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Xerox 128 Printer User Manual

1. SSS Figure 4 6 Area 7 DocuTech 128 155 180 HighLight Color Operator Guide 4 9 Problem Solving Figure 4 7 Area 8 NOTE f a jammed sheet rips as you are removing it from area 8 4 you may have to use the pinch lever in area 9 to remove the paper Refer to the Note following the area 14 figure for additional instructions 4 10 DocuTech 128 155 180 HighLight Color Operator Guide Problem Solving A mmm Figure 4 8 Area 9 To clear jams from area 9 1 Lower and pull out tray 1 to give you better access to area 9 2 Pullthe area 9 green lever toward you to unlatch it Be sure to relatch the lever after you have cleared any paper in this area To further facilitate removing sheets wedged in this area pull out tray 1 and hold the green lever down 3 Turn the green knob located to the right of the lever to move jammed sheets further along the paper path to where they are more accessible and easier to remove 4 If paper rips as you are
2. Item Description U S part number Paper Xerox paper quantities are 10 reams 5 000 sheets to a carton unless otherwise noted below 8 5 x 11 inch Xerox Business 4200 3R2047 A4 Xerox Business 4200 3R2594 8 5 x 14 inch Xerox Business 4200 3R2051 8 5 x 11 inch Xerox Business 4200 3 hole 3R2641 8 5 x 17 inch Xerox Business 4200 3R3761 8 5 x 11 inch Xerox Business 4200 4 hole 3R3008 8 5 x 11 inch Xerox Business 4200 7 hole 3R3010 8 5 x 11 inch 4200 Smooth 3R2675 8 5 x 14 inch 4200 Smooth 3R2677 8 5 x 11 inch Dual Purpose Colors Blue 3R3052 8 5 x 11 inch Dual Purpose Colors Blue 3 3R3068 hole 8 5 x 14 inch Dual Purpose Colors Blue 3R3084 8 5 x 11 inch Dual Purpose Colors Green 3R3056 8 5 x 11 inch Dual Purpose Colors Green 3 3R3072 hole 8 5 x 14 inch Dual Purpose Colors Green 3R3088 8 5 x 11 inch Dual Purpose Colors Pink 3R3058 8 5 x 11 inch Dual Purpose Colors Pink 3 hole 3R3074 8 5 x 14 inch Dual Purpose Colors Pink 3R3090 8 5 x 11 inch Dual Purpose Colors Yellow 3R3054 8 5 x 11 inch Dual Purpose Colors Yellow 3 hole 3R3070 8 5 x 14 inch Dual Purpose Colors Yellow 3 R3086 8 5 x 11 inch Dual Purpose Colors Buff 3R3060 8 5 x 11 inch Dual Purpose Colors Buff 3 hole 3R3076 8 5 x 14 inch Dual Purpose Colors Buff 3R3092 8 5 x 11 inch Dual Purpose Colors Goldenrod 3R3062 8 5 x 11 inch Dual Purpose Colors Goldenrod 3R3078 3 hole 8 5 x 14 i
3. Figure 4 1 Area 2 M fa WA A Figure 4 2 Area 3 DocuTech 128 155 180 HighLight Color Operator Guide 4 7 Problem Solving ELL F o SB SAS ADN ay ZA J iT e Figure 4 3 Area 4 Figure 4 4 Area 5 4 8 DocuTech 128 155 180 HighLight Color Operator Guide Problem Solving Figure 4 5 Area 6 S
4. 0 0 cece eee 3 33 Cleaning the DVD drive 2 0 0c tte eee 3 33 Cleaning the diskette drive 0 0 0 c ett 3 33 Cleaning the sensors and the reflecting surfaces 0 00 cee eee 3 34 Cleaning the Q850 and Q861 sensor auauna eens 3 34 Cleaning the Q1011 1009 sensor and mirror 0000 c eee eee 3 36 Cleaning the Q1106 and Q1166 sensors 0 00 cee 3 36 Cleaning the Q1107 Sensor 0 cece tee 3 37 Cleaning the Q1164 sensor 0 cece tenes 3 38 Cleaning the display 0000 ccc tte 3 39 Cleaning the exterior surfaces of the system 00000 cece eee eee 3 39 Clearing or cleaning the finisher Sensors 00 00 cee eee eee eee 3 40 Clearing the Q1201 sensor ee ene een eens 3 40 Clearing the Q1202 and Q1203 sensors n nannan aaa teens 3 41 Cleaning the Q1222 and Q1210 sensors 0 0 00 cece 3 43 Clearing the Q1205 Q1206 and Q1207 sensors 0 0 c eee ees 3 44 Clearing the Q1213 sensor n nnana anaana 3 45 Clearing the Q1221 Q1218 and Q1227 sensors 0 ees 3 46 Cleaning the binder 000 cect ttt eee 3 47 Cleaning the binder tape guides 0 20 3 49 Cleaning the binder platen 0 00 cette eee 3 49 Cleaning the flappers 0 0 0 ett 3 50 Cleaning the calipers 0 0 0 ccc ete 3 51 Closing the DInd6 cris sandid eiaa lee eke Re ee ae be eee ee 3 52 Replacing the stitcher Ss
5. LCDS 300 by 300 dpi 600 x 2400 dpi High volume printer only PostScript and PCL 300 by 300 dpi or 600 600 x 2400 dpi High volume printer by 600 dpi 600 x 600 dpi Production publisher Data formats supported The Xerox DocuTech 128 155 180 HLC can print the following data formats e ASCII LCDS gt IPDS e PCL PDF e PostScript e TIFF e PPML NOTE Not supported on the Production publisher configuration at this time The system prints LCDS data from a mainframe host computer emulating an IBM 4245 or 3211 page printer The printing system can receive data over a channel through bus and tag cables and through the Socket Gateway or lpr using TCP IP protocol The system also prints PostScript and PCL data submitted over a network Ethernet or AppleTalk from a variety of clients PCs Windows and Windows NT Sun workstations UNIX UNIX command line clients lpr including p and Xerox Command Line Client CLC NetWare Q Server through a Novell print server bindery mode only Apple Macintosh workstations DocuTech 128 155 180 HighLight Color Operator Guide 2 3 System components Paper weights Special stocks Stock specifications The success of any print run depends on proper selection care and handling of the paper or other stock that is used It is very important to select store condition and load print media properly in order to keep your prin
6. XEAO61A Figure 3 54 Rewinding the remaining wire 6 Insert the plug into the measuring bracket as shown in figure 3 55 DocuTech 128 155 180 HighLight Color Operator Guide 3 55 Routine maintenance OA196A Figure 3 55 The measuring bracket 7 Release and remove stitcher spool A a Locate the green pin release handle under spool B as shown in figure 3 56 XEA062A Figure 3 56 Removing the stitcher spool pin b Pull and hold the handle forward and remove the pin c Release the handle and remove stitcher spool A 3 56 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance 8 Install the new stitcher spool a Slide the new stitcher spool into position with the paper wrapper still in place b Replace the stitcher spool pin Push it down until it locks into place as shown in figure 3 57 el o gt CLOT OS g y l S S XEAO65A Figure 3 57 Replacing the pin 9 Remove any damaged wire WARNING Hold the wire on the spool to prevent eye injury and A to keep the wire from unwinding a Locate the end of the wire on the new spool b Using the wire cutters carefully clip any bent or twisted wire from the lead end of the wire c Hold onto the end of the wire and carefully remove the paper wrapper as shown in figure 3 58 DocuTech 128 155 180 HighLight Color Operator Guide 3 57 Routine maintenance XEAO66A Figure 3 58 Remo
7. Domestic Household Environment Application of this symbol on your equipment is confirmation that you should not dispose of the equipment in the normal household waste stream In accordance with European legislation end of life electrical and electronic equipment subject to disposal must be segregated from household waste Private households within EU Member States may return used electrical and electronic equipment to designated collection facilities free of charge Please contact your local disposal authority for information In some Member States when you purchase new equipment your local retailer may be required to take back your old equipment free of charge Please ask your retailer for information Professional Business Environment Application of this symbol on your equipment is confirmation that you must dispose of this equipment in compliance with agreed national Procedures In accordance with European legislation end of life electrical and electronic equipment subject to disposal must be managed within agreed procedures Prior to disposal please contact your local dealer or Xerox representative for end of life take back information T DocuTech 128 155 180 HighLight Color Operator Guide DocuTech 128 155 180 HighLight Color Operator Guide Table of Contents 1 Safety notices SYSIEM SALCLY sara nese eee aed Wee tates De ee ek Ree ee Pe Pe ee 1 1 Laser Safety 2 hese dopa hav esachd A E a eet dee ech ead a
8. System Hardware The basic hardware components of the DocuTech 128 155 180 HLC systems are the DocuSP controller and the printer The DocuSP controller The DocuSP controller is the connection between you and the system You communicate through the DocuSP software by selecting and managing the jobs displayed on the screen and sending them to the printer for production The system also communicates messages and instructions to you on the Print Services interface screen The controller consists of a specially configured workstation and uses proprietary Xerox hardware firmware and software Specifications can be obtained from your Xerox customer representative or by accessing the Setup System Configuration feature on the DocuSP user interface NOTE Controller hardware configurations are subject to change 4 to keep up with advances in technology lt Controller overview The controller receives LCDS IPDS PostScript and PCL data streams from a mainframe host or a workstation client processes the data and sends it to the printer The controller also provides the printer with print data and commands and receives status information from the printer The controller consists of a workstation which is run by the Sun Solaris Operating environment Also resident on the controller is the Document Services Platform application software known as DocuSP software which manages all printing diagnostic and administrative f
9. Use the Image Shift or Reduce Enlarge options to avoid printing near the holes Fan the paper and check the paper for loose paper plugs before loading the paper into the trays Never tear 3 hole drilled Load the paper into trays 1 and 2 with holes to the right load the paper into trays 3 4 and 5 with holes to the left Do not bind or run 2 sided prints Never tear Do not bind or run 2 sided prints 5 8 DocuTech 128 155 180 HighLight Color Operator Guide Technicalinformation Stock Type Instructions for use 3 hole drilled edge reinforced 4024 DP paper Do not stitch or bind Do not run with tabs Tabs can be inserted off line For optimum satisfaction use the paper trays 1 and 2 plate assembly The plate assembly can be ordered by a Customer Service Representative Up to 500 sheets can be placed in the tray Load the paper into all trays with holes to the left reinforced side down Select lt Properties gt on the Trays pull down menu On the Stock window under Type select lt Drilled gt Image quality problems may occur near the reinforcement with side 2 printing Remove the paper immediately before use to ensure that prints stay flat Print with no more than 200 sheets in a tray Select a quantity of 50 or fewer at a time Transparencies with a 0 5 inch 13 mm white stripe Load the stock with the white stripe to the right into trays 1 and 2 Loa
10. 1 2 DocuTech 128 155 180 HighLight Color Operator Guide Safety notices The power cable is damaged or frayed Liquid is spilled into the system The system is exposed to water Any part of the system is damaged e Always use materials and supplies specifically designed for your Xerox equipment Use of unsuitable materials may result in poor performance and can possibly create a hazardous situation Never attempt any maintenance function that is not specifically described in this Operator Guide Never remove any covers or guards that are fastened with screws There are no operator serviceable areas within these covers e Never use supplies or cleaning materials for other than their intended purposes Keep all materials out of the reach of children European Union declaration of conformity Approvals and The CE marking applied to this product symbolizes Xerox Europe certification Declaration of Conformity with the following applicable Directives of the European Union as of the dates indicated below e January 1 1995 Council Directive 73 23 EEC amended by Council Directive 93 68 EC approximation of the laws of the member states related to low voltage equipment e January 1 1996 Council Directive 89 336 EC approximation of the laws of the member Stated related to electromagnetic compatibility March 9 1999 Council Directive 1995 5 EC on radio equipment and telecommunications terminal equip
11. approximately 425 F 218 TC and may cause serious burns If the binder has been in a Ready condition allow the binder drawer to cool at least one hour before continuing the procedure 1 Open the finisher doors 2 Grasp the green handle on the binder drawer and pull the drawer out until it stops lt ie i i XEA070A Figure 3 62 Opening the binder drawer 3 Remove the tape from the drive roll a Lift the pressure roll release handle and remove the tape from the drive roll DocuTech 128 155 180 HighLight Color Operator Guide 3 61 Routine maintenance XEAO71A Figure 3 63 Removing the tape b Rewind the tape onto the tape reel 4 Slide the tape reel off the tape reel drive a Move the reel retainer in the center of the reel to the horizontal unlocked position TA810A Figure 3 64 Unlocking the reel b Remove the tape reel 4 NOTE Ensure that the larger center hole in the reel faces the drive 5 Slide the new tape reel onto the tape reel drive a lf necessary rotate the tape reel slightly until it clicks into position 3 62 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance i NOTE The tape will not feed properly if the retainer is not 4 locked b Move the reel retainer to the locked position TA809A Figure 3 65 Locking the reel NOTE Ensure that the tape passes through the binder tape 4 sensor 6 Follow the instructions on the bi
12. 4 3 Resolving a finisher problem Sheets are spilling out of the top tray The capacity of the top tray is 500 sheets of substance 20 75 g m2 or 2 inches 51 mm in height When intermixed stock or paper heavier than substance 20 75 g m2 is being run the capacity of the top tray is reduced 500 sheets of substance 20 75 g m2 is equal to approximately 415 sheets of substance 24 90 g m2 310 sheets of substance 32 120 g m2 225 sheets of substance 110 200 g m2 If using any paper heavier than substance 20 75 g m2 or intermixed stock of different weights unload the top tray before the count in the tray reaches its capacity limit Refer to the satisfaction guides in the Technical information chapter Binder tape fault 4 NOTE Production publisher configuration only a To clear a binder tape fault 1 Open the finisher doors 2 Open the top cover WARNING The binder tape adhesive is hot approximately 425 F A 218 C Allow the binder to cool for 5 minutes with the finisher doors and top cover open before touching the binder tape 3 Follow the instructions on the screen to determine the area 17 or 18 that should be cleared 4 lf area 17 is displayed and the binder tape is present stop and follow the WARNING Remove the binder tape and paper Proceed to step 6 5 If area 17 is displayed and the binder tape is not present follow the instructions on the area 17 label and remove
13. a Locate the fuser drawer b Grasp the green handle on the fuser drawer and pull it out until it stops Ne Figure 3 21 Opening the fuser drawer WARNING Fuser lubricant contains silicone which can cause irritation upon contact with the eye Make sure that you wash your hands with soap and water after you finish this procedure CAUTION Fuser lubricant can cause damage to the CCU if any of the it is spilled into the unit Use extra care to ensure that no fuser lubricant is dripped into the CCU 4 Wipe the fuser lubricant filler area to remove any residual lubricant 5 Fill the fuser lubricant reservoir a Pull the fuser lubricant reservoir out until it stops b Remove the reservoir cap by turning it counterclockwise 3 24 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance Figure 3 22 Preparing to add fuser blend WARNING Fuser lubricant spills cause the floor to be slippery If A any fuser lubricant is spilled onto the floor it must be removed immediately c Open a new box of fuser lubricant and remove a bottle Remove the cap from the bottle of fuser lubricant d Carefully pour the fuser lubricant into the reservoir until the level reaches the MAX line Avoid spilling the fuser lubricant or overfilling the reservoir CAUTION Do not push the fuser lubricant bottle into the reservoir
14. by 10 inch enablement kit allows the printing system to print on 7 by 10 inch 178 by 254 mm paper size with throughput speed of up to 206 PPM Paper paths The paper path is the route that materials paper transparencies labels and so on follow through the printer from the feeder trays to the output bins or finisher DocuTech 128 155 180 HighLight Color Operator Guide System components High volume printer paper path The following figure shows the path the paper takes through the high volume printer fe 9b 9a 10b ee 8 8 a 12 9c 10c 7 gt key 6 a 12c 12b 1 3 4 2 3c 4c Figure 2 11 Route of paper through the high volume printer Processor feeder tray 1 Processor feeder tray 2 High capacity feeder tray 3 a Side 1 of sheet leaving feeder tray b Drilled holes on right edge c Origin 0 0 portrait orientation DocuTech 128 155 180 HighLight Color Operator Guide System components 4 High capacity feeder tray 4 a Side 1 of sheet leaving feeder tray b Drilled holes on right edge c Origin 0 0 portrait orientation Paper inverter Duplex inverter Sample tray ONO High capacity stacker bin A a Side 2 of sheet stacked in bin b Drilled holes on left edge c Origin 0 0 portrait orientation 9 High capacity stacker bin B a Side 2 of sheet stacked in b
15. cart pedal until you hear or feel the pedal catch The pedal should stay locked down The pallet within the cart is raised 8 Unlatch the CCU by turning the photoreceptor backup roller handle clockwise for a quarter turn to an upright position DocuTech 128 155 180 HighLight Color Operator Guide 3 17 Routine maintenance 5 Then turn the yellow CCU handle a quarter turn clockwise Figure 3 13 Unlatching the CCU 9 Using the metal flange of the color CCU pull the CCU out of the printer until it is completely in the cart The flange is located directly below the bottle a 0CD00005A SOF Figure 3 14 Removing the CCU from the printer 10 Push down firmly on the cart pedal until you hear or feel a click The pallet which now contains the CCU is lowered into 3 18 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance the cart If the pallet does not move check that the CCU is all the way out of the printer and push down on the pedal again Figure 3 15 Closing the top cover 11 Close the top cover and store it Inserting a CCU To insert a CCU follow these steps 1 Open the top cover of the cart containing the new color CCU 2 Push the cart up to the printer lining up the yellow knob on the cart with the yellow recess on the printer inner cover Make sure the cart is level OCD00007A SOR Figure 3 16 CCU on cart 3 Push t
16. conflict messages may occur for stock lengths in these ranges Job and stock programming work arounds may be required Paper stock rotation This section identifies the limitations on the rotation of paper stock in the DocuTech 128 155 180 HLC Bypass Transport when using a third party finishing device Background Due to the physical limitations of the DocuTech 128 155 180 HLC Bypass Transport some paper stocks will be damaged or will jam while being rotated Currently when using an external finishing device that is not a Signature Booklet Maker there is no message DocuTech 128 155 180 HighLight Color Operator Guide 5 11 Technical information displayed on the DocuSP controller to warn the Print Services Operator that the paper stock to be rotated will not fit in the Bypass Transport The Signature Booklet Maker attached to a DocuTech 128 155 180 HLC printer is only capable of handling paper stock up to 9 inches 229 mm in length in a portrait orientation With the introduction of other DFA complaint finishing devices for use with the DocuTech 128 155 180 HLC family of printers additional paper stock sizes can be handled by the finishing devices both straight from the Bypass Transport or rotated Limitations Do not rotate paper sizes that will not fit through the DocuTech 128 155 180 HLC Bypass Transport to a third party finishing device Before creating a document to be rotated by the Bypass T
17. date bake aoa 1 1 Ozone safety lt se sereia tasnia i ie OR woe a an ee AR en Dae ae es ade 1 2 Operation safety anana eaaa aa 1 2 European Union declaration of conformity saasaa eee eee 1 3 Certification to 1999 5 EC Radio Equipment and Telecommunications Terminal Equipment Directive 1 4 Electricity at Work Regulation UK suasanana cee tees 1 5 Check your understanding 0c eect teens 1 6 Additional QUENGS pia evades baad bal eet idee beaded Be ale eae es 1 7 2 System components Electronic reprographics proceSS 00 0c cece ete eee 2 1 DocuSP Controller nai sia aura vend etek Hebd Vea eb ERRA NRA ER A eds 2 1 DocuTech Printer 0 0 00 2 1 Optional Components 000 eee ete 2 2 Functional overview 00 0 ee eee eee 2 2 Paper WeightS 2 23 vcidavs tex eelade doa k eee peeled ete Wel eel ie bay wel ae dais 2 4 Special STOCKS see stccie acecigctieries digo nperi lgketices ENARE EEE EE NANE ged edly eee aid a a ae 2 4 General paper characteristics 0 0 0 0c eee eee es 2 5 Graphical user interface overview 0 000 eee 2 5 System software and job floW 0 tte eee 2 6 Printer OVervieW 1 2 eee eee 2 7 High volume pinter ssas seneta s daaa aaa aaa ete teens 2 8 Production publisher sessi cirie is Ers EI tte 2 14 TAG SYSIOM dsied ch wu irene i ia eiea a daa a deena da a aed dl ach a aed doh e Bea ee ed 2 23 System Hardware 0 cee
18. eee tenes 2 23 Paper sizing and print speed 1 0 eee 2 26 3 Routine maintenance Cleaning and maintenance overview 0 aasaran aaee 3 1 Necessary Precautions 2 ce eee ees 3 1 Finisher precaution 2 evisu vale Pa ba oe oe eae eae eR ee ee eS 3 2 PADOT a ersa nene waite ewe Rewer aed Guin ESAE ee ate SG een ae Ce a eee 3 3 St ring pape eki beat placa yee dented die dat 3 3 Conditioning paper 0 0 c eet eee 3 4 PapercCurl reerde wif he eae E eM ea eay O Lae mean Pade end Pea 3 5 Adding paper to tray 1 Or2 2 eee 3 6 Using the custom transfer assist blade 0 000000 eee ee 3 7 Adjusting for paper curl serisi isss rrinin EEEN ee ees 3 9 Adjusting the decurler lever 1 0 cc eee ae 3 11 Maintaining the printer erretenen etke kir eE eens 3 12 Replacing the black dry ink bottle 0 2 0 cee eee 3 12 Replacing the highlight color container 0 00 eee ee 3 14 Changing the highlight color Customer Changeable Units 3 16 Adding fuser shield 0 0 cee tees 3 23 DocuTech 128 155 180 HighLight Color Operator Guide iii Waste containerS o 0 ee eee eee 3 27 Wire Module Removal and Replacement 0 0 0 e eee ee eee 3 30 Cleaning the system and its components 0 0c c cece een eens 3 32 Cleaning the 18 36 track cartridge tape drive 00 cee eee eee 3 32 Cleaning the 26 track cartridge tape drive
