing the Color Printing

Introduction
The colors can be manually tested by using the 'Color check' menu. In doing so the full
and half tone of each individual color is measured and optimized using a reference test
print job. This mode can last up to 20 minutes. When optimization is complete, normal
print operation can be restarted.
All the colors used in the printing system can be calibrated and as a result the active raster
kit adjusted by using the 'Calibrate color' menu. Two different types of color calibration
are supported:
■ Manual Calibration
Print samples are taken and manually tested using a handheld measuring instrument.
The measured data is then used to adjust the active raster kit.
Manual calibration can be carried out either on the console of the operator panel or
on an external measuring station.
■ Automatic Calibration
The measured values from the control strips, which are determined automatically
during the print operation, are used to calculate the new raster kit.
Note:
In the standard version, the 'Calibrate color' menu can be displayed from the "Key
Operator" user group. If necessary, a "Key Operator" for the "Operator" user group can
activate the menu.
Overview
The following tables display various applications for which optimization is recommended:
Note:
In many cases the cause of non-optimal print results may be due to non-optimal data
preparation.

Application Recommendation
For very high quality requirements after longer ‘Performing a Color Test’ on page
phases without full color printing 242
For very high quality requirements after longer
period of time in standby
For very high quality requirements if the color
control is switched on again after longer phases of
print operation with the color control switched
off
If the tone transfer curve is to be checked in the
current status of the printing system
If there are large differences in the tone transfer Perform automatic calibration
curve between the upper and the lower print unit (see ‘Calibrating the Colors of the
Printing System — Overview’ on
page 244).
For an error message triggered by the internal half- ‘Performing a Color Test’ on page
tone control: 242
EL.117.089 ... EL.117.093 / EL.117.124 ...
EL.117.128
EU.117.089 ... EU.117.093 / EU.117.124 ...
EU.117.128
Example:
EL.117.089: 'OPC lower print unit (developer
station 10): Determined tone transfer curve outside
the limit range'
For an error message triggered by the external half- Perform automatic calibration
tone control: (see ‘Calibrating the Colors of the
EL.362.124 ... EL.362.128 Printing System — Overview’ on
EU.362.124 ... EU.362.128 page 244).
Example:
EL.362.124: 'OPC lower print unit (developer
station 10): Determined tone transfer curve outside
the limit range'
When using new paper with very different color- Perform manual calibration for
metric properties (for example, if the paper is this new paper type (see ‘Calibrat-
changed from white to yellow) ing the Colors of the Printing Sys-
tem — Overview’ on page 244).

If the 'Color check' has been performed unsuccess- Perform automatic calibration
fully twice in succession (see ‘Calibrating the Colors of the
If the tone transfer curve is still insufficient after Printing System — Overview’ on
'Color check' has been completed successfully page 244).
Examples: Light raster not visible, dark raster not
distinguishable, graduations throughout
If the results of automatic calibration are not satis- Perform manual calibration (see
factory ‘Calibrating the Colors of the
Printing System — Overview’ on
page 244).
#
Print quality problems that do not affect the tone In these cases the 'Calibrate col-
transfer curve directly, for example: or' and 'Color check' functions
■ Background will not be successful.
■ Passage More detailed information on
■ Differences in paper width these cases can be found in the
■ Fluctuations in the cycle ‘Correcting Print Image Errors’ on
■ Poor full tone coloration page 484 section.
■ Spottiness

Performing a Color Test
Introduction
The colors can be manually tested via the 'Color check' menu. In doing so the full and
half tone of each individual color is measured and optimized using a reference test print
job. This mode can last up to 20 minutes. When optimization is complete, normal print
operation can be restarted.
Applications
The 'Color check' function is recommended in the following cases:
■ If the tone transfer curve is to be checked in the current status of the printing system
■ For very high quality requirements after longer phases without full color printing
■ For very high quality requirements after longer period of time in standby
■ For very high quality requirements if the color control is switched on again after longer
phases of print operation with the color control switched off

■ For error messages regarding internal half tone control (EL.117.089 ... EL.117.093 /
EL.117.124 ... EL.117.128 / EU.117.089 ... EU.117.093 / EU.117.124 ...

EU.117.128)
Example:
EL.117.089: 'OPC lower print unit (developer station 10): Determined tone transfer
curve outside the limit range'
Prerequisites
Requirements for performing a color test:
■ No data has been provided.
■ A test print job for full color printing is installed.
To perform the color check

#
Proceed as follows:
'Configuration' -> 'Color' -> 'Color check'.

Proceed as follows:
2. Click the 'Activate' button.
This mode can last up to 20 minutes. 'Result of color check:'
■ 'Successful'
or
■ 'Not successful'
Note:
If the 'Color check' function is carried out unsuccessfully twice in succession, then auto-
matic calibration should be carried out (see ‘Calibrating the Colors of the Printing System
— Overview’ on page 244).

Calibrating the Colors of the Printing System — Overview
Calibrating the Colors of the Printing System

Introduction
All the colors used in the printing system can be calibrated and as a result the active raster
kit adjusted by using the 'Calibrate color' menu. Two different types of color calibration
are supported:
■ Manual Calibration
Print samples are taken and manually tested using a handheld measuring instrument.
The measured data is then used to adjust the active raster kit.
Manual calibration can be carried out either on the console of the operator panel or
on an external measuring station.
■ Automatic Calibration
The measured values from the control strips, which are determined automatically
during the print operation, are used to calculate the new raster kit.
Attention:
Color calibration should always be carried out with well aligned coloration levels of the
individual colors and with proper expendables.
Note:
In the standard version, the 'Calibrate color' menu can be displayed from the "Key
Operator" user group. If necessary, a "Key Operator" for the "Operator" user group can
activate the menu.
Note:
Automatic calibration can only be performed if the relevant raster kit or toner has already
been calibrated manually on at least one occasion.
As an alternative to automatic calibration, the more elaborate process of manual calibra-
tion can be used if necessary.
Applications for Automatic Calibration

Automatic calibration should be performed:
■ If there are large differences in the tone transfer curve between the upper and the
lower print unit

■ If the tone transfer curve is still insufficient after 'Color check' has been completed
successfully
Examples: Light raster not visible, dark raster not distinguishable, graduations
throughout
■ If the 'Color check' has been performed unsuccessfully twice in succession
■ For an error message triggered by the external half-tone control:
EL.362.124 ... EL.362.128
EU.362.124 ... EU.362.128
Example:
EL.362.124: 'OPC lower print unit (developer station 10): Determined tone transfer
curve outside the limit range'
Applications for Manual Calibration

Manual calibration should be performed:
■ If the results of automatic calibration are not satisfactory
■ When using new paper with very different colormetric properties (for example, if the
paper is changed from white to yellow)
Overview
■ ‘Printing Test Pages for Color Calibration’ on page 246
■ ‘Scanning Test Pages for Color Calibration’ on page 249
■ ‘Analyzing Test Pages for Color Calibration’ on page 253

Printing Test Pages for Color Calibration
Introduction
Requirements for printing test pages for color calibration:
■ The printing system is in the 'Stop' status.
■ No other print job must be active.
Note:
The widest possible paper should be used to allow you to print and test as many blocks
as possible. The minimum paper width is 6,5“ = 165 mm.
To Print Test Pages for the Color Calibration

#
Proceed as follows:
1. Select the following menu on the operator panel: 'Configuration' -> 'Color' -
> 'Calibrate color' -> 'Print' menu.
The current configuration of the printing system is established and displayed
on the right of the menu page.
Note
The wider the paper, the more test strips can be printed and checked.
2. If you wish to change this configuration:
■ Insert the paper web that is to be used to calibrate the printing system.
Make the relevant settings in the 'Paper' menu.

■ Load the desired raster kit in the 'Raster' menu.
■ Switch to the required color configuration in the 'Configurator' menu.
3. If you change the configuration:

■ Go back to the 'Calibrate color' -> 'Print' menu.

Proceed as follows:
4. Under 'Calibration type', select:
■ '<html>Automatic determination of correction data by inline sensor</html>'
The measured values from the control strips, which are determined auto-
matically during the print operation, are used to calculate the new raster
kit.
■ '<html>Manual printout scanning via the operator panel</html>'
Print samples are taken and manually tested using a handheld measuring
instrument. The measured data is then used to adjust the selected raster
kit.
■ '<html>Manual printout scanning via the external measuring sta-
tion</html>'
The print samples are manually scanned onto an external measuring station
using a handheld measuring instrument. 'Step 2: Record' on the operator
panel is skipped in this case.
5. Under 'Test print control':

■ Using the 'Warm-up with paper path' checkbox, select whether the printing
system is to be warmed up with paper path or no paper. Less paper is used

when warming up without the paper path. Depending on the post print
processing, this may lead to problems with repeated proof.
■ Selecting the test print job (see ‘'5C_PrintQualityInspection.600' Test Print
Job’ on page 202)

■ Click the 'Start test print' button.
Example:

Proceed as follows:
Note
Before the color calibration is started, the current settings are automatically
stored in a "calibration setup". When the color calibration is cancelled, this
configuration is then restored.
6. The following additional steps are required for manual scanning of the print-
outs:
■ Cut at least three test print job sets from the printed paper web. (see ‘Re-
moving the paper web ’ on page 155).

■ From each printed set, cut the page with the printed 'Identification number'
on a suitable surface to the appropriate paper size.

■ ‘Scanning Test Pages for Color Calibration’ on page 249 all entries in the list.
If the correction data is determined automatically, you can go directly to 'Step

3: Evaluate' (see ‘Analyzing Test Pages for Color Calibration’ on page 253).
7. ‘Scanning Test Pages for Color Calibration’ on page 249 all entries in the list.

Scanning Test Pages for Color Calibration
Introduction
The measuring device required for the manual scanning of the test print pages is supplied
with all Océ ColorStream printing systems by default; the guide rail and clipboard are
also provided.
Note:
■ The scan program can be operated independently of the other operator panel compo-
nents. This means that you can continue to print with the printing system while
scanning.
■ The scan program can also be installed and operated on a separate PC. When the
Printing System Manager is started, it provides a link via which you can download
the scan program. The data can then be imported via a USB stick connected to a
USB port on the printing system. For more information, please contact your Service
center.
The following describes the scanning process using the operator panel PC of the
printing system.
■ If the measuring device is not used for long periods, it should be stored in its original
packaging until it is next required.
Note:
White balancing adapts the measuring device to differing lighting conditions in the
room.
To Scan Test Pages for the Color Calibration

#
Proceed as follows:
1. If you have not yet selected the 'Record' menu, choose the following on the
operator panel:
'Configuration' -> 'Color' -> 'Calibrate color' -> 'Record' menu
2. Click the 'Start scanning program' button.

Proceed as follows:
3. On the 'Configuration' page, enter or select the following:
■ 'Enter ID no.':
The ID number printed on the test page.

■ 'Number of test pages for upper print unit'/'Number of test pages for
lower print unit':

Number of test pages from the upper or lower print unit that are to be
scanned.
■ 'Select print job':
Test print job and, depending on the paper width, the number of test
blocks.
■ Under 'Upper print unit' and 'Lower print unit' click on the 'Scanning'
checkbox for those color stations that need calibrating.

Click the 'Next' button.
4. Connect the USB cable of the
measuring device to the operator
panel PC of the console.
5. Place the measuring device in the

cup.
Click the 'Next' button on the
operator panel.

Proceed as follows:
6. To warm up the measuring de-
vice, depress the button on the
left side of the measuring device
for approximately 20 seconds.
If the measuring device has been
taken out of the cup: Place the
measuring device back in the
cup.
7. Click the 'Start' button on the operator panel to start the white balancing.
After a short time, the 'Strip scanning of test pages' page is displayed automat-
ically.
Note
In the following, the scanning is described using a clipboard and a guide rail.
For wider paper the clipboard does not need to be used, but the guide rail
should then be used.
8. Press down on the clip and insert
the printout from the upper
print unit into the clipboard.

Proceed as follows:
9. Scan the test strips:
■ Place the measuring device in
the guide rails as shown and

move it next to the first test
strip.
■ Depress the button on the
left of the measuring device

until you hear a beep.
■ Draw the measuring device
across the entire test strip

with a slow and smooth
movement. You can scan
from left to right or right to
left.
Note
The individual test strips of the blocks are displayed on the operator panel.
■ When a test strip has been fully scanned, the display above the relevant test
strip changes to green and a confirmation sound is emitted.

■ If not all fields of the test strip were scanned, an error message is displayed.
The scanning of this test strip must then be repeated.
10. Once the test strips of all blocks for the upper print unit have been scanned,
press the 'Record next page' button and repeat steps 8 and 9 for the test print
of the lower print unit.
11. When you have successfully completed the scanning process, press the 'Cancel
recording' button.
12. Select where the scanned data is to be transferred:
■ 'Data storage on file system'
The data can be transferred to a USB removable storage device (Memory

Stick) for later evaluation.
■ 'Transmission of data to printer'
The data is transferred to the transfer area (a directory on the drive of the
controller hard disk).
13. Depending on the selection click the 'Save' or 'Transfer and close' button.
14. ‘Analyzing Test Pages for Color Calibration’ on page 253

Analyzing Test Pages for Color Calibration
To Analyze Test Pages for Color Calibration

#
Proceed as follows:
1. If you have not yet selected the 'Evaluate' menu, choose the following on the
operator panel:
'Configuration' -> 'Color' -> 'Calibrate color' -> 'Evaluate' menu
The system checks for scanned data in the "transfer area" of the printing system.
2. Click the 'Import scan data' but-
ton and select the source from
which the scan data is to be im-
ported if the scan data has been
manually recorded.
Insert the USB memory stick

with the data into the USB
port. The USB port is located
below the operator panel near
the paper input (see image).
■ Transfer area (a directory on
the drive of the controller

hard disk)
If the scan data was entered auto-
matically:
Click the 'Start' button.

Proceed as follows:
3. The system displays the recorded data for each color station in the upper and
lower print units. Each field in the test strips is displayed in color:
■ Green
The values for this field are OK; no correction is necessary.

■ Red
The values for this field were measured outside of the tolerance area; a
checkmark is set under 'Correction'. The test strips should be re-scanned.
If a visual check of the relevant test strip determines that it is OK, the cor-
rection can be deactivated by clicking on the checkbox.
In the following example, correction is recommended for black and magenta;
cyan, blue and yellow are OK:
4. For those color stations requiring corrections, the printing, scanning and
evaluation of the test print pages must be repeated (see ‘Printing Test Pages for
Color Calibration’ on page 246).
5. Once you have completed the evaluation of the test print pages, press the
'Complete calibration' button.
Result
Once the data has been imported into the printing system, the active raster kit is adjusted.
This completes the calibration process.
Note:
If the color calibration is cancelled, the original raster kit is then restored.

Correcting Color Separation Shifts
Introduction
In the case of color printing, the individual color separations are first collected in succession
on the transfer belt and then transferred together to the paper web. Under certain circum-
stances, the longitudinal register between black and the various colors used may vary.
If a very high level of accuracy is required for the longitudinal register when printing in
color, the individual color separation shifts can be checked and corrected accordingly by
members of the "Key Operator" user group or above.
To Correct Color Separation Shifts

#
Proceed as follows:
1. Approximately 10 accumulative cycles of the test print job for full-color
printing:
■ ‘Printing Test Print Jobs — Overview’ on page 200
■ For information on the test sequences, see: ‘'5C_PrintQualityInspection.600'
Test Print Job’ on page 202.
2. Stop the test print and remove the paper web if necessary:
■ To make corrections to the upper side of the paper web, see: ‘Checking the
print image ’ on page 199.

■ Likewise, to correct values for the underside of the paper web, see: ‘Removing
the paper web ’ on page 155.
Proceed as follows:
3. Measure the longitudinal register in the color-nonius fields of the last two ac-
cumulative cycles:
All color fields are based on black. The numerical values indicate shifts from
the black color separation:
■ Above the lines: in µm
■ Beneath the lines: in mpt

Proceed as follows:
4. If necessary, adjust the color separation shift of the colors to an optimal level
in relation to one another:
■ On the operator panel, select the 'Configuration' -> 'Color' -> 'Color plane
shift' menu.
■ Enter correction values for each color on the 'Upper print unit' or 'Lower
print unit' tab.

Notes:
■ The settings for the register apply to the color print sequence; they are not
linked to a particular color. If the color sequence is changed in the 'Color

sequence' menu, the values already set for the register will remain un-
changed.
■ Register values can be set using the control slider or by entering numerical
values (in increments of 14 mpt).

The permitted threshold values are displayed. The unit of measurement
can be selected from the list. Rounding is accurate to the mpt.
■ All color separation shifts in the upper or lower print unit can be reset to
the default setting of "0" using the 'Set to 0' button.
5. If the paper web has been removed from the printing system: ‘Affixing the paper
web’ on page 152.

Calibrating the Data Integrity Mark Sensor
Introduction
Data integrity marks can be used to monitor the following:
■ Whether the color layers printed on a page belong together
■ Whether the printed front and back pages belong together
■ Whether the pages are printed in the right order.
Note:
Data integrity marks should always be used. If you disable data integrity marks, you
leave the highest possible data integrity security level.
Note:
Data integrity marks must be printed in a color that can be clearly read by the sensors
in the printing system. Black is normally used as the mark color. If black is not used for
printing, the darkest color should be selected as the mark color.
Dimensions of a data integrity mark

A A
B B
1
C
2
E
D
3
F
1
C
Dimensions
A 1/5" (5.08 mm)
B 1/6" (4.23 mm)
C 5/12" (10.58 mm)
D 3/25" (3.05 mm)
E 1/25" (1.02 mm)
F 2/25" (2.03 mm)

Area Description
1 Protected area (must remain unprinted)
2 Code segment 1
3 Code segment 2
Requirements
A sensor may require calibration for data integrity marks when a different developer station
or a different color is used. A message to this effect will be displayed on the operator
panel.
Requirements for sensor calibration for data integrity marks:

■ The user rights are available for this menu
■ The access ticket for this operator panel is requested
■ The printing system is in the 'Stop' status
■ No replacement function is being executed.
To Calibrate a Data Integrity Mark Sensor

#
Proceed as follows:
1. Click on the 'Configuration' -> 'Print parameters' -> 'Data integrity' -> 'Cali-
brate sensor' menu.
The 'Calibrate sensor' menu page opens.
2. Select settings:
■ depending on the message, 'Automatic' or 'Specify mark'
■ depending on the message, 'Upper sensor' or 'Lower sensor'

The necessary work steps are displayed.
For information on the icons displayed on the operator panel under 'Steps':
Each step is described in more detail under 'Details'.

Proceed as follows:
3. Switch off web buffer module
and vacuum unit at the operat-
ing switches.
4. Only for 'Specify mark':

If the paper web is not yet in the
printing system with the pages
correctly aligned, you first need
to position it. Move the horizon-
tal perforation or a mark to the
insert mark of the printing sys-
tem using the 'ADVF' or 'AD-
VR' buttons.
5. Click the 'OK' button to confirm that the paper web is properly aligned:
Calibration is starting.

Proceed as follows:
6. Reactivate the web buffer mod-
ule and vacuum unit at the oper-
ating switches.
7. Click on the 'OK' button to complete the calibration.

When the process is finished, the status display 'Last calibration - upper print
unit' or 'Last calibration - lower print unit' is updated.
When the 'Failed' result is displayed, recalibration is necessary. If the 'Very
good contrast' result is displayed, the menu can be closed.

Converting the Printing System
Prerequisites
The following prerequisites have to be satisfied for conversion of the printing system:
■ The relevant activation is installed.
■ The access ticket has been requested.
■ The printing system is in the 'Stop' or 'Operator intervention necessary' status.
To Convert the Printing System

#
Proceed as follows:
1. On the operator panel, select the 'Configuration' -> 'Print parameters' ->
'Configurator' menu.
2. Select the desired printer type under 'Selecting the printer type'.
3. Select whether 'I mode support of PDF containers' is required.
4. Click the 'Next' button and select the available settings one after the other,
e.g.
■ Print Speed
■ Color Setup
By loading a setup, all settings are made that were saved for the selected
printer type.
■ Job Setup
■ Raster kit
If necessary, you can return to the previous menu window using the 'Back'
button.
Note
Raster angle, tone transfer curve sets and coloration levels are automatically
set depending on the configuration.

Proceed as follows:
5. When all settings are complete, click the 'Apply' button.
6. If necessary, any required mechanical conversion steps are reported via error
messages after configuration. You can find more detailed information on the
procedure under:
■ ‘Removing the paper web ’ on page 155
■ ‘Inserting the Paper Web’ on page 143

Emptying Condensation Water
Emptying Condensation Water
Introduction
By default, the condensation water that is created during operation of the heat exchanger
and the recooler is routed directly into the domestic drains.
If this is not possible, the provided containers should be used. The fill level is monitored
here by a water level indicator.
Note:
Before the two 9 V-E block batteries of the water level indicator become flat, a warning
will sound every 2–3 minutes. The batteries must then be replaced.
To empty the condensation water

#
Proceed as follows:
1. If necessary, insert the hose in
the second container and empty
the full container.

Switching off the Printing System
To Switch off the Printing System

#
Proceed as follows:
1. Click the 'Stop' button.
The printing system is switched to 'Stop' status.
2. Deactivate active channel links on the operator panel. To do this click the
'Channel control' button.
The 'Channels' menu is displayed.
Click on the following button to deactivate the channel:
During the time needed for deactivation, the connecting icon is shown in
yellow.
A deactivated channel is represented by the following icon:
3. Click on the following button on the operator panel:
and confirm the 'Do you really want to power off the printing system?' query.
When the printing system has switched to standby mode after around three
minutes, the Operator Attention Light goes out and the "ON" key lights up
yellow. For cooling, the fans of the fuser station continue running for another
half hour.
Caution
Observe the waiting period
The controller requires this time to back up the data. Switching off prematurely
via the main circuit breaker can lead to data loss.