19. for clearing jams in area 18 Sometimes the controller messages direct you to discard the last sheet delivered to the stack following a jam in area 18 Check for this message when clearing an area 18 paper jam If your printer has frequent jams in this area you may need to clean the Q1107 sensor If your printer has a bypass transport module you should check for paper jams in areas 19 and 20 after clearing an area 18 paper jam Clearing a paper jam in the bypass transport 4 NOTE High volume printer configuration only 1 Open the bypass transport module door 2 Press the area 19 green lever in the direction of the arrow printed on it DocuTech 128 155 180 HighLight Color Operator Guide Problem Solving NS nla vial ZG Vg LAT eatin A T E Figure 4 18 Area 19 3 Remove any paper from the exposed area Press the green lever to the left until the latch catches 5 Press the area 20 green lever in the direction of the arrow printed on it DocuTech 128 155 180 HighLight Color Operator Guide 4 19 Problem Solving g Figure 4 1
20. from the Input Queue The printing process and job flow is different for PostScript PCL TIFF ASCII PDF jobs that is non LCDS jobs and for LCDS jobs PostScript PCL When the job is sent from the application for printing a print data TIFF ASCII IPDS file is created This file becomes the job that is submitted to the and PDF jobs printer for printing The print data file and the job request are submitted to the selected queue Jobs are processed by priority within the designated queue once the job reaches the queue from a given application NOTE PDS and LCDS are not supported on the Production 4 publisher configuration at this time lt Printer overview The printer receives data from the controller and prints the document according to the print options specified by the user The printer also stacks and collates the printed output The printer system is available in two configurations 1 High volume printer with inverter feeder stacker and up to three feeder stackers 2 Production publisher with a 2 tray interposer and finisher DocuTech 128 155 180 HighLight Color Operator Guide 2 7 System components High volume printer The components special features and configurations of the Xerox DocuTech 128 155 180 HLC printer are shown in the following figures DPCO204A SOR Figure 2 2 Printer with inverter feeder stacker feeder stacker standard base configuration Feeder tray Samp
21. instructions for replacing the stitcher spool A Refer to this label if needed The following steps must be performed to replace the stitcher spool A 3 52 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance 1 Open the finisher doors 2 Lift the stitcher panel which is located directly above the stitcher spools 3 Pull the green stitcher head release handle forward and up until it latches into place as shown in figure 3 51 XE059D Figure 3 51 Releasing the stitcher head 4 Remove the stitcher wire plug a The stitcher wire plug is located above the binder area as shown in figure 3 52 b Press and hold down the release clip Pull the plug out of the stitcher head DocuTech 128 155 180 HighLight Color Operator Guide 3 53 Routine maintenance TA828A Figure 3 52 Removing the stitcher wire plug 5 Perform one of the following steps e If there is no wire on the spool use the wire cutters to pull the remaining wire carefully out of the tubing as shown in figure 3 53 NOTE The wire cutter tool needed to perform this procedure 4 is located next to stitcher spool B 3 54 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance XEA084A Figure 3 53 Removing the wire from the tubing If there is wire on the spool hold it on the spool and carefully rewind the remaining wire out of the tubing and onto the stitcher spool as shown in figure 3 54
22. is removed from the grooves on the binder platen surface which align with the top and bottom edges of the book XEAO028A Figure 3 48 Cleaning the binder platen Cleaning the flappers 4 NOTE Production publisher configuration only Using the binder platen cleaner clean the top and side surfaces of the binder flappers until all the glue is removed 3 50 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance Figure 3 49 Cleaning the flappers Cleaning the calipers NOTE Production publisher configuration only Using the binder platen cleaner clean the binder caliper surfaces until all the glue is removed DocuTech 128 155 180 HighLight Color Operator Guide 3 51 Routine maintenance Figure 3 50 Cleaning the calipers Closing the binder 4 NOTE Production publisher configuration only Perform the following steps to close the binder 1 Push in the binder drawer until it stops 2 Close the finisher doors 3 Place the platen cleaner in a safe place Replacing the stitcher spool A 4 NOTE Production publisher configuration only Bi Use this procedure to replace stitcher spool A in the system Check stitcher spools A and B visually during the warm up cycle Stitcher spool A is the spool on top and stitcher spool B is the spool on the bottom If spool B needs new wire call the customer support center There is a label behind the stitcher panel that gives
23. operations When this indicator glows the bin has been made ready to receive output Feeder stacker modules The feeder stacker modules contain the high capacity feeder trays and the stacker bins The printer may have up to four feeder stacker modules including the inverter feeder stacker containing feeder trays 3 4 5 and 6 and stacker bins A B C and D Each module contains one high capacity feeder tray and one high capacity stacker bin The high capacity feeder HCF trays are located in the bottom half of the feeder stacker modules Each HCF tray can hold up to 2500 sheets of 20 pound or 80 gsm paper The high capacity feeder trays can handle paper sized from 8 by 10 inches 203 by 254 mm to 17 by 14 02 inches 432 by 356 mm Unlike the processor feeder trays the HCF trays have Paper Level switches which detect the position of the elevator to determine the fullness of the tray DocuTech 128 155 180 HighLight Color Operator Guide System components High capacity The high capacity stacker HCS bins are located in the top half of stackers the feeder stacker modules accessed through double doors Two high capacity stacker bins are standard with up to two additional bins available as options providing up to four bins total Each bin holds up to 2500 sheets of 20 pound or 80 gsm paper More High volume printer configurations In addition the high volume printer is available with three or four f
24. or Xerographic bond paper in Slightly curled paper Avoid the following condition good condition Coated papers Drilled paper Drilled stock with reinforced edges Transparencies as inserts Excessively curled paper Never tear paper Stock not defined here is included in the Using various stocks section in this guide Table 5 13 Top tray satisfaction guide Stock Reliable stacking may be Less reliable stacking may Suggested alternatives expected be expected Size 8 x 10 inches to 11 x 17 Intermixed sizes Smaller or larger sizes cannot inches 203 x 254 mm to be used 279 x 432 mm Weights Substance 16 to 110 60 to Substance 16 60 g m2 Weights outside the limits 200 g m2 over 9 x 14 inches 229 x shown are not recommended Weights cannot be 356 mm may yield stacking intermixed registration problems Capacity 500 sheets substance 20 If using a paper heavier than substance 20 75 g m2 unload the tray before the count in the tray reaches 500 Check the stitch quality DocuTech 128 155 180 HighLight Color Operator Guide Technical information Table 5 13 Top tray satisfaction guide Stock Reliable stacking may be Less reliable stacking may Suggested alternatives expected be expected Type or Xerographic bond paper in These may yield stacking Do not use excessively curled condition good condition registration problems paper Drilled paper Slightly curled paper Stock not defined her
25. packaged 100 Gummed sheets to a box 8 5 x 11 inch 33 labels per sheet 3R3139 8 5 x 11 inch 6 labels per sheet 3R3146 8 5 x 11 inch Custom form uncut Contact Xerox Supplies Order Service 6 6 DocuTech 128 155 180 HighLight Color Operator Guide Service and supplies Item Description U S part number Dry Ink Black Packaged 3 cartridges per 6R206 US CA carton 220K carton with 6 black only area coverage Dry Ink Blue 300K Carton with 1 5 area 6R1191 US CA coverage as highlight color 6R90343 EU Dry Ink Red 300K Carton with 1 5 area 6R1192 US CA coverage as highlight color 6R90344 EU Dry Ink Green 300K Carton with 1 5 area coverage as highlight color 6R1193 US CA 6R90345 EU Dry Ink Royal Blue 300K Carton with 1 5 area coverage as highlight color 6R1255 US CA 6R90356 EU Dry Ink Cardinal Red 300K Carton with 1 5 area coverage as highlight color 6R1277 US CA 6R90358 EU Dry Ink Cyan 300K Carton with 1 5 area coverage as highlight color 6R1284 US CA 6R90359 EU Dry Ink Waste Bottle 500K bottle 93K1393 HLC Developer Waste Container 800K bottle with 1 5 highlight color area coverage 604K24870 4 Black Developer Packaged 2 bottles per carton Developer effective life is dependent upon the number of charged images printed and the size of the stock Xerox developer is guaranteed by Xerox for
26. removing it from area 9 or if you have difficulty removing paper from this area use the pinch lever located further inside area 9 Paper may be caught in this area during duplex printing e CAUTION This area of the printer may be hot Be careful when inserting your hand Using the pinch To use the pinch lever located inside area 9 lever to access area 1 Locate the green pinch lever directly behind area 9 above the 9 green knob and further inside area 9 2 Carefully reaching your hand into the area squeeze the edges of the pinch lever and lift it up 3 Remove any paper caught in this area Turn the green pinch lever to its original position Make sure that you relatch the lever after you have cleared any paper in this area DocuTech 128 155 180 HighLight Color Operator Guide 4 11 Problem Solving JANN eTo Le R_L E o e 2007 RS Fea S Ss SS WS dS S m Figure 4 9 Area 10 M r k p 4 EP o WAN hoc A Figure 4 10 Area 11 all feeder stackers NOTE High volume printer configuration only DocuTech 128 155 180 HighLight Color Operator Guide Problem Solving Fi
27. that they will not use a solvent that will set the dry ink stain 1 Open the front processor access door and locate the highlight color container at the right side of the processor 2 Place a drop cloth on the floor under the highlight color container area DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance 3 Remove the empty container by grasping its handle With a slow firm motion remove the container Figure 3 11 Highlight color container Pull the container out until it stops 5 Remove the container and discard it 6 To insert a new bottle place the bottle on the edge of the bottle guide With a slow firm motion push the bottle into the dispense position over the hopper 7 After the bottle is in the dispense position remove the seal You may encounter some resistance 8 Close the processor door DocuTech 128 155 180 HighLight Color Operator Guide 3 15 Routine maintenance Changing the highlight color Customer Changeable Units The highlight color Customer Changeable Unit CCU consists of the color dry ink bottle and supporting equipment In order to change the highlight color or to service the wire module you need to remove the highlight color CCU from the printer If you have more than one highlight color CCU a CCU cart is provided to allow you to change and store the CCU If you have only one highlight color CCU a service cart is provided to allow you
28. the sides of the set The combination of the heat in the binder and the pressure of the flappers glues the tape to the set NOTE For information about adjusting the binder tape registration and the binder tape length refer to the on line help system The top tray NOTE Production publisher configuration only Prints are delivered to the top tray because the prints are oversized or because the top tray was selected on the screen The bypass transport device is not available for this configuration four feeder stacker modules The printer is available in a Production configuration which includes a two tray Interposer and the in line Binder Stitcher Bypass transport The printing system is available in several configurations and may be configured with a bypass transport Function of the The bypass transport moves paper from the stacker to a third bypass transport party finisher such as a stitcher booklet maker tape binder and so on By making selections on the user interface windows you can program the printer to send output to the bypass transport which feeds the output to the finishing equipment Paper stocks The bypass transport accepts all paper stocks on which the printer supported on can print and it accommodates simplex and duplex printing bypass transport DocuTech 128 155 180 HighLight Color Operator Guide 2 17 System components DFA support The bypass transport meets the Xerox Document
29. the top cover of the last feeder stacker module the one containing the purge tray To clean the sensor 1 Brush or wipe the sensor windows lightly 2 Remove any paper dust present in the area 3 38 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance Figure 3 35 Q1164 sensor Cleaning the display The display should be cleaned as required Clean the display with a soft lint free cloth dampened with a glass or lens and mirror cleaner Do not spray the liquid directly onto the display because it may cause damage Cleaning the exterior surfaces of the system Clean the exterior surfaces of the printer daily if possible Clean the exterior surfaces with a mild household detergent that has been poured or sprayed onto a cloth lightly dampened with water Do NOT saturate the cloth just dampen it CAUTION Liquids must not be allowed to drip onto anything electrical or mechanical Also never spray or pour any cleaner directly onto the keyboard or the exterior surfaces of the system DocuTech 128 155 180 HighLight Color Operator Guide 3 39 Routine maintenance Clearing or cleaning the finisher sensors 4 NOTE Production publisher configuration only lt Clearing the finisher sensors should be performed only when directed by a Customer Support Center Representative NOTE The finisher sensors are located under the processor top 4 cover under the finisher top
30. to remove the CCU for service CAUTION CCU carts should be used exclusively for changing and storing CC Us You should always have at least one empty cart at your site if your printer has more than one color CCU Do not attempt to remove or install a CCU without a cart CAUTION Do not remove the CCU after a hard stop such as caused by a paper jam system crash or restart or opening a door during printing without first allowing the system to cycle up and continue processing for a proper recovery Removing the CCU using the CCU cart To remove the highlight color CCU from the printer 1 If the printer is not cycled down Pause the system before you open the doors and attempt to remove the CCU 2 Open the printer doors and locate the color housing area in the center of the printer 3 Open the top cover of an empty cart Push the cart up to the printer lining up the yellow knob on the cart with the yellow recess on the printer inner cover 5 Push the cart firmly against the printer until you can feel the two latch together 6 Make sure the cart is level a If the cart is not level loosen the locknut holding the height adjustment knob in place b Use the height adjustment knob to regulate the level DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance c When the HLC unit is level tighten the lock nut 0CD00002A SOR Figure 3 12 Leveling the cart 7 Push down firmly on the
31. with excessive force There is an anti splash seal in the reservoir that could be damaged DocuTech 128 155 180 HighLight Color Operator Guide 3 25 Routine maintenance Figure 3 23 Adding the fuser blend e Replace the reservoir cap by turning it clockwise approximately one full turn Do not overtighten the cap f Inspect the area around the fuser to ensure no fuser blend was spilled Clean as required g Push the fuser blend reservoir in until it stops 6 Push the fuser drawer in until it latches into place Figure 3 24 Closing the fuser drawer 3 26 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance 7 Close the processor doors The fuser blend message disappears after the system makes approximately 20 prints Waste containers The waste containers in the DT 128 155 180 HLC collect dry ink and developer after it has been used by the printer When a container becomes full it must be replaced or the printer eventually stops printing This section contains the procedures for replacing the toner and developer waste containers Replacing the 128 155 180 HLC developer waste container To replace the developer waste container 1 Open the processor doors and locate the dry ink cartridge at the lower center of the printer The developer waste container is located below and to the right of the color dry ink bottle 0800009A SOR
32. 0 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance Position the wire module on the HLC developer module Snap the wire module retainer springs behind the tabs Slide the HLC developer module into the machine Latch the CCU into place Remove the cart or service stand ee a Close the doors DocuTech 128 155 180 HighLight Color Operator Guide 3 31 Routine maintenance Cleaning the system and its components NOTE Follow the procedures in this section only when directed by Xerox Customer Support center personnel Cleaning tasks consist of the following e Cleaning the 18 36 track cartridge tape drive e Cleaning the 26 track cartridge tape drive e Cleaning the DVD drive e Cleaning the diskette drive e Cleaning the sensors and the reflecting surfaces e Cleaning the display e Cleaning the exterior surfaces of the system Cleaning the 18 36 track cartridge tape drive Ses A cleaning cartridge is shipped with each 18 36 track cartridge tape drive This cartridge should be replaced after 500 uses When the tape drive needs to be cleaned CLEAN appears in the message display after a cartridge is unloaded and during a rewind or locate operation NOTE CLEAN is a status message not an error message CAUTION Never power off the tape drive without following the cleaning procedure once the CLEAN message appears CAUTION The cleaning cartridge must be undamaged and clean To clean
33. 28 155 180 HighLight Color Operator Guide Routine maintenance XE042C Figure 3 44 Locating the Q1221 Q1218 and Q1227 sensors Cleaning the binder 4 NOTE Production publisher configuration only Keep the binder clean to prevent binder tape jams Clean the binder once a week or as needed and also when changing the binder tape It is highly recommended that the binder be cleaned before the binder warm up cycle begins or before switching the system on The following steps must be performed to clean the binder tape are hot approximately 425 F 218 C and may cause a serious burn If the binder has been in a Ready condition allow the binder to cool for at least one hour before continuing the procedure WARNING All areas of the binder drawer including the binder 1 Open the finisher doors on the tape spool sometimes occurs as a result of removing the WARNING A sharp edge on the plastic binder platen cleaner or cleaner This sharp edge could cause finger cuts CAUTION To avoid damage to the system do not use any liquids or any abrasive material to clean the binder Use the plastic binder platen cleaner on the tape reel or use a clean lint free cloth 2 Grasp the green handle on the binder drawer Pull the drawer out until it stops DocuTech 128 155 180 HighLight Color Operator Guide 3 47 Routine maintenance lt z pe i 4 gaea XEA070A Figure 3 45 Opening the binder dr
34. 3 to 432 mm Length 10 to 14 33 inches 254 to 364 mm Capacity 2600 sheets substance 20 75 g m2 pre or post process NOTE This tray information applies to the Production publisher 4 configuration lt Additional paper capacities Inverter or duplex tray Stock sizes 8 x 10 inches to 17 x 11 inches 203 x 254 mm to 432 x 279 mm Top tray 8x10 inches to 17 x 11 inches 203 x 254 mm to 432 x 279 mm Stock sizes Capacity 500 sheets substance 20 75 g m2 Stacker 8 x 10 inches to 9 x 14 inches 203 x 254 mm to 229 x 356 mm Stock sizes DocuTech 128 155 180 HighLight Color Operator Guide 5 3 Technical information Capacity Stitcher Stock sizes Capacity Stitches per spool Binder Stock sizes Capacity Binds per spool 3000 sheets 1500 inboard and 1500 outboard substance 20 75 g m2 8 x 10 inches to 9 x 14 inches 203 x 254 mm to 229 x 356 mm 2 to 70 sheets substance 20 75 g m2 Approximately 35 000 8 5 x 11 inches 216 x 279 mm 15 sheets 7 sheets with index covers to 125 sheets of substance 20 75 g m2 or equivalent thickness Approximately 425 Printer satisfaction guides Use the following information to ensure your satisfaction with the feeding of the print material Stock storage Although the system was designed to handle a wide range of stock many factors can affect performance and print quality One of the factors that can affect system performance is paper curl
35. 4 inches 282 to 290 mm 11 8 inches to 12 1 inches 300 to 307 mm NOTE With these paper sizes transfer efficiency may be reduced CAUTION To avoid damage to the photoreceptor you must set the tray size with the transfer assist blade The custom transfer assist blade comes in a package containing detailed instructions Be sure you follow the instructions carefully CAUTION To prevent damage to the system have your service representative show you the procedure before you attempt to customize and install a transfer assist blade for the first time When you are using the custom transfer assist blade you must set the tray length Use the following two tables to determine the tray length setting to use Table 3 2 Tray length settings for custom transfer assist blades U S markets Paper Size Set Paper Size 11 5 to 11 7 inches 292 to 297 mm 11 7 inches 297 mm 12 1 to 12 9 inches 307 to 328 mm 13 inches 330 mm 13 to 13 9 inches 330 to 353 mm 14 inches 356 mm Table 3 3 Try length settings fro custom transfer assist blades Non U S markets Paper Size Set Paper Size 10 to 10 9 inches 254 to 277 mm 11 inches 279 mm 11 5 to 11 6 inches 292 to 294 mm 11 7 inches 3297 mm 12 1 to 12 9 inches 307 to 328 mm 13 inches 330 mm 3 8 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance Adjusting for paper curl Each sheet of paper has a
36. 4 to 356 mm 1100 sheets substance 20 75 g m2 US letter 8 1 2 x 11 inches US legal 8 1 2 x 14 inches 9 x 11 inches A4 8 1 2 x 13 inches 223 x 297 mm Custom Width 8 to 9 inches 203 to 229 mm Length 10 to 14 inches 254 to 356 mm 600 sheets substance 20 75 g m2 US Letter 8 1 2 x 11 inches US Legal 8 1 2 x 14 inches US Ledger 17 x 11 inches 9 x 11 inches A3 A4 8 1 2 x 13 inches 223 x 297 mm ISO B4 JIS B4 Custom Width 8 to 17 inches 203 to 432 mm Length 10 to 14 33 inches 254 to 364 mm 2600 sheets substance 20 75 g m2 NOTE This tray information is applicable to trays 3 6 on the High volume printer configuration and tray 3 on the Production publisher configuration US Letter 8 1 2 x 11 inches US Legal 8 1 2 x 14 inches 5 2 DocuTech 128 155 180 HighLight Color Operator Guide Technicalinformation US Ledger 17 x 11 inches 9 x 11 inches A3 A4 8 1 2 x 13 inches 223 x 297 mm ISO B4 JIS B4 Custom Width 8 to 17 inches 203 to 432 mm Length 10 to 14 33 inches 254 to 364 mm Capacity 550 sheets substance 20 75 g m2 post process only NOTE This tray information applies to the Production publisher configuration lt Tray 5 US Letter 8 1 2 x 11 inches Stock Sizes US Legal 8 1 2 x 14 inches US Ledger 17 x 11 inches 9 x 11 inches A3 A4 8 1 2 x 13 inches 223 x 297 mm ISO B4 JIS B4 Custom Width 8 to 17 inches 20
37. 500 000 pages of 8 5 x 11 inches 216 x 279 mm or A4 stock Effective life is approximately one carton per 500 000 pages 5R161 US CA 5R90095 EU Blue Developer Packaged 2 bottles per carton 5R688 Effective life is approximately one carton per 500 000 pages Red Developer Packaged 2 bottles per carton 5R689 Effective life is approximately one carton per 500 000 pages Green Packaged 2 bottles per carton 5R690 Developer Effective life is approximately one carton per 500 000 pages Cardinal Red Packaged 2 bottles per carton 5R717 Developer Effective life is approximately one carton per 500 000 pages DocuTech 128 155 180 HighLight Color Operator Guide 6 7 Service and supplies Item Description U S part number Royal Blue Packaged 2 bottles per carton 5R715 Developer Effective life is approximately 5R716 FX one carton per 500 000 pages Cyan Packaged 2 bottles per carton 5R719 Developer Effective life is approximately one carton per 500 000 pages Fuser shield Consumption rate is 8R4077 1 approximately one bottle per 200 000 pages Fuser blend Consumption rate is 8R12938 1 approximately one bottle per 8R12939 6 200 000 pages bottles Cleaning Foam tipped swabs 99P87256 supplies Lint free towels 35P2163 Cartridge tape 4mm blank cartridge 8 GB 109R00314 Diskettes 3 5 inch double sided dual 8R3704 density 1 44 MB unfor
38. 9 Area 20 Remove any paper from the exposed area Press the green lever down and to the left until the latch catches 8 Close the bypass transport module door Clearing a misfeed feeder tray fault NOTE High volume printer configuration only lt 1 If the Ready to Open indicator is not lit press the Tray Unlock button located on the feeder tray control panel J Ba B B Figure 4 20 2 When the Ready to Open indicator lights open the feeder tray Pull the tray all the way out for best results 4 20 DocuTech 128 155 180 HighLight Color Operator Guide Problem Solving 3 For the processor feeder trays press the green lever to unlatch the paper feeder assembly Figure 4 21 4 Remove and discard any partially fed paper Ensure that The paper supply is neatly stacked The stack is not higher than the MAX line on the length guide e The length guide is firmly touching the back edge of the stack For the high capacity feeder trays also ensure the side guide is firmly touching the side of the stack NOTE You do not need to discard transparencies and other stiff 4 materials unless they are damaged 5 For the processor feeder trays relatch the paper feeder assembly by pressing the green dot until the assembly clicks into place DocuTech 128 155 180 HighLight Color Operator Guide 4 21 Problem Solving Figu
39. Feeding and Finishing Architecture DFA specifications The system software supports DFA However in order for the bypass transport to function correctly you need to set up finishing personality profiles to identify your finishing device to the printing system The customer support representative for your finishing device can give you the information you need to create a personality profile for your third party finishing device For information on marketing partners that provide solutions for support and interface with finishers contact your local Xerox sales representative Bypass transport on the production publisher Depending on the finisher configuration the bypass transport is located inside the finisher module on the Production publisher configuration Bypass transport function is the same as the external bypass transport module NOTE The Production publisher finisher is available with or without the bypass transport Bypass transport on the High volume printer Connected to the last feeder stacker module The bypass transport option enables third party finishing devices to interface directly with the printing system The bypass transport allows you to customize your printer for increased efficiency and specialized applications involving finishing NOTE Systems configured with the external bypass transport can have a maximum of two 2 feeder stacker modules See figure 2 13 7 by 10 inch enablement kit The 7
40. Figure 3 25 HLC developer waste container 2 Using your right hand grasp the container by the handle on top With your thumb depress the latch located above the frame of the machine Lift the edge of the container from the tray and remove Unscrew the cap from the front of the waste container and use it to close the open end of the waste container 3 Discard the waste material and container appropriately DocuTech 128 155 180 HighLight Color Operator Guide 3 27 Routine maintenance 4 Insert the new waste HLC developer waste container into the transport assembly Push the retainer out of the way with your thumb Continue seating the new waste container onto the tray and release the container latch 5 Close the processor doors Replacing the 128 155 180 toner waste bottle To replace the toner waste bottle 1 Open the HLC module door O0CD00010A SOR Figure 3 26 Opening the HLC module door 2 Remove the toner waste bottle 3 Remove the flat cap from the top front of the bottle 3 28 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance 0CD00011A SOR Figure 3 27 Flat cap on waste bottle 4 Place the flat cap on the round bottle opening and snap it down This prevents spillage when discarding the bottle 5 Discard the waste material and container by placing the container in the trash 6 Obtain a new bottle and open it placing the cap at the front of the bottle an
41. Guide You need to decide how many operators will be responsible for performing these maintenance tasks Most maintenance procedures are covered in the initial operator training provided shortly after installation Meter reading and reporting As print jobs are processed the DocuSP controller accumulates saves and maintains usage data During the last five working days of each month you need to review and transmit the data to Xerox for billing purposes Refer to the section on Billing in the Help on the DocuSP controller for complete information on how to view and print the billing meter readings Consumable supplies table The following table lists the supplies that are available from Xerox for your printer Use this table to help you determine your printer needs The following symbols are used in the table 5 16 inch drilled holes Rainbow pack contains 750 sheets each of blue and yellow 500 sheets each of green and pink and 250 sheets each of buff gray goldenrod and ivory NOTE Non United States customers The part numbers in this table are for the United States only Contact your local representative for supplies ordering information CAUTION Do not use any supplies not approved by Xerox You can damage the system by using supplies other than those recommended 6 4 DocuTech 128 155 180 HighLight Color Operator Guide Service and supplies Table 6 1 Consumable supplies
42. Humidity and moisture cause the natural paper curl to increase Too much curl causes jams in the system The following practices minimize paper curl during storage of the paper stock e Keep the paper wrapped as long as possible Do not unwrap the paper until it is needed Store the reams of paper in their carton Do not leave the carton directly on the floor Place something beneath the carton such as a wooden pallet Improving the feeding reliability The following practices improve the feeding reliability of the system e Plan the jobs to minimize the amount of paper left in the system during the night e Load the paper quantity based on the number of prints required When paper is taken from a storage area with a different humidity or temperature keep it in the room where it will be used for at least 48 hours before loading the paper into the system To make adjustments to the DocuTech 128 155 180 HLC for 5 4 DocuTech 128 155 180 HighLight Color Operator Guide Technicalinformation the curl in the paper refer to the Routine maintenance and Problem solving sections of this guide Stock satisfaction guides Table 5 1 Satisfaction guide for paper trays 1 and 2 Reliable feeds may Less reliable feeds may be Stock be expected expected Suggested alternatives Size 8 x 10 inches to 9 x 14 Stock smaller than 8 x 10 inches inches 203 x 254 mm canno
43. OWLEDGE AND EXPERIENCE TO CARRY OUT SUCH TESTS Please contact the Xerox Europe Customer Service Organization for further information THE USE OF INAPPROPRIATE TEST PROCEDURES AND TEST EQUIPMENT MAY PROVIDE MISLEADING RESULTS AND MAY CAUSE DEATH PERSONAL INJURY AND OR DAMAGE TO PROPERTY would like to carry out my own safety tests on the Xerox equipment in my premises You may of course request such tests as you deem necessary to satisfy yourself that your Xerox equipment is safe Your Xerox Europe Customer Support will be pleased to advise you on such testing require records of all tests After safety testing your Xerox Europe Customer Service Engineer will provide you with a certificate which details the results of all tests completed In the event of any defect being noted the Xerox equipment will be switched off and disconnected from the supply until the defect has been corrected You will be advised of such action to enable such defects to be corrected Please contact the Xerox Europe Technical Centre or your authorized Xerox representative if you have any queries regarding the information provided in this document DocuTech 128 155 180 HighLight Color Operator Guide 1 7 Safety notices 1 8 DocuTech 128 155 180 HighLight Color Operator Guide 2 System components The Xerox DocuTech HLC printers are electronic reprographics systems They are high volume printers available in multiple configurations
44. Services main menu displays on the controller screen DocuTech 128 155 180 HighLight Color Operator Guide 2 5 System components System software and job flow This section describes how the system software processes are used as a typical job flows through the system NOTE There are no job flow differences between the High volume printer and the Production publisher configurations QTC0102A TOR Figure 2 1 Job flow Job Input Queue Decomposer Output queue Or oe Ooh Printer Job The job and the job ticket if applicable are received from the network by one of the protocol gateways Input queue The Job Pool Manager JPM process transfers the job into the input queue The virtual printer name and job attributes are attached to the job The job remains in the Input Queue until it can be printed for example held and faulted jobs reside in the input queue Decomposer The Job Chooser reconciles the job attributes with the virtual printer attributes Once the job is ready for print the Job Chooser gives the job to the appropriate decomposer PostScript or PCL 2 6 DocuTech 128 155 180 HighLight Color Operator Guide System components Output queue After decomposition the job is stored in the output queue Printer The marker transfers the job from the Output Queue to the printer After the job has successfully printed it is removed from the Output Queue and also
45. Solving Fold a piece of copy paper in half lengthwise Place the folded sheet of copy paper under the stitcher head as shown in figure 4 27 e Pull out the stitcher knob and allow it to snap back into place to free any stitcher wire fragments Remove the copy paper carefully being sure not to drop any wire fragments into the system XE175A Figure 4 27 Removing the wire fragments 10 Push the green stitcher head release handle down and back 11 Pull the plug from the measuring bracket 12 Insert the plug into the stitcher head until the plug snaps into place NOTE Ensure that the wire cutters are not touching the stitcher spools This can prevent the stitcher wire from feeding properly 13 Place the wire cutters in the storage bracket NOTE Ensure that the stitcher panel has been lowered The stacker will not deliver printed sets if the stitcher panel is left in the up position 14 Lower the stitcher panel 15 Close the finisher doors The printer icon indicates Ready DocuTech 128 155 180 HighLight Color Operator Guide 4 29 Problem Solving Checking paper curl You can adjust the decurler lever to correct most paper curl problems Refer to the paper curl chart later in this chapter to determine the amount of curl in the paper stock Perform the following to measure paper curl 1 Print five one sided simplex 8 5 by 11 inch or A4 sheets 2 Hold the printed sheets by the top center
46. These versatile high performance printing systems enable personal computers and other network connected devices such as workstations and graphic scanners to produce documents incorporating graphics forms logos signatures and fonts Electronic reprographics process The Xerox DocuTech HLC system consists of a DocuSP controller and a DocuTech printer DocuSP controller The DocuSP controller accepts electronic print input created by client software in ASCII TIFF HP PCL PostScript PPML LCDS IPDS VIPP or PDF format This print input is passed on to the system through a network connection The DocuSP software performs the necessary data conversion creating an electronic file which is stored temporarily in a print queue on the DocuSP controller This electronic image is then passed directly on to the printer for production DocuTech Printer The DocuTech 180 prints up to 180 prints per minute using 8 5 x 11 inch A4 216 x 279 mm stock The DocuTech 155 prints up to 155 prints per minute using 8 5 x 11 inch A4 216 x 279 mm stock The DocuTech 128 prints up to 128 prints per minute using 8 5 x 11 inch A4 216 x 279 mm stock NOTE The DocuTech HLC prints in black and white plus one highlight color NOTE Prints per minute vary depending on paper size for all printers lt DocuTech 128 155 180 HighLight Color Operator Guide 2 1 System components Optional Components Functional overv
47. XEROX Version 51 xx October 2006 701P25101 DocuTech 128 155 180 HighLight Color Operator Guide Prepared by Xerox Corporation Global Knowledge and Language Services 800 Phillips Road Bldg 845 17S Webster New York 14580 USA 2006 by Xerox Corporation All rights reserved Copyright protection claimed includes all forms and matters of copyrightable material and information now allowed by statutory judicial law or hereinafter granted including without limitation material generated from the software programs displayed on the screen such as icons screen displays or looks Printed in the United States of America XEROX and all Xerox product names mentioned in this publication are trademarks of XEROX CORPORATION Other company trademarks are also acknowledged Changes are periodically made to this document Changes technical inaccuracies and typo graphic errors will be corrected in subsequent editions Product Recycling and Disposal If you are managing the disposal of your Xerox product please note that the product contains lead mercury and other materials whose disposal may be regulated due to environmental considerations in certain countries or states The presence of lead and mercury is fully consistent with global regulations applicable at the time that the product was placed on the market European Union Some equipment may be used in both a domestic household and a professional business application
48. Xerox equipment should however be properly and regularly serviced and maintained at all times DocuTech 128 155 180 HighLight Color Operator Guide 1 5 Safety notices Check your understanding Question Answer Question Answer Question Answer Question Answer Question Answer Please review the questions and answers that follow to ensure that you understand the Electricity at Work Regulation in England and Wales What is the Electricity at Work Regulation The Electricity at Work Regulation 1989 came into force in England and Wales on 1 April 1990 This 1989 Regulation places a duty on all employers and self employed persons to ensure the electrical systems in their premises are constructed maintained and operated in such a manner as to prevent so far as reasonably practicable danger This includes ensuring all electrical products connected to such electrical systems are safely constructed maintained and operated Does Xerox Europe comply with the Electricity at Work Regulation The regulation places a duty on all employers and self employed persons to ensure the electrical systems in their premises are effectively safe This regulation does not impose on amongst others manufacturers or suppliers of such electrical systems However rest assured that all Xerox equipment which Xerox Europe and its authorized distributors supply to customers conforms with all the relevant safety legislation and sta
49. a folded sheet of paper under each sensor to clear any obstructions as shown in figure 3 39 XE039B Figure 3 39 Clearing the Q1202 and Q1203 sensors 4 Close the finisher top cover 3 42 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance Cleaning the Q1222 and Q1210 sensors 4 NOTE Production publisher configuration only Cleaning the Q1222 and the Q1210 sensors should be performed only when directed by a Customer Support Center Representative 1 Open the finisher top cover 2 Look down at the rear section of the tilt bed area as shown in figure 3 40 to view the sensors RE E ss E XEAOQ99A Figure 3 40 Locating the Q1222 and Q1210 sensors 3 Locate the Q1222 and Q1210 sensors as shown in figure 3 41 DocuTech 128 155 180 HighLight Color Operator Guide 3 43 Routine maintenance XE041C Figure 3 41 Locating the Q1222 and Q1210 sensors 4 Wipe each sensor gently with a soft cloth to clean them 5 Close the finisher top cover Clearing the Q1205 Q1206 and Q1207 sensors 4 NOTE Production publisher configuration only Di Clearing the Q1205 Q1206 and Q1207 sensors should be performed only when directed by a Customer Support Center Representative 1 Open the finisher front doors 2 Open the bindexer door 3 Locate the Q1205 Q1206 and Q1207 sensors as shown in figure 3 42 3 44 DocuTech 128 155 180 HighLight Color Op
50. added the printer stops after approximately 5 000 prints and not run until fuser shield is added Please read the important note below NOTE n 2006 the formula for the DocuTech HLC fuser lubricant 4 was changed to provide better image quality and to prevent image transfer The new fuser formula is called Fuser Shield The fuser blend and the fuser shield CANNOT be intermixed in a DocuTech HLC To change from one fuser lubricant to another requires a service call and cleaning or replacing components The two fuser formulas are identified with different color bottles and caps Be sure the color of the cap of the bottle you are filing from matches the color of the cap already in the system Fuser shield description blue bottle white cap with black printing Fuser blend description yellow bottle black cap with white printing WARNING The fuser area can reach temperatures of A approximately 425 F 218 C Exercise care to prevent burns when working in this area DocuTech 128 155 180 HighLight Color Operator Guide 3 23 Routine maintenance CAUTION Fuser lubricant for other printers is not compatible Do not use DocuTech and DocuPrint fuser agent in a DocuTech HLC system Do not use DocuTech HLC fuser shield in a DocuTech 61xx or DocuPrint 1xx system The fuser lubricants are not compatible and will contaminate the system Open the processor doors 2 Place adrop cloth on the floor under the fuser area 3 Open the fuser drawer
51. all paper 6 Ensure that area 17 is clear of all binder tape adhesive If the area is not clear clean the binder using the procedure Cleaning the binder in this guide 218 C Allow the binder to cool for 5 minutes with the finisher WARNING The binder tape adhesive is hot approximately 425 F doors and top cover open before touching the binder tape 7 lf area 18 is not displayed proceed to step 10 8 If area 18 is displayed and the entire binder tape length is not aligned with the tape feeder assembly stop and follow the WARNING Proceed to step 10 9 If area 18 is displayed and the entire binder tape length is aligned with the tape feeder assembly proceed to step 10 10 Remove the binder tape DocuTech 128 155 180 HighLight Color Operator Guide 4 25 Problem Solving 11 Ensure that area 18 is clear of all binder tape adhesive If it is not clean the binder using the procedure Cleaning the binder in the Routine maintenance chapter 12 Close the finisher doors 13 Close the top cover Stitcher spool A fault 4 NOTE Production publisher configuration only Repeated jams in area 17 may be caused by the following problems 1 2 Stitcher wire not feeding properly A kink in the stitcher wire Open the finisher doors Lift the stitcher panel which is located directly above the stitcher spools NOTE f the spool is empty replace the stitcher spool A Refer to on
52. ance 4 Place a dry cleaning pad on the sensor and move it from left to right to clean the sensor 5 Lower the Area 4 green handle 6 Close the printer doors Cleaning the Q1011 1009 sensor and mirror 1 Open the right and left doors of the printer and locate the Q1011 1009 sensor S NRG gt S Lo Lif NGS Lo Ss Figure 3 32 Q1011 1009 sensor and mirror 2 Apply asmall amount of lens and mirror cleaner to a cleaning pad 3 Wipe the sensor gently with the cleaning pad Cleaning the Q1106 and Q1166 sensors NOTE High volume printer configuration only To access sensors Q1106 and Q1166 open the top cover of the high capacity stacker To clean the sensors 1 Brush or wipe the sensor windows lightly 2 Remove any dust present in the area 3 36 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance Figure 3 33 Q1106 and Q1166 sensors Cleaning the Q1107 sensor t NOTE High volume printer configuration only lt To access sensor Q1107 open the top cover of the high capacity stacker To clean the sensor 1 Brush or wipe the sensor windows lightly 2 Remove any dust present in the area DocuTech 128 155 180 HighLight Color Operator Guide 3 37 Routine maintenance Figure 3 34 Q1107 sensor Cleaning the Q1164 sensor 4 NOTE High volume printer configuration only lt To access sensor Q1164 open
53. aper The system does not notify you when the tray is full DocuTech 128 155 180 HighLight Color Operator Guide System components Inverter feeder stacker 4 NOTE High volume printer configuration only Each output feeder stacker has offsetting capability and a capacity of 2500 sheets of 20 pound or 80 gsm paper This capacity does not apply to 11 by 17 inch and A3 papers Because of the additional weight these large sheets add to the bins each bin is restricted to hold only up to 1500 sheets of A3 or 11 by 17 inch papers for safety reasons E g Figure 2 4 High capacity stackers HCS The stackers can stack the printed output in the bin three ways 1 Directly onto the bin platform 2 Into a container that is set on top of the bin platform NOTE The stacking capacity is approximately 100 to 150 sheets 4 less when stacking into a container 3 Onto a pallet without a container for paper sizes 11 by 17 inches or A3 only Using the stacking windows on the user interface you can select the level to which paper will be stacked in the HCS A stacking elevator maintains the paper at the proper level for stacking and lowers the stack for unloading An offset mechanism offsets printed sets toward the front or back of the HCS bin The elevator platform lowers under the following conditions e The bin capacity has been reached A select