Proceed as follows:
4. If the printing system is to be
disconnected from the power
supply:
Turn off the main circuit break-
er.
5. If necessary, the main circuit

breaker can also be secured
against accidental switching on:
Swivel the safety handle down.

Proceed as follows:
6. Set the main circuit breaker of
the external recooler to 'OFF'.

Chapter 7
Cleaning the Printing Sys-
tem
Cleaning the Printing System — Overview
Introduction
This section shows you how often to clean the different components and how to carry
out this cleaning.
Caution:
■ Printing system could start unexpectedly.
Before cleaning, ensure that the printing system is in the 'Stop' status and that the
printing system is not being remotely controlled by another operator panel.
■ There is a danger of slipping on toner or developer spill.
Clean up spilled toner or developer immediately using a damp cloth or vacuum
cleaner. Do not use warm water as it makes the material soft and sticky.
■ There can be a high build-up of static charge when vacuuming the toner spill.
and filter set for fine dust. For larger toner quantities, the industrial vacuum cleaner
must be explosion-proof.
Attention:
■ The printing system may be damaged if the wrong cleaning materials or equipment
are used. Only use the prescribed cleaning materials and equipment (see ‘Cleaning
Agents and Cleaning Intervals’ on page 270). Please follow the manufacturer's safety
directives. Do not use chemical solvents or other aggressive cleaning materials.
■ Spilled toner is contaminated.
Re-using spilled toner causes printing problems. Never use spilled toner for printing.
Note:
■ To remove the paper web from the printing system before cleaning: see ‘Removing
the paper web ’ on page 155.
■ To reinsert the paper web after cleaning: see ‘Inserting the Paper Web’ on page 143.
Overview
■ ‘Cleaning Agents and Cleaning Intervals’ on page 270
268 Chapter 7 - Cleaning the Printing System

■ ‘Cleaning the Surface of the Developer Stations — Overview’ on page 273

■ ‘Cleaning the Paper Input’ on page 283
■ ‘Cleaning the Paper Output’ on page 286
■ ‘Cleaning the Paper Path’ on page 289
■ ‘Checking the Paper Path’ on page 296
■ ‘Cleaning the Toner Suction System’ on page 301
■ ‘Cleaning the Paper Brake Dust Filter’ on page 305
■ ‘Cleaning the Surface of the Printing System’ on page 307
■ ‘Cleaning the replacement cart for developer stations (option)’ on page 308
■ ‘Cleaning the Developer Station Shelf (Optional)’ on page 309
Chapter 7 - Cleaning the Printing System 269

Cleaning Agents and Cleaning Intervals
Cleaning Agent
The following resources should be used to clean the printing system:
#
Cleaning agent Purpose Comment

Cleaning agents To clean painted Caution
(standard store- and lacquered sur- Do not use chemical solvents or
bought quality) faces other aggressive cleaning agents.
Paper towels To clean areas Standard store-bought, lint-free tissues
soiled with toner, (e.g. KLEENEX, KALLE etc.)
developer and dust
Foam cloth To clean surfaces MOLTOPREN or similar qualities
Vacuum cleaner To remove paper Caution
dust and residue, The vacuum cleaner must have
toner and develop- a grounded suction tube.
er residue For vacuuming large quantities
of toner, use an explosion-proof
industrial vacuum cleaner.
Cleaning Intervals
The tables show the regular cleaning operations required for reliable and stable print op-
eration.
Each shift:
#
Cleaning location See section ...

Developer station ‘Cleaning the Surface of the Developer Stations —
Overview’ on page 273
Paper brake dust filter ‘Cleaning the Paper Brake Dust Filter’ on page 305


Paper input: ‘Cleaning the Paper Input’ on page 283
■ Paper width sensor
■ Paper web tensioner
■ Paper guide plates
■ Reject roller
■ Pressure rollers
■ Unclamp plate for autofeed
clamp
■ Paper brake
■ Pre-centering
Paper output: ‘Cleaning the Paper Output’ on page 286

■ Tension roller
■ Paper movement sensor
■ Data integrity sensor
■ Paper web
■ Paper guide plates
■ Additional feed
Each week:
#

Toner bottle holder ‘Cleaning the Toner Suction System’ on page 301
Waste toner box ‘Replace waste toner box’ on page 331
Additional Cleaning Operations

Every time the photoconductor belt and photoconductor blade are replaced:
#

Photoconductor unit rollers and ‘Removing Photoconductor Belt in Upper Print Unit
profiles and Replacing Photoconductor Blade’ on page 352
‘Removing Photoconductor Belt in Lower Print Unit
and Replacing Photoconductor Blade. ’ on page 364
Every time corotron wires are replaced:


Corotron slide-in unit ‘Replacing the corotron — overview’ on page 412
If there is a corresponding error message:

#

Paper path If unfused paper has been moved through the pa-
per output
or
If there are still bits of paper in the printing system
following a paper tear:
‘Cleaning the Paper Path’ on page 289
If there may still be bits of paper in the printing
system following a paper tear:
‘Checking the Paper Path’ on page 296
Toner suction system ‘Replacing the cleaning felt’ on page 448
If dirty:
#

Surfaces of the printing system ‘Cleaning the Surface of the Printing System’ on page
307
Maintenance cart for developer ‘Cleaning the replacement cart for developer stations
stations (optional) (option)’ on page 308
Movable developer station shelf ‘Cleaning the Developer Station Shelf (Optional)’
(optional) on page 309

Cleaning the Surface of the Developer Stations — Overview
Cleaning the Surface of the Developer

Stations
Cleaning the Surface of the Developer Stations — Overview
Caution:
■ The motor covers of the developer stations can be hot after extended printing.
Touching these components can result in burns.
Let the developer stations cool down, and put on heat-protecting gloves.
■ Also observe the other safety directives in the ‘Cleaning the Printing System — Overview’
on page 268 section.
Attention:
When vacuuming the toner, do not scratch the roller.
Use only a plastic or rubber attachment on the vacuum.
To Clean the Surfaces of the Developer Stations

#
Proceed as follows:
1. ‘Swiveling off Developer Stations’ on page 274.
2. ‘Cleaning Developer Station Surface’ on page 275.
3. ‘Swiveling on developer stations’ on page 282.

Swiveling off Developer Stations
Swiveling off Developer Stations
To Swivel off the Developer Stations

#
Proceed as follows:
2. On the operator panel, select the following menus and elements:
■ 'Select task':
All developer stations in a print unit at the same time ('All - upper print
unit' / 'All - lower print unit')
or 'Individual developer station'
■ If developer stations are to be swiveled individually, then also:
'Select print unit': 'Upper print unit' or 'Lower print unit'

'Select developer station': 'Station 5:' / ... / 'Station 1:'
3. To start the swivel off process for the selected developer stations, click the 'OK'
button.
4. To complete the swivel off process for the selected developer stations, click the
'OK' button.
The printing system remains in the 'Special functions' status.
5. Only if another developer station is to be swiveled off individually: repeat the
work steps from step 2.
6. Cleaning developer station surface see ‘Cleaning Developer Station Surface’ on

page 275.

Cleaning Developer Station Surface
To Clean the Surface of the Developer Station

#
Proceed as follows:
1. Open the doors on the printing system:
For a developer station in the lower print unit: ‘Opening Left Doors’ on page
161.
2. For a developer station in the upper print unit: ‘Opening Right Doors’ on page
157.
Proceed as follows:
Caution
guide rails. Take care not to stretch the toner hoses.
3. For every developer station, press
the lock button and slowly and
evenly pull the developer station
out to the stop point.

Proceed as follows:
Caution
■ There can be a high build-up of static charge when vacuuming the toner
spill.
When vacuuming, always use an explosion-proof industrial vacuum cleaner
with a grounded suction tube, rubber nozzle and filter set for fine dust.
■ When vacuuming the toner, do not scratch the rollers.
Use only a rubber attachment on the vacuum cleaner.
4. Vacuum the toner from the

housing and guide rails using the
vacuum cleaner.
5. Vacuum the entire width of the

photoconductor belt suction slot.
Caution
Do not damage roller.
Carefully hold the suction profile using both hands.

Proceed as follows:
6. Remove the suction profile from
the developer catch roller:
■ Pull out locking pin.
■ Carefully lift the suction pro-
file upwards using both

hands.
7. Vacuum suction profile.

Proceed as follows:
8. Remove the plastic caps from
both sides of the suction profile.
9. Carefully tap out the suction

profile onto a cloth or other soft
padding.
Caution
Always clean the holes on both sides of the suction profile in order to ensure
the necessary pressure balance for the suction.

Proceed as follows:
10. Vacuum both holes on both
sides of the suction profile.
Caution
When vacuuming the toner, do not scratch the roller.
Use only a rubber attachment on the vacuum cleaner.
Under no circumstances use brushes or other cleaning materials.
11. Carefully vacuum the entire
length of the developer catch
roller and slot.

Proceed as follows:
12. Reattach the plastic caps on both
sides of the suction profile.
Do not damage roller.

Carefully hold the suction profile using both hands.
13. Install the developer catch roller
suction profile:
■ Pull out locking pin.
■ Carefully insert the suction
profile using both hands.

■ Snap in locking pin.
■ Check whether the toner
hose is still firmly attached to

the connecting pipe.
Caution
Take care not to pinch the hose when pushing in the developer stations.
Hold the hose to one side.

Proceed as follows:
14. Reinsert all developer stations
until they latch into place.
15. Close all printing system doors:

16. ‘Swiveling on developer stations’ on page 282.

Swiveling on developer stations
Swiveling on developer stations
To Swivel on a Developer Station

#
Proceed as follows:
1. Switch printing system on.
■ 'Select task':
All developer stations in a print unit at the same time ('All - upper print
unit' / 'All - lower print unit')
'Individual developer station' or
■ 'Select action to be executed': 'Swivel on'
■ If developer stations are to be swiveled individually:
'Select print unit': 'Upper print unit' or 'Lower print unit'

'Select developer station': 'Station 5:' to 'Station 1:' (it is essential to note
the following sequence: 1 - 2 - 3 - 4 - 5)
3. To start the swivel on process for the selected developer stations, click on the
'OK' button.
Information on the icons displayed on the operator panel under 'Steps': ‘Expla-
nation of icons’ on page 134.
4. To complete the swivel on process for the selected developer stations, click on
the 'OK' button.
5. Only if another developer station needs to be swiveled on individually: Repeat
steps from step 2.
6. To complete swiveling on the developer stations:
■ To carry out further maintenance work directly afterwards, click the 'OK'
button.
■ To complete all maintenance work, click the 'Ready' button.
All printing system assemblies are checked (duration around two minutes),
before the printing system is switched to the 'Stop' status.
To switch the printing system to the 'Ready' status, click the 'Ready' button
again.

Cleaning the Paper Input
Caution:
There can be a high build-up of static charge when vacuuming the toner spill.
and filter set for fine dust. For larger toner quantities, the industrial vacuum cleaner must
be explosion-proof.
Caution:
Before cleaning, observe the safety directives in the ‘Cleaning the Printing System —
Overview’ on page 268 section.
To Clean the Paper Input

#
Proceed as follows:
■ 'Replace consumables' -> 'Cleaning the printing system' menu
■ 'Select cleaning function': 'Clean paper input'
Caution
The paper input rocker opens automatically.
Do not stand directly in front of the rocker.
3. Click the 'OK' button to start
cleaning the paper input.
The paper input rocker is
opened.
For information on the icons displayed on the operator panel under 'Steps',

Proceed as follows:
4. Carefully clean the paper width
sensor on both sides with a dry
cloth.
Caution
Always use an industrial vacuum cleaner with a grounded suction tube, rubber
nozzle and filter set for fine dust. For larger toner quantities, the industrial
vacuum cleaner must be explosion proof.
5. Clean the following with a vacu-
um cleaner and dry cloth:
■ Paper web tensioner and
plate opposite the paper web

tensioner
■ Paper guide plates (including
all joints, edges and ventila-

tion holes)

■ Reject roller
(turn the rollers to ensure

complete cleaning)

Proceed as follows:
■ Unclamp plate for the aut-
ofeed clamp
■ Paper brake
■ Pre-centering
8. Push the paper input rocker

down until it latches.
9. Complete cleaning the paper input on the operator panel:

button.
again.

Cleaning the Paper Output
Caution:
be explosion-proof.
Caution:
To Clean the Paper Output

#
Proceed as follows:
■ 'Select cleaning function': 'Clean paper output'

Proceed as follows:
Caution
The flap of the paper output opens automatically.
Do not stand directly in front of the flap.
3. Click the 'OK' button to start

cleaning the paper output.
The flap on the paper output is
opened.
4. Using a dry cloth, carefully clean
the following:
■ Both tension rollers and all
pressure rollers (turn the

rollers to ensure complete
cleaning)
■ Paper movement sensor (turn
the wheel to ensure complete

cleaning)
Caution
vacuum cleaner must be explosion-proof.

5. Vacuum paper web and paper

guide plates.
6. Close paper output flap.
7. Complete cleaning the paper output on the operator panel:

button.
again.

Cleaning the Paper Path
Caution:
be explosion-proof.
Caution:
To Clean the Paper Path

#
Proceed as follows:
■ 'Select cleaning function': 'Clean paper path'
Caution
The paper input rocker and the paper output flap open automatically.
Do not stand directly in front of the paper input or output.
3. To start cleaning the paper path, click the 'OK' button.
Caution
Wait until preparation is complete
The doors must not be opened before the relevant message is displayed on the
operator panel.

Proceed as follows:
4. Open all doors on the printing system:
■ ‘Opening Right Doors’ on page 157.
■ ‘Opening Left Doors’ on page 161.
5. At the paper input:

Carefully clean the paper width
sensor on both sides with a dry
cloth.
Caution
■ Paper web tensioner and
plate opposite the paper web

tensioner
■ Paper guide plates (including
all joints, edges and ventila-

tion holes)

Proceed as follows:
■ Reject roller
(turn the rollers to ensure

complete cleaning)

■ Unclamp plate for the aut-
ofeed clamp
■ Paper brake
■ Pre-centering


Proceed as follows:
10. At the paper output, carefully
clean the following with a dry
cloth:
■ Both tension rollers and all
pressure rollers (turn the

rollers to ensure complete
cleaning)
■ Paper movement sensor (turn
the wheel to ensure complete

cleaning)
Caution
11. Vacuum paper web and paper
guide plates.

Proceed as follows:
12. On both sides of the printing
system:
Carefully check the entire paper
path in the print unit and re-
move all paper residue and vacu-
um the paper dust.
13. Open the paper cooling cover on

the left-hand side of the printing
system.
14. Swivel up the blower unit using

the handle.

Proceed as follows:
Caution
Beware of the edges of the open blower unit.
Watch out for the edges of the blower unit when checking and cleaning the
nozzle casing.
15. Check nozzle casing and remove
all paper residue and vacuum the
paper dust.
16. Close the blower unit and paper cooling cover.

Caution
The fuser station may only be opened and worked on by Service.
When checking the paper path, do not open the covers of the fuser station.
17. From the open paper output:
Check the paper path inside the
fuser station for paper residue.
Also check from both sides of
the print unit.
If you find paper residue in the
fuser station: Notify Service.

Proceed as follows:
19. If the sensors have detected paper web residue in the printing system, respond
to the additional query on the operator panel:
■ If absolutely all paper web residue has been removed from the paper input,
the print unit, paper cooling and paper output, click the 'Yes' button.
■ If you were unable to remove all paper web residue or there is still paper
residue in the fuser station, click the 'No' button and notify Service.
20. Close all printing system doors.

■ ‘Closing Left Doors’ on page 163.
■ ‘Closing Right Doors’ on page 159.
21. Complete the cleaning of the paper path on the operator panel:
button.
again.

Checking the Paper Path
Caution:
To Check the Paper Path

#
Proceed as follows:
■ 'Select cleaning function': 'Check paper path'
Caution
The paper input rocker and the paper output flap open automatically.
Do not stand directly in front of the paper input or output.
3. Click the 'OK' button to start checking the paper path.
Information on the icons displayed on the operator panel under 'Steps':
‘Explanation of icons’ on page 134
Caution
operator panel.
4. Open all doors on the printing system:

Proceed as follows:
5. On both sides of the printing
system:
Carefully check the entire paper
path in the print module and re-
move all paper residue and vacu-
um the paper dust.
6. Push paper input rocker down

until it latches.
7. Open the paper cooling cover on

the left-hand side of the printing
system.

Proceed as follows:
8. Swivel up blower unit by the
handle.
Caution
Watch out for the edges of the blower unit when checking and cleaning the
nozzle casing.
9. Check nozzle casing and remove
all paper residue and vacuum the
paper dust.
10. Close blower unit and paper cooling cover.

Caution
The fuser station may only be opened and worked on by Service.
When checking the paper path, do not open the covers of the fuser station.

Proceed as follows:
11. From the open paper output:
■ Check the paper path inside
the fuser station for paper

residue.
■ Also check from both sides of
the printing module.

■ If you find paper residue in
the fuser station: Notify Ser-

vice.
13. Join the ends of the paper rips together and check whether bits of paper are
missing.
If the sensors have detected paper web residue in the printing system, respond
to the additional query on the operator panel:
■ When all paper web residue has been properly removed, click on the 'Yes'
button.
■ If you were unable to remove all paper web residue or there is still paper
residue in the fuser station, click the 'No' button and notify Service.


Proceed as follows:
15. Complete the paper path inspection on the operator panel:
button.
again.

Cleaning the Toner Suction System
Caution:
be explosion-proof.
Caution:
To Clean the Toner Suction System

#
Proceed as follows:
2. Open the doors on the console.
3. Use the handle to pull the toner

bottle holder out.

Proceed as follows:
4. Tip the toner bottle holder for-
ward by the locking lever until
it latches.
5. Pull the locking lever upwards

and open the lock.
Caution
This can soil hands and clothing.
Wear gloves.
6. Remove the toner bottle.
Caution

Proceed as follows:
7. Use an explosion-proof industrial
vacuum cleaner and a lint-free
cloth to clean the following:
■ Reader
■ Surface of the toner suction
head
■ Toner suction hose (through
the toner suction head).

■ Toner bottle holder
8. Open the door shown on the

right-hand side of the printing
system.

left-hand side of the printing
system.

Proceed as follows:
10. ■ On the left-hand side of the
printing system:
Remove the hose from the
respective developer station
and vacuum it clean.
Then reattach hose.
■ On the right-hand side of the
printing system:
Remove the hose from the
respective developer station
and vacuum it clean.
Then reattach hose.
11. Reinsert the toner bottle into the

toner bottle holder on the con-
sole.
Press the locking lever of the
toner suction head down, thus
closing the toner bottle.
12. Pull handle upwards until toner

bottle holder is turned.
Then push the handle back to
swivel the toner bottle holder
back into the printing system to
the stop point.
13. Close all doors.

Cleaning the Paper Brake Dust Filter
Caution:
be explosion-proof.
Caution:
To Clean the Paper Brake Dust Filter

#
Proceed as follows:
2. Undo the knurled screw, unlock
the cover plate in the direction
of the arrow and remove.

Proceed as follows:
3. Clean the dust filter and vacuum
off paper dust.
4. Refit the cover plate and tighten

the knurled screw.

Cleaning the Surface of the Printing System
Cleaning the Surface of the Printing System
Caution:
be explosion-proof.
Caution:
To Clean the Surface of the Printing System

#
Proceed as follows:
1. Clean the floor around the printing system with a vacuum cleaner.
Caution
Fluid can get inside the printing system. This could cause irreparable damage
to the electrical and mechanical components.
Do not place cleaning fluids on top of or in the immediate vicinity of the
printing system and ensure that no fluids enter the printing system.
2. Cleaning the surface of the housing:
■ Add some mild household detergent to water and dip a soft cloth into the
solution.
■ Wring the cloth out well. Use it to wipe down the surface of the housing.

Cleaning the replacement cart for developer stations (option)
Cleaning the replacement cart for developer stations (option)
Caution:
be explosion-proof.
Attention:
Avoid damage
Do not use high pressure cleaners to clean, as these may damage the electronics and the
undercarriage.
To clean the replacement cart for developer stations (option)

#
Proceed as follows:
1. Vacuum off toner and developer residue.
2. Clean the replacement cart with a cleaning agent suitable for varnished surfaces,
aluminum and stainless steel (observe the information from the manufacturer
of the cleaning agent).
3. Dry the replacement cart with a cloth.

Cleaning the Developer Station Shelf (Optional)
Caution:
■ Heavy weight
When fully equipped with 4 developer stations, the developer station shelf weighs
approx. 360 kg/800 lb. Secure the developer station shelf to prevent it from rolling
away. Take care on steep slopes and ramps.
■ Hot surfaces
Caution:
be explosion-proof.
Attention:
The developer station shelf must not be cleaned while developer stations are fitted.
Liquid or dirt could get inside a developer station and damage or destroy it.
To Clean the Developer Station Shelf

#
Proceed as follows:
1. If the developer station shelf is not empty: Use the hoisting lift to remove all
developer station and place them on a stacking tray (see ‘Removing the Devel-
oper Station from the Developer Station Shelf’ on page 183).
2. Remove large amounts of dust or toner using the vacuum cleaner.
3. Clean the surfaces of the developer station shelf using a soft, dry cloth. If nec-
essary, use a lightly damp cloth (water with a small amount of washing-up
liquid) that has been wrung out.
4. Remove any dirt jammed into the casters.
5. If required: Use the hoisting lift to replace the developer stations in the devel-
oper station shelf (see ‘Storing the Developer Station in the Developer Station
Shelf’ on page 177).