54. awer 3 Perform the following steps a Locate and remove the plastic binder platen cleaner from the binder tape reel as shown in the following figure XEA092 Figure 3 46 Binder platen cleaner b If binder tape is in the area of the cleaner pull the reel slightly away from the tape to avoid tape damage Lift up on the cleaner and push down against the single end tab Move the cleaner back and forth until the end tab breaks 3 48 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance d Continue to move the cleaner in the same manner until the 2 sided tabs break i NOTE Ensure that the following cleaning procedures are 4 performed in the order listed Cleaning the binder tape guides NOTE Production publisher configuration only The following steps must be performed to clean the binder tape guides 1 Use the binder platen cleaner to clean the surfaces and grooves of the tape guides 2 Ensure that all the glue is removed from the grooves on the tape guides XEA027A Figure 3 47 Cleaning the tape guides Cleaning the binder platen NOTE Production publisher configuration only The following steps must be performed to clean the binder platen 1 Use the binder platen cleaner to clean the top and side surfaces of the binder platen until all the glue is removed DocuTech 128 155 180 HighLight Color Operator Guide 3 49 Routine maintenance 2 Ensure that the glue
55. ax appears in angle brackets for example List Fonts lt Pattern gt Bold Within procedures text and numbers that you enter are shown in bold for example enter boot Enter Within procedures the two step process of keying in data and pressing lt RETURN gt for example enter y ltalics Document and library names are shown in italics for example the Xerox Document Services Platform Series System Guide Square brackets Names of options you select are shown in square brackets for example Select Exit Quotes Keywords you can enter as arguments appear in quotes for example US Letter Vertical bars Alternatives to specified arguments are separated by vertical bars for example pdl lt ps hppcl ascii tiff gt NOTE Notes contain important supplemental information pertaining to the task that you should read CAUTION Cautions alert you to an action that could damage hardware software or your data WARNING Warnings alert you to conditions that may affect the safety of people viii DocuTech 128 155 180 HighLight Color Operator Guide System safety Laser safety Safety notices It is your responsibility to ensure your Xerox equipment is safe at all times This section includes equipment safety notices related to laser safety ozone safety and operation safety M WARNING Use of controls or adjustments or performances other than specified herein may result in haza
56. been evaluated and tested for use in this system There are many other stocks available some of which may not provide the same degree of user satisfaction Refer to the Using non standard stock section in this guide DocuTech 128 155 180 HighLight Color Operator Guide 5 7 Technical information Table 5 5 Satisfaction guide for various stocks Stock Type Instructions for use Substance 13 49 g m2 paper Use trays 3 4 or 5 Do not run 2 sided prints Load the paper with seam side down into tray 3 Optimum satisfaction can be expected with 8 5 x 11 inch 216 x 279 mm or larger paper Substance 16 60 g m2 paper Load paper with seam side up into trays 1 and 2 seam side down into tray 3 4 or 5 Optimum satisfaction can be expected from tray 3 4 or 5 Substance 20 75 g Load the paper with seam side up into trays 1 Substance 110 200 g m2 long grain index m2 paper and 2 seam side down into trays 3 4 and 5 Card stock Card stock can be run from any tray Xerox substance 65 Reduce set size if frequent paper jams or 176 g m2 bindexer jams occur If collated unfinished another solution is to lower the value of the bindexer capacity set in the SWITCHES mode Xerox 4024 substance 20 75 g m2 3 hole drilled 4 hole drilled 7 hole drilled Load the paper into trays 1 and 2 with holes to the right load the paper into trays 3 4 and 5 with holes to the left
57. bstance 20 m2 to 10 of the sheet count 75 g m2 75 g m2 in a set Avoid adjacent inserts for substance greater than 24 90 g m2 Transparencies or never tear paper cannot be used as inserts when binding DocuTech 128 155 180 HighLight Color Operator Guide Technicalinformation Table 5 12 Binder satisfaction guide Stock Reliable stacking may be expected Less reliable stacking may be expected Suggested alternatives Set size limits Maximum collated 125 sheets of substance 20 75 g m2 or equivalent thickness Minimum collated 15 sheets of substance 20 75 g m2 7 sheets with index covers or equivalent thickness Maximum uncollated 100 sheets of substance 20 75 g m2 Minimum uncollated 15 sheets of substance 20 75 g m2 7 sheets with index covers or equivalent thickness 125 sheets of substance 16 60 g m2 Consider stitching for set sizes smaller than 15 sheets or equivalent thickness Reduce the number of sheets to maintain a maximum set thickness of 0 5 inch 13 mm when using heavier than substance 20 75 g m2 for main body or inserts 75 g m2 or less 415 sheets substance 24 90 g m2 310 sheets substance 32 120 g m2 225 sheets substance 110 200 g m2 Stacker Delivers 12 sets inboard To allow continuous run capacity and 12 sets outboard unload outer stack before inner stack reaches capacity Type
58. ches 457 mm and therefore can be rotated Those sizes whose dimensions are located to the right of the curve have diagonals greater than 18 0 inches 457 mm and therefore cannot be rotated Some common ISO sizes and US sizes are shown on the graph as examples Finisher satisfaction guides NOTE Production publisher configuration only The following guides summarize the stacker stitcher binder and top tray capabilities Table 5 10 Stacker capacity Reliable stacking may be Less reliable stacking may Stock expected be expected Suggested alternatives Size 8 x 10 inches to 9 x 14 Use the top tray for larger inches 203 x 254 mm to sizes 229 x 356 mm Weight Substance 16 to 20 60 to Weights outside the limits 75 g m2 shown are not recommended 5 14 DocuTech 128 155 180 HighLight Color Operator Guide Technicalinformation Reliable stacking may be Less reliable stacking may Stock expected be expected Suggested alternatives Set or stack Substance 16 to 20 60 to Over substance 20 75 g When using copy paper size 75 g m2 m2 stock as sets or stacks heavier than substance 20 75 increases the likelihood of g m2 limit the stack or set bindexer jams size by dividing the set into parts Combine prints when completed and finish offline if required For collated unfinished sets the maximum sheet capacity of the bindexer can be set to between 50 and 125 Stacker Unf
59. conditions that affect paper especially moisture Figure 3 60 shows good storage conditions for the binder tape DocuTech 128 155 180 HighLight Color Operator Guide 3 59 Routine maintenance XE157B Figure 3 60 Storing binder tape in a cool dry place Perform the following steps to store the binder tape wheels 1 Always store binder tape in a dry place cooler than 90 F 32 C Keep stored rolls in their original unopened containers Use rolls with older dates first Save the original foil containers for reuse in storing partially used rolls 4 Place partially used rolls of binder tape in their original resealable foil containers Ensure that the edge is sealed tightly XE158A Figure 3 61 Storing the binder tape 5 Store the partially used rolls of binder tape in a dry place cooler than 90 F 32 C 3 60 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance Replacing the binder tape reel 4 NOTE Production publisher configuration only lt Use this procedure to replace the binder tape in the system To ensure proper binding and to reduce binder tape jams do not leave binder tape in the system when the binder is not in use If necessary refer to the label on the binder for instructions on how to replace the binder tape The following steps must be performed to replace the binder tape wheel WARNING All areas of the binder drawer including the binder A tape are hot
60. continues If an exact match is not found the operator can specify in the job for the printer to do one of the following Stop printing the job and print an error sheet Print the data on an oversized sheet If you encounter any problems related to paper sizing contact your lead operator or Xerox service representative 2 26 DocuTech 128 155 180 HighLight Color Operator Guide System components Long and short edge To feed through the printer the leading edge of the paper must be feeding at least 10 inches long Therefore the following standard sizes of paper must be loaded so that sheets feed long edge first 7 by 10 inch B5 A4 US letter B4 US legal The following papers which have long edges greater than 14 33 inches 364 mm must feed short edge first A3 US ledger or US tabloid 4 NOTE JIS B4 can be fed either long edge or short edge first DocuTech 128 155 180 HighLight Color Operator Guide 2 27 System components 2 28 DocuTech 128 155 180 HighLight Color Operator Guide 3 Routine maintenance This section describes the routine activities you perform to maintain the reliability and productivity of your printer Cleaning and maintenance overview lt Some printer components need to be cleaned periodically to help keep the system operating reliably and to ensure that the print quality is consistent When supplies get low an indicator will appear in the DocuSP Print Ser
61. cover and behind the finisher and bindexer doors a Use the following procedure to clear any obstructions from the finisher sensors 1 Fold a sheet of 8 5 x 11 inch 216 x 279 mm paper as shown in figure 3 36 lt SS XEA037A Figure 3 36 Folding the paper 2 Use the folded sheet of paper to clear any obstructions in the following sensor areas Clearing the Q1201 sensor 4 NOTE Production publisher configuration only lt Clearing the Q1201 sensor should be performed only when directed by a Customer Support Center Representative 1 Open the processor top cover NOTE The Q1201 sensor is located under the processor top 4 cover on the right side 2 Locate the Q1201 sensor as shown in figure 3 37 3 40 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance XE038B Figure 3 37 Locating the Q1201 sensor 3 Brush a folded sheet of paper under the sensor to clear any obstructions 4 Close the processor cover Clearing the Q1202 and Q1203 sensors 4 NOTE Production publisher configuration only Clearing the Q1202 and Q1203 sensors should be performed only when directed by a Customer Support Center Representative 1 Open the finisher top cover 2 Locate the Q1202 and Q1203 sensors as shown in figure 3 38 DocuTech 128 155 180 HighLight Color Operator Guide 3 41 Routine maintenance XEAO98A Figure 3 38 Locating the Q1202 and Q1203 sensors 3 Brush
62. d the Attention light flashes e Messages appear on the controller informing you of the paper jam and its location in the printer e Selecting the message displays a printer mimic graphic that shows the area of a paper jam and lists instructions for clearing the jam NOTE t is important that you clear the sheets only in the areas indicated on the controller Checking job integrity following a paper jam When printing resumes following a paper jam there is a slight possibility that duplicate sheets may be printed or sheets may be missing from a job For that reason you should check job integrity after the job has been printed 1 The printer offsets the first sheet printed following a paper jam Locate that sheet in the stack 2 Check the sheets immediately before and after the offset sheet to see if there are any missing or duplicate sheets in the output NOTE A message may appear on the controller screen telling you that there is a suspected page delivery error and advising you to check the output 4 6 DocuTech 128 155 180 HighLight Color Operator Guide Problem Solving Clearing paper jams in printer areas 2 through 10 for both configurations In the following figures the printer jam clearance areas have arrows pointing to them or circles drawn around them i Tm
63. d snapping it down 7 Insert the new bottle into the waste module 0CD00012A SOR Figure 3 28 Inserting a new waste bottle 8 Close the HLC module door DocuTech 128 155 180 HighLight Color Operator Guide 3 29 Routine maintenance Wire Module Removal and Replacement Replace the wire module only when directed to by the Customer Support Center CAUTION n the following instructions do not pull on the locating arm of the developer housing A bent or damaged locating arm can cause component damage or image quality artifacts Do no touch the Electrostatic Voltage ESV mounted to the top of the developer housing when removing the wire module The ESV is fragile and susceptible to damage from electrostatic discharge To remove the wire module 1 Open the processor doors 2 Using the CCU cart or service stand slide the HLC developer module out of the printer Refer to the procedures on using the CCU cart or service stand N yi A keh U D A Muy Y 0CD00013A SO Figure 3 29 Wire module retainer springs 3 Release the wire module retainer springs There is one at each end at the front and back of the developer housing CAUTION Handle the wire module with care since the wires can be damaged or broken easily Do not touch the donor rolls Touching the roll surface with your fingers can contaminate the surface causing image quality problems To replace the wire module 3 3
64. d the shiny side up for optimum performance Removable stripe transparencies Do not load more than 50 removable stripe transparencies into trays 1 and 2 With the white stripe to the right place the transparencies on top of approximately 50 sheets of paper in the tray Do not run as inserts to a bound job Printing is not allowed on inserts Tabs Mylar tabs should be run out of tray 4 Preprinted stock Preprinted forms must be made up of ink that has the following characteristics Can withstand temperatures up to 400 F 204 C Can withstand pressure of 140 psi at the above temperature Can withstand the above conditions for 25 milliseconds High speed Load the stock with the stripe to the right in transparencies with trays 1 and 2 white stripe Label stock Load the stock face up into trays 1 and 2 face down into trays 3 4 and 5 Do not select 2 sided prints Letterhead preprinted Load the paper into trays 3 4 and 5 side 1 with the printed side down top edge to the front of the tray Load the paper into trays 1 and 2 side 1 up with the top edge to the front of the tray Do not use freshly preprinted paper in trays 1 and 2 DocuTech 128 155 180 HighLight Color Operator Guide 5 9 Technical information Stock Type Instructions for use Textured paper Heavily textured paper may produce prints with a ragged character appearance or deletions To
65. e chapter Refer to the binder tape storage information in this guide Refer to the binder cleaning information in this guide Refer to information on calling the Customer Support Center in this guide Stitcher fault codes displayed in the fault frame Fault Code P12 218 Fault Code P12 219 Select the Finishing button on the Printer Manager window Deselect Stitcher on the Finishing window and refer to the procedure Calling for assistance in this guide Stitcher A problems Perform the procedure Clearing a stitcher spool A fault in this guide Stitcher B problems Refer to information on calling the Customer Support Center in this guide Poor stitch quality or short stitches Reliable stitching can be expected with up to 65 sheets of substance 20 75 g m2 or 0 28 inch 7 mm thick sets Less reliable stitching can be expected with over 70 sheets of substance 20 75 g m2 Running intermixed stock heavier than substance 20 75 g m2 will reduce the capacity of the stitcher To avoid short clinches use the stitch override only when using a lightweight paper Stitch override allows the system to run beyond the stitching limit The system will shut down at 125 sheets Reduce the stock weight to enable the stitching of more sheets per set Refer to the satisfaction guides in the Technical information chapter 4 24 DocuTech 128 155 180 HighLight Color Operator Guide Problem Solving Table
66. e is Precut tabs cannot be sent included in the Using various to the top tray stocks section in this guide 5 18 DocuTech 128 155 180 HighLight Color Operator Guide 6 Service and supplies After the installation of your printer there are a few ongoing tasks that must be performed These tasks may include all or some of the following e Maintaining an adequate inventory of consumable supplies e Overseeing routine maintenance and meter reporting e Arranging additional operator training e Printing additional documentation e Placing service calls for hardware problems As the installation coordinator it is your responsibility to designate a person or persons to perform these tasks This chapter describes these tasks and some of the support services available to customers There is also a description of commonly used consumable supplies and a supplies checklist Xerox support services Many services are provided in support of your printer This section contains information on the following services e Customer Support Center e Customer Education e Supplies Order Service Prior to installation your sales representative is available to answer your questions about products services or billing However if you need assistance in resolving application related problems or questions call Customer Support refer to the following section of this chapter Your systems analyst is also available to assist you with applications dev
67. ed at recommended intervals to prevent read and write disk errors To clean the diskette drive If there is a diskette in the floppy disk drive remove it Insert the cleaning diskette into the disk drive Follow the directions on the cleaning diskette to clean the diskette drive 4 Remove the cleaning diskette DocuTech 128 155 180 HighLight Color Operator Guide 3 33 Routine maintenance Cleaning the sensors and the reflecting surfaces CAUTION Never use abrasive materials or strong solvents when cleaning sensors The following is a list of sensors to clean Q850 and Q861 sensor e Q1011 1009 sensor and mirror e High Capacity Feeder Stacker configuration e Q1106 sensor e Q1166 sensor e Q1107 sensor e Q1164 sensor Production publisher configuration finisher sensors e Q1201 sensor e Q1202 and Q1203 sensors e Q1205 Q1206 and Q1207 sensors e Q1213 sensor e Q1221 Q1218 and Q1227 sensors e Q1222 and Q1210 sensors Cleaning the Q850 and Q861 sensor 1 Open the right and left doors of the printer and locate Area 4 2 Raise the Area 4 green handle until it locks into place 3 34 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance S S NNS Figure 3 30 Area 4 and green handle 3 Locate the Q850 and Q861 sensor Figure 3 31 Q850 and Q861 sensor DocuTech 128 155 180 HighLight Color Operator Guide 3 35 Routine mainten
68. edge of the book 3 Open the finisher doors 4 Measure the distance between the top of the binder tape and the top of the book 5 Locate the black binder tape knob on the front of the binder drawer DocuTech 128 155 180 HighLight Color Operator Guide 3 65 Routine maintenance XE159A Figure 3 70 Locating the binder tape knob The knob is spring loaded and moves in increments to change the location of the binder tape Each increment equals a change of 0 1mm up or down on the edge of the book One full rotation of the knob is equal to 0 04 inch 1mm 6 Pull the knob toward you to rotate it for the adjustment 7 Adjust the tape position by performing one of the following steps e Pull the knob and rotate it clockwise to move the tape toward the top edge of the book as shown in figure 3 71 3 66 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance XE160A Figure 3 71 Adjusting the tape position up e Pull the knob and rotate it counterclockwise to move the tape toward the bottom edge of the book XE161A Figure 3 72 Adjusting the tape position down 8 Close the finisher doors 9 Runa test binder job to check your adjustment 10 Perform the procedure again as needed DocuTech 128 155 180 HighLight Color Operator Guide 3 67 Routine maintenance 3 68 DocuTech 128 155 180 HighLight Color Operator Guide 4 Problem Solving The system is designed to help you
69. eeder stacker modules DPCO0208A SOR Figure 2 6 Printer with inverter feeder stacker feeder stacker feeder stacker __ ee Se U CZT Figure 2 7 Printer with inverter feeder stacker feeder stacker feeder stacker feeder stacker The illustrations above show a High volume printer configuration with two feeder stacker modules and a bypass transport and a printer with three feeder stacker modules and a bypass transport With the bypass transport installed the printer can support up to three feeder stacker modules including the inverter feeder stacker DocuTech 128 155 180 HighLight Color Operator Guide 2 13 System components Production publisher The standard base components special features and configurations of the Xerox DocuTech 180 HLC production publisher printer are shown in the following figures DPC0204A TOR Figure 2 8 Production publisher Printer 2 tray interposer stitcher binder Convenience tray Interposer Finisher PO Top tray Convenience tray The convenience tray provides an area to place documents or other items while you are at the printer 2 14 DocuTech 128 155 180 HighLight Color Operator Guide System component
70. elopment Customer support The customer support center is available to address your application problems or to direct you to the appropriate documentation DocuTech 128 155 180 HighLight Color Operator Guide 6 1 Service and supplies The key to effective use of the support center is correct identification of the problem Before calling the support center it is helpful to have the following information available e A list of any error messages e An explanation of how output is different from what you expected An assessment of whether the symptoms follow a pattern or occur randomly e A list of special conditions that may have caused the problem New applications Changes made to the software Recent service performed Previous conditions under which the application has printed properly To contact the U S Xerox Customer Support Center call 1 800 821 2797 The Xerox Customer Support Center provides 24 hour support Operator training Operator training is conducted either at your location or at a Xerox Customer Education Center shortly after the printer is installed The training includes hands on practice running basic jobs performing routine maintenance and solving problems Determine the number of operators you want to attend the initial training and schedule training dates and times through your sales representative Supplies service To avoid downtime always have an adequate amount