Chapter 8
Replacing Consumables
Replacing Consumables — Overview
Replacing Consumables — Overview
Replacing consumables
This section describes in detail all the steps required to replace consumables. It also provides
the order numbers and package units for all consumables.
Overview
Note:
An error message in the operator panel notifies you that it is time to replace a consumable.
If the consumable is not replaced before a particular number of pages are printed, the
printing system stops and displays an error message. The consumable must then be re-
placed.

■ ‘Order Numbers and Packing Units’ on page 313
Toner:
■ ‘Toner Bottle Identification with Océ TonerSafe’ on page 314
■ ‘Toner Supply with Additional Colors’ on page 317
■ ‘Refilling Toner (Standard: 6 kg / 13.2 lb Toner Bottle)’ on page 318
■ ‘Refilling Toner (Option: 1 kg / 2.2 lb Toner Bottle)’ on page 324
■ ‘Replace waste toner box’ on page 331
■ ‘Filling a Toner Box’ on page 335
Developer:
■ ‘Replacing the Developer - Overview’ on page 336
312 Chapter 8 - Replacing Consumables

Order Numbers and Packing Units
Order Numbers and Packing Units
Introduction
We recommend that you use toner and developer from Océ Printing Systems GmbH to
ensure the highest printing and fusing quality and to maintain high standards of availabil-
ity for the printing system.
Toner
#
Consumable Packaging unit/order number

Toner Color name Default: Two bot- Option: Six bot-
tles of 6 kg tles of 1 kg (2.2 lb)
(13.2 lb) each each
black OCT20A01 KK01-C65-G10 —
Cyan OCT55C01 CU02-C65-G20 —
Magenta OCT56M01 MU02-C65-G20 —
yellow OCT88Y01 YU02-C65-G20 —
blue OCT36B01 BU02-C65-G20 BU02-C65-R20
green OCT66G01 GU02-C65-G20 GU02-C65-R20
red OCT57R01 RU02-C65-G20 RU02-C65-R20
Note:
Many other Océ CustomTone colors are available upon request. For more information,
please contact our Oce Service personnel.
Developer
#
Consumable Packing Unit Order number

Developer 1 bottle weighing 5 kg KK01-C35-L10
(11.0 lb).
Chapter 8 - Replacing Consumables 313

Toner Bottle Identification with Océ TonerSafe
Toner
Introduction
Replacing toner bottles is not only easy, but also safe with Océ TonerSafe. Whenever a
toner bottle is inserted into the printing system, the data on the toner bottle RFID
transponder is read via a reader and analyzed by the printing system. This toner bottle
identification ensures that the toner bottle is assigned correctly and clearly to the developer
stations.
Note:
The most important toner data and current filling level are displayed on the operator
panel in the 'Toner bottle identification' menu.
Important Components for Toner Bottle Identification

#
Toner bottle with 6 kg (13.2 lb):
4
2

Toner bottle with 1 kg (2.2 lb):
1
3
2
4
1 Transponder
2 Toner bottle
3 Reader
4 Toner bottle holder
Description
If a toner bottle with the proper toner type is identified, toner is drawn from the toner
bottle into the toner boxes of the assigned developer stations.
To avoid printing a print job with the wrong color or an unknown toner, the printing
process is stopped when printing starts if:
■ a toner bottle with an incorrect toner type is identified. A message is displayed on the
operator panel notifying the operator that the toner bottle must be replaced by a toner
bottle with the correct toner type.
■ the toner bottle cannot be identified at all (because either no toner bottle is inserted
or the transponder on the toner bottle is faulty or missing, or the reader is faulty). A

message is displayed on the operator panel listing several possible ways to remedy the
situation.
Caution
If desired, TonerSafe can be permanently turned off. Although not recommend-
ed, disabling TonerSafe will enable the printing system to use toner that is not
best suited to the developer stations, such as non-Océ approved toner. The
operator will be warned if the toner cannot be verified and given the choice
to continue or try a new bottle.
If the operator confirms that printing should continue, toner continues to be
drawn from the toner bottle into the toner boxes of the assigned developer
stations. This may result in toner of the wrong color being sucked in, which
will result in considerable soiling of the toner suction system and the developer
stations. Damage to the printing system cannot be ruled out in this case.
Customers wishing to disable TonerSafe should notify Service in accordance
with the instructions in the 'Service ticket' menu.

Toner Supply with Additional Colors
Toner Supply with Additional Colors
Introduction
By default, the developer stations are supplied by a toner suction system consisting of
toner bottles weighing 6 kg (13.2 lb) each (see ‘Refilling Toner (Standard: 6 kg / 13.2 lb
Toner Bottle)’ on page 318). As an option, the developer stations for CustomTone colors
can also be filled with 1kg (2.2 lb) each (see ‘Refilling Toner (Option: 1 kg / 2.2 lb Toner
Bottle)’ on page 324).
Attention:
Asymmetric Configuration
For CustomTone printing systems, different colors can be used in the upper and lower
print units. Asymmetric configurations of developer stations are possible between the
upper and lower print units. In this way, for example, it is possible for Service to enable
three slots in the upper print unit and two slots in the lower print unit.
In the case of full-color printing systems, a fixed installation sequence is defined for CMYK
color stations. Additional CustomTone color stations can be configured asymmetrically.
Additional Color Stations

In the case of CustomTone printing systems, free and unoccupied slots for developer
stations can also be used as "shelves" for developer stations with additional colors after
being prepped by Service personnel. This enables the activation of different color stations.
If more colors are required than the number of slots available, it is necessary to replace
the developer station (see ‘Replacing the developer station — overview’ on page 165).

Refilling Toner (Standard: 6 kg / 13.2 lb Toner Bottle)
Caution:
■ Do not allow toner to come into contact with the eyes. In the event of contact with
the eyes, rinse eyes with plenty of cold water and seek medical attention.
■ Avoid contact with the skin. In the event of contact with the skin, wash toner off with
plenty of cold water.
■ Do not inhale toner. Avoid accumulation of dust. If, after inhaling toner, you experi-
ence symptoms such as nausea, headaches or dizziness, go out into the fresh air imme-
diately.
■ Do not spill toner. You can slip on spilled toner. Clean up spilled toner or developer
immediately using a damp cloth or vacuum cleaner. Do not use warm water as it
makes the toner soft and sticky.
■ Always use an industrial vacuum cleaner with a grounded suction tube, rubber nozzle
must be explosion proof.
■ Keep toner out of the reach of children and store it away from containers used for
food and drink.
Attention:
■ Only use permitted toner that is suitable for the developer being used.
■ Only use original, sealed toner bottles secured by an intact band.
■ Do not re-use toner.
■ Always store toner in a cool (< 35° C/95° F), dry, and well-ventilated space.
■ Never expose toner to direct heat (sunlight, heaters, etc.)
Note:
Toner can be refilled during print operations. Depending on the print image, you still
have a few minutes after the warning is displayed before the printing system stops due
to lack of toner.
To Refill the Toner (Standard: 6 kg / 13.2 lb Toner Bottle)

#
Proceed as follows:
1. Open the doors on the console.

Proceed as follows:
Note
The graphics here show an example of how the toner is refilled in the console
at installation position 1. More detailed information about the color allocation
in the console can be found in the ‘Console’ on page 62 section.
2. Use the handle to pull the toner
bottle holder out.
3. Tip the toner bottle holder for-

ward using the locking lever un-
til it latches.

Proceed as follows:
4. Pull the locking lever upwards
and open the lock.
5. Remove the empty toner bottle.

Note
Only use permitted toner suitable for the developer being used (see ‘Order
Numbers and Packaging Units for Expendables’ on page 349).
6. Tip the new toner bottle of the
same toner type briefly down-
wards and upwards once, then
remove the adhesive tape.
7. Screw the lid of the new toner bottle onto the empty toner bottle.

Proceed as follows:
8. Place the new toner bottle into
the toner bottle holder.
Press the locking lever of the
toner suction head down, there-
by closing the toner bottle.

Proceed as follows:
Caution
The inserted toner bottle is then
checked.
The LED beside the toner bottle
holder (white arrow) indicates
whether the inserted toner bottle
contains the correct toner type
and whether the toner suction
head is locked:
■ Green
Toner bottle identified and

toner suction head locked.
Continue with step 9.
■ Yellow
Toner suction head not

locked. Check that the toner
bottle has been fitted correct-
ly. Then repeat step 8.
■ Flashing yellow
Toner bottle empty. Repeat

procedure from step 2.
■ Red
The toner bottle could not

be identified. No toner bottle
has been inserted or the
transponder on the toner
bottle is faulty or not present,
or the reader is faulty. Cor-
rect the problem according
to the information in the er-
ror message displayed on the
operator panel.

Proceed as follows:
9. Pull handle upwards until toner
bottle holder is turned.
Then push the handle back to
swivel the toner bottle holder
back into the printing system to
the stop point.
10. Close door.

The message is automatically deleted from the operator panel.
Caution
The empty toner bottle is used to replace a waste toner box.
Keep the empty toner bottle.

Refilling Toner (Option: 1 kg / 2.2 lb Toner Bottle)
Caution:
diately.
food and drink.
Attention:
■ Only use permitted toner that is suitable for the developer being used.
■ Only use original, sealed toner bottles secured by an intact band.
■ Always store toner in a cool (< 35° C/95° F), dry, and well-ventilated space.
■ Never expose toner to direct heat (sunlight, heaters, etc.)
Note:
The toner for CustomTone colors can be refilled from 1 kg (2.2 lb) toner bottles during
active printing. Depending on the print image, you still have a few minutes after the
warning is displayed before the printing system stops due to lack of toner. However, if
highest levels of print quality are to be maintained, we recommend that the toner from
1 kg (2.2 lb) toner bottles is not refilled during printing since this requires the opening
of a door on the printing system.

To Refill the Toner (Option: 1 kg / 2.2 lb Toner Bottle)

#
Proceed as follows:
1. If toner needs to be filled in the
lower print unit:
Open the door shown on the
system.
If toner needs to be filled in the

upper print unit:
system.
Caution
Only use permitted toner suitable for the developer being used (see ‘Order
Numbers and Packing Units’ on page 313).
Proceed as follows:
2. Shake the new, sealed toner bot-
tle vigorously.

Proceed as follows:
Caution
The toner bottle must be shaken
vigorously enough so that the
toner moves like a fluid in the
toner bottle. The shaken volume
increases with the locked-in air
to such an extent that the toner
almost completely fills the toner
bottle (see illustration).

Proceed as follows:
3. Insert the new toner bottle into
the reader on the inside of the
door.
The toner bottle is checked. The
LED on the reader (white arrow)
indicates:
■ Flashing yellow
The toner bottle is being

identified; the process is not
yet complete.
■ Green
The toner bottle has been

identified.
■ Red
The toner bottle could not

be identified. No toner bottle
has been inserted or the
transponder on the toner
bottle is faulty or not present,
or the reader is faulty.
Correct the problem accord-
ing to the information in the
error message displayed on
the operator panel.
The LED on the toner box of the associated developer station indicates:
■ Flashing green/green/off
This toner box is full or still sufficiently filled.

■ Flashing yellow/yellow
The toner supply is nearly empty. Toner should be refilled.

■ Flashing red/red
The toner supply has run out. Toner must be refilled.

Proceed as follows:
4. Remove the toner bottle from
the reader and shake vigorously
again for a few seconds.
Caution
The toner bottle must be shaken
vigorously enough so that the
toner moves like a fluid in the
toner bottle. The shaken volume
increases with the locked-in air
to such an extent that the toner
almost completely fills the toner
bottle (see illustration).
5. Insert the toner bottle into the

holder on the toner box as
shown and tip it backwards until
it engages.

Proceed as follows:
6. Pull out the handle under the
toner bottle in order to open the
filler cap of the toner box.
The filler cap of the toner box
releases the opening of the toner
bottle at the same time.
Caution
Wait until the toner bottle is empty.
Do not tap against the toner bottle and do not shake the toner bottle.
Tapping or shaking the toner bottle can damage the developer station. Tapping
or shaking will not help toner to flow into the toner box. Instead, if the toner
bottle does not completely empty:
■ Push the handle under the toner bottle in again to close the filler cap of
the toner box (see step 7).

■ Tip the toner bottle forward and remove it (see step 8).
■ Shake the toner bottle vigorously again for a few seconds.
■ Insert the toner bottle into the holder on the toner box and tip it backwards
until it engages (see step 5).

■ Pull out the handle under the toner bottle in order to open the filler cap
of the toner box (see step 6).

Proceed as follows:
7. When the toner bottle is com-
pletely emptied, push the handle
under the toner bottle in again
to close the filler cap of the toner
box.
The filler cap of the toner box
closes the opening of the toner
bottle at the same time.
Caution
The handle under the toner bottle must be pushed in to be able to remove the
toner bottle.
8. Tip the toner bottle forwards
and remove, as illustrated.
9. Close door.

Replace waste toner box
Introduction
The used developer is also sucked into the waste toner box via a vacuum system. When
the waste toner box has reached its maximum filling level, a warning appears on the op-
erator panel. Depending on the print image, you still have approx. 30 minutes after the
warning is displayed before the printing system stops and displays an error message.
Caution:
diately.
food and drink.
Attention:
■ The waste toner box can only be replaced when printing is stopped.
■ Keep used toner ready for collection by Service or the contracted shipping company.
To Replace the Waste Toner Box

#
Proceed as follows:
1. If the printing system has not yet stopped, click the 'Ready' button.

Proceed as follows:
2. Open the door on the filter
module.
3. Pull the locking lever down and

tip the waste toner box forward
to the stop point.
4. Remove the lid from the empty

toner bottle and screw it onto
the full toner bottle.
Remove the full toner bottle.
Caution

Proceed as follows:
5. Clean the interior and exterior
of the waste toner box using an
explosion-proof industrial vacu-
um cleaner and a lint-free cloth.
6. Insert the empty toner bottle as

shown.
7. Push the locking lever upwards

with a swiveling motion and lock
the waste toner box.

Proceed as follows:
8. Vacuum the vat beneath the
waste toner box using an explo-
sion-proof industrial vacuum
cleaner.
9. Close door.

Filling a Toner Box
Filling a Toner Box
Introduction
Note:
The developer station toner boxes normally always contain a sufficient amount of toner,
as toner is automatically fed from the toner bottle to the toner box when required. Filling
a toner box will therefore only be necessary in exceptional cases. It is only possible to fill
a toner box in the 'Ready' or 'Operator intervention necessary' status.
To Fill the Toner Box

#
Proceed as follows:
■ 'Replace consumables' -> 'Fill toner box' menu
■ 'Select print unit': 'Upper print unit' or 'Lower print unit'
■ 'Select developer station'
2. Click the 'OK' button to start filling the toner box.

Information on the icons displayed on the operator panel under 'Steps': see
‘Explanation of icons’ on page 134.
3. Exit toner box filling:
button.
All printing system assemblies are checked (duration approx. two minutes)
again.

Replacing the Developer - Overview
Developer
Replacing the Developer - Overview
Caution:
■ Do not allow developer to get into eyes. In the event of contact with eyes, rinse eyes
out with plenty of water and seek medical attention.
■ Avoid contact with the skin. If the developer comes into contact with the skin, wash
with plenty of water.
■ Do not inhale developer. Avoid accumulation of dust. If after inhaling developer, you
experience symptoms such as nausea, headaches or dizziness, go out into the fresh air
immediately.
■ Do not spill developer. You can slip on spilled developer. Clean up developer spills
immediately.
and filter set for fine dust. For larger quantities, the industrial vacuum cleaner must
be explosion proof.
■ Keep developer out of the reach of children and store it away from containers used
for food and drink.
Attention:
■ The developer can only be replaced when printing is stopped.
■ Only use approved developer (see ‘Order Numbers and Packing Units’ on page 313).
■ Only use original, sealed developer bottles secured by an intact band for refilling.
■ Do not re-use developer.
■ Always store developer in a cool (< 35°C/95°F), dry and well-ventilated space.
■ Never expose developer to direct heat (sunlight, heaters etc.)
■ Keep used developer ready for collection by Service or the contracted shipping com-
pany.
Overview
The printing system automatically detects the end of the developer's service life and displays
a warning on the operator panel. The procedure for replacing the developer is the same
for the upper and the lower print unit:
■ ‘Draining the Developer Mixture’ on page 337
■ ‘Fill in Developer’ on page 340

Draining the Developer Mixture
Caution:
Observe the safety directives in the ‘Replacing the Developer - Overview’ on page 336 section.
Attention:
The used developer mixture is sucked into the waste toner box via a vacuum system.
Before draining the developer mixture, check whether there is still enough space for it in
the waste toner box; you should also ensure that the waste toner box can still be lifted
out when filled with the additional developer mixture (approx. 5.5 kg/12.1 lb). Otherwise,
the waste toner box must be changed first (see ‘Replace waste toner box’ on page 331).
To Drain the Developer Mixture

#
Proceed as follows:
1. If the printing system has not yet stopped, click the 'Ready' button:
■ 'Replace consumables' -> 'Replace developer' menu
■ 'Select developer station': 'Station 1:' to 'Station 5:'
■ 'Select action': 'Drain mixture'
3. Click the 'OK' button to start developer replacement.

Caution
Wait until preparation is complete:
operator panel.

Proceed as follows:
4. To drain the developer mixture
from a developer station in the
lower print unit:
system.
To drain the developer mixture

from a developer station in the
upper print unit:
system.
5. Turn the vacuum hose to the left

and pull it out of the support.
(The following illustrations show
developer station 1 in the upper
print unit. The procedure is the
same for all developer stations.)
6. Insert the vacuum hose into the

opening below the developer
station and turn it to the right
to lock.
The suction of the developer is
started automatically. After ap-
prox. nine minutes, the suction
stops and the blower keeps run-
ning.
7. Repeat as needed. To do this, click on the 'Yes' button on the operator panel.
When the developer has been completely removed, click the 'No' button.

Proceed as follows:
8. Turn the vacuum hose to the left
and remove it.
9. Put the vacuum hose back onto

the support and turn it to the
right to lock.
The blower stops automatically.
10. On the operator panel, select whether the new developer is to be refilled now:
■ Click the 'Yes' button to fill the developer directly afterward.
The printing system remains in the 'Stop' status. The developer can be
filled.
■ To fill the developer later, click the 'No' button.
Close doors. All printing system assemblies are checked (duration approx.
two minutes).
Result
The developer mixture is fully drained. Detailed information on filling the developer is
provided in section ‘Fill in Developer’ on page 340.
Note:
To avoid the waste toner box becoming too heavy, we recommend changing it every
time you drain the developer mixture (see ‘Replace waste toner box’ on page 331).

Fill in Developer
Fill in Developer
Caution:
Observe the safety directives in the ‘Replacing the Developer - Overview’ on page 336 section.
Attention:
Ensure that there is enough toner in the developer station.
In order to achieve the necessary mixture, there must always be sufficient toner in the
developer station before the developer can be filled.
To Fill the Developer

#
Proceed as follows:
1. If the developer is not filled immediately after draining:
On the operator panel, select the following menus and elements:
■ 'Replace consumables' -> 'Replace developer' menu
■ 'Select developer station': 'Station 1:' to 'Station 5:'
■ 'Select action': 'Refill developer'
Click the 'OK' button to start the process.

Caution
operator panel.

Fill in Developer
Proceed as follows:
2. To fill the developer in a develop-
er station in the lower print unit:
system.
To fill the developer in a develop-

er station in the upper print unit:
system.
3. Place filling aid funnel and hose

at the ready.
4. Remove the lid of the developer

bottle and put the developer
bottle into the filling aid insert.

Fill in Developer
Proceed as follows:
5. Put the funnel onto the develop-
er bottle, fit the seal onto the in-
sert and press down.
6. Snap the hose onto the filler cap

of the developer station and hang
the developer bottle upside down
on the support.
Adjust the height of the support
so that there is no bend in the
hose.
7. Remove the sealing clamp from

the hose.
8. Click the 'OK' button to start the filling process.

The blower is switched on automatically. The developer runs into the developer
station without being shaken. After approx. four minutes, the filling process
is completed; the blower continues to run.

Fill in Developer
Proceed as follows:
9. Check hose to see if the developer bottle is completely empty:
■ If the developer bottle was not completely emptied, restart process. To do
this, click on the 'Yes' button on the operator panel.

■ If the developer bottle has already been completely emptied, click the 'No'
button.
10. Reaffix the sealing clamp to the

hose, then remove the hose from
the filler cap.
11. Remove the developer bottle from the support and put the filling aid aside.
12. Close doors.
When the doors have been closed, the developer is automatically prepared, i.e.
mixed with toner.
13. Complete the developer replacement procedure on the operator panel:
button.
again.
In both cases, the message on the operator panel is automatically deleted, the
replacement of the developer is recorded in the 'Consumable history' menu
and the consumables counter is reset.

Fill in Developer

Chapter 9
Replacing Expendables
Replacing Expendables — Overview
Replacing expendables
This section describes in detail all the steps required to replace expendables. It also provides
the order numbers and package units for all expendables.
Overview
In section ‘Order Numbers and Packaging Units for Expendables’ on page 349 you will find
a list of all the order numbers and packing units for the expendables.
Note:
A warning is displayed on the operator panel before the service life of an expendable
ends.
You can check the current counter values and the respective limit values for each expend-
able in the 'Consumable history' menu.
Note:
Each expendable can be replaced individually and independently of the other expendables.
With expert mode, however, several expendables, which will soon reach the end of their
remaining service life, can be replaced together. As the necessary preparation and com-
pletion phases for replacing expendables are only executed once in expert mode, the time
required is significantly reduced.
#
Expendable See section

Photoconductor belt in the upper print ‘Replacing the Belt — Overview’ on page
unit 350
Photoconductor belt in the lower print
unit
Transfer belt in the upper print unit
Transfer belt in the lower print unit
346 Chapter 9 - Replacing Expendables


Charge corotron of the photoconductor ‘Replacing the corotron — overview’ on
unit in the upper print unit page 412
Charge corotron of the photoconductor
unit in the lower print unit
Cleaning corotron of the photoconductor
unit in the upper print unit
Cleaning corotron of the photoconductor
Cleaning corotron of the transfer unit in
the upper print unit
Cleaning corotron of the transfer unit in
the lower print unit
Reload corotron of the transfer unit in
the upper print unit
Recharge corotron of the transfer unit in
the lower print unit
Cleaning brush of the photoconductor ‘Replacing the cleaning brush — overview’
unit in the upper print unit on page 433
Cleaning brush of the photoconductor
Cleaning brush of the transfer unit in the
upper print unit
Cleaning brush of the transfer unit in the
lower print unit
Fine filter in the filter module ‘Replacing fine filter’ on page 443
Smoothing rollers in the smoothing ‘Replacing the smoothing rollers —
module overview’ on page 454
Cleaning felt in the fuser module ‘Replacing the cleaning felt’ on page 448
Chapter 9 - Replacing Expendables 347


Several expendables together: ‘Replacing Expendables in Expert Mode’ on
■ Developer Station page 469
■ Photoconductor belt/photoconductor
blade
■ Transfer belt
■ Charge corotron
■ Cleaning Corotron
■ Transfer corotron
■ Recharge corotron
■ Cleaning Brush
■ Fine filter

Order Numbers and Packaging Units for Expendables
Order Numbers and Packaging Units for Expendables
Expendables
#
Expendable Order number Packing unit

(quantity)
Photoconductor belt in the upper or S29312-F1293 1
lower print unit
Photoconductor blade (= cleaning blade) S29312-F1726 2
of the photoconductor unit in the upper
or lower print unit
Transfer belt in the upper or lower print S29312-F1516 1
unit
Corotrons: S29312-F1212 14
■ Cleaning corotron of the photoconduc-
tor unit in the upper or lower print

unit
■ Charge corotron of the photoconduc-
tor unit in the upper or lower print

unit
■ Cleaning corotron of the transfer unit
in the upper or lower print unit

■ Reload corotron of the transfer unit
in the upper print unit

■ Recharge corotron of the transfer unit
in the lower print unit
Cleaning brush of the photoconductor S29312-F1219 1

unit in the upper or lower print unit
Cleaning brush of the transfer unit in the S29312-F1224 1
upper or lower print unit
Fine filter S29312-F1209 1
Cleaning felt in the smoothing module S29312-F1413 2
Felt strips in the smoothing module S29312-F1718 5
Smoothing roller in smoothing module S29312-F1430 1
(hard)
Smoothing roller in smoothing module S29312-F1431 1
(soft)

Replacing the Belt — Overview
Replacing the Belt

Attention:
■ The photoconductor belt, photoconductor blade and transfer belt must only be used
for the intended purpose in each case.
■ The replacement must only be carried out by the operator after prior training or in-
struction by Service.
■ The replacement procedure can only take place when printing is stopped.
■ During replacement, always wear the gloves provided.
■ The surface of the photoconductor belt is extremely sensitive and can be easily damaged.
Avoid exposure to direct sunlight and do not touch.
■ The soft transfer belt is extremely sensitive to creasing and touch. Kinks and touching
the belt with hard objects should be strictly avoided.
The inner sliding surfaces of the slide foils must be clean. Dirt on the sliding surfaces
can damage the soft transfer belt.
■ If the life of the photoconductor belt, the photoconductor blade or the transfer belt
was very short, the cause of the damage must be clarified in order to prevent further
damage.
■ Store new photoconductor belts or transfer belts appropriately:
Do not store together with flammable substances.
Store in the closed original carton in a dry environment at 15 – 25°C.
Overview
The procedure for replacing a photoconductor belt and photoconductor blade is different
for the upper and lower print units:
Upper print unit:

■ ‘Removing Photoconductor Belt in Upper Print Unit and Replacing Photoconductor Blade’
on page 352
■ ‘Insert a photoconductor belt in the upper print unit’ on page 358
Lower print unit:

■ ‘Removing Photoconductor Belt in Lower Print Unit and Replacing Photoconductor Blade.
’ on page 364
■ ‘Inserting a Photoconductor Belt in the Lower Print Unit’ on page 370

The procedure for replacing a transfer belt is different for the upper and lower print units:
Upper print unit:

■ ‘Removing the Transfer Belt in the Upper Print Unit - Preparation’ on page 376
‘Removing Transfer Belt in the Upper Print Unit’ on page 380

■ ‘Insert the Transfer Belt in the Upper Print Unit’ on page 385
‘Insertion of a Transfer Belt in the Upper Print Unit (Completion)’ on page 392
Lower print unit:

■ ‘Removing the Transfer Belt in the Lower Print Unit - Preparation’ on page 395
‘Removing the Transfer Belt in the Lower Print Unit ’ on page 398
■ ‘Inserting the Transfer Belt in the Lower Print Unit’ on page 402
‘Inserting the Transfer Belt in the Lower Print Unit’ on page 408
The procedure for running in a photoconductor belt or transfer belt is the same for all
types of belt:
■ ‘Running in a Belt’ on page 411

Removing Photoconductor Belt in Upper Print Unit and Replacing Photoconductor Blade
Replacing the Photoconductor Belt in the Upper

Print Unit
Removing Photoconductor Belt in Upper Print Unit and Re-
placing Photoconductor Blade
Attention:
Observe the safety directives in the ‘Replacing the Belt — Overview’ on page 350 section.
To Remove the Photoconductor Belt in the Upper Print Unit and Replace the
Photoconductor Blade
#
Proceed as follows:
■ 'Replace consumables' -> 'Replace belt' menu
■ 'Select print unit': 'Upper print unit'
■ 'Select assembly': 'Photoconductor unit'
■ 'Select action to be executed': 'Replace belt'
3. Click the 'OK' button to start the photoconductor belt replacement.

The replacement of the photoconductor belt is being prepared. The developer
stations are swiveled off.
For information on the icons displayed on the operator panel under 'Steps': see

Proceed as follows:
Caution
operator panel.
Proceed as follows:
4. Open all doors on the right-hand side of the printing system (see ‘Opening Right
Doors’ on page 157).
5. Open all doors on the left-hand side of the printing system (see ‘Opening Left
Proceed as follows:
Caution
guide rails.
printing system:
Press the lock button on each
developer station in the upper
print unit and slowly and evenly
pull the developer station out to
the stop point.

Proceed as follows:
printing system:
To swivel off the toner mark
sensor, pull the unit outwards by
the handle.
8. Open the handles on the locking

flaps.
9. Fold up the locking flaps.

The locking flaps automatically
lock into position when they
have been folded up far enough.

Proceed as follows:
10. Release the locking lever and
carefully pull the handle to re-
move the photoconductor blade
and place it to one side.
11. Open packaging with the new photoconductor blade.

12. Carefully insert the new photo-
conductor blade with the metal
side facing up until the stop
point is reached and close the
locking lever.
13. Turn the rotating handle to the

left to release the locking device.
When the photoconductor unit
is unlocked, both color displays
near the handle change from red
to green.
Caution
The surface of the photoconductor belt is extremely sensitive and can be easily
damaged.
Wear the gloves provided in the packaging.

Proceed as follows:
14. Pull the rotating handle until the
photoconductor unit is pulled
out and engages on both sides.
15. Turn the belt tensioner by 180°

in the direction of the arrow to
the stop point to slacken the
photoconductor belt.
16. Carefully remove the photocon-

ductor belt from the photocon-
ductor unit and put it aside.
Caution
Do not use solvents for cleaning.
The cleaning cloth must be damp (preferably with lukewarm water) and lint
and chemical-free.

Proceed as follows:
17. Clean ceramic and aluminum
profiles and all rollers on the
upper and lower side of the
photoconductor unit using a
damp, lint-free cloth.
Proceed as follows:
18. ‘Insert a photoconductor belt in the upper print unit’ on page 358.

Insert a photoconductor belt in the upper print unit
Attention:
To Insert the Photoconductor Belt in the Upper Print Unit

#
Proceed as follows:
1. Open packaging of the new
Caution
damaged.
2. Remove photoconductor belt
from the packaging by the green
tube.
One red tube is already in the
photoconductor belt, a second
red tube initially remains in the
packaging.

Proceed as follows:
printing system:
Slip the green tube with the
photoconductor belt onto the
photoconductor unit at the posi-
tion marked in green.
Then pull the photoconductor
belt forwards to the edge of the
tube so that there are no creases.
4. Slip the red tube onto the photo-

conductor unit at the lower red
point.
5. Take the empty red tube out of

the packaging and slip it onto
the photoconductor unit at the
second red point.

Proceed as follows:
6. Slide the photoconductor belt
evenly and carefully onto the
photoconductor unit. Carefully
rotate the photoconductor belt
on insertion.
7. Remove all three tubes from the photoconductor unit.

Note
Keep the tubes. You can use them to insert a used but undamaged photocon-
ductor belt at a later date if necessary.
8. Remove the protective paper
from the photoconductor belt
and move the photoconductor
belt in such a way that the edge
of the photoconductor belt is at
the tip of the arrow within the
1 mm (0.39") wide marking.
The gloves are no longer re-
quired.

the stop point to tighten the

Proceed as follows:
10. Carefully push the photoconduc-
tor unit against the catch point
and push it into the printing
system.
11. Turn the handle clockwise to

tighten and lock the photocon-
ductor unit.
is locked, both color displays
near the handle change from
green to red.
Caution
The movement of the photoconductor belt is checked by the device control.
If the test run is not successful, the photoconductor belt was not pushed up to
the mark. In this case, again:
■ Release the locking device of the photoconductor unit
■ Pull out the photoconductor unit
■ Release the belt tensioner
■ Wearing gloves, push the photoconductor belt to the mark and repeat the
work steps from step 8 onwards.

Proceed as follows:
12. Swivel locking flaps down
against the catch point.
Then close the handles.
13. To swivel on the toner mark

sensor, push the unit in by the
handle.
Caution
Take care not to pinch the hose when pushing in a developer station.
printing system:
Push the developer stations back
in until they snap in.
15. Close all doors on the left-hand side of the printing system.

Proceed as follows:
16. Close all doors on the right-hand side of the printing system.
17. On the operator panel, enter whether a new photoconductor belt has been in-
serted and a new photoconductor blade used:
■ When you click the 'Yes' button:
The message on the operator panel is automatically deleted, the replacement

of the photoconductor belt and the photoconductor blade is documented
in the 'Consumable history' menu, and the consumables counter is reset.
■ When you click the 'No' button:
The consumables counter is not reset.
Proceed as follows:
18. On the operator panel, enter whether the belt is to be run in:
The printing system remains in the 'Special functions' status. The belt can
be run in immediately afterwards (see ‘Running in a Belt’ on page 411).
again.

Removing Photoconductor Belt in Lower Print Unit and Replacing Photoconductor Blade.
Replacing the Photoconductor Belt in the Lower

Print Unit
Removing Photoconductor Belt in Lower Print Unit and Re-
placing Photoconductor Blade.
Attention:
To Remove the Photoconductor Belt in the Lower Print Unit and Replace the
Photoconductor Blade
#
Proceed as follows:
■ 'Replace consumables' Menu-> 'Replace belt'
■ 'Select print unit': 'Lower print unit'
3. Click the 'OK' button to start the photoconductor belt replacement.

The replacement of the photoconductor belt is being prepared. The developer

Proceed as follows:
Caution
operator panel.
Proceed as follows:
4. Open all doors on the left-hand side of the printing system (see ‘Opening Left
Proceed as follows:
Caution
guide rails.
printing system:
Press the lock button on each
developer station in the lower
print unit and slowly and evenly
pull the developer station out to
the stop point.

Proceed as follows:
7. To swivel off the toner mark
sensor, pull the unit outwards by
the handle.

printing system:
Open the handles on the locking
flaps.


Proceed as follows:
10. Release the locking lever and
carefully pull the handle to re-
move the photoconductor blade
and place it to one side.
11. Open packaging with the new photoconductor blade.

12. Carefully insert the new photo-
conductor blade with the metal
side facing up until the stop
point is reached and close the
locking lever.
13. Turn the rotating handle to the

left to release the locking device.
is unlocked, both color displays
near the handle change from red
to green.
Caution
damaged.

Proceed as follows:
14. Pull the rotating handle until the
photoconductor unit is pulled
out and engages on both sides.

the stop point to slacken the
16. Carefully remove the photocon-

ductor belt from the photocon-
ductor unit and put it aside.
Caution
and chemical-free.

Proceed as follows:
17. Clean ceramic and aluminum
profiles and all rollers on the
upper and lower side of the
photoconductor unit using a
damp, lint-free cloth.
Proceed as follows:
18. ‘Inserting a Photoconductor Belt in the Lower Print Unit’ on page 370.

Inserting a Photoconductor Belt in the Lower Print Unit
Attention:
To Insert the Photoconductor Belt in the Lower Print Unit

#
Proceed as follows:
Caution
damaged.
2. Remove photoconductor belt
from the packaging by the green
tube.
photoconductor belt, a second
red tube initially remains in the
packaging.

Proceed as follows:
printing system:
Slip the green tube with the
photoconductor belt onto the
photoconductor unit at the point
marked in green, then pull the
photoconductor belt forwards to
the edge of the tube.
4. Slip the red tube onto the photo-

conductor unit at the lower red
point.
5. Take the empty red tube out of

the packaging and slip it onto
the photoconductor unit at the
second red point.

Proceed as follows:
6. Slide the photoconductor belt
evenly and carefully onto the
photoconductor unit. Carefully
rotate the photoconductor belt
on insertion.
7. Remove all three tubes from the photoconductor unit.

Note
Keep the tubes. You can use them to insert a used but undamaged photocon-
ductor belt at a later date if necessary.
8. Remove the protective paper
from the photoconductor belt
and move the photoconductor
belt in such a way that the edge
of the photoconductor belt is at
the tip of the arrow within the
1 mm (0.39") wide marking.
quired.

the stop point to tighten the

Proceed as follows:
10. Carefully push the photoconduc-
tor unit against the catch point
and push it into the printing
system.
11. Turn the handle clockwise to

tighten and lock the photocon-
ductor unit.
is locked, both color displays
near the handle change from
green to red.
Caution
The movement of the photoconductor belt is checked by the device control.
If the test run is not successful, the photoconductor belt was not pushed up to
the mark. In this case, again:
■ Release the locking device of the photoconductor unit
■ Pull out the photoconductor unit
■ Release the belt tensioner
■ Wearing gloves, push the photoconductor belt to the mark and repeat the
work steps from step 8 onwards.

Proceed as follows:
against the catch point.

printing system:
To swivel on the toner mark
sensor, push the unit in by the
handle.
Caution
Take care not to pinch the hose when pushing in a developer station.
14. Push the developer stations back
in on the right-hand side of the
printing system until they snap
in.

Proceed as follows:
17. On the operator panel, enter whether a new photoconductor belt has been in-
serted and a new photoconductor blade used:
The message on the operator panel is automatically deleted, the replacement

of the photoconductor belt and the photoconductor blade is documented
in the 'Consumable history' menu, and the consumables counter is reset.
Proceed as follows:
18. On the operator panel, enter whether the belt is to be run in:
again.

Removing the Transfer Belt in the Upper Print Unit - Preparation
Replacing the Transfer Belt in the Upper Print

Unit
Removing the Transfer Belt in the Upper Print Unit - Prepara-
tion
Attention:
To Prepare to Remove a Transfer Belt in the Upper Print Unit

#
Proceed as follows:
■ 'Select assembly': 'Transfer unit'
3. Click the 'OK' button to start transfer belt replacement.

The replacement of the transfer belt is being prepared.

Proceed as follows:
Caution
operator panel.
Proceed as follows:
Proceed as follows:
printing system:
Unlock the cleaning corotron of
the transfer belt cleaning system
for the upper print unit.
6. Completely remove cleaning

corotron.

Proceed as follows:
7. Open handle on the locking flap
shown.
8. Fold locking flap upwards.

The locking flap locks into posi-
tion automatically when it has
been folded up far enough.
9. Pull the reload corotron handle

and swivel the reload corotron
upwards.

Proceed as follows:
10. Turn rotating handle 180° in the
direction of the arrow to the stop
point to slacken the transfer belt.
Proceed as follows:
11. ‘Removing Transfer Belt in the Upper Print Unit’ on page 380.

Removing Transfer Belt in the Upper Print Unit
Attention:
To Remove a Transfer Belt in the Upper Print Unit

#
Proceed as follows:
1. Prepare the original packaging of the soft transfer belt and place it next to the
printing system.
Caution
The inner sliding surfaces of the slide foils must be clean. Dirt on the sliding
surfaces can damage the soft transfer belt.
2. Carefully insert the sliding foil
snugly between the transfer belt
and cover.
3. Push the sliding foil around the

roller in the direction of the ar-
row.

Proceed as follows:
4. Open the insertion tool.
5. Guide the insertion tool with the

sliding foil into the area of the
mark (white arrow). At the same
time, push the sliding foil careful-
ly between the transfer belt and
cover.
6. Close the insertion tool and in-

sert it until the edge of the
transfer belt is between the four
embossing marks.

Proceed as follows:
7. Hold the insertion tool with
both hands and move the trans-
fer belt evenly and carefully to-
gether with the sliding foil
around the roller in the direction
of the arrow until the sliding foil
wraps around the roller.
Caution
The soft transfer belt is extremely sensitive to creasing and touch. Kinks and
touching the belt with hard objects should be strictly avoided.
When being pulled off, the transfer belt may rub against the autofeed rope
positioned at the bottom. Ensure that the transfer belt does not touch the
autofeed rope.
8. Hold onto transfer belt on the
left and right-hand sides and
push it carefully past the aut-
ofeed rope.
If necessary, carefully push the
autofeed rope down slightly.

Proceed as follows:
9. Attach the three tubes from the
original packaging (green to
green/red to red) and evenly pull
the transfer belt together with
the insertion tool and sliding foil
out of the tube.
10. Carefully loosen the insertion tool and sliding foils from the transfer belt and
set them to the side.
11. Completely remove the soft
transfer belt:
■ First remove and hold onto
the green tube together with

the transfer belt.
■ Then loosen the other two
tubes. Leave the lower red

tube in the loop of the trans-
fer belt. Place the other red
tube on the outside.
■ Carefully roll the transfer belt
with the tubes into a bundle.

Proceed as follows:
12. Place the bundle to the side in the original packaging.
13. ‘Insert the Transfer Belt in the Upper Print Unit’ on page 385.

Insert the Transfer Belt in the Upper Print Unit
Attention:
To Insert a Transfer Belt in the Upper Print Unit

#
Proceed as follows:
Caution
Note the belt type
Always reinsert a soft transfer belt (for order number see ‘Order Numbers and
Packaging Units for Expendables’ on page 349).
transfer belt.
Caution
Do not damage the surface of the transfer belt.
2. Remove transfer belt from the
packaging by the green tube.
One red tube is in the transfer
belt; a second red tube initially
remains in the packaging.

Proceed as follows:
3. Slip the green tube with the
transfer belt onto the transfer
unit where it is marked in green,
then pull the transfer belt for-
ward again to the edge of the
tube.
4. Slip the red tube onto the trans-

fer unit at the lower red point.
5. Remove empty red tube from

packaging and slip it onto the
transfer unit at the second red
point.

Proceed as follows:
6. Push the sliding foil between the
transfer belt and the lower red
tube.
7. Pull the sliding foil up until it

wraps around the two red tubes.
8. Align the sliding foil so that the

edge of the transfer belt is visible
in the center of the two viewing
windows.

Proceed as follows:

transfer belt and the green tube.
The sliding foil must completely
wrap around the green tube.

Proceed as follows:
11. Push the sliding foil in until the
edge of the transfer belt is posi-
tioned between the four emboss-
ing marks.
The distance between the inser-
tion tool and the green tube
must not be greater than 5 cm
(2").
12. Close the insertion tool, thereby lowering it to the transfer belt.

Proceed as follows:
13. Holding the insertion tool with
your left hand and the lower
sliding foil with your right hand,
evenly and carefully push the
unit until the control LED turns
green.
14. Remove all three tubes from the transfer unit and place them in the original
packaging.
Note
Keep the tubes. You can use them to insert a used but undamaged transfer
belt at a later date, if necessary.
both hands and carefully move
it in the direction of the arrow
up to the mark (white arrow).
The control LED must turn
green.