71. ent Keep the processor in an upright vertical position Allow at least 6 inches 152 mm of unobstructed space at the front and rear of the processor so the fan and vents are not blocked CAUTION Do not place the monitor on top of the processor Do not block any fan or vent on the front sides or rear of the processor Do not Do not place the monitor and processor on a desk or table top Do not place the monitor on top of the processor Do not allow any piece of equipment to blow warm air into the air intake vents of the processor Do not place the processor on its side or in any other position but the upright vertical position achieved by using the controller stand Do not place the processor or monitor on top of the printer Tape drives overview The DocuTech 128 155 180 HLC supports several types of tape drives that may be used to load resources forms fonts etc or to submit offline LCDS print jobs A 26 track cartridge tape drive can be used only to import resources to the system disk A 9 track or 36 track tape drive can be used to submit print jobs to the printer or to load resources 2 24 DocuTech 128 155 180 HighLight Color Operator Guide System components The DocuSP Tape Client software enables transmission of data from a cartridge or open reel tape to the DocuSP controller via the Socket gateway The 4 GB external SCSI quarter inch cartridge QIC tape drive is an external device The ca
72. erator Guide Routine maintenance XE040B Figure 3 42 Locating the Q1205 Q1206 and Q1207 sensors 4 Brush a folded sheet of paper across each sensor to clear any obstruction 5 Close the bindexer and finisher doors Clearing the Q1213 sensor 4 NOTE Production publisher configuration only lt Clearing the Q1213 sensor should be performed only when directed by a Customer Support Center Representative 1 Open the finisher doors WARNING The top of the binder is approximately 425 F 218 A Do not touch the heated areas or you may get burned If the binder has been in a Ready condition allow it to cool for at least 1 hour before continuing the procedure 2 Grasp the green handle on the binder drawer Pull the drawer out until it stops 3 Locate the Q1213 sensors as shown in figure 3 43 DocuTech 128 155 180 HighLight Color Operator Guide 3 45 Routine maintenance XEA101A Figure 3 43 Q1213 sensor 4 Brush a folded sheet of paper across the sensor to clear any obstruction 5 Close the binder drawer and the finisher doors Clearing the Q1221 Q1218 and Q1227 sensors NOTE Production publisher configuration only Clearing the Q1221 Q1218 and Q1227 sensors should be performed only when directed by a Customer Support Center Representative 1 Open the finisher front doors 2 Locate the Q1221 Q1218 and Q1227 sensors as shown in figure 3 44 3 46 DocuTech 1
73. es off unexpectedly refer to the procedure Calling for assistance in this guide Processor power is off unexpectedly and the ground fault protector did not trip as Select the Reset icon on the fault frame Call for maintenance or electrical assistance within your facility in order to determine whether power is available at the electrical panel box within your facility 3 Do not clear the paper path unless directed to do so The system will maintain job integrity DocuTech 128 155 180 HighLight Color Operator Guide 4 5 Problem Solving Solving print quality problems A print quality problem means that the job was submitted successfully but does not print correctly NOTE f the Image Quality parameters are changed you must restart or reboot the DocuSP software in order for the changes to take affect NOTE The image quality default settings are optimized for the printer If changes have been made you can restore the factory installed defaults by selecting Defaults Selecting Reset sets the image quality parameters to the most recently applied setting Clearing paper jams 4 The paper path is the route that materials paper transparencies labels and so on follow through the printer from the feeder trays to the stacker bins sample tray or purge tray Paper jams can occur at any stage of the paper path After a paper jam the printer stops and the following happens If enable
74. find and solve problems as they happen The system detects hardware and software problems displays error or fault messages and screens and sounds an alert tone if it is enabled when a problem needs to be corrected This section of the operator guide describes how the system informs you of problems When you know there is a system problem you can take measures suggested by the system to correct the problem You can also use the problem and solution tables in this section to resolve recurring problems Included are detailed procedures that are required to resolve some of the problems If you are not able to correct a problem or you have a question about system operation you should call the Customer Support Center If a customer support representative cannot solve your problem over the phone a service representative will be dispatched How problems are displayed Hardware problems show themselves by way of messages document misfeeds paper jams poor prints fault codes and system components that do not operate correctly Software problems usually show up as messages in the status area of the screen or as fault codes on the fault frames Some software problems affect hardware behavior For example the printer may operate without producing any prints This is a condition called dead cycling Printer faults and fault windows When the printer needs attention it is called a fault There are three types of faults those that requ
75. following notes ensures the continued safe operation of your equipment e The system is heavy Ensure that the floor is level and strong enough to support the weight of the system Do not place the system near a heat source To move the system call a Service Representative Do not use an extension cord Always connect the system power cable to a properly grounded power source receptacle If in doubt have the receptacle checked by a qualified electrician Do not use an adaptor plug to connect the system to an electrical outlet that lacks a ground connection terminal WARNING mproper connection of the equipment grounding conductor can result in risk of electrical shock Do not locate the system where people may walk on the system power cable Do not place objects on the system power cable e Never override or disable electrical or mechanical interlocks WARNING Do not push objects into slots and openings on the system Making contact with a voltage point or shorting out a part could result in fire or electrical shock e Ifyou hear unusual noises or smell strange odors switch off the system power immediately Disconnect the system power cables from the electrical outlet and call a service representative Do not place containers of coffee or other liquids on the system e Switch off the system power disconnect the power cables and call a service representative when any of the following conditions occur
76. gure 4 11 Area 12 all feeder stackers NOTE High volume printer configuration only DocuTech 128 155 180 HighLight Color Operator Guide 4 13 Problem Solving Clearing paper jams in the Feeder Stackers Figure 4 12 Area 13 NOTE Figures 4 12 and 4 13 applicable on the high volume 4 printer configuration only Figure 4 13 Area 14 DocuTech 128 155 180 HighLight Color Operator Guide Problem Solving even though there is no message indicating a jam in this area Discard the paper 4 NOTE You may sometimes find paper lying on top of area 14 K PN Figure 4 14 Area 15 4 NOTE High volume printer configuration only DocuTech 128 155 180 HighLight Color Operator Guide 4 15 Problem Solving ian O YA Za I f Figure 4 15 Area 16 4 NOTE High volume printer configuration only 4 16 DocuTech 128 155 180 HighLight Color Operator Guide Problem Solving Figure 4 16 Area 17 NOTE f your printer has frequent jams in this area you may need to clean the Q1106 sensor 4 NOTE High volume printer configuration only DocuTech 128 155 180 HighLight Color Operator Guide 4 17 Problem Solving Figure 4 17 Area 18 Points to note
77. h the package wrapper seam side facing up NOTE When loading drilled paper be sure to fan the edge where the holes are located Position the stack against the front right corner of the tray as shown in Figure 3 4 This is indicated by the green arrow on the bottom of the tray 3 6 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance For stock outside the recommended limits refer to the Technical information chapter in this guide W Figure 3 4 Positioning the stack 8 Move the rear guide forward until it touches the edge of the stack 9 Lower the feed belt 10 Close the tray slowly but firmly until it latches Using the custom transfer assist blade The custom transfer assist blade in the printer assures good print quality for your jobs A kit is available allowing you to customize the transfer assist blade for use with nonstandard paper sizes You cannot use the custom transfer assist blade for print jobs that use more than one paper size In addition the following paper lengths cannot use the blade DocuTech 128 155 180 HighLight Color Operator Guide 3 7 Routine maintenance lt Installing the custom transfer assist blade Setting tray size with the custom transfer assist blade In U S markets 11 1 to 11 4 inches 282 to 290 mm 11 8 to 12 1 inches 300 to 307 mm 13 to 13 5 inches 330 to 343 mm In non U S markets 11 1 inches to 11
78. he cart firmly against the printer until you can feel the two latch together DocuTech 128 155 180 HighLight Color Operator Guide 3 19 Routine maintenance 4 Push down firmly on the cart pedal until you hear or feel the pedal catch The pedal should stay locked down The pallet containing the CCU is raised 5 Using the CCU metal flange firmly push the CCU into the printer 6 Turn the yellow CCU handle counterclockwise for a quarter turn If it does not turn check that the CCU is firmly seated in the printer O0CD00004A SOR Figure 3 17 Turning the backup roller handle counterclockwise 7 Turn the photoreceptor backup roller handle counterclockwise for a quarter turn 8 Make sure that the CCU is completely inserted into the machine to prevent photoreceptor damage 9 Push down firmly on the cart pedal until you hear or feel a Click If the pallet does not drop check that the CCU is all the way in the printer and the pallet is released then push down on the pedal again 10 Remove the cart from the printer and close the cart top cover 11 Close the printer doors 12 Store the cart 3 20 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance Storing the cart and CCU NOTE f any dry ink gets on your hands wash them with soap 4 and cold water Heat sets the ink permanently If any dry ink gets on your clothes brush them with a dry paper towel or a stiff bristled br
79. ide Refer to the binder tape reel storage information in this guide DocuTech 128 155 180 HighLight Color Operator Guide Problem Solving Table 4 3 Resolving a finisher problem Binder tape not positioned correctly on the top edge of the output prints Adjust the binder tape registration using the procedure Adjusting the binder tape registration in this guide Binder tape is too long or too short on the bottom edge of the output prints Adjust the binder tape length using the procedure entitled Adjusting the binder tape registration in the Routine maintenance chapter If an adjustment is made to the binder tape length during a job it will not take effect until the next job is printed If it is necessary to adjust the binder tape length during a job adjust it using the procedures in the on line help Loose binder tape along the spine of the completed bound book This is a symptom of excessive moisture in the tape Replace the tape reel with a new reel using the procedure Replacing the binder tape reel in the Routine maintenance chapter Refer to the binder tape storage guidelines in this guide Repeated tape feeding problems such as binder tape not unwinding from the reel If the binder tape is sticking together or if there are cosmetic defects in the bound book replace the tape reel with a new reel using the procedure Replacing the binder tape reel in the Routine maintenanc
80. iew e Inverter Feeder Stacker and up to 3 Feeder Stackers e 2 Tray Interposer and Finisher Production publisher configuration NOTE The initial release of the Production publisher Interposer and Finisher configuration is 180 PPM only and does not support LCDS amp IPDS The Xerox DocuTech HLC prints high quality high resolution documents in simplex or duplex mode at high production speeds from LCDS PostScript PCL and other data streams The system can switch between printing different types of data streams without a need for rebooting or reconfiguring software The printer supports e Duplex printing e Media handling of multiple weights sizes and types e Optional modules for enhanced finishing and output to third party finishing devices e Optional enabling of a third party roll feeder e Depending on your configuration optional high capacity feeder stacker modules which provide additional feeder trays and output bins Depending on your configuration Interposer Finisher Binder e High resolution of LCDS PostScript and PCL data streams shown in the following table NOTE The initial release of the Production publisher Interposer and Finisher configuration is 180 PPM only and does not support LCDS amp IPDS 2 2 DocuTech 128 155 180 HighLight Color Operator Guide System components Table 1 Data stream resolution Data stream Input resolution Print resolution DP128 155 180 HLC
81. in b Drilled holes on left edge c Origin 0 0 portrait orientation 10 Purge tray 11 Bypass transport a Side 2 of sheet passing through bypass transport b Drilled holes on left edge c Origin 0 0 portrait orientation 2 20 DocuTech 128 155 180 HighLight Color Operator Guide System components Production publisher paper path The following figure shows the path the paper takes through the production publisher YY DPC0202A TOR Figure 2 12 Route of paper through the production publisher 9 Om Oo Pe NS Processor feeder tray 1 Processor feeder tray 2 High capacity paper tray Paper inserter tray High capacity paper tray Duplex inverter Purge tray Bypass transport Bindexer area 10 Bind area 11 Stitch area 12 Stacker area Bypass transport paper path The following figures show the paper path through the bypass transport viewed from the front of the printer DocuTech 128 155 180 HighLight Color Operator Guide 2 21 System components High volume printer bypass transport paper path Co Sheet path 10 6mm 0 4i Sheet path 1418 4mm 56in 87 5mm 3 4in 860mm 34in Floor Figure 2 13 Bypass transport paper path high volume printer configuration shown 1 Sheet path 2 Exit rollers 3 Floor 2 22 DocuTech 128 155 180 HighLight Color Operator Guide System components The System
82. inished sheets To allow a continuous run capacity 3300 sheets substance unload outer stack before 16 60 g m2 inner stack reaches capacity 3000 sheets substance 20 75 g m2 2500 sheets substance 24 90 g m2 1875 sheets substance 32 120 g m2 1360 sheets substance 110 200 g m2 Type or Xerographic bond paper in Slightly curled paper Do not use excessively curled condition good condition paper Drilled paper Transparencies must contain some opaque sheets to avoid finisher jams Stock not defined here is included in the Using various stocks section in this guide Table 5 11 Stitcher satisfaction guide Stock Reliable stacking may be Less reliable stacking may Suggested alternatives expected be expected Size 8 x 10 inches to 9 x 14 Use the top tray for larger inches 203 x 254 mm to sizes 229 x 356 mm Weight Substance 16 to 110 60 to Weights outside the limits 200 g m2 shown are not recommended Set size limit Collated Up to 65 sheets Collated Up to 70 sheets of Reduce the paper weight to due to copy of substance 20 75 g m2 substance 20 75 g m2 enable stitching more sheets paper weight or 0 28 inch 7 mm thick per collated set sets Check the stitch quality Uncollated 50 copies maximum per stitch 0 28 inch 7 mm thick sets Stacker Stacker capacity adjusts To allow a continuous run capacity automatically to suit unload outer stack before variou
83. ion to lower the platform is entered at the printer control console or a user interface window e The job being printed reaches a designated unload boundary Each HCS bin has unlinked double doors to give you easy and safe access for unloading output from the printer The elevator bin platform automatically rises when the doors are closed after the stacker has been unloaded Bin control panels Each stacker bin has a control panel consisting of buttons and on stackers indicators DocuTech 128 155 180 HighLight Color Operator Guide 2 11 System components Ready to Unload indicator on stacker bins Please Wait indicator on stacker bins Bin Unload button on stacker In Use indicator on stacker bin High capacity feeders 1 2 3 4 Figure 2 5 High capacity stacker bin control panel 1 Ready to Unload indicator on stacker bins 2 Please Wait indicator on stacker bins 3 Bin Unload button on stacker 4 In Use indicator on stacker bin When this indicator glows you can remove printed sheets from the stacker bin When this indicator glows the elevator is in motion This indicator turns off when the platform reaches its destination Lowers the bin elevator e Ifthe bin is in use when this button is pressed the printed pages begin stacking in the other stacker bin if auto switching has been enabled e Ifthe bin is not in use pressing this button does not affect printing
84. ire immediate attention those that provide information and those that require service Examples of faults that would require immediate attention are misfeeds in the paper path or paper jams Examples of a fault that is informational is low dry ink If this type of fault is not resolved a fault requiring immediate attention will result eventually DocuTech 128 155 180 HighLight Color Operator Guide 4 1 Problem Solving When a fault occurs When a fault occurs in the printer an indicator appears on the DocuSP Print Services window and a Printer Faults message appears NOTE The printers also have an attention light on top of the finisher module A flashing light indicates a fault requiring immediate attention a steady light indicates a fault that can be cleared at a later time Refer to the on line help or System Guide for additional information on printer faults Resolving a processor problem A If you have a recurring processor problem perform the following activities Find the problem in the Problem column of the problem solving charts below e Follow the instructions in the Suggested solutions column of the problem solving charts in this guide WARNING Remember that the fuser and binder area surfaces are hot Proceed with caution when clearing all jams Table 4 1 Resolving a processor problem Problem Suggested Solution Paper tray elevator Ensure that the stock is loaded proper
85. iskettes call the Xerox Supply Center weekdays between 7 30 a m and 6 00 p m Pacific Standard time If you prefer you may mail orders to the following address Xerox Corporation P O Box 25075 Santa Ana CA 92799 5075 e To order cleaning supplies call the Xerox Customer Parts and Product Support Center weekdays between 5 30 a m and 5 00 p m Eastern Standard time at 1 800 828 5881 U S only You may also mail cleaning supplies orders to the following address Xerox Corporation Parts Marketing Center Building 214 07S P O Box 1020 Webster NY 14580 Please provide the following information when placing orders e Your customer number provided by your sales representative e Your printer model e Your supply order including the following information Item name Part number Quantity desired If your company requires a purchase order for payment of an invoice you need to provide the purchase order number to Xerox at the time you place the order DocuTech 128 155 180 HighLight Color Operator Guide 6 3 Service and supplies Routine maintenance There are a number of routine maintenance tasks that must be performed to ensure maximum efficiency of your printer These tasks include the following e Adding dry ink e Cleaning the exterior surfaces of the system Step by step instructions on performing these routine maintenance tasks are contained in your DocuTech 128 155 180 Operator
86. k wider than 9 inches 229 mm other than 17 x 11 inches or A3 may increase the risk of misregistration skew and tray 3 elevator problems 5 10 DocuTech 128 155 180 HighLight Color Operator Guide Technicalinformation Table 5 7 Stock length impact on system performance Stock length Impact on performance Over 11 inches 279 mm to less than 11 7 inches 297 mm Over 11 7 inches 279 mm to less than 13 inches 330 mm Over 13 inches 330 mm to less than 14 inches 356 mm Over 14 inches 356 mm The transfer assist mechanism is preset to optimize image transfer for the exact stock lengths of 11 inches 279 mm 11 7 inches 297 mm 13 inches 330 mm and 14 inches 356 mm Stock lengths falling between these exact lengths present an increased risk for bottom edge deletions 14 33 inches B4 JIS Background smudging or white spaces may occur when printing between the 14 inch area and the edge of the paper 10 inches 254 mm to less than 11 inches 279 mm Because the 11 inch transfer mechanism is used for all stock lengths less than 11 inches 279 mm there is an increased risk of contaminating the back side of sheets after switching back to longer stock 11 2 inches 284 mm to less than 11 5 inches 292 mm 11 9 inches 302 mm to less than 12 2 inches 310 mm 13 5 inches 343 mm to less than 13 7 inches 348 mm Unresolved stock size mismatch
87. l set up Modification connection to external control software or to external control apparatus not authorized by Xerox will invalidate its certification Electricity at Work Regulation UK The Electricity at Work Regulation applies only to England and Wales The Regulation The Electricity at Work Regulation 1989 came into force in England and Wales on 1 April 1990 This 1989 Regulation places a duty on all employers and self employed persons to ensure the electrical systems in their premises are constructed maintained and operated in such a manner as to prevent so far as reasonably practical danger This includes ensuring all electrical equipment connected to such electrical systems are safely constructed maintained and operated All Xerox equipment have been designed to exacting safety standards They have all undergone a variety of stringent safety tests including earth bond insulation resistance and electrical strength tests Xerox Europe manufacturing plants have been awarded ISO 9000 quality certification and are subject to regular audits by the British Standards Institution or equivalent national standards body Xerox equipment which has been properly and regularly serviced and maintained should not have to undergo additional specific safety tests pursuant to the 1989 Regulation Customers wishing to complete safety testing should contact Xerox Europe Technical Centre for advice prior to any test implementation
88. latform Series to supplement the information in this guide Before using this guide become familiar with its contents and conventions WARNING Both power cords with the printer must be disconnected from the printer in order to completely power down the machine This section lists the contents of this guide System components contains an explanation of each of the system components Routine maintenance describes the routine activities you perform to maintain the reliability and productivity of your printer Problem solving describes how the system informs you of problems When you know there is a system problem you can take measures suggested by the system to correct the problem You can also use the problem and solution tables in this section to resolve recurring problems DocuTech 128 155 180 HighLight Color Operator Guide vii Introduction Conventions Technical information contains the hardware and software capacity guidelines for the DocuTech 128 155 180 HLC systems Supplies lists the supplies that you might want to keep in stock and the information you need to order them This guide uses the following conventions Pr e All caps and angle brackets Within procedures the names of keys are shown in all caps within angle brackets for example press lt RETURN3 gt Angle brackets Variable information or the position of a specified argument in the command synt
89. le tray Attention light Purge tray Feeder stacker modules Inverter feeder stacker Ole NS Feeder paper tray High volume printer Multiple feeder paper trays can be configured to feed paper for jobs in the most effective manner For example the trays can provide nonstop printing of a complex job that requires many paper stocks or only a few stocks by using the trays continuous loading capability A different input tray can also be selected for each copy of a specific page in a print job for example to provide different paper colors for specific pages The printing system may have up to six feeder paper trays two processor feeder trays and two to four high capacity trays Four addressable input trays are standard with the system and two additional high capacity trays are optional 2 8 DocuTech 128 155 180 HighLight Color Operator Guide System components Processor feeder Two processor feeder paper trays trays 1 and 2 are located in paper trays the main part of the printer Trays 1 and 2 can handle paper sized from 8 by 10 inches 203 by 254 mm to 9 02 by 14 02 inches 230 by 356 mm Feeder paper tray Depending on your configuration the feeder paper trays have the capacity following capacities based on 20 pound or 80 gsm grams per square meter paper Tray 1 1100 sheets Tray 2 600 sheets Trays 3 4 5 and 6 high capacity trays 2600 sheets each An elevator moves each tray up or down when it is in u
90. line help for details 3 Ensure that there is wire on the spool 4 Pull the green stitcher head release handle forward and up until it latches into place as shown in figure 4 23 XE059D Figure 4 23 Stitcher head release handle 4 26 DocuTech 128 155 180 HighLight Color Operator Guide Problem Solving TA828A Figure 4 24 Removing the stitcher wire plug 5 Remove the stitcher wire plug The stitcher wire plug is located above the binder area as shown in figure 4 24 e Press and hold down the release clip Pull the plug out of the stitcher head 6 Remove any damaged wire e Using the wire cutters slowly and carefully pull approximately 3 feet 1 meter of wire out of the stitcher plug e The wire cutter tool needed to perform this procedure is located next to stitcher spool B as shown in the lower left corner of figure 4 23 e Cut the wire carefully leaving approximately 2 inches 50 mm of wire extending from the stitcher plug as shown in figure 4 25 DocuTech 128 155 180 HighLight Color Operator Guide 4 27 Problem Solving XEA084A Figure 4 25 Cutting the wire Insert the plug into the measuring bracket as shown in figure 4 26 7 XEAO85A Figure 4 26 The measuring bracket 8 Feed the wire until the wire touches the back of the measuring bracket 9 Remove any stitcher wire fragments DocuTech 128 155 180 HighLight Color Operator Guide 4 28 Problem
91. lvents to remove dry ink from your skin or clothing The heat or solvent will set the dry ink and make it difficult to remove CAUTION f any dry ink should get on your clothes brushing with a dry paper towel or a stiff bristled brush may remove the ink If not launder your clothes with detergent and cold water Tell a commercial dry cleaner that the spot is dry ink or toner so that they will not use a solvent that will set the dry ink stain Replace the black dry ink bottle The following steps must be performed to replace the black dry ink bottle 1 Open the front processor access door and locate the black dry ink bottle at the left side of the processor Place a drop cloth on the floor under the dry ink bottle area Remove the empty bottle by grasping the bottle handle With a slow firm motion pull the bottle from the bottle guide a Pull the empty dry ink bottle out until it stops b Move the green handle to the unlatched position c Remove the empty bottle and discard it DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance a EF ea Da pr ps 2 ay eae A Figure 3 8 Removing the empty bottle 4 To insert a new bottle place the bottle on the edge of the bottle guide a With a slow firm motion push the bottle into the dispense position over the hopper b Turn a new bottle of dry ink upside down and shake the bottle thoro
92. ly in the paper trays with the rear fails to rise or lower and side guides against the stock stack e Ifthe elevator fails to rise or lower in paper tray 1 or 2 latch the paper feeder by pressing down on the green dot inside the tray e Do not slam the trays closed Push the trays in slowly but firmly e Ensure that all misfed stock has been removed from the immediate area of the paper trays 4 2 DocuTech 128 155 180 HighLight Color Operator Guide Problem Solving Problem Suggested Solution Paper path jams Check the area where the jams are occurring to ensure that the paper path is clear of paper and other obstructions If a jammed sheet of paper tears when being removed ensure that you have removed all of the sheet pieces Ensure that the paper path baffles are in the correct seated position Ensure that the stock is loaded properly in the trays with the rear and side guides against the stack Ensure that the stock is not loaded above the bottom of the red line in the paper tray Ensure that the stock has no bent corners or tears and that the edges are straight Remove any damaged sheets Repeated jamming may be due to a paper curl problem that can be resolved by adjusting the decurler lever Refer to the procedure Adjusting for paper curl in this guide Paper weight less than substance 20 75 g m2 will require careful setting of the decurler Refer to the procedure Adjusting for pa
93. mage the system e Keep supplies in stock as listed in the Service and supplies chapter Whenever you use or remove a part from the system handle the part carefully Note any informative labels on the system Keep atomized and aerosol sprays away from the system Pour cleaning liquids onto a cloth Do not pour or spray liquids directly onto system parts Before reinstalling a system part that has been cleaned with a liquid ensure that the part is dry Always use a drop cloth when replacing the dry ink bottle highlight color container or when adding fuser shield e Some parts of the system such as the fuser get hot during operation To ensure that you do not burn yourself be careful when working around these parts WARNING The fuser can reach a temperature of approximately A 425 F 218 C Exercise care to prevent burns when working near this area Finisher precaution 4 NOTE Production publisher configuration only The system uses stitcher wire from two spools located below the stacker Stitcher spool A is used for portrait top corner stitches When stitcher spool A is empty it must be replaced with a new stitcher spool Stitcher spool B is used for portrait dual stitches and landscape stitches To replace stitcher spool B contact the Customer Support Center refer to the section Calling for assistance in this guide To replace stitcher spool A refer to the section Replacing the s
94. matted Packaged 10 per box Wire Modules 1 unit per package 802K26190 802K26191 in 8 04 Stitcher Wire Packaged 1 reel per carton 8R1174 Consumption rate is approximately 32 000 stitches per reel Binder Tape Black 8R7186 White 8R7187 Gray 8R7188 Blue 8R7189 Packaged 1 reel per carton Consumption rate is approximately 425 binds per carton CAUTION CAUTION Do not use DT DP Fuser Agent 8R2955 in a DT HLC printer Do not use DT HLC Fuser Blend in other DocuTech or DocuPrint systems Fuser blend and Fuser shield are NOT switching from one to the other interchangeable Contact your Xerox representative before NOTE Developer is ordered and stocked by the Xerox Service 4 Representative for your site The part numbers are provided here for informational purposes only 6 8 DocuTech 128 155 180 HighLight Color Operator Guide Service and supplies Use the following table to help record the supplies and accessories you require the date on which the order should be placed and the actual date of the order Table 6 2 Supplies checklist Date of Date Item Description Quantity order ordered Paper Dry ink Developer Fuser shield Labels Transparencies Cleaning supplies Other DocuTech 128 155 180 HighLight Color Operator Guide 6 9 Service a
95. ment and the mutual recognition of their conformity A full declaration defining the relevant directives and referenced standards can be obtained from your Xerox Europe representative WARNING Changes or modification to this equipment not specifically approved by Xerox Europe may void user s authority to operate the equipment Shielded cables must be used with this equipment to maintain compliance with the EMC Directive 89 336 EEC WARNING This is a Class A product In a domestic environment A this product may cause radio interference in which case the user may be required to take adequate measures gt DocuTech 128 155 180 HighLight Color Operator Guide 1 3 Safety notices A A WARNING This system is certified manufactured and tested in compliance with strict safety and radio frequency interference regulations Any unauthorized alteration which includes the addition of new functions or the connections of external devices may impact this certification Please contact your local Xerox Europe representative for a list of approved accessories Shielded cables must be used with this equipment to maintain compliance with the EMC Directive 89 336 EEC This equipment is not primarily intended for use in a domestic environment WARNING n order to allow this equipment to operate in proximity to industrial scientific and medical ISM equipment the external radiation from the ISM equipment may have to be limited
96. n guides 0 5 5 Using non standard stock 0 c cette eee 5 10 Paper stock rotation oeuse 2 00 a eee teens 5 11 Finisher satisfaction guides 0 0 eet eee 5 14 6 Service and supplies Xerox SUPPO SEIVICES wise Ved Pee VO ea GN ade bbe bee ea eee ee 6 1 Customer support zi seradas i aai teens 6 1 Operator training ossessi sanda eadar Ca aa aad ehe a Aa aah EE a a bee ead eel eee 6 2 Supplies service n 0 0 tenes 6 2 Routine maintenance 0 2 een ets 6 4 Meter reading and reporting 0 6 4 Consumable supplies table 0 0000 tees 6 4 DocuTech 128 155 180 HighLight Color Operator Guide vi DocuTech 128 155 180 HighLight Color Operator Guide About this guide Contents Introduction The DocuTech 128 155 180 HLC Operator Guide is one of a number of publications that make up the Xerox Document Services Platform Series The guide is intended for Xerox DocuTech 128 155 180 HLC operators whose job consists of the routine operation of this printing system operating each of the system components running print jobs solving simple system problems and performing basic maintenance tasks such as replenishing printer supplies If you are a lead operator or your job involves some programming or systems administration tasks as well as operating the DocuTech 128 155 180 HLC system use the on line help system and the other documents in the Xerox Document Services P
97. n trays 4 and 5 Make sure the stock in trays 4 and 5 meet the specifications for these trays as indicated in the Satisfaction guides in chapter 4 Technical Information Finisher problems 4 NOTE Production publisher configuration only lt Table 4 3 Resolving a finisher problem Problem Suggested solutions Repeated jams in area 14 bindexer The bindexer contains three bins used by the system to sort sets The capacity of each bin is 125 sheets of substance 20 75 g m2 or 0 5 inch 13 mm thickness Include inserts and covers when considering the output capacity of the bindexer 125 sheets of substance 20 75 g m2 is equal to approximately 104 sheets of substance 24 90 g m2 78 sheets of substance 32 120 g m2 47 sheets of substance 110 200 g m2 Check that the sets in the bindexer are less than 0 5 inch 13 mm thick If the set exceeds 0 5 inch 13 mm thickness reprogram the job for fewer sheets or reduce the number of heavy weight sheets When running collated unfinished sets the maximum sheet capacity of the bindexer can be set between 50 and 125 When running anything other than collated unfinished sets the maximum sheet capacity of the bindexer will remain at 125 Jammed binder tape such as binder tape sticking together or cosmetic defects in the bound book Replace the tape reel with a new reel using the procedure Replacing the binder tape reel in this gu
98. natural curve called the curl Storing or using the paper under humid conditions may increase the curl When too much curl causes paper handling problems adjust the decurler in the processor The decurler flattens the paper after fusing Measuring the paper curl 1 Program and print five 1 sided 8 5 x 11 inch 216 x 279 mm sheets to the top tray 4 NOTE Keep the image toward you as shown in Figure 3 5 2 Measure the amount of curl in the prints by holding the five prints in the top center of the short edge a 7 Figure 3 5 Measuring the paper curl 3 Place the bottom edge of the prints over the paper curl measurement chart in this guide e Ifthe print curl on the printed paper measures between 1 and 2 do not change the decurler setting Ifthe curl is between 2 and 3 or 3 and 4 refer to the procedure Adjusting the decurler lever in this section NOTE Superior performance for greater than substance 32 4 120 g m2 can be achieved between 1 and 1 curl DocuTech 128 155 180 HighLight Color Operator Guide 3 9 Routine maintenance Note Corners of the sheets of paper should not exceed curl shown in this chart Move green Move green decurler levert gt 6curler lever Figure 3 6 Measuring the paper curl 3 10 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance Adjusting the decurler lever Perform the following
99. nch Dual Purpose Colors Goldenrod 3R3094 8 5 x 11 inch Dual Purpose Colors Ivory 3R3064 8 5 x 11 inch Dual Purpose Colors Ivory 3 3R3080 hole DocuTech 128 155 180 HighLight Color Operator Guide 6 5 Service and supplies Item Description U S part number 8 5 x 14 inch Dual Purpose Colors Ivory 3R3096 8 5 x 11 inch Dual Purpose Colors Gray 3R3066 8 5 x 11 inch Dual Purpose Colors Gray 3 3R3802 hole 8 5 x 14 inch Dual Purpose Colors Gray 3R3098 8 5 x 11 inch Dual Purpose Colors Rainbow 3R3107 Pack 35 000 sheets carton 250 sheets pack 8 5 x 11 inch 10 Series Dual Purpose Paper 3R2950 8 5 x 11 inch 10 Series Dual Purpose Paper 3R2952 3 hole 8 5 x 11 inch 10 Series Dual Purpose Paper 3R3016 3 hole 8 5 x 14 inch 10 Series Dual Purpose Paper 3R2954 8 5 x 11 inch 10 Series Smooth 3R54 8 5 x 14 inch 10 Series Smooth 3R83 8 5 x 11 inch 4200 Dual Purpose reinforced 3 3R2057 hole Image LX Laser White 8 5 x 11 inch 5000 sheets 3R3874 Xerographic carton Paper Image LX White 8 5 x 11 inch 3 hole 5000 3R3875 sheets carton Image LX White 8 5 x 14 inch 4000 sheets 3R3876 carton Image LX White 11 x 17 inch 4000 sheets 3R3877 carton Transparencies Xerox transparencies are packaged 100 sheets to a box 8 5 x 11 inch Clear with a white strip on the 3R2780 edge Labels Xerox labels are
100. nd supplies Date of Date Item Description Quantity order ordered 6 10 DocuTech 128 155 180 HighLight Color Operator Guide
101. ndards Is Xerox equipment safe All Xerox equipment supplied by Xerox Europe and their authorized distributors conforms to all relevant safety legislation and standards Is the Xerox equipment in my premises safe All Xerox equipment supplied by Xerox Europe and their authorized distributors conforms to all relevant safety legislation and standards However like all electrical equipment they have to be regularly serviced and maintained by competent persons Xerox Europe Customer Service Engineers ensure Xerox equipment is serviced and maintained to exacting Xerox safety standards If you would like your Xerox equipment to be serviced and maintained to such high standards please contact your local Xerox Europe Customer Service Organization They will be pleased to assist you Does the Xerox equipment in my premises comply with the Electricity at Work Regulations All employers and self employed persons must ensure that the electrical systems in their premises are safe This will include ensuring Xerox equipment in such premises is safe Xerox Europe s Product Safety function has prepared a guide which contains a list of tests which may be completed by your Xerox Europe Customer Service Organization THESE TESTS 1 6 DocuTech 128 155 180 HighLight Color Operator Guide Safety notices Question Answer Question Answer Additional queries MUST BE CARRIED OUT ONLY BY PERSONS WHO POSSESS THE RELEVANT SKILL KN
102. nder tape loading label and thread the tape through the tape feeder TA615C Figure 3 66 Threading the tape through the tape feeder 7 Thread the tape around the drive roll to the edge of the pressure roll DocuTech 128 155 180 HighLight Color Operator Guide 3 63 Routine maintenance Figure 3 67 Threading the tape to the pressure roll 8 Turn the green knob clockwise until the tape extends at least 2 inches 51mm beyond the tape guides Figure 3 68 Feeding the tape manually 9 Cut the tape a Lift up on the green tape cutter handle as shown in figure 3 69 3 64 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance b Remove the cut piece of tape XEAO078A Figure 3 69 Cutting the tape 10 Close the binder drawer 11 Close the finisher doors Adjusting the binder tape registration NOTE Production publisher configuration only gt The binder tape knob is used to align the registration of the binder tape to the top edge of a bound book This procedure has no effect on the length of the tape but you should perform this procedure before adjusting the tape length To adjust the length refer to the on line help Perform the following steps to adjust the binder tape registration 1 Ensure that the tape guides are clean and free of glue residue Refer to the procedure Cleaning the binder in this section 2 Determine the adjustment amount for the top
103. ng Problem Suggested Solution Missing sheets in a set immediately after a jam After recovering from a jam an incomplete set may be purged and the set reprinted Check the prints to ensure that you are not confusing the purged output with the completed set Printer is dead cycling it is running but not making any prints If the printer is running but not making any prints and no message is displayed on the screen open a processor door to stop the printer If this problem repeats refer to the procedure Calling for assistance in this guide Fuser jams WARNING The fuser surfaces are hot To avoid injury proceed with caution when removing all jams Use a piece of paper to remove jammed sheets from the fuser The jammed sheets in the fuser require careful handling because they may not be fused properly Images that extend all the way to the edge of the prints may cause increased frequency of jams Do not place dense images to be printed at the right or left lead and trail edges of the paper This may cause fuser jams e Ifthe above adjustment does not resolve the problem contact the Site Administrator to access the Lead Edge Screening feature on the Printer Switches window There are three settings available in the Lead Edge Screening feature e Use the Off setting when it is necessary to print all of the document e Use the Standard setting when the documents have narrow black lines or n
104. ng system serial number which is located on a panel inside the printer behind the small door on the left f o o X XEROX Wg Figure 4 29 Location of printing system serial number e Your name e Your company name e The system condition or status NOTE The printer serial number and fault codes can also be 4 seen on the Tools display of the printer control console This information is given to a customer service representative who calls you back to discuss the information and gives you an estimated time of arrival or to assist you over the phone to resolve the problem DocuTech 128 155 180 HighLight Color Operator Guide 4 31 Problem Solving 4 32 DocuTech 128 155 180 HighLight Color Operator Guide 5 Technical information This section contains the hardware and software capacity guidelines for the DocuTech HLC systems It includes the printer specifications the satisfaction guides for paper trays and stock and Tips on storing paper and improving printing reliability For complete system specifications refer to the appropriate Installation Planning Guide DocuTech printer specifications Printer rates This section contains information on expected print rates for the DocuTech printers as well as informati
105. ngage the pins with the holes and the slot The end of the service stand may need to be lifted slightly to ensure pin engagement With the service stand in position against the machine and the pins engaged in the docking bracket engage the locking mechanism by applying a force forward on the lever and compressing the latch spring while turning it to the position shown Locate the pin squarely to the machine by ensuring that the two 2 locating pins in the service stand are in contact with the docking bracket With the service stand properly located to the machine and while observing the level turn the rear jack screws to adjust the height of the service stand so that it is level Tighten the lock nuts on the jack screws to lock the jack screws in position Unlatch the CCU by turning the photoreceptor backup roller handle clockwise for a quarter turn to an upright position O0CD00004A SOR Figure 3 19 Unlatching the CCU 3 22 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance g OCDO0005A SOF Figure 3 20 Removing the CCU from the printer 11 Using the metal flange of the color CCU pull the CCU out of the printer until it is completely in the stand The flange is located directly below the bottle 12 To replace the CCU reverse the above steps Adding fuser shield When directed by a message add fuser lubricant as soon as possible If it is not