Proceed as follows:
16. Slowly pull out the insertion tool
with the upper sliding foil.
17. Carefully pull out the lower

sliding foil.
quired.

printing system:
Keep the insertion tool and slid-
ing foil on the inside of the door.
19. ‘Insertion of a Transfer Belt in the Upper Print Unit (Completion)’ on page 392.

Insertion of a Transfer Belt in the Upper Print Unit (Completion)
Insertion of a Transfer Belt in the Upper Print Unit (Comple-

tion)
Attention:
To Complete Insertion of a Transfer Belt in the Upper Print Unit

#
Proceed as follows:
1. Turn the belt tensioner 180° in
the direction of the arrow to the
stop point to tighten the transfer
belt.
Caution
The device control checks the belt path of the transfer belt.
If the test run is not successful, the transfer belt was not pushed up to the
correct position. In this case, again:
■ Release the belt tensioner.
■ Move the transfer belt so that the control LED turns green.
■ Tighten the transfer belt.
2. Pull handle of the reload

corotron and swivel reload
corotron downwards.

Proceed as follows:
3. Swivel locking flap down against
the stop point.
4. Close the handle.
5. Push cleaning corotron back into

the guide up to the stop point.

Proceed as follows:
7. On the operator panel, enter whether a new transfer belt was inserted:
The message on the operator panel is deleted automatically, the replacement

of the transfer belt is recorded in the 'Consumable history' menu and the
consumable counter is reset.
The consumable counter is not reset.
8. On the operator panel, enter whether the transfer belt is to be run in:
again.

Removing the Transfer Belt in the Lower Print Unit - Preparation
Replacing the Transfer Belt in the Lower Print

Unit
Removing the Transfer Belt in the Lower Print Unit - Prepara-
tion
Attention:
To Prepare to Remove a Transfer Belt in the Lower Print Unit

#
Proceed as follows:
3. Click the 'OK' button to start transfer belt replacement.

The replacement of the transfer belt is being prepared.

Proceed as follows:
Caution
operator panel.

Proceed as follows:
printing system:
Unlock the cleaning corotron of
the transfer belt cleaning system
for the lower print unit and
completely remove it.

printing system:
Open handle on the locking flap
shown.

Proceed as follows:
7. Fold locking flap upwards.
The locking flap locks into posi-
tion automatically when it has
been folded up far enough.
8. Turn rotating handle 180° in the

direction of the arrow to the stop
point to slacken the transfer belt.
9. ‘Removing the Transfer Belt in the Lower Print Unit ’ on page 398.

Removing the Transfer Belt in the Lower Print Unit
Attention:
To Remove a Transfer Belt in the Lower Print Unit

#
Proceed as follows:
1. Prepare the original packaging of the soft transfer belt and place it next to the
printing system.
Caution
The inner sliding surfaces of the slide foils must be clean. Dirt on the sliding
surfaces can damage the soft transfer belt.
2. Carefully slide the sliding foil in
snugly between the transfer belt
and cover and push it around the
roller in the direction of the ar-
row.

Proceed as follows:
4. Guide the insertion tool with the
sliding foil into the area of the
mark (white arrow). At the same
time, push the sliding foil careful-
ly between the transfer belt and
cover.
5. Close the insertion tool and in-

sert it until the edge of the
transfer belt is between the four
embossing marks:

Proceed as follows:
both hands and move the trans-
fer belt together with the sliding
foil evenly and carefully around
the roller until the sliding foil
wraps around the roller.
Caution
The soft transfer belt is extremely sensitive to creasing and touch. Kinks and
touching the belt with hard objects should be strictly avoided.
7. Attach the three tubes from the
original packaging (green to
green/red to red) and evenly pull
the transfer belt together with
the insertion tool and sliding foil
out of the tube.
8. Carefully loosen the insertion tool and sliding foils from the transfer belt and
set them to the side.

Proceed as follows:
9. Completely remove the soft
transfer belt:
■ First remove and hold onto
the green tube together with

the transfer belt.
■ Then loosen the other two
tubes. Leave the lower red

tube in the loop of the trans-
fer belt. Place the other red
tube on the outside.
■ Carefully roll the transfer belt
with the tubes into a bundle.
10. Place the bundle to the side in the original packaging.
11. ‘Inserting the Transfer Belt in the Lower Print Unit’ on page 402.

Inserting the Transfer Belt in the Lower Print Unit
Attention:
To Insert a Transfer Belt in the Lower Print Unit

#
Proceed as follows:
Caution
Note the belt type
Always reinsert a soft transfer belt (for order number see ‘Order Numbers and
Packaging Units for Expendables’ on page 349).
transfer belt.
Caution
Do not damage the surface of the transfer belt.
2. Remove transfer belt from the
packaging by the green tube.
transfer belt, a second red tube
initially remains in the packag-
ing.

Proceed as follows:
3. ■ Slip the green tube with the
unit where it is marked in
green, then pull the transfer
belt forward again to the edge
of the tube.
■ Slip the red tube onto the
transfer unit at the lower red
point.
4. Remove the empty red tube

from packaging and slip it onto
the transfer unit at the lower red
point.
5. ■ Push the sliding foil between

the transfer belt and the low-
er red tube.
■ Pull the sliding foil up until
it wraps around the lower red
tube.

Proceed as follows:
6. Align the sliding foil so that the
edge of the transfer belt is visible
in the center of the two viewing
windows.

transfer belt and the green tube.
The sliding foil must completely
wrap around the green tube and
the insertion tool must be cen-
tered between the tubes.

Proceed as follows:
9. Push the sliding foil in until the
edge of the transfer belt is posi-
tioned between the four emboss-
ing marks.
10. Close the insertion tool, thereby lowering it to the transfer belt.
11. Holding the insertion tool with
your left hand and the lower
sliding foil with your right hand,
evenly and carefully push the
unit until the control LED turns
green.
12. Remove all three tubes from the transfer unit and place them in the original
packaging.
Note
Keep the tubes. You can use them to insert a used but undamaged transfer
belt at a later date, if necessary.

Proceed as follows:
both hands and carefully move
it in the direction of the arrow
up to the mark (white arrow).
The control LED must turn
green.
14. Slowly pull out the insertion tool

with the upper sliding foil.
15. Carefully pull out the lower

sliding foil.
quired.

Proceed as follows:
printing system:
Keep the insertion tool and slid-
ing foil on the inside of the door.
17. ‘Inserting the Transfer Belt in the Lower Print Unit’ on page 408.

Attention:
To Complete Insertion of the Transfer Belt in the Lower Print Unit

#
Proceed as follows:
1. Turn the belt tensioner 180° in
the direction of the arrow to the
stop point to tighten the transfer
belt.
Caution
The movement of the transfer belt is checked by the device control.
If the test run is not successful, the transfer belt was not pushed up to the
correct position. In this case, again:
■ Release the belt tensioner.
■ Move the transfer belt so that the control LED turns green.
■ Tighten the transfer belt.
2. Swivel locking flap down against

the catch point.

Proceed as follows:
3. Close the handle.

printing system:
Push cleaning corotron back into
the guide up to the stop point.
6. On the operator panel, enter whether a new transfer belt was inserted:

of the transfer belt is recorded in the 'Consumable history' menu and the
consumables counter is reset.

7. On the operator panel, enter whether the transfer belt is to be run in:
again.

Running in a Belt
Running in a Belt
If the Belt Is Not To Be Run In Immediately after Replacement
Attention:
A new photoconductor belt or transfer belt can only be run in when printing is stopped.
Proceed as follows:
■ 'Select assembly': 'Photoconductor unit' or 'Transfer unit'
■ 'Select action to be executed': 'Run in belt'
3. Run in the belt (see below).
To Run in the Belt

#
Proceed as follows:
1. Click the 'OK' button.
The belt is run in after a preparation period.
For information on the icons displayed on the operator panel under 'Steps', see
2. Complete the run-in procedure at the operator panel:
button.
again.

Replacing the corotron — overview
Replacing Corotrons
Replacing the corotron — overview
Attention:
■ Corotrons can only be replaced when printing is stopped.
■ Corotrons may only be used for the purpose for which they were originally intended.
■ If the corotron had a short service life, the cause of the damage must be clarified in
order to prevent further damage.
■ When replacing a corotron, always wear the gloves provided. Ensure that you do not
touch or damage the corotron wires.
Overview
#
Expendable See section Note

Cleaning corotron of ‘Removing the cleaning corotron The procedure is the
the photoconductor slide-in unit or charge corotron same for the upper and
unit slide-in unit of the photoconductor the lower print unit.
Charge corotron of the unit’ on page 413
photoconductor unit
Cleaning corotron of ‘Removing the cleaning corotron
the transfer unit slide-in unit of the transfer unit’
on page 418
Reload corotron of the ‘Removing the reload corotron A reload corotron is
transfer unit slide-in unit of the transfer unit’ only used in the upper
on page 421 print unit.
Recharge corotron of ‘Removing the recharge corotron A recharge corotron is
the transfer unit slide-in unit of the transfer unit’ only used in the lower
on page 425 print unit.
The procedure for replacing a corotron wire is the same for all corotrons: ‘Replacing
corotron wire’ on page 428.

Removing the cleaning corotron slide-in unit or charge corotron slide-in unit of the photoconductor unit
Removing the cleaning corotron slide-in unit or charge

corotron slide-in unit of the photoconductor unit
Attention:
Observe the safety directives in the ‘Replacing the corotron — overview’ on page 412 section.
Note:
The procedure is the same for the upper and the lower print unit.
To Remove the Cleaning Corotron Slide-in Unit or Charge Corotron Slide-in Unit
of the Photoconductor Unit
#
Proceed as follows:
1 If the printing system has not yet stopped, click the 'Stop' button.
■ Menu 'Replace consumables' -> 'Replace corotrons'
■ 'Select corotron': 'Cleaning' or 'Charge'
3. Click the 'OK' button to start corotron replacement.

Replacement of the corotron is being prepared. The developer stations are
swiveled off.
Caution
operator panel.
4. To remove a corotron slide-in unit in the upper print unit:
Open all doors on the right-hand side of the printing system.

Proceed as follows:
5. To remove a corotron slide-in unit in the lower print unit:
Open all doors on the left-hand side of the printing system.

flaps.

8. Unlock corotron slide-in unit

and remove:
A) Cleaning corotron slide-in
unit
B) Charge corotron slide-in unit
Caution
Do not touch or damage the corotron wires.

Proceed as follows:
9. Place the corotron slide-in unit
with the corotron wires facing
upwards on a table. (The illustra-
tion shows the charge corotron
slide-in unit with three corotron
wires; the cleaning corotron
slide-in unit only has two
corotron wires).
10. ‘Replacing corotron wire’ on page 428.

Installing the cleaning corotron slide-in unit or charge corotron slide-in unit of the photoconductor unit
Installing the cleaning corotron slide-in unit or charge

corotron slide-in unit of the photoconductor unit
Attention:
To Install the Cleaning Corotron Slide-in Unit or the Charge Corotron Slide-in
Unit of the Photoconductor Unit
#
Proceed as follows:
1. Push in corotron slide-in unit
until it latches:
B
A) Cleaning corotron slide-in
unit
B) Charge corotron slide-in unit
A The gloves are no longer re-
quired.

against the stop point.
3. When installing a corotron slide-in unit in the upper print unit:

Close all doors on the right-hand side of the printing system.

Installing the cleaning corotron slide-in unit or charge corotron slide-in unit of the photoconductor unit
Proceed as follows:
4. When installing a corotron slide-in unit in the lower print unit:
Close all doors on the left-hand side of the printing system.
5. On the operator panel, enter whether a new corotron was installed:


of the corotron is recorded in the 'Consumable history' menu and the
6. Complete the corotron replacement on the operator panel:

button.
again.

Removing the cleaning corotron slide-in unit of the transfer unit
Removing the cleaning corotron slide-in unit of the transfer

unit
Attention:
Note:
The procedure is the same for the upper and the lower print unit.
To Remove the Cleaning Corotron Slide-in Unit of the Transfer Unit

#
Proceed as follows:
■ 'Select corotron': 'Cleaning'

Replacement of the corotron is being prepared.
Caution
operator panel.
4. Open all doors on the right-hand side of the printing system.
Caution

Removing the cleaning corotron slide-in unit of the transfer unit
Proceed as follows:
5. Unlock corotron slide-in unit
and remove:
A) Upper print unit
B) Lower print unit

upwards on a table.

Installing the cleaning corotron slide-in unit of the transfer unit
Installing the cleaning corotron slide-in unit of the transfer

unit
Attention:
To Install the Cleaning Corotron Slide-in Unit of the Transfer Unit

#
Proceed as follows:
until it latches:
A) Upper print unit
B) Lower print unit
quired.



button.
again.

Removing the reload corotron slide-in unit of the transfer unit
Removing the reload corotron slide-in unit of the transfer

unit
Attention:
Note:
A reload corotron is only used in the upper print unit in the transfer unit.
To Remove the Reload Corotron Slide-in Unit of the Transfer Unit

#
Proceed as follows:
■ 'Replace consumables' -> 'Replace corotrons' menu
■ 'Select corotron': 'Charge'

Replacement of the corotron is being prepared.
Caution
operator panel.
system.

Removing the reload corotron slide-in unit of the transfer unit
Proceed as follows:
5. Pull handle of the corotron slide-
in unit and swivel corotron slide-
in unit up.
Caution
6. Remove corotron slide-in unit.

upwards on a table.

Installing the reload corotron slide-in unit of the transfer unit
Attention:
To Install the Reload Corotron Slide-In Unit of the Transfer Unit

#
Proceed as follows:
until it latches.
quired.
2. Pull handle of the corotron slide-

in unit and swivel the corotron
slide-in unit down.
3. Close door.

Proceed as follows:


button.
again.

Removing the recharge corotron slide-in unit of the transfer unit
Removing the recharge corotron slide-in unit of the transfer

unit
Attention:
To Remove the Recharge Corotron Slide-in Unit for the Transfer Unit
#
Proceed as follows:
■ 'Select corotron': 'Charge'

Replacement of the corotron is being prepared. The developer stations are
swiveled off.
Caution
operator panel.
4. Open all doors on the left-hand side of the printing system.
Caution

Removing the recharge corotron slide-in unit of the transfer unit
Proceed as follows:
5. Unlock the corotron slide-in
unit and remove.

upwards on a table.

Installing the recharge corotron slide-in unit of the transfer unit
Installing the recharge corotron slide-in unit of the transfer

unit
Attention:
To Install the Recharge Corotron Slide-in Unit of the Transfer Unit

#
Proceed as follows:
until it latches.
quired.



button.
again.

Replacing corotron wire
Caution:
be explosion-proof.
Attention:
Each time the corotron wires are replaced, the corotron slide-in unit must be cleaned.
To Replace the Corotron Wire

#
Proceed as follows:
Caution
1. Open packaging with the new corotron wires.
2. Pick up the change receiver for
corotron wires.

Proceed as follows:
3. Place the change receiver over
the first corotron wire and snap
it into the two holes.
4. Press down the lock at the back

of the corotron.
5. Push the change receiver with

the corotron wire away from the
handle until the wire is free.

Proceed as follows:
6. Remove the change receiver with
the corotron wire with an up-
ward motion.
7. Remove all other corotron wires from the corotron slide-in unit with the change
receiver (repeat from step 3 in each case).
Caution
8. Vacuum out the empty corotron
slide-in unit.
9. Also vacuum out any visible dirt

from the other side of the
corotron slide-in unit.
Other parts of the corotron slide-
in unit must not be cleaned.

Proceed as follows:
Caution
and chemical-free.
10. Clean empty corotron slide-in
unit with a damp, lint-free cloth.
11. Also clean any visible dirt from

the other side of the corotron
slide-in unit with a damp, lint-
free cloth.
12. Remove a new corotron wire from the packaging with the change receiver.
13. Insert the corotron wire into the
corotron slide-in unit and push
it towards the handle until it en-
gages.

Proceed as follows:
14. Remove the change receiver in
an upwards motion.
15. Install all other corotron wires (repeat from step 12 in each case).
16. Re-insert the corotron slide-in unit:
■ ‘Installing the cleaning corotron slide-in unit or charge corotron slide-in unit
of the photoconductor unit ’ on page 416

■ ‘Installing the cleaning corotron slide-in unit of the transfer unit ’ on page 420
■ ‘Installing the reload corotron slide-in unit of the transfer unit’ on page 423
■ ‘Installing the recharge corotron slide-in unit of the transfer unit’ on page 427

Replacing the cleaning brush — overview
Replacing the Cleaning Brush

Replacing the cleaning brush — overview
Caution:
■ Avoid contact with the skin and wear gloves.
■ In the event of contact with the skin, wash toner off with plenty of cold water.
Attention:
■ Cleaning brushes may only be used for the purpose for which they were originally
intended.
■ If the cleaning brush had a short service life, the cause of the damage must be clarified
in order to prevent further damage.
Note:
The cleaning brush can be replaced when the paper web is inserted. The paper will not
come into contact with toner.
Overview
The procedure is the same for the upper and the lower print unit:
■ ‘Removing the cleaning brush of the photoconductor unit’ on page 434
■ ‘Removing the cleaning brush of the transfer unit’ on page 439

Removing the cleaning brush of the photoconductor unit
Caution:
Observe the safety directives in the ‘Replacing the cleaning brush — overview’ on page 433
section.
To Remove the Cleaning Brush of the Photoconductor Unit

#
Proceed as follows:
■ menu'Replace consumables' -> 'Replace brush'
3. Click the 'OK' button to start the replacement of the cleaning brush.
The brush exchange is being prepared. The developer stations are swiveled off.
Caution
operator panel.
4. When removing the cleaning brush in the upper print unit:
Open all doors on the right-hand side of the printing system.
When removing the cleaning brush in the lower print unit:

Open all doors on the left-hand side of the printing system.

Proceed as follows:
flaps.

Caution
7. Turn the interlock lid to the left
and unlock.

Proceed as follows:
8. Carefully remove the cleaning
brush by the interlock lid.
9. Place the cleaning brush in the

old packaging and remove the
interlock lid.
10. ‘Installing the cleaning brush of the photoconductor unit’ on page 437.

Installing the cleaning brush of the photoconductor unit
Caution:
section.
To Install the Cleaning Brush of the Photoconductor Unit

#
Proceed as follows:
1. Open packaging and place inter-
lock lid on the new cleaning
brush as shown.
2. Remove new cleaning brush from the packaging using the interlock lid.
3. Push in cleaning brush to the
stop point and lock (flat side of
the interlock lid to the photocon-
ductor belt).
quired.

Proceed as follows:
against the stop point.
5. If installing the cleaning brush in the upper print unit:

Close all doors on the right-hand side of the printing system.
If installing the cleaning brush in the lower print unit:

Close all doors on the left-hand side of the printing system.
6. Indicate on the operator panel whether a new cleaning brush was installed:

of the cleaning brush is recorded in the 'Consumable history' menu and
the consumable counter is reset.
7. Complete the brush replacement on the operator panel:

button.
again.

Removing the cleaning brush of the transfer unit
Caution:
section.
To Remove the Cleaning Brush of the Transfer Unit

#
Proceed as follows:
■ Menu 'Replace consumables' -> 'Replace brush'
3. Click the 'OK' button to start the replacement of the cleaning brush.
Caution
operator panel.
4. Open all doors on the right-hand side of the printing system.
Caution

Proceed as follows:
5. Turn the respective interlock lid
to the left and unlock:
A) Upper print unit
B) Lower print unit
6. Carefully remove the cleaning

brush by the interlock lid.
(The illustration shows the
cleaning brush for the upper
print unit).
7. Place the cleaning brush in the

old packaging and remove the
interlock lid.
8. ‘Installing the cleaning brush of the transfer unit.’ on page 441.

Installing the cleaning brush of the transfer unit.
Caution:
section.
To Install the Cleaning Brush of the Transfer Unit

#
Proceed as follows:
1. Open packaging and place inter-
lock lid on the new cleaning
brush as shown.
2. Remove new cleaning brush on the interlock lid from the packaging and remove
edge protection.
3. Push cleaning brush in until it
latches (flat side of the interlock
lid to the transfer belt).
quired.

Proceed as follows:
5. Indicate on the operator panel whether a new cleaning brush was installed:

of the cleaning brush is recorded in the 'Consumable history' menu and
the consumable counter is reset.
6. Complete the brush replacement on the operator panel:

button.
again.

Replacing fine filter
Introduction
The printing system monitors the differential pressure on the fine filter. If the differential
pressure exceeds a warning threshold, a warning is displayed on the operator panel.
Caution:
diately.
food and drink.
Attention:
■ The replacement procedure for the fine filter can only take place when printing is
stopped.
■ Keep the used fine filter for collection by Service or the contracted shipping company.
To Replace the Fine Filter

#
Proceed as follows:
'Replace consumables' -> 'Replace fine filter'

Proceed as follows:
3. Click the 'OK' button to start fine filter replacement.
Caution
operator panel.
4. Open the door on the filter
module.
Caution
5. Release interlock lever by push-
ing it upwards to open the filter
housing.

Proceed as follows:
6. Pull handle and swivel filter
housing to the front.
7. Pull fine filter out by the loops

and put it aside.
Caution
8. If necessary, clean the surrounding area of the filter housing with a vacuum
cleaner.
Caution
Do not tear or throw away new fine filter packaging.
This packaging is used to repack the old fine filter.

Proceed as follows:
9. Take new fine filter from the
packaging and insert.
10. Repack old fine filter.