106. o dark areas on the lead edge This is the system default setting and is the recommended setting e Use the Stress setting when the system is experiencing fuser jams and the Standard option is selected e Use the Erase All Edges setting when the system is experiencing jams and the image prints to the edges of the paper Holes are on the wrong side of the prints Ensure that the stock is loaded correctly Refer to the label on the tray Paper curl Adjust the decurler Refer to the procedure Adjusting for paper curl in this guide Fault Code P10 216 This is a printer problem Switch the printer off and on Allow a minimum of 30 seconds between switching the printer off and switching the printer back on Fault Code P09 418 If this fault is persistent replace the wire module If the fault continues call for service Refer to the wire module removal and replacement procedure in this guide 4 4 DocuTech 128 155 180 HighLight Color Operator Guide Problem Solving Problem Suggested Solution Processor power is off unexpectedly The processor or the DocuSP controller may have an electrical problem If the DocuSP controller has an electrical problem it may shut off the power to the processor 1 Determine if the DocuSP controller power and the processor power are off e If the controller s screen is blank and the power indicator light is not blinking the controller power i
107. of the necessary supplies To do this you need to establish a procedure for checking and ordering supplies A supplies checklist is provided at the end of this chapter to help you with this task It lists the supplies needed for the printer and contains a column for you to enter the date when you want to place the order and a column to record the date of the actual order The consumable supplies table also located at the end of this chapter contains a list of supplies available for the printer It is important that you check your supplies regularly and order before you run out Plan on approximately five working days for the delivery after placing the order You can make arrangements to receive them sooner in emergency situations 6 2 DocuTech 128 155 180 HighLight Color Operator Guide Service and supplies Your sales representative can help you submit the initial order of supplies needed for installation These items include paper dry ink fuser blend and developer Once your printer volume is established planning ahead and buying Xerox supplies in quantity can save you money Your supply specialists can help you NOTE The supplies resources listed below are for the United 4 States only Multinational customers should contact their local representatives for supplies ordering information There are two centers available to assist you e To order Xerox paper transparencies labels dry ink developer fuser blend and d
108. of the short edge keeping the image toward you Figure 4 28 Paper curl chart 3 Place the bottom edge of the prints over the paper curl measurement chart on the line that best represents the curve of the sheets Ifthe curl on the printed paper stock measures between 2 and 2 do not change the decurler setting Ifthe curl is between 2 and 3 or 3 and 4 adjust the decurler lever Customer Support Center Before calling the Customer Service Support Center for service ensure you have read this information and have tried the corrective actions described here If the problem persists gather the necessary information details follow and call the appropriate Customer Service Support Center phone number Your site 4 30 DocuTech 128 155 180 HighLight Color Operator Guide Problem Solving representative can supply you with the telephone number for the Customer Service Support Center in your area The correct phone number is attached to your printer at installation time Before calling for service make note of e Print job fault messages or status messages that appear on the controller Indicator lights that may or may not be lit e Status codes that appear in the message display of the tape drive control panel if there is a tape drive problem Your call is answered by a representative who asks you for your equipment model You are also asked for e Your printi
109. on on the weight sizes and capacities for their paper trays Print rate per minute DT HLC 180 180 prints per minute 8 5 x 11 inch 216 x 279 mm 8 5 x 14 inch 216 x 254 mm and A4 stock 77 prints 17 x 11 inch 432 x 279 mm or A3 stock DT HLC 155 155 prints per minute 8 5 x 11 inch 216 x 279 mm 8 5 x 14 inch 216 x 254 mm and A4 stock fewer prints 17 x 11 inch 432 x 279 mm or A3 stock DT HLC 128 128 prints per minute 8 5 x 11 inch 216 x 279 mm 8 5 x 14 inch 216 x 254 mm and A4 stock fewer prints 17 x 11 inch 432 x 279 mm or A3 stock 128 155 or 180 prints custom stock depending upon the size specified for the stock Performance can be less than optimal for the some unique stock sizes For example for stock having a process direction dimension that is equal to or greater than 8 6 inches 218 mm and less than or equal to 9 inches 229 mm the performance at best will be 175 pages per minute Paper tray capacities Stock weight all trays Substance 16 to 110 60 to 200 g m2 DocuTech 128 155 180 HighLight Color Operator Guide 5 1 Technical information Tray 1 Stock sizes Capacity Tray 2 Stock sizes Capacity Tray 3 Stock Sizes Capacity Tray 4 Stock Sizes US letter 8 1 2 x 11 inches US legal 8 1 2 X 14 inches 9 x 11 inches A4 8 1 2 x 13 inches 223 x 297 mm Custom Width 8 to 9 inches 203 to 229 mm Length 10 to 14 inches 25
110. on only When the job requires stitched output the stitcher cuts and inserts the wire stitches into each print set The stitch length is related to such factors as the number of pages in the print set and the print stock weight A single stitch can be placed in the portrait or landscape print position Dual stitching is available for landscape and portrait prints Stitch placement can be changed through the DocuSP software NOTE For more information about setting stitch placement refer to the on line help system 2 16 DocuTech 128 155 180 HighLight Color Operator Guide System components The stacker 4 NOTE Production publisher configuration only The stacker collects unfinished or finished stitched or bound jobs When the stacker is full or the job is completed the stacker door opens and the stacker drawer that holds the prints comes out After the stacker drawer is unloaded the system retracts the drawer and closes the door The stacker also can be unloaded during the printing cycle to check the quality of the print sets by changing the printer options NOTE For more information refer to the on line help system The binder NOTE Production publisher configuration only When a job requires bound output a length of pre glued paper tape is placed on a heated surface called the binder platen The system aligns the pages of each print set before placing the set on the tape Binder flappers then press the tape to
111. or special mitigation measures taken Certification to 1999 5 EC Radio Equipment and Telecommunications Terminal Equipment Directive This Xerox product has been self certified by Xerox for pan European single terminal connection to the analogue public switched telephone network PSTN in accordance with Directive 1999 5 EC The product has been designed to work with the national PSTNs and compatibles PBXs of the following countries e Austria Belgium Denmark France Finland e Germany e Greece e Iceland ireland e Italy e Luxembourg e Netherlands e Norway Portugal e Spain e Sweden e Switzerland e United Kingdom 1 4 DocuTech 128 155 180 HighLight Color Operator Guide Safety notices In the event of problems you should contact your local Xerox representative in the first instance The product has been tested to and is complaint with TBR21 a specification for terminal equipment for use on analogue switched telephone networks in the European Economic Area The product may be configured to be compatible with other country networks Please contact your Xerox representative if it needs to be reconnected to another country s network There are no user adjustable settings in the product NOTE Although this product can use either loop disconnect 4 pulse or DTMF tone signalling it is recommended that it is set to use DTMF signalling DTMF signalling provides reliable and faster cal
112. per curl in this guide Fan the stock thoroughly Ensure that the stock is within the limitations described in the satisfaction guides in the Technical information chapter Paper weight less than substance 20 75 g m2 will require careful storage and handling Refer to the Technical information chapter Paper misfeeds and multifeeds Ensure that the stock is loaded properly in the paper trays with the rear and side guides against the stack Ensure that the stock is not loaded above the bottom of the red line in the paper tray Ensure that the stock has no bent corners or tears and that the edges are straight Remove any damaged sheets Check the sheets in the bottom of the paper tray for damage If they are damaged discard the sheets Ensure that the stock to be fed out of the paper tray is not excessively curled Refer to the procedure Adjusting for paper curl in this guide If the misfeeds are occurring in the paper tray ensure that the paper feeder is latched by pressing down on the green dot inside the tray Fan the stock at all four corners Change it if it has uneven edges or if it was not drilled properly The stock should be kept in the original wrapper and stored correctly Refer to the Technical information chapter Ensure that the stock is within the limits described in the Technical information chapter DocuTech 128 155 180 HighLight Color Operator Guide 4 3 Problem Solvi
113. poolA 0 00 20 3 52 Storing the binder tape reels 1 2 0 0 teens 3 59 Replacing the binder tape reel 0 0 cee tees 3 61 Adjusting the binder tape registration 0 uuaa ce eee 3 65 4 Problem Solving How problems are displayed 00 eee 4 1 Printer faults and fault windows 000 c ee teen eeee 4 1 When a tault OCCurs suam midd adak a ree eres cates anges ae EAA ATA AEE eae 4 2 Resolving a processor problem ussasusaauaanauannaanna rnaar nananana 4 2 Solving print quality problems s sasaaa uaaa 4 6 Clearing paper jaMS 0 0 0 cette eee 4 6 Incorrect paper Size message 1 ae 4 22 Interposer problems 0 0 0 eee te eae 4 23 Finisher problems sic viwa kek adhe deka EES is beeen gee eV ed ae a 4 23 Binder tape fault voxt waiee tin ad Gate ee ie Cae G wee eee boa a Ree aed 4 25 Stitcher spool A fault ss cece ced wees ne eee ea Ph eed Pe oe ee eee 4 26 Checking paper Curl 0 00 c ett teens 4 30 Customer Support Center 20 00 0 cette teen eee 4 30 5 Technical information DocuTech printer specifications 0 0 eee 5 1 PIINICH EEEE Fhe arate EE E EE AEA EE E E T timed Ga T 5 1 Paper tray capacities ss as madada eee Mega a aa A A aae AR eee A ER ee AA A 5 1 Additional paper capacities anuanua 5 3 Printer satisfaction guides ssirsrreririsniierrii teuk E Ek eee 5 4 DocuTech 128 155 180 HighLight Color Operator Guide Stock satisfactio
114. r Paper curl Before the manufacturer cuts paper into sheets it is stored on large rolls After it is cut and packaged it retains some of the curl from the rollers Although it is unnecessary to load paper with the curl facing up or down best results occur when you are consistent For example if you open paper with the wrapper seam up always load it in the tray that way DocuTech 128 155 180 HighLight Color Operator Guide 3 5 Routine maintenance Adding paper to tray 1 or 2 The following steps must be performed to add paper to tray 1 or 2 1 Press the Tray unlock button on the front of the tray Wait for the red Please wait light to go off When the green Ready to open light comes on pull the tray out until it stops Steps 3 through 5 of loading paper into tray 1 or 2 are illustrated in Figure 3 3 Press the green release tab Lift the metal handle on the feed belt and remove any paper under the belt Move the rear guide to the back of the tray TA786A Figure 3 3 Preparing the paper tray NOTE To load the paper correctly refer to the label located on the inside panel at the front of the paper tray Remove any damaged sheets from the top of the stack CAUTION Do not load the paper above the red line A jam could occur if too much paper is loaded in the tray 6 Load the required paper into the paper tray Load paper with the curl side facing down Load Xerox paper wit
115. ransport set the paper stock size required to fit within the limitations detailed in the following tables and as follows e The diagonal dimension of the paper stock must be equal to or less than 18 inches 457 mm e The paper stock must be within the paper stock size parameters of the DocuTech 128 155 180 HLC printer paper trays Refer to the DocuSP controller on line help system for information on setting finisher devices and finisher profiles to enable rotation to a third party finisher Table 5 8 Common US paper sizes an Comment Common Inches x Millimeter ma Can be rni Diagonal in inches similar to or the size name inches equivalent rotated same as 8 0 x 10 75 203 x 273 13 40 YES US Letter US 8 5 x 11 0 216 x 279 13 90 YES 2 up of US 5 5 x A size 8 5 in statement 9 0 x 12 0 229 x 305 15 00 YES 2 up of US 6 0 x 9 0 in common book size US Legal 8 5 x 14 0 216 x 356 16 38 YES ISO Foolscap 9 0 x 14 0 229 x 356 16 64 YES 2 up of US 7 0 x 9 0 in 9 0 x 15 0 229 x 381 17 49 NO 2 up of US 7 5 x 9 0 in 5 12 DocuTech 128 155 180 HighLight Color Operator Guide Technicalinformation ae Comment Common Inches x Millimeter maa Can be ani Diagonal in inches similar to or the size name inches equivalent rotated same as 10 5 x 14 5 267 x 368 17 90 NO 2 up of US 7 25 X 10 5 in Executive US Ledger 11 0 x 17 0 279
116. rdous radiation exposure The Xerox DocuTech 128 155 180 HLC models are certified to comply with laser performance standards set by the U S Department of Health Education and Welfare as Class 1 laser products This is a class of laser products that does not emit hazardous radiation This is possible only because the laser beam is totally enclosed during all modes of customer operation When performing operator functions laser warning labels may be visible These labels are to alert and remind the service representative and are placed on or near panels or shields which require a tool for removal THE PANELS TO WHICH THESE LABELS ARE FIXED OR NEAR ARE NOT TO BE REMOVED BY ANYONE OTHER THAN AUTHORIZED TRAINED PERSONNEL DANGER LASER RADIATION WHEN OPEN AVOID DIRECT EXPOSURE TO BEAM Figure 1 1 Laser warning label DocuTech 128 155 180 HighLight Color Operator Guide 1 1 Safety notices Ozone safety This product produces ozone during normal operation The ozone produced is dependent on copy volume and is heavier than air Providing the proper environmental parameters as specified in the Xerox installation instructions ensures that concentration levels meet safe limits Operation safety Your Xerox equipment and supplies have been designed and tested to meet strict safety requirements These include safety agency examination and approval and compliance to established environmental standards Attention to the
117. re 4 22 6 Slide the tray back into the printer until the tray latches and press the Continue button to resume printing 7 Discard any pages sent to the sample tray purge tray or unused stacker bin when the misfeed was detected Incorrect paper size message Perform this procedure when printing stops and a incorrect paper size message appears on the controller 1 Check the paper in the indicated tray If the paper is not the correct size for the job either load the correct size paper or select another feeder tray containing the correct size paper 2 If the paper size is correct press the Continue button to resume printing The message may have been caused by a damaged sheet NOTE n order to assure good print quality for your jobs the 4 printer purges any dog eared or skewed sheets In addition the printer may stop and issue an incorrect paper size message 4 22 DocuTech 128 155 180 HighLight Color Operator Guide Problem Solving Interposer problems 4 NOTE Production publisher configuration only Table 4 2 Resolving an interposer problem Problem Suggested solutions Repeated jams in interposer Follow the jam clearance diagram in the Printer Fault Clearance window carefully to ensure all paper has been cleared Make sure the stock in trays 4 and 5 have been loaded correctly Refer to the Satisfaction guides in chapter 4 Technical Information for information on loading stock i
118. rtridge tape drive connects to the controller through the SCSI port on the processor back panel Like the diskette and DVD drives this tape drive is not an input source for print jobs or for any other data or application You can use it to load resource files and the service representative uses it to load system maintenance files or to save diagnostic information Figure 2 14 26 track cartridge tape drive 36 track cartridge An 18 36 track cartridge tape drive is an option You can use this tape drive drive to load resources and to submit offline LCDS print jobs Peripheral cabinet 9 track and 18 36 track tape drives Some Xerox customers may already have a peripheral cabinet that houses a 9 track magnetic and an 18 36 track cartridge tape drive If a peripheral cabinet has either of the following 18 track tape drives they are not supported STK 4220 MOD 1 tape drive STK 4220 MOD 2 tape drive DocuTech 128 155 180 HighLight Color Operator Guide 2 25 System components i TD F I Figure 2 15 Peripheral cabinet 1 9 track magnetic tape drive 2 18 36 track cartridge tape drive Paper sizing and print speed The printer paper trays have edge guide sensors that detect paper length and width The system selects correct paper trays for the print job based on the paper parameters such as size weight color or coating specified in the job as follows e If an exact match is found the print job
119. s Interposer 4 NOTE Production publisher configuration only The two tray Interposer module is located between the print engine and the Finisher The Interposer inserts blank or preprinted sheets as required N Ow QTCO0100A TOR Figure 2 9 Interposer production publisher only The following lists the interposer components Paper transport lower Paper transport upper Inserter tray Feeder inserter tray POON DocuTech 128 155 180 HighLight Color Operator Guide 2 15 System components Finisher 4 NOTE Production publisher configuration only Soct ae E ehaoid In the finisher prints can be collated and stitched or bound as required for a job The following lists the finisher components Bindexer Stitcher Stacker Binder Binder tape reel Stitcher wire spools Top tray Figure 2 10 Finisher NORWOOD The bindexer NOTE Production publisher configuration only The bindexer is a three bin sorter that collates the pages of each print set As the pages of the print set are fed to the bindexer the bindexer moves up and down to collate them The stitcher 4 NOTE Production publisher configurati
120. s off Refer to the System Guide Ifthe paper tray lights are out the power to the processor is off Proceed with step 2 2 Determine if the processor has a ground fault protector If there is not a ground fault protector installed refer to the procedure Calling for assistance in this guide 3 Ifthe processor has a ground fault protector determine whether the protector has shut off the power Ifthe red light is visible on the protector proceed with step 4 Ifthe red light is not visible something other than the protector has shut off the power Refer to the problem Processor power is off unexpectedly and the ground fault protector did not trip in this section 4 Press the reset button on the processor ground fault protector Ifthe red light switches off proceed with step 5 Ifthe red light does not switch off or immediately switches on again refer to the procedure Calling for assistance in this guide 5 Switch the white handled circuit breakers near the protector to the on up position If the power comes on proceed with step 6 Ifthe circuit breakers immediately switch off again refer to the procedure Calling for assistance in this guide Select the Reset icon on the fault frame This should clear the fault Clear any other faults that may be declared Do not clear the paper path unless directed to do so The system will maintain job integrity 8 Ifthe power repeatedly switch
121. s reliable feeds may be Stock be expected expected Suggested alternatives Weight Substance 16 to 110 Weights outside the limits shown 60 to 200 g m2 are not recommended Substance 110 200 g m2 must be long grain except 17 x 11 inch 432 x 279 mm substance 110 200 g m2 which must be short grain Capacity 550 sheets substance 20 75 g m2 Type or Xerographic bond Slightly curled paper Do not use excessively curled condition paper in good Intermixed weights paper condition Xerox vellum Substance 110 200 g m2 must Drilled stock fanned Full cut tabs be long grain Do not use short thoroughly Label stock grain Adhesive drafting film Refer to the Using various Paper with reinforced edges stocks section for any stock not defined in this guide Table 5 3 Satisfaction guide for paper trays 3 4 5 and 6 NOTE High volume printer configuration only Reliable feeds may Less reliable feeds may be Stock be expected expected Suggested alternatives Size 8 x 10 inches to 17 x Smaller or larger sizes cannot be 11 inches 203 x 254 used mm to 432 x 279 mm Weight Substance 16 to 110 Weights outside the limits shown 60 to 200 g m2 are not recommended Substance 110 200 g m2 must be long grain except 17 x 11 inch 432 x 279 mm substance 110 200 g m2 which must be short grain Capacity 2600 sheets substance 20 75 g m2 5 6 DocuTech 128 155 180 HighLight Color Opera
122. s set sizes inner stack reaches capacity DocuTech 128 155 180 HighLight Color Operator Guide 5 15 Technical information Table 5 11 Stitcher satisfaction guide Stock Reliable stacking may be Less reliable stacking may Suggested alternatives expected be expected Type or Xerographic bond paper in Slightly curled paper Do not use excessively curled condition good condition paper Drilled paper Transparencies must contain some opaque sheets to avoid finisher jams Stock not defined here is included in the Using various stocks section in this guide Table 5 12 Binder satisfaction guide Stock Reliable stacking may be Less reliable stacking may Suggested alternatives expected be expected Size 8 x 10 inches to 9 x 14 Consider stitching for smaller inches 203 x 254 mm to or larger sizes 229 x 356 mm Weight Main Substance 20 to 24 75 to Substance 16 60 g m2 Avoid weights less than Body 90 g m2 Without covers substance 16 60 g m2 or greater than substance 24 90 g m2 Consider stitching for weights outside these limits Weight Maximum substance 65 Heavier than substance 65 Avoid removable stripe Covers 176 g m2 176 g m2 transparencies Transparencies Weight Insert Maximum substance 65 Heavier than substance 65 Limit the inserts outside of 176 g m2 176 g m2 substance 16 to 24 60 to 90 g Minimum substance 20 Lighter than su