11. Close filter housing.
quired.
12. Swivel handle down, thus lock-

ing the filter housing.

Proceed as follows:
13. Close door.
14. Indicate on the operator panel whether a new fine filter was installed:

of the fine filter is recorded in the 'Consumable history' menu and the
15. Complete the fine filter replacement on the operator panel:

button.
again.

Replacing the cleaning felt
Caution:
Risk of slipping
When removing the slide-in unit oil can drip on the floor. In this case, wipe the oil off
with an absorbent cloth.
Attention:
■ Cleaning felt may only be used for the purpose for which it was originally intended.
■ If the cleaning felt had an extremely short service life, the cause of the problem must
be identified to prevent further damage.
Note:
The cleaning felt can be replaced when the paper web is inserted.
To replace the cleaning felt

#
Proceed as follows:
■ Menu 'Replace consumables' -> 'Replace cleaning felt'
■ 'Select cleaning felt': 'Upper and lower' or 'Upper only' or 'Lower only'
3. To start replacement of the cleaning felt, click the 'OK' button.

The cleaning felt replacement is being prepared.
Caution
operator panel.

Proceed as follows:
4. Unlock the sliding door on the
system and push it down.
Caution
■ Risk of slipping
When removing the slide-in unit oil can drip on the floor. In this case,
wipe the oil off with an absorbent cloth.
■ This can soil hands and clothing.
5. Pull out the slide-in unit by the

handle until it snaps in:
■ A) Slide-in unit for upper
A cleaning felt
■ B) Slide-in unit for lower
cleaning felt

Proceed as follows:
6. Press the spring latch (arrow),
then remove the slide-in unit
entirely and place on work sur-
face.
(The illustration shows the slide-
in unit for the upper cleaning
felt. The spring latch for the
lower slide-in unit is at the bot-
tom).
7. First press the roll with the

rolled-out felt against the spring
bearing and detach sideways,
then the roll with the rolled-up
felt.
8. Clean the slide-in unit with an

absorbent cloth.

Proceed as follows:
9. Clean the guide rail with an ab-
sorbent cloth.
10. Remove the old felt strip, clean

the oil housing with an ab-
sorbent cloth and place a new
felt strip in the oil housing.
11. Hook in the rolls for the new

cleaning felt, observing the roll-
out direction.
(The correct roll-out direction is
shown on a sticker on the slide-
in unit.)
12. If the other cleaning felt is also to be replaced, repeat steps from step 5.

Proceed as follows:
13. Reinsert the slide-in unit into the
guide and push into the smooth-
ing module:
A ■ A) Slide-in unit for upper
cleaning felt
■ B) Slide-in unit for lower
cleaning felt
B
14. Unlock the sliding door at the

clip, push it up and snap in.
15. On the operator panel, enter whether a new cleaning felt was installed:

of the cleaning felt is recorded in the 'Consumable history' menu, and the

Proceed as follows:
16. Complete the replacement of the cleaning felt on the operator panel:
button.
All aggregates of the printing system are inspected (duration around two
minutes), before the printing system is switched to the 'Stop' status.
again.

Replacing the smoothing rollers — overview
Replacing the Smoothing Rollers

Replacing the smoothing rollers — overview
Note:
The 'Replace smoothing roller' menu is released by Service if necessary. The smoothing
rollers are to be replaced if:
■ the bearings of the smoothing rollers are stiff or heavily worn
■ significant signs of wear or damage are visible or noticeable on the surface of the
smoothing rollers
■ significant differences in the level of smoothness are identifiable over the paper width
■ paper path problems occur that can be traced back to the smoothing rollers.
Attention:
■ Switch off the paper post-processing unit/ensure that the paper web cannot be advanced
by the paper post-processing unit any more.
■ Smoothing rollers may only be used for the purpose for which they were originally
intended.
■ If the smoothing rollers had a very short service life, the cause of the damage must be
clarified in order to prevent further damage.
Overview
■ ‘Removing the smoothing rollers’ on page 455
■ ‘Installing smoothing rollers’ on page 461

Removing the smoothing rollers
Caution:
Observe the safety directives in the ‘Replacing the smoothing rollers — overview’ on page
454 section.
To Remove the Smoothing Rollers

#
Proceed as follows:
■ 'Replace consumables' -> 'Replace smoothing roller' menu
■ 'Select smoothing roller': 'Upper and lower' or 'Upper only' or 'Lower only'
In the event of extremely varied wear of the smoothing rollers or only one-
sided surface defects, only the defective smoothing roller has to be replaced.
3. Click the 'OK' button to start smoothing roller replacement.

The replacement of the smoothing roller is being prepared. The developer
Caution
operator panel.
printing system:
Unlock the sliding door of the
smoothing module and slide it
downwards.

Proceed as follows:
5. ■ If the upper smoothing roller
is to be replaced:
Pull the slide-in unit for the
A upper cleaning felt (A)
halfway out by the handle,
until it snaps in.
■ If the lower smoothing roller
B is also (or only) to be re-
placed:
Pull the slide-in unit for the
lower cleaning felt (B)
halfway out by the handle,
until it snaps in.

printing system:
Open paper cooling cover.
Caution
Open the blower unit fully and beware of the edges of the blower unit during
the following actions.

Proceed as follows:
7. Swivel up blower unit by the
handle.
Caution
Do not damage the discharge brush
Ensure that you do not bend the discharge brush.
8. Remove the upper discharge
brush.
To do this, carefully pull the
discharge brush out of the clamp
springs on both sides.
Caution
If the smoothing rollers have not cooled down yet, you may sustain burns if
you touch them.
Put on heat protection gloves to continue working.
Caution
Do not damage the smoothing roller
Ensure that you do not damage the smoothing rollers on the edges of the
blower unit.

Proceed as follows:
9. Remove the upper smoothing
roller:
■ Push the bearing bolts up-
wards on the left-hand side

(in paper path direction).
■ Push the bearing bolts up-
2
3 wards on the right-hand side
1 ■ Carefully remove the
smoothing roller from the

guide rails
10. If the lower smoothing roller is to be replaced: continue with step 11.
If only the upper smoothing roller is to be replaced: More information in sec-
tion ‘Installing smoothing rollers’ on page 461.
11. Cut the paper web off at a clean
right angle.
12. At the paper output:

Pull out the cut-off paper web:

Proceed as follows:
printing system:
Bend the paper web over towards
the paper input as shown and
wedge it in. The lower cooling
fins must remain clear.
14. Remove the two cooling fins

shown:
First lift on the left-hand side (in
paper path direction) and then
pull diagonally upwards on the
right-hand side (in paper path
direction).
Caution
15. Remove the lower discharge
brush:
To do this, carefully pull the
discharge brush out of the clamp
springs on both sides.
Caution
If the smoothing rollers have not cooled down yet, you may sustain burns if
you touch them.
Put on heat protection gloves to continue working.
blower unit.

Proceed as follows:
16. Remove the lower smoothing
1 roller:
3 ■ Open the locking mechanism
2 on the left-hand side (in pa-
per path direction) and push
the bearing bolts downwards.
■ Open the locking mechanism
on the right-hand side (in

paper path direction) and
push the bearing bolts down-
wards.
■ Carefully remove the
smoothing roller from the

guide rails
17. ‘Installing smoothing rollers’ on page 461.

Installing smoothing rollers
Caution:
Observe the safety directives in the ‘Replacing the smoothing rollers — overview’ on page
454 section.
Attention:
Observe the smoothing roller combination
It is recommended that you install the hard smoothing roller (gray surface, order number
S29312-F1430) in the upper print unit and the soft smoothing roller (red surface, order
number S29312-F1431) in the lower print unit.
To install the smoothing rollers

#
Proceed as follows:
1. If the lower smoothing roller is to be replaced: continue with step 2.
If only the upper smoothing roller is to be replaced: continue with step 7.
Caution
blower unit.

Proceed as follows:
printing system: Install the new
1 2 smoothing roller for the lower
print unit (soft smoothing roller
3 with red surface):
■ Insert the smoothing roller
carefully onto the swivel

levers.
■ Insert the bearing of the
smoothing roller into the

groove of the left swivel lever
Press the bearing bolt on the
left-hand side upwards and
close the latch bolt.
■ Press the bearing bolt on the
right-hand side (in paper

path direction) upwards and
close the latch bolt.
Caution
3. Insert the lower discharge brush
in the direction of the smoothing
roller, with the brush side facing
upwards:
■ First push the discharge
brush in on the right-hand

side (in paper path direction)
until it snaps in,
■ then snap the discharge brush
into place on the left-hand

side (in paper path direction).

Proceed as follows:
4. Insert the two cooling fins
shown:
First insert on the right-hand
and then press downwards on
the left-hand side (in paper path
direction).
Caution
Observe the sensors
The paper web must be inserted below the sensors.
5. Fold back the paper web and
carefully push it through the pa-
per output.
In doing so insert the paper web
below the sensors.
6. Affix the paper web with any

popular adhesive (for example,
Scotch ATG 700). Make sure
that the offset of the reference
edge is minimal (< 1mm / <
0.04"), and that the edge is as
flush as possible. Depending on
the utilized paper, either:
■ affix to the stack (1),
■ or affix overlapping (2). Al-
ways fold back the projecting

edge of an overlap so that it
cannot cause a jam.

Proceed as follows:
Caution
Take care not to damage the smoothing rollers on the edges of the blower unit
when installing them.
7. Install the new upper smoothing
roller (hard roller with gray sur-
3 face):
■ Insert the smoothing roller
2 carefully onto the swivel

1
levers.
■ Insert the bearing of the
smoothing roller into the

groove of the left swivel lever
Push the bearing bolt on the
left-hand side downwards.
■ Press the bearing bolt on the
right-hand side (in paper

path direction) downwards.
Caution
8. Insert the upper discharge brush
in the direction of the smoothing
roller, with the brush side facing
downwards:
■ First push the discharge
brush in on the right-hand

until it snaps in,
■ then insert the discharge
brush on the left-hand side


Proceed as follows:
9. Close the blower unit.
10. Close the cover of the paper

cooling system.

Proceed as follows:
printing system:
■ If the upper smoothing roller
A is to be replaced:
Push the slide-in unit for the
upper cleaning felt (A) by the
handle until it snaps into
B place in the smoothing mod-
ule.
■ If the lower smoothing roller
is also (or only) to be re-

placed:
Push the slide-in unit for the
lower cleaning felt (B) by the
handle until it snaps into
place in the smoothing mod-
ule.
12. Unlock the sliding door at the

clip, push it up and snap in.

Proceed as follows:

Caution
If the adhesive joint is moved too quickly, the paper web may be damaged or
torn
Only move the affixed paper web with the 'ADVF' button and monitor the
paper transport. If you use the 'Eject' button to move the paper, you might
overlook damage to the paper web and not be able to prevent this damage in
time.
15. Move the affixed paper web with the 'ADVF' button until the splice has
completely passed through the paper post-processing unit.
16. Enter on the operator panel whether new smoothing rollers were installed:
Replacement of the smoothing rollers is documented in the 'Consumable

history' menu.
No replacement is recorded in the 'Consumable history' menu.

Proceed as follows:
17. Complete the replacement of the smoothing rollers on the operator panel:
button.
again.

Replacing Expendables in Expert Mode
Attention:
It is only possible to replace expendables in expert mode when print operation is stopped.
Note:
Each expendable can be replaced individually and independently of the other expendables.
With expert mode, however, several expendables, which will soon reach the end of their
remaining service life, can be replaced together. As the necessary preparation and com-
pletion phases for replacing expendables are only executed once in expert mode, the time
required is significantly reduced.
To Replace Expendables in Expert Mode

#
Proceed as follows:
'Replace consumables' -> 'Expert mode' menu
3. To start the replacement of expendables in expert mode, click the 'Start' button.
The replacement is being prepared; this can take up to two minutes.
Caution
Wait until preparation is complete.
operator panel.


Caution
Observe the safety directives
When replacing the individual expendables, observe the safety directives in the
relevant sections of the documentation.
5. Replace the relevant expendables one after the other. For more detailed infor-
mation on replacing the individual expendables, see:
■ ‘Replacing the Belt — Overview’ on page 350 (photoconductor belt, photo-
conductor blade, transfer belt)

■ ‘Replacing the corotron — overview’ on page 412
■ ‘Replacing the cleaning brush — overview’ on page 433
■ ‘Replacing fine filter’ on page 443
Proceed as follows:
6. In the 'Consumables' table, highlight all expendables that were replaced in expert
mode by clicking on these items.
Note
All replaced belts must be run in; they cannot be removed from the selection.
Optionally, belts that have been removed for inspection and refitted can be run
in.
7. Under 'Select belts to be run in:', highlight all photoconductor and transfer
belts that are to be run in one after the other.

Proceed as follows:
8. Ensure that:
■ All belts have been inserted to the point where the correct belt position is
confirmed and have been tensioned

■ The toner mark sensors and the reload corotron have been swiveled on
■ All locking flaps have been closed
■ All developer stations have been pushed in.
9. Close all printing system doors:

Proceed as follows:
10. To end the replacement of expendables in expert mode, click the 'Exit' button.
This means:
■ The developer stations are swiveled on again
■ The selected belts are run in one after the other
■ The counters for all expendables that were highlighted in the table are reset
■ A summary of the replaced expendables and the belts that have been run in
is displayed.
11. Complete the replacement in expert mode on the operator panel:

button.
again.


Chapter 10
Correcting Errors
Correcting Errors — Overview
Correcting Errors — Overview
Correcting Errors
This section shows you how to locate and remedy errors using the messages displayed on
the operator panel. It also describes how you can enable remote access to allow remote
diagnosis by Service during print operation . You will also find information on how to
correct any fusing or print image errors.
Overview
■ ‘Processing messages on the operator panel ’ on page 475
■ ‘Allowing Remote Access — Overview’ on page 479
■ ‘Correcting Fusing Problems’ on page 483
■ ‘Correcting Print Image Errors’ on page 484
474 Chapter 10 - Correcting Errors

Processing messages on the operator panel
Introduction
All error messages, warnings and information are displayed on the operator panel, sorted
by priority and time.
The icons at the start of the line indicate the priority:
#
Icon Meaning
Error message
When an error occurs, the printing system stops and the button in the
toolbar flashes.
Warning
When there is a warning, the printing system continues to print and
the button flashes in the toolbar.
If there is also an error message, the error message icon flashes too.
Information
When there is information, the printing system also continues to print,
and the button flashes in the toolbar.
If there is also a warning, the warning icon flashes.
If there is also an error message, the error message icon flashes too.
Controlling the Printer View

#
Button Function
Switches back to the preset standard view after modifications.
Zooms in on the current printer view.
Zooms out from the current printer view.
Shifts the visible cutout in the direction of the arrow.
Turns the printer view in the respective direction.
The following additional buttons are available in the 'Errors and warnings' menu:
Switches to the previous/next message.
Chapter 10 - Correcting Errors 475

Button Function
Changes the view between:
■ only list of 'Errors and warnings', without printer view
■ list of 'Errors and warnings' with printer view
■ only printer view, without list of 'Errors and warnings'
To edit messages on the operator panel

#
Proceed as follows:
1. To edit a message, click on the respective button in the toolbar: or or .
The 'Errors and warnings' menu is displayed. All error messages, warnings and
information messages that have occurred are listed in the upper area, sorted
by priority and time.

Proceed as follows:
2. Click on the message in the 'Errors and warnings' list.
Additional information on this message is displayed in the lower area:
- Either the relevant component is located in the three-dimensional printer
view...
- Or a button with a link to the menu in which the problem can be corrected
is displayed:
If settings in multiple menus have to be changed, these menus are displayed

for selection.
- Or a button is displayed to reset an error message quickly:
3. Press the F1 button or click the button next to the error message.
The context-sensitive Direct Help appears for the selected message. It contains
detailed information on the cause of the error and how to correct it, e.g.:
4. Eliminate the reason why printing stopped as indicated by the information in

the error message.

Proceed as follows:
5. Resume printing. The procedure depends on whether information was lost or
not when printing stopped:
■ Print stop without loss of information: The printing system has stopped at
the start of a page.

Click on the 'Ready' button.
The printing operation is continued without any impairment to print or
fusing quality.
■ Print stop with loss of information: To avoid damage, the printing system
stopped immediately and therefore stopped in the middle of a page.

Click on the 'Ready' button.
The print image on the damaged print pages is fused to ensure that the
tension roller and post-processing are not soiled. Alternately, you can move
the damaged pages from the printing system by pressing the 'Eject' button.
Restart print job.
Result
Inform Service according to the information in the 'Service ticket' menu, if:
■ the error cannot be eliminated,
■ the same error recurs repeatedly,
■ the printing system cannot be rendered operational after the error has been eliminated.

Allowing Remote Access — Overview
Remote Diagnosis
Allowing Remote Access — Overview
Introduction
With the prior agreement of the agent operating the printing system, Service can use remote
access to:
■ Perform remote diagnosis during print operation
■ Access the operator panel in the printing system directly (= remote support). This also
allows Service to assist the operator in changing settings on the operator panel.
Note:
The buttons only appear if a specific remote access agreement was made with Service.
Overview
■ ‘Permitting or Blocking Remote Diagnosis’ on page 480
■ ‘Activating or Deactivating Remote Support’ on page 481

Permitting or Blocking Remote Diagnosis
Permitting or Blocking Remote Diagnosis
Introduction
Service can make a remote diagnosis during printing using remote access if this has been
agreed beforehand.
To Enable Remote Diagnosis

#
Proceed as follows:
1. Click on the following button in the toolbar:
or click the 'Remote diagnostics disabled' button in the 'Configuration' ->

'Special functions' -> 'Remote diagnostics' menu.
The status display shows that remote diagnosis is enabled:
To Disable Remote Diagnosis

#
Proceed as follows:
1. Click on the following button in the toolbar:
or click the 'Remote diagnostics permitted' button in the 'Configuration' ->

'Special functions' -> 'Remote diagnostics' menu.
'Remote diagnostics disabled' is displayed.

Activating or Deactivating Remote Support
Introduction
With the prior agreement of the agent operating the printing system, Service can use remote
access to:
■ Perform remote diagnosis during print operation
■ Access the operator panel in the printing system directly (= remote support). This also
allows Service to assist the operator in changing settings on the operator panel.
Note:
The buttons only appear if a specific remote access agreement was made with Service.
Caution:
By activating this function, the printing system can be started remotely. A high operational
risk is associated with activation. In order to avoid causing personal injury or damage to
property, the operator must take appropriate measures to secure the production area
where the printing system is located or delegate this task to an Operator/Key Operator
before activating remote support.
This function is activated and executed solely at the operator's own risk.
Activating Remote Support

#
Proceed as follows:
1. Click on the 'Switch on...' button in the 'Configuration' -> 'Special functions'
-> 'Remote diagnostics' -> 'Remote support for operator panel interface' menu.
2. After reading the warning notices, activate the function with 'Yes'.
Note
Remote support is initially activated for 30 minutes. The remaining time is
displayed. One minute before the session expires, the display flashes and a
message appears stating that the function will be deactivated if the remote
support session is not extended.
Using the 'Extend' button, the remote support session can be extended at user-
defined intervals of up to 30 minutes.

Deactivating Remote Support

#
Proceed as follows:
1. Click on the 'Switch off' button in the 'Configuration' -> 'Special functions'
-> 'Remote diagnostics' -> 'Remote support for operator panel interface' menu.

Correcting Fusing Problems
Correcting Fusing Problems
Check Paper and Operation

Poor fusing quality is indicated by a print image on the paper that can be wiped off or
erased.
If the fusing quality of the print image is poor, check the following points before you call
Service:
■ Does the paper meet the requirements of the paper specification (see ‘Other Documents’
on page 27)?
■ Was the paper stored correctly?
■ Was the printing system operated incorrectly (e. g. was the 'ADVF' button pressed
too long, or the fusing temperature lowered)?

Correcting Print Image Errors
General Information
There can be many causes behind print image errors. If the print image errors cannot be
corrected by the options described, then let Service know.
Note:
If print image errors appear on the front page, then the cause lies in the upper print unit;
if the print image errors appear on the back page, then the cause lies in the lower print
unit. The setting in the 'Print image' -> 'Job control' menu must be observed for this:
■ 'Face up'
Front page = top side

■ 'Face down'
Front page = bottom side
Note:
If the print image errors only occur in one color, then the cause lies with the relevant
color station in the upper and/or lower print unit.
Note:
The photoconductor belt together with the photoconductor blade and the transfer belt
must only be replaced when print image errors occur that are clearly caused by these
expendables. The photoconductor belt and the transfer belt can only be the cause for
print image errors if the print image errors regularly occur after a belt rotation, i.e. after
approx. 1.78 m (69.9 inch).
Note:
Preinstalled test print jobs can be started via the 'Configuration' -> 'Emulations' -> 'Test
print' menu. These print jobs, which are grouped in test sequences, can be used to opti-
mize the print quality for a certain application. These optimized settings can then be
saved in a setup.

Lightening (Patchy Print Image)
Possible Cause Correction

Charge corotron of the photoconductor Replace corotron wire of the charge
unit: Torn corotron wire corotron in the photoconductor unit (see
‘Replacing the corotron — overview’ on
page 412).
Lightening at the Edge of Listing Paper

Moisture at the edge of listing paper Replace paper and check storage (see sec-
tion ‘Paper specifications’ on page 78).

Light Spots

Dirty transfer belt First remove the belt, turn it round and
Damaged photoconductor belt install it again. If the error pattern mi-
grates along, replace the belt: see ‘Replac-
ing the Belt — Overview’ on page 350.
Black Spots

If black spots repeat within one belt loop: First remove the belt, turn it round and
Damaged photoconductor belt install it again. If the error pattern mi-
grates along, replace the belt: see ‘Replac-
ing the Belt — Overview’ on page 350.

Uneven Coloration Left to Right

Blocked toner suction system ‘Cleaning the Toner Suction System’ on
page 301
Vertical Streaks

Developer station soiled Clean developer station (see ‘Cleaning the
Surface of the Developer Stations —
Overview’ on page 273).
Contact with an object in the printing Notify Service.
system or cleaning is not working proper-
ly

Ghost Image

Insufficient cleaning of the photoconduc- Replace the cleaning brush (see ‘Replacing
tor belt or transfer belt. the cleaning brush — overview’ on page
The print image is repeated after approx. 433).
two loops of the photoconductor belt or
approx. one loop of the transfer belt.
Toner Bombs
#

Developer station soiled Clean developer station (see ‘Cleaning the
Surface of the Developer Stations —
Overview’ on page 273).
Uneven Coloration Front Side to Rear Side

#

The coloration levels on the operator Adjust the coloration levels for the front
panel have not been set correctly and back pages in the 'Contrast' menu.
Detailed information on this menu is
available from the context-sensitive direct
help. To go to this, call up the 'Contrast'
menu and press the F1 button.

Blistering and Offsetting Heat

#

Blistering Reduce the fusing temperature in the
Due to the heat generated when 'Print image' -> 'Fusing temperature'
preprinting paper, water can run from the menu.
color and lead to air bubbles. Detailed information on this menu is
Offsetting heat available from the context-sensitive direct
Toner residue on the roller is noticeable help. To go to this, call up the 'Print im-
on the print image. age' menu and press the F1 button.


Appendix A
Technical Data
Technical Data — Overview
Technical Data — Overview
Technical data
This section contains the most important technical data for the printing system.
You can use the ruler for controlling the paper path synchronization to assign the marks
on the paper input to certain form lengths.
Overview
■ ‘Technology and Print Speed’ on page 493
■ ‘Paper’ on page 496
■ ‘Electrical Values and Power Input’ on page 498
■ ‘Mechanical Conditions’ on page 500
■ ‘Environmental Conditions’ on page 502
■ ‘Replacement cart for developer stations (option)’ on page 503
■ ‘Ruler for Checking Paper Path Synchronization’ on page 504
492 Appendix A - Technical Data

Technology and Print Speed
Printing Systems
#
ColorStream Description
9410/10010 Continuous printing system for black/white printing
(1/1)
9420 / 10020 Continuous printing system for black/white printing
with one additional Océ CustomTone color (2/2)
9430/10030 Continuous printing system for black/white printing
with two additional Océ CustomTone colors (3/3)
9440/10040 Continuous printing system for full-color printing
(CMYK – 4/4)
9450/10050 Continuous printing system for full-color printing
(CMYK) with an additional Océ CustomTone color
(5/5)
Technology
#
Printing method Electrophotographic with LED technology

1/1, 2/2, 3/3, 4/4, 5/5 and mixed, 1/0, 2/0, 3/0, 4/0,
5/0 and mixed
Simplex and single pass duplex
Fusing method Contactless infrared radiation fusing
Dot Matrix for 600 x 600 dpi
Print quality ColorStream 9000:
■ Standard (bilevel)
ColorStream 10000:
■ GraphicArts (dot modulation/multilevel) for 1/1, 4/4
and 5/5
■ Standard (bilevel) for 2/2 and 3/3
Data Streams
■ IPDS
■ PCL 5c
Appendix A - Technical Data 493

■ PDF (by Océ PRISMA®production)
Network Connection
■ IBM/390 (ESCON)
■ Gigabit Ethernet (10/100/1000 Mbit), copper
■ Gigabit Ethernet (1000 Mbit), optical fiber
Interfaces for Pre/Post-Processing

■ Typ1
■ UP3I
Processing Speed
59.52 m/min (195.28 ft/min)
Print Speed
Note:
The actual print speed depends on the composition of the print job and ranges between
the minimum and maximum value. Dynamical optimization of the print mode allows
the average print speed to be increased.
#
Prints per minute ColorStream 9410 ColorStream 9420

ColorStream 10010 ColorStream 10020
Duplex Simplex Duplex Simplex
(1/1) (1/0) (2/2–1/1) (2/0–1/0)
2 x DIN A4 portrait (2- 800 400 344–800 172–400
up)
3 x DIN A5 portrait (3- 1700 850 727–1700 364–850
up)
2 x letter portrait (2-up) 852 426 352–852 176–426
6 x 9" (3-up) 1562 781 642 – 1562 321 – 781

Prints per minute ColorStream 9430 ColorStream 9440

ColorStream 10030 ColorStream 10040
Duplex Simplex Duplex Simplex
(3/3 – 1/1) (3/0 – 1/0) (4/4 – 1/1) (4/0–1/0)
2 x DIN A4 portrait (2- 228–800 114–400 168–800 84–400
up)
3 x DIN A5 portrait (3- 480–1700 240–850 358–1700 179–850
up)
2 x letter portrait (2-up) 232–852 116–426 172–852 86–426
6 x 9" (3-up) 419–1562 210–781 311–1562 156–781
#
Prints per minute ColorStream 9450

ColorStream 10050
Duplex Simplex
(3/3–1/1) (3/0 – 1/0)
2 x DIN A4 portrait (2- 136–800 68–400
up)
3 x DIN A5 portrait (3- 284–1700 142–850
up)
2 x letter portrait (2-up) 136–852 68–426
6 x 9" (3-up) 247–1562 124–781

Paper
Paper
Note:
The paper specifications (see ‘Other Documents’ on page 27) contain exact information
on the permissible papers. The most important paper requirements are listed below.
Requirements
#
Paper transport Pinless

Continuous paper Single ply, with or without guide holes, perforated, color or
pre-printed
Paper input Roller, stack, high stack
#
Print width 165–482.6 mm (6.5–19 inches)

Format width 165–495.3 mm (6.5–19.5 inches)
Note
If a 19" application is printed on a 19.5" paper web, then an
unprinted border of 0.5" is always left on the right-hand side,
rather than a 0.25" border on both sides.
For example:
Format height in 76.2–1371.6 mm (3–54 inches)

mode 1/1–4/4 Notes:
■ In special cases, a switch to 1524 mm (60") is possible after
successful testing by Service.

■ Format heights between 762–1016 mm (30–40 inches) are
not supported.

Paper
Format height in 76.2 – 762 mm (3 – 30 inches)

mode 5/5
Grammage 36–240 g/m2
■ Standard area: 50–160 g/m2
■ Extended area (after additional tests):
36–49 g/m2
160–240 g/m2 (with adjusted processing speed)

Electrical Values and Power Input
Electrical Values
#
EU USA
Power frequency 50 Hz ± 1 Hz 60 Hz ± 1 Hz
Supply voltage 230/400 V ± 10% 208 V ± 10%
Internal device circuit 4 x 125 A 3 x 250 A
breaker
Power Input
Note:
Average power consumption for a printing system when printing A4 2-up with 70 g/m2
(19 lbs) paper.
(standby values in brackets)
#
EU USA
Maximum true power 71 kW 75 kW
PT
Average true power PT 28 kW 26 kW
Maximum apparent 76 kVA 80 kVA
power PA
Average apparent power 31 kVA 30 kVA
PA
Heat emission Q 99000 (20500) kJ/h 93600 (20160) kJ/h
Additional values for external recooler

#
Power frequency/supply 50 Hz/400 V ± 60 Hz/400 V ± 60 Hz/460 V ±

voltage 10% 10% 10%
Power consumption 8.0A 9.7A 8.0A
Starting current 34.9A 35.4A 35.4A
Cooling capacity when TW 6000 W 6600 W 6600 W
= 18 °C, TU = 32 °C

Power frequency/supply 50 Hz/400 V ± 60 Hz/400 V ± 60 Hz/460 V ±

voltage 10% 10% 10%
Cooling capacity when TW 4800 W 5150 W 5150 W
= 10 °C, TU = 32 °C
Note:
The following power supply systems are converted via an external transformer:
■ USA: 208 V ± 10%/60 Hz/3 phases
■ Japan: 200 V ± 10%/50 Hz or 60 Hz/3 phases
■ Japan: 220 V ± 10%/50 Hz or 60 Hz/3 phases

Mechanical Conditions
Dimensions (length x width x height)

#
Total (with console, approximate 5430 x 3800 x 2020 mm (213.8 x 149.6 x 79.5
value) inches)
Print unit 2720 x 1520 x 2020 mm (107.1 x 59.8 x 79.5
inches)
Fuser module 2800 x 1120 x 1200 mm (110.2 x 44.1 x 47.2
inches)
Filter module 800 x 680 x 2020 mm (31.5 x 26.8 x 79.5 inches)
Console 1570 x 790 x 1480 mm (61.8 x 31.1 x 58.3 inches)
#
Web buffer 1872 x 985 x 2172 mm (73.7 x 38.8 x 85.5 inches)
Recooler dimensions (length x width x height)

#
Total 645 x 600 x 1050 mm (25.4 x 23.6 x 41.3 inches)
Weight (approximate value)

#
Print unit: …
■ without developer stations ■ 2000 kg (4410 lbs)
■ with eight developer stations ■ 2500 kg (5512.5 lbs)
Fuser module 950 kg (2094.8 lbs)

Filter module 300 kg (661.5 lbs)
Console (with toner supply for 250 kg (551.3 lbs)
four colors)
#
Web Buffer 447 kg (985.6 lbs)
Recooler weight (approximate value)

#
Recooler operating weight 155 kg (341.8 lbs)

Load
#
Surface load 7500 N/m2

Concentrated load <= 6000 N/floor element (500 x 500 or 600 x 600
mm)

Environmental Conditions
Environmental Conditions
Room Temperature and Humidity

#
Room Tempera- 20°C to 25°C (68°F to 77°F)

ture
Relative humidity 40% to 60% (maximum 50% at 25°C/77°F)
Climatization is recommended
Absolute humidity 5 g/m3 to 12 g/m3
Cooling air, fresh air, and air purity

#
Thermal equilibri- To maintain the thermal equilibrium for climatic class 3K2
um (general office climate) at the printing system location, a com-
bination of heat extraction of 80% of the thermal energy along
with air conditioning to reduce the temperature of the remaining
20% is recommended.
Cooling air At 50 Hz: 3000 m3/h
At 60 Hz: 3120 m3/h
Fresh air The air supply should contain 20% fresh air.
Air cleanliness Air purity level 2
Ozone concentration
#
Ozone concentra- maximum 0.1 ppm (0.2 mg/m 3)

tion
Operating Noise
#
Operating noise Maximum 80 dB(A)

Replacement cart for developer stations (option)
Replacement cart for developer stations (option)
Technical data
#
Type name Lift & Drive 125

Weight approx. 45 kg (99.2 lb) with developer station adapter
Noise level less than 70 dB (A) during lifting process
Squared average for vibra- under 2.4 m/s2 during lifting process
tions
Load capacity of the lift approx. 105 kg (231.5 lb) with developer station
adapter
Stroke distance approx. 1442 mm (56.77")
Length approx. 917 mm (36.1")
Width approx. 1110 mm (43.7") with developer station
adapter
Height approx. 2000 mm (78.7")
Brake Immobilization brake with additional directional lock
Batteries: -15° C to + 50° C (5° F to 122° F)
■ Operating temperature 6.5 Ah
■ Capacity 18 V (12 V + 6 V in series)
■ Power supply

Ruler for Checking Paper Path Synchronization
Introduction
Some common form lengths are already printed on the ruler. You can take other form
lengths from the assignment in the tables and, if necessary, add them to the ruler using
a water soluble pen.
Ruler
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55
11" 12" 17"

14"
28"
Assignment of the Form Lengths

#
Inch- Pos. Inch- Pos. Inch- Pos. Inch- Pos. Inch- Pos.
es es es es es
3" 5 82/6" 5 134/6" 40 21" 49 382/6" 14
31/6" 11 83/6" 13 135/6" 45 211/6" 53 383/6" 15
32/6" 14 84/6" 19 14" 49 245/6" 3 384/6" 16
33/6" 15 85/6" 28 141/6" 54 25" 5 385/6" 18
34/6" 15 9" 36 145/6" 1 251/6" 8 39" 19
35/6" 14 91/6" 42 15" 5 252/6" 11 391/6" 21
4" 11 92/6" 4 151/6" 10 253/6" 13 392/6" 23
41/6" 5 93/6" 11 152/6" 14 254/6" 15 393/6" 25
42/6" 19 94/6" 16 153/6" 17 255/6" 17 394/6" 27
43/6" 13 95/6" 23 154/6" 21 26" 19 395/6" 29
44/6" 4 10" 30 155/6" 26 261/6" 22 40" 30
45/6" 16 101/6" 37 16" 30 262/6" 25 401/6" 32
5" 5 102/6" 43 161/6" 35 263/6" 28 402/6" 34
51/6" 17 103/6" 49 162/6" 39 264/6" 30 403/6" 36
52/6" 4 104/6" 4 163/6" 42 265/6" 33 404/6" 37

Inch- Pos. Inch- Pos. Inch- Pos. Inch- Pos. Inch- Pos.
es es es es es
53/6" 15 105/6" 10 164/6" 46 27" 36 405/6" 39
54/6" 27 11" 15 165/6" 50 271/6" 38 41" 40
55/6" 10 111/6" 20 17" 54 272/6" 40 411/6" 41
6" 19 112/6" 27 184/6" 4 273/6" 42 412/6" 43
61/6" 31 113/6" 33 185/6" 7 274/6" 45 413/6" 45
62/6" 11 114/6" 39 19" 11 275/6" 47 414/6" 46
63/6" 19 115/6" 44 191/6" 14 28" 49 415/6" 48
64/6" 30 12" 49 192/6" 16 281/6" 52 42" 49
65/6" 6 121/6" 55 193/6" 19 282/6" 54 421/6" 51
7" 15 122/6" 55 194/6" 23 365/6" 40 422/6" 53
71/6" 24 123/6" 5 195/6" 27 371/6" 2 423/6" 54
72/6" 34 124/6" 11 20" 30 372/6" 4 — —
73.6" 5 125/6" 15 201/6" 34 373/6" 5 — —
74/6" 14 13" 19 202/6" 37 374/6" 7 — —
75/6" 21 131/6" 25 203/6" 40 375/6" 9 — —
8" 30 132/6" 30 204/6" 43 38" 11 — —
81/6" 39 133/6" 36 205/6" 46 381/6" 12 — —


Appendix B
Comments
Your comments on this User Manual
Introduction
We are interested in your opinion on User Manual for the Océ ColorStream. This will
help us improve this User Manual. Please fill out these pages and fax them back to us:
+49 (0)8121 72 3420
Or send your comments by e-mail to:

[email protected]
Thank you for your help.
Comments
Can you find the information you need quickly and easily?
O Yes
O No
Are your activities described fully and in sufficient detail?

O Yes
O No
Is the text easy to understand?

O Yes
O No
Are the illustrations easy to understand?

O Yes
O No — too abstract
O No — too detailed
Is the amount of background information sufficient for your needs?

O Yes
O No — not enough
O No — too much
What did you use to find the required information?

O Table of contents
O Index
Are you satisfied with this user guide?

O Yes
O No
508 Appendix B - Comments

What should we omit from, change or add to the user guide?
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
Sender
Name:
Occupation:
Phone:
Company:
Address:
City:
Country:
Date:
(If you prefer to remain anonymous, please only fill in your occupation.)
Appendix B - Comments 509

Index
Button
Index Access ticket ...................................................90
ADVF ............................................................84
ADVR ............................................................84
Autofeed .........................................................84
Access ticket Back .............................................................133
Button ............................................................90 Cancel Print Job .............................................86
request ..........................................................116 Change user ....................................................90
Adapters Channel Control ............................................86
Adapters .......................................................165 Clear Buffer ....................................................86
Additional Color Clear Printer ...................................................86
Additional Color ............................................64 Consumables Counter ....................................86
Toner Supply ...............................................317 Delete (user) .................................................111
Additional Operator Panels Deleting (resources) ......................................132
Additional Operator Panels ............................67 Deleting all (resources) .................................132
Adjusting the sliding brackets Display Errors .................................................86
Replacement cart ..........................................169 Display information ........................................86
ADVF Display Warnings ...........................................86
Button ............................................................84 Eject ...............................................................84
Key .................................................................70 Help ...............................................................90
ADVR Installing (Resource) .....................................130
Button ............................................................84 Job Control ....................................................86
Key .................................................................70 Next .............................................................133
Agent NPRO ............................................................84
Agent ..............................................................38 océ ..................................................................90
Assembly Off .................................................................90
Safety directives ..............................................42 Ready .............................................................84
Asymmetric Configuration Remote Diagnosis ...........................................86
Asymmetric Configuration ...........................317 Service Ticket .................................................86
AUTOFEED Stop ................................................................84
Key .................................................................70 Test print .......................................................86
Autofeed User profile .....................................................90
Button ............................................................84
Autofeed: Insert paper
Status display ..................................................88 C
Autofeed: Paper feed Calibrating
Status display ..................................................88 Data Integrity Mark Sensor ..........................257
Autofeed: Remove paper Calibrating the Printing System
Status display ..................................................88 Overview ......................................................244
Autofeed: Started Calibration
Status display ..................................................88 Evaluating test print pages ............................253
Overview ......................................................244
Printing Test Pages .......................................246
B Scanning Test Print Pages ............................249
Back Cancel Print Job
Button ..........................................................133 Button ............................................................86
Bilevel CE Mark
Bilevel .............................................................64 CE Mark ........................................................48
Black/White Printing System Channel Control
Black/White Printing System ..........................64 Button ............................................................86
510
Index
Charge Corotron Photoconductor Unit Cleaning Tasks

Position ..........................................................58 Cleaning Tasks .............................................270
Charge corotron photoconductor unit Clear Buffer
Installing ......................................................416 Button ............................................................86
Removing .....................................................413 Clear Printer
Charging the batteries Button ............................................................86
Replacement cart ..........................................169 Climate and paper
Check Climate and paper ..........................................78
Paper Path ....................................................296 Climatic Conditions
Cleaning Climatic Conditions .....................................502
Corotron ......................................................270 Color Calibration
Developer Station Shelf ................................309 Overview ......................................................244
Developer Station Surface ............................273 Color Collection Mode
Housing Surface ...........................................307 Color Collection Mode ...................................64
Paper Brake Dust Filter ................................305 Color Mapping Table
Paper Input ..................................................283 Test Print .....................................................215
Paper Output ...............................................286 Color Profiles
Paper Path ....................................................289 Test Print .....................................................211
Printing System ............................................268 Color Separation Shifts
Replacement cart ..........................................308 correcting .....................................................255
Safety directives ..............................................40 Color Spaces
Toner Suction System ..................................301 Test Print .....................................................208
Vat under Toner Bottle Holder ....................301 ColorStream
Cleaning Agent Menu ..............................................................97
Cleaning Agent .............................................270 Concentrated load
Cleaning Brush Concentrated load ........................................501
Photoconductor unit ......................................58 Condensation Water
Cleaning brush Condensation Water ....................................263
Replacing .....................................................433 Configuration
Transfer unit ..................................................60 Menu ...........................................................100
Cleaning brush of photoconductor unit Console
Installing ......................................................437 Console ....................................................56, 62
Removing .....................................................434 Consumables
Cleaning brush of transfer unit Replacing .....................................................312
Installing ......................................................441 Consumables Counter
Removing .....................................................439 Button ............................................................86
Cleaning Corotron Contents
Photoconductor unit ......................................58 Contents .........................................................18
Cleaning corotron Context-sensitive Direct Help
Transfer unit ..................................................60 Context-sensitive Direct Help .........................21
Cleaning corotron photoconductor unit Continuing printing after errors have been corrected
Installing ......................................................416 Continuing printing after errors have been correct-
Removing .....................................................413 ed .................................................................475
Cleaning corotron transfer unit Cooling
Installing ......................................................420 Cooling ..........................................................40
Removing .....................................................418 Cooling down
Cleaning felt Status display ..................................................88
replacing .......................................................448 Copyright
Cleaning Intervals Copyright ...........................................................
Cleaning Intervals .........................................270 Corotron
Cleaning .......................................................270
511
Index
Replacing .....................................................412 Diagnosis by Service