123. se In each tray a control panel consisting of a button indicators and paper level displays controls the elevator tray and indicates its status UWWew S sS B B Figure 2 3 Feeder paper tray control panel 1 Ready to Open indicator 2 Please Wait indicator 3 Tray Unlock button 4 Paper Level indicators Ready to Open Glows green when the tray can be pulled out and paper can be indicator added to it Please Wait Shows that the tray is in motion This indicator is lit red when the indicator Tray Unlock button is pressed while the tray is lowering and while the tray is rising The indicator goes off when the tray elevator reaches its destination Tray Unlock button Enables the tray to be opened e Ifthe tray is in use when this button is pressed the feed selection switches to the backup tray if one has been identified Otherwise printing stops e Ifthe tray is in use and selected as a backup tray pressing the Tray Unlock button causes the tray elevator to lower and the tray to be unavailable for auto switching Ifthe tray elevator is in the raised position and the tray is not in use or selected as a backup tray pressing this button causes the elevator to lower with no effect on printing operations This button functions when the Please Wait indicator is off DocuTech 128 155 180 HighLight Color Operator Guide 2 9 System components Paper Level indicators Display the appro
124. steps to adjust the decurler lever CAUTION Do not use any paper that is not suitable for system use 1 Open the right door of the processor 2 Locate the decurler lever in area 7 of the paper path as shown in the figure below Figure 3 7 Loc Locating the decurler lever 3 Ifthe print curl is 2 or more move the green decurler lever to the right 4 Ifthe print curl is 3 or more move the green decurler lever to the left 5 If the decurler adjustment does not eliminate the paper curl problem or for other curl problems turn the stack of paper over in the paper tray 6 If there is still a curl problem perform steps 1 to 4 again NOTE A final solution to the curl problem may be to load a 4 new ream of paper 7 Close the processor door DocuTech 128 155 180 HighLight Color Operator Guide 3 11 Routine maintenance Maintaining the printer A screen message is displayed when it is necessary to replace system supplies To ensure that the system runs efficiently replace the supplies as soon as possible Replacing the black dry ink bottle When directed by a screen message replace the black dry ink bottle If the bottle is not replaced the printer will eventually stop and it will not operate until a new bottle is installed CAUTION To prevent dry ink spills remove the bottle only when directed to do so by a message on the screen CAUTION Do not use warm or hot water or general cleaning so
125. t be used to 229 x 356 mm For stock larger than 9 x 14 inches 229 x 356 mm refer to the tray 3 satisfaction guide Weight Substance 20 to 110 Substance 16 to 19 60 to 72 g Weights outside the limits shown 75 to 200 g m2 m2 are not recommended Substance 110 200 g m2 must be long grain Do not use short grain Capacity Tray 1 1100 sheets For greater capacity use tray 3 substance 20 75 g m2 Tray 2 600 sheets substance 20 75 g m2 Type or Xerographic bond Slightly curled paper intermixed Do no use excessively curled condition paper in good weight Transparencies Label paper condition Drilled stock Adhesive drafting film Substance 110 200 g m2 must stock fanned Paper with reinforced edges be long grain Do not use short thoroughly Tab stock grain in perfectly flat Use transparencies with a white condition stripe Freshly printed offset prints use tray 3 Refer to the Using various stocks section for any stock not defined in this guide Table 5 2 Satisfaction guide for paper tray 4 Interposer ONLY NOTE Production publisher configuration only Reliable feeds may Less reliable feeds may be Stock be expected expected Suggested alternatives Size 8 x 10 inches to 17 x Smaller or larger sizes cannot be 11 inches 203 x 254 mm to 432 x 279 mm used DocuTech 128 155 180 HighLight Color Operator Guide 5 5 Technical information Reliable feeds may Les
126. ter running at optimum efficiency The printer functions best and produces the best print quality when using stocks that have the correct e Size e Weight Type e Color For more comprehensive information on paper stocks for Xerox printers refer to Helpful facts about paper 721P82493 The DT 128 155 180 HLC supports the following range of paper weights 16 110 pound 60 200 gsm Other paper weights should not be used The equivalent grams per square meter of 20 pound paper is actually 75 gsm However there is no standard 75 gsm paper The available stock that is closest in weight to 20 pound paper is 80 gsm The following special stocks can be used with the DocuTech 128 155 180 HLC Labels Must be the type designed for high speed printers and must meet the specifications described in the section above Loading instructions are printed on all paper trays e Transparencies Must be the type designed for high speed printers and must meet the specifications described in the section above Loading instructions are printed on all paper trays e Colored paper Available in a variety of colors colored paper has many uses including calling attention to certain printed material separating special sections or dividing chapters of a report e Preprinted paper May be letterhead forms or logos Refer to the Helpful Facts about Paper guide to verify that the preprinting inks used on your stock are the kind form
127. test run a proof print Window stock Run if the window is 2 2 to 4 inches 57 to 102 mm from the top edge of the paper and at least 1 inch 25 4 mm from each side of the paper Run only as the first page or a front cover to avoid finisher bin jams Load the window stock face up into a tray tray 1 or 2 is recommended with the top edge toward the front of the tray If running plastic covered window stock there may be some distortion To test runa proof copy Xerox Carbonless Xerox Carbonless Paper is recommended Do not use the following stocks e Multipart forms e Stocks outside of the recommended size and weight ranges Using non standard stock Using stock of non standard width or length in the printer may have a negative impact on system performance Refer to the following table for a listing of sizes and possible resulting impacts Table 5 6 Stock width impact on system performance Stock width Impact on performance 8 67 to 9 inches 221 to 229 mm in trays 1 2 3 4 and 5 Extended runs may increase the risk of temporary background Increased risk of lead edge image deletions on each successive sheet Stock programming errors may go undetected because stock width checking is not performed 9 inches 229 mm to less than 14 2 inches 361 mm in trays 3 4 and 5 Image offset may occur following a printer malfunction for example fuser jams Running stoc
128. the 18 36 track cartridge tape drive read write heads 1 Remove any cartridge loaded in the tape drive 2 Insert the cleaning cartridge The cleaning cycle takes approximately 15 seconds 3 Remove the cleaning cartridge when it is unloaded 4 Mark the usage on the tape label Do not use a grease pencil You must clean the 18 36 track cartridge tape drive regularly to keep it functioning properly 3 32 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance Cleaning the 26 track cartridge tape drive The 26 track or quarter inch cartridge QIC tape drive heads should be cleaned at least once a week If you use the drive for eight hours or more per day then you should clean the drive daily The process is simple and requires little time 1 If there is a cartridge in the tape remove it 2 Insert the cleaning cartridge in the tape drive and close the door Cleaning begins automatically once the tape is inserted 3 Allow the tape to run for approximately 30 seconds then remove it NOTE Replace the foam pad on the cleaning cartridge after it 4 has been used three times The cleaning cartridge itself can be used 100 times Cleaning the DVD drive Follow the DVD cleaning directions and recommended cleaning frequency 1 If there is a DVD disk in the drive remove it 2 Follow the directions to clean the DVD drive Cleaning the diskette drive The floppy disk drive must be clean
129. titcher spool A in this guide The system applies binder tape from a reel mounted in the binder drawer in the finisher You will need to replace the binder tape periodically WARNING All areas of the binder drawer including the binder A tape are approximately 425 F 218 CT and may cause a serious burn to the operator If the binder has been in a Ready condition allow the binder to cool for at least one hour before attempting to clean the binder 3 2 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance Paper You can add the same kind of paper to a tray when the supply is low without stopping the printer You must have the same paper or stock loaded in two trays for the system to continue printing while you are loading the other tray Storing paper It is important to store paper correctly Temperature and humidity affect the way your printer processes paper Store paper in the cartons it came in To reduce the possibility of moisture absorption always place cartons on a wooden pallet or store them in a cabinet off the floor After removing the paper from its carton always store it In its wrapper On a flat surface In a closed cabinet In a cool dry area In 68 to 76 F 20 to 24 4 C In 35 to 55 humidity Figure 3 1 Storing paper correctly DocuTech 128 155 180 HighLight Color Operator Guide 3 3 Routine maintenance Figure 3 2 Recommended temperat
130. tor Guide Technicalinformation Reliable feeds may Less reliable feeds may be Stock be expected expected Suggested alternatives Type or Xerographic bond Slightly curled paper Do not use excessively curled condition paper in good Intermixed weights paper condition Xerox vellum Substance 110 200 g m2 must Drilled stock fanned Full cut tabs be long grain Do not use short thoroughly Label stock grain Adhesive drafting film Precut tabs use tray 1 or 2 Paper with reinforced edges Transparencies with a white stripe use tray 1 or 2 Freshly printed offset prints use tray 3 Refer to the Using various stocks section for any stock not defined in this guide Table 5 4 Satisfaction guide for 2 sided printing Stock ve Ae Less M a may be Suggested alternatives Size 8 x 10 inches to 17 x 17 x 11 inch 432 x 279 mm 11 inches 203 x 254 paper can only be sent to the top mm to 432 x 279 mm tray Weight Substance 16 to 110 Weights outside the limits shown 60 to 200 g m2 are not recommended Substance 110 200 g m2 must be long grain Type or Xerographic bond Slightly curled paper Do not use excessively curled condition paper in good Paper with reinforced edges paper condition Refer to the Using various Drilled stock fanned stocks section for any stock not thoroughly defined in this guide Using various stocks The following table lists stock that have
131. ughly to loosen the contents Insert the full bottle until it stops Figure 3 9 Inserting and latching the bottle c Slide the full bottle all the way into the system d Hold the bottle in place with one hand and remove the DocuTech 128 155 180 HighLight Color Operator Guide 3 13 Routine maintenance paper seal by pulling it toward you with the other hand Discard the seal along with the drop cloth y p oa A Figure 3 10 Removing the paper seal 5 Close the processor access door NOTE f any dry ink should get on your skin wash with mild soap and cold water Replacing the highlight color container The highlight color container holds the color dry ink When directed by a screen message replace the highlight color container If the highlight color container is not replaced the printer stops and it will not operate until the highlight color container is replaced CAUTION Do not use warm or hot water or general cleaning solvents to remove dry ink from your skin or clothing The heat or solvent will set the dry ink and make it difficult to remove If any dry ink should get on your skin wash with mild soap and cold water If any dry ink should get on your clothes brushing with a dry paper towel or a stiff bristled brush may remove the ink If not launder your clothes with detergent and cold water Tell a commercial dry cleaner that the spot is dry ink or toner so
132. ulated for use in laser printers 2 4 DocuTech 128 155 180 HighLight Color Operator Guide System components Predrilled paper Has holes for use in binders or binder rings Before loading predrilled paper fan it to remove any loose plugs that could cause paper jams Perforated paper Have been pierced with one or more rows of holes to permit easy tearing or separating into sections Read and follow the instructions on the ream packaging Precut or full tabs Carbonless paper Is paper that is treated or coated to produce an image under pressure without the use of carbon paper After opening close and seal the original ream wrapper to store Do not leave in paper trays overnight Read and follow the instructions on the ream packaging General paper characteristics When selecting paper look for the following Low moisture content a paper to moisture ratio below 5 7 percent Paper with higher moisture content may curl and jam Smooth surface Moisture resistant wrapping No defects such as bent edges or uneven surfaces Grain runs parallel with the long side of paper Graphical user interface overview The graphical user interface GUI on the controller enables you to interact with the printing system It contains windows icons and menus through which you can issue commands and perform operation and system administration tasks When the workstation controller is powered on and booted the DocuSP Print
133. unctions on the printing system The DocuSP software includes a full color graphical user interface which enables you to interact with the printing system to set up and configure the system to set up and implement system options to run print jobs etc Online Help menus and buttons provides access to online help that contains information when requested NOTE LCDS is not available on the Production publisher 4 configuration at this time DocuTech 128 155 180 HighLight Color Operator Guide 2 23 System components Accessing DocuSP remotely Remote Workflow Remote Workflow a remote graphical user interface GUI is available for installation from a CD Remote Workflow allows you to manage your DocuSP based printers from a single PC or Sun workstation You may set your preferences from the remote client to disable or enable some or all connections Remote Workflow allows you to configure the printers that you want to manage and provides real time status of the printers You may switch between the printers that you are managing but you can display only one printer GUI at a time The remote client GUI looks and functions the same as the local DocuSP GUI on the controller Moving the controller To ensure consistent performance and avoid any damage to equipment follow these rules for placing the components of the workstation controller Do Use the controller stand that comes with your printing system equipm
134. ure and humidity for paper storage Conditioning paper Because temperature and humidity affect paper performance in the printer you need to condition paper before using it To condition paper store it for a specified length of time in the same type of environment as your printer The length of time you should condition your paper depends on the amount of paper and the difference between the storage and operating temperatures Use the following chart to determine the number of hours needed to condition stacked cartons of paper NOTE The numbers in the top two rows indicate the temperature difference between the storage area and the operating environment not actual room temperatures 3 4 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance Table 3 1 Paper conditioning Temperature difference between storage and operating areas Fahrenheit 10 15 20 25 30 40 50 Centigrade 55 85 119 13 17 22 26 Cartons Hours needed to condition the paper 1 4 8 11 14 17 24 34 5 5 9 12 15 18 25 35 10 8 14 18 22 27 38 51 20 11 16 23 28 35 48 67 40 14 19 26 32 38 54 75 Example If you want to move ten cartons of paper from a storage area with a temperature of 90 F to an operating area with a temperature of 70 F a 20 difference you should do so at least 18 hours before using the pape
135. ush If this does not remove the ink immediately launder with detergent and cold water Tell the dry cleaners that the spot is dry ink for a printer so they will not use a solvent that sets the stain When you are not using a cart and CCU store them in a dry dust free area that has little variation in temperature and humidity The storage area should have a similar temperature and humidity to the printer room Maintain the temperature in the range of 60 to 80 F 15 to 26 C and a relative humidity of 30 to 65 percent Removing the CCU using the service stand Use the service stand to withdraw the highlight color CCU from the printer Use this stand if you do not have a cart To set up the service stand 1 If the printer is not cycled down Pause the system before you open the doors and attempt to remove the CCU 2 Open the printer doors and locate the color housing area in the center of the printer Place the service stand next to the developer housing By turning the jack screws adjust the height of the front feet so that the alignment pins in the service stand are positioned just below the hole and the docking bracket Tighten the lock nuts on the jack screws to lock the jack screws in position b sph is Figure 3 18 Service stand DocuTech 128 155 180 HighLight Color Operator Guide 3 21 Routine maintenance 10 Slide the stand toward the machine to e
136. vices window on the DocuSP controller You should respond to the fault or message as soon as possible to avoid a printer shut down The system provides dry ink to the printer from a bottle located in the printer When the screen displays an empty message a full dry ink bottle must be installed Waste dry ink empties into a container located at the side of the printer under the toner filter When this container becomes full it must be replaced Fuser lubricant must be added to the fuser reservoir in the printer when a low message on the screen directs you to do so Fill the fuser reservoir at this time or the printer shuts down For information on cleaning the processor sensors the reflecting surfaces and the finisher sensors refer to the Problem solving chapter NOTE The DocuTech HLC fuser oil is a specially blended fuser shield specifically for the DocuTech HLC systems CAUTION The DocuTech HLC fuser shield must not be used in any other Xerox product CAUTION Use only the DocuTech HLC fuser shield in the DocuTech HLC systems Necessary Precautions For your own safety and to protect the system it is important to take the following precautions whenever you perform cleaning and replacement tasks e Use only the cleaning and replacement supplies that are DocuTech 128 155 180 HighLight Color Operator Guide 3 1 Routine maintenance approved or recommended by Xerox If you use other supplies you may da
137. ving the paper wrapper NOTE Hold the wire between the thumb and forefinger of 4 both hands 10 Feed the wire slowly into the tubing until the wire extends from the stitcher plug as shown in figure 3 59 XE154A Figure 3 59 Feeding the wire 11 Remove the stitcher plug from the measuring bracket 3 58 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance 12 Slowly and carefully pull about 3 feet 1 meter of wire from the spool 13 Cut the wire leaving about 2 inches 51mm of wire extending from the end of the stitcher plug 14 Insert the plug into the measuring bracket 15 Continue to feed the wire until it touches the back plate of the measuring bracket 16 Push the green stitcher head release handle down and back 17 Pull the plug from the measuring bracket 18 Insert the plug into the stitcher head until the plug snaps into place 19 Place the wire cutters in the storage bracket NOTE Ensure that the wire cutters are not touching the 4 stitcher spools This can prevent the stitcher wire from feeding properly 20 Lower the stitcher panel NOTE Ensure that the stitcher panel has been lowered The 4 stacker will not deliver prints if the stitcher panel is left in the up position 21 Close the finisher doors Storing the binder tape reels 4 NOTE Production publisher configuration only Binder tape contains paper that makes the tape sensitive to the same
138. x 432 20 25 NO 2 up of US 8 5 x US B Size 11 0 in Letter Although the diagonal meets the 18 inch 457 mm rotation limit the paper stock long dimension exceeds the processor path width The sheet must stay in the short edge feed orientation throughout the paper path NOTE Non United States customers The part numbers in this 4 table are for the United States only Contact your local representative for common sizes used in Europe Japan Canada etc Table 5 9 Other paper sizes that can be rotated me Comment Common Inches x Millimeter as Can be ra P Diagonal in inches similar to or the size name inches equivalent rotated same as Largest 12 73 x 12 73 323 x 323 18 00 YES square Largest 10 89 x 14 33 277 x 364 18 00 YES Length is rectangle constrained by paper path width For media sizes that are not listed in the above tables view the graph shown in figure 5 1 The graph can be used to determine which sizes of media can and cannot be rotated within the Bypass Transport DocuTech 128 155 180 HighLight Color Operator Guide 5 13 Technical information ISO A4 LEF ISO A3 SEF 8 5x11 LEF 11x17 SEF Process Width inches Process Length inches T305000A CO1 Figure 5 1 Rotatable and non rotatable sizes as loaded media size Sizes whose dimensions are located on the left of the curve or on the line itself have a diagonal that is less than or equal to 18 0 in
139. ximate quantity of paper in the tray Each display shows paper by quarter reams up to one ream and then by full reams The green indicator appears above its Paper Level indicator Sample tray NOTE High volume printer configuration only The sample tray located on top of the printer receives output such as transparencies sample sheets from printing jobs prints from system files such as forms and waste sheets that cannot be sent to the purge tray Monitor the sample tray and empty it when it contains 100 sheets The system does not notify you when the tray is full Attention light NOTE High volume printer configuration only An Attention light is mounted on top of the inverter module This light either blinks or modulates alternately brightens and dims when the printer requires operator attention The light has three states Off No printer problems exist that require attention Steady light A situation exists that needs attention soon Flashing The printer has stopped and requires your attention immediately NOTE When the Attention light starts flashing an explanatory message appears on the controller screen Purge tray NOTE High volume printer configuration only The purge tray is located on top of the last feeder stacker module Aborted sheets for example damaged sheets or sheets cleared after a paper jam are sent to this tray The purge tray should be emptied when it has received 100 sheets of p

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