Corotron wire Diagnosis by Service .....................................479
Replacing .....................................................428 Dimensions
Covers Dimensions ..................................................500
Covers ............................................................54 Direct Help
Closing .........................................................156 Open ..............................................................21
Opening .......................................................156 Displays
CSVID Menus ............................................................99
change ..........................................................124 Disposal
CustomTone Printing System Océ disposal concept ......................................44
CustomTone Printing System ........................64 Disposal concept
Disposal ..........................................................44
Doors
D Doors .............................................................54
Danger points Closing .........................................................156
Danger points .................................................35 Opening .......................................................156
Data Integrity Dot Matrix
Calibrating Mark Sensor ...............................257 Dot Matrix ...................................................493
Mark Dimensions .........................................257 Dot Modulation
Data Integrity Mark Sensor Dot Modulation ...........................................493
Calibrating ...................................................257 Draining
Data Integrity Sensor Developer mixture ........................................337
Data Integrity Sensor ....................................286
Data Streams
Data Streams ................................................493 E
Delete EJECT
Resources .....................................................132 Key .................................................................70
Delete (user) Eject
Button ..........................................................111 Button ............................................................84
Deleting (resources) Electrical Values
Button ..........................................................132 Electrical Values ...........................................498
Deleting all (resources) Elements
Button ..........................................................132 activating ......................................................113
Developer blocking .......................................................113
Filling ...........................................................340 Entering values
Order Numbers ............................................313 Entering values .............................................121
Packing Units ...............................................313 Environmental Conditions
Replacing .....................................................336 Environmental Conditions ...........................502
Developer mixture Error
Draining .......................................................337 Display (Button) .............................................86
Developer Station Print Image ..................................................484
Developer Station ...........................................58 Error messages
Cleaning the Surface .....................................273 locating ........................................................475
Developer station Errors
Adapters .......................................................165 Correcting ....................................................474
Change .........................................................165 Evaluating test print pages
Maintenance Cart .........................................165 Evaluating test print pages ............................253
Slots .............................................................317 Expendables
Developer Station Shelf Expert Mode ................................................469
Developer Station Shelf ................................165 Order Numbers ............................................349
512
Index
Packing Units ...............................................349 GraphicArts

Replacing .....................................................346 GraphicArts ..................................................493
Expert Mode
Expert Mode ................................................469
Export H
Setup ............................................................127 Heat Exchanger
Extended password protection Heat Exchanger ..............................................56
Extended password protection ......................109 Height
External Stop Height ..........................................................500
External Stop ..................................................72 Help
Button ............................................................90
Open ..............................................................16
F Highlight Color Tone Transfer Curve
Filling Test Print .....................................................214
Developer .....................................................340 Humidity
Toner Box ....................................................335 Humidity .....................................................502
Filter module
Filter module ..................................................61
Fine filter I
position ..........................................................61 Import
Replacing .....................................................443 Setup ............................................................125
Fire Index
Safety directives ..............................................44 Index ..............................................................19
Foreign bodies Information
Foreign bodies ................................................40 Display (Button) .............................................86
Format Height locating ........................................................475
Format Height .............................................496 Information signs
Format Width Information signs ...........................................35
Format Width ..............................................496 Infrared Lamp
Frame toolbar Infrared Lamp ................................................56
Frame toolbar .................................................90 Initialization
Full text search Status display ..................................................88
Full text search ...............................................20 Inserting
Full Tone Coloration Lower Photoconductor belt (OPC Belt) .......370
Test Print .....................................................213 Paper Web ....................................................143
Full-color Printing System The Lower Transfer Belt ..............................402
Full-color Printing System ..............................64 Upper Photoconductor Belt (OPC Belt) ......358
Fuser module Upper Transfer belt ......................................385
Fuser module ..................................................56 Installation
Fusing method Safety directives ..............................................42
Fusing method .............................................493 Installing
Fusing Problems Charge corotron photoconductor unit ..........416
Fusing Problems ...........................................483 Cleaning brush of photoconductor unit ........437
Cleaning brush of transfer unit .....................441
Cleaning corotron photoconductor unit .......416
G Cleaning corotron transfer unit ....................420
General Light Protection Cover .................................197
Menu ..............................................................93 Lower Photoconductor Blade .......................364
Grammage Recharge corotron transfer unit ....................427
Grammage ...................................................496 Reload corotron transfer unit ........................423
513
Index
Resources .....................................................130 Load .............................................................501

Smoothing rollers .........................................461 Log in
The Lower Transfer Belt ..............................402 as user ...........................................................116
Upper Photoconductor Blade .......................352 Log off
Upper Transfer belt ......................................385 as user ...........................................................120
Installing (Resource)
Button ..........................................................130
Intended Purpose M
Intended Purpose ............................................33 Main Color
Interfaces Main Color .....................................................64
Interfaces ......................................................494 Main switch
Main switch ....................................................67
Maintenance Cart
J Maintenance Cart .........................................165
Job Control Manufacturer
Button ............................................................86 Manufacturer ..................................................28
Job feed Mechanical Conditions
Status display ..................................................88 Mechanical Conditions ................................500
Menu
Add User ......................................................110
K ColorStream ...................................................97
Key Configuration ...............................................100
ADVF ............................................................70 Delete user ...................................................111
ADVR ............................................................70 General ...........................................................93
AUTOFEED ..................................................70 Replacing consumables .................................102
EJECT ...........................................................70 Security ..........................................................96
NPRO ............................................................70 Setup ............................................................101
READY ..........................................................70 User ................................................................95
STOP .............................................................70 User management ...........................................94
Key Operator Menu display
Key Operator ..................................................38 Menu display ................................................104
Key Operator Panels Menu Tree
Key Operator Panels .......................................67 Menu Tree .....................................................91
Menus
activating ......................................................113
L blocking .......................................................113
Language Calling up .......................................................91
change ..........................................................119 Displays ..........................................................99
set .................................................................114 Paper Path Manager .......................................91
LED Web Buffer .....................................................91
Reader ..........................................................324 Modules
Toner Box ....................................................324 Modules .........................................................53
LED Print Head Multilevel
LED Print Head .............................................58 Multilevel .......................................................64
Length
Length ..........................................................500
Light Protection Cover N
Installing ......................................................197 Navigation Tree
Removing .....................................................194 Navigation Tree ..............................................91
Load Network Connection
514
Index
Network Connection ....................................494 Overview ......................................................239

Next Order Number
Button ..........................................................133 Order Number ....................................................
Noises Order Numbers
Noises .............................................................40 Developer .....................................................313
NPRO Expendables .................................................349
Button ............................................................84 Toner ...........................................................313
Key .................................................................70 Ozone concentration
Ozone concentration ....................................502
O
océ P
Button ............................................................90 Packing Units
Off Developer .....................................................313
Button ............................................................90 Expendables .................................................349
On Key Toner ...........................................................313
On Key ...........................................................67 Page advance
Online Help Status display ..................................................88
Button ............................................................90 Paper
OPAL Technical Data .............................................496
OPAL .............................................................72 Paper advance backwards
OPC Belt (Photoconductor Belt) Status display ..................................................88
Inserting in the Lower Print Unit .................370 Paper advance forwards
Inserting in the Upper Print Unit .................358 Status display ..................................................88
position ..........................................................58 Paper Brake Dust Filter
Removing in the Lower Print Unit ...............364 Cleaning .......................................................305
Removing in the Upper Print Unit ...............352 Paper Cooling
Replacing .....................................................350 Paper Cooling .................................................56
running in ....................................................411 Paper handling
Operating Elements Paper handling ...............................................78
Additional Operator Panels ............................67 Paper Input
Key ON ..........................................................67 Cleaning .......................................................283
Operator Attention Light ...............................67 Position ..........................................................56
Overview ........................................................67 Paper Input Module
Operating elements Paper Input Module .......................................53
in the printing system .....................................77 Paper measurement
Operating Noise Status display ..................................................88
Operating Noise ...........................................502 Paper Movement Sensor
Operation Paper Movement Sensor ...............................286
Safety Directives .............................................39 Paper Output
Operator Cleaning .......................................................286
Operator .........................................................38 Position ..........................................................56
Operator Attention Light Paper Path
Displays ..........................................................72 Checking ......................................................296
Position ..........................................................67 Cleaning .......................................................289
Operator intervention necessary Paper Path Manager
Status display ..................................................88 Menus ............................................................91
Optical wave guide Paper Rip
Optical wave guide .........................................41 Paper Rip .....................................................270
Optimizing the Color Printing Paper Specification
515
Index
Paper Specification .........................................27 Photoconductor unit

Paper specifications Cross Section ..................................................58
Paper specifications .........................................78 Power Input
Paper types Power Input .................................................498
Paper types .....................................................78 Powering down
Paper Web Status display ..................................................88
inserting .......................................................143 Powering On
Paper web Printing system .............................................139
Affixing ........................................................152 Recooler .......................................................139
removing ......................................................155 Powering on
Paper width is being adjusted the printing system .......................................264
Status display ..................................................88 Pre-/post-processing unit not ready
Paper Width Sensor Status display ..................................................88
Paper Width Sensor ......................................283 Preparation
Parameters Status display ..................................................88
Applying .......................................................122 Pressure Rollers
Resetting ......................................................122 adjusting .......................................................148
Password Cleaning .......................................................286
Change .........................................................118 Print image
See Password ................................................118 checking .......................................................199
Set ................................................................112 Print Image Error
Password protection Print Image Error .........................................484
Password protection .....................................109 Print Speed
PDF Color Spaces Print Speed ...................................................494
Test Print .....................................................219 Print Unit
PDF Raster Angle Print Unit .......................................................53
Test Print .....................................................223 Lower .............................................................56
PDF Raster Width Upper .............................................................56
Test Print .....................................................223 Print Width
PDF Reference Images Print Width ..................................................496
Test Print .....................................................225 Printing
PDF Tone Transfer Curves Status display ..................................................87
Test Print .....................................................222 Printing method
Performing a Printing method .............................................64
color test .......................................................242 Printing System
Photoconductor Cleaning .......................................................268
Lower .............................................................56 Conversion ...................................................261
Upper .............................................................56 Description .....................................................52
Photoconductor Belt (OPC Belt) Main Modules ................................................53
Inserting in the Lower Print Unit .................370 Printing system
Inserting in the Upper Print Unit .................358 Internal View ..................................................56
Position ..........................................................58 Powering On ................................................139
Removing in the Lower Print Unit ...............364 switching to ready after print stop ................142
Removing in the Upper Print Unit ...............352 Printing system stopping
Replacing .....................................................350 Status display ..................................................88
running in ....................................................411 Printing Systems
Photoconductor Blade Printing Systems ...........................................493
Photoconductor unit ......................................58 Printing Test Pages
Replace in the Lower Print Unit ...................364 Calibration ...................................................246
Replacement in the Upper Print Unit ...........352 Problem
516
Index
Fusing ..........................................................483 Removing

Process optimization Charge corotron photoconductor unit ..........413
Status display ..................................................87 Cleaning brush of photoconductor unit ........434
Processing Speed Cleaning brush of transfer unit .....................439
Processing Speed ..........................................494 Cleaning corotron photoconductor unit .......413
Pull-back Length Cleaning corotron transfer unit ....................418
Pull-back Length ..........................................504 Light Protection Cover .................................194
Lower Photoconductor belt (OPC Belt) .......364
Lower Photoconductor Blade .......................364
R Lower transfer belt (TFB belt) ......................395
Raster Angle Paper web .....................................................155
Test Print .....................................................214 Recharge corotron transfer unit ....................425
Raster Width Reload corotron transfer unit ........................421
Test Print .....................................................214 Smoothing rollers .........................................455
Reader Top Transfer Belt (TFB Belt) .......................376
Reader ..........................................................314 Upper Photoconductor Belt (OPC Belt) ......352
LED .............................................................324 Upper Photoconductor Blade .......................352
READY Repairs
Key .................................................................70 Safety directives ..............................................42
Ready Replace
Button ............................................................84 Developer station .........................................165
Status display ..................................................87 Replacement cart
Ready power save Adjusting the sliding brackets .......................169
Status display ..................................................88 Charging the batteries ..................................169
Readying Technical data ..............................................503
Status display ..................................................87 Replacing
Recharge corotron transfer unit Cleaning brush .............................................433
Installing ......................................................427 Cleaning felt .................................................448
Removing .....................................................425 Consumables ................................................312
Recooler Corotron ......................................................412
Recooler .........................................................56 Corotron wire ...............................................428
Powering On ................................................139 Developer .....................................................336
Standards ........................................................46 Expendables .................................................346
Reference Images Fine filter ......................................................443
Test Print .....................................................216 Lower Photoconductor Blade .......................364
Refilling Photoconductor Belt (OPC Belt) .................350
Toner (1 kg/2.2 lb) .......................................324 Smoothing rollers .........................................454
Toner (6 kg/13.2 lb) .....................................318 Transfer Belt (TFB Belt) ..............................350
Reload corotron transfer unit Upper Photoconductor Blade .......................352
Installing ......................................................423 Waste toner box ...........................................331
Position ..........................................................60 Replacing consumables
Removing .....................................................421 Completing ..................................................133
Remote Menu ...........................................................102
diagnosis .......................................................480 Starting ........................................................133
Overview ......................................................479 Replacing expendables
support .........................................................481 Completing ..................................................133
Remote Diagnosis Starting ........................................................133
Button ............................................................86 Replacing the smoothing rollers
Remote diagnosis by Service Replacing the smoothing rollers ....................454
Remote diagnosis by Service .........................479 Request
517
Index
access ticket ..................................................116 Remote Diagnosis ........................................479

Resources Service Ticket
Delete ...........................................................132 Button ............................................................86
installing .......................................................130 Settings
Managing .....................................................129 Applying .......................................................122
Rocker Resetting ......................................................122
Rocker ............................................................56 Setup
Room Temperature change ..........................................................124
Room Temperature ......................................502 creating new .................................................124
Ruler for Paper Path Synchronization exporting ......................................................127
Ruler for Paper Path Synchronization ...........504 importing .....................................................125
Running in Menu ...........................................................101
Photoconductor Belt (OPC Belt) .................411 Status display ..................................................88
Transfer Belt (TFB Belt) ..............................411 Signs
Signs ...............................................................35
Smoothing Module
S Smoothing Module ........................................56
Safety Smoothing rollers
Safety ..............................................................32 Installing ......................................................461
Safety covers Removing .....................................................455
Safety covers ...................................................39 Special functions
Safety Directives Status display ..................................................88
Operation .......................................................39 Standards
Safety directives Standards ........................................................45
Assembly ........................................................42 Starting
Fire .................................................................44 Status display ..................................................88
Flagging ..........................................................34 Status display
Installation .....................................................42 Autofeed: Insert paper ....................................88
Repairs ...........................................................42 Autofeed: Paper feed .......................................88
Transport .......................................................42 Autofeed: Remove paper .................................88
Safety information Autofeed: Started ............................................88
Safety information ..........................................27 Cooling down .................................................88
Safety regulations Initialization ...................................................88
Safety regulations ............................................45 Job feed ..........................................................88
Sample Operator Operator intervention necessary ......................88
Sample Operator ..........................................107 Page advance ..................................................88
Scanning Test Print Pages Paper advance backwards ................................88
Scanning Test Print Pages ............................249 Paper advance forwards ...................................88
Search Paper measurement .........................................88
Search .............................................................20 Paper width is being adjusted ..........................88
Security Powering down ...............................................88
Menu ..............................................................96 Pre-/post-processing unit not ready .................88
Selecting settings Preparation .....................................................88
Selecting settings ..........................................121 Printing ..........................................................87
Sensor Printing system stopping ................................88
Data Integrity ...............................................286 Process optimization .......................................87
Paper Movement ..........................................286 Ready .............................................................87
Paper Width .................................................283 Ready power save ............................................88
Service Readying ........................................................87
Service ............................................................38 Setup ..............................................................88
518
Index
Special functions .............................................88 Test print

Starting ...........................................................88 activate .........................................................200
Stop ................................................................88 Button ............................................................86
Stop Power Save .............................................88 cancel ...........................................................200
Warming up ...................................................88 Test Print Jobs
Statutory requirements Test Print Jobs .............................................200
Statutory requirements ...................................29 TFB Belt
STOP Inserting in the Lower Print Unit .................402
Key .................................................................70 Inserting in the Upper Print Unit .................385
Stop Replacing .....................................................350
Button ............................................................84 TFB belt
Status display ..................................................88 Position ..........................................................60
with loss of information ................................475 TFB Belt (Transfer Belt)
without loss of information ..........................475 Removing in the Lower Print Unit ...............395
Stop Power Save Removing in the Upper Print Unit ...............376
Status display ..................................................88 running in ....................................................411
Subtractive Color Mixing Tone Transfer Curves
Subtractive Color Mixing ...............................64 Test Print .....................................................213
Surface load Toner
Surface load ..................................................501 Order Numbers ............................................313
Switching off Packing Units ...............................................313
Powering on .................................................264 Refilling (1 kg/2.2 lb) ...................................324
Printing system .............................................264 Refilling (6 kg/13.2 lb) .................................318
Switching to ready Toner Bottle Identification
Printing system after print stop .....................142 Toner Bottle Identification ...........................314
Symbol Toner Box
in diagrams and illustrations ...........................25 Toner Box ......................................................58
in the text .......................................................24 Filling ...........................................................335
Synchronization LED .............................................................324
Ruler ............................................................504 Toner Feed Unit
Synchronizing Toner Feed Unit .............................................56
Paper Path ....................................................150 Toner Mark Sensor
Synchronizing the Paper Path Toner Mark Sensor .........................................58
Synchronizing the Paper Path .......................150 Toner Suction System
cleaning ........................................................301
Toner Supply
T Additional Color ..........................................317
Technical Data toner supply
Technical Data .............................................492 toner supply ....................................................62
Electrical Values ...........................................498 TonerSafe
Environmental Conditions ...........................502 TonerSafe .....................................................314
Mechanical Conditions ................................500 Toolbar
Paper ............................................................496 Toolbar ..........................................................83
Power Input .................................................498 Trademarks
Technical data Trademarks .........................................................
Replacement cart ..........................................503 Training
Tension Roller Training ..............................................................
Tension Roller ..............................................286 Transfer Belt
Test Data Inserting in the Lower Print Unit .................402
Print .............................................................200 Inserting in the Upper Print Unit .................385
519
Index
Removing in the Lower Print Unit ...............395 Weight .........................................................500

Removing in the Upper Print Unit ...............376 Width
Replacing .....................................................350 Width ..........................................................500
running in ....................................................411
Transfer belt
Position ..........................................................60
Transfer Unit
Lower .............................................................56
Upper .............................................................56
Transfer unit
Cross section ...................................................60
Transponder
Transponder .................................................314
Transport
Safety directives ..............................................42
U
User
Add ..............................................................110
change (button) ..............................................90
Delete ...........................................................111
log in ............................................................116
logging off ....................................................120
Menu ..............................................................95
User management
Menu ..............................................................94
User profile
Button ............................................................90
User Settings
Key Operator ...............................................107
Operator ......................................................115
W
Warming up
Status display ..................................................88
Warning signs
Warning signs .................................................35
Warnings
Display (Button) .............................................86
locating ........................................................475
Waste toner box
position ..........................................................61
Replacing .....................................................331
Web Buffer
Menus ............................................................91
Web Inspection Stop
Web Inspection Stop ....................................199
Weight
520
+3
+3
+3
Beyond the Ordinary
o
Printing for
Professionals
Océ works with people who are changing the world.

Companies all over the world use technical documenta-
tion systems from Océ in production, architecture, engi-
neering and construction. Each week, millions of trans-
action documents such as bank statements and bills are
produced on high-speed printing systems from Océ. In
offices across the world, people use professional documen-
tation systems from Océ to keep the wheels turning in
their company or organization. Océ is also involved in
publishing on demand, newspaper production, outsourc-
ing in documentation management and large-format
color printing for spectacular displays. In this way, we
help our professional customers to achieve exceptional
results in numerous areas of print and document man-
agement.
You can find more information about our products and

services at
www.oce.com

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Océ

More Power When

Copyright © Océ 2008–2009

We also offer courses in our Training Center for Océ ColorStream.

Océ Printing Systems GmbH

Doors and Covers.....................................................................................54

Managing User Settings (Key Operator)..............................................107

Closing Left Doors............................................................................163

Optimizing the Color Printing................................................................239

Replacing the Developer - Overview..............................................336

Replacing the Cleaning Brush...............................................................433

Notes on the Printing System Documentation — Overview

Storage Tray for the User Guide

■ ‘Notes on the Help - Overview’ on page 15

■ ‘Symbols in the text’ on page 24

■ ‘Symbols in figures’ on page 25

■ ‘Other Documents’ on page 27

■ ‘Manufacturer of the printing system’ on page 28

■ ‘Statutory requirements’ on page 29

12 Chapter 1 - Notes on the Printing System Documentation

Guide through the Documentation

Description of the printing system

Description of the Operator Panel

Working with the operator panel

Operating the printing system

Cleaning the printing system

Chapter 1 - Notes on the Printing System Documentation 13

Your comments on this user guide

14 Chapter 1 - Notes on the Printing System Documentation

Help target group

■ 'VarioStream' or 'ColorStream' or 'JetStream'

Océ ColorStream, also: 'Web Buffer'

‘Opening Help’ on page 16

‘Opening Direct Help’ on page 21

Chapter 1 - Notes on the Printing System Documentation 15

The Help window opens. The navigation area is displayed initially:

16 Chapter 1 - Notes on the Printing System Documentation

Function of the Buttons in the Help Window

When the navigation area is hidden, more space is available to view

Chapter 1 - Notes on the Printing System Documentation 17

To call up Help topics via the contents

3. Click on a help topic.

18 Chapter 1 - Notes on the Printing System Documentation

To select information via the Index

3. Click on a help topic

Chapter 1 - Notes on the Printing System Documentation 19

To call up information via the full text search

20 Chapter 1 - Notes on the Printing System Documentation

Opening Direct Help

■ Operating elements in menus

■ Errors and warnings

Selected element with a blue frame:

Chapter 1 - Notes on the Printing System Documentation 21

To call up the Direct Help

select operating element

22 Chapter 1 - Notes on the Printing System Documentation

Function of the Buttons in the Help Window

When the navigation area is hidden, more space is available to view

Chapter 1 - Notes on the Printing System Documentation 